Description:FIELD OF INVENTION

The present disclosure relates to a battery pack, and more particularly to a system for thermal management in the battery pack and a method for the same.

BACKGROUND

In general, the battery pack includes one or more cells. As used herein, a cell is a device that stores chemical energy and converts into electrical energy. The temperature of the one or more cells may increase while charging and discharging which will heavily impact the temperature level of the battery pack.

An atmospheric temperature also impacts the temperature level of the one or more cells and the battery pack. Increased temperature levels of the battery pack may lead to a fire accident and thermal runaway in the worst scenario. Maintaining the temperature level of the battery pack with optimal temperature is a difficult task.

In a conventional approach, automobile, or Electric Vehicle (EV) manufacturers use a coolant method and a heat sink which reduces the temperature level of the cells and the battery pack, but this method makes the system big, complex, and expensive.

In other conventional approaches, automobile or EV manufacturers use an encapsulation technique to restrict thermal distribution among the one or more cells. In the encapsulation technique, an encapsulation structure covers individual cells (of the one or more cells) entirely. So that, there will be a high chance of thermal traps which may increase the temperature level of the one or more cells. The increased temperature level of the one or more cells may lead to a thermal runaway.
In other conventional approaches, automobile or EV manufacturers use the encapsulation technique to restrict thermal distribution among the one or more cells. The encapsulation technique restricts thermal distribution by covering the one or more cells without any gap between the one or more cells and the encapsulation structure. Since there is no gap between the one or more cells and the encapsulation structure, there is no place to fill a Phase-Changing Material (PCM) to absorb the heat energy produced by the one or more cells. Since there is no heat absorption, the temperature level of the one or more cells may increase which leads to thermal runaway. So, the conventional approaches are not efficient to solve above mentioned problems. In some cases, the PCM may be in a liquid state, or a solid state based on temperature of the one or more cells or the battery pack. There will be a chance of leaking the PCM and mixing with a thermally conductive layer when the PCM is in a liquid state. The thermally conductive layer is poured into a bottom battery casing to absorb heat of the one or more cells.

Accordingly, there remains a need for an improved system for thermal management in the battery pack and therefore address the aforementioned issues.

SUMMARY

Accordingly, the embodiments herein disclose a system for thermal management in a battery pack. The battery pack includes one or more components. The one or more components include a battery casing, a bottom cell holder, one or more cells, a predetermined shaped thermally insulative structure, a thermally conductive layer, and a heat absorbing material. The battery casing is mechanically configured to provide space to fill the thermally conductive layer up to a predetermined height from a bottom portion of the battery pack. The predetermined height depends on the heat generated by the one or more cells or the battery pack. The bottom cell holder, the one or more cells, the predetermined shaped thermally insulative structure, the thermally conductive layer, and the heat absorbing material are placed on the battery casing. The bottom cell holder includes one or more holding arrangements. The one or more holding arrangements are mechanically configured to hold the predetermined shaped thermally insulative structure and allow the thermally conductive layer into the predetermined shaped thermally insulative structure. The one or more cells include a top axial surface, a bottom axial surface, and a circumferential surface. The predetermined shaped thermally insulative structure is positioned on the bottom cell holder using the one or more holding arrangements of the bottom cell holder. The predetermined shaped thermally insulative structure is configured to arrest the heat energy of the one or more cells. The predetermined shaped thermally insulative structure includes one or more openings. The one or more openings are configured to allow the predetermined shaped thermally insulative structure to cover the circumferential surface of the one or more cells. The one or more openings configured to maintain a predetermined space between the predetermined shaped thermally insulative structure and the one or more cells.

In one embodiment, the bottom cell holder, the one or more cells, the predetermined shaped thermally insulative structure, the thermally conductive layer, and the heat absorbing material are placed on the battery casing before filing the thermally conductive layer up to the predetermined height from the bottom portion of the battery pack.

In another embodiment, the system further includes a predetermined shaped thermally insulative sheet. The predetermined shaped thermally insulative sheet is configured to arrest the heat energy of the one or more cells.

In yet another embodiment, the predetermined shaped thermally insulative sheet is positioned on the predetermined shaped thermally insulative structure using one or more connecting mechanisms, wherein the one or more connecting mechanisms include a gluing.

In yet another embodiment, the predetermined shaped thermally insulative sheet is positioned on a neck portion of the one or more cells.

In yet another embodiment, the system further includes a top cell holder. The predetermined shaped thermally insulative structure is positioned between the bottom cell holder, and the top cell holder.

In yet another embodiment, the one or more openings of the predetermined shaped thermally insulative structure include a hexagon shape, a circular shape, a triangular shape, a rectangular shape, a square shape, an elliptical or a polygonal shape.

In yet another embodiment, the one or more holding arrangements are positioned on a top portion of the bottom cell holder. The one or more holding arrangements are projected upwards from the bottom cell holder to hold the predetermined shaped thermally insulative structure. The one or more holding arrangements are partially constructed projections or predetermined shaped projections. The predetermined shaped projections depend on the shape of the one or more openings of the predetermined shaped thermally insulative structure.

In yet another embodiment, the thermally conductive layer is configured to cover the bottom axial surface and the circumferential surface of the one or more cells to absorb the heat.
In yet another embodiment, the thermally conductive layer includes a resin, an organic/a non-organic, a polymeric/non-polymeric material, a polyurethane, an epoxy, or a silicon.

In yet another embodiment, the heat absorbing material is filled in the predetermined space between the predetermined shaped thermally insulative structure and the one or more cells. The heat absorbing material is configured to cover the circumferential surface of the one or more cells to absorb the heat.

In yet another embodiment, the heat absorbing material includes a solid Phase Changing Material (PCM), a liquid PCM, an organic/a non-organic, and a dielectric material. The heat absorbing material releases one or more gases at the time of phase changing or heat absorption.

In yet another embodiment, the predetermined space between the predetermined shaped thermally insulative structure and the one or more cells includes a predetermined gap to provide space for the one or more gases released from the heat absorbing material at the time of phase changing.

In yet another embodiment, the predetermined shaped thermally insulative structure and the predetermined shaped thermally insulative sheet are made up of thermally insulative materials. The thermally insulative materials include mica, microporous silica, ceramic fiber, mineral wool, or combinations thereof.

In yet another embodiment, the bottom cell holder, and a predetermined length of the predetermined shaped thermally insulative structure are immersed in the thermally conductive layer.
In yet another embodiment, the thermally conductive layer is poured in one or more locations of the battery pack.

Accordingly, embodiments herein disclose a method of thermal management in a battery pack. The method includes the following steps: (a) providing space to fill a thermally conductive layer on a battery casing up to a predetermined height; (b) filling the thermally conductive layer on the battery casing to the predetermined height, (i) the predetermined height depends on heat generated by one or more cells, or the battery pack; (c) placing a bottom cell holder into the thermally conductive layer to hold the one or more cells; (d) positioning, the one or more cells using the bottom cell holder; (e) positioning a predetermined shaped thermally insulative structure on the bottom cell holder in a manner a predetermined gap is maintained between the one or more cells and the predetermined shaped thermally insulative structure using one or more holding arrangements, (i) the one or more holding arrangements are positioned on the cell holder towards upper direction; (f) allowing the thermally conductive layer into the predetermined shaped thermally insulative structure; (g) covering a bottom axial surface of the one or more cells, a circumferential surface of the one or more cells, and a partial surface of the predetermined shaped thermally insulative structure; (h) pouring a heat-absorbing material into the predetermined gap to absorb heat generated by the one or more cells; (i) arresting heat of the one or more cells using the predetermined shaped thermally insulative structure; and (j) closing, by placing a thermal insulative sheet, the predetermined shaped thermally insulative structure.

In one embodiment, the method further includes placing one or more components inside the battery casing after filling the thermally conductive layer on the battery casing to the predetermined height. The one or more components include, but not limited to, the bottom cell holder, the one or more cells, the predetermined shaped thermally insulative structure, the thermally conductive layer and the heat absorbing material.

In another embodiment, the method further includes positioning the predetermined shaped thermally insulative sheet on the predetermined shaped thermal insulative structure.

In yet another embodiment, the method further includes positioning the predetermined shaped thermally insulative sheet on neck of the one or more cells.

In yet another embodiment, the method further includes placing the one or more components on the battery casing, and pouring the thermally conductive layer on the battery casing to the predetermined height to cover the bottom axial surface of the one or more cells, and the circumferential surface of the one or more cells, and the partial surface of the predetermined shaped thermally insulative structure.

These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the invention thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF FIGURES

This invention is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:

FIG. 1 illustrates a cross-sectional view of a thermal management system in a battery pack, according to an embodiment herein;

FIG. 2A illustrates an isometric view of the predetermined shaped thermally insulative structure of the battery pack, according to an embodiment herein;

FIG. 2B illustrates a top view of the predetermined shaped thermally insulative structure with one or more cells, according to an embodiment herein; and

FIG. 3A&3B is a flow diagram illustrating a method of thermal management in a battery pack, according to an embodiment herein.

DETAILED DESCRIPTION OF INVENTION

In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.
The ensuing description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.

The word “exemplary” and/or “demonstrative” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” and/or “demonstrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive—in a manner similar to the term “comprising” as an open transition word—without precluding any additional or other elements.

Reference throughout this specification to “one embodiment” or “an embodiment” or “an instance” or “one instance” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.

Accordingly, the embodiments herein disclose a system for thermal management in a battery pack. The battery pack includes one or more components. The one or more components include a battery casing, a bottom cell holder, one or more cells, a predetermined shaped thermally insulative structure, a thermally conductive layer, and a heat absorbing material. The battery casing is mechanically configured to provide space to fill the thermally conductive layer up to a predetermined height from a bottom portion of the battery pack. The predetermined height depends on the heat generated by the one or more cells or the battery pack. The bottom cell holder, the one or more cells, the predetermined shaped thermally insulative structure, the thermally conductive layer, and the heat absorbing material are placed on the battery casing. The bottom cell holder includes one or more holding arrangements. The one or more holding arrangements are mechanically configured to hold the predetermined shaped thermally insulative structure and allow the thermally conductive layer into the predetermined shaped thermally insulative structure. The one or more cells include a top axial surface, a bottom axial surface, and a circumferential surface. The predetermined shaped thermally insulative structure is positioned on the bottom cell holder using the one or more holding arrangements of the bottom cell holder. The predetermined shaped thermally insulative structure is configured to arrest the heat energy of the one or more cells. The predetermined shaped thermally insulative structure includes one or more openings. The one or more openings are configured to allow the predetermined shaped thermally insulative structure to cover the circumferential surface of the one or more cells. The one or more openings configured to maintain a predetermined space between the predetermined shaped thermally insulative structure and the one or more cells.

Referring now to the drawings, and more particularly to FIGS. 1 to 3, where similar reference characters denote corresponding features consistently throughout the figures, these are shown preferred embodiments.

FIG. 1 illustrates a cross-sectional view of a thermal management system 100 in a battery pack 102, according to an embodiment herein. The battery pack 102 includes one or more components 104. As used herein, the battery pack 102 is defined as a set of any number of (preferably) identical batteries or individual battery cells and may be configured in a series, parallel, or a mixture of both to deliver the desired voltage, capacity, or power density. The one or more components 104 include a battery casing 106, a bottom cell holder 108, one or more cells 110, a predetermined shaped thermally insulative structure 112, a predetermined shaped thermally insulative sheet 114, a thermally conductive layer 116, and a heat absorbing material 118.

The battery casing 106 is mechanically configured to provide space to fill the thermally conductive layer 116 up to a predetermined height from a bottom portion of the battery pack 102. The predetermined height depends on heat generated by the one or more cells 110, or the battery pack 102. The bottom cell holder 108, the one or more cells 110, the predetermined shaped thermally insulative structure 112, the thermally conductive layer 116, and the heat absorbing material 118 are placed on the battery casing 106 before filing the thermally conductive layer 116 up to the predetermined height from the bottom portion of the battery pack 102.

The bottom cell holder 108, and the one or more cells 110 are placed on the battery casing 106. The thermally conductive layer 116 is filled on the bottom battery casing 106 to the predetermined height. In one embodiment, the one or more cells 110, and the bottom cell holder 108 are dipped inside the thermally conductive layer 116 which is already poured into one or more locations of the battery pack 102. In another embodiment, the one or more cells 110, and the bottom cell holder 108 are placed into the battery pack 102 then the thermally conductive layer 116 is dispensed to the battery pack 102.

The bottom cell holder 108, and the one or more cells 110 are placed on the battery casing 106. As used herein, the one or more cells 110 are defined as a single-unit device that converts chemical energy into electric energy. The bottom cell holder 108 includes one or more holding arrangements 120. The one or more holding arrangements 120 are mechanically configured to hold the predetermined shaped thermally insulative structure 112 and allow the thermally conductive layer 116 into the predetermined shaped thermally insulative structure 112. In one embodiment, the one or more holding arrangements 120 is positioned on a top portion of the bottom cell holder 108. In another embodiment, number of the one or more holding arrangements 120 may be varied based on the size and weight of the predetermined shaped thermally insulative structure 112.

In yet another embodiment, the one or more holding arrangements 120 are projected upwards from the bottom cell holder 108 to hold the predetermined shaped thermally insulative structure 112. The one or more holding arrangements 120 are partially constructed projections or predetermined shaped projections. In one embodiment, the predetermined shaped projections depend on the shape of the one or more openings of the predetermined shaped thermally insulative structure 112. In addition to that, the bottom cell holder 108 is configured to hold the one or more cells 110 and provide a predetermined distance between the bottom battery casing 106 and the one or more cells 110. The bottom cell holder 108 further provides structural rigidity to the battery pack 100.

The one or more cells 110 include a top axial surface 122, a bottom axial surface 124, and a circumferential surface 126. In one embodiment, the one or more cells 110 may include, but not limited to, nickel cadmium, alkaline, nickel metal hydride (NIMH), lithium-ion, nickel hydrogen, nickel-zinc, lithium iron phosphate or LFP, sodium ion, electrochemical cells, and the like.

The predetermined shaped thermally insulative structure 112 is positioned on the bottom cell holder 108 using the one or more holding arrangements 120 of the bottom cell holder 108. The predetermined shaped thermally insulative structure 112 is configured to arrest heat energy of the one or more cells 110. The predetermined shaped thermally insulative structure 112 includes one or more openings. The one or more openings are configured to allow the predetermined shaped thermally insulative structure 112 to cover the circumferential surface 126 of the one or more cells 110. In one embodiment, the predetermined shaped thermally insulative structure 112 and the predetermined shaped thermally insulative sheet 114 are made up of thermally insulative materials. The thermally insulative materials may include, but not limited to, mica, microporous silica, ceramic fiber, mineral wool, or combinations thereof.

The one or more openings are configured to maintain a predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110. In one embodiment, the one or more openings of the predetermined shaped thermally insulative structure 112 include a hexagon shape, a circular shape, a triangular shape, a rectangular shape, a square shape, an elliptical or a polygonal shape.
The predetermined shaped thermally insulative sheet 114 is positioned on the predetermined shaped thermally insulative structure 112 using one or more connecting mechanisms. The one or more connecting mechanisms may include a gluing. In one embodiment, the predetermined shaped thermally insulative sheet 114 is positioned on a neck portion of the one or more cells 110. The predetermined shaped thermally insulative sheet 114 is configured to arrest the heat energy of the one or more cells 110. In one embodiment, the predetermined shaped thermally insulative sheet 114 may be a layer. In another embodiment, the predetermined shaped thermally insulative sheet 114 may be a block. In yet another embodiment, shape of the predetermined shaped thermally insulative sheet 114 may include, but not limited to, a hexagon shape, a circular shape, a triangular shape, a rectangular shape, a square shape, an elliptical or a polygonal shape.

The thermally conductive layer 116 is configured to cover the bottom axial surface 124 and the circumferential surface 126 of the one or more cells 110 to absorb the heat. In an embodiment, the thermally conductive layer 116 may include, but not limited to a resin, an organic/a non-organic, a polymeric/non-polymeric material, a polyurethane, an epoxy, or a silicon. The bottom cell holder 108, and a predetermined length of the predetermined shaped thermally insulative structure 112 are immersed in the thermally conductive layer 116. The predetermined shaped thermally insulative sheet 114 includes fire retardant characteristics. In one embodiment, the predetermined length of the predetermined shaped thermally insulative structure 112 that is immersed in the thermally conductive layer 116 may be varied based on the size of the battery pack 102.

The heat absorbing material 118 is filled in the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110. The heat absorbing material 118 is configured to cover the circumferential surface 126 of the one or more cells 110 to absorb the heat. In one embodiment, the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110 may be varied based on the thermal efficiency and thermal conductivity of the heat absorbing material 118 and/or type of the one or more cells 110. In an embodiment, the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110 includes a predetermined gap to provide the space for the one or more gases released from the heat absorbing material 118 at the time of phase changing.

In one embodiment, the heat absorbing material 118 includes, but not limited to a solid Phase Changing Material (PCM), a liquid PCM, an organic/a non-organic, and or a dielectric material. The heat-absorbing material 118 releases one or more gases at the time of phase changing. In one embodiment, the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110 includes the predetermined gap to provide the space for the one or more gases released from the heat absorbing material 118 at the time of phase changing. In one embodiment, the battery pack 102 further includes a top cell holder. The predetermined shaped thermally insulative structure 112 is positioned between the bottom cell holder 108, and the top cell holder.

FIG. 2A illustrates an isometric view of the predetermined shaped thermally insulative structure 112 of the battery pack 102, and FIG. 2B illustrates a top view of the predetermined shaped thermally insulative structure 112 with the one or more cells 110 according to an embodiment herein. The predetermined shaped thermally insulative structure 112 includes one or more holding arrangements 120. The one or more holding arrangements 120 are mechanically configured to hold the predetermined shaped thermally insulative structure 112 and allow the thermally conductive layer 116 into the predetermined shaped thermally insulative structure 112. The predetermined shaped thermally insulative structure 112 is positioned on the bottom cell holder 108 using the one or more holding arrangements 120 of the bottom cell holder 108. The predetermined shaped thermally insulative structure 112 is configured to arrest the heat energy of the one or more cells 110. The predetermined shaped thermally insulative structure 112 includes one or more openings 128. The one or more openings 128 are configured to allow the predetermined shaped thermally insulative structure 112 to cover the circumferential surface 126 of the one or more cells 110.
The one or more openings 128 are configured to maintain the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110. The predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110 includes a predetermined gap to provide space for the one or more gases released from the heat absorbing material 118 at the time of phase changing. The one or more holding arrangements 120 are positioned on a top portion of the bottom cell holder 108. The one or more holding arrangements 120 are projected upwards from the bottom cell holder 108 to hold the predetermined shaped thermally insulative structure 112. The one or more holding arrangements 120 are partially constructed projections or predetermined shaped projections. The predetermined shaped projections depend on shape of the one or more openings 128 of the predetermined shaped thermally insulative structure 112. The one or more openings 128 of the predetermined shaped thermally insulative structure 112 include a hexagon shape, a circular shape, a triangular shape, a rectangular shape, a square shape, or a polygonal shape.

The heat absorbing material 118 is filled in the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110. The heat absorbing material 118 is configured to cover the circumferential surface of the one or more cells 110 to absorb the heat. The heat absorbing material 118 includes a solid Phase Changing Material (PCM), a liquid PCM, an organic/a non-organic, and a dielectric material.

The heat absorbing material 118 releases one or more gases at the time of phase changing or heat absorption. The predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110 includes a predetermined gap to provide space for the one or more gases released from the heat absorbing material 118 at the time of phase changing. The predetermined shaped thermally insulative structure 112 and the predetermined shaped thermally insulative sheet 114 are made up of thermally insulative materials. In one embodiment, the thermally insulative materials may include, but not limited to, mica, microporous silica, ceramic fiber, mineral wool, or combinations thereof.

The above thermal management system 100 provides the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110 to absorb the heat of the one or more cells 110.
Furthermore, the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110 includes the predetermined gap to provide space for the one or more gases released from the heat absorbing material 118 at the time of phase changing.

FIG. 3A&3B is a flow diagram illustrating a method 300 of thermal management in a battery pack 102 according to an embodiment herein.

At step 302, providing space to fill a thermally conductive layer 116 on a battery casing 106 up to a predetermined height. In one embodiment, the predetermined height depends on the heat generated by the one or more cells 110 or the battery pack 102.

At step 304, filling the thermally conductive layer 116 on the battery casing 106 to a predetermined height. The predetermined height depends on heat generated by the one or more cells 110, or the battery pack 102. The predetermined height depends on heat generated by the one or more cells 110 or the battery pack 102.

In one embodiment, the thermally conductive layer 116 is configured to cover the bottom axial surface 124, the circumferential surface of the one or more cells 110, a partial surface of the thermal insulative structure 112 to absorb the heat. In another embodiment, the thermally conductive layer 116 may include, but not limited to, a resin, an organic/a non-organic, a polymeric/non-polymeric material, a polyurethane, an epoxy, or a silicon.

At step 306, placing a bottom cell holder 108 into the thermally conductive layer 116 to hold the one or more cells 110.
At step 308, positioning the one or more cells 110 using the bottom cell holder 108. In one embodiment, the bottom cell holder 108 is configured to hold the one or more cells 110.

At step 310, positioning a predetermined shaped thermally insulative structure 112 on the bottom cell holder 108 in a manner that a predetermined gap is maintained between the one or more cells 110 and the predetermined shaped thermally insulative structure 112 using the one or more holding arrangements 120. In one embodiment, the one or more holding arrangements 120 are positioned on the cell holder towards the upper direction.

At step 312, allowing the thermally conductive layer 116 into the predetermined shaped thermally insulative structure 112. In one embodiment, the predetermined shaped thermally insulative structure 112 and the predetermined shaped thermally insulative sheet 114 made up of thermally insulative materials. The thermally insulative materials may include, but not limited to, mica, microporous silica, ceramic fiber, mineral wool, or combinations thereof.

In one embodiment, the bottom cell holder, and a predetermined length of the predetermined shaped thermally insulative structure 112 are immersed in the thermally conductive layer 116.

At step 314, covering a bottom axial surface 124 of the one or more cells, a circumferential surface of the one or more cells 110, and a partial surface of the predetermined shaped thermally insulative structure 112.

At step 316, pouring a heat absorbing material 118 into the predetermined gap to absorb the heat generated by the one or more cells 110.
In one embodiment, the heat absorbing material 118 is filled in the predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110. The heat absorbing material 118 is configured to cover the circumferential surface of the one or more cells 110 to absorb the heat. The heat absorbing material 118 includes a solid Phase Changing Material (PCM), a liquid PCM, an organic/a non-organic, and a dielectric material.

In another embodiment, the heat absorbing material 118 releases one or more gases at the time of phase changing or heat absorption. The predetermined space between the predetermined shaped thermally insulative structure 112 and the one or more cells 110 includes a predetermined gap to provide space for the one or more gases released from the heat absorbing material 118 at the time of phase changing. The predetermined shaped thermally insulative structure 112 and the predetermined shaped thermally insulative sheet 114 are made up of thermally insulative materials. In one embodiment, the thermally insulative materials may include, but not limited to, mica, microporous silica, ceramic fiber, mineral wool, or combinations thereof.

At step 318, arresting the heat energy of the one or more cells 110 using the predetermined shaped thermally insulative structure 112.

In one embodiment, the predetermined shaped thermally insulative structure 112 includes one or more openings 128. The one or more openings 128 are configured to allow the predetermined shaped thermally insulative structure 112 to cover the circumferential surface 126 of the one or more cells 110. In one embodiment, the predetermined shaped thermally insulative structure 112 and the predetermined shaped thermally insulative sheet 114 are made up of thermally insulative materials. In another embodiment, the thermally insulative materials may include, but not limited to, mica, microporous silica, ceramic fiber, mineral wool, or combinations thereof.
At step 320, closing the predetermined shaped thermally insulative structure 112 by placing the predetermined shaped thermally insulative sheet 114.

In one embodiment, the method 300 further includes placing one or more components 104 inside the battery casing 106 after filling the thermally conductive layer 116 on the battery casing 106 to the predetermined height. In one embodiment, the one or more components 104 includes the bottom cell holder 108, the one or more cells 110, the predetermined shaped thermally insulative structure 112, the thermally conductive layer 116, and the heat absorbing material 118.

In another embodiment, the method 300 further includes positioning the predetermined shaped thermally insulative sheet 114 on the predetermined shaped thermal insulative structure 112.

In yet another embodiment, the method 300 further includes positioning the predetermined shaped thermally insulative sheet 114 on a neck portion of the one or more cells 110.

In yet another embodiment, the method 300 further includes placing the one or more components 104 on the battery casing 106 and pouring the thermally conductive layer 116 on the battery casing 106 to the predetermined height to cover the bottom axial surface 124 of the one or more cells 110, and the circumferential surface of the one or more cells 110, and the partial surface of the predetermined shaped thermally insulative structure 112.
The proposed approach avoids thermal traps due to the encapsulation technique. Furthermore, the proposed approach reduces the heat of the one or more cells 110 by pouring/placing the PCM (e.g., liquid or solid) into the predetermined gap. In addition to that, the proposed approach immerses the predetermined shaped thermally insulative structure 112 into the thermally conductive layer 116 up to the predetermined length to avoid leaking and mixing of the PCM to the thermally conductive layer 116.

The foregoing description of the specific embodiments will 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 scope of the embodiments as described herein. , Claims:1. A system (100) for thermal management in a battery pack (102) comprising:
the battery pack (102) comprises one or more components (104), wherein the one or more components (104) comprise a battery casing (106), a bottom cell holder (108), one or more cells (110), a predetermined shaped thermally insulative structure (112), a thermally conductive layer (116), and a heat absorbing material (118);
a battery casing (106) is mechanically configured to provide space to fill the thermally conductive layer (116) up to a predetermined height from a bottom portion of the battery pack (102), wherein the predetermined height depends on heat generated by the one or more cells (110) or the battery pack (102), wherein the bottom cell holder (108), the one or more cells (110), the predetermined shaped thermally insulative structure (112), the thermally conductive layer (116), and the heat absorbing material (118) are placed on the battery casing (106);
the bottom cell holder (108) comprises one or more holding arrangements (120), wherein the one or more holding arrangements (120) are mechanically configured to hold the predetermined shaped thermally insulative structure (112) and allow the thermally conductive layer (116) into the predetermined shaped thermally insulative structure (112);
the one or more cells (110) comprise a top axial surface (122), a bottom axial surface (124), and a circumferential surface (126); and
the predetermined shaped thermally insulative structure (112) is positioned on the bottom cell holder (108) using the one or more holding arrangements (120) of the bottom cell holder (108), wherein the predetermined shaped thermally insulative structure (112) is configured to arrest heat energy of the one or more cells (110), wherein the predetermined shaped thermally insulative structure (112) comprises one or more openings (128), wherein the one or more openings (128) configured to allow the predetermined shaped thermally insulative structure (112) to cover the circumferential surface (126) of the one or more cells (110), wherein the one or more openings (128) configured to maintain a predetermined space between the predetermined shaped thermally insulative structure (112) and the one or more cells (110).

2. The system (100) as claimed in claim 1, wherein the bottom cell holder (108), the one or more cells (110), the predetermined shaped thermally insulative structure (112), the thermally conductive layer (116), and the heat absorbing material (118) are placed on the battery casing (106) before filing the thermally conductive layer (116) up to the predetermined height from the bottom portion of the battery pack (102).

3. The system (100) as claimed in claim 1, wherein the system further comprises a predetermined shaped thermally insulative sheet (114), wherein the predetermined shaped thermally insulative sheet (114) is configured to arrest heat energy of the one or more cells (110).

4. The system (100) as claimed in claim 1, wherein the predetermined shaped thermally insulative sheet (114) is positioned on the predetermined shaped thermally insulative structure (112) using one or more connecting mechanisms.

5. The system (100) as claimed in claim 1, wherein the system further comprises a top cell holder, wherein the predetermined shaped thermally insulative structure (112) is positioned between the bottom cell holder (108), and the top cell holder.

6. The system (100) as claimed in claim 1, wherein the one or more openings (128) of the predetermined shaped thermally insulative structure (112) comprise a hexagon shape, a circular shape, a triangular shape, a rectangular shape, a square shape, an elliptical or a polygonal shape.


7. The system (100) as claimed in claim 1, wherein the one or more holding arrangements (120) are positioned on a top portion of the bottom cell holder (108), wherein the one or more holding arrangements (120) are projected upwards from the bottom cell holder (108) to hold the predetermined shaped thermally insulative structure (112), wherein the one or more holding arrangements (120) are partially constructed projections or predetermined shaped projections, wherein the predetermined shaped projections depend on shape of the one or more openings (128) of the predetermined shaped thermally insulative structure (112).

8. The system (100) as claimed in claim 1, wherein the thermally conductive layer (116) is configured to cover the bottom axial surface (124) and the circumferential surface of the one or more cells (110) to absorb heat.

9. The system (100) as claimed in claim 1, wherein the thermally conductive layer (116) comprises a resin, an organic/a non-organic, a polymeric/non-polymeric material, a polyurethane, an epoxy, or a silicon.

10. The system (100) as claimed in claim 1, wherein the heat absorbing material (118) is filled in the predetermined space between the predetermined shaped thermally insulative structure (112) and the one or more cells (110), wherein the heat absorbing material (118) is configured to cover the circumferential surface of the one or more cells (110) to absorb the heat.

11. The system (100) as claimed in claim 1, wherein the heat absorbing material (118) comprises a solid Phase Changing Material (PCM), a liquid PCM, an organic/a non-organic, and a dielectric material, wherein the heat absorbing material (118) releases one or more gases at the time of phase changing or heat absorption.

12. The system (100) as claimed in claim 1, wherein the predetermined space between the predetermined shaped thermally insulative structure (112) and the one or more cells (110) comprises a predetermined gap to provide space for the one or more gases released from the heat absorbing material (118) at the time of phase changing.

13. The system (100) as claimed in claim 1, wherein the predetermined shaped thermally insulative structure (112) and the predetermined shaped thermally insulative sheet (114) are made up of thermally insulative materials, wherein the thermally insulative materials comprise mica, microporous silica, ceramic fiber, mineral wool, or combinations thereof.

14. The system (100) as claimed in claim 1, wherein the bottom cell holder (108), and a predetermined length of the predetermined shaped thermally insulative structure (112) are immersed in the thermally conductive layer (116).

15. The system (100) as claimed in claim 1, wherein the thermally conductive layer (116) is poured in one or more locations of the battery pack (102).

16. A method (300) of thermal management in a battery pack (102) comprising:
providing space to fill a thermally conductive layer (116) on a battery casing (106) up to a predetermined height;
filling the thermally conductive layer (116) on the battery casing (106) to the predetermined height, wherein the predetermined height depends on heat generated by one or more cells (110), or the battery pack (102);
placing a bottom cell holder (108) into the thermally conductive layer (116) to hold the one or more cells (110);
positioning, using the bottom cell holder (108), the one or more cells (110);
positioning, using one or more holding arrangements (120), a predetermined shaped thermally insulative structure (112) on the bottom cell holder (108) in a manner a predetermined gap is maintained between the one or more cells (110) and the predetermined shaped thermally insulative structure (112), wherein the one or more holding arrangements (120) are positioned on the cell holder towards upper direction;
allowing the thermally conductive layer (116) into the predetermined shaped thermally insulative structure (112);
covering a bottom axial surface (124) of the one or more cells (110), a circumferential surface of the one or more cells (110), and a partial surface of the predetermined shaped thermally insulative structure (112); and
pouring a heat absorbing material (118) into the predetermined gap to absorb heat generated by the one or more cells (110);
arresting, using the predetermined shaped thermally insulative structure (112), heat of the one or more cells (110); and
closing, by placing a predetermined shaped thermally insulative sheet (114), the predetermined shaped thermally insulative structure (112).

17. The method (300) as claimed in claim 16, wherein the method (300) further comprises:
placing one or more components (104) inside the battery casing (106) after filling the thermally conductive layer (116) on the battery casing (106) to the predetermined height, wherein the one or more components (104) comprise the bottom cell holder (108), the one or more cells (110), the predetermined shaped thermally insulative structure (112), the thermally conductive layer (116), and the heat absorbing material (118).

18. The method (300) as claimed in claim 16, wherein the method (300) further comprises:
positioning the predetermined shaped thermally insulative sheet (114) on the predetermined shaped thermal insulative structure (112).

19. The method (300) as claimed in claim 16, wherein the method (300) further comprises:
placing the one or more components (104) on the battery casing (106); and
pouring the thermally conductive layer (116) on the battery casing (106) to the predetermined height to cover the bottom axial surface (124) of the one or more cells (110), and the circumferential surface of the one or more cells (110), and the partial surface of the predetermined shaped thermally insulative structure (112).