DESC:TITLE OF INVENTION
Integrated hybrid device for optimized thermal control in energy storage system

FIELD OF INVENTION
The present invention generally relates to the field of energy storage system, particularly to thermal control in energy storage system. More particularly, the present invention relates an integrated hybrid device for optimized thermal control in energy storage system.

BACKGROUND OF INVENTION
Patent application number “CN115455345” titled “Distributed energy thermal management method, device and equipment” describes “he invention discloses a distributed energy heat management method, device and equipment, and the method comprises the steps: providing a distributed heat management model based on a heat conduction differential equation, and the model comprises a rectangular coordinate and/or cylindrical coordinate and/or spherical coordinate heat conduction control model and a temperature uniformity model; converting the distributed thermal management model into an algebraic equation and compiling the algebraic equation; monitoring point data are collected and input into the compiled distributed thermal management model, thermal field distribution data are obtained, and the thermal field distribution data are used for obtaining non-monitoring point data. A distributed thermal management model is adopted, and an electric-thermal control relation (algebraic equation) is established. The energy management system calculates and obtains temperature information of each node of the energy storage system according to an electro-thermal control relation, so that the energy management system (EMS) can calculate 1000-10000 temperature nodes, and only 100 temperature collectors need to be arranged for every 1000 batteries in the energy storage system”.

None of the above-mentioned prior articles neither teach nor disclose about an integrated hybrid device for optimized thermal control in energy storage system.

wherein, the present invention is an integrated hybrid device for optimized thermal control in energy storage system.

OBJECTS OF INVENTION
One or more of the problems of the conventional prior art may be overcome by various embodiments of the system of present invention.

It is the primary object of the present invention is an integrated hybrid device for optimized thermal control in energy storage system.

It is another object of the present invention is the design features dynamic cooling modes, including eco, performance, and extreme executed by the control unit to adjust cooling efficiency in real-time based on data from the sensor unit and the assembly incorporates quick-disassembly modular cap top and modular cap bottom with a conductive bottom surface and insulating top surface, improving maintenance and reliability.
It is yet another object of the present invention is the inclusion of optically-activated thermal switches allows for non-contact thermal management controlled by the control unit, while smart microstructures create fluid circulation channels controlled by the control unit and generate high-frequency acoustic waves controlled by the control unit to achieve heat dissipation rates between 100 W/m²•K and 3000 W/m²•K and the device can integrate fans to enhance airflow controlled by the control unit, increasing heat dissipation efficiency by 20–30% compared to passive systems, particularly for ground-based electric vehicle applications.

SUMMARY OF INVENTION
It is an aspect of the invention is an integrated hybrid device for optimized thermal control in energy storage system, comprising:
A middle casing;
A top cover;
A bottom cover;
A fluid pipeline;
A plurality of bolts;
A battery pack;
A cell holder;
A top part;
A bottom part;
A modular cap top;
A modular cap bottom;
A plurality of a gasket;
A sensor unit; and
A control unit,
Characterised that,
The battery pack containing multiple cells arranged in a predefined configuration and the cell holder designed to hold the battery pack, with provisions for sliding into and out of the middle casing for ease of assembly, maintenance, and replacement, therein, the top part and the bottom part of the cell holder for securely housing with modular cap top and modular cap bottom and providing contact with the covers;
wherein, the modular cap top and modular cap bottom configured to connect the cells in series or parallel to achieve the desired voltage and current therein, the insulating material in the modular cap top and modular cap bottom prevents electrical losses being discharged by the covers and also restricting the vertical movement of the battery pack;
wherein, the plurality of gaskets for sealing the casing in applications requiring water resistance, such as underwater remotely operated vehicles (UROVs) and in the active mode, the fluid pipeline circulates a heat-transfer fluid through the cell holder and the casing to a radiator arrangement for efficient heat dissipation via conduction, convection, or radiation;
wherein, the sensor unit reads the battery parameters and then inputs to the control unit, therein the sensor unit comprises of voltage sensor, current sensor, and temperature sensor, thereby, based on the sensor unit data, the control unit takes necessary actions in maintaining the optimal temperature of the battery pack; and
wherein, in the passive mode, the system uses fin arrangements on the casing, the top cover, and the bottom cover to dissipate heat directly to the surroundings without fluid circulation therein, the cell holder is constructed from multiple welded pieces to enable precise alignment of fluid pipeline channels and efficient heat transfer from the battery cells to the fluid, and the system integrates advanced materials, such as phase-changing materials in the cell holder for enhanced heat stabilization and anti-icing nanocoatings on external components for frost prevention in sub-zero environments.

It is an another aspect of invention is the design features dynamic cooling modes, including eco, performance, and extreme executed by the control unit to adjust cooling efficiency in real-time based on data from the sensor unit and the assembly incorporates quick-disassembly modular cap top and modular cap bottom with a conductive bottom surface and insulating top surface, improving maintenance and reliability.

It is yet another aspect of invention is the inclusion of optically-activated thermal switches allows for non-contact thermal management controlled by the control unit, while smart microstructures create fluid circulation channels controlled by the control unit and generate high-frequency acoustic waves controlled by the control unit to achieve heat dissipation rates between 100 W/m²•K and 3000 W/m²•K and the device can integrate fans to enhance airflow controlled by the control unit, increasing heat dissipation efficiency by 20–30% compared to passive systems, particularly for ground-based electric vehicle applications.

BRIEF DESCRIPTION OF DRAWING
Figure 1 represents an exploded view of the proposed hybrid battery heat dissipation system assembly

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING FIGURES
The present invention as herein described about an integrated hybrid device for optimized thermal control in energy storage system.

Referring to figure 1 which shows the exploded view of the hybrid battery heat dissipation system, according to one embodiment of the present invention. As shown in the illustration, the system includes a middle casing (100), a top cover 101(a), a bottom cover 101(b), and a fluid pipeline (102). The entire setup features a mounting provision (using bolts (103) in the top cover 101(a) or bottom cover 101(b)) to attach it to the vehicle's body, serving as its power source which is not provided in the illustrations. The middle casing includes electrical connection provisions for charging and discharging the battery pack. The system includes multiple cells (104) (AA size cells are used in the battery pack, as illustrated) held by the cell holder (105). The distance between adjacent cells in the battery pack is 180mm. The slot arrangement in the middle casing (100) allows the cell holder (105) (which holds the battery pack (104) to easily slide into it. The slot aids in easy mounting and removal of the battery pack (104) for service, maintenance or replacement of cells. The tolerance within the slot region between the cell holder (105) and middle casing (100) is precisely adjusted to ensure minimal effort is needed to detach the cell holder (105) from the middle casing (100). Additionally, the cell holder 105 can be of various shapes (hexagonal, circular, rectangular, etc.) and sizes, depending on the preferred cell type. Moreover, a top part 106(a) and a bottom part 106(b) of the cell holder (105) are fixed at the top and bottom of the cell holder. The present embodiment has a modular cap top (107) and a modular cap bottom (108) replace traditional welding methods for ESS assembly, comprising of a bottom surface of highly conductive material for thermal and electrical contact with ESS components; a top surface acting as an electrical insulator with high thermal conductivity. These modular cap top (107) and modular cap bottom (108) assembly allows quick disassembly and reassembly, improving ESS maintenance and reliability. The modular cap top (107) and modular cap bottom (108) also prevent the vertical movement of the battery pack 104. As insulating material is utilized, it prevents the discharge of current from the battery pack 104 to the top cover 101(a) or the bottom cover 101(b). The top part 106(a) of the cell holder 105 touches the top cover 101(a) and the bottom part 106(b) of the cell holder 105 touches the bottom cover 101(b) upon completely assembling the proposed hybrid battery heat dissipation system. A provision is provided in the top cover 101(a) and bottom cover 101(b) such that top part 106(a) and bottom part 106(b) of the cell holder 105 are fixed in the provision. In other ways, the top part 106(a) can be welded to top cover 101(a) and the bottom part 106(b) welded to bottom cover 101(b) to make the assembly simple. The top cover 101(a) and bottom cover 101(b) close the top and bottom openings of the middle casing 100 through the support of bolts 103. In case of using the proposed hybrid battery heat dissipation system for ground-based and aerial electric vehicle, the usage of gasket 109(a) and 109(b) can be removed. However, gaskets are mostly preferred for the Underwater Remotely Operated Vehicle (UROV) applications. Further, sensor unit (110) senses the battery parameters and inputs to control unit (111). The sensor unit comprises of several sensors such as, voltage sensor, current sensor, temperature sensors, and so on. Based on the sensor unit (110) data, the control unit (111) takes necessary actions in maintain the temperature of the ESS. The proposed hybrid battery heat dissipation system can be used as an active or passive heat dissipation system depending on the requirement. In case of active battery heat dissipation system, the fluid pipeline (102) is inserted through the hole provision provided in the middle casing (100) and then the fluid pipeline (102) reaches the cell holder (105). In the cell holder (105), hole provision is provided through which the fluid pipeline (102) is inserted. Upon completely assembling the proposed hybrid battery heat dissipation system, the holes in the middle casing 100 and also holes in cell holder (105) align (concentric) such that the inserted fluid pipeline (102) from one end of the middle casing (100) completely exists the other end of the middle casing (100). The number of fluid pipeline, shape and dimensions are not restricted within the illustration, any size, shape, and dimensions can be preferred. Moreover, any type of fluid flow connection such as serial, parallel, or series-parallel (hybrid connection) can be utilized. The fluid pipeline (102) has an outer diameter of 4mm and an inner diameter of 3mm. The fluid pipeline materials can be aluminium, steel or alloy. Moreover, a complete through hole is required in the cell holder (105), and manufacturing it is complicated. Thus, multiple pieces of cell holder (105) is fabricated and then it is welded to make it as the single piece cell holder (105). The heat from the cells in the battery pack (104) is transferred to the cell holder (105) and then the heat in cell holder (105) is carried by the fluids in the fluid pipeline (102) and then reaches the radiator arrangement through which the heat is dissipated through conduction, convection or radiation methods. Moreover, in the case of a fluid-based cooling system, the fin arrangements in the middle casing 100, the top cover 101(a), and the bottom cover 101(b) can be removed. In case of passive heat dissipation system, fluids are not utilized or circulated through the pipeline (102). Here the heat from the cell holder (105) is conveyed to the middle casing 100 at the slot region where they make contact. Through conduction or radiation, the heat transferred from the cells moves to the cell holder (105) and then from the cell holder (105) to the middle casing (100), the top cover 101(a) and the bottom cover 101(b). Ultimately, heat is dissipated to the surroundings from the middle casing 100, the top cover 101(a) and the bottom cover 101(b) through fin arrangements, utilizing conduction, convection, or radiation methods. Further, multiple sensors can be included and data can be utilized for thermal management. In case of the using the proposed hybrid battery heat dissipation system for UROV (if the proposed hybrid battery heat dissipation system is placed outside of the body of the UROV where it is exposed to water), a plurality of gaskets 109(a) and 109(b) are used in-between the middle casing (100) and the top cover 101(a) and the bottom cover 101(b), respectively. These gaskets prevent the water from reaching the battery pack. The heat from the battery cells are transferred to the cell holder 105, and from the cell holder, the heat is transferred to the middle casing (100) and also to the top cover 101(a) and the bottom cover 101(b) through the top part 106(a) and bottom part 106(b). The heat in the middle casing (100), top cover 101(a), and bottom cover 101(b) are transferred to the water via fin arrangements through the process of convection and radiation. Moreover, the dimensions of these all the components can be varies depending on the applications. Especially in case of UROV, based on the maximum depth that the UROV can travel, the dimensions of all the components can be varied (not shown in illustration) in order to withstand the hydrostatic pressure. Furthermore, in UROV, if fluid pipeline (105) is removed and the entire casing is exposed to water, the holes in the middle casing (100) are sealed (not shown in illustrations) in order to prevent water entering the battery pack via holes.
For the middle casing (100), the top cover 101(a), the bottom cover 101(b), the cell holder 105, the top part 106(a) and the bottom part 106(b) similar material is preferred. Furthermore, phase-changing materials can also be utilized (specifically at the cell holder (105) to enhance further/stabilize the heat dissipation. Furthermore, in case of subzero environment, thermal insulation materials are incorporated that prevent heat loss and enable efficient heat retention. Moreover, through the support of the fluid pipeline (102), heat can be induced to the cells in order to maintain optimal operating temperature when exposed to colder environment. Consequently, the proposed device comprising a dynamic cooling system that switches between eco, performance, and extreme modes based on real-time energy demands, optimizing thermal management efficiency. An external components are coated with an anti-icing nanocoating, preventing frost accumulation and ensuring reliable operation in icy environments. Moreover, the smart microstructures create fluid circulation channels and produce vibrations to achieve heat dissipation rates of 100 W/m²•K to 3000 W/m²•K. Here the vibrations generate high-frequency acoustic waves to enhance thermal conductivity at high-temperature zones. Further device comprises optically-activated thermal switches responsive to specific wavelengths of light, providing a non-contact method of thermal regulation. The present invention can be integrated to fans to enhance airflow, increasing heat dissipation efficiency by 20–30% compared to passive systems, particularly for ground-based electric vehicles.
,CLAIMS:CLAIMS:
I Claim,
1. An integrated hybrid device for optimized thermal control in energy storage system, comprising:
A middle casing (100);
A top cover 101(a);
A bottom cover 101(b);
A fluid pipeline (102);
A plurality of bolts (103);
A battery pack (104);
A cell holder (105);
A top part 106(a);
A bottom part 106(b);
A modular cap top (107);
A modular cap bottom (108);
A plurality of a gasket 109(a) and 109(b);
A sensor unit 1(10); and
A control unit (111),
Characterised that,
The battery pack (104) containing multiple cells arranged in a predefined configuration and the cell holder (105) designed to hold the battery pack (104), with provisions for sliding into and out of the middle casing (100) for ease of assembly, maintenance, and replacement, therein, the top part (106(a)) and the bottom part (106(b)) of the cell holder (105) for securely housing with modular cap top (107) and modular cap bottom (108) and providing contact with the covers (101(a) and 101(b));
wherein, the modular cap top (107) and modular cap bottom (108) configured to connect the cells in series or parallel to achieve the desired voltage and current therein, the insulating material in the modular cap top (107) and modular cap bottom (108) prevents electrical losses being discharged by the covers and also restricting the vertical movement of the battery pack (104);
wherein, the plurality of gaskets (109(a), 109(b)) for sealing the casing in applications requiring water resistance, such as underwater remotely operated vehicles (UROVs) and in the active mode, the fluid pipeline (102) circulates a heat-transfer fluid through the cell holder (105) and the casing (100) to a radiator arrangement for efficient heat dissipation via conduction, convection, or radiation;
wherein, the sensor unit (110) reads the battery parameters and then inputs to the control unit (111) therein, the sensor unit (110) comprises of voltage sensor, current sensor, and temperature sensor thereby, based on the sensor unit (110) data, the control unit (111) takes necessary actions in maintaining the optimal temperature of the battery pack; and
wherein, in the passive mode, the system uses fin arrangements on the casing (100), the top cover (101(a)), and the bottom cover (101(b)) to dissipate heat directly to the surroundings without fluid circulation therein, the cell holder (105) is constructed from multiple welded pieces to enable precise alignment of fluid pipeline channels and efficient heat transfer from the battery cells to the fluid, and the system integrates advanced materials, such as phase-changing materials in the cell holder (105) for enhanced heat stabilization and anti-icing nanocoatings on external components for frost prevention in subzero environments.

2. The integrated hybrid device for optimized thermal control in energy storage systems as claimed in claim 1 wherein, the design features dynamic cooling modes, including eco, performance, and extreme executed by the control unit (111) to adjust cooling efficiency in real-time based on data from the sensor unit (110) and the assembly incorporates quick-disassembly modular cap top (107) and modular cap bottom (108) with a conductive bottom surface and insulating top surface, improving maintenance and reliability.

3. The integrated hybrid device for optimized thermal control in energy storage systems as claimed in claim 1 wherein, the inclusion of optically-activated thermal switches allows for non-contact thermal management controlled by the control unit (111), while smart microstructures create fluid circulation channels controlled by the control unit (111) and generate high-frequency acoustic waves controlled by the control unit (111) to achieve heat dissipation rates between 100 W/m²•K and 3000 W/m²•K and the device can integrate fans to enhance airflow controlled by the control unit (111), increasing heat dissipation efficiency by 20–30% compared to passive systems, particularly for ground-based electric vehicle applications.