Description:TECHNICAL FIELD
[001] The present disclosure relates to the field of battery systems. In particular, the present disclosure relates to a fluid-cooled battery pack assembly for mitigating temperature variations through controlled non-uniform fluid flow within a battery pack case.

BACKGROUND
[002] Air cooling is a preferred mode of heat dissipation for electric vehicle battery packs due to inherent lower cost, simplicity in packaging demands, and greater reliability compared to liquid cooling. However, battery packs and modules with uniformly spaced cells, and thus uniform heat flux, end up with significant temperature gradients along a width (transverse to the flow direction) in the case of uni-directional air cooling. This non-uniformity in cell temperatures can lead to differential performance and aging within the battery that cause potential long-term risks. Air cooling involves the presence of thermal gradients transverse to the flow direction. However, this is generally accepted as an inevitable trade-off for achieving overall temperature control.
[003] Therefore, there is a need to address the above-mentioned drawbacks, along with any other shortcomings, or at the very least, to provide a viable alternative battery pack assembly in an electric vehicle.

OBJECTS OF THE PRESENT DISCLOSURE
[004] A general objective of the present disclosure relates to an efficient and a reliable battery pack assembly that overcomes the limitations of existing battery pack assembly.
[005] An object of the present disclosure relates to a fluid-cooled battery pack assembly for mitigating temperature variations through controlled non-uniform fluid flow within a battery pack case.
[006] Another object of the present disclosure relates to a fluid-cooled battery pack assembly that includes an inlet fluid interface portion to intake incoming fluid that circulates in a non-uniform pattern within a case for maintaining uniform temperature differences in the battery pack assembly.

SUMMARY
[007] Aspects of the present disclosure relates to the field of battery systems. In particular, the present disclosure relates to a fluid-cooled battery pack assembly for mitigating temperature variations through controlled non-uniform fluid flow within a battery pack case.
[008] An aspect of the present disclosure relates to a fluid-cooled battery pack assembly. The fluid-cooled battery pack assembly includes a battery pack assembly case, a plurality of cooling fins, and an inlet fluid interface portion. The battery pack assembly case defines an enclosure to accommodate a plurality of energy storage modules on a first surface of a horizontal base of the battery pack assembly case. The plurality of cooling fins are configured on a second surface opposite to the first surface of the horizontal base, where the plurality of cooling fins extends parallelly from a first end to a second end of the horizontal base. The inlet fluid interface portion is configured proximal to the first end along a first vertical wall of the battery pack assembly case in such a manner that inlet fluid incident on the inlet fluid interface portion circulates in a non-uniform pattern along the plurality of cooling fins to maintain a uniform thermal gradient across a cross section of the horizontal base of the battery pack assembly case.
[009] In an embodiment, the plurality of cooling fins may have a predetermined length and thickness and may be spaced apart by a predetermined gap.
[010] In an embodiment, the predetermined length of the plurality of cooling fins may be substantially equal to a distance between a first end and a second end of the horizontal base.
[011] In an embodiment, the inlet fluid interface portion may be integrated with the first vertical wall of the battery pack assembly case.
[012] In an embodiment, the inlet fluid interface portion may include one or more openings having one or more cross section profiles.
[013] In an embodiment, the one or more cross section profiles may correspond to a circular profile, a polygonal profile, an elliptical profile, and a triangular profile.
[014] In an embodiment, the one or more cross section profiles of the one or more openings may be inversely proportional to a distance between a geometric centre of the respective one or more openings from a geometric centre of the inlet fluid interface portion.
[015] In an embodiment, the inlet fluid interface portion may include an opening having a predefined cross section profile, where a volume of the inlet fluid passing through the opening at an influx point of the predefined cross section profile may be inversely proportional to a distance of the influx point from a geometric centre of the inlet fluid interface portion.
[016] In an embodiment, the assembly may include an outlet port on a second vertical wall opposite to the first vertical wall to let out the inlet fluid passing along the plurality of cooling fins.
[017] In an embodiment, the inlet fluid interface portion may extend in an orthogonal direction from the first vertical wall, and where the inlet fluid interface portion may include a plurality of vanes disposed vertically on a base of the inlet fluid interface portion, where each of the plurality of vanes may be disposed oblique to a direction of the inlet fluid incident thereto.
[018] In an embodiment, the inlet fluid interface portion may include an opening having a predefined cross section profile, where a volume of inlet fluid passing through the opening at an influx point of the predefined cross section profile may be inversely proportional to a distance of the influx point from a geometric centre of the inlet fluid interface portion.
[019] In an embodiment, a volume of inlet fluid passing inwardly through a predefined cross section profile of the inlet fluid interface portion may vary based on an obliqueness profile of obliqueness of each of the plurality of vanes.
[020] In an embodiment, the plurality of vanes may have a predetermined degree of obliqueness with respect to the direction of incident inlet fluid.
[021] In an embodiment, the predetermined degree of obliqueness may be in a range of about 10 degrees to about 80 degrees.
[022] In an embodiment, the inlet fluid may correspond to air.
[023] In an embodiment, a count of the one or more openings and the one or more cross section profiles may be based on a length of a first end and/or a distance between the first end and a second end of the horizontal base.
[024] In an embodiment, a count of the plurality of vanes and the predetermined degree of obliqueness of each of the plurality of vanes may be based on a length of a first end and/or a distance between the first end and a second end of the horizontal base.
[025] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent components.

BRIEF DESCRIPTION OF THE DRAWINGS
[026] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[027] FIG. 1 illustrates a schematic view of an Electric Vehicle (EV), in accordance with embodiments of the present disclosure.
[028] FIG. 2 illustrates a schematic view of non-uniformity in a fluid flow across a fluid-cooled battery pack assembly, in accordance with embodiments of the present disclosure.
[029] FIG. 3A illustrates an isometric view of the fluid-cooled battery pack assembly with discrete openings of an inlet fluid interface portion, in accordance with embodiments of the present disclosure.
[030] FIG. 3B illustrates a bottom view of the fluid-cooled battery pack assembly with the discrete openings of the inlet fluid interface portion, in accordance with embodiments of the present disclosure.
[031] FIG. 3C illustrates an exploded view of the fluid-cooled battery pack assembly with the discrete openings of the inlet fluid interface portion, in accordance with embodiments of the present disclosure.
[032] FIG. 4A illustrates an isometric view of the fluid-cooled battery pack assembly with continuous openings of the inlet fluid interface portion, in accordance with embodiments of the present disclosure.
[033] FIG. 4B illustrates a bottom view of the fluid-cooled battery pack assembly with the continuous openings of the inlet fluid interface portion, in accordance with embodiments of the present disclosure.
[034] FIG. 4C illustrates an exploded view of the fluid-cooled battery pack assembly with the continuous openings of the inlet fluid interface portion, in accordance with embodiments of the present disclosure.
[035] FIG. 5A illustrates an isometric view of the fluid-cooled battery pack assembly configured through an inlet duct with vanes, in accordance with embodiments of the present disclosure.
[036] FIG. 5B illustrates a bottom view of the fluid-cooled battery pack assembly configured through the inlet duct with the vanes, in accordance with embodiments of the present disclosure.
[037] FIG. 5C illustrates an exploded view of the fluid-cooled battery pack assembly configured through the inlet duct with the vanes, in accordance with embodiments of the present disclosure.
[038] FIG. 6 illustrates a graphical representation of a temperature gradient using different types of inlet fluid interface portion, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION
[039] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosures as defined by the appended claims.
[040] For the purpose of understanding of the principles of the present disclosure, reference will now be made to the various embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present disclosure is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the present disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present disclosure relates.
[041] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the present disclosure and are not intended to be restrictive thereof.
[042] Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more” or “one or more elements is required.”
[043] Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.
[044] Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
[045] Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.
[046] The terms “comprise”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by “comprises... a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.
[047] Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
[048] For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in Figure 1. Similarly, reference numerals starting with digit “2” are shown at least in Figure 2.
[049] An Electric Vehicle (EV) or a battery powered vehicle including, and not limited to two-wheelers such as scooters, mopeds, motorbikes/motorcycles; three-wheelers such as auto-rickshaws, four-wheelers such as cars and other Light Commercial Vehicles (LCVs) and Heavy Commercial Vehicles (HCVs) primarily work on the principle of driving an electric motor using the power from the batteries provided in the EV. Furthermore, the electric vehicle may have at least one wheel which is electrically powered to traverse such a vehicle. The term ‘wheel’ may be referred to any ground-engaging member which allows traversal of the electric vehicle over a path. The types of EVs include Battery Electric Vehicle (BEV), Hybrid Electric Vehicle (HEV) and Range Extended Electric Vehicle. However, the subsequent paragraphs pertain to the different elements of a Battery Electric Vehicle (BEV).
[050] FIG. 1 illustrates a schematic view of an Electric Vehicle (EV), in accordance with an embodiment of the present disclosure.
[051] In construction, an EV (10) typically comprises a battery or battery pack (12) enclosed within a battery casing and includes a Battery Management System (BMS), an on-board charger (14), a Motor Controller Unit (MCU), an electric motor (16) and an electric transmission system (18). The primary function of the above-mentioned elements is detailed in the subsequent paragraphs: The battery of an EV (10) (also known as Electric Vehicle Battery (EVB) or traction battery) is re-chargeable in nature and is the primary source of energy required for the operation of the EV, wherein the battery (12) is typically charged using the electric current taken from the grid through a charging infrastructure (20). The battery may be charged using Alternating Current (AC) or Direct Current (DC), wherein in case of AC input, the on-board charger (14) converts the AC signal to DC signal after which the DC signal is transmitted to the battery via the BMS. However, in case of DC charging, the on-board charger (14) is bypassed, and the current is transmitted directly to the battery via the BMS.
[052] The battery (12) is made up of a plurality of cells which are grouped into a plurality of modules in a manner in which the temperature difference between the cells does not exceed 5 degrees Celsius. The terms “battery”, “cell”, and “battery cell” may be used interchangeably and may refer to any of a variety of different rechargeable cell compositions and configurations including, but not limited to, lithium-ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium-ion polymer, nickel metal hydride, nickel cadmium, nickel hydrogen, nickel-zinc, silver zinc, or other battery type/configuration. The term “battery pack” as used herein may be referred to multiple individual batteries enclosed within a single structure or multi-piece structure. The individual batteries may be electrically interconnected to achieve a desired voltage and capacity for a desired application. The Battery Management System (BMS) is an electronic system whose primary function is to ensure that the battery (12) is operating safely and efficiently. The BMS continuously monitors different parameters of the battery such as temperature, voltage, current and so on, and communicates these parameters to the Electronic Control Unit (ECU) and the Motor Controller Unit (MCU) in the EV using a plurality of protocols including and not limited to Controller Area Network (CAN) bus protocol which facilitates the communication between the ECU/MCU and other peripheral elements of the EV (10) without the requirement of a host computer.
[053] The MCU primarily controls/regulates the operation of the electric motor based on the signal transmitted from the vehicle battery, wherein the primary functions of the MCU include starting of the electric motor (16), stopping the electric motor (16), controlling the speed of the electric motor (16), enabling the vehicle to move in the reverse direction and protect the electric motor (16) from premature wear and tear. The primary function of the electric motor (16) is to convert electrical energy into mechanical energy, wherein the converted mechanical energy is subsequently transferred to the transmission system of the EV to facilitate movement of the EV. Additionally, the electric motor (16) also acts as a generator during regenerative braking (i.e., kinetic energy generated during vehicle braking/deceleration is converted into potential energy and stored in the battery of the EV). The types of motors generally employed in EVs include, but are not limited to DC series motor, Brushless DC motor (also known as BLDC motors), Permanent Magnet Synchronous Motor (PMSM), Three Phase AC Induction Motors and Switched Reluctance Motors (SRM).
[054] The transmission system (18) of the EV (10) facilitates the transfer of the generated mechanical energy by the electric motor (16) to the wheels (22a, 22b) of the EV. Generally, the transmission systems (18) used in EVs include single speed transmission system and multi-speed (i.e., two-speed) transmission system, wherein the single speed transmission system comprises a single gear pair whereby the EV is maintained at a constant speed. However, the multi-speed/two-speed transmission system comprises a compound planetary gear system with a double pinion planetary gear set and a single pinion planetary gear set thereby resulting in two different gear ratios which facilitates higher torque and vehicle speed.
[055] In one embodiment, all data pertaining to the EV (10) and/or charging infrastructure (20) are collected and processed using a remote server (known as cloud) (24), wherein the processed data is indicated to the rider/driver of the EV (10) through a display unit present in the dashboard (26) of the EV (10). In an embodiment, the display unit may be an interactive display unit. In another embodiment, the display unit may be a non-interactive display unit.
[056] Embodiments explained herein relate to battery systems. In particular, the present disclosure relates to a fluid-cooled battery pack assembly for mitigating temperature variations through controlled non-uniform fluid flow within a battery pack case.
[057] The present disclosure addresses a problem of thermal gradients typically encountered in air-cooled assembly, where the central parts of a heat source end up hotter than peripheral parts. These thermal gradients are particularly undesirable in battery packs that leads to differential ageing of cells within the battery packs and consequently voltage imbalances. Various embodiments with respect to the present disclosure will be explained in detail with reference to FIGs. 2-6.
[058] FIG. 2 illustrates a schematic view (200) of non-uniformity in a fluid (204) flow across a fluid-cooled battery pack assembly (300), in accordance with embodiments of the present disclosure.
[059] Referring to FIG. 2, the fluid-cooled battery pack assembly (300) may include a battery pack assembly case (302) that defines an enclosure that accommodate energy storage modules (206). The non-uniformity in the velocity profile of the fluid (204) flow may extend across a width of the fluid-cooled battery pack assembly (300). For example, highest flow speeds may be directed at a mid-section, and the lower speeds may be directed over the periphery. In an embodiment, thermal parameters such as fins and thermal interface, remain constant, a local heat dissipation is directly tied to the local fluid (204) flow velocity. As a result, the higher speeds in the middle portion effectively reduce temperatures by enhancing heat dissipation, while the lower speeds at the periphery lead to warmer peripheral cells with lesser heat dissipation compared to the middle portion. This configuration leads to maintain temperature variations more effectively in the fluid-cooled battery pack assembly (300). In exemplary embodiments, the fluid (204) may be, but not limited to coolant, air, liquid, refrigerant, heat dissipation liquid, hydraulic fluid, and other cooling agents.
[060] FIG. 3A illustrates an isometric view of the fluid-cooled battery pack assembly (300) with discrete openings (304A) of an inlet fluid interface portion (304), in accordance with embodiments of the present disclosure.
[061] Referring to FIG. 3A, the fluid-cooled battery pack assembly (300) may include a battery pack assembly case (302), cooling fins (306), an inlet fluid interface portion (304). The battery pack assembly case (302) may define an enclosure to accommodate energy storage modules (206). The energy storage modules (206) may stack in a vertical orientation on a first surface of a horizontal base of the battery pack assembly case (302). In some embodiments, the enclosure may be of, but not limited to, a cubical shape, a cuboidal shape, a circular shape, a rectangular shape, a square shape, a triangular shape, and the like. The cooling fins (306) may be configured at a second surface that is opposite to the first surface of the horizontal base.
[062] The inlet fluid interface portion (304) may be configured proximal to the first end (308A) along a first vertical wall (310) of the battery pack assembly case (302). In an embodiment, the inlet fluid interface portion (304) may integrate with the first vertical wall (310) of the battery pack assembly case (302). In such a manner that inlet fluid (204) incident on the inlet fluid interface portion (304) circulates in a non-uniform pattern along the cooling fins (306). This circulation may be designed to maintain a uniform thermal gradient across the cross-section of the horizontal base of the battery pack assembly case (302). In an embodiment, the inlet fluid interface portion (304) may include openings that may have cross-section profiles. For example, the cross-section profiles may include, but not limited to a circular profile, a polygonal profile, an elliptical profile, a triangular profile, and the like.
[063] In some embodiments, the cross-section profiles of the openings may be inversely proportional to a distance between a geometric centre of the respective openings from the geometric centre of the inlet fluid interface portion (304). In exemplary embodiments, an amount or volume of inlet fluid (204) may pass inwardly through the openings is inversely proportional to the distance between the geometric centre of the respective openings from the geometric centre of the inlet fluid interface portion (304). Similarly, the amount or volume of the inlet fluid (204) may pass through the opening at an influx point of a predefined cross section profiles. This predefined cross section profiles may be inversely proportional to the distance of the influx point from the geometric centre of the inlet fluid interface portion (304). The fluid-cooled battery pack assembly (300) may include an outlet port (314) on a second vertical wall (312) opposite to the first vertical wall (310) to let out the inlet fluid passing along the cooling fins (306). In some embodiments, in the inlet fluid interface portion (304), a count of openings and the cross section profiles are based on a length of the first end (308A) and a distance between the first end (308A) and a second end (308B) of the horizontal base.
[064] For example, when the fluid (204) flow approaching a heat transfer surface i.e., the cooling fins (306) of the battery pack assembly case (302), may generally uniform across the width, a certain level of non-uniformity may be introduced by a front grille i.e., the first vertical wall (310) located just upstream of the cooling fins (306) of the battery pack assembly case (302). This front grille may be designed with wider openings near the middle of the width of the battery pack assembly case (302) to allow maximum fluid (204) flow in that region, consequently lowering temperatures for cells in the middle row. This design contrasts with conventional uniform air-cooling, where the middle row cells tend to be hotter. On the other hand, the front grille openings may narrow near sides of the battery pack assembly case (302) that creates higher back pressure and reducing fluid (204) flow along sides of the battery pack assembly case (302). This results in relatively higher temperatures for cells (206) in side rows. The overall effect is a reduction in the thermal gradient between the middle and side rows of fluid-cooled battery pack assembly (300).
[065] Referring to FIG. 3A, the discrete openings (304A) may allow for more precise control over the inflow of the fluid (204) that enables targeted cooling in specific areas. This level of control may contribute to a more efficient thermal management in the battery pack assembly case (302).
[066] FIG. 3B illustrates a bottom view of a fluid-cooled battery pack assembly (300) with discrete openings (304A) inlet of an inlet fluid interface portion (304), in accordance with embodiments of the present disclosure.
[067] Referring to FIG. 3B, in the bottom view of the fluid-cooled battery pack assembly (300), cooling fins (306) may be configured at a second surface opposite to a first surface of the horizontal base. The cooling fins (306) may extend parallelly from a first end (308A) to a second end (308B) of a horizontal base. The cooling fins (306) may be spaced apart by a predetermined gap and the cooling fins (306) may have a predetermined length and thickness. In an embodiment, the predetermined length of the cooling fins (306) may substantially equal to a distance between the first end (308A) and the second end (308B) of the horizontal base.
[068] FIG. 3C illustrates an exploded view of a fluid-cooled battery pack assembly (300) with discrete openings (304A) inlet of an inlet fluid interface portion (304), in accordance with embodiments of the present disclosure.
[069] Referring to FIG. 3C, in the exploded view, a bottom plate (316) may cover a bottom portion of a battery pack assembly case (302) with the configuration of the discrete openings (304A) inlet. The bottom plate (316) may serve as a protective and structural component that contributes an overall integrity and enclosure of the battery pack assembly case (302). The bottom plate (316) may enhance a structural cohesion of the battery pack assembly case (302) that contributes to the robustness and protective features of an overall design.
[070] FIG. 4A illustrates an isometric view of a fluid-cooled battery pack assembly (300) with continuous openings (402) of an inlet fluid interface portion (304), in accordance with embodiments of the present disclosure.
[071] Referring to FIG. 4A, the continuous openings (402) may allow a more consistent and uninterrupted flow of fluid (204) into a battery pack assembly case (302). This continuous flow pattern enhances the efficiency of heat dissipation by promoting a smooth and uniform distribution of fluid (204) across heat transfer surfaces. In some embodiments, in the inlet fluid interface portion (304), a count of openings and cross section profiles are based on a length of a first end (308A) and a distance between the first end (308A) and a second end (308B) of the horizontal base. In an embodiment, the fluid-cooled battery pack assembly (300) features a rhombus-shaped continuous opening (402) with wider openings concentrated at the centre part of the inlet fluid interface portion (304) and narrower openings along the edge part of the inlet fluid interface portion (304). For example, the continuous openings (402) are inversely proportional to a distance between a geometric centre of the respective continuous openings from a geometric centre of the inlet fluid interface portion (304).
[072] FIG. 4B illustrates a bottom view of a fluid-cooled battery pack assembly (300) with continuous openings (402) of an inlet fluid interface portion (304), in accordance with embodiments of the present disclosure. Referring to FIG. 4B, the continuous openings (402) may optimize an efficiency of the fluid-cooled battery pack assembly (300) that enhance effective temperature regulation.
[073] FIG. 4C illustrates an exploded view of the fluid-cooled battery pack assembly (300) with the continuous openings (402) of an inlet fluid interface portion (304), in accordance with embodiments of the present disclosure. In the exploded view, a bottom plate (316) may cover a bottom portion of a battery pack assembly case (302) with a configuration of the continuous openings (402) inlet.
[074] FIG. 5A illustrates an isometric view of a fluid-cooled battery pack assembly (300) configured through an inlet duct with vanes (502), in accordance with embodiments of the present disclosure.
[075] Referring to FIG. 5A, an inlet fluid interface portion (304) may extend in an orthogonal direction from a first vertical wall (310). The inlet fluid interface portion (304) may include the vanes (502) disposed vertically on a base of the inlet fluid interface portion (304). The vanes (502) may be disposed oblique to a direction of inlet fluid (204) incident thereto. The inlet fluid interface portion (304) may include an opening having a predefined cross section profiles. An amount or volume of the inlet fluid (204) passing through the opening at an influx point of the predefined cross section profiles is inversely proportional to the distance of the influx point from the geometric centre of the inlet fluid interface portion (304). In an embodiment, the amount or volume of the inlet fluid (204) may pass inwardly through the predefined cross section profiles of the inlet fluid (204) interface portion varies based on the obliqueness profile or degree of obliqueness of each of the vanes (502). The vanes (502) may have a predetermined degree of obliqueness with respect to the direction of incident inlet fluid (204). For example, the predetermined degree of obliqueness is in a range of about 10 degrees to about 80 degrees. In some embodiments, in the inlet fluid interface portion (304), a count of the vanes (502) and the predetermined degree of obliqueness of each of the vanes (502) may be based on a length of a first end (308A) and/or a distance between the first end (308A) and a second end (308B) of a horizontal base.
[076] In an embodiment, the inlet fluid interface portion (304) may include two vanes (502) disposed oblique to a direction of inlet fluid (204) incident thereto on the base of the inlet fluid interface portion (304).
[077] In an embodiment, the inlet duct may be integrated with the battery pack assembly case (302) slightly upstream of heat transfer surfaces i.e., cooling fins (306). The interior of the inlet duct features multiple guiding vanes (502) for the incoming uniform flow. The vanes (502) may be angled with respect to axial flow direction that convers towards the downstream part of the duct. This ensures that the middle rows of the battery pack assembly case (302) may be cooled by more than their proportionate share of the uniform inflow, while side rows have lesser fluid (204) flow available for their cooling requirements that results in lower temperatures for middle rows and relatively higher temperatures for the side rows. This helps in mitigating temperature gradient across the battery pack width.
[078] FIG. 5B illustrates a bottom view of a fluid-cooled battery pack assembly (300) configured through an inlet duct with vanes (502), in accordance with embodiments of the present disclosure. Referring to FIG. 5B, an inlet fluid interface portion (304) may extend in an orthogonal direction from a first vertical wall (310). The inlet duct with vanes (502) may optimize an efficiency of the fluid-cooled battery pack assembly (300) that enhance effective temperature regulation.
[079] FIG. 5C illustrates an exploded view of a fluid-cooled battery pack assembly (300) configured through an inlet duct with vanes (502), in accordance with embodiments of the present disclosure. In the exploded view, a bottom plate (316) may cover a bottom portion of a battery pack assembly case (302). The bottom plate (316) size may correspond to the length of the inlet fluid interface portion (304).
[080] FIG. 6 illustrates a graphical representation (600) of a temperature gradient using a different types of inlet fluid interface portion (304), in accordance with embodiments of the present disclosure.
[081] Referring to FIG. 6, a comparison with an existing base design reveals that the temperature maintenance may be significantly improved. This improvement may be achieved by configuring the inlet fluid interface portion (304) with various designs such as vanes-based configuration, a perforations or grille-based configuration, and a tapered opening-based configuration. In an embodiment, the vanes-based configuration may represent the temperature reduction compared to the existing base design. Additionally, in some embodiments, the perforations or grille-based configuration may represent the temperature reduction compared with the existing base design. In an exemplary embodiment, the tapered opening-based configuration may reduce the temperature compared with the existing base design as illustrated in FIG. 6. Further, FIG. 6 illustrates the temperature reduction compared among the vanes-based configuration, the perforations or grille-based configuration, and the tapered opening-based configuration in relation to the existing base design. For example, referring to FIG. 6, the temperature of the existing base design is 4.8°C, the temperature of the fluid-cooled battery pack assembly (300) using the vanes-based configuration may be around 4°C. Similarly, the temperature of the fluid-cooled battery pack assembly (300) using the perforations or grille-based configuration may be around 3.2°C and the temperature of the fluid-cooled battery pack assembly (300) using the tapered opening-based configuration may be around 3.9°C.
[082] In some embodiments, this cooling method may additionally be applied to other components or assemblies that require thermal management but are sensitive to spatial thermal gradients. High temperature gradients in some components may lead to uneven thermal expansion/contraction that potentially cause warpage or mechanical failure. Non-uniform flow rates may mitigate extreme temperatures in such cases. For instance, fluid-cooled electronics packages could implement this cooling method to address temperature differences among components mounted on Printed Circuit boards (PCBs) to achieve a more uniform thermal spread would contribute to similar lifetime performance and reliability of these components.
[083] In this application, unless specifically stated otherwise, the use of the singular includes the plural and the use of “or” means “and/or.” Furthermore, use of the terms “including” or “having” is not limiting. Any range described herein will be understood to include the endpoints and all values between the endpoints. Features of the disclosed embodiments may be combined, rearranged, omitted, etc., within the scope of the disclosure to produce additional embodiments. Furthermore, certain features may sometimes be used to advantage without a corresponding use of other features.
[084] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The scope of the disclosure is determined by the claims that follow. The disclosure is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the disclosure when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE
[085] The present disclosure relates to a fluid-cooled battery pack assembly for directing more fluid flow to regions with higher heat dissipation needs, thereby enhancing cooling efficiency in critical areas and preventing localized overheating.
[086] The present disclosure relates to a fluid-cooled battery pack assembly that minimizes temperature gradients within a battery pack assembly case.
[087] The present disclosure relates to a fluid-cooled battery pack assembly that maintains a controlled temperature environment through non-uniform fluid flow, thereby contributing to sustained and optimized performance of battery cells.
, Claims:1. A fluid-cooled battery pack assembly (300), comprising:
a battery pack assembly case (302) defining an enclosure to accommodate a plurality of energy storage modules (206) on a first surface of a horizontal base of the battery pack assembly case (302);
a plurality of cooling fins (306) configured on a second surface opposite to the first surface of the horizontal base, wherein the plurality of cooling fins (306) extends parallelly from a first end (308A) to a second end (308B) of the horizontal base; and
an inlet fluid interface portion (304) configured proximal to the first end (308A) along a first vertical wall (310) of the battery pack assembly case (302) in such a manner that inlet fluid incident on the inlet fluid interface portion (304) circulates in a non-uniform pattern along the plurality of cooling fins (306) to maintain a uniform thermal gradient across a cross section of the horizontal base of the battery pack assembly case (302).
2. The fluid-cooled battery pack assembly (300) as claimed in claim 1, wherein the plurality of cooling fins (306) have a predetermined length and thickness and are spaced apart by a predetermined gap.
3. The fluid-cooled battery pack assembly (300) as claimed in claim 2, wherein the predetermined length of the plurality of cooling fins (306) is substantially equal to a distance between the first end (308A) and the second end (308B) of the horizontal base.
4. The fluid-cooled battery pack assembly (300) as claimed in claim 1, wherein the inlet fluid interface portion (304) is integrated with the first vertical wall (310) of the battery pack assembly case (302).
5. The fluid-cooled battery pack assembly (300) as claimed in claim 1, wherein the inlet fluid interface portion (304) comprises one or more openings having one or more cross section profiles.
6. The fluid-cooled battery pack assembly (300) as claimed in claim 5, wherein the one or more cross section profiles correspond to a circular profile, a polygonal profile, an elliptical profile, and a triangular profile.
7. The fluid-cooled battery pack assembly (300) as claimed in claim 5, wherein the one or more cross section profiles of the one or more openings are inversely proportional to a distance between a geometric centre of the respective one or more openings from a geometric centre of the inlet fluid interface portion (304).
8. The fluid-cooled battery pack assembly (300) as claimed in claim 7, wherein a count of the one or more openings and the one or more cross section profiles are based on a length of the first end (308A) and/or a distance between the first end (308A) and the second end (308B) of the horizontal base.
9. The fluid-cooled battery pack assembly (300) as claimed in claim 1, wherein the inlet fluid interface portion (304) comprises an opening having a predefined cross section profile, wherein a volume of the inlet fluid passing through the opening at an influx point of the predefined cross section profile is inversely proportional to a distance of the influx point from a geometric centre of the inlet fluid interface portion (304).
10. The fluid-cooled battery pack assembly (300) as claimed in claim 1, comprising an outlet port (314) on a second vertical wall (312) opposite to the first vertical wall (310) to let out the inlet fluid passing along the plurality of cooling fins (306).
11. The fluid-cooled battery pack assembly (300) as claimed in claim 1, wherein the inlet fluid interface portion (304) extends in an orthogonal direction from the first vertical wall (310), and wherein the inlet fluid interface portion (304) comprises a plurality of vanes (502) disposed vertically on a base of the inlet fluid interface portion (304), wherein each of the plurality of vanes (502) is disposed oblique to a direction of the inlet fluid incident thereto.
12. The fluid-cooled battery pack assembly (300) as claimed in claim 11, wherein the inlet fluid interface portion (304) comprises an opening having a predefined cross section profile, wherein a volume of the inlet fluid passing through the opening at an influx point of the predefined cross section profile is inversely proportional to a distance of the influx point from a geometric centre of the inlet fluid interface portion (304).
13. The fluid-cooled battery pack assembly (300) as claimed in claim 11, wherein a volume of the inlet fluid passing inwardly through a predefined cross section profile of the inlet fluid interface portion (304) varies based on an obliqueness profile of obliqueness of each of the plurality of vanes (502).
14. The fluid-cooled battery pack assembly (300) as claimed in claim 11, wherein the plurality of vanes (502) have a predetermined degree of obliqueness with respect to the direction of the inlet fluid incident thereto.
15. The fluid-cooled battery pack assembly (300) as claimed in claim 14, wherein the predetermined degree of obliqueness is in a range of about 10 degrees to about 80 degrees.
16. The fluid-cooled battery pack assembly (300) as claimed in claim 14, wherein a count of the plurality of vanes (502) and the predetermined degree of obliqueness of each of the plurality of vanes (502) are based on a length of the first end (308A) and/or a distance between the first end (308A) and the second end (308B) of the horizontal base.
17. The fluid-cooled battery pack assembly (300) as claimed in claim 1, wherein the inlet fluid corresponds to air.