FIELD OF THE INVENTION: The present invention relates to a solder less battery pack. Particularly it relates to a solder less battery pack with the heat management assembly and provide dynamic voltage and current.

BACKGROUND OF THE INVENTION:

A battery is a device consisting of one or more electrochemical cells with external connections for powering electrical devices such as flashlights, mobile phones, and electric cars. When a battery is supplying electric power, its positive terminal is the cathode and its negative terminal is the anode. The terminal marked negative is the source of electrons that will flow through an external electric circuit to the positive terminal. When a battery is connected to an external electric load, a redox reaction converts high-energy reactants to lower-energy products, and the free-energy difference is delivered to the external circuit as electrical energy. Historically the term "battery" specifically referred to a device composed of multiple cells, however the usage has evolved to include devices composed of a single cell.

Generally, batteries are used in various industrial and commercial applications. Batteries can be broadly classified into chargeable and rechargeable batteries. Multiple conventional rechargeable batteries may be arranged in series or parallel to obtain any desired voltage or current. For example, a set of batteries may be arranged in parallel by sandwiching the batteries between two conductors to obtain a desired current. Many of the parallel sets may be coupled in series to obtain a desired voltage of the larger set. The larger set may be electrically coupled in series or parallel with other similarly sized sets to obtain an even higher voltage or current. The prior technologies describes one method of managing the electrical connections in the smaller sets of batteries, in which multiple batteries are sandwiched in parallel between two cells. Recent technologies also describes a bracket which is laid into holes in the conductor and wave soldered to the conductor. The holes are aligned over the end terminals of the batteries, and the bracket is then welded to the batteries.

Further, rechargeable batteries such as lithium-ion cells tend to be more prone to thermal runaway than chargeable batteries. The lithium ion battery is subjected to high increase in temperatures particularly during fast charging of the battery pack. The heat from individual cells of the battery pack needs to be removed in order to prevent the cells from thermal run away. Thermal runaway is a condition where the temperature of an individual cell increases rapidly and makes the complete pack to become vulnerable for a thermal run away failure. Therefore, it becomes highly essential to monitor and keep the temperature of the battery pack in optimum temperatures throughout the working of the battery pack. The thermal runaway situation may lead to an unsafe situation for the rider and for the surrounding environment and hence it needs to be addressed.

For example, rechargeable batteries are used in vehicular applications that include electric and hybrid electric vehicles. In electric or hybrid vehicles, large battery packs are provided for storing and providing electrical energy for the electrical engine. The batteries are arranged in close proximity in a battery pack which generates significant heat during operation. Many of the prior arts disclosing the battery pack.

US9172254B2 discloses a source of environmental pollution is the burning of fuel by the transportation vehicles (e.g., cars, trucks). The use of electric vehicles (EVs) is perceived as an essential step towards better utilization of energy. Current EVs make use of an electric engine and a battery pack that provides energy to that engine. The technology of electric engines is well developed because of the common use of such engines in trains, submarines and industrial facilities. But, while the battery packs used in EVs have made a lot of progress in the last couple of years, these battery packs still have problems. These battery packs are expansive, heavy, and limited in the amount of energy that they can provide. This obstacle is a major factor that limits the use of EVs today in the mass market. Described herein is an improved EV battery pack system.

IN 201947016314 discloses a battery pack comprises unit cells which have a cell body that includes a power-generating element and is formed in a flat shape, and an electrode tab extends out from the cell body, and which are stacked in the thickness direction of the cell body; a bus bar electrically connected to the electrode tab by laser welding; and a plate portion that forms a stacked structure together with the electrode tab along an irradiation direction of the laser.

US4842326A discloses a battery pack includes: paired supporting members; a battery module disposed between the supporting members; and a stack member supporting the battery module by linking the supporting members to each other. An extending portion protruding from the battery module is formed by extending an end portion of the stack member, Accessories are attached to a side surface on a side where the extending portion of the stack member is disposed, the side surface being one of side surface of the battery pack which are provided with the paired supporting members.

The problems associated with available battery packs is that the welding process is time consuming and leads to failure. Also, due to the soldering/welding, it is difficult to examine unit cell (single cell) and replace a unit cell without disturbing the neighbourhood cells. It is also difficult to examine the connection between each battery and the cells. Also, the battery pack of the prior technologies are not much safer in case of fire. There also need to continuously monitoring the temperature of the battery pack. To eliminate the essentiality of soldering or welding; fire proof in case of fire; and improved heat management, it is desirable to develop an improved solder less battery pack.

Inventors of present invention have surprisingly found the solution to all above mentioned problems by developing solder less battery pack with the heat management assembly and provide dynamic voltage and current as described herein.

OBJECT OF THE INVENTION:

The principle object of the present invention is to overcome all the mentioned and existed drawbacks of the prior arts by providing a solder less battery pack.

Another object of the present invention is to provide a solder less battery pack which eliminate the essentiality of welding or soldering the terminals.

Another object of the present invention is to provide a solder less battery pack with the heat management assembly.

Another object of the present invention is to provide a solder less battery pack with the temperature and humidity sensing element which continuously monitors the temperature and humidity within the battery pack.

Another object of the present invention is to provide a solder less battery pack in which a unit cell can be checkable and replaceable without disturbing the neighbourhood cells.

Another object of the present invention is to provide a solder less battery pack with intelligent PCB which can track location of the battery cell and provides the maintenance and other health related alerts. Another object of the present invention is to provide a solder less battery pack which is lighter in weight so the vehicle or any other moving assembly can incorporate multiple battery pack at the same time.

Another object of the present invention is that the solder less battery pack of the present invention can be used for any application like in vehicles, invertors, generators etc by combining multiple battery pack as per end use.

SUMMARY OF THE INVENTION:

This summary is provided to introduce a selection of concepts in a simplified form that are further disclosed in the detailed description of the invention. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter.

The present invention is all about a solder less battery pack which eliminate the essentiality of soldering/welding.

The main aspect of the present invention is to provide a solder less battery pack, comprising a frame covered from sides with an outer plate to form housing; an inner plate with plurality of holes incorporated on the inner side of said frame and forming an inner confined space between outer side plate and inner side plate; a battery cells arranged in serial and parallel combination to provide dynamic voltage and current; a heat management assembly; an intelligent PCB; and a temperature and humidity sensing element; characterized in that, said heat management assembly includes a fabric assembly being surrounded by the frame housing; said fabric assembly having plurality of cavity, dipped with a coolant mixture; said fabric assembly involves an unique terminals having hole, joined on each side; said terminals arranged in such a way that there is no requirement of soldering or welding; said fabric assembly covered with a respective top cover and a bottom cover; a contact surface where the terminal contacts is sealed to prevent the leakage of said coolant mixture; and said intelligent PCB being capable to control the dynamic voltage and current, tracking or monitoring GPS location, history of charge cycles, usage and maintenance information, status of health including temperature and its rate of rise during use of said battery cell.

Another aspect of the present invention is to provide a solder less battery pack in which heat management assembly having temperature and humidity sensing element which continuously monitors the temperature and humidity inside the battery pack and take appropriate heat management action for safety trigger on the intelligent PCB.

Another aspect of the present invention is to provide unique terminals which can be single link terminal, double link terminal or combination thereof. With the use of these unique terminals the essentiality of soldering/welding is rendered less essential. The main advantage of these is that the unit cell can be checkable and replaceable without disturbing the neighborhood cells. In such case if end user soldered/welded the unique terminal, then also the unit cell can be replaceable and checkable. Yet another aspect of the present invention is to provide a solder less battery pack in which the battery cells are scalable in the combination of series and parallel structure and larger battery packs created by combining multiple packs as per the end user requirement. BRIEF DESCRIPTION OF THE DRAWINGS :

The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. FIG. 1 represent the exploded view of the solder less battery pack assembly along with the intelligent PCB .

FIG. 2 represent the schematic view of the frame.

FIG. 3 represent the inner plate with the plurality of holes. FIG. 4 represent the cross section view of the fabric assembly.

FIG. 5 represent the top cover and bottom cover for the fabric assembly.

FIG. 6 represent the view of the single terminal.

FIG. 7 represent the view of the double terminal.

FIG. 8 represent the cut section of the terminal.

DETAILED DESCRIPTION OF THE INVENTION:

Detailed embodiments of the present invention are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. The present invention overcomes the aforesaid drawbacks of conventional battery packs. The objects, features, and advantages of the present invention will now be described in greater detail. Also, the following description includes various specific details and is to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that: without departing from the scope and spirit of the present disclosure and its various embodiments there may be any number of changes and modifications described herein.

It must also be noted that as used herein and in the appended claims, the singular forms "a", "an," and "the" include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred, systems are now described.

Throughout the specification, the term battery pack is set of any number of identical batteries or individual battery cells. They may be configured in a series, parallel or a mixture of both to deliver the desired voltage, capacity, or power density.

The main embodiment of the present invention is to provide a solder less battery pack, and more particularly, to a solder less battery pack with the heat management assembly and provide dynamic voltage and current. The heat management assembly having fabric assembly which dipped in the coolant mixture to cool the battery cells especially during the fast charging. The battery pack using unique terminals which eliminate the requirement of the absolute necessity of welding/ soldering.

As per detail embodiments of the present invention, a solder less battery pack (1), comprising: a. a frame (2) covered from sides with an outer plate (21) to form housing (2a); b. an inner plate (3) with plurality of holes (3 a) incorporated on the inner side of said frame (2) and forming an inner confined space between outer side plate (21) and inner side plate (3); c. a battery cells (22) arranged in serial and parallel combination to provide dynamic voltage and current; d. a heat management assembly; e. an intelligent PCB (8); f. a temperature and humidity sensing element (9); and characterized in that, said heat management assembly includes a fabric assembly (4) being surrounded by the frame housing (2a); said fabric assembly (4) having plurality of cavity (41), dipped with a coolant mixture; said fabric assembly (4) involves an unique terminals (6,7) having hole (61), joined on each side; said terminals (6,7) arranged in such a way that there is no requirement of soldering or welding; said fabric assembly (4) covered with a respective top cover and a bottom cover (5); a contact surface where the terminal (6,7) contacts is sealed to prevent the leakage of said coolant mixture; and said intelligent PCB (8) being capable to control the dynamic voltage and current, tracking or monitoring GPS location, history of charge cycles, usage and maintenance information, status of health including temperature and its rate of rise during use of said battery cell (22).

As per detailed embodiment of the present invention, said battery pack (1) comprising the heat management assembly that is built by using the fabric assembly (4) and the inner confined space formed between the outer plate (21) and the inner plate (3). Said heat management assembly help to manage the temperature of the battery pack within the safe range. The heat management assembly will manage the battery pack (1) temperature within the desired range and avoid thermal run away of the same and also avoid fire catching condition due to thermal run away situation. As the battery pack (1) works in normal temperature during its whole work life, it will result in performance and also hep to increase battery pack life.

As per detailed embodiment of the present invention, said fabric assembly (4) forming by group of individual fabric sheet having plurality of cavities (41). The fabric assembly (4) is dipped in the coolant mixture. The battery cells (22) being surrounded by said cavities (41). The fabric assembly (4) covered with the top and bottom cover (5) which is sealed to prevent the leakage of said coolant mixture. The fabric assembly (4) also having a temperature and humidity sensing element (9) to sense the temperature and humidity of the battery pack (1). The said fabric assembly

(4) works efficiently to manage the temperature and humidity inside the battery pack (1) with the help of combination and special arrangement of fabric sheet and coolant mixture. During working condition, when temperature inside battery pack rises, the fabric assembly (4) which is dipped in coolant mixture will get activated and cool it down by absorbing the heat resulting in evaporation of coolant mixture and once temperature resumes to normal, said evaporated coolant mixture gets condensed back over fabric sheet. Further, as the fabric assembly (4) covered with the top cover (5) and bottom cover (5) which is sealed to avoid leakage of coolant mixture when it is getting evaporated due to higher temperature. The same cycle will get repeated as and when there is need of thermal management inside battery pack (1).

As per detailed embodiment of the present invention, said inner plate (3) is positioned on each sides of the frame (2). The inner plate (3) having plurality of holes (3a) being capable to flow in and flow out the coolant mixture. The outer side of said frame is sealed with the outer plate (21). In between of the inner plate (3) and the outer plate (21), confined space is created. The coolant mixture being capable to flow in from the inner plate (3) to the confined space and flow out in the fabric assembly (2) through the inner plate (3) but cannot go outside as the top cover

(5) and bottom cover (5) is sealed.

As per the detailed embodiment of the present invention, said battery cells (22) connected with other neighborhood cells through the unique terminals (6, 7). Said unique terminals can be a single link terminal (6), double link terminal (7) or combination thereof. The battery cells (22) can be scalable in series and parallel combination for the attaining desired dynamic voltage and current. If the series parallel combination of the battery cells (22) is in the odd numbers, in that case the terminals also used in the combination of one single terminal (6) and rest double terminal (7). The terminals (6, 7) having plurality of holes (61) on the surface for the checking the continuity of the cells (22). For the sake of the understanding only, in the proposed invention shown in Fig. 1 is seven series and five parallel (7s5p) combination. Likewise any combination can be prepared as per end user requirement. This makes the battery pack of present invention unique and universal kind of thing which can be used with any appliances with varying voltage or current specification. As per detailed embodiment of the present invention, said battery pack (1) is solder less as the battery cells (6, 7) being connected with the unique terminals (6, 7). With this arrangement the unit cell can be checkable and replaceable without disturbing the neighborhood cells. For the advantageous embodiment, the terminal (6, 7) of the present invention also provided with the possible area (62) for the soldering/ welding. Though, the terminals (6, 7) soldered/ welded then also the unit cell can be checkable and replaceable without disturbing the neighborhood cells. One of the major problem with current battery pack is, it is difficult to check and replace individual battery cells (22) and therefore sometime or majority times, whole battery pack (1) needs to be replaced even though the problem is only in one battery cell (22). The battery pack (1) of present invention overcomes this problem by providing unique way of arranging or structuring battery cells (22) through unique terminals (6,7) which provides user an option to check and monitor individual battery cells (22) and if found faulty or not working, can be replaced without disturbing neighborhood cell and the whole battery pack (1). Again due to this arrangement, the said battery pack of present invention make it solder free or wielding free which consumes so much energy, labour and also impacting the finishing of the battery pack and also lead to increase in cost as well as replacement cost. As per one embodiment, still there is a provision of soldering or welding if required in certain case but even though if soldering or wielding is done, still the advantage of checking and replacing individual battery cells (22) is still available.

As detailed embodiment of the present invention, said battery pack (1) produce heat inside it which result the rise in temperature and humidity. The gradual increase of the temperature might damage the battery pack (1) and whole assembly too. Thus the sensing element (9) in accordance with the present invention can detect the temperature and humidity inside the battery pack. Said temperature and humidity sensing element (9) has been placed along with the fabric assembly (4).

As per detail embodiment of the present invention, said battery pack (1) having an intelligent PCB which can monitor and control all the embodiment of said battery pack (1). The intelligent PCB (8) can control the dynamic voltage and current flow as per the end user requirement. The intelligent PCB (8) continuously in the sync with the temperature and humidity sensing element (9) and take appropriate heat management action for safety trigger. Said intelligent PCB (8) can also track the location of individual battery cells via GPS location. Due to this, in case of the larger battery packs it is easy to identify unit cell for the maintenance purpose.

As mentioned above, the said battery pack can be created by multiplication of different battery pack for required end use, the location tracking feature will help the user or manufacturer to identify the faulty battery cell or battery pack and can be repaired or replaces easily quickly.

As per one embodiment of the present invention, coolant mixture is mixture of coolant and distilled water. The coolant can be selected from propylene glycol, mono ethylene glycol, dynalene, perfluropolyether fluorinated fluid, perfluorohexane. Said mixture having 50% amount of coolant and 50 % amount of the distilled water. The coolant mixture is mixture of water and solvent to prevent water from freezing in subzero temperatures. As per one embodiment of the present invention, said terminal (6, 7) made of metal selected from copper or beryllium copper. As per one preferred embodiment, beryllium copper is used. As per one preferred embodiment, beryllium copper can be selected from the range of beryllium: copper in the ratio of 2:98 to 8:92.

As per one embodiment of the present invention, said fabric assembly (4) made with non-woven fabric material. The fabric assembly (4) is made up with the fire resistance material. In some case, where battery pack (1) assembly get exposed to higher temperature either from inside or from outside, the water present in coolant mixture will get evaporated leaving behind only the coolant solvent. In such situation, there are chance of catching fire. However, as per present invention, the fabric used in fabric assembly (4) is of fire resistance nature and therefore, will not allow the fire to get spread or go outside the assembly and will save whole assembly or the machine or appliances where the said battery pack is installed.

As per the detailed mechanism of the present invention, said battery pack (1) having the number of battery cells (22) arranged in the combination of series and parallel. The battery cells (22) provide the dynamic voltage and current to the respective assembly. The battery cells (22) can experience the rise in the temperature while in operation, exposed directly to the sun or during the charging. To prevent this situation, the temperature and humidity sensing element (9) continuously monitor the temperature and humidity inside the battery pack (1). Said sensing element (9) continuously in the sync with the intelligent PCB (8) for the triggering alarm or alert in case of sudden rise in the temperature. For the cooling purpose, said battery cells (22) surrounded with the fabric assembly (4). Said fabric assembly (4) dipped with the coolant mixture which being capable to flow from the confined space to fabric assembly (4) or vice versa. The battery cells (22) connected internally with each other through the unique terminal (6, 7). Said terminal can be single terminal (6) or double terminal (7) or combination of both. Said terminal (6, 7) arrange with the top cover (5) and bottom cover (5) of said battery pack (1). To ensure the efficiency of thermal management of the solderless battery pack of present invention, a thermography test was conducted on unconnected battery pack of present invention and conventional battery pack (filed with only water) by exposing both to solar radiation. The outcome showed a cooler surface only where water was in contact while rest all sides, there was higher temperature observed. Further, mixture of water and coolant was used to check the cooling efficiency. The battery pack with fabric assembly wetted with the 50%-50% mix of coolant and distilled water was exposed to sun for similar periods and thermography tests conducted for comparing efficacy of cooling. The fabric assembly cools the entire battery pack over the region of its exposure by an average of 2.5 to 7.5 degrees depending on surface and angle of exposure to sun and shade in comparison to the conventional battery pack.

Referring to figures 1 and 2 of the present invention, exploded view of the assembly with the intelligent PCB has shown. The battery pack (1) having hollow frame structure (2) as shown in Fig. 2 covering each side with the outer plates (21) to form a housing (2a). The inner side of the frame (2) covering with the inner plate (3) having plurality of holes (3a). Said housing incorporates the fabric assembly (4) forming with plurality of individual fabric sheets having plurality of cavities (41) formed on it. The fabric assembly (4) dipped with the coolant mixture to cool the battery cells especially during the fast charging. The coolant mixture can vent in and out through the fabric layer to confined space and confined space to the fabric layer. The confined space is created in between of the inner layer (3) and the outer layer (2a). The battery cells (22) accommodated in the cavity (41) of the fabric assembly (4). The fabric assembly (4) covered with the top (5) and bottom cover (5). The battery cells sealed with the top and bottom cover (5) to prevent the leakage of the coolant mixture for the fabric assembly (4). The cells connected with the unique terminals (6, 7) such a way that it eliminates the essentiality of the soldering/ welding. The fabric assembly (4) also having a temperature and humidity sensing element (9) to monitoring the temperature and humidity of the battery pack (1). As shown in Fig. 1, the intelligent PCB (8) connected at the outer plate (21). Battery pack (1) covered from top and bottom with the outer plate (21).

Referring to Fig. 3, it shows the inner plate (3) with the plurality of holes (3a) in it. The inner plate (3) incorporated on the sides of the said frame (2). The holes (3a) allowing the coolant mixture to flow in and flow out from the fabric assembly (4) to confined space or vice versa.

Referring to Fig. 4 and 5, said fabric assembly (4) formed with the plurality of the individual fabric sheets having plurality of cavity (4a) formed on it. The plurality of the 1 mm thick fabric sheets dipped in 50%-50% coolant mixture of coolant and distilled water. The battery cells (22) accommodated in the respective cavities. The fabric assembly covered with the top and bottom cover (5) as shown in Fig. 5. The battery cells (22) sealed at the top cover (5) and bottom cover (5) to prevent the leakage of the coolant mixture.

Referring to Fig. 7 to Fig. 9, the single terminal (6) has been shown in the Fig. 7. The terminals (6, 7) made of beryllium copper. The double terminal (7) has been shown in the Fig. 8. It formed with the series and parallel structure. If the series parallel combination of the cells (22) in the odd number in that case one single terminal (6) and rest are double terminal (7) can be used. If the end user want use single terminals (6) more than one it is possible to use with all the combination. The cross section of the terminal (6, 7) has shown in Fig. 9. The cross section of the terminal (6, 7) clearly shows the through hole (61) for the checking the continuity of the cell (22) joints.

Without further description, it is believed that one of ordinary skill in the art can, using the preceding description and the illustrative examples, make and utilize the present invention and practice the claimed methods. It should be understood that the foregoing discussion and examples merely present a detailed description of certain preferred embodiments. It will be apparent to those of ordinary skill in the art that various modifications and equivalents can be made without departing from the spirit and scope of the invention.

ADVANTAGES OF THE INVENTION:

• The present invention creates an easy and effective way to cool the batteries with heat management assembly.

• With the use of unique terminals essentiality of welding/shouldering eliminates.

• Unit cell can be checkable and replaceable.

• If the cells being solder/welded in that case also the unit cell can be checkable and replaceable.

• Fire resistance fabric assembly helps to protect the assembly or machinery on which battery pack installed.

• Larger battery pack can be created with the number of battery packs.

• Intelligent PCB can control the dynamic voltage and current, tracking or monitoring GPS location, history of charge cycles, usage and maintenance information, status of health including temperature and its rate of rise during use of said battery cell. LIST OF REFERENCE NUMERALS :

Solder less battery pack (1) Frame (2)

Outer plate (21) Battery cells (22)

Housing (2a);

Inner plate (3)

Holes (3 a)

Fabric assembly (4) Cavity (41)

Top cover and a bottom cover (5) Single terminal (6)

Hole (61)

Possible area for the soldering/ welding (62) Double terminal (7) Intelligent PCB (8)

Temperature and humidity sensing element (9)