Description:FIELD
The present disclosure generally relates to the field of thermal regulation and absorption of impact energy due to environmental impact on a cooling plate of a battery pack. Particularly, the present disclosure relates to an assembly for preventing water condensation and stagnation on a top-mounted cooling plate of a battery pack assembled in an electric commercial vehicle.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Presently, a cooling plate includes a bottom cooling layer and a top-channel cooling layer. The cooling plate is coupled to a battery pack of the vehicle to regulate the temperature of the cell assembled in the battery pack. However, the thermal performance of the top channel cooling layer can further deteriorate due to draft airflow over the top channel cooling layer due to assembled location in an electric commercial vehicle between the ladder frame of the vehicle. The draft airflow can reduce the effectiveness of the top channel cooling layer in dissipating heat from the battery pack, which can result in higher temperatures within the battery pack. High temperatures can negatively impact the performance and lifespan of the battery. Additionally, if the top channel cooling layer is designed to also provide heating, the draft airflow can interfere with the heating process as well. To maintain optimal thermal performance, it may be necessary to minimize or control the draft airflow over the top channel cooling layer.
Further, it is addressed that due to the presence of a gap between the cabin of the vehicle and the load body of the commercial vehicle, objects may fall on the battery from a certain height through the gap, which damages the top channel cooling layer. Objects falling onto the battery pack can cause physical impacts and potentially damage the battery pack, including the top channel cooling layer. The top channel cooling layer is vulnerable to such impacts. Damages to the top channel cooling layer can affect its ability to properly cool or heat the battery pack.
Moreover, the top channel cooling layer has formed channels, therefore, during condensation, water may get stagnated between channels, which leads to galvanic corrosion and durability issues. During condensation, when water vapor in the air comes into contact with a cooler surface like the top channel cooling layer, it turns into water. If there are formed channels on the top channel cooling layer, there is a possibility that water may accumulate and get trapped between these channels, leading to stagnation. The presence of stagnant water can lead to corrosion of the top channel cooling layer, thus, reducing its effectiveness and potentially causing leaks or structural damage.
There is, therefore, felt a need to develop a thermal regulation assembly for a battery pack to alleviate the aforementioned disadvantages.
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 an assembly for preventing water condensation and stagnation on a top-mounted cooling plate of a battery pack.
Another object of the present disclosure is to provide an assembly that improves the thermal performance of the cooling plate.
Another object of the present disclosure is to provide an assembly that prevents the battery pack or the top channel cooling layer from any environmental impact energy levels.
Yet another object of the present disclosure is to provide an assembly that prevents water condensation and stagnation over the top channel cooling layer.
Another object of the present disclosure is to provide an assembly that reduces assembly time during the battery pack assembly process
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 an assembly for preventing water condensation and stagnation on a top-mounted cooling plate of a battery pack assembled in an electric commercial vehicle.
The assembly comprises a cooling plate and a top cover. The cooling plate includes a bottom cooling layer and a top-channel cooling layer. The bottom cooling layer of the cooling plate is configured for being in thermal communication with battery cells assembled inside the battery pack. The top channel cooling layer of the cooling plate is configured for being mounted on the top surface of the bottom cooling layer and forming a plurality of cooling channels for facilitating a coolant to flow therewithin to absorb heat dissipated by the battery cells. The top cover is secured along the peripheral edges of the bottom cooling layer. Foam material is filled between the top channel cooling layer and the top cover so as to prevent condensation between the top channel cooling layer and the top cover.
In an embodiment, the top channel cooling layer includes a plurality of channel troughs that are in contact with the bottom cooling layer to form the plurality of cooling channels.
In an embodiment, the plurality of channel troughs that are in contact with the bottom cooling layer is fused together with a furnace brazing technique to obtain the plurality of cooling channels.
In an embodiment, peripheral edges of the top cover are secured with corresponding edges of the bottom cooling layer to enclose the top channel cooling layer. The peripheral edges of the top cover are fused with the corresponding edges of the bottom cooling layer using the furnace brazing technique.
In an embodiment, the foam material is a liquid foam. The liquid foam is polymer foam selected from a group consisting of polyurethane foam, styrofoam, polyester, and polyethylene.
In an embodiment, the top cover includes at least one opening for injecting the foam material between the top cover and the top channel cooling layer.
In an embodiment, the bottom cooling layer, the top channel cooling layer, and the top cover are metal sheets. The top channel cooling layer is manufactured by using the stamping press technique.
In an embodiment, the cooling channels are connected to at least one coolant inlet port and to at least one coolant outlet port, and a coolant reservoir is connected to at least one coolant inlet port and to at least one coolant outlet port to circulate the coolant within the cooling channels to cool or heat the battery cells.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
An assembly for preventing condensation on a top-mounted cooling plate of a battery pack of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates an exploded view of an assembly for preventing condensation on a top-mounted cooling plate of a battery pack assembled in an electric commercial vehicle, in accordance with an embodiment of the present disclosure; and
Figure 2 illustrates a sectional view along the A-A’ of Figure 1, in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS USED IN THE DESCRIPTION AND DRAWING:
100 Assembly
10 Bottom Cooling Layer
20 Top Channel Cooling Layer
20a Cooling Channels
20b Channel Troughs
21 Fusing Brazing Joints
22 Fusing Brazing Joint
30 Top Cover
30a Peripheral Edges
30b Opening
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 assembly 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, 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.
When an element is referred to as being “mounted on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected, or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The present disclosure envisages an assembly 100 for preventing water condensation and stagnation on a top-mounted cooling plate of a battery pack assembled in an electric commercial vehicle and is now described with reference to Figure 1. Figure 1 illustrates an exploded view of the assembly 100, and Figure 2 illustrates a sectional view along the A-A’ of Figure 1.
The assembly 100 comprises a cooling plate and a top cover 30.
The cooling plate includes a bottom cooling layer 10 and a top channel cooling layer 20.
The bottom cooling layer 10 is configured to be in thermal communication with battery cells assembled inside the battery pack.
The top channel cooling layer 20 is mounted on the top surface of the bottom cooling layer 10 and forms a plurality of cooling channels 20a for facilitating a coolant to flow therewithin to absorb heat dissipated by the battery cells. The top channel cooling layer 20 includes a plurality of channel troughs 20b that are in contact with the bottom cooling layer 10 to form a plurality of cooling channels 20a. In an embodiment, the plurality of channel troughs 20b that is in contact with the bottom cooling layer 10 are fused together as fusing brazing joints 21 with a furnace brazing technique to obtain the plurality of cooling channels 20a. In an embodiment, the cooling channels 20a are connected to at least one coolant inlet port and at least one coolant outlet port. A coolant reservoir is connected to at least one coolant inlet port and to at least one coolant outlet port to circulate the coolant within the cooling channels 20a to cool the battery cells.
The top cover 30 is secured along the peripheral edges of the bottom cooling layer 10. In an embodiment, peripheral edges 30a of the top cover 30 are secured with corresponding edges of the bottom cooling layer 10 to enclose the top surface of the top channel cooling layer 20. The peripheral edges 30a of the top cover 30 are fused with corresponding edges of the bottom cooling layer 10 forming a fusing brazing joint 22 using the furnace brazing technique.
Further, a foam material is filled between the top channel cooling layer 20 and the top cover 30. The foam material is configured to absorb energy caused due to environmental impact on the top cover 30 and is further configured to prevent water condensation or stagnation between the top channel cooling layer 20 and the top cover 30.
In an embodiment, the foam material is a liquid foam. The liquid foam is polymer foam selected from a group consisting of polyurethane foam, styrofoam, polyester, and polyethylene. Liquid foam once dispensed into a cavity, it expands/solidifies & fills all over the cavity volume, and takes the shape of the cavity by completely displacing air molecules. The foam material absorbs kinetic energy into inelastic energy by deforming or cushioning with or without plastic deformation. In an embodiment, the foam material thickness, density, and toughness depend on the load condition and cushion curves of the foam. For a non-limiting experiment, a 50J impact energy is absorbed by the foam material with no functionality loss of the cover/cooling plate, and 200J impact energy is absorbed by the foam material with an acceptance hazard level. Further, as an air gap between the top cover 30 and the top channel cooling layer 20 is filled with the foam material having specified porosity, which replaces most of the air gap or space which induces condensation.
In an embodiment, the top cover 30 includes at least one opening 30b for injecting the foam material between the top cover 30 and the top channel cooling layer 20.
In an embodiment, the bottom cooling layer 10, the top channel cooling layer 20 and the top cover 30 are metal sheets. In a preferred embodiment, the metal sheets are either aluminum sheets or steel sheets.
In an embodiment, the top channel cooling layer 20 is manufactured by using the stamping press technique, plastic working (or) dimple forming, hydroformed and like techniques.
The assembly 100 provides the followings advantages:
A. Improves thermal performance: The assembly 100 improves the thermal performance of the cooling plate that is coupled to the battery pack. This includes minimizing the negative impact of draft air flow over the cooling plate to ensure efficient cooling and heating processes, because of the top cover 30. By maintaining optimal thermal performance, the assembly 100 prevents higher temperatures within the battery pack, which can negatively affect battery performance and lifespan.
B. Prevents damage to the cooling plate: The assembly 100 address the issue of objects falling onto the battery pack due to the gap between the cabin and the load body of the vehicle. The top cover 30 of the assembly 100 prevents physical impacts that can potentially damage the cooling plate, thus, ensuring the durability and proper functioning of the cooling plate.
C. Mitigating condensation-related issues: Generally, water gets stagnated between the formed channels of the cooling plate during condensation. The foam material present between the top cover 30 and the cooling plate helps to prevent condensation, thus mitigating corrosion of the cooling plate and other durability issues.
D. External solid foam will not cover the complete surface whereas liquid foam has this advantage. Reduces separate plate and foam assembly time on the battery pack.
The assembly 100 collectively contributes to maintaining the efficiency, durability, and longevity of the cooling plate.
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
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of an assembly for preventing condensation on a top-mounted cooling plate of a battery pack, which:
• improves the thermal performance of the cooling plate;
• prevents the battery pack or the cooling plate from any environmental impact;
• prevents condensation over the cooling plate; and
• eases assembly & reduces assembly time.
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. , C , Claims:WE CLAIM:

1. An assembly (100) for preventing condensation on a top-mounted cooling plate of a battery pack assembled in an electric commercial vehicle, said assembly (100) comprising:
a) a bottom cooling layer (10) of said cooling plate configured for being in thermal communication with battery cells assembled inside the battery pack;
b) a top channel cooling layer (20) of said cooling plate configured for being mounted on the top surface of said bottom cooling layer (10) and forming a plurality of cooling channels (20a) for facilitating a coolant to flow therewithin to absorb heat dissipated by the battery cells;
c) a top cover (30) secured along peripheral edges of said bottom cooling layer (10); and
d) a foam material filled between said top channel cooling layer (20) and said top cover (30) so as to prevent condensation between said top channel cooling layer (20) and said top cover (30).
2. The assembly (100) as claimed in claim 1, wherein said top channel cooling layer (20) includes a plurality of channel troughs (20b) that are in contact with said bottom cooling layer (10) to form said plurality of cooling channels (20a).
3. The assembly (100) as claimed in claim 2, wherein said plurality of channel troughs (20b) that are in contact with said bottom cooling layer (10) are fused together as fusing brazing joints (21) with a furnace brazing technique to obtain said plurality of cooling channels (20a).
4. The assembly (100) as claimed in claim 1, wherein said peripheral edges (30a) of said top cover (30) are secured with corresponding edges of said bottom cooling layer (10) to enclose said top channel cooling layer (20).
5. The assembly (100) as claimed in claim 4, wherein said peripheral edges (30a) of said top cover (30) are fused with corresponding edges of said bottom cooling layer (10) for forming a fusing brazing joint (22) using the furnace brazing technique.
6. The assembly (100) as claimed in claim 1, wherein the foam material is a liquid foam.
7. The assembly (100) as claimed in claim 6, wherein said liquid foam is polymer foam selected from a group consisting of polyurethane foam, styrofoam, polyester, and polyethylene.
8. The assembly (100) as claimed in claim 1, wherein said top cover (30) includes at least one opening (30b) for injecting the foam material between said top cover (30) and said top channel cooling layer (20).
9. The assembly (100) as claimed in claim 1, wherein said bottom cooling layer (10), said top channel cooling layer (20), and said top cover (30) are metal sheets.
10. The assembly (100) as claimed in claim 1, wherein said top channel cooling layer (20) is manufactured by using the stamping press technique or other plastic forming techniques.
11. The assembly (100) as claimed in claim 1, wherein said cooling channels (20a) are connected to at least one coolant inlet-port and at least one coolant outlet-port and a coolant reservoir is connected to the at least one coolant inlet-port and to the at least one coolant outlet-port to circulate the coolant within said cooling channels (20a) to cool the battery cells.
Dated this 14th day of July, 2023

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