Description:FIELD
The present disclosure relates to cooling plates of battery pack assemblies.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
The batteries in the high voltage battery pack tend to reject more heat and are hence subjected to high temperatures during maximum charging and discharging cycle in events like DC fast charging or sudden acceleration. Such high battery temperatures result in potential failure mode of the thermal runaway of the battery. Conversely, when the battery is suddenly subjected to low temperatures, its life is adversely impacted. Therefore, it is necessary that the batteries are operated at optimum temperature range. A cooling plate is an essential component of a high voltage battery pack assembly that helps in maintaining an optimum battery temperature by either cooling or heating the batteries.
Cooling plates allow a coolant to pass therethrough to help dissipate heat from the batteries. Conventional cooling plates are provided with flow channels provided in battery module-wise cooling sections. Further, different cooling sections mean uneven discharge rates. To bring uniformity to the uneven discharge rate, local throttling sections are introduced in the flow channels of the conventional plates. However, manufacturing such flow channels is tedious and often causes variations in the dimensions of the throttling sections, thereby killing the very purpose of providing the throttling sections. Further, the battery module-wise cooling sections means asymmetric configuration of the cooling plate.
There is therefore felt a need for a cooling plate that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a cooling plate for a battery pack assembly.
Another object of the present disclosure is to provide a cooling plate having a global cooling channel configuration instead of a local cooling channel configuration.
Yet another object of the present disclosure is to provide a cooling plate that has relatively better structural rigidity and flatness.
Another object of the present disclosure is to provide a cooling plate that maintains an optimum temperature of the battery pack.
Still another object of the present disclosure is to provide a cooling plate that eliminates the need of provision of throttling.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a cooling plate for a battery pack assembly. The cooling plate is configured to accommodate a plurality of batteries thereon. The cooling plate is defined by an operative inner surface and an operative outer surface. The cooling plate comprises an operative first region, an operative second region and an operative central region defined on the operative inner surface. An inlet port is configured on the plate to receive a coolant. At least one flow channel is configured on each of the operative first region, the operative second region and the operative central region, in fluid communication with the inlet port to receive the coolant therefrom to facilitate cooling of the batteries. An outlet port is configured on the plate. The outlet port is configured to fluidly communicate with the flow channels to receive the coolant from the channels, and is further configured to discharge the coolant.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A cooling plate, of the present disclosure, for a battery pack assembly will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a top view of the cooling plate of the present disclosure;
Figure 2 illustrates a bottom top view of the cooling plate of Figure 1;
Figure 3 illustrates an exploded view of the cooling plate and the battery frame with batteries;
Figure 4 illustrates a schematic top view of the cooling plate with the batteries accommodated thereon;
Figure 5 illustrates a close-up top view of a conventional cooling plate showing the flow channels configured on the conventional cooling plate;
Figure 6 illustrates a close-up view of a cross-section of the conventional cooling plate, of Figure 5, depicting the channels;
Figure 7 illustrates a close-up top view of the cooling plate, of Figure 1, showing the flow channels configured on the cooling plate;
Figure 8 illustrates a close-up view of a cross-section of the cooling plate, of Figure 7, depicting the channels of the cooling plate; and
Figure 9 illustrates foam pads provided on the cooling plate of Figure 2.
LIST OF REFERENCE NUMERALS
05 battery frame
10 battery
30 conventional cooling plate
35 flow channel of conventional cooling plate
100 cooling plate
102 operative first region
104 operative central region
106 operative second region
108 inlet port
110 flow channel
112 outlet port
114 inflow passage
116 subchannel
117 point of mergence
118 first channel
119 second channel
120 first hole
122 contours
124 second hole
126 depression
130 foam pad
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”, “includes” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
A cooling plate (100), of the present disclosure, for a battery pack assembly will now be described in detail with reference to Figure 1 through Figure 8.
The cooling plate (100) is configured to be provided on a battery frame. The cooling plate (100) is defined by a channel plate and a flat plate brazed with each other to form a single cooling plate (100). The cooling plate (100) has an operative inner surface and an operative outer surface. A plurality of batteries (10) is provided below the cooling plate (100) which helps in dissipating heat generated by the batteries (10). Typically, the operative outer surface of the cooling plate (100) is configured to abut the batteries (10).
The plate (100) comprises an operative first region (102), an operative second region (106) and an operative central region (104) defined on the operative inner surface. An inlet port (108) is configured on the plate (100), and is configured to receive a coolant. At least one flow channel (110) is configured on each of the operative first region (102), the operative central region (104) and the operative second region (106) . The flow channels (110) are configured to fluidly communicate with the inlet port to receive the coolant therefrom to facilitate cooling of the batteries (10). An outlet port (112) is configured to fluidly communicate with the flow channels (110) to receive the coolant from the channels, and is further configured to discharge the coolant.
In an operative configuration of the cooling plate (100), the coolant is configured to be received through the inlet port (108) at a first predetermined temperature in the range of 20°C to 30°C, and is configured to be discharged through the outlet port (112) at a second predetermined temperature in the range of 25°C to 35°C. While passing through the flow channels (110), the coolant absorbs heat from the batteries (10) and cools the batteries (10).
In an embodiment, the cooling plate (100) is configured to maintain the battery pack assembly at an optimum temperature varying in the range of 25°C to 35°C.
In one embodiment, each flow channel (110) includes an inflow passage (114) configured to extend from the inlet port. In another embodiment, the inflow passage (114) has a wavy configuration. The wavy configuration helps in balancing the coolant flow rate in the cooling plate .
In another embodiment, the inflow passage (114) is bifurcated into a pair of subchannels (116) that are configured to extend in an operative longitudinal axis with respect to the cooling plate (100). Each of the subchannels (116) has a meandering configuration provided with at least two meander bends.
In yet another embodiment, the subchannels (116) are configured to fluidly communicate with each other.
In an embodiment, each flow channel (110) includes an outflow passage defined by a first channel (118) and a pair of second channels (119). The first channel (118) is configured on the plate (100) along an operative lateral axis. The first channel (118) is configured to fluidly communicate with downstream of each of the subchannels (116) to facilitate confluence of the coolant from the subchannels (116). In another embodiment, the first channels (118) of the operative first region (102), the operative second region (106) and the operative central region (104) are all configured to merge into a single channel. In yet another embodiment, the first channels (118) are configured along the lateral peripheral edges of the plate (100). Each of the pair of second channels (119) is configured to extend from either operative ends of the first channel (118) in the operative longitudinal axis. The second channels (119) are configured to fluidly communicate with the outlet port (112) to enable flow of the coolant to the outlet port (112). In an embodiment, the second channels (119) are configured along either longitudinal peripheral edges of the plate (100).
In an embodiment, the operative first region (102) and the operative second region (106) are symmetrical to each other.
In an embodiment, a plurality of compartments is defined on each flow channel. Each compartment being configured to accommodate a battery thereon. In another embodiment, the flow channels (110) of the operative first region (102) and the operative second region (106) can each accommodate at least four batteries (10) thereon. In still another embodiment, the flow channel (110) of the operative central region (104) can accommodate at least three batteries (10) thereon.
In an embodiment, a plurality of first holes (120) is configured on the plate (100) at a predetermined spaced apart distance from each other. The first holes (120) are configured to receive a first set of fasteners for facilitating attachment of the cooling plate (100) with a battery frame, more specifically the cross-members of the battery frame.
In another embodiment, contours (122) are configured along the subchannels (116) to accommodate the first holes (120) therebetween.
In an embodiment, a plurality of second holes (124) is configured on the plate (100) at a predetermined spaced apart distance from each other. The second holes (124) are configured to receive a second set of fasteners for facilitating attachment of the cooling plate (100) with the battery frame, more specifically the long-members of the battery frame.
In an embodiment, a plurality of depressions (126) is embossed on the operative outer surface of the cooling plate (100) such that the depressions (126) protrude out through the operative inner surface of the cooling plate (100) through the space between the subchannels (116). The depressions (126) are configured to facilitate proper abutment of the cell module top brackets of the cells on the cooling plate (100).
In a conventional cooling plate, as shown in Figure 5, there is no point of mergence between the inflow passages of the cooling plate. Further, the flat plate is brazed to the channel plate throughout its surface area as shown in Figure 6. However, many a time, due to manufacturing variability of the inflow passages brazing does not take place as desired, and a gap is formed between the plates which causes internal leakage between the various passages. More specifically, as the inflow passages are configured such that they do not merge at any point of contact, the coolant passing through the passages mix with each other through the gap.
To counter this issue, the subchannels (116) of each flow channel (110) are configured to merge with each other to facilitate a smooth flow therebetween. The point of mergence (117), as shown in Figure 7, between the subchannels (116) also defines the end of the depression (126), thereby allowing the cell to nest thereagainst. Further, it avoids the need for brazing at the location of mergence, instead brazing need be done only at specific locations between the flat plate and the channel plate of the cooling plate, as illustrated by Figures 7 and 8.
In an embodiment, the cooling plate (100) is manufactured from aluminium or steel.
In another embodiment, the coolant is selected from a group of liquids consisting of water, a refrigerant, or ethylene glycol.
The cooling plate (100), of the present disclosure, has a longer cooling channel configuration as compared to the conventional module-wise cooling configuration which is shorter in length, as a result of which the stiffness and the flatness of the plate (100) is comparatively improved. Further, the cooling plate (100) succeeds in eliminating the need of provision of throttling, thereby avoiding uneven flow caused due to uneven manufacturing of the throttling means.
In an embodiment, thickness of the cooling plate (100) ranges between 1-2 mm. The relatively thicker plate (100) combined with passivation helps avoid top cover of the battery frame assembly. The cooling plate (100) itself acts as the top cover to protect the battery pack against outside intrusion. The configuration of the flow channels (110) facilitates avoiding of the overlap of hot coolant with the battery surface, and helps in cooling the battery terminals first to reduce peak temperature. Further, the symmetric configuration of the first region (102) and the second region (106) reduces the number of leakage joints.
In an embodiment, a foam pad is provided on an operative inner surface of the cooling plate (100) at the regions devoid of the batteries (10), as shown in Figure 9. The foam pad is configured to absorb water accumulated due to the process of thermal condensation achieved as a by-product of operation of the cooling plate, thereby protecting the electrical components of the battery pack from damage due to moisture.
In an embodiment, the foam pad is of polyurethane (PU).
In another embodiment, the foam pad is of silicon.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of a cooling plate for a battery pack assembly which:
• is provided with global cooling channel configuration instead of local cooling channel configuration that adds structural rigidity to the plate and improves the cooling plate flatness;
• maintains an optimum temperature of the battery pack; and
• eliminates the need of provision of throttling.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of 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 cooling plate (100) for a battery pack assembly, said cooling plate (100) configured to accommodate a plurality of batteries (10) thereon, said cooling plate (100) having:
• an operative inner surface; and
• an operative outer surface;
said cooling plate (100) comprising:
• an operative first region (102), an operative second region (106) and an operative central region (104) defined on said operative inner surface;
• an inlet port (108) configured to receive a coolant; and
• at least one flow channel (110) configured on each of said operative first region (102), said operative second region (106) and said operative central region (104), in fluid communication with said inlet port to receive the coolant therefrom to facilitate cooling of the batteries (10); and
• an outlet port (112) configured to fluidly communicate with said at least one flow channel (110) to receive the coolant from said channels, and further configured to discharge the coolant.
2. The cooling plate (100) as claimed in claim 1, wherein each flow channel (110) includes an inflow passage (114) configured to extend from said inlet port (108).
3. The cooling plate (100) as claimed in claim 2, wherein said inflow passage (114) has a wavy configuration.
4. The cooling plate (100) as claimed in claim 2, wherein said inflow passage (114) is bifurcated into a pair of subchannels (116) configured to extend in an operative longitudinal axis, each of said subchannels (116) having a meandering configuration provided with at least two meander bends.
5. The cooling plate (100) as claimed in claim 4, wherein each flow channel (110) includes an outflow passage defined by a first channel (118) configured on said plate (100) along an operative lateral axis, and configured to fluidly communicate with downstream of each of said subchannels (116) to facilitate confluence of the coolant from said subchannels (116).
6. The cooling plate (100) as claimed in claim 5, wherein the first channels (118) of said operative first region (102), said operative second region (106) and said operative central region (104) are configured to merge into a single channel.
7. The cooling plate (100) as claimed in claim 6, wherein said outflow passage includes a pair of second channels (119), each second channel (119) being configured to extend from either operative ends of said first channel (118) in said operative longitudinal axis, said second channels (119) being configured to fluidly communicate with said outlet port (112) to enable flow of the coolant to said outlet port (112).
8. The cooling plate (100) as claimed in claims 5 and 7, wherein said first channels (118) and said second channels (119) are configured along the peripheral edges of said plate (100).
9. The cooling plate (100) as claimed in claim 1, wherein said operative first region (102) and said operative second region (106) are symmetrical to each other.
10. The cooling plate (100) as claimed in claim 1, wherein a plurality of compartments is defined on each flow channel, each compartment being configured to accommodate a battery (10) thereon.
11. The cooling plate (100) as claimed in claim 1, wherein a plurality of first holes (120) is configured on said cooling plate (100) at a predetermined spaced apart distance from each other, said first holes (120) configured to receive a first set of fasteners for facilitating attachment of said cooling plate (100) with a battery frame.
12. The cooling plate (100) as claimed in claim 1, wherein contours (122) are configured along said subchannels (116) to accommodate said first holes (120) therebetween.
13. The cooling plate (100) as claimed in claim 1, wherein a plurality of second holes (124) is configured on said cooling plate (100) at a predetermined spaced apart distance from each other, said second holes (124) configured to receive a second set of fasteners for facilitating attachment of said cooling plate (100) with the battery frame.
14. The cooling plate (100) as claimed in claim 1, wherein a plurality of depressions (126) is configured on the operative outer surface of the cooling plate (100) such that the depressions (126) protrude out through the operative inner surface of the cooling plate (100) through the space between the subchannels (116), said depressions (126) being configured to facilitate abutment of the cell module top brackets of the cells on said cooling plate (100).
15. The cooling plate (100) as claimed in claim 1, wherein thickness of said cooling plate (100) ranges between 1-2mm.
16. The cooling plate (100) as claimed in claim 1, wherein said cooling plate (100) is configured to maintain the battery pack assembly at a cell temperature in the range of 25°C to 35°C.
17. The cooling plate (100) as claimed in claim 1, wherein said cooling plate (100) is manufactured from aluminium or steel.
18. The cooling plate (100) as claimed in claim 1, wherein the coolant is selected from a group of liquids consisting of water, a refrigerant, or ethylene glycol.
19. The cooling plate (100) as claimed in claim 1, wherein the coolant is configured to be received through said inlet port (108) at a first predetermined temperature in the range of 20°C to 30°C and the coolant is configured to be discharged through said outlet port (112) at a second predetermined temperature in the range of 25°C to 35°C.

Dated this 28th day of March, 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