[0001] The present subject matter relates to battery modules. More particularly, end connections of the battery modules are disclosed in the patent application number 202041010274 and the present subject matter offers an improvement over the subject matter as claimed in aforementioned patent application.

BACKGROUND

[0002] Existing research in battery technology is directed to rechargeable batteries, such as sealed, starved electrolyte, lead/acid batteries, are commonly used as power sources in different applications, such as, vehicles and the like. However, the lead-acid batteries are heavy, bulky, and have short cycle life, short calendar life, and low turn around efficiency, resulting in limitations in applications.

[0003] Thus, in order to overcome problems associated with conventional energy storage devices including the lead-acid batteries, a lithium ion battery provides an ideal system for high energy-density applications, improved rate capability, and safety. Further, the rechargeable energy storage devices - lithium-ion batteries exhibit one or more beneficial characteristics which make it useable on powered devices. First, for safety reasons, the lithium ion battery is constructed of all solid components while still being flexible and compact. Secondly, the energy storage device including the lithium ion battery exhibits similar conductivity characteristics to primary batteries with liquid electrolytes, i.e., deliver high power and energy density with low rates of self-discharge. Thirdly, the energy storage device as the lithium ion battery is readily manufacturable in a manner that it is both reliable and cost-efficient. Finally, the energy storage device including the lithium ion battery is able to maintain a necessary minimum level of conductivity at sub-ambient temperatures.

[0004] In a known structure for an energy storage device, one or more energy storage cells including lithium ion battery cells are disposed in at least one holder structure in series and parallel combinations using at least one interconnecting structure. The interconnecting structure is adapted for electrically interconnecting the energy storage cells with a battery management system (BMS). An output voltage and an output current generated by the energy storage device is transmitted to one or more electronic and electrical components configured to be powered by the energy storage device via end connections after being monitored and regulated by the BMS. The design of the end connections is critical to the safety, serviceability, and maintainability of the energy storage device.

BRIEF DESCRIPTION OF DRAWINGS [0005] The detailed description is described with reference to the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.

[0006] Figs. 1A-1B exemplarily illustrate a perspective view and an exploded view of a first embodiment of a battery module;

[0007] Fig. 2 exemplarily illustrates a partial exploded view of the battery pack showing the first end connection of the first embodiment of the battery module; [0008] Fig. 3 exemplarily illustrates a perspective view of a first end connection of the first embodiment of the battery module;

[0009] Fig. 4 exemplarily illustrates an exploded view of the first end connection of the first embodiment of the battery module;

[00010] Fig. 5 exemplarily illustrates a plan view of at least one connector of the terminal holder of the first embodiment of the battery module;

[00011] Fig. 6 exemplarily illustrates a plan view of the terminal holder of the first embodiment of the battery module;

[00012] Fig. 7 exemplarily illustrates a perspective view of a second embodiment of a battery module;

[00013] Fig. 8 exemplarily illustrates an exploded perspective view of the battery module exemplarily illustrated in Fig. 7;

[00014] Figs. 9A-9B exemplarily illustrate perspective views of a second end connection of the second embodiment of the battery module; [00015] Figs. 10A-10C exemplarily illustrate perspective views of a first end connection of the second embodiment of the battery module; and [00016] Figs. 11A-11B exemplarily illustrate a perspective sectional view of the second embodiment of the battery module with the first end connection and the second end connection.

DETAILED DESCRIPTION OF THE INVENTION

[00017] The energy storage device is connected to subsequent energy storage devices, on-board or external chargers, and electrical and electronic loads of a power supply system via a plurality of end connections. Typically, the output of the energy storage cells is connected to the battery management system (BMS) circuit board by means of wires and the output voltage and the output current from the end connections connect to the electronic and electrical loads in the power supply system by means of wires. Such interconnecting wires have a potential of short circuit while assembly of the energy storage device.

[00018] To prevent occurrences of such untoward events, in the existing structures of the energy storage device, the end connections are molded into an end cover of the energy storage device. Such end connections are not removable, requiring replacement of the entire end cover in case of repair of the end connections. In some other structures of the energy storage devices, the end connections are positioned on a printed circuit board (PCB) located in the energy storage device in addition to the BMS in the energy storage device. Such PCBs are inflexible and are under stress during the assembly of the energy storage device, leading to failure of the PCB in the energy storage device. Further, additional components in the energy storage device increase the weight of the energy storage device and the cost associated with the manufacturing, servicing, and replacement of the energy storage device.

[00019] Further, the output of the cells of the energy storage device passes through a safety device, such as, a fuse to the end connection on the body of the energy storage device. The assembly of the safety device needs to be performed prior to the mounting of the end cover of the energy storage device. Since, wires are used to connect the cells to the end connection; the safety device is connected to the wires. In the assembly of the energy storage device, the fuse will be hanging from the wires and difficult to connect to the end connection in the end cover. The stated difficulty in assembly of the energy storage device and safety protection on assembly of the energy storage device drives the need for an improved design of the energy storage device.

[00020] There exists a need for an improved design of an energy storage device with end connections that ensure safety during assembly, maintainability, and serviceability of the energy storage device overcoming all problems disclosed above as well as other problems of known art.

[00021] The present subject matter discloses an energy storage device, that is, a battery module comprising an improved and simplified design of end connections for facilitating connection of the battery module to a battery controller, a charging unit, or subsequent battery modules in a powered device, for example, a vehicle. In an embodiment of the present invention, a battery module for a powered device is disclosed. The battery module comprises a plurality of cells enclosed in a casing, at least one end cover securely attached to the casing, and a battery management system (BMS) board positioned proximal to the at least one end cover in the casing. Further, the battery module comprises at least one end connection removably attached to the BMS board. In an embodiment, the at least one end connection comprises a first end connection, corresponding to at least one power line of the battery module, comprising at least one protection device connected to the at least one power line for providing electrical protection to the battery module. The first end connection comprises one of a first terminal holder and a second terminal holder removably attached to the battery management system board.

[00022] The first terminal holder comprises a base member with at least one connector attached to a bottom surface of the base member at predetermined locations and an attaching member at a first corner for removably attaching the base member to the BMS board. The at least one protection device is attached to the at least one connector to form a positive terminal of the battery module. [00023] In an embodiment, a first end of the at least one connector connects to positive terminals of the plurality of cells at one of the predetermined location through at least one interconnect sheet and a second end of the at least one connector connects to the at least one protection device. In an embodiment, a second end of the at least one connector connects to the at least one protection device and a first end of the at least one connector forms the positive terminal of the battery module. In an embodiment, the at least one connector is a metal connector with mounting provisions en-molded in the base member. In an embodiment, the terminal holder comprises at least one guiding means to route at least one cable on the BMS board. In an embodiment, the base member comprises at least one stiffener between the at least one connector and the at least one protection device for reinforcing the base member.

[00024] In an embodiment, the first end connection comprises the second terminal holder removably attached to the BMS board, a positive terminal stud and a negative terminal stud extending from the second terminal holder for connecting to external components, and the at least one protection device connected to the positive terminal stud in a path of current from the BMS board to the positive terminal stud. The positive terminal stud and the negative terminal stud project from the battery management system board through the at least one end cover. In an embodiment, the positive terminal stud and the negative terminal stud have different geometries.

[00025] The second terminal holder comprises a base member with at least one connector attached on a bottom surface of the base member at predetermined locations. One of the at least one connector connects the at least one protection device to the positive terminal stud. In an embodiment, the at least one end connection further comprises a second end connection corresponding to signal lines of the battery module.

[00026] The second end connection comprises at least one female signal connector comprising at least one hollow pin securely attached to the BMS board, and at least one corresponding male signal connector comprising at least one plug removably engaged with the at least one hollow pin of the at least one female signal connector for connecting the battery module to a battery controller.

[00027] In an embodiment, the at least one male signal connector further comprises clips for secure and tight locking of the at least one plug with the at least one hollow pin of the at least one female signal connector. In an embodiment, the second end connection facilitates parallel connection of the battery module with other battery modules of similar type. The battery module further comprises a third end connection corresponding to negative terminals of the plurality of cells. In an embodiment, the at least one end connection on the BMS board is connected to an external connection on the at least one end cover of the battery module for charging, discharging, and controlling operation of the battery module. In an embodiment, the end cover further comprises guiding means and a holding clamper to route power cables and signal cables connected to the first end connection and the second connection respectively.

[00028] Another embodiment of a battery module for a powered device is disclosed. The battery module comprises a plurality of cells enclosed in a casing, at least one end cover, with an external connection, securely attached to the casing, and a BMS board positioned proximal to the at least one end cover in the casing. The battery module further comprises a first end connection comprising a first terminal holder and at least one protection device positioned on the BMS board, forming a positive terminal of the battery module, a second end connection positioned on the battery management system board, corresponding to signal lines of the battery module, and a third end connection positioned on the battery management system board, connecting to negative terminals of the plurality of cells. The first end connection, the second end connection, and the third end connection on the BMS board are connected to the external connection on the at least one end cover of the battery module for charging, discharging, and controlling operation of the battery module.

[00029] In this embodiment, the first terminal holder comprises a base member with at least one connector attached to a bottom surface of the base member at predetermined locations and an attaching member at a first corner for removably attaching the base member to the battery management system board. The at least one protection device is fastened to the at least one connector to form a positive terminal of the battery module. In an embodiment, a first end of the at least one connector connects to positive terminals of the plurality of cells through at least one interconnect sheet at one of the predetermined fastening locations and a second end of the at least one connector connects to the at least one protection device. In another embodiment, a second end of the at least one connector connects to the at least one protection device and a first end of the at least one connector forms the positive terminal of the battery module. In an embodiment, the at least one connector is a metal connector with mounting provisions en- molded in the base member. The base member comprises at least one guiding means to route at least one cable on the battery management system board. In another embodiment, the base member comprises at least one stiffener between the at least one connector and the at least one protection device for reinforcing the base member.

[00030] The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[00031] Figs. 1A-1B exemplarily illustrate a perspective view and an exploded view of a first embodiment of a battery module 100. The battery module 100 comprises a plurality of cells forming a battery pack 105 housed within a casing. The external casing 101 encloses the battery pack 105 from top and bottom. The battery module 100 further comprises a first end cover 103 and a second end cover 104 that enclose the battery pack 105 from the rear and the front respectively. The cells 107 in the battery pack 105 are arranged in a particular sequence in a cell holder 106. The cells 107 are electrically connected in series and/or parallel configuration to form an array of cells. Such arrays of cells are electrically connected to a battery management system (BMS) board 108 within the battery module 100. The BMS 108 is a printed circuit board with one or more integrated circuits integrally built on it as exemplarily illustrated in Fig. IB. The BMS board 108 is attached to one of the sides of the battery pack 105. In an embodiment, the BMS board 108 is located between the battery pack 105 and the first end cover 103.

[00032] The external casing 101 has mounting provisions for the second end cover 104 and the first end cover 103. The second end cover 104 and the first end cover 103 are fastened to the external casing 101 using a plurality of attachment means, such as, fasteners. The battery pack 105 has mounting provisions for the BMS board 108. The BMS board 108 is screwably attached to the cell holder 106 of the battery pack 105.

[00033] An external connection 102 is mounted on the first end cover 103. The external connection 102 of the battery module 100 facilitates connection of the battery module 100 for charging, discharging, series and parallel connection with other battery modules or controlling operation by a battery controller in the powered device. In an embodiment, the external connection 102 may be positioned in a mounting provision in the end cover 103 to facilitate the connection of the battery module 100 to external components in the powered device. The powered device may be a vehicle, be it a two-wheeled vehicle, a three- wheeled vehicle, multi-wheeled vehicle, etc.

[00034] The battery module 100 comprises power lines that provide the voltage and current output of the battery module 100 and signal lines that provide status of the battery module 100 to be used further by the external components in the powered device. As exemplarily illustrated, the battery module 100 comprises at least one end connection 109, 110, 111 removably attached to the BMS board 108. The at least one end connection may be a first end connection 109, a second end connection 110, and/or a third end connection 111. As exemplarily illustrated, all of the first end connection 109, the second end connection 110, and the third end connection 111 are removably attached to the BMS board 108. In an embodiment, at least one of the first end connection 109, the second end connection 110, and the third end connection 111 is removably attached to the BMS board 108.

[00035] The first end connection 109 exemplarily illustrated in Fig. IB corresponds to at least one power line, that is, the positive terminal of the battery module 100. The positive terminals of the cells 107 of the battery module 100 culminate in the first end connection 109 and the first end connection 109 corresponds to the positive terminal of the battery module 100. The second end connection 110 corresponds to signal lines of the battery module 100. The third end connection 111 corresponds to negative terminals of the plurality of cells 107. The negative terminals of the cells 107 culminate in the third end connection 111. The first end connection 109, the second end connection 110, and the third end connection 111 connect to the external connection 102 as shown. On the external connection 102, the on-board charger, or components of the powered device are connected for charging, discharging, or controlling the battery module 100.

[00036] Fig. 2 exemplarily illustrates a partial exploded view of the battery pack 100 showing the first end connection 109. As exemplarily illustrated, the first end connection 109 is mounted onto the BMS board 108. The first end connection 109 carries current from the BMS board 108 in and out of the battery module 100. The current from the cells 107 in the battery pack 105 culminate into a positive terminal and a negative terminal on the BMS board 108 through the interconnect sheets 204. The first end connection 109 comprises a first terminal holder 201 removably attached using at least one mounting provision 202 to the BMS board 108 of the battery module 100. The BMS board 108 is mounted to the cell holder 106 using the mounting provisions, such as, 203.

[00037] Fig. 3 exemplarily illustrates a perspective view of a first end connection 109. As exemplarily illustrated, the first end connection 109 comprises the first terminal holder 201 and at least one protection device 301. The first terminal holder 201 is a bus bar with mounting provisions 202a, 202b to mount the first end connection 109 onto the BMS board 108. The positive terminals of the cells 107 connect to the first terminal holder 201 and the output terminal 303 of the first terminal holder 201 forms the positive terminal of the battery module 100. In an embodiment, the positive terminals of the cells 107 culminate on the BMS board 108 through the interconnect sheets 204 and the positive terminal of the BMS board 108 is connected to the first terminal holder 201. The first terminal holder 201 comprises at least one guiding means 302 to route at least one cable on the BMS board. The first terminal holder 201 comprises a base member 401 and at least one connector 202a, 202b as will be described in Fig. 4.

[00038] Fig. 4 exemplarily illustrates an exploded perspective view of the first end connection 109. The terminal holder 201 of the first end connection 109 comprises the base member 401 onto which the protection device 301 is mounted. At least one connector 202a, 402 is attached to a bottom surface of the base member 401 at predetermined locations. The base member 401 comprises at least one attaching member 202b at a first comer of the base member 401 on a top surface. The attaching member 202b is a mounting provision for mounting the terminal holder 201 to the BMS board 108. The base member 401 is made of a polymeric material, for example, plastic. The protection device 301 is mounted on the base member 401 at predetermined locations using fasteners 403a, 403b, such as, screw and nut assemblies shown in Fig 4. The at least one protection device 301 on the terminal holder 401 is, for example, a fuse exposed to direct currents of a predetermined value. As per an embodiment, the predetermined value can be 70 Amperes. The fuse is a self-acting circuit break appliance for protection of the battery module 100 against excessive currents. Excessive currents in the battery module 100 could be due to incorrect wiring of the components within the battery module 100, shorting of the positive terminal of the BMS board 108, or overloading of the battery module 100, etc. The fuse is located in close proximity to the positive terminal of the BMS board 108 and connected to the positive terminal 303 of the battery module 100. In case of fault between the fuse and the electrical load connected to the external connection 102, the fuse blows and the current flow to the loads stops from the positive terminal 303 of the battery module 100. The protection device 301 is mounted using the attachment means 403a and 403b, for example, screws and nuts at the predetermined locations 404a and 404b on the base member 401. In an embodiment, gaskets, such as, O-ring seals are provided around the screws for tight sealing at the predetermined locations.

[00039] Fig. 5 exemplarily illustrates a plan view of at least one connector 202a, 402 of the terminal holder 201. The terminal holder 201 comprises two connectors 202a, 402 fastened to the bottom surface of the base member 401 at predetermined locations. One of the connectors 202a connects to the positive terminal of the BMS board 108 and also functions as a mounting provision to mount the terminal holder 201 to the BMS board 108. A first end 501a of the connector 202a connects to the positive terminal of the cells 107 at a predetermined location on the BMS board 108 and a second end 501b of the connector 202a connects to the protection device 301. A second end 502b of the connector 402 connects to one end of the protection device 301 and a first end 502a of the connector 402 forms the output terminal 303 of the terminal holder 201 and the positive terminal of the battery module 100. The connectors 202a, 402 have the protection device 301 connected between them and the free ends 501a, 502a of the connectors 202a, 402 respectively form the input terminal of the terminal holder 201 and the output terminal 303 of the terminal holder 201. The current from the cells 107 is passed to the metal connector 202a at the end 501a and then passed to the end 501b. At the end 501b, the protection device receives the current and if condition of the battery module is good, the protection device passes the current to the end 502b of the connector 402. From the end 502b, the current passes to the end 502a of the connector 402 to pass to the output terminal 303 of the terminal holder 201.

[00040] In an embodiment, the connectors 202a, 402 are metal connectors that are en-molded by the plastic base member 401. The connectors 202a, 402 are en-molded in a manner to expose the input terminal and the output terminal 303 of the terminal holder 201 and the predetermined locations for mounting the protection device 301. In an embodiment, the connectors 202a, 402 are made of a metal, such as, casted brass. In an embodiment, the connectors 202a, 402 are made of sheet metal. The design of the connectors 202a, 402 may be same or different. The contour of the connectors 202a, 402 is made in the base member of the terminal holder 201 for correct and guided positioning of the connectors 202a, 402 in their respective locations.

[00041] Fig. 6 exemplarily illustrates a plan view of the terminal holder 201. The attaching member 202b at the first corner of the base member 401 on the top surface comprises metal hollow connectors with threads en-molded in the plastic base member 401. In an embodiment, gaskets, such as, O-ring seals may be provided at all the predetermined locations for tight sealing. The gaskets provide a rugged sealed connection of the input terminal, the output terminal of the terminal holder 201 from water and dust for IP67 compliance of the battery module 100. Further, the base member 401 comprises at least one stiffener, 601 such as, grooves, ridges, or any pattern between the connectors 202a, 402 and the protection device 301 for reinforcing the base member 401.

[00042] Fig. 7 exemplarily illustrates perspective view of a second embodiment of a battery module 700. The battery module 700 comprises a plurality of cells arranged in a particular sequence in a cell holder. The cells are electrically connected in series and/or parallel configuration to form an array of cells. Such arrays of cells are electrically connected to a battery management system (BMS) within the battery module 700. The BMS is a printed circuit board with one or more integrated circuits integrally built on it as exemplarily illustrated in Fig. 8.

[00043] As exemplarily illustrated, the battery module 700 comprises an external casing 701 with a dovetail pattern that is vibration proof and shock resistant, a first end cover 702, a second end cover (not shown), and a battery pack. The dovetail pattern of the external casing 701 facilitates easy mounting and un-mounting of the battery module 700 in the space in a device or powered product. The external casing 701 encloses the battery pack from top and bottom. The second end cover (not shown) and the front-end cover 702 enclose the battery pack from the rear and the front respectively.

[00044] The terminal studs of a plurality of end connections 703a and 703b extend from the first end cover 702 as exemplarily illustrated. The first end cover 702 further comprises guiding means 704 and a holding clamper 705 to route power cables 706 and signal cables connected to the end connections 703a and 703b of the battery module 700.

[00045] Fig. 8 exemplarily illustrates an exploded perspective view of the second embodiment of the battery module 700. As exemplarily illustrated, the battery pack 804 is enclosed between the second end cover 803, the external casing 701, the first end cover 702. The BMS board 806 is attached to one of the sides of the battery pack 804. In an embodiment, the BMS board 806 is located between the battery pack 804 and the first end cover 702. The end connections 703a and 703b (exemplarily illustrated in Fig. 7) are removably attached to the BMS board 806. The external casing 701 has mounting provisions for the second end cover 803 and the first end cover 702. The second end cover 803 and the first end cover 702 are fastened to the external casing 701 using a plurality of attachment means 802 and 809 respectively. As per a preferred embodiment, the attachment means can be fasteners. The battery pack 804 has mounting provisions for the BMS board 806. The BMS board 806 is screwably attached to the cell holder 804a of the battery pack 804. Further, the end cover 803 has a vent plug 801 for release of by-product gases from the battery pack 804.

[00046] The plurality of end connections 703a and 703b include a first end connection 703a and a second end connection 703b. The first end connection 703a, exemplarily illustrated in Fig. 7, corresponds to the power lines of the battery module 700. The first end connection 703a is mounted on the BMS board 806. The second end connection 703b corresponds to signal lines of the battery module 700. The second end connection 703b is a two-part signal connector including a female signal connector 807 and a male signal connector 808 that is fastened to the BMS board 806.

[00047] Figs. 9A-9B exemplarily illustrate perspective view of the second end connection 703b of the battery module 700. The second end connection 703b comprises the female signal connector 807 and the corresponding male signal connector 808. The female signal connector 807 comprises at least one hollow pin, such as, six hollow pins 901 centrally located on its body. The corresponding male signal connector 808 removably engages with the female signal connector 807. The female signal connector 807 is fastened on the BMS board 806 directly using fasteners 805 as exemplarily illustrated in Fig. 8. The at least one hollow pins 901 are molded into the body of the female signal connector 807. Corresponding to the hollow pins 901, the BMS board 806 comprises corresponding at least one mounting provisions, such as, holes 806a as exemplarily illustrated in Fig. 8, to removably attach the female signal connector 807 with the pins 901 to the BMS board 806 using fasteners 805 from the surface of the BMS board 806 that is in contact with the battery pack 804. The male signal connector 808 comprises six banana plugs 902 protruding from a rear surface 808a to engage with the six pins 901 in the female signal connector 807. The hollow pin 901 of the female signal connector 807 engages with the plug 902 of the male signal connector 808. On a first surface 808b of the male signal connector 808, the six banana plugs 902 facilitate signal lines of the battery pack 804 to be accessed from outside.

[00048] Further, the male signal connector 808 comprises clips 903 on both sides for ease in mating and disengaging of the male signal connector 808 with the female signal connector 807. For mating of the banana plugs 902 with the hollow pins 901, the inner diameter of the hollow pins 901 are greater than or engageably conforming with the diameter of the banana plugs 902 and the banana plugs 902 are inserted into the hollow space of the hollow pins 901 to achieve an operable & stable electrical contact cum connection. While mating the banana plugs 902 with the hollow pins 901, the clips 903 are pressed, for example, inwards towards the banana plugs 902. Once the banana plugs 902 are engaged with the hollow pins 901, the clips 903 are released. The clips 903 ensure secure and tight locking of the banana plugs 902 with the hollow pins 901. To disengage the banana plugs 902 from the hollow pins 901, the clips 903 are again pressed in a lateral direction towards each other and the banana plugs 902 are pulled out from the hollow pins 901. The pins 901 correspond to the signals from the BMS board 806. The second end connection 703b facilitates parallel connection of the battery module 700 with other battery modules of similar type. Also, the second end connection 703b aids in communication of the battery module 700 to the battery controller in the powered device, for example, a vehicle.

[00049] Figs. 10A-10C exemplarily illustrate perspective views of the first end connection 703a of the battery module 700. The first end connection 703a carries current from the BMS board 806 out of the battery module 700 to electrical loads. The current from the cells in the battery pack 804 culminate into a positive terminal and a negative terminal on the BMS board 806. The first end connection 703a comprises a second terminal holder 1001 removably attached using at least one mounting provision 1002a and 1002b to the BMS board 806 of the battery module 700. As exemplarily illustrated, the second terminal holder 1001 is a bus bar with mounting provisions to mount at least one protection device 1004, a positive terminal stud 1005a, and a negative terminal stud 1005b of the battery module 700. The positive terminal of the BMS board 806 is connected to the positive terminal stud 1005a and the negative terminal of the BMS board 806 is connected to the negative terminal stud 1005b. Between the positive terminal stud 1005a and the negative terminal stud 1005b, the electrical loads of the battery module 700 or a charger of the battery module 700 to recharge the battery module 700 are connected. The positive terminal stud 1005a and the negative terminal stud 1005b protrude through the first end cover 702. The positive terminal stud 1005a and the negative terminal stud 1005b are located in a depression (not shown) in the front-end cover 702 as exemplarily illustrated in Fig. 7.

[00050] The at least one protection device 1004 on the second terminal holder 1001 is, for example, a fuse exposed to direct currents of predetermined value. As per an embodiment, the predetermined value can be 70 Amperes. The fuse is a self-acting circuit break appliance for protection of the battery module 700 against excessive currents. Excessive currents in the battery module 700 could be due to incorrect wiring of the components within the battery module 700, shorting of the positive terminal of the BMS board 806, or overloading of the battery module 700, etc. The fuse is located in close proximity to the positive terminal of the BMS board 806 and connected to the positive terminal. The negative terminal is connected to the ground. In case of fault between the fuse and the electrical load, the fuse blows and as a result the current flow to the loads stops. The protection device 1004 is mounted using the attachment means 1003a and 1003b, for example, screws and nuts at the mounting provisions 1006a and 1006b on the second terminal holder 1001.

[00051] The positive terminal stud 1005a and the negative terminal stud 1005b are securely attached to the terminal holder 1001 at designated locations on the second terminal holder 1001. As per an embodiment, the positive terminal stud 1005a is a bolt 1008a in which a conductor from the positive terminal of the BMS board 806 is placed and fastened with a nut, such as, 1009 to the second terminal holder 1001. Similarly, as per an embodiment, the negative terminal stud 1005b is a bolt 1008b in which a conductor from the negative terminal of the BMS board 806 is placed and fastened with a nut, such as, 1009 to the second terminal holder 1001. Each of the positive terminal stud 1005a and the negative terminal stud 1005b is fastened to the second terminal holder 1001 using a fastener 1009, for example, a screw and a washer from bottom of the second terminal holder 1001. In an embodiment, each of the positive terminal stud 1005a and the negative terminal stud 1005b comprise gaskets 1007a and 1007b, such as O-ring seals for tight sealing at the positive terminal stud 1005a and the negative terminal stud 1005b. The gaskets 1007a and 1007b provide a rugged sealed connection of the terminal studs 1005a and 1005b from water and dust for IP67 compliance of the battery module 700.

[00052] In an embodiment, the second terminal holder 1001 is a plastic base member 1011 to which metal connectors, such as, 1010, 1012, and 1013 are screwably attached or en-molded on a bottom surface of the plastic base member 1011 at predetermined fastening locations as exemplarily illustrated in Fig. IOC. The metal connectors 1012 and 1013 facilitate detachably attaching the terminal holder 1001 to the BMS board 806. The metal connectors 1012 and 1013 have the mounting provisions 1002a and 1002b to mount the plastic base member 1011 to the BMS board 806 of the battery module 700. The metal connector 1010 connects the fuse in series with the positive terminal of the BMS board 806 at the positive terminal stud 1005a.

[00053] The positive terminal stud 1005a and the negative terminal stud 1005b extend from the plastic base member 1011 through the first end cover 702 for sourcing power to external loads. The positive terminal stud 1005a and the negative terminal stud 1005b form the first end connection 703a exemplarily illustrated in Fig. 7. As per an embodiment, the positive terminal stud 1005a and the negative terminal stud 1005b have different geometries to avoid interchanging of polarities during manufacturing, assembly, or servicing of the battery module 700. In an embodiment, the positive terminal stud 1005a and the negative terminal stud 1005b have anti-rotation feature for ensuring tight fastening of the positive terminal stud 1005a and the negative terminal stud 1005b to the terminal holder 1001.

[00054] Figs. 11A-11B exemplarily illustrate a perspective sectional view of the battery module 700 exemplarily illustrated in Fig. 7 with the first end connection 703a and the second end connection 703b. The battery pack 804 of the battery module 700 comprises a plurality of cells 1101 positioned on a cell holder structure 804a and connected in series and parallel connections using an interconnecting sheet 1102 as exemplarily illustrated. The terminals of the cells 1101 are connected to the interconnecting sheet 1102 and connected to the BMS board 806. An enlarged view of the sectional view of the second end connection 703b is exemplarily illustrated in Fig. 11B. In the second end connection 703b, the at least one banana plug 902 of the male signal connector 808 engages with the at least one pin 901 of the female signal connector 807. The male signal connector 808 comprises locking elements or clips 903 on both sides for ease in insertion and removal of the male signal connector 808 from mating and disengaging of the male signal connector 808 with the female signal connector 807.

[00055] The positive terminal stud 1005a and the negative terminal stud 1005b extend from the BMS board 806 and protrude through the first end cover 702. Eye terminals of the power lines of the battery pack 804 are screwed on the terminal studs 1005a and 1005b. The signal lines of the battery pack 804 are soldered or crimped into the banana plugs 902. The signal lines originate from at least one of a temperature sensor installed on the battery pack 804, a current measurement of an individual cell in the battery pack 804, or a voltage level detector of an individual cell in the battery pack 804, etc.

[00056] The first end cover 702 also includes guiding means 704 for guiding the cables 706 arising from the positive terminal stud 1005a and the negative terminal stud 1005b as exemplarily illustrated in Fig. 7. The guiding means 704 are located in depressions on the first-end cover 702 to guide the cable through the depressions in the first end cover 702. The first end cover 702 has projections over the positive terminal stud 1005a and the negative terminal stud 1005b beyond which the positive terminal stud 1005a and the negative terminal stud 1005b do not extend. The guiding means 704 and the projections ensure the cables 706 extending from the positive terminal stud 1005a and the negative terminal stud 1005b are press fit into the guiding means 704 and do not bulge from the surface of the first end cover 702 avoiding stress and damage on the cables 706, when the battery module 700 is to be compactly positioned in a powered device, for example, a vehicle. The holding clamper 705 holds the guided cables and prevents dangling of the cables 706 to avoid damage to the cables 706.

[00057] The end connections in the different embodiments of the battery module provide technical advancement in battery technology as follows: In the first embodiment of the battery module, such a first end connection ensures the positive terminals of the cells are routed separately to the external connection and avoids interference with the negative terminals of the cells and the signal lines of the battery module. Also, the first end connection, the second end connection and the third connection are mounted on the BMS board and other internal components such as bus bars are avoided. The connection of the cells to the BMS board happens through the interconnect sheets in contact with the cells. The common external connection of the battery module where the first end connection, the second end connection, and the third end connection converge ensures simplicity in manufacture and use of the battery module. The components of the powered device interfacing with the battery module are all connected through the same external connection. The design of the first end connection includes guiding means for guiding cables on the BMS board and the stiffeners such as grooves to strengthen the base member of the terminal holder. The connectors to connect the protection device have different geometries and shapes to differentiate between them during the process of assembly and servicing of the battery module. Further, the presence of the protection device within the battery module protects the battery module from occurrence of any short-circuit, fluctuations, etc., within it and saves the powered device from any catastrophe.

[00058] In the second embodiment of the battery module with such first end connection and second end connection avoids interference of the signal lines with the power lines. The clampers guide the cables from the first end connection further, thereby avoiding crimping, stripping, and tangling of the cables. The first end connections and the second end connections are rugged in construction allowing multiple times of engagement and disengagement of the cables from the first end connections and the second end connections, improving durability and reliability of the battery module. The gaskets in the end connections prevent dust and water entry into the battery module through the end connections resulting in a waterproof and dust resistant battery module. The different geometries of the terminal studs in the first end connections prevents interchanging of the polarities of the terminal studs and eases assembly and servicing of the battery module, thereby saving man hours in assembly, servicing, and maintenance of the battery module.

[00059] Such different embodiments of the battery modules allow uninterrupted supply to drive the powered device as the end connections facilitate interconnection of multiple such battery modules. The mounting of the protection device on the BMS board reduces the chances of mounting of the protection device in the wrong terminal. Also, the losses due to wire lengths between the cells and the external connection are reduced. The assembly of the protection device and the terminals of the battery module can be safely performed. Additionally, the positive terminal wire of the battery module is prevented to come in contact with the BMS board and its components by the terminal holder, while assembly of the battery module. The terminal holder also avoids direct transfer of stress to the surface of the BMS board by the wires originating from the cells. The terminal holder also ensures the interconnect sheets of the battery module are in position and fastened tightly. The fasteners, such as, screw and nut assembly, at the predetermined location on the end connections ensures firm fastening of the end connection to the BMS board and also ensures establishing robust electrical connections between the different parts of the end connections and the BMS board.

[00060] Improvements and modifications may be incorporated herein without deviating from the scope of the invention.

LIST OF REFERENCE NUMERALS

100- First embodiment of a Battery Module

101- Casing

102- External connection

103- First end cover

104- Second end cover

105- Battery pack

106- Cell holder

107- Cells

108-BMS board

109- First end connection

110- second end connection

111 -third end connection

201- Terminal holder

202- Mounting provisions 202a-connector 202b-attaching member

203 -mounting provisions on cell holder

204-interconnect sheet

301- Protection device

302-guiding means

303-positive terminal of battery module

401- Base member

402- Connector

403a, 403b- fasteners for fastening the protection device 404a, 404b- location of fastening the protection device 501a, 501b- ends of connector 202a 502a, 502b- ends of connector 402 601- stiffener

700- Second embodiment of battery module

701- Casing 702-first end cover 703a, 703b- end connections

704- Guiding means

705- Holding clamper

706- Cables 801- Vent plug

802, 809- attachment means for end covers

803- Second end cover

804- Battery pack 804a- cell holder

805- Fasteners for fastening the female signal connector

806- BMS board

806a- holes for fastening the female signal connector

807- Female signal connector

808- Male signal connector

808a, 808b- surfaces of the male signal connector

901 -hollow pins

902- Banana plugs

903- Clips

1001- Second terminal holder 1002a, 1002b- mounting provisions 1003a, 1003b-attachment means 1004-protection device 1005a- positive terminal stud 1005b- negative terminal stud

1006a, 1006b-mounting provisions on second terminal holder 1007a, 1007b- gaskets 1008a, 1008b- bolt 1009- Nut

1010, 1012, 1013- connectors 1011- Base member 1101- Cells in cell holder