WO2022200899A1

WO2022200899A1 - A battery pack assembly

Info

Publication number: WO2022200899A1
Application number: PCT/IB2022/052149
Authority: WO
Inventors: Sachin Anant Jadhav
Original assignee: Sachin Anant Jadhav
Priority date: 2021-03-22
Filing date: 2022-03-10
Publication date: 2022-09-29

Abstract

The present disclosure relates to a battery pack assembly(100) having a plurality of cells(1) enclosed in a casing(13) and a socket connector(16) attached thereon. The socket connector(16) configured on operative top surface of the casing(13) to enable external devices that need power. The assembly(100) comprises a cage defining a first tray(3a) and a second tray(3b) having a plurality of holders(2) therein, a strip arrangement defined by a plurality of strips(4), (4a) and (4b), a first half and second half frame(5a, 5b), a battery management system (BMS) (9), and a pair of conducting cables (32,33). The first and second tray (3a, 3b) has the plurality of cells(l) uniformly sandwiched therebetween. Advantageously, the defined gap between the casing(13) and the monolithic battery (40) package prevents from electric shock and helps in thermal management of the assembly(100). Also, since the assembly(100) is un-potted, therefore provides easy recycling or repairing of the cell.

Description

A BATTERY PACK ASSEMBLY

FIELD

The present disclosure generally relates to battery devices for supplying electrical power and, more particularly, to a removable battery pack assembly for supplying electrical power to an electronic device in a two-wheeled vehicle.

BACKGROUND

The background information herein below relates to the present disclosure but is not necessarily prior art.

The desire to reduce the automotive fuel consumption and emissions, the electrified vehicles are being developed. The demand for electric bikes is on a sharp rise as more and more people are becoming aware of green energy sources. In general, the electrified vehicles differ from conventional motor vehicles because they are selectively driven by one or more battery powered electric machines. A high voltage battery packs typically powers the electric machines. The battery pack for the electric bike is typically a lithium ion battery pack, which is fragile in nature and hence, requires a protective frame to conduct a safe operation.

However, the protective frames of the conventional battery packs have a relatively poor quality and safety standards. Further, these battery packs do not have a standard size, which makes it further difficult to produce standard protective components. As a result, the battery packs is prone to poor thermal management and potential hazards. Further, the conventional battery packs are potting with epoxy resins. When the battery pack is subjected to any accidental fall or shock load, the internal connections between the batteries may get disturbed, and the complete battery packs become useless.

There is therefore felt a need for a battery pack assembly that alleviates the aforementioned drawbacks. OBJECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows: An object of the present disclosure is to provide a battery pack assembly.

Another object of the present disclosure is to provide a battery pack assembly that has a robust configuration.

Yet another object of the present disclosure is to provide a battery pack assembly that is lightweight and offers relatively better thermal management.

Still another object of the present disclosure is to provide a battery pack assembly that has a compact configuration.

Another object of the present disclosure is to provide a battery pack assembly that offers easy installation. Still another object of the present disclosure is to provide a battery pack assembly which is recyclable.

Another object of the present disclosure is to provide a battery pack assembly that is capable of absorbing shocks.

Still another object of the present disclosure is to provide a battery pack assembly that provides un-potted structure.

Another object of the present disclosure is to provide a battery pack assembly that offers common area network (CAN) based communications.

Still another object of the present disclosure is to provide a battery pack assembly that facilitates monitoring of battery health status. Another object of the present disclosure is to provide a battery pack assembly which provides overcurrent protection.

Still another object of the present disclosure is to provide a battery pack assembly that offers charging of battery cells.

Another object of the present disclosure is to provide a battery pack assembly that offers remote monitoring of the temperature, the voltage and the current of the battery pack assembly. Still another object of the present disclosure is to provide a battery pack assembly that provides protection against short circuit.

Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure. SUMMARY

The present disclosure envisages a battery pack assembly having a plurality of cells enclosed in a casing and a socket connector attached thereon. The socket connector is configured on the operative top surface of the casing to enable external devices that need power. The assembly comprises a cage defining a first tray and a second tray having a plurality of holders configured therein, a strip arrangement defined by a plurality of strips, a frame having a first half frame and a second half frame, a battery management system (BMS), and a pair of conducting cables.

The first tray and the second tray have the plurality of cells uniformly sandwiched therebetween. The positive and negative terminals of the plurality of the cells are exposed and interlinked on either face of the first tray and the second tray.

In an embodiment, one end of the cell is snap-fitted on the holder configured on the first tray and sandwiched by the similar array of holders configured on the second tray.

The strips are secured to the like terminals of the plurality of the cells where each face of the cage with the attached plurality of the strips forms a monolithic battery. The frame consists of an insulating frame element for sandwiching the monolithic battery. The battery management system is mounted on the operative top of the frame and configured to selectively charge and discharge the monolithic battery to a predetermined number of cycles. Also, the pair of conducting cables are separately connected to the positive terminal and the negative terminal of the monolithic battery. The conducting cables are configured to communicate with the battery management system (BMS)

In an embodiment, the strip arrangement is a rhombic-interlinked structure.

In another embodiment, the battery management system is configured to control the output voltage. In another embodiment, the battery management system is configured to limit the output current in a range from 28 amperes to 50 amperes.

In another embodiment, the battery management system is configured to cut-off the power supply to limit the output current. In another embodiment, the battery management system configured to cut-off the power supply to limit the battery temperature in a range from -2°C to 75°C.

In another embodiment, the battery management system is configured to monitor the health of the plurality of the cells encased in the battery assembly.

In another embodiment, the battery management system is configured to charge the battery pack assembly by means of an external electric source.

Advantageously, the defined gap between the casing and the monolithic battery package prevents from electric shock and also helps in thermal management of the battery pack assembly. Also, since the battery pack assembly is un-potted, the cells can be recycled or repaired easily. Further, the socket connector is configured to be received in a socket attached to the BMS. The socket connector is configured with a charging cable, a powering cable, and a data communication cable.

In an embodiment, the data communication cable is configured to communicate real-time data’s from the battery assembly to a common area network (CAN) by means of different sensors attached to the BMS.

In another embodiment, each of the strips is metallic sheets, configured to conduct the electric charge.

In another embodiment, the first half frame and the second half frame are configured with a mounting bracket configured on each operative edges of the first half frame and the second half frame.

In another embodiment, the casing is configured to be a portable casing provided with a handle thereon. In one embodiment, the battery pack assembly is configured as a power-bank. Advantageously, the frame is damp-proof; therefore, the frame can absorb random vibrations and shock loads.

Further, since the battery pack assembly is provided with the BMS attachment configured with the CAN based communication; therefore real-time monitoring of the temperature, the voltage and the current of the battery pack assembly is possible.

Furthermore, the battery pack assembly is provided with the attached BMS; therefore, the same battery pack assembly can be used as an inverter.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

A battery pack assembly, of the present disclosure, will now be described with the help of the accompanying drawing, in which:

Figure 1 illustrates an isometric view of a cell;

Figure 2 illustrates an isometric view of an array of cell holder;

Figure 3 illustrates an isometric view of a cage defined by the plurality of cell holders of Figure 2; Figure 4 illustrates an isometric view of the first tray, of Figure 3, having cells, of Figure 1, disposed on the cell holder of Figure 2;

Figure 5a and Figure 5b illustrates an isometric view of the first tray and the second tray disposed on the plurality of the cells, of Figure 4;

Figure 6 illustrates an isometric view of strip arrangement; the strips are secured to the terminals of the cells disposed on the second tray of Figure 5;

Figure 7 illustrates an isometric view of strip arrangement; the strips are secured to the terminals of the cells disposed on the first tray of Figure 6;

Figure 8 illustrates an isometric view of a monolithic battery having a frame attached thereon; Figure 9 and Figure 10 illustrate an isometric view of wires soldered to the monolithic battery of Figure 9; Figure 11 illustrates an isometric view of a battery management system attached to the monolithic battery of Figures 9 and 10;

Figure 12 illustrates an isometric view of a bottom cover of the battery pack assembly;

Figure 13 illustrates an isometric view of a gasket with the bottom cover of Figure 12; Figure 14 illustrates an isometric view of a casing of the battery pack assembly;

Figure 15 illustrates an isometric view of the bottom cover of Figure 13 attached to the casing of figure 14;

Figure 16 illustrates an isometric view of the monolithic battery sliding inside the casing of Figure 15; Figure 17 illustrates an isometric view of the monolithic battery and the casing;

Figure 18 illustrates an isometric view of a top housing of the casing;

Figure 19 illustrates an isometric view of the top housing with a socket connector assembly fitted thereon;

Figure 20 illustrates an isometric view of the top housing with the socket connector assembly and an O-ring fitted thereon;

Figure 21 illustrates an isometric view of the top housing having a handle fitted thereon;

Figure 22 illustrates an isometric view of the top housing having the handle fitted thereon with pins;

Figure 23 illustrates an isometric view of the top housing having a gasket; Figure 24 illustrates an isometric view of the battery pack assembly, in accordance with an embodiment of the present disclosure;

Figure 25 illustrates an exploded view of the battery pack assembly with the monolithic battery;

Figure 26 illustrates an exploded view of the battery pack assembly of Figure 24; Figure 27 illustrates an isometric view and the front view of the casing having battery pack assembly and provided with a pair of USB connectors and a three pin socket attached thereon; and

Figure 28 illustrates a side view and a front view of the battery pack assembly with attached socket connector therein.

LIST OF REFERENCE NUMERALS

1 CELL

2 CELL HOLDER

3A LIRST TRAY 3B SECOND TRAY

4 STRIP

4A POSITVE TERMINAL CONNECTION STRIP 4B NEGATIVE TERMINAL CONNECTION STRIP

5 FRAME 5A FIRST HALF FRAME

5B SECOND HALF FRAME

6 FRAME LOCKING TOP SIDE B OLT

7 FRAME LOCKING BOTTOM SIDE BOLTS

8 FRAME LOCKING NUTS 9 BATTERY MANAGEMENT SYSTEM (BMS)

10 BMS FITMENT SCREW

11 BOTTOM COVER

12 GASKET TOPSIDE & BOTTOM SIDE 13 CASING

14 B OTTOM COVER FITMENT SCREW

15 TOP HOUSING

16 SOCKET CONNECTOR 17 O-RING

18 HANDLES

19 PLASTIC PIN

20 CHARGING CONNECTOR NUTS

21 TOP COVER LOCKING SCREW 22 SOCKET SCREW

23 BMS MOUNTING BRACKET

24 SWITCH

25 SWITCH SEALING

26 BATTERY LEVEL INDICATOR LENS PCB 27 BATTERY LEVEL INDICATOR LENS PCB MOUNTING SCREW

28 THERMAL INSULATION STRIP

30 3 PIN SOCKET

31 USB PORT

32 POSITIVE TERMINAL CONDUCTING CABLE 33 NEGATIVE TERMINAL CONDUCTING CABLE

34 DATA COMMUNICATION CABLE (CAN) OF SOCKET 34A DATA COMMUNICATION CABLE (CAN) OF SOCKET CONNECTOR

35 CHARGING CABLE OF SOCKET

35A CHARGING CABLE OF SOCKET CONNECTOR

36 POWERING CABLE OF SOCKET 36A POWERING CABLE OF SOCKET CONNECTOR

37 SERIES CONNECTION CABLE

38 SOCKET

39 BATTERY LEVEL INDICATOR

40 MONOLITHIC BATTERY 100 BATTERY PACK ASSEMBLY

DETAILED DESCRIPTION

Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.

Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an”, and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including”, and “having”, are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

When an element is referred to as being “mounted on”, “engaged to”, “connected to”, or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.

The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region or section from another component, region, or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.

Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper”, and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.

Typically, a conventional battery pack for the electric bike is a lithium-ion battery pack, which is fragile in nature and hence, requires a protective frame to conduct a safe operation. However, the protective frames of the conventional battery packs have a relatively poor quality and safety standards. Further, these battery packs do not have a standard size, making it further difficult to produce standard protective components. As a result, the battery packs is prone to poor thermal management and potential hazards.

Further, the conventional battery packs are potting with epoxy resins. When the battery pack is subjected to accidental fall or shock load, the internal connections between the batteries may get disturbed, and the complete battery packs may become useless.

The present disclosure envisages a battery pack assembly having a plurality of cells 1 enclosed in a casing 13 and a socket connector 16 attached thereon. The socket connector 16 is configured on the operative top surface of casing 13 to enable external devices that need power. The present disclosure is hereinafter described with reference to Figures 1-28. The battery pack assembly 100 as disclosed in the present disclosure is used in electric vehicle; however the battery pack assembly 100 can be used in supplying power to any of the Four- wheeled vehicles, and in heavy commercial vehicles, as well as for household application.

An embodiment of a battery pack assembly 100, of the present disclosure, of an electric bike, will now be described with reference to Figure 1 through Figure 8. The preferred embodiment does not limit the scope and ambit of the present disclosure.

The battery pack assembly 100 comprises a plurality of lithium ion cells 1, a cage defining a first tray 3a and a second tray 3b having a plurality of holders therein, a strip arrangement defined by a plurality of strips 4, 4a and 4b, a frame splits in to a first half frame 5a and a second half frame 5b, a battery management system (BMS) 9, and a pair of conducting cables 32, 33. The Figure 1 illustrates an isometric view of the cell having an operative positive terminal at one end and an operative negative terminal at other end of the cell 1. The Figure 2 illustrates an isometric view of an array of cell holders 2 to receive the operative end of the cell 1 therein. The Figure 3 illustrates an isometric view of the cage like structure defined by the plurality of the cell holders 2 of Figure 2 arranged in 2-dimensional array.

The Figure 4 illustrates an isometric view of the first tray, of Figure 3, having the operative terminals of the cells 1, of Figure 1, disposed on the cell holder 2 of Figure 2. The Figure 5A and Figure 5B illustrates an isometric view of the first tray 3a and the second tray 3b disposed on the operative terminals of the plurality of the cells 1 , of the Figure 4. Each of the first tray 3a and the second tray 3b has the plurality of cell holder 2 interlocked with each other, and having a plurality of openings configured thereon to form the cage like structure. Each opening of the cell holder 2 is configured to receive the cell 1 therein which is first snap- fitted with the cell holder 2. The first tray 3a and the second tray 3b have the plurality of cells 1 uniformly sandwiched therebetween. The positive terminals and negative terminals of the plurality of the cells are exposed and interlinked on either face of the first tray 3a and the second tray 3b as shown in Figure 6 and Figure 7.

Further the strips 4, 4a and 4b are attached on each of the battery terminal by spot-welding the strips 4, 4a and 4b on the cells terminal. The strips 4, 4a and 4b are configured to ensure electric connection between the cells 1 by forming positive and negative terminals at each operative end of the connecting strip 4, 4a and 4b. The Figure 6 illustrates an isometric view of strip arrangement; the strips 4, 4a and 4b are secured to the terminals of the cells 1 disposed on the second tray 3b of Figure 5A. The Figure 7 illustrates an isometric view of the strip arrangement; the strips 4, 4a and 4b are secured to the terminals of the cells 1 disposed on the first tray 3a of Figure 4 or Figure 5B. The strips 4, 4a and 4b are secured to the like terminals of the plurality of the cells where each face of the cage with the attached plurality of the strips 4, 4a and 4b forms a monolithic battery 40. The Figure 7 illustrates an isometric view of the monolithic battery 40.

In an embodiment, the cell connecting strips 4, 4a and 4b form a parallel electric connection between each other. The pair of conducting cables 32, 33 are soldered to both positive and negative terminals of each cell connecting strips 4, 4a and 4b, and then electrically connected to each other to form a series electric connection between the strips 4, 4a and 4b. In another embodiment, the strips 4, 4a and 4b are metallic strips, configured to provide electrical connection between the terminals of the plurality of the cells 1. In an embodiment, the strip arrangement is forming a rhombic-interlinked structure.

In an embodiment, the cell connecting strips 4, 4a and 4b are of steel. In another embodiment, the cell connecting strips 4 are of nickel. In an embodiment, the first tray 3a and the second tray 3b are of polymer.

In another embodiment, the first tray 3a and the second tray 3b includes at least ten cell connecting strips 4, 4a and 4b.

In one embodiment, the first tray 3a and the second tray 3b are configured to hold 120 cells 1 in a rectangular pattern, therein. In one embodiment, for a given dimension of the casing 13, the number of cells 1 could be varied in the battery pack assembly.

In an exemplary embodiment, the monolithic battery 40 configured with 144 cells in the battery pack assembly.

The first half frame 5a and the second half frame 5b configured with a mounting bracket on each operative edges of the first half frame 5a and the second half frame 5b. The frame consists of an insulating frame element for sandwiching the monolithic battery 40. The first half frame 5a and the second half frame 5b are attached to the monolithic battery 40 with the help of fasteners 6, 7, 8 screwed on the mounting bracket. The Figure 8 illustrates an isometric view of the monolithic battery 40 having the frame attached thereon. In an embodiment, the first half frame 5a and the second half frame 5b provides strength and rigidity to the monolithic battery 40.

The battery management system (BMS) 9 is provided with a circuit board having a picture circuit board (PCB) therein. The PCB is configured with plurality of electronic elements such as sensors, capacitors, DC convertor or transformer to control the output current or voltage. Moreover, the BMS 9 is also configured to charge the monolithic battery 40 to a predetermined number of cycles. Also, the PCB of the BMS 9 is provided with a common area network (CAN) based communication system.

In one embodiment, the BMS is provided with a battery level indicator PCB 26. The battery level indicator PCB 26 is configured with a switch provided on the top housing 15. By pressing the switch, a plurality of LED’s provided on the top housing configured to light up to indicate the charging status of the battery pack assembly 100.

Advantageously, the CAN based communication allows access for the real-time monitoring of the temperature, the voltage and the current of the battery pack assembly 100 remotely.

Further, the battery management system (BMS) 9 is attached on the top of the frame by means of the BMS mounting screw 23. The pair of conducting cables 32, 33 is separately connected to the positive terminal and the negative terminal of the monolithic battery 40. The conducting cables 32, 33 are configured to communicate with the battery management system (BMS) 9. The output from the BMS 98 is supplied to a socket 38 operatively mounted on top housing 15 of casing 13. The socket 38 is configured to receive the socket connector 16 so as to facilitate powering of external device that needs power. The socket 38 is screwed to the top housing 15 by means of a pair of socket screw 23. Also, the BMS 9 is configured to continuously monitor the health of the cells 1, report if any discrepancies are observed, and balance the output voltage or current generated in case any cell dies.

The Figure 9 and Figure 10 illustrate an isometric view of wires soldered to the monolithic battery 40 of Figure 9. The Figure 11 illustrates an isometric view of the battery management system 9 attached to the monolithic battery 40 of Figures 9 and 10. The monolithic battery 40 having the BMS attached on the frame forms the battery pack assembly 100.

In an embodiment, the BMS 9 is configured to cut-off the power supply if the output current rises beyond 50A or falls below 28A. In another embodiment, the battery management system 9 is configured to cut-off the power supply to limit the battery temperature in a range from -2°C to 75°C.

Further, the battery pack assembly 100 is enclosed in casing 13. The casing 13 is defined by sidewalls, and the top housing 15 and a bottom cover 11 is attached to the side walls with the help of fasteners. A gasket 12 is disposed between the top housing 15 and edges of the side walls, and between the edges of the side walls and bottom cover 11. In an embodiment, air vents are configured on a pair of lateral opposite faces of the casing 13. The socket connector 16, which includes a 3-lid plug, is configured to be received in the socket 38 attached to the top housing 15. The 3 -lid socket connector 16 is configured with a charging cable 35a, a powering cable 36a, and a data communication cable 34a. Also, the socket 38 is configured with a data communication cable 34, a charging cable 35, and a powering cable 36. The Figure 12 illustrates an isometric view of the bottom cover of the casing 13. The Figure 13 illustrates an isometric view of the gasket with the bottom cover of Figure 12; The Figure 14 illustrates an isometric view of the casing 13 of the battery pack assembly 100. The Figure 15 illustrates an isometric view of the bottom cover of Figure 13 attached to the casing 13 of figure 14. The Figure 16 illustrates an isometric view of the monolithic battery 40 sliding inside the casing 13 of Figure 15. The Figure 17 illustrates an isometric view of the monolithic battery 40 and the casing 13. The Figure 18 illustrates an isometric view of the top housing 15 of the casing 13. The Figure 19 illustrates an isometric view of the top housing 15 with the socket connector 16 assembly fitted thereon.

In an embodiment, the data communication cable 34a is configured to communicate real-time data’s from the battery assembly to a common area network (CAN) by means of different sensors attached to the BMS.

In an embodiment, the socket connector 16 is configured to facilitate electronic communication of the prime mover of the bike with the battery pack assembly 100.

In one embodiment, the casing 13 is of aluminum. In an embodiment, the battery pack assembly 100, of the present disclosure, can be used for a pedal assisted on-road legal electric 2 wheeler.

In one embodiment, the socket connector 16 facilitates charging of the plurality of the cells 1 of the battery pack assembly 100. While charging the battery pack assembly 100, the power is supplied from an external source through the charging cable 35a in to the BMS 9. The BMS 9 supplies the power to the plurality of strips by means of a plurality of series connection cable 37 attached on the strips 4, 4a and 4b on either side of the monolithic battery 40.

Further, the casing 13 is configured to be a portable casing, and hence includes a handle 18 that can be unfolded to assist in carrying the battery pack assembly 100, is attached to the casing 13 with the help of plastic pin 19. In an embodiment, an aperture is configured on the opposite lateral walls, in which an O-ring 17 is inserted. The O-ring 17and the aperture receive the handle 18 which is then fastened with the help of the plastic pin 19. The Figure 20 illustrates an isometric view of the top housing 15 with the socket connector 16 assembly and the O-ring 17 fitted thereon. The Figure 21 illustrates an isometric view of the top housing 16 having the handle 18 fitted thereon. The Figure 22 illustrates an isometric view of the top housing 15 having the handle 18 fitted thereon with pins 19. The Figure 23 illustrates an isometric view of the top housing 15 having the gasket. The Figure 24 illustrates an isometric view of the battery pack assembly 100, in accordance with an embodiment of the present disclosure.

Furthermore, the casing is provided with a defined gap between the casing and the monolithic battery package. A plurality of the thermal insulation strips 28 are provided between the casing 13 and the monolithic battery 40 package.

Advantageously, the defined gap between the casing and the monolithic battery package prevents a user from electric shock and the thermal insulation strips helps in thermal management of the battery pack assembly. Also, since the battery pack assembly is un-potted, therefore the cells can be easily recycled or repaired.

The Figure 25 illustrates an exploded view of the battery pack assembly 100 with the monolithic battery 40. The Figure 26 illustrates an exploded view of the battery pack assembly 100 of Figure 24. The Figure 27 illustrates an isometric view and the front view of the casing 13 having battery pack assembly 100 and provided with a pair of USB ports 31 and a three pin socket 30 attached thereon. The Figure 28 illustrates a side view and a front view of the battery pack assembly 100 with attached socket connector 16 therein.

Advantageously, since the battery pack assembly is provided with the USB port and the three pin socket attachment, therefore the battery pack assembly can be used as a power-bank. The present disclosure also envisages a method for assembly a battery pack assembly 100. The method comprises the following steps:

• assembling a plurality of lithium ion battery cells 1 on the first tray 3a;

• attaching the second tray 3b on the plurality of the assembled cells 1 ;

• spot-welding cell connecting strips 4, 4a and 4b on both ends of each of the plurality of the cells 1 to form the monolithic battery 40 having the positive and negative terminals thereof;

• soldering conducting cables on either terminals of each cell 1 connecting strip 4, 4a and 4b;

• fastening the first half frame 5a and the second half frame 5b on the monolithic battery 40;

• attaching the battery management system (BMS) 9 on top surface of the monolithic battery 40 having the first half frame 5a and the second half frame 5b thereon;

• connecting the connecting cables to the BMS 9;

• attaching the gasket 12 to an operative bottom portion of a casing 13;

• attaching the bottom cover 11 to the operative bottom portion of the casing 13;

• inserting the monolithic battery 40 having the attached BMS 9 in the casing 13;

• attaching the gasket 12 to an operative top portion of the casing 13;

• attaching the top housing 15 to the operative top portion of the casing 13;

• fitting the socket connector 16 on an operative top surface of the top housing 15; and

• attaching the handle 18 to the top housing 15.

In an embodiment, the potential difference of the battery pack assembly 100 is in the range from 40 volts to 60 volts.

In another embodiment, the dimension of the casing 13 is 231 mm* 101 mm* 349 mm.

Advantageously, the frame is damp-proof; therefore, the frame can absorb random vibrations and shock loads.

Furthermore, the battery pack assembly 100 is provided with the attached BMS 9; therefore, the same battery pack assembly 100 can be used as an inverter.

The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a battery pack assembly, that:

• provides easy recycling or repairing of the cell, since the battery pack assembly is un potted which can be dismantle easily;

• provides damp-proof frame construction; therefore, the frame can absorb random vibrations and shock loads;

• provides a robust and lightweight configuration;

• offers relatively better thermal management of the battery pack assembly;

• provides real-time monitoring of the health status of the battery pack assembly, since the battery pack assembly is provided with the BMS attachment configured with the CAN communication;

• has a compact configuration;

• provides easy installation;

• provides easy charging of the battery pack assembly;

• provides protection against short circuit and electrical shock, and

• the battery pack assembly can be used as an inverter, since the battery pack assembly is provided with the attached BMS.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

Any discussion of devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation

Claims

CLAIMS:

1. A battery pack assembly, said assembly (100) having a plurality of cells (1) enclosed in a casing (13) and a socket connector () mounted on an operative top surface of the casing (13) to facilitate powering of external device that needs power, said assembly comprising:

• a cage defining a first tray (3a) and a second tray (3b) having a plurality of holders (2) therein, said first tray (3a) and said second tray (3b) having the plurality of cells (1) uniformly sandwiched therebetween, such that the positive terminals and the negative terminals of the plurality of the cells (1) are exposed and interlinked on either face of said first tray (3a) and said second tray (3b);

• a strip arrangement defined by a plurality of strips (4), (4a) and (4b), said strips (4), (4a) and (4b) secured to the like terminals of the plurality of the cells (1), each face of said cage with attached said plurality of the strips (4), (4a) and (4b) forms a monolithic battery (40);

• a frame comprising insulating frame element for sandwiching said monolithic battery (40), said frame configured with a first half frame (5a) and a second half frame (5b);

• a battery management system (9) mounted on an operative top of said frame (5), said battery management system (9) configured to selectively charge and discharge said monolithic battery (40) to a predetermined number of cycles; and

• a pair of conducting cables (32, 33) separately connected to the positive terminal and the negative terminal of said monolithic battery (40), said conducting cables (32, 33) configured to be in communication with said battery management system (BMS) (9).

2. The assembly (100) as claimed in claim 1, wherein said strip arrangement is a rhombic-interlinked structure.

3. The assembly (100) as claimed in claim 1, wherein said battery management system (9) configured to control the output voltage.

4. The assembly (100) as claimed in claim 1, wherein said battery management system (9) configured to limit the output current in a range from 28 amperes to 50 amperes.

5. The assembly (100) as claimed in claim 1, wherein said battery management system

(9) configured to cut-off the power supply to limit the output current.

6. The assembly (100) as claimed in claim 3, wherein said battery management system (9) configured to cut-off the power supply to limit the battery temperature in a range from -2°C to 75°C.

7. The assembly (100) as claimed in claim 1, wherein said battery management system (9) configured to monitor the health of the plurality of the cells encased in said battery assembly (100).

8. The assembly (100) as claimed in claim 1, wherein said battery management system (9) configured to charge said monolithic battery (10) by means of an external electric source.

9. The assembly (100) as claimed in claim 1, wherein the socket connector (16) is configured to be received in a socket (38) attached to said BMS (9), the socket connector (16) configured with a charging cable (35a), a powering cable (36a) and a data communication cable (34a).

10. The assembly (100) as claimed in claim 1, wherein said data communication cable (34a) configured to communicate real-time data’s from said battery assembly (100) to common area network (CAN) by means of different sensors attached to said BMS (9).

11. The assembly (100) as claimed in claim 1, wherein each of said strips (4), (4a) and (4b) are metallic plates, configured to conduct the electric charge.

12. The assembly (100) as claimed in claim 1, wherein said half frame (5a) and said second half frame (5b) configured with a mounting bracket configured on each operative edges of said first half frame (5a) and said second half frame (5b).

13. The assembly (100) as claimed in claim 1, wherein said battery pack assembly is configured as a power-bank.

14. The assembly (100) as claimed in claim 1, wherein said casing (13) configured to be a portable casing provided with a handle (18) thereon.