Description:FIELD
The present disclosure generally relates to a support structure for supporting a cooling plate of a battery. The present invention provides a simple bracket design for cooling plate support at coolant ports. The present invention eases the bracket weld with the frame and keeps the Foam-in-place (FIP) profile as conventional inside the mainframe and does not cross/fall the Foam-in-place (FIP) profile on the bracket weld beam. The present invention protects the Foam-in-place (FIP) leakage from prone weld joints.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
A liquid cooling system is generally composed of a liquid cooling plate, liquid cooling pipeline, cooling pump, cooling valve, and so on. Among them, the liquid cooling plate is one of the most critical parts of the liquid cooling system of the battery pack, and the supporting buffer of the liquid cooling plate is particularly important. A common support buffer scheme is to support the liquid-cooling plate with a support bracket. The support bracket is directly fixed on the battery pack case to ensure the stability of the liquid-cooling plate.
However, the existing support and buffer solutions have the following disadvantages: First, the liquid-cooling plate would undergo frequent vibrations in vehicle maneuvers. However, as a hard elastic material, the plate can quickly absorb the unexpected vibrations that the vehicle suffers, but such unexpected vibrations will also make a large impact on the liquid-cooling plate. The liquid-cooling plate is supported by multiple joints, which results in excessive stress on the local area of the liquid-cooling plate, uneven overall force, and poor stability of the entire supporting structure. Secondly, the liquid-cooling plate is connected to the case by a mechanical structure, such as a nut. When the car is driven for a long time, the support bracket and liquid-cooling plate are prone to wear. In particular, the liquid cooling plate and the case are generally made of aluminum, and there is a risk of deformation and leakage. The leakage of the liquid medium will seriously endanger the safety of the battery pack.
Moreover, to provide firm support to the cooling plate at overhang/coolant ports, slots for coolant outlets were provided. These slots protect the cooling plate from vibrations in vehicle maneuver conditions. Such a design feature also facilitates the secure bolting of the cooling plate to the support bracket alongwith bracket's critical welding with a main frame. As a result of this welding, the Foam-in-Place (FIP) profile intersects with the main frame.
Figures 1A-4A illustrate the conventional/existing cooling plate bracket support. The conventional support bracket is formed through casting, which is welded to the main frame to provide structural support for the cooling plate at the designated cooling port of the battery pack. The welding process involves attaching the support bracket to the frame at both the top and bottom, thereby ensuring a secure and stable foundation for the cooling plate. In this particular conventional design, Foam-in-Place (FIP) is utilized to seal the structure effectively, and its application follows the locations of the screws. Notably, the Foam-in-Place (FIP) profile intersects with the main frame envelope, playing a crucial role in sealing the battery in conjunction with the cooling plate. In the conventional design as shown in Figures 1A-4A, it is imperative to emphasize the significance of welding the bracket completely around the main frame to achieve optimal stability. However, it is essential to note that the accessibility for using a welding torch is limited due to the all-around welding requirement. Additionally, the Foam-in-Place (FIP) profile would cross the weld beam at the balcony, as depicted in Figure 4A, which is critical for sealing.
Therefore, there is a need in the art to implement a support structure for supporting a cooling plate of a battery.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
The main object of the present invention is to propose a support structure for supporting a cooling plate of a battery.
Another object of the present invention is to overcome the drawback by providing a support structure for supporting a cooling plate of a battery so as to have a Foam-in-Place (FIP) profile inside the main frame envelope.
Yet another object of the present invention is to provide firm support to the cooling plate at the coolant spouts of a battery.
Yet another object of the present invention is to design a support structure for supporting a cooling plate of a battery that is a simple sheet metal type support structure.
Yet another object of the present invention is to reduce the unnecessary bracket joint welding all around the main frame.
Yet another object of the present invention is to design a support structure for supporting a cooling plate of a battery such that the Foam-in-Place (FIP) sealing profile does not interface with the weld bead.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
This summary is provided to introduce concepts related to the design of a support structure for supporting a cooling plate of a battery. The present invention provides a simple bracket design for cooling plate support at coolant ports. The present invention eases the bracket weld with the frame and keeps the Foam-in-Place (FIP) profile as conventional inside the mainframe and does not cross/fall the Foam-in-Place (FIP) profile on the bracket weld beam. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
The present disclosure envisages a support structure for supporting a cooling plate of a battery. The support structure comprises a first portion that is horizontally arranged and connectable to a lower floor of a base assembly. A second portion that is vertically arranged and extending perpendicularly from one longitudinal edge of the first portion and connectable to a vertical wall rising from the lower floor of the base assembly. A third portion is horizontally arranged and extending perpendicularly from the second portion in the direction of the first portion, so as to obtain a C-shape profile for the support structure and provide a balcony support portion for a main frame to seal the battery with the cooling plate.
In an aspect, the first portion, the second portion, and the third portion form a one-piece C-shape support structure.
In an aspect, the support structure is made of aluminum.
In an aspect, the first portion and the second portion are connectable to the base assembly by forming multiple weld beams.
In an aspect, the first portion in its middle portion has a U-shaped cutout forming two legs for being welded with the base assembly.
In an aspect, the second portion in its middle portion has a U-shaped cutout for being welded with the base assembly and receiving coolant spouts or ports.
In an aspect, the third portion has two cutouts for receiving coolant spouts or ports, and one of the cutouts of the third portion extends from the U-shaped cutout of the second portion.
In an aspect, the third portion has a pair of holes configured to receive a fastening means for securing the cooling plate.
In an aspect, the third portion has curved ends on a longitudinal edge distant from the second portion.
In an aspect, the third portion has a length and width greater than the length and width of the first portion.
In an aspect, the height of the second portion corresponds to the height of the vertical wall of the base assembly.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
A support structure for supporting a cooling plate of a battery of the present disclosure will now be described with the help of the accompanying drawings, in which:
Figure 1A illustrates an isometric view of a conventional/existing cooling plate support bracket, in accordance with an embodiment of the prior art;
Figure 2A illustrates an isometric view of a conventional/existing support bracket welded on a mainframe, in accordance with an embodiment of the prior art;
Figure 3A illustrates an isometric view of a conventional/existing support bracket as cast, in accordance with an embodiment of the prior art;
Figure 4A illustrates a top view of a conventional/existing foam-in-place profile with a support bracket, in accordance with an embodiment of the prior art;
Figure 1B illustrates an isometric view of a support structure for supporting a cooling plate of a battery, in accordance with an embodiment of the present disclosure;
Figure 2B illustrates an isometric view of a support structure welded on the main frame, in accordance with an embodiment of the present disclosure;
Figure 3B illustrates an isometric view of a support structure for supporting a cooling plate of a battery, in accordance with an embodiment of the present disclosure; and
Figure 4B illustrates a top view of foam in place profile with support structure, in accordance with an embodiment of the present disclosure;

REFERENCE NUMERALS
100, 100’ Support Structure
101, 101’ Cooling Plate
102 First Portion
103 Lower Floor
104 Base Assembly
105 Second Portion
106 Vertical Wall
107 Third Portion
108, 108’ Main Frame
109 Coolant Spouts Or Ports
110 Pair Of Holes
111, 111’ Weld Beams
112, 112’ Foam-in-Place (FIP) Profile

DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
The present disclosure relates, in general, to the field of support structure. More specifically, embodiments of the present invention relate to a support structure for supporting a cooling plate of a battery.
A liquid cooling system is generally composed of a liquid cooling plate, liquid cooling pipeline, cooling pump, cooling valve, and so on. Among them, the liquid cooling plate is one of the most critical parts of the liquid cooling system of the battery pack, and the supporting buffer of the liquid cooling plate is particularly important. A common support buffer scheme is to support the liquid-cooling plate with a support bracket. The support bracket is directly fixed on the battery pack case to ensure the stability of the liquid-cooling plate.
However, the existing support and buffer solutions have the following disadvantages: First, the liquid-cooling plate would undergo frequent vibration in vehicle maneuvers. However, as a hard elastic material, the plate can quickly absorb the unexpected vibrations that the vehicle suffers, but such unexpected vibrations will also make a large impact on the liquid-cooling plate. The liquid-cooling plate is supported by multiple joints, which results in excessive stress on the local area of the liquid-cooling plate, uneven overall force, and poor stability of the entire supporting structure. Secondly, the liquid-cooling plate is connected to the case by a mechanical structure such as a nut. When the car is driven for a long time, the support bracket and liquid-cooling plate are prone to wear. In particular, the liquid cooling plate and the case are generally made of aluminum, and there is a risk of deformation and leakage. The leakage of the liquid medium will seriously endanger the safety of the battery pack.
Moreover, to provide firm support to the cooling plate at overhang/coolant ports, slots for coolant outlets were provided. These slots protect the cooling plate from vibrations in vehicle maneuver conditions. Such a design feature also facilitates the secure bolting of the cooling plate to the support bracket alongwith bracket's critical welding with a main frame. As a result of this welding, the Foam-in-Place (FIP) profile intersects with the main frame.
Figures 1A-4A illustrate the conventional/existing cooling plate 101’ bracket support 100’. The conventional support bracket 100’, is formed through casting, that is welded to the main frame 108’ to provide structural support for the cooling plate 101’ at the designated cooling port of the battery pack. The welding process involves attaching the support bracket 100’ to the frame 108’ at both the top and bottom, thereby ensuring a secure and stable foundation for the cooling plate 101’. In this particular conventional design, Foam-in-Place (FIP) 112’ is utilized to seal the structure effectively, and its application follows the locations of the screws. Notably, the Foam-in-Place (FIP) profile 112’ intersects with the main frame 108’ envelope at the balcony support, playing a crucial role in sealing the battery in conjunction with the cooling plate 101’. In the conventional design as shown in Figures 1A-4A, it is imperative to emphasize the significance of welding the bracket completely around the main frame 108’ to achieve optimal stability. However, it is essential to note that the accessibility for using a welding torch is limited due to the all-around welding requirement. Additionally, the Foam-in-Place (FIP) profile 112’ would cross the weld beam at the balcony, as shown in Figure 4A, which is critical for sealing as the critical balcony welding provided at the junction of the main frame 108’.
Therefore, there is a need in the art to implement a support structure (herein referred to as a support structure “100”) for supporting a cooling plate 101 of a battery. This innovative design eases bracket weld with frame 108 and keeps the Foam-in-Place (FIP) profile 112 inside the mainframe and does not cross/fall the Foam-in-Place (FIP) profile 112 on the bracket weld beam 111. This innovative design will protect the Foam-in-Place (FIP) 112 leakage from prone weld joints.
Figure 1B illustrates an isometric view of a support structure 100 for supporting a cooling plate 101 of a battery. In an aspect, the support structure 100 is being manufactured using aluminium. The support structure 100 comprises a first portion 102 that is horizontally arranged and connectable to a lower floor 103 of a base assembly 104. A second portion 105 is vertically arranged and extending perpendicularly from one longitudinal edge of the first portion 102 and connectable to a vertical wall 106 rising from the lower floor of the base assembly 104. A third portion 107 is horizontally arranged and extends perpendicularly from the second portion in the direction of the first portion 102, so as to obtain a C-shape profile for the support structure 100 and provide a balcony support portion for a main frame 108 to seal the battery with the cooling plate 101.
Figure 2B illustrates an isometric view of a support structure 100 welded on the main frame 108, in accordance with an embodiment of the present disclosure. The first portion 102 and the second portion 105 are connectable to the base assembly 104 by forming multiple weld beams 111. In an embodiment, the first portion 102 in its middle portion has a U-shaped cutout forming two legs for being welded with the base assembly 104. The second portion 105 in its middle portion has a U-shaped cutout for being welded with the base assembly 104 and receiving coolant spouts or ports 109. The third portion 107 has two cutouts for receiving coolant spouts or ports 109, wherein one of the cutouts of the third portion 107 extends from the U-shaped cutout of the second portion 105. In an embodiment, the third portion 107 has a pair of holes 110 which are configured to receive a fastening means for securing the cooling plate 101. In an embodiment, the third portion 107 has curved ends on a longitudinal edge distant from the second portion 105. In an embodiment, the third portion 107 has a length and width greater than the length and width of the first portion 102. In an embodiment, the height of the second portion 105 corresponds to the height of the vertical wall 106 of the base assembly 104.
Figure 3B illustrates an isometric view of a support structure 100 for supporting a cooling plate 101 of a battery, in accordance with an embodiment of the present disclosure. The first portion 102, the second portion 105, and the third portion 107 form a one-piece C-shape support structure. In an aspect, the support structure 100 is made of aluminum.
Figure 4B illustrates an isometric view of Foam-in-Place (FIP) Profile 112 with the support structure 100, in accordance with an embodiment of the present disclosure. As illustrated in Figure 4B, the support structure 100 for supporting the cooling plate 101 of a battery has a Foam-in-Place (FIP) profile 112 inside the main frame 108 envelope. The Foam-in-place (FIP) sealing profile 112 does not interface with the weld bead. In an aspect, in the present invention, there is no need for balcony welding at the junction of the main frame 109 of the cooling plate 101. In an aspect, Foam-in-place (FIP) profile 112 is kept inside the mainframe 108 envelopes and maintained inline at the screw axis.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, a support structure for supporting a cooling plate of a battery that:
• provides firm support to the cooling plate at the coolant spouts of a battery;
• has a Foam-in-Place (FIP) profile inside the main frame envelope;
• is a simple sheet-metal type support structure;
• protects the cooling plate from vibrations in vehicle maneuver conditions;
• eliminates weld criticality; and
• the foam-in-place (FIP) sealing profile does not interface with the weld bead.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles, or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions, or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A support structure (100) for supporting a cooling plate (101) of a battery, said support structure (100) comprises:
a first portion (102) horizontally arranged and connectable to a lower floor (103) of a base assembly (104);
a second portion (105) vertically arranged and extending perpendicularly from one longitudinal edge of said first portion (102) and connectable to a vertical wall (106) rising from the lower floor of said base assembly (104); and
a third portion (107) horizontally arranged and extending perpendicularly from said second portion in the direction of said first portion (102), so as to obtain a C-shape profile for the support structure (100) and provide a balcony support portion for a main frame (108) to seal the battery with the cooling plate (101).
2. The support structure (100) as claimed in claim 1, wherein said first portion (102), said second portion (105), and said third portion (107) form a one-piece C-shape support structure;
wherein said support structure (100) is made of aluminum.
3. The support structure (100) as claimed in claim 1, wherein said first portion (102) and the second portion (105) are connectable to said base assembly (104) by forming multiple weld beams (111).
4. The support structure (100) as claimed in claim 1, wherein said first portion (102) in its middle portion has a U-shaped cutout forming two legs for being welded with said base assembly (104).
5. The support structure (100) as claimed in claim 1, wherein said second portion (105) in its middle portion has a U-shaped cutout for being welded with said base assembly (104) and receiving coolant spouts or ports (109).
6. The support structure (100) as claimed in claim 1, wherein said third portion (107) has two cutouts for receiving coolant spouts or ports (109), and wherein one of said cutouts of said third portion (107) extends from the U-shaped cutout of said second portion (105).
7. The support structure (100) as claimed in claim 1, wherein said third portion (107) has a pair of holes (110) configured to receive a fastening means for securing the cooling plate (101).
8. The support structure (100) as claimed in claim 1, wherein said third portion (107) has curved ends on a longitudinal edge distant from said second portion (105).
9. The support structure (100) as claimed in claim 1, wherein said third portion (107) has length and width greater than the length and width of said first portion (102).
10. The support structure (100) as claimed in claim 1, wherein said height of said second portion (105) corresponds to the height of said vertical wall (106) of said base assembly (104).

Dated this 26th day of December, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI