WO2022201205A1 - Spot welding less modular battery pack assembly system - Google Patents

Spot welding less modular battery pack assembly system Download PDF

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Publication number
WO2022201205A1
WO2022201205A1 PCT/IN2022/050304 IN2022050304W WO2022201205A1 WO 2022201205 A1 WO2022201205 A1 WO 2022201205A1 IN 2022050304 W IN2022050304 W IN 2022050304W WO 2022201205 A1 WO2022201205 A1 WO 2022201205A1
Authority
WO
WIPO (PCT)
Prior art keywords
pcb
closure
assembly system
connector
battery assembly
Prior art date
Application number
PCT/IN2022/050304
Other languages
French (fr)
Inventor
Praveen Bhaskar Reddi
Sourya Pradeep Taduthuri
Giridhar Potnuru
Original Assignee
Praveen Bhaskar Reddi
Sourya Pradeep Taduthuri
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Praveen Bhaskar Reddi, Sourya Pradeep Taduthuri filed Critical Praveen Bhaskar Reddi
Publication of WO2022201205A1 publication Critical patent/WO2022201205A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/482—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for several batteries or cells simultaneously or sequentially
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/258—Modular batteries; Casings provided with means for assembling
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/284—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with incorporated circuit boards, e.g. printed circuit boards [PCB]
    • H01M50/287—Fixing of circuit boards to lids or covers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/291—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by their shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/298—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the wiring of battery packs
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/507—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/509—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the type of connection, e.g. mixed connections
    • H01M50/51—Connection only in series
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/509—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the type of connection, e.g. mixed connections
    • H01M50/512—Connection only in parallel
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4271—Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing

Definitions

  • the present disclosure generally relates to battery assembly system, and more particularly, to spot-welding-less modular battery assembly system.
  • a battery pack assembly system for holding a plurality of battery via by pressure mechanism is provided.
  • a battery assembly system in one aspect of the present disclosure, includes a top connector.
  • the top connector includes a first top closure, a first Printed Circuit Board (PCB), and a first bottom closure, the first PCB is fixedly assembled between the first top closure and the first bottom closure to provide electrical connection for one or more positive terminals of one or more batteries, and one or more negative terminals of the one or more batteries.
  • the system further includes a holder tray that is configured to fixedly hold the one or more batteries.
  • the holder tray further provide assembly to the one or more batteries that are arranged in series or parallel arrangement such that first row and last row accepts same and opposite polarities of the one or more batteries, respectively.
  • the battery assembly system further includes a bottom connector that includes a second top closure, a second PCB, and a second bottom closure.
  • the bottom connector further includes the second PCB that is fixedly assembled between the second top closure and the and the second bottom closure to provide electrical connection.
  • the first PCB includes a negative busbar terminal and a positive busbar terminal in that the negative busbar terminal provides a common negative terminal, one or more negative terminals, one or more positive terminals for the one or more negative terminals and the positive busbar terminal provides a common positive terminal for the one or more positive terminals.
  • the first PCB and the second PCB further includes first set of circular projections and second set of circular projections, respectively in that that the first set of circular projections and second set of circular projections is soldered or preset metal piece is utilized.
  • a first connector and a second connector is disclosing in that the first connector and the second connector are coupled with the positive busbar terminal and the negative busbar terminal, respectively, and configured to provide the common positive terminal and the common negative terminal, respectively.
  • processing circuitry that is coupled to the top connector, the holder tray, and the bottom connector, and configured to monitor one or more parameters associated with each battery of the one or more batteries.
  • the one or more parameters of the processing circuitry are configured to detect health of each battery of the one or more batteries, and detect the damaged battery.
  • the first top closure and the second bottom closure comprises set of top through holes and set of bottom through holes, respectively, in that set of top through holes and set of bottom through holes are adapted to receive wirings associated with the processing circuitry to provide electrical connections.
  • first set of fasteners that are configured to fixedly hold the top connector, the holder tray, and the bottom connector in an assembled configuration of the battery assembly system.
  • second set of fasteners configured to fixedly hold the first top closure, the first bottom closure, and the first PCB through second set of fasteners cavity to enclose the first top closure, the first PCB, the first bottom closure.
  • third set of fasteners configured to fixedly hold the second top closure, the second bottom closure, and second the PCB through third set of fasteners cavity to enclose the second top closure, the second PCB, the second bottom closure.
  • the first bottom closure and the second top closure includes first set of circular grooves and second set of circular grooves respectively, to accept the one or more batteries.
  • the first top closure and the second bottom closure further includes a first rectangular cavity and a fourth rectangular cavity, respectively, wherein the first rectangular cavity and the fourth rectangular cavity are configured to accept the first PCB and the second PCB, respectively, in the assembled configuration of top connector and the bottom connector, respectively.
  • FIG. 1 A illustrates a perspective view of a battery assembly system, in accordance with an aspect herein;
  • FIG. IB illustrates an exploded view of the battery assembly system, in accordance with an aspect herein;
  • FIG. 2 illustrates top view of a first top closure of the battery assembly system, in accordance with an aspect herein;
  • FIG. 3 illustrates bottom view of a bottom closure of the battery assembly system, in accordance with an aspect herein;
  • FIG. 4 illustrates a perspective view of a first printed circuit board (PCB), respectively, in accordance with an aspect herein;
  • FIG. 5 illustrates a perspective view of a holder tray of the battery assembly system, in accordance with an aspect herein;
  • FIG. 6 illustrates top view of a second bottom closure of the battery assembly system, in accordance with an aspect herein;
  • FIG. 7 illustrates bottom view of a second bottom closure of the battery assembly system, in accordance with an aspect herein; and FIG. 8 illustrates a perspective view of a second PCB of the battery assembly system, in accordance with an aspect herein.
  • FIG. 1A illustrates a perspective view of a battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
  • the battery assembly system 100 may include a top connector 102, a holder tray 104, a bottom connector 106, and processing circuitry 108.
  • the battery assembly system 100 may be configured to provide detachable and flexible lithium-ion battery unit/array that can combine batteries without spot welding.
  • the top connector 102 may be shown in rectangular shape and is not limited to any particular dimensions or shape. Further, the top connector 102 may be shown in rectangular shape and is not limited to any particular dimensions or shape.
  • the top connector 102 may be assembled to provide upper support to one or more batteries 110 that may be assembled in the battery assembly system 100.
  • the holder tray 104 may provide cavities to the one or more batteries 110.
  • the holder tray 104 may be shown in rectangular shape and is not limited to any particular dimensions or shape.
  • the bottom connector 106 may be assembled to provide lower support to the one or more batteries 110 that may be assembled in the battery assembly system 100. Further, the bottom connector 106 may be shown in rectangular shape and is not limited to any particular dimensions or shape.
  • the top connector 102 may be coupled with the holder tray 104 and the bottom connector 106 to enclose the one or more batteries 110.
  • the one or more batteries 110 may be read in a row-column arrangement, where each row-column may include arrangement of the one or more batteries in series or parallel arrangement. It will be apparent to the person skilled in the art that the number and arrangement of batteries constituting the assembled battery are not particularly limited. It does not matter if they are not arranged in one row but may be arranged in a plurality of rows. The number and arrangement of the assembled batteries constituting the assembled battery assembly are not particularly limited.
  • cell battery cell
  • battery cell battery cell
  • battery cell battery cell
  • battery cell battery cell
  • battery cell battery cell
  • prismatic lithium-ion type batteries are predominantly referred to herein, other types of batteries may be utilized without departing from the spirit and scope of the invention.
  • the processing circuitry 108 may be coupled to the top connector 102, the holder tray 104, and the bottom connector 106, and configured to monitor one or more parameters 108-2 that may be associated with each battery of the one or more batteries 110.
  • the processing circuitry 108 may be shown in rectangular shape and is not limited to any particular dimensions or shape.
  • FIG. IB illustrates an exploded view of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
  • the battery assembly system 100 may further include first set of fasteners 112.
  • the first set of fasteners 112 may be assembled in the top connector 102, the holder tray 104, and the bottom connector 106 to enclose the top connector 102, the holder tray 104, the bottom connector 106, and the one or more batteries 110. It will be apparent to a person skilled in art that the first set of fasteners 112 may include any material to tighten the top connector 102, the bottom connector 106, and the holder tray 104. Alternatively, other types of fasteners to assemble the one or more batteries 110 between the top connector 102 and the bottom connector 106 may be utilized that includes, but are not limited to nuts & bolts, rivets, shoulder bolts, hex head bolts, square head bolts, and the like without departing from the spirit and scope of the invention.
  • the top connector 102 may include a first top closure 114, a first Printed Circuit Board (PCB) 116, a first bottom closure 118, and the second set of fasteners 120.
  • PCB Printed Circuit Board
  • the first PCB 116 may be assembled between the first top closure 114 and the first bottom closure 118.
  • the second set of fasteners 120 may be assembled in the first top closure 114, the first PCB 116, and the first bottom closure 118 to enclose the first top closure 114, the first PCB 116 and the first bottom closure 118. It will be apparent to a person skilled in art that the second set of fasteners 120 may include any material to tighten the first top closure 114, the first PCB 116, and the first bottom closure 118.
  • the bottom connector 106 may include a second top closure 122, a second Printed Circuit Board (PCB) 124, a second bottom closure 126, and the third set of fasteners 128.
  • PCB Printed Circuit Board
  • the third set of fasteners 128 may be assembled in the second top closure 122, the second PCB 124, and the second bottom closure 126 to enclose the second top closure 122, the second PCB 124 and the second bottom closure 126. It will be apparent to a person skilled in art that the third set of fasteners 128 may include any material to tighten the second top closure 120, the second PCB 122, and the second bottom closure 124. Alternatively, other types of fasteners to enclose the second top closure 122, the second PCB 124, and the second bottom closure 126 may be utilized that includes, but are not limited to deck screws, hex leg screws, self-drilling screws, and the like without departing from the spirit and scope of the invention.
  • the holder tray 104 may be configured to fixedly hold the one or more batteries 110.
  • FIG. 2 illustrates top view of the first top closure 114 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
  • the first top closure 114 may include a positive busbar terminal 202, a negative busbar terminal 204, set of top through holes 206, first rectangular cavity 208, first set of fasteners cavity 210, and second set of fasteners cavity 212.
  • the second set of fasteners 120 may be assembled in the first top closure 114 and the first bottom closure 118 through the second set of fasteners cavity 212 to enclose the first rectangular cavity 208, the first top closure 114, and the first bottom closure 118.
  • the first set of top through holes 206 may be coupled to the first top closure 114.
  • the first set of top through holes 206 may be adapted to receive wirings associated with the processing circuitry 108 to provide electrical connections.
  • FIG. 3 illustrates bottom view of the first bottom closure 118 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
  • the first bottom closure 118 may include first set of circular grooves 302 and second rectangular cavity 304.
  • the first set of circular grooves 302 may be coupled in the first bottom closure 118.
  • the first set of circular grooves 302 may be configured to fixedly hold the one or more batteries 110.
  • the second rectangular cavity 304 may be configured to attach the processing circuitry 108. It will be apparent to a person skilled in the art that the shapes and dimensions of the second rectangular cavity 304 is not limited to the rectangular shape and other types of shapes may be utilized depending upon the shapes and dimensions of the processing circuitry 108 without departing from the spirit and scope of the invention.
  • FIG. 4 illustrates a perspective view of the first printed circuit board (PCB) 116, in accordance with an exemplary aspect of the present disclosure.
  • the first PCB 116 may include first set of conducting paths 402, a first set of circular projections 404, first connector 406, second connector 409, and fuses 410.
  • the first PCB 112 may further include the first set of fasteners cavity 210 and the second set of fasteners cavity 212.
  • the first PCB 116 may be fixedly assembled to the first rectangular cavity 208. It will be apparent to a person skilled in art that the dimensions and shapes of the first PCB 116 is shown in rectangular shape and is not limited to any particular dimensions or shapes. Accordingly, the shape and dimensions of the first rectangular cavity 208 may vary in the similar manner without departing from the spirit and scope of the invention. In an example, the first PCB 116 may be a double layer PCB, a multi-layer PCB, high frequency PCB, and the like.
  • the first set of conducting paths 402 may be fixedly assembled in the first PCB 116 in a row- column matrix arrangement.
  • the first set of circular projections 404 may be fixedly attached with the first set of conducting paths 402.
  • the first set of circular projections 404 may provide electrical connection to the one or more batteries 110.
  • the first set of circular projections 404 may be soldered.
  • a preset metal piece may be provided to the first set of circular projections 404.
  • the shape of the first set of circular projections 404 is shown in a circular shape and is not limited to any particular shape. Accordingly, the shape of the conducting paths 402 is shown in a cylindrical shape and may be further utilized in any particular shape without departing from the spirit and scope of the invention.
  • the positive busbar terminal 202 provides a common positive terminal 202-2 for the one or more positive terminals 202-6.
  • the negative busbar terminal 204 provides a common negative terminal 204-2 for the one or more negative terminals 204-6.
  • the first connector 406 and the second connector 408 may be further fixedly coupled to the first PCB 116.
  • the first connector 406 may be coupled to the positive busbar terminal 202.
  • the second connector 408 may be coupled to the negative busbar terminal 204.
  • the first connector 406 may be coupled to the first row of the first set of conducting paths 402 and the positive busbar terminal 202 to provide the positive charge of the one or more batteries 110.
  • FIG. 5 illustrates a perspective view of the holder tray 104 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
  • the holder tray 104 may include third rectangular cavity 502.
  • the third rectangular cavity 502 may be coupled in the holder tray 104 to assemble the processing circuitry 108. It will be apparent to a person skilled in art that the holder tray 104 is shown in the rectangular shape and is not limited to the any particular shapes and dimensions.
  • the one or more batteries 110 may be assembled and enclosed in the holder tray 104 in a row-column matrix.
  • FIG. 6 illustrates top view of the second top closure 122 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
  • the second top closure 122 may include fourth rectangular cavity 604, third set of fasteners 606, the third set of fasteners cavity 608, fifth rectangular cavity 610, and second set of circular grooves 612.
  • the second top closure 122 further includes first set of fasteners cavity 210.
  • the third set of fasteners 606 may be assembled in the second top closure 122 and the second bottom closure 124 through the third set of fasteners 606 to enclose the fourth rectangular cavity 604, the second top closure 122, and the second bottom closure 124.
  • the fourth rectangular cavity 604 may be provided to assemble the second PCB 124.
  • the shape fifth rectangular cavity 610 may be configured to assemble the processing circuitry 108.
  • the second set of circular grooves 612 may be configured to assemble the one or more batteries 110.
  • FIG. 7 illustrates bottom view of the second bottom closure 126 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
  • the second bottom closure 126 may include set of bottom through holes 702.
  • the set of bottom through holes 702 may be adapted to receive wirings associated with the processing circuitry 108 to provide electrical connections
  • the first set of circular grooves 302 may be coupled in the first bottom closure 118.
  • the first set of circular grooves 302 may be configured to fixedly hold the one or more batteries 110.
  • the second rectangular cavity 304 may be configured to attach the processing circuitry 108. It will be apparent to a person skilled in the art that the shapes and dimensions of the second rectangular cavity 304 is not limited to the rectangular shape and other types of shapes may be utilized depending upon the shapes and dimensions of the processing circuitry 108 without departing from the spirit and scope of the invention.
  • the first set of top through holes 206 may be coupled to the first top closure 114.
  • the first set of top through holes 206 may provide casing for wires associated with the processing circuitry 108 and the first PCB 116.
  • FIG. 8 illustrates a perspective view of the second printed circuit board (PCB) 124, in accordance with an exemplary aspect of the present disclosure.
  • the second PCB 124 may include second set of conducting paths 802 and second set of circular projections 804.
  • the second PCB 124 may further include the first set of fasteners cavity 210.
  • the second PCB 124 may be fixedly assembled to the first rectangular cavity 208. It will be apparent to a person skilled in art that the dimensions and shapes of the second PCB 124 is shown in rectangular shape and is not limited to any particular dimensions or shapes. Accordingly, the shape and dimensions of the fourth rectangular cavity 604 may vary in the similar manner without departing from the spirit and scope of the invention.
  • the second PCB 124 may be a double layer PCB, a multi layer PCB, high frequency PCB, and the like.
  • the second set of conducting paths 802 may be fixedly assembled in second PCB 124 in a row- column matrix arrangement.
  • the second set of circular projections 804 may be fixedly attached with the second set of conducting paths 802.
  • the second set of circular projections 804 may provide electrical connection to the one or more batteries 110.
  • the second set of circular projections 404 may be soldered.
  • a preset metal piece may be provided to the first set of circular projections 804.
  • the shape of the first set of circular projections 804 is shown in a circular shape and is not limited to any particular shape. Accordingly, the shape of the conducting paths 802 is shown in a cylindrical shape and may be further utilized in any particular shape without departing from the spirit and scope of the invention.
  • the second set of conducting paths 802 may be fixedly assembled in the second PCB 124 in a row- column matrix arrangement.
  • the second set of circular projections 804 may be fixedly attached with the second set of the conducting paths 802.
  • the second set of circular projections 804 may provide electrical connection to the one or more batteries 110.
  • the shape of the second set of circular projections 804 is shown in a circular shape and is not limited to any particular shape. Accordingly, the shape of the second set of conducting paths 802 is shown in a cylindrical shape and may be further utilized in any particular shape without departing from the spirit and scope of the invention.
  • the processing circuitry 108 may be coupled to the top connector 102, the holder tray 104, and the bottom connector 106.
  • the processing circuitry 108 may be further assembled in the second rectangular cavity 304, the third rectangular cavity 502, and the fifth rectangular cavity 610.
  • the processing circuitry 108 may be configured to determine status of each battery of one or more batteries 110 and detect the temperature of each battery of the one or more batteries 110.
  • the processing circuitry may be a Battery Management System (BMS) that may be configured to manage the one or more batteries 110.
  • BMS Battery Management System
  • the processing circuitry 108 may include a processor, electronic device, and the like. Other types of devices may be utilized without departing from the spirit and scope of the invention.
  • the shape of the processing circuitry 108 is shown in rectangular shape.
  • the shape of the processing circuitry 108 is not limited to the rectangular shape and other types of shapes may be utilized without departing from the spirit and scope of the invention. Accordingly, the shape of the second rectangular cavity 304, the third rectangular cavity 502, and the fifth rectangular cavity 610 may vary.
  • the processing circuitry 108 may perform functions that includes, but are not limited to calculate minimum and maximum voltage of each battery of the one or more batteries 110, calculate state of charge to indicate the charging status of the one or more batteries 110, calculate state of health, calculate state of power, calculate state of safety, calculate energy, calculate impedance, calculate operating time, calculate total number of cycles, monitor temperature, and the like. Furthermore, the processing circuitry 108 implements cell modelling techniques of the one or more batteries 110.
  • the battery assembly system 100 includes enhanced mechanical strength on account of less moving components and further provides optimized replacement of individual component of the whole battery assembly. Furthermore, the battery assembly system 100 provides more scalability to multiple shapes and sizes.
  • the present aspect may easily be produced in other specific forms without departing from its essential characteristics. The present aspects are, therefore, to be considered as merely illustrative and not restrictive, the scope being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

SPOT WELDING LESS MODULAR BATTERY PACK ASSEMBLY SYSTEM Disclosed is a battery assembly system (100) that includes a top connector (102) that further includes a first top closure (114), a first Printed Circuit Board (PCB) (116), and a first bottom closure (118). The battery assembly system (100) further includes a 5 holder tray (104), and a bottom connector (106). The battery assembly system (100) provides assembly to one or more batteries (110) in a pressurized mechanism.

Description

SPOT WELDING LESS MODULAR BATTERY ASSEMBLY SYSTEM
FIELD OF INVENTION
The present disclosure generally relates to battery assembly system, and more particularly, to spot-welding-less modular battery assembly system.
BACKGROUND OF THE INVENTION This section is intended only to provide background information pertaining to the similar field of the present invention, and may be used only to enhance the understanding of the present invention and not as admissions of prior art.
There are endless ways for assembling lithium battery packs in the industry, and various assembly methods are used more and more widely in the battery field. The assembly structure in the industry is dominated by spot welding, for example Glue bonding Nickel strip spot welding and internal bracket assembly, nickel strip spot welding. Here, the shape and structure of the battery pack are fixed and difficult to change, resulting in a single battery pack application range. However, the introduction of new products has led to more and more complicated assembly of multiple series and parallel structures. Moreover, the spot-welded battery pack structure is extremely inconvenient in terms of battery maintenance and replacement. The battery contains excessive amounts of heavy metal components which pollute the environment, and the disposal of discarded batteries is also very complicated. If the battery is not handled properly, it will cause serious pollution to the environment. The scaling of battery pack and mechanical strength is an issue. Moreover, there are challenges in battery pack assembly system to fix batteries in different cell sizes, shapes, form factors, and capacities.
In view of the foregoing, there is a need to develop a system to provide a detachable lithium-ion battery unit that can combine batteries without spot welding in response to the deficiencies of the prior. SUMMARY
In the view of foregoing, a battery pack assembly system for holding a plurality of battery via by pressure mechanism is provided.
In one aspect of the present disclosure, a battery assembly system is provided. The battery assembly system includes a top connector. The top connector includes a first top closure, a first Printed Circuit Board (PCB), and a first bottom closure, the first PCB is fixedly assembled between the first top closure and the first bottom closure to provide electrical connection for one or more positive terminals of one or more batteries, and one or more negative terminals of the one or more batteries. The system further includes a holder tray that is configured to fixedly hold the one or more batteries. The holder tray further provide assembly to the one or more batteries that are arranged in series or parallel arrangement such that first row and last row accepts same and opposite polarities of the one or more batteries, respectively. The battery assembly system further includes a bottom connector that includes a second top closure, a second PCB, and a second bottom closure. The bottom connector further includes the second PCB that is fixedly assembled between the second top closure and the and the second bottom closure to provide electrical connection.
In some aspects of the present disclosure, the first PCB includes a negative busbar terminal and a positive busbar terminal in that the negative busbar terminal provides a common negative terminal, one or more negative terminals, one or more positive terminals for the one or more negative terminals and the positive busbar terminal provides a common positive terminal for the one or more positive terminals.
In some aspects of the present disclosure, the first PCB and the second PCB further includes first set of circular projections and second set of circular projections, respectively in that that the first set of circular projections and second set of circular projections is soldered or preset metal piece is utilized. In some aspects of the present disclosure, a first connector and a second connector is disclosing in that the first connector and the second connector are coupled with the positive busbar terminal and the negative busbar terminal, respectively, and configured to provide the common positive terminal and the common negative terminal, respectively.
In some aspects of the present disclosure, processing circuitry that is coupled to the top connector, the holder tray, and the bottom connector, and configured to monitor one or more parameters associated with each battery of the one or more batteries.
In some aspects of the present disclosure, the one or more parameters of the processing circuitry are configured to detect health of each battery of the one or more batteries, and detect the damaged battery.
In some aspects of the present disclosure, the first top closure and the second bottom closure comprises set of top through holes and set of bottom through holes, respectively, in that set of top through holes and set of bottom through holes are adapted to receive wirings associated with the processing circuitry to provide electrical connections.
In some aspects of the present disclosure, first set of fasteners that are configured to fixedly hold the top connector, the holder tray, and the bottom connector in an assembled configuration of the battery assembly system. In some aspects of the present disclosure, second set of fasteners configured to fixedly hold the first top closure, the first bottom closure, and the first PCB through second set of fasteners cavity to enclose the first top closure, the first PCB, the first bottom closure.
In some aspects of the present disclosure, third set of fasteners configured to fixedly hold the second top closure, the second bottom closure, and second the PCB through third set of fasteners cavity to enclose the second top closure, the second PCB, the second bottom closure. In some aspects of the present disclosure, the first bottom closure and the second top closure includes first set of circular grooves and second set of circular grooves respectively, to accept the one or more batteries.
In some aspects of the present disclosure, the first top closure and the second bottom closure further includes a first rectangular cavity and a fourth rectangular cavity, respectively, wherein the first rectangular cavity and the fourth rectangular cavity are configured to accept the first PCB and the second PCB, respectively, in the assembled configuration of top connector and the bottom connector, respectively.
BREIF DESCRIPTION OF THE DRAWINGS Other objects, features, and advantages of the aspect will be apparent from the following description when read with reference to the accompanying drawings. In the drawings, wherein like reference numerals denote corresponding parts throughout the several views:
FIG. 1 A illustrates a perspective view of a battery assembly system, in accordance with an aspect herein;
FIG. IB illustrates an exploded view of the battery assembly system, in accordance with an aspect herein;
FIG. 2 illustrates top view of a first top closure of the battery assembly system, in accordance with an aspect herein; FIG. 3 illustrates bottom view of a bottom closure of the battery assembly system, in accordance with an aspect herein;
FIG. 4 illustrates a perspective view of a first printed circuit board (PCB), respectively, in accordance with an aspect herein;
FIG. 5 illustrates a perspective view of a holder tray of the battery assembly system, in accordance with an aspect herein; FIG. 6 illustrates top view of a second bottom closure of the battery assembly system, in accordance with an aspect herein;
FIG. 7 illustrates bottom view of a second bottom closure of the battery assembly system, in accordance with an aspect herein; and FIG. 8 illustrates a perspective view of a second PCB of the battery assembly system, in accordance with an aspect herein.
DETAILED DESCRIPTION OF THE PREFERRED ASPECTS
The aspects herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting aspects that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the aspects herein. The examples used herein are intended merely to facilitate an understanding of ways in which the aspects herein may be practiced and to further enable those of skill in the art to practice the aspects herein. Accordingly, the examples should not be construed as limiting the scope of the aspects 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.
Throughout the prior arts, there remains a need to develop a system to provide a detachable and flexible lithium-ion battery unit/array that can combine batteries without spot welding in response to the deficiencies of the above-mentioned drawbacks. FIG. 1A illustrates a perspective view of a battery assembly system 100, in accordance with an exemplary aspect of the present disclosure. The battery assembly system 100 The battery assembly system 100 may include a top connector 102, a holder tray 104, a bottom connector 106, and processing circuitry 108.
The battery assembly system 100 may be configured to provide detachable and flexible lithium-ion battery unit/array that can combine batteries without spot welding. The top connector 102 may be shown in rectangular shape and is not limited to any particular dimensions or shape. Further, the top connector 102 may be shown in rectangular shape and is not limited to any particular dimensions or shape.
The top connector 102 may be assembled to provide upper support to one or more batteries 110 that may be assembled in the battery assembly system 100. The holder tray 104 may provide cavities to the one or more batteries 110. The holder tray 104 may be shown in rectangular shape and is not limited to any particular dimensions or shape.
The bottom connector 106 may be assembled to provide lower support to the one or more batteries 110 that may be assembled in the battery assembly system 100. Further, the bottom connector 106 may be shown in rectangular shape and is not limited to any particular dimensions or shape.
The top connector 102 may be coupled with the holder tray 104 and the bottom connector 106 to enclose the one or more batteries 110. In an example, the one or more batteries 110 may be read in a row-column arrangement, where each row-column may include arrangement of the one or more batteries in series or parallel arrangement. It will be apparent to the person skilled in the art that the number and arrangement of batteries constituting the assembled battery are not particularly limited. It does not matter if they are not arranged in one row but may be arranged in a plurality of rows. The number and arrangement of the assembled batteries constituting the assembled battery assembly are not particularly limited. The term “cell”, “battery cell”, “battery”, or “batteries” are used interchangeably in the context and defines electrochemical batteries made of at least one positive electrode, at least one negative electrode, an electrolyte, and a separator membrane. It should further be appreciated that the person skilled in the art, though prismatic lithium-ion type batteries are predominantly referred to herein, other types of batteries may be utilized without departing from the spirit and scope of the invention.
The processing circuitry 108 may be coupled to the top connector 102, the holder tray 104, and the bottom connector 106, and configured to monitor one or more parameters 108-2 that may be associated with each battery of the one or more batteries 110. The processing circuitry 108 may be shown in rectangular shape and is not limited to any particular dimensions or shape.
It will be apparent to a person skilled in art that the shape and size of the battery assembly system 100 is shown in cubical shape and is not limited to any particular shapes and sizes. FIG. IB illustrates an exploded view of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
The battery assembly system 100 may further include first set of fasteners 112.
The first set of fasteners 112 may be assembled in the top connector 102, the holder tray 104, and the bottom connector 106 to enclose the top connector 102, the holder tray 104, the bottom connector 106, and the one or more batteries 110. It will be apparent to a person skilled in art that the first set of fasteners 112 may include any material to tighten the top connector 102, the bottom connector 106, and the holder tray 104. Alternatively, other types of fasteners to assemble the one or more batteries 110 between the top connector 102 and the bottom connector 106 may be utilized that includes, but are not limited to nuts & bolts, rivets, shoulder bolts, hex head bolts, square head bolts, and the like without departing from the spirit and scope of the invention. The top connector 102 may include a first top closure 114, a first Printed Circuit Board (PCB) 116, a first bottom closure 118, and the second set of fasteners 120.
The first PCB 116 may be assembled between the first top closure 114 and the first bottom closure 118. The second set of fasteners 120 may be assembled in the first top closure 114, the first PCB 116, and the first bottom closure 118 to enclose the first top closure 114, the first PCB 116 and the first bottom closure 118. It will be apparent to a person skilled in art that the second set of fasteners 120 may include any material to tighten the first top closure 114, the first PCB 116, and the first bottom closure 118. Alternatively, other types of fasteners to enclose the first top closure 114, the first PCB 116, and the first bottom closure 118 may be utilized that includes, but are not limited to deck screws, hex leg screws, self-drilling screws, and the like without departing from the spirit and scope of the invention. In an aspect, ‘tightening’ or the ‘fastening’ is defined when the battery assembly system 100 are under compression. The bottom connector 106 may include a second top closure 122, a second Printed Circuit Board (PCB) 124, a second bottom closure 126, and the third set of fasteners 128.
The third set of fasteners 128 may be assembled in the second top closure 122, the second PCB 124, and the second bottom closure 126 to enclose the second top closure 122, the second PCB 124 and the second bottom closure 126. It will be apparent to a person skilled in art that the third set of fasteners 128 may include any material to tighten the second top closure 120, the second PCB 122, and the second bottom closure 124. Alternatively, other types of fasteners to enclose the second top closure 122, the second PCB 124, and the second bottom closure 126 may be utilized that includes, but are not limited to deck screws, hex leg screws, self-drilling screws, and the like without departing from the spirit and scope of the invention.
The holder tray 104 may be configured to fixedly hold the one or more batteries 110. FIG. 2 illustrates top view of the first top closure 114 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
The first top closure 114 may include a positive busbar terminal 202, a negative busbar terminal 204, set of top through holes 206, first rectangular cavity 208, first set of fasteners cavity 210, and second set of fasteners cavity 212.
The second set of fasteners 120 may be assembled in the first top closure 114 and the first bottom closure 118 through the second set of fasteners cavity 212 to enclose the first rectangular cavity 208, the first top closure 114, and the first bottom closure 118.
The first set of top through holes 206 may be coupled to the first top closure 114. The first set of top through holes 206 may be adapted to receive wirings associated with the processing circuitry 108 to provide electrical connections.
FIG. 3 illustrates bottom view of the first bottom closure 118 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
The first bottom closure 118 may include first set of circular grooves 302 and second rectangular cavity 304.
The first set of circular grooves 302 may be coupled in the first bottom closure 118. The first set of circular grooves 302 may be configured to fixedly hold the one or more batteries 110.
The second rectangular cavity 304 may be configured to attach the processing circuitry 108. It will be apparent to a person skilled in the art that the shapes and dimensions of the second rectangular cavity 304 is not limited to the rectangular shape and other types of shapes may be utilized depending upon the shapes and dimensions of the processing circuitry 108 without departing from the spirit and scope of the invention.
FIG. 4 illustrates a perspective view of the first printed circuit board (PCB) 116, in accordance with an exemplary aspect of the present disclosure. The first PCB 116 may include first set of conducting paths 402, a first set of circular projections 404, first connector 406, second connector 409, and fuses 410. The first PCB 112 may further include the first set of fasteners cavity 210 and the second set of fasteners cavity 212.
The first PCB 116 may be fixedly assembled to the first rectangular cavity 208. It will be apparent to a person skilled in art that the dimensions and shapes of the first PCB 116 is shown in rectangular shape and is not limited to any particular dimensions or shapes. Accordingly, the shape and dimensions of the first rectangular cavity 208 may vary in the similar manner without departing from the spirit and scope of the invention. In an example, the first PCB 116 may be a double layer PCB, a multi-layer PCB, high frequency PCB, and the like.
The first set of conducting paths 402 may be fixedly assembled in the first PCB 116 in a row- column matrix arrangement. The first set of circular projections 404 may be fixedly attached with the first set of conducting paths 402. In an aspect, the first set of circular projections 404 may provide electrical connection to the one or more batteries 110. The first set of circular projections 404 may be soldered. In an aspect, a preset metal piece may be provided to the first set of circular projections 404.
It will be apparent to a person skilled in art that the shape of the first set of circular projections 404 is shown in a circular shape and is not limited to any particular shape. Accordingly, the shape of the conducting paths 402 is shown in a cylindrical shape and may be further utilized in any particular shape without departing from the spirit and scope of the invention.
The positive busbar terminal 202 provides a common positive terminal 202-2 for the one or more positive terminals 202-6. The negative busbar terminal 204 provides a common negative terminal 204-2 for the one or more negative terminals 204-6.
The first connector 406 and the second connector 408 may be further fixedly coupled to the first PCB 116. The first connector 406 may be coupled to the positive busbar terminal 202. The second connector 408 may be coupled to the negative busbar terminal 204.
In an aspect, the first connector 406 may be coupled to the first row of the first set of conducting paths 402 and the positive busbar terminal 202 to provide the positive charge of the one or more batteries 110.
FIG. 5 illustrates a perspective view of the holder tray 104 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
The holder tray 104 may include third rectangular cavity 502.
The third rectangular cavity 502 may be coupled in the holder tray 104 to assemble the processing circuitry 108. It will be apparent to a person skilled in art that the holder tray 104 is shown in the rectangular shape and is not limited to the any particular shapes and dimensions. The one or more batteries 110 may be assembled and enclosed in the holder tray 104 in a row-column matrix.
FIG. 6 illustrates top view of the second top closure 122 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
The second top closure 122 may include fourth rectangular cavity 604, third set of fasteners 606, the third set of fasteners cavity 608, fifth rectangular cavity 610, and second set of circular grooves 612. The second top closure 122 further includes first set of fasteners cavity 210. The third set of fasteners 606 may be assembled in the second top closure 122 and the second bottom closure 124 through the third set of fasteners 606 to enclose the fourth rectangular cavity 604, the second top closure 122, and the second bottom closure 124. The fourth rectangular cavity 604 may be provided to assemble the second PCB 124.
It will be apparent to a person skilled in art that the shapes and dimensions of the second top closure is not limited to rectangular shape and any type of shapes and dimensions may be used departing from the scope and spirit of the invention. The shape fifth rectangular cavity 610 may be configured to assemble the processing circuitry 108. The second set of circular grooves 612 may be configured to assemble the one or more batteries 110. FIG. 7 illustrates bottom view of the second bottom closure 126 of the battery assembly system 100, in accordance with an exemplary aspect of the present disclosure.
The second bottom closure 126 may include set of bottom through holes 702.
The set of bottom through holes 702 may be adapted to receive wirings associated with the processing circuitry 108 to provide electrical connections The first set of circular grooves 302 may be coupled in the first bottom closure 118. The first set of circular grooves 302 may be configured to fixedly hold the one or more batteries 110.
The second rectangular cavity 304 may be configured to attach the processing circuitry 108. It will be apparent to a person skilled in the art that the shapes and dimensions of the second rectangular cavity 304 is not limited to the rectangular shape and other types of shapes may be utilized depending upon the shapes and dimensions of the processing circuitry 108 without departing from the spirit and scope of the invention.
The first set of top through holes 206 may be coupled to the first top closure 114. The first set of top through holes 206 may provide casing for wires associated with the processing circuitry 108 and the first PCB 116.
FIG. 8 illustrates a perspective view of the second printed circuit board (PCB) 124, in accordance with an exemplary aspect of the present disclosure.
The second PCB 124 may include second set of conducting paths 802 and second set of circular projections 804. The second PCB 124 may further include the first set of fasteners cavity 210. The second PCB 124 may be fixedly assembled to the first rectangular cavity 208. It will be apparent to a person skilled in art that the dimensions and shapes of the second PCB 124 is shown in rectangular shape and is not limited to any particular dimensions or shapes. Accordingly, the shape and dimensions of the fourth rectangular cavity 604 may vary in the similar manner without departing from the spirit and scope of the invention. In an example, the second PCB 124 may be a double layer PCB, a multi layer PCB, high frequency PCB, and the like.
The second set of conducting paths 802 may be fixedly assembled in second PCB 124 in a row- column matrix arrangement. The second set of circular projections 804 may be fixedly attached with the second set of conducting paths 802. In an aspect, the second set of circular projections 804 may provide electrical connection to the one or more batteries 110. The second set of circular projections 404 may be soldered. In an aspect, a preset metal piece may be provided to the first set of circular projections 804.
It will be apparent to a person skilled in art that the shape of the first set of circular projections 804 is shown in a circular shape and is not limited to any particular shape. Accordingly, the shape of the conducting paths 802 is shown in a cylindrical shape and may be further utilized in any particular shape without departing from the spirit and scope of the invention.
The second set of conducting paths 802 may be fixedly assembled in the second PCB 124 in a row- column matrix arrangement. The second set of circular projections 804 may be fixedly attached with the second set of the conducting paths 802. In an aspect, the second set of circular projections 804 may provide electrical connection to the one or more batteries 110. It will be apparent to a person skilled in art that the shape of the second set of circular projections 804 is shown in a circular shape and is not limited to any particular shape. Accordingly, the shape of the second set of conducting paths 802 is shown in a cylindrical shape and may be further utilized in any particular shape without departing from the spirit and scope of the invention. The processing circuitry 108 may be coupled to the top connector 102, the holder tray 104, and the bottom connector 106. The processing circuitry 108 may be further assembled in the second rectangular cavity 304, the third rectangular cavity 502, and the fifth rectangular cavity 610. The processing circuitry 108 may be configured to determine status of each battery of one or more batteries 110 and detect the temperature of each battery of the one or more batteries 110. In an aspect, the processing circuitry may be a Battery Management System (BMS) that may be configured to manage the one or more batteries 110. It will be apparent to a person skilled in art that the processing circuitry 108 may include a processor, electronic device, and the like. Other types of devices may be utilized without departing from the spirit and scope of the invention. In an aspect, the shape of the processing circuitry 108 is shown in rectangular shape. It will be apparent to a person skilled in the art that the shape of the processing circuitry 108 is not limited to the rectangular shape and other types of shapes may be utilized without departing from the spirit and scope of the invention. Accordingly, the shape of the second rectangular cavity 304, the third rectangular cavity 502, and the fifth rectangular cavity 610 may vary.
Additionally, the processing circuitry 108 may perform functions that includes, but are not limited to calculate minimum and maximum voltage of each battery of the one or more batteries 110, calculate state of charge to indicate the charging status of the one or more batteries 110, calculate state of health, calculate state of power, calculate state of safety, calculate energy, calculate impedance, calculate operating time, calculate total number of cycles, monitor temperature, and the like. Furthermore, the processing circuitry 108 implements cell modelling techniques of the one or more batteries 110.
In an aspect, the battery assembly system 100 includes enhanced mechanical strength on account of less moving components and further provides optimized replacement of individual component of the whole battery assembly. Furthermore, the battery assembly system 100 provides more scalability to multiple shapes and sizes. As will be readily apparent to those skilled in the art, the present aspect may easily be produced in other specific forms without departing from its essential characteristics. The present aspects are, therefore, to be considered as merely illustrative and not restrictive, the scope being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.

Claims

WE CLAIM
1. A battery assembly system (100) comprising: a top connector (102) having (i) a first top closure (114), (ii) a first Printed Circuit Board (PCB) (116), and (iii) a first bottom closure (118), wherein the first PCB (114) is fixedly assembled between the first top closure (114) and the first bottom closure (118) to provide electrical connection for one or more positive terminals (202-6) of one or more batteries (110), and one or more negative terminals (204-6) of the one or more batteries (110). a holder tray (104) configured to fixedly hold the one or more batteries (110), wherein the one or more batteries (110) are arranged in series or parallel arrangement such that first row and last row accepts same and opposite polarities of the one or more batteries (110), respectively; and a bottom connector (106) having a second top closure (122), a second PCB (124), and a second bottom closure (126), wherein the second PCB (126) is fixedly assembled between the second top closure (122) and the and the second bottom closure (126) to provide electrical connection.
2. The battery assembly system (100) as claimed in claim 1, wherein the first PCB (116) comprises a negative busbar terminal (204) and a positive busbar terminal (202) such that (i) the negative busbar terminal (204) provides a common negative terminal (204-2) one or more negative terminals (204-6) one or more positive terminals (202-6) for the one or more negative terminals (204-6) and (ii) the positive busbar terminal (202) provides a common positive terminal (202-2) for the one or more positive terminals (202-6).
3. The battery assembly system (100) as claimed in claim 1, wherein the first PCB (116) and the second PCB (124) further comprises first set of circular projections
(404) and second set of circular projections (804), respectively such that the first set of circular projections (404) and second set of circular projections (804) is soldered or preset metal piece is utilized.
4. The battery assembly system (100) as claimed in claim 1, further comprising a first connector (406) and a second connector (408) such that the first connector (406) and the second connector (408) are coupled with the positive busbar terminal (202) and the negative busbar terminal (204), respectively, and configured to provide the common positive terminal (202-2) and the common negative terminal (204-2), respectively.
5. The battery assembly system (100) as claimed in claim 1, further comprising processing circuitry (108) that is coupled to the top connector (102), the holder tray
(104), and the bottom connector (106), and configured to monitor one or more parameters associated with each battery of the one or more batteries (110).
6. The battery assembly system (100) as claimed in claim 6, wherein the one or more parameters (108-2) of the processing circuitry (108) are configured to (i) detect health of each battery of the one or more batteries (100), and (ii) detect the damaged battery.
7. The battery assembly system (100) as claimed in claim 1, wherein the first top closure (114) and the second bottom closure ( 126) comprises set of top through holes (206) and set of bottom through holes (602), respectively, wherein set of top through holes (206) and set of bottom through holes (602) are adapted to receive wirings associated with the processing circuitry (108) to provide electrical connections.
8. The battery assembly system (100) as claimed in claim 1, further comprising first set of fasteners (112) that are configured to fixedly hold the top connector (102), the holder tray (104), and the bottom connector (106) in an assembled configuration of the battery assembly system (100).
9. The battery assembly system (100) as claimed in claim 1, further comprises second set of fasteners (120) configured to fixedly hold the first top closure (114), the first bottom closure (118), and the first PCB (116) through second set of fasteners cavity (210) to enclose the first top closure (114), the first PCB (116), the first bottom closure (118).
10. The battery assembly system (100) as claimed in claim 1, further comprises third set of fasteners (128) configured to fixedly hold the second top closure (122), the second bottom closure (126), and second the PCB (124) through third set of fasteners cavity (608) to enclose the second top closure (122), the second PCB (124), the second bottom closure (126).
11. The battery assembly system (100) as claimed in claim 1, wherein the first bottom closure (118) and the second top closure (122) comprises first set of circular grooves (302) and second set of circular grooves (612) respectively, to accept the one or more batteries (110). 12. The battery assembly system (100) as claimed in claim 1, wherein the first top closure (114) and the second bottom closure (126) further comprises a first rectangular cavity (208) and a fourth rectangular cavity (604), respectively, wherein the first rectangular cavity (208) and the fourth rectangular cavity (604) are configured to accept the first PCB (116) and the second PCB (124), respectively, in the assembled configuration of top connector (102) and the bottom connector (106), respectively.
PCT/IN2022/050304 2021-03-25 2022-03-25 Spot welding less modular battery pack assembly system WO2022201205A1 (en)

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Cited By (1)

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Publication number Priority date Publication date Assignee Title
FR3143873A1 (en) * 2022-12-20 2024-06-21 Renault S.A.S Assembly of battery modules, battery module and method of producing a modular battery.

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WO2017004078A1 (en) * 2015-06-30 2017-01-05 Faraday&Future Inc. Vehicle energy-storage systems
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WO2017004078A1 (en) * 2015-06-30 2017-01-05 Faraday&Future Inc. Vehicle energy-storage systems
US20200243814A1 (en) * 2019-01-28 2020-07-30 Samsung Sdi Co., Ltd. Battery pack

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