Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]

TITLE OF INVENTION
Cooling System for a Battery Pack

APPLICANT
TVS MOTOR COMPANY LIMITED, an Indian company, having its address at “Chaitanya”, No.12 Khader Nawaz Khan Road, Nungambakkam, Chennai 600 006, Tamil Nadu, India.

PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
[001] Present invention relates to a cooling system for a battery pack. Embodiments of the present invention relate to the cooling system for the battery pack of a vehicle.

BACKGROUND OF THE INVENTION
[002] In recent past, advancements have been made in batteries for electric vehicles, for delivery of power while minimizing charging cycles. However, one of the biggest challenges that still remains for batteries is the ability to provide an effective cooling system or a cooling mechanism. This is due to the fact that, batteries work based on the principle of a voltage differential. At high temperatures, electrons inside the batteries are excited which decreases the difference in voltage between an anode side and a cathode side of the battery.
[003] Further, batteries are typically manufactured to operate within a temperature range and thus stop working when temperature in the battery exceeds the temperature range. Also, if a large internal temperature difference is developed in the battery, charge and discharge rates of each cell in the battery may become inconsistent. Consequently, deteriorating performance of the battery, which is undesirable. Additionally, potential thermal stability issues, such as capacity degradation, thermal runaway, and fire explosion, could occur if the battery overheats or if there is non-uniform temperature distribution in the battery pack, which can be catastrophic.
[004] Thus, there is a need for a cooling system for a battery pack, which addresses at least one or more aforementioned problems.

SUMMARY OF THE INVENTION
[005] In one aspect, a cooling system for a battery pack is disclosed. The cooling system comprises a tray member adapted to receive one or more cell modules of the battery pack. One or more case members extend from an outer periphery of the tray member. Each of the one or more case members is adapted to surround the one or more cell modules of the battery pack and comprises an inlet port and an outlet port, wherein a cooling passage is provided between an inner surface of each of the case members and an outer surface of the one or more cell modules. The cooling passage is fluidly connected to the inlet port and the outlet port. Further, a blower unit is mounted to the one or more case members and is coplanar to each of the one or more cell modules. The blower unit is coupled to the inlet port for routing cooling fluid into the cooling passage for cooling the one or more cell modules of the battery pack.
[006] In an embodiment, each of the one or more cell modules comprises a plurality of fins, wherein the blower unit is positioned on the one or more case member to be coplanar with the plurality of fins.
[007] In an embodiment, the inlet port is disposed on an aft portion of the blower unit and the outlet port is disposed on a fore portion of the blower unit.
[008] In an embodiment, one or more temperature sensors and one or more pressure sensors are disposed in the one or more case members. Each of the one or more temperature sensors is adapted to procure a temperature parameter of the battery pack and each of the one or more pressure sensors is adapted to monitor a pressure parameter within the battery pack.
[009] In an embodiment, each of the one or more temperature sensors and the one or more pressure sensors are communicably coupled to a control unit. The control unit is adapted to determine temperature of the battery pack based on the temperature parameter and pressure within the battery pack based on the pressure parameter, wherein the control unit is adapted to activate the blower unit for circulating the cooling fluid into the one or more case members, when at least one of the temperature of the battery pack exceeds a predetermined temperature value and the pressure within the battery pack exceeds a predetermined pressure value.
[010] In an embodiment, the cooling system is mounted below a driver seat and under a cabin assembly in a passenger vehicle.
[011] In an embodiment, the cooling system is mounted in at least one of under a load deck in a cargo vehicle.
[012] In an embodiment, each of the one or more case members comprises at least one baffle plate disposed in each of the one or more case members and positioned rearwardly to the aft portion of the blower unit. The baffle plate is adapted to separate an exhaust fluid from an inlet fluid entering through the blower unit in the cooling passage.
[013] In an embodiment, each of the one or more case members comprises a top rim surface. The top rim surface is adapted to engage with a top portion of the one or more cell modules, wherein the top rim surface upon engagement with the top portion of the one or more cell modules ensures sealing of the cooling passage.
[014] In an embodiment, the blower unit is disposed above one or more base members of the tray member.

BRIEF DESCRIPTION OF THE DRAWINGS
[015] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 is an exploded view of a cooling system including a battery pack, in accordance with an exemplary embodiment of the present invention.
Figure 2 is a perspective view of the cooling system including the battery pack, in accordance with an exemplary embodiment of the present invention.
Figure 3 is a perspective view of one or more case members of the cooling system for one or more cell modules of the battery pack, in accordance with an exemplary embodiment of the present invention.
Figure 4 is a bottom view of the one or more case members, in accordance with an exemplary embodiment of the present invention.
Figure 5 is a front view of the one or more case members, in accordance with an exemplary embodiment of the present invention.
Figure 6 is a bottom view of the cooling system depicting flow of cooling fluid, in accordance with an exemplary embodiment of the present invention.
Figure 7 is a top view of the cooling system, in accordance with an exemplary embodiment of the present invention.
Figure 8 is a partial exploded view of the cooling system, in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[016] The present invention relates to a cooling system for a battery pack. Particularly, the present invention relates to the cooling system for the battery pack in a vehicle which may be a three-wheeled vehicle or a three-wheeled cargo vehicle or a multi-wheeled vehicle. In an embodiment, the battery pack may comprise a single cell module or battery module or a plurality of cell modules or battery modules encased within a housing.
[017] Figure 1 is an exploded view of a cooling system 100 for a battery pack 102, in accordance with an exemplary embodiment of the present invention. The cooling system 100 in accordance with the present disclosure is capable of providing a uniform distribution of a cooling fluid around the battery pack 102 for cooling, thereby enhancing battery performance and durability. In an embodiment, the cooling system 100 is disposed in a vehicle such as a three-wheeled vehicle or a cargo vehicle or a multi-wheeled vehicle as per requirement.
[018] In an embodiment, the cooling system 100 is placed under a driver seat (not shown) and under a cabin assembly (not shown) in a passenger vehicle. Such a placement of the cooling system 100 in the vehicle, ensures that a cooling fluid such as natural air is directed towards the cooling system 100, thereby ensuring supply of fresh cooling fluid for cooling the battery pack 102. In this scenario, the driver seat may be rotatably mounted on a seat frame member (not shown) of the vehicle, so that the driver seat may be readily removed or operated to an open condition (not shown) for accessing the cooling system 100.
[019] In another embodiment, the cooling system 100 may be provided under a loading deck (not shown) in a cargo vehicle. Such a placement of the cooling system 100 in the vehicle, ensures that the cooling fluid is directed towards the cooling system 100, thereby ensuring supply of the fresh cooling fluid for cooling the battery pack 102.
[020] In the present embodiment, the battery pack 102 may comprise of one or more cell modules 106a, 106b. In the present embodiment, the one or more cell modules 106a, 106b comprises a first cell module 106a and a second cell module 106b, wherein the first cell module 106a and the second cell module 106b are mounted adjacent to one another. Alternatively, the battery pack 102 may comprise of a single cell module, as per power delivery requirements.
[021] In an embodiment, each of the one or more cell modules 106a, 106b comprises an outer surface 134 provided with a plurality of fins 118. The plurality of fins 118 enhances an outer surface area of each of the one or more cell modules 106a, 106b for dissipation of heat and for contact with the cooling fluid. Thus, enhancing cooling efficiency of the cooling system 100. In an embodiment, the outer surface 134 is referenced as 134a for the first cell module 106a, and as 134b for the second cell module 106b for ease of understanding and clarity.
[022] In the present embodiment, the plurality of fins 118 comprises a first plurality of fins 118a and a second plurality of fins 118b. The first plurality of fins 118a are provided on the outer surface 134a of the first cell module 106a. The second plurality of fins 118b are provided on the outer surface 134b of the second cell module 106b.
[023] In an embodiment, the plurality of fins 118 may extend linearly on the outer surface 134 along a longitudinal plane (not shown) of each of the one or more cell modules 106a, 106b. Alternatively, the plurality of fins 118 may be a trapezoidal fin, a rectangular fin or a concave fin as per design feasibility and requirement.
[024] Referring to Figure 2 in conjunction with Figure 1, the cooling system 100 comprises a tray member 104 adapted to receive and support each of the one or more cell modules 106a, 106b of the battery pack 102. The tray member 104 may be an elongated support member for supporting each of the one or more cell modules 106a, 106b. In an embodiment, the tray member 104 comprises one or more base members 104b for supporting each of the one or more cell modules 106a, 106b. The one or more base members 104b may be a plate-like member for supporting a bottom surface (not shown) of each of the one or more cell modules 106a, 106b. In the present embodiment, the tray member 104 is adapted to support the first cell module 106a and the second cell module 106b. The first cell module 106a and the second cell module 106b are positioned adjacent to one another along a length of the tray member 104.
[025] An outer periphery 104a of the tray member 104 extends perpendicularly from the one or more base members 104b and is adapted to retain each of one or more cell modules 106a, 106b on the one or more base members 104b. As such, the outer periphery 104a acts as a vertical rim surface for containing the one or more cell modules 106a, 106b within the tray member 104. In an embodiment, the outer periphery 104a may be fastened or welded to the one or more base members 104b as per requirement.
[026] Further, the outer periphery 104a may comprise a front surface 136, a rear surface 138, a left-side surface 140 and a right-side surface 142. The front surface 136, the rear surface 138, the left-side surface 140 and the right-side surface 142 extend vertically from respective a front portion (not shown), a rear portion (not shown), a left-side portion (not shown) and a right-side portion (not shown) of the one or more base members 104b. The vertical extension of the front surface 136, the rear surface 138, the left-side surface 140 and the right-side surface 142 is considered based on the dimensions of the one or more cell modules 106a, 106b being supported on the one or more base members 104b.
[027] In an embodiment, the one or more base members 104b may be a made of a single support member or multiple support members positioned strategically on the tray member 104, for receiving and supporting the bottom surface of each the one or more cell modules 106a, 106b. In an embodiment, the tray member 104 (i.e. the one or more base members 104b and the outer periphery 104a) may be made of at least one of a metallic material or a non-metallic material or a composite material for supporting the one or more cell modules 106a, 106b as per design feasibility and requirement. In an embodiment, the dimensions of the tray member 104 are selected based on the dimensions of the one or more cell modules 106a, 106b. In an embodiment, the one or more base members 104b are placed in a cavity (not shown) provided in the tray member 104 for supporting the one or more cell modules 106a, 106b.
[028] In an embodiment, one or more vertical wall members 128a, 128b are provided at selective locations on the outer periphery 104a of the tray member 104. Each of the one or more vertical wall members 128a, 128b are capable of engaging with the one or more cell modules 106a, 106b for restricting movement of the one or more cell modules 106a, 106b upon mounting on the tray member 104 in the up-down direction. The tray member 104 restricts movement of the one or more cell modules 106a, 106b along a lateral axis and a linear axis. In the present embodiment, the one or more vertical wall members 128a, 128b comprises a first vertical wall member 128a and a second vertical wall member 128b. The first vertical wall member 128a is adapted to engage with the first cell module 106a, while the second vertical wall member 128b is adapted to engage with the second cell module 106b. As such, the first vertical wall member 128a is adapted to restrict movement of the first cell module 106a, while the second vertical wall member 128b is adapted to restrict movement of the second cell module 106b.
[029] In an embodiment, the first vertical wall member 128a may be mounted on the right-side surface 142 and/or the left-side surface 140 of the outer periphery 104a for engagement with the first cell module 106a. In an embodiment, the first vertical wall member 128a may be mounted on the right-side surface 142 and/or the left-side surface 140 of the outer periphery 104a through conventional mounting techniques known in the art such as fastening, welding and the like.
[030] In an embodiment, the second vertical wall member 128b may be mounted on the right-side surface 142 and/or the left-side surface 140 of the outer periphery 104a for engagement with the second cell module 106a. In an embodiment, the second vertical wall member 128b may be mounted on the right-side surface 142 and/or the left-side surface 140 of the outer periphery 104a through conventional mounting techniques known in the art such as fastening, welding and the like.
[031] In an embodiment, one or more cap members 130a, 130b are provided for securely positioning the one or more cell modules 106a, 106b and for engaging with the one or more vertical wall members 128a, 128b, respectively. Each of the one or more cap members 130a, 130b have a central portion (not shown) that interface with a top surface (not shown) of the one or more cell modules 106a, 106b and edge portions (not shown) that engage with the one or more wall portions 128a, 128b, thereby engaging the one or more cell modules 106a, 106b with the one or more wall portions 128a, 128b.
[032] In the present embodiment, the one or more cap members 130a, 130b comprises a first cap member 130a and a second cap member 130b. The first cap member 130a is adapted to interface with the first cell module 106a and engage with the first vertical wall member 128a, while the second cap member 130b is adapted to interface with the second cell module 106b and engage with the second vertical wall member 128b.
[033] In an embodiment, the one or more cap members 130a, 130b are engaged to the one or more vertical wall members 128a, 128b through conventional mounting techniques known in the art such as fastening, snap fitting. Accordingly, the first cap member 130a is fastened to the first vertical wall member 128a, while the second cap member 130b is fastened to the second vertical wall member 128b.
[034] Referring to Figure 3 in conjunction with Figures 1 and 2, the cooling system 100 further comprises one or more case members 108a, 108b extending vertically from the outer periphery 104a of the tray member 104. Each of the one or more case members 108a, 108b is adapted to surround the one or more cell modules 106a, 106b of the battery pack 102. The one or more case members 108a, 108b surround the one or more cell modules 106a, 106b such that, a cooling passage 114 (shown in Figure 6) is provided between an inner surface (indicated as 132a, 132b in Figure 3) of each of the one or more case members 108a, 108b and the outer surface 134 (shown in Figures 1 and 6) of the one or more cell modules (106a, 106b). The cooling passage 114 ensures that the cooling fluid directed to the cooling system 100 is circulated around each of the one or more cell modules 106a, 106b. In an embodiment, the cooling passage 114 may comprise a first cooling passage 114a (shown in Figure 6) and a second cooling passage 114b (shown in Figure 6).
[035] Further, each of the one or more case members 108a, 108b comprises an inlet port 110 and an outlet port 112. The inlet port 110 is adapted to route the cooling fluid into the cooling passage 114 for circulation around each of the one or more cell modules 106a, 106b through the cooling passage 114a and 114b. The outlet port 112 is adapted to discharge the cooling fluid from each of the one or more case members 108a, 108b, upon circulation around each of the one or more cell modules 106a, 106b.
[036] In the present embodiment, the one or more case members 108a, 108b comprises a first case member 108a. The first case member 108a comprises a left-side wall 144a, a right-side wall 146a and a rear wall 148a extending vertically from the tray member 104. The left-side wall 144a extends from the left-side surface 140, the right-side wall 146a from the right-side surface 142 and the rear wall 148a from an intermediate portion of the left-side surface 140 and the right-side surface 142 of the outer periphery 104a of the tray member 104. The left-side wall 144a, the right-side wall 146a and the rear wall 148a are adapted to surround the first cell module 106a, such that the first cooling passage 114a is formed between the inner surface 132a of the first case member 108a and the outer surface 134a of the first cell module 106a. In an embodiment, inner surface 132a corresponds to inner surface of the left-side wall 144a, the right-side wall 146a and the rear wall 148a of the first case member 108a. A first inlet port 110a is formed on one of the left-side wall 144a and the right-side wall 146a and is oriented to be positioned at a front side 150a of the first case member 108a. The first inlet port 110a is adapted to route the cooling fluid into the first cooling passage 114a for circulation around the first cell module 106a. A first outlet port 112a is also provided for the first case member 108a. The first outlet port 112a is provided on the front side 150a on the remaining of the left-side wall 144a or the right-side wall 146a and is located adjacent to the first inlet port 110a. The first outlet port 112a is adapted to discharge the cooling fluid from the first case member 108a, upon circulation around the first cell module 106a. In an embodiment, the first inlet port 110a is mounted on one of the left-side wall 144a and the right-side wall 146a through conventional mounting techniques known in the art.
[037] In an embodiment, the first case member 108a comprises a mounting member 152 provided on at least one of the left-side wall 144a and/or the right-side wall 144a. The mounting member 152 is adapted to engage or receive the first vertical wall member 128a (as shown in Figures 2 and 8). The mounting member 152 upon engagement with the first vertical wall member 128a restricts the movement of the first case member 108a in a top-down direction. In an embodiment, the mounting member 152 may comprise one or more slots (not shown) for engagement with the first vertical wall member 128a.
[038] In the present embodiment, the one or more case members 108a, 108b comprises a second case member 108b. The second case member 108b comprises a left-side wall 144b, a right-side wall 146b and a rear wall 148b extending vertically from the tray member 104. The left-side wall 144b extends from the right-side surface 142, the right-side wall 146b from the left-side surface 140 and the rear wall 148b from the intermediate portion of the left-side surface 140 and the right-side surface 142 of the outer periphery 104a of the tray member 104. The second case member 108b is located adjacent to the first case member 108a such that, the rear wall 148b of the second case member 108b faces the rear wall 148a of the first case member 108a. The left-side wall 144b, the right-side wall 146b and the rear wall 148b are adapted to surround the second cell module 106b, such that the second cooling passage 114b is formed between the inner surface 132b of the second case member 108b and the outer surface 134b of the second cell module 106b. In an embodiment, the inner surface 132b corresponds to inner surface of the left-side wall 144b, the right-side wall 146b and the rear wall 148b of the second case member 108b. A second inlet port 110b is formed on the left-side wall 144b or the right-side wall 146b and is oriented to be positioned at a front side 150b of the second case member 108b. The second inlet port 110b is adapted to route the cooling fluid into the second cooling passage 114b for circulation around the second cell module 106b. A second outlet port 112b is also provided for the second case member 108b. The second outlet port 112b is provided on the front side 150b and is located adjacent to the second inlet port 110b. The second outlet port 112b is adapted to discharge the cooling fluid from the second case member 108b, upon circulation around the second cell module 106b. In an embodiment, the second inlet port 110b is mounted on one of the left-side wall 144b and the right-side wall 146b through conventional mounting techniques known in the art.
[039] In an embodiment, the inlet port 110 is the first inlet port 110a in instances pertaining to the first case member 108a. Also, the inlet port 110 is the second inlet port 110b in instances pertaining to the second case member 108b. As such, the embodiments pertaining to the inlet port 110 may be considered for the first inlet port 110a and the second inlet port 110b.
[040] In an embodiment, the inlet port 110 may be an opening or aperture provided on the one or more case members 108a, 108b. In an embodiment, the first inlet port 110a and the second inlet port 110b may be the opening provided on the front side 150a of the first case member 108a and the front side 150b of the second case member 108b. In an embodiment, the outlet port 112 may be an aperture provided on the one or more case members 108a, 108b. In an embodiment, the first outlet port 112a and the second outlet port 112b may be apertures provided on the front side 150a of the first case member 108a and the front side 150b of the second case member 108b.
[041] In an embodiment, the second case member 108b comprises a mounting bracket 154 provided on the left-side wall 144b and/or the right-side wall 146b. The mounting bracket 154 being adapted to engage or receive the second vertical wall member 128b (as shown in Figure 8). The mounting bracket 154 upon engagement with the second vertical wall member 128b restricts the movement of the second case member 108b in the up-down direction. In an embodiment, the mounting bracket 154 may comprise one or more slits (not shown) for engagement with the second vertical wall member 128b.
[042] In an embodiment, the cooling passage 114 is configured to circulate the cooling fluid through each of the one or more cell modules 106a, 106b for cooling. In another embodiment, the first cooling passage 114a and the second cooling passage 114b may be coupled to one another and include one inlet port 110 for receiving the cooling fluid and one outlet port 112 for discharging the cooling fluid from each of the one or more case members 108a, 108b.
[043] Referring to Figure 4 in conjunction with Figures 1-3, a blower unit 116 is mounted to each of the one or more case members 108a, 108b is depicted. The blower unit 116 is coplanar to each of the one or more cell modules 106a, 106b. The blower unit 116 is coupled to the inlet port 110 for drawing in the cooling fluid into the cooling passage 114 for cooling the one or more cell modules 106a, 106b of the battery pack 102. In an embodiment, the inlet port 110 may be provided with a filter (not shown) for filtering the cooling fluid entering the cooling passage 114. In the present embodiment, the inlet port 110 may be provided with an air filter for filtering the ambient air entering the cooling passage 114.
[044] In an embodiment, the blower unit 116 is mounted to one of the left-side wall 144a or the right-side wall 146a of the first case member 108a, and located at the front side 150a of the first case member 108a. In an embodiment, the blower unit 116 is mounted to one of the left-side wall 144a or the right-side wall 146a of the first case member 108a through a support bracket 156.
[045] In an embodiment, the blower unit 116 is mounted to one of the left-side wall 144b or the right-side wall 146b of the second case member 108b, and located at the front side 150b of the second case member 108a. In an embodiment, the blower unit 116 is mounted to one of the left-side wall 144a or the right-side wall 146a of the first case member 108a through the support bracket 156.
[046] In an embodiment, location of the blower unit 116 is selected such that uniform air flow (i.e. front and rear uniform velocity of air achieved) is achieved in the cooling passage 114. In conventional systems, there are occasions where one region of the battery pack 102 is warmer while an other region is colder. The blower unit 116 is positioned such that a uniform temperature distribution is achieved in the cooling passage 114 so that the one or more cell modules 106a, 106b are cooled uniformly. In an embodiment, the blower unit 116 may be provided to each of the first cell module 106a and the second cell module 106b, so that the first cell module 106a and the second cell module 106b are cooled uniformly. Consequently, a lower temperature gradient is achieved between the first cell module 106a and the second cell module 106b.
[047] In an embodiment, the blower unit 116 may be coupled to a coolant supplying device (not shown). As such, the blower unit 116 may draw in the cooling fluid from the coolant supply device. In another embodiment, the blower unit 116 is adapted to employ air as the cooling fluid, and thus the blower unit 116 is adapted to draw in ambient air from the surrounding for cooling the battery pack 102. In another embodiment, the blower unit 116 is adapted to draw in a ram air from the surroundings during a dynamic condition of the vehicle for cooling the battery pack 102.
[048] Referring to Figure 5, the blower unit 116 mounted to the one or more case members 108a, 108b is depicted. As shown in Figure 5, the blower unit 116 is positioned to be coplanar with the one or more case members 108a, 108b. Particularly, the blower unit 116 is positioned to be coplanar with the plurality of fins 118 of the one or more case members 108a, 108b. Such a construction ensures that the cooling fluid routed by the blower unit 116 impinges onto the plurality of fins 118 directly. Additionally, path traversed by the cooling fluid discharged from the blower unit 116 is along the direction of disposition of the plurality of fins 118, thus ensuring that heat radiating out of the plurality of fins 118 is absorbed or transferred onto the cooling fluid. Also, configuration of the cooling path along the direction of disposition of the plurality of fins 118 ensures maximum surface area of contact between the cooling fins and the cooling fluid, thus entailing a higher cooling efficiency than conventional cooling systems. In an embodiment, the blower unit 116 is positioned to be coplanar with the first plurality of fins 118a of the first cell module 106a and with the second plurality of fins 118b of the second cell module 106b. In an embodiment, the blower unit 116 is located in proximity to the tray member 104 or the base member 104b in order to be coplanar with the plurality of fins 118.
[049] Further, the blower unit 116 is coupled to the inlet port 110 and the outlet port 112, wherein the inlet port 110 is provided in an aft portion 116a or on a right-side of the blower unit 116. The outlet port 112 is provided in a fore portion 116b or on a left-side of the blower unit 116. Such a disposition of the inlet port 110 and the outlet port 112 prevents merging of the inlet fluid and the exhaust fluid wherein the inlet fluid refers to the cooling fluid entering through the inlet port 110 and the exhaust fluid refers to the cooling fluid leaving through the outlet port 112 after circulation along the cooling path 114. For ensuring separation of the inlet fluid and the exhaust fluid, one or more baffle plate 122 (as shown in figure 3) may be provided in each of the one or more case members 108a, 108b. That is, in the present embodiment, the baffle plate 122 may be provided in the first case member 108a and the second case member 108b. The baffle plate 122 is positioned rearwardly to the aft portion 116a of the blower unit 116. Such a position of the baffle plate 122 ensures separation of the exhaust fluid from the inlet fluid entering through the blower unit 116 in the cooling passage 114.
[050] In an embodiment, the baffle plate 122 may be a plate member that is oriented vertically and extends throughout a height of the one or more case member 108a. 108b. In other words, the baffle plate 122 extends through the height of the first case member 108a and the second case member 108b.
[051] In an embodiment, each of the one or more case members 108a, 108b is provided with a top rim surface 124. That is, the top rim surface 124 is provided for the first case member 108a and the second case member 108b. The top rim surface 124 extends laterally and inwardly towards the one or more cell modules 106a, 106b such that, the top rim surface 124 engages with a top portion 158 (shown in Figures 1 and 2) of each of the one or more cell modules 106a, 106b. In other words, the top rim surface 124 engages with the top portion 158 of the first case member 108a and the second case member 108b. The top rim surface 124 upon engagement with each of the one or more cell modules 106a, 106b ensures sealing of the cooling passage 114.
[052] Further, the cooling system 100 comprises one or more temperature sensors 120 and one or more pressure sensors 126 disposed in the one or more case members 108a, 108b. In the present embodiment, the one or more temperature sensors 120 and the one or more pressure sensors 126 may be provided to each of the first case member 108a and the second case member 108b. In an embodiment, the one or more pressure sensors 126 are placed in the vicinity or proximity of the battery pack 102. The vicinity or proximity of the battery pack 102 will include an area inside or outside or nearby to the battery pack 102. Each of the one or more temperature sensors 120 is adapted to procure a temperature parameter of the battery pack 102 and each of the one or more pressure sensors 126 is adapted to procure a pressure parameter within the battery pack 102. The temperature parameter and the pressure parameter are communicated to a control unit (not shown). The control unit based on the temperature parameter determines the temperature of the battery pack 102. Also, the control unit based on the pressure parameter determines the pressure within the battery pack 102. In an embodiment, the temperature and pressure determined by the control unit may be temperature and pressure of an electrolyte (not shown) provided in the battery pack 102.
[053] The control unit is also electrically coupled to the blower unit 116. Thus, the control unit selectively operates the blower unit 116 for ensuring that the battery pack 102 operates in an optimum temperature. In the present embodiment, the control unit is adapted to operate the blower unit 116 for drawing in the cooling fluid into the cooling passage 114 when the temperature and/or the pressure within the battery pack 102 exceeds a predetermined temperature value and a predetermined pressure value respectively. In an embodiment, the predetermined temperature value is 40 degrees or 55 degrees.
[054] In an embodiment, the control unit may be a Vehicle Control Unit (VCU) of the vehicle or may be an Electronic Control Unit (ECU) of the vehicle or any other controller equipped with a micro-processor which is capable of carrying out analysis steps and control steps required for operating the cooling system 100.
[055] Referring to Figures 7 and 8 in conjunction with Figures 1-6, assembly of the cooling system 100 is described. The assembly is described in view of the one or more cell modules 106a, 106b and the one or more case members 108a, 108b for the sake of brevity. Accordingly, the description is relevant for the first cell module 106a, the first case member 108a, the second cell module 106b and the second case member 108b within the scope of the present disclosure.
[056] Firstly, the one or more cell modules 106a, 106b are placed onto the tray member 104. The one or more case members 108a, 108b are then placed onto the tray member 104 such that, the one or more case members 108a, 108b surrounds the one or more cell modules 106a, 106b. At this juncture, the mounting member 152 or the mounting bracket 154 receives the one or more vertical wall members 128a, 128b and thus locking movement of the one or more case member 108a, 108b. Subsequently, the one or more cap members 130a, 130b are mounted over the one or more cell modules 106a, 106b such that the central portion of the one or more cap members 130a, 130b interface or mate with the one or more cell modules 106a, 106b. At the same time, the edge portion of the one or more cap members 130a, 130b are fastened to the one or more vertical members 128a, 128b (as shown in Figure 8), thereby fastening or securing both the one or more cell modules 106a, 106b and the one or more case members 108a, 108b onto the tray member 104. Subsequently, the blower unit 116 is mounted onto the one or more case members 108a, 108b such that, the inlet port 110 is in the aft portion 116a and the outlet port 112 is in the fore portion 116b of the blower unit 116. The baffle plate 122 is also positioned within the one or more case members 108a, 108b proximal to the aft portion 116a. The one or more temperature sensors 120 and the one or more pressure sensors 126 are also provided within the one or more case members 108a, 108b, such that a thermal contact is established with the one or more cell modules 106a, 106b. The blower unit 116, the one or more temperature sensors 120 and the one or more pressure sensors 126 are electrically connected to the control unit through a wired communication means or a wireless communication means.
[057] In an operational embodiment, the control unit initially monitors the pressure and the temperature of the battery pack 102. When at least one of the pressure parameter and the temperature parameter exceeds the predetermined pressure value and the predetermined temperature value, the control unit provides an operating signal to the blower unit 116. The blower unit 116, upon receiving an operating signal from the control unit, draws in the cooling fluid into the cooling passage 114 through the inlet port 110. The cooling fluid impinges onto the plurality of fins 118 and circulates around the one or more cell modules 106a, 106b (as depicted through arrow heads in Figure 6). The circulation results in heat extraction from the one or more cell modules 106a, 106b, thereby cooling the battery pack 102. The exhaust fluid is then discharged from the one or more case members 108a. 108b.
[058] The claimed invention as disclosed above is not routine, conventional or well understood in the art, as the claimed aspects enable the following solutions to the existing problems in conventional technologies. Specifically, the claimed aspect of providing the cooling system which ensures uniform and efficient cooling of the battery pack. Particularly, the blower unit being coplanar to the one or more cell modules of the battery pack ensures that the cooling fluid impinges directly onto the one or more cell modules, thereby ensuring uniform cooling. Also, the blower unit is positioned coplanar to the plurality of fins, and thus ensuring that cooling fluid directly impinges onto the plurality of fins for effective cooling. Additionally, the baffle plate ensures separation of the incoming fluid from the exhaust fluid. Also, the one or more case members can be removed from the tray member for servicing of the blower or even the temperature sensors, thereby providing ease of assembly and serviceability of the cooling system. Further, the cooling system of the present invention incurs reduced material and component cost as compared to conventional cooling systems, particularly, when the cooling fluid is ram air. Further, the one or more case members protect the battery pack from vibrational loads, impact load as well as external environmental factors such as dust, rain, etc. as there is a sealing being formed between the battery pack and the external casing. The cooling system of the present invention is theft proof, as the fastening units require a specific tool for assembly and disassembly. Furthermore, the cooling system of the present invention is capable of being accommodated in any vehicle as well as equipment layout using battery packs. Thus, no minimal constructional modifications may be required for integrating the cooling system onto the vehicle and/or the equipment layout.
[059] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

List of Reference Numerals and Characters

100 Cooling system
102 Battery pack
104 Tray member
104a Outer periphery of the tray member
104b One or more base members
106a, 106b One or more cell modules
106a First cell module
106b Second cell module
108a, 108b One or more case members
108a First case member
108b Second case member
110 Inlet port
110a First inlet port
110b Second inlet port
112 Outlet port
112a First outlet port
112b Second outlet port
114 Cooling passage
114a First cooling passage
114b Second cooling passage
116 Blower unit
116a Aft portion
116b Fore portion
118 Plurality of fins
118a First plurality of fins
118b Second plurality of fins
120 One or more temperature sensors
122 Baffle plate
124 Top rim surface
126 Pressure sensor
128a, 128b Vertical wall members
128a First vertical wall member
128b Second vertical wall member
130a, 130b Cap members
130a First cap member
130b Second cap member`
132a, 132b Inner surface of case member
134a, 134b Outer surface of cell module
136 Front surface of the outer periphery
138 Rear surface of the outer periphery
140 Left-side surface of the outer periphery
142 Right-side surface of the outer periphery
144a, 144b Left-side wall of case members
146a, 146b Right-side wall of case members
148a, 148b Rear wall of case members
150a, 150b Front side of case members
152 Mounting member
154 Mounting bracket
156 Support bracket
158 Top portion of one or more cell modules
, Claims:WE CLAIM:
1. A cooling system (100) for a battery pack (102), the cooling system (100) comprising:
a tray member (104) adapted to receive one or more cell modules (106a, 106b) of the battery pack (102);
one or more case members (108a, 108b) extending from an outer periphery (104a) of the tray member (104), each of the one or more case members (108a, 108b) being adapted to surround the one or more cell modules (106a, 106b) of the battery pack (102), and the one or more case members (108a, 108b) comprising an inlet port (110) and an outlet port (112),
wherein a cooling passage (114) being provided between an inner surface (132a, 132b) of each of the case members (108a, 108b) and an outer surface (134a, 134b) of the one or more cell modules (106a, 106b), the cooling passage (114) being fluidly connected to the inlet port (110) and the outlet port (112); and
a blower unit (116) mounted to the one or more case members (108a, 108b) and being coplanar to each of the one or more cell modules (106a, 106b), and the blower unit (116) being coupled to the inlet port (110) for routing cooling fluid into the cooling passage (114) for cooling the one or more cell modules (106a, 106b) of the battery pack (102).

2. The cooling system (100) as claimed in claim 1, wherein each of the one or more cell modules (106a, 106b) comprises a plurality of fins (118), and
wherein the blower unit (116) being positioned on the one or more case member (108a, 108b) to be coplanar with the plurality of fins (118).

3. The cooling system (100) as claimed in claim 1, wherein the inlet port (110) being disposed on an aft portion (116a) of the blower unit (116), and the outlet port (112) being disposed on a fore portion (116b) of the blower unit (116).

4. The cooling system (100) as claimed in claim 1 comprising one or more temperature sensors (120) and one or more pressure sensors (126) disposed in the one or more case members (108a, 108b), each of the one or more temperature sensors (120) being adapted to procure a temperature parameter of the battery pack (102), and each of the one or more pressure sensors (126) being adapted to procure a pressure parameter within the battery pack (102).

5. The cooling system (100) as claimed in claim 4, wherein each of the one or more temperature sensors (120) and the one or more pressure sensors (126) being communicably coupled to a control unit, the control unit being adapted to determine temperature of the battery pack (102) based on the temperature parameter and pressure within the battery pack (102) based on the pressure parameter, and
wherein the control unit being adapted to activate the blower unit (116) for circulating the cooling fluid into the one or more case members (108a, 108b), when at least one of the temperature of the battery pack (102) exceeds a predetermined temperature value and the pressure within the battery pack (102) exceeds a predetermined pressure value.

6. The cooling system (100) as claimed in claim 1 being mounted on at least one of below a driver seat and under a cabin assembly in a passenger vehicle.

7. The cooling system (100) as claimed in claim 1 being mounted under a load deck in a cargo vehicle.

8. The cooling system (100) as claimed in claim 1, wherein each of the one or more case members (108a, 108b) comprises at least one baffle plate (122) disposed in each of the one or more case members (108a, 108b) and positioned rearwardly to the aft portion (116a) of the blower unit (116), wherein the baffle plate (122) being adapted to separate an exhaust fluid from an inlet fluid entering through the blower unit (116) in the cooling passage (114).
9. The cooling system (100) as claimed in claim 1, wherein each of the one or more case members (108a, 108b) comprises a top rim surface (124), the top rim surface (124) being adapted to engage with a top portion of the one or more cell modules (106a, 106b), wherein the top rim surface (124) upon engagement with the top portion of the one or more cell modules (106a, 106b) ensures sealing of the cooling passage (114).

10. The cooling system (100) as claimed in claim 1, wherein the blower unit (116) being disposed above one or more base members (104a) of the tray member (104).

Dated this 30th day of May 2023
TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471