Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of automobile. More specifically, the present disclosure relates to thermal management systems for use in power battery applications in automobiles. In particular, the present disclosure pertains to a battery pack for a vehicle with integrated plurality of cooling channels for maintaining temperature uniformity inside the battery pack.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Lithium battery packs, particularly Lithium ions battery packs are widely used in various applications due to their high energy density, relatively long cycle life, and rechargability. While Lithium-Ion batteries are generally safe when handled properly, they can pose safety risks if abused, damaged, or manufactured with defects. Issues such as thermal runaway, which can lead to overheating and potentially fire or explosion, are carefully managed through advanced battery management systems (BMS) and design considerations.
[0004] In existing Lithium battery pack, battery cells are typically stacked or arranged in a way that maximizes the use of available space. Generally, in the existing lithium battery pack, heat dissipation takes through a surface of the battery box casing. The battery cells in a central region of the battery pack can be surrounded by other cells on multiple sides, which can trap heat generated during operation. Thus, temperature of the cells in contact with the battery box casing wall are favoured more in terms of heat dissipation, whereas the cells in the central region are not in direct physical contact with the casing wall. Thus, the centrally located cells inside the battery pack are generally at high temperatures as compared to the cells in contact with the battery casing walls. This temperature non-uniformity of the cell temperature across the battery pack is responsible for unequal battery degradation of cells. The cells which are routinely exposed to high temperatures degrade faster than the cells which are exposed to lower temperature. This unequal rates in degradation mechanisms leads to decreased capacity utilization of the battery pack.
[0005] Patent document US20230369677A1 entitled, “Battery Pack” describes a battery pack includes battery cells and a spacer arranged between two adjacent battery cells. Each battery cell includes an electrode body and a case. The electrode body includes an upper curved portion, a flat portion, and a lower curved portion. The spacer presses one side wall of the case of one of the adjacent battery cells toward an inner side of the case at a part where the side wall opposes a region from the upper curved portion to the lower curved portion. The spacer forms passages for cooling air between the spacer and the side wall. A first cooling efficiency of the cooling air per unit area at a first opposing portion of the side wall that opposes the upper curved portion is less than a second cooling efficiency per unit area at a second opposing portion of the side wall that opposes the flat portion.
[0006] Another patent document EP3731300A1 entitled, “Power supply device, and separator for power supply device” describes a power supply device includes a plurality of rectangular battery cells stacked in a thickness direction, and a plurality of separators interposed between adjacent battery cells. The separator includes an insulating separator frame that forms a defined space surrounded in a frame shape, and a separator core that is inserted into the defined space surrounded by the separator frame and is disposed between the adjacent battery cells.
[0007] Yet another patent document US8642204B2 entitled, “Battery pack with covering member and vehicle with the battery pack” describes a battery pack has a battery module unit that is formed from a plurality of arranged battery modules, each of which has a plurality of cells in a case, a cooling air flow passage where a cooling air flow flows, and a gas exhaust duct which forms a gas exhaust passage. The gas exhaust duct extends in an arrangement direction S of the plurality of the battery modules while being contiguous to the battery module unit, and takes in the gas released in the case from the cell, then exhausts the gas from the battery module. The gas exhaust duct is provided with a gas inlet for taking in the gas, which communicates with a gas emission hole formed on a surface of the case, and an air intake that serves to take in the cooling air flow.
[0008] While the cited reference discloses an air flow passage between the battery cells to cool down the cell of the battery pack and maintain a uniform temperature, there is a possibility of providing a further improved layout of air flow passages in the battery pack that overcomes the above stated problem.
[0009] In view thereof, there is need of an innovative solution to address the aforementioned issues by providing some cooling means to allow uniform heat dissipation from all exposed surfaces of the cells, and presence of high temperature hotspots on the cells and across the battery pack is avoided, thereby maintaining the Lithium ion battery pack in good health.
[0010] There is, therefore, a need to overcome the above-mentioned drawbacks, shortcomings, and limitations associated with the existing battery assemblies, by providing a battery pack with integrated thermal management system for maintaining temperature uniformity inside the battery pack.

OBJECTS OF THE INVENTION
[0011] A general object of the present disclosure is to overcome the problems associated with the existing battery assemblies.
[0012] An object of the present disclosure is to provide a battery pack for a vehicle having a plurality of cooling channels for maintaining temperature uniformity inside the battery pack.
[0013] An object of the present disclosure is to provide a simple and improved battery pack which ensure that each battery cell within the battery pack receives adequate cooling.
[0014] An object of the present disclosure is to provide an efficient battery pack which can maximize performance of the battery.
[0015] Another object of the present disclosure is to provide a battery pack that can ensure safe operation of the battery during its operation.
[0016] Yet another object of the present disclosure is to provide a battery pack which can extend lifespan of the battery.
[0017] Yet another object of the present disclosure is to provide a battery pack having an integrated plurality of cooling channels for use in three-wheeler automotive applications, and which provides high thermal response time thereby keeping the battery temperature within desired range under all operating conditions.
[0018] Still yet another object of the present disclosure is to provide a battery pack that can be cost-effective.

SUMMARY
[0019] Aspects of the present disclosure relate generally to the field of automobiles. More specifically, the present disclosure relates to thermal management systems for use in power battery applications in automobiles. In particular, the present disclosure pertains to a battery pack with integrated plurality of cooling channels for maintaining temperature uniformity inside the battery pack.
[0020] According to an aspect, the present disclosure elaborates upon a battery pack for a vehicle. The battery pack comprises a casing configured to accommodate one or more components of the battery pack. The battery pack comprises a plurality of cell modules secured within the casing. Each cell module housing a plurality of battery cells. Further, the battery pack comprises a plurality of cooling channels. The plurality of cooling channels are configured within the plurality of cell modules, and between each battery cell in each cell module.
[0021] In addition, the plurality of cooling channels provide increased exposed surface area of the battery cells in contact with a coolant flowing through the plurality of cooling channels to enhance thermal management by optimizing heat dissipation and maintaining uniform operating temperature across the battery pack. The coolant is adapted to exchange heat or thermal energy with the plurality of cell modules.
[0022] In an aspect, the plurality of cooling channels may comprise a plurality of first cooling channels. The plurality of first cooling channels may be configured within the cell modules, to extract heat from side surfaces of the cell module.
[0023] In an aspect, the plurality of cooling channels may comprise a plurality of second cooling channels. The plurality of second cooling channels may be configured between adjacent battery cells in each cell module, to extract heat from a surface area of each battery cell.
[0024] In an aspect, the plurality of cooling channels within each cell of each module may be configured in a parallel arrangement to enhance flow efficiency of the coolant.
[0025] In an aspect, the plurality of cooling channels comprise a plurality of cooling tubes arranged between the plurality of cell modules may be integrated into a structural frame of the battery pack to provide mechanical support and thermal management.
[0026] In an aspect, the battery pack may comprise a control unit. The control unit may comprise a processor configured to receive, from one or more sensors, provided in the casing, a current temperature of the plurality of cell modules. The control unit may be configured to operate a cooling mechanism to enable a suitable flow rate of the cooling fluid in the plurality of cooling tubes to facilitate a corresponding thermal energy exchange with the cell module to enable limiting operating temperature of the cell module to within a desired range.
[0027] In an aspect, the plurality of battery cells within each module may be electrically interconnected to form a series or parallel configuration. The plurality of battery cells may be lithium-ion energy cells.
[0028] In an aspect, the coolant circulated through the plurality of cooling tubes may comprise air or a liquid coolant selected from water, ethylene glycol, propylene glycol, or a mixture thereof.
[0029] In an aspect, a cross-sectional shape of each of the plurality of cooling tubes may be selected from a group consisting of: rectangular, circular, ellipse or square.
[0030] In an aspect, the plurality of cooling tubes may be made of material selected from a group consisting of: copper, aluminium, stainless steel, polymer composites, and titanium.
[0031] 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 like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0032] 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.
[0033] FIG. 1A illustrates an exemplary layout design of a proposed battery pack for a vehicle, in accordance with an embodiment of the present disclosure.
[0034] FIG. 1B illustrates an exemplary layout design of cooling channels (airflow passages) inside the proposed battery pack of FIG.1A, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0035] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such details 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 disclosure as defined by the appended claims.
[0036] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[0037] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0038] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0039] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0040] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0041] Embodiments explained herein relate to a battery pack with integrated plurality of cooling channels for maintaining temperature uniformity inside the battery pack, which can facilitate uniform heat dissipation from all exposed surface of battery cells, and avoid presence of high temperature hotspots on the battery cells and across the battery pack, thereby help in maintaining health of the battery pack.
[0042] According to an aspect, the present disclosure discloses a battery pack for a vehicle. The battery pack includes a casing configured to accommodate one or more components of the battery pack. The battery pack includes a plurality of cell modules secured within the casing. Each cell module housing a plurality of battery cells. Further, the battery pack includes a plurality of cooling channels. The plurality of cooling channels are configured within the plurality of cell modules, and between each battery cell in each module.
[0043] In addition, the plurality of cooling channels provide increased exposed surface area of the plurality of battery cells in contact with a coolant flowing through the plurality of cooling channels to enhance thermal management by optimizing heat dissipation and maintaining uniform operating temperature across the battery pack. The coolant is adapted to exchange heat or thermal energy with the plurality of cell modules.
[0044] In an embodiment, the plurality of cooling channels can include a plurality of first cooling channels. The plurality of first cooling channels can be configured within the cell modules, to extract heat from side surfaces of the cell module.
[0045] In an embodiment, the plurality of cooling channels can include a plurality of second cooling channels. The plurality of second cooling channels can be configured between adjacent battery cells in each battery module, to extract heat from a surface area of each battery cell.
[0046] In an embodiment, the plurality of cooling channels within each cell of each module can be configured in a parallel arrangement to enhance flow efficiency of the coolant.
[0047] In an embodiment, the plurality of cooling channels may comprise a plurality of cooling tubes arranged between the plurality of cell modules can be integrated into a structural frame of the battery pack to provide mechanical support and thermal management.
[0048] In an embodiment, the battery pack can include a control unit. The control unit can include a processor configured to receive, from one or more sensors, provided in the casing, a current temperature of the plurality of cell modules. The control unit can be configured to operate a cooling mechanism to enable a suitable flow rate of the cooling fluid in the plurality of cooling tubes to facilitate a corresponding thermal energy exchange with the cell module to enable limiting operating temperature of the cell module to within a desired range.
[0049] In an embodiment, the plurality of battery cells within each module can be electrically interconnected to form a series or parallel configuration. The plurality of battery cells can be lithium-ion energy cells.
[0050] In an embodiment, the coolant circulated through the plurality of cooling tubes can include an air or a liquid coolant selected from water, ethylene glycol, propylene glycol, or a mixture thereof.
[0051] In an embodiment, a cross-sectional shape of each of the plurality of cooling tubes can be selected from a group consisting of: rectangular, circular, ellipse or square.
[0052] In an embodiment, the plurality of cooling tubes can be made of material selected from a group consisting of: copper, aluminium, stainless steel, polymer composites, and titanium.
[0053] Referring to FIGs. 1A to 1B, the proposed battery pack 100 for a vehicle includes a casing 102 configured to accommodate one or more components of the battery pack 100. The one or more components can include but not limited to protection circuitry such as fuses, circuit breakers, and the like, structural components such as brackets, mounts and frames, without limitations. The one or more components may include wiring, connectors, insulations and sealing. The vehicle can include but not limited to an electric vehicle, a hybrid electric vehicle, and a plug-in hybrid electric vehicle. The vehicle can be selected from but not limited to two-wheeler vehicle, three wheeler vehicle, four wheeler vehicles, and the like. The battery pack 100 includes a plurality of cell modules 104-1, 104-2, 104-3, 104-4 (collectively referred as 104 herein) secured within the casing 102. Each cell module 104 housing a plurality of battery cells 106. Further, the battery pack 100 includes a plurality of cooling channels 108 (also referred as airflow channels, airflow passages or cooling channels herein). The plurality of cooling channels 108 are configured within the plurality of cell modules 104, and between each battery cell 106 in each cell module 104.
[0054] In addition, the plurality of cooling channels 108 provide increased exposed surface area of the plurality of battery cells 106 in contact with a coolant flowing through the plurality of cooling channels 108 to enhance thermal management by optimizing heat dissipation and maintaining uniform operating temperature across the battery pack 100. The coolant is adapted to exchange heat or thermal energy with the plurality of cell modules 104. The coolant circulated through the plurality of cooling channels 108 can include but not limited to air or a liquid coolant selected from water, ethylene glycol, propylene glycol, or a mixture thereof.
[0055] In an embodiment, the plurality of cooling channels 108 can include a plurality of first cooling channels 108-1, 108-2, 108-3, 108-4, 108-5 configured within the cell modules 104, to extract heat from side surfaces of the cell module 104. Further, the plurality of cooling channels 108 can include a plurality of second cooling channels 108-6, 108-7, 108-8, 108-21 that are configured between adjacent battery cells 106 in each cell module 104, to extract heat from a surface area of each battery cell 106. The plurality of second cooling channels 108-6, 108-7, 108-8, 108-21 can be in contact with a larger surface area of the battery cell 106, thereby enhancing the heat transfer rate. The natural convection of the coolant through the plurality of first and second cooling channels 108-1, 108-2, 108-3,……108-21 can extract the heat evenly from all the plurality of battery cells 106 in the battery pack 100, thereby maintaining temperature uniformity.
[0056] In an embodiment, the plurality of cooling channels 108 can include a plurality of cooling tubes 108 arranged between the plurality of cell modules 104 are integrated into a structural frame of the battery pack 100 to provide mechanical support and thermal management. A cross-sectional shape of each of the plurality of cooling tubes 108 can be selected from but not limited to a group consisting of: rectangular, circular, ellipse or square. Most preferably, the plurality of cooling tubes 108 can be the rectangular tubes. The rectangular tubes offer a large surface area as compared to narrow channels, which improve airflow and enhances heat dissipation. In addition, the rectangular tubes can also provide structural support to the battery pack 100. The rectangular tubes can be integrated into the casing 102, thereby enhancing rigidity and durability of the battery pack 100. Further, the plurality of cooling tubes 108 can be made of material including, without limitations, copper, aluminium, stainless steel, polymer composites, and titanium.
[0057] In an embodiment, the battery pack 100 can include a control unit comprising a processor. The processor can be configured to receive, from one or more sensors, provided in the casing 102, a current temperature of the plurality of cell modules 104, where the control unit may be configured to operate a cooling mechanism to enable a suitable flow rate of the cooling fluid in the plurality of cooling tubes 108 to facilitate a corresponding thermal energy exchange with the cell module 104 to enable limiting operating temperature of the cell module 104 to within a desired range.
[0058] The one or more sensors may be selected from but not limited to thermocouples, resistance temperature detectors (RTDs), thermistors, Infrared (IR) sensors, Integrated circuit (IC) temperature sensors, and fibre optic sensors. The one or more sensors can be strategically placed within the casing 102 of the battery pack 100 to ensure accurate readings of the temperature of the plurality of battery cells 106.
[0059] In an embodiment, the control unit may comprise one or more processor(s) (interchangeably referred to as processor, hereinafter), a memory and one or more interface(s). The one or more processors may be implemented as one or more microprocessors, microcomputers, microcontrollers, edge or fog microcontrollers, digital signal processors, central processing units, logic circuitries, and/or any devices that process data, based on operational instructions. Among other capabilities, the processor) may be configured to fetch and execute computer-readable instructions stored in a memory of the control unit. The memory may be configured to store one or more computer-readable instructions or routines in a non-transitory computer readable storage medium, which may be fetched and executed to collect a plurality of data associated with temperature of the plurality of battery cells 106 from one or more sensors. The memory may comprise any non-transitory storage device including, for example, volatile memory such as Random Access Memory (RAM), or non-volatile memory such as Erasable Programmable Read-Only Memory (EPROM), flash memory, and the like.
[0060] In an embodiment, the control unit may also include the one or more interface(s). The interface(s) may include a variety of interfaces, for example, interfaces for data input and output devices referred to as I/O devices, storage devices, and the like. The interface(s) may facilitate communication of the control unit with various components coupled to the control unit. In an embodiment, the control unit may feature a user interface for local interaction. The user interface can include status indicators (LEDs), switches, or a display to provide feedback on battery pack status and allow for manual control or configuration adjustments.
[0061] During the charge and discharge process each cell temperature is monitored using the one or more sensors. The temperature values are logged in the control unit. A threshold set point temperature value of the Li-ion cell is programmed in the Control Unit. As soon as the temperature of Li-ion cell crosses above a set point temperature, the cooling mechanism gets activated to increase airflow through the plurality of cooling tubes 108, ensuring effective cooling. The coolant flows through the plurality of cooling tubes 108 and absorb the heat generated by the cell modules 104. In automotive applications, the control unit interfaces with the vehicle’s battery management system (BMS). The control unit coordinates with other subsystems to optimize performance, manage energy flow, and ensure seamless integration with the overall system architecture.The control unit integrates with the battery management system (BMS) to respond to temperature-related alarms or faults. In case of overheating detected through the plurality of cooling tubes 108, the control unit can initiate protective measures such as but not limited to reducing charging rates, activating cooling systems, or even isolating affected modules to prevent damage.
[0062] Further, the battery pack 100 can also include ducts, or vents designed to guide airflow and promote efficient heat dissipation, enhancing the overall efficiency and lifespan of the battery pack 100.
[0063] In an embodiment, the cooling mechanism can include fans or blowers that actively circulate air through the plurality of cooling tubes 108. The fans or blowers can improve cooling efficiency by increasing airflow rates, thereby enhancing heat transfer away from the battery cells 106.
[0064] Those skilled in the art would appreciate that the design layout of the proposed battery pack 100 that allows free flow of the coolant or air movement within the battery pack 100. Further, the plurality of cooling tubes 108, specifically the rectangular cooling tubes can increase the exposed surface area of the battery cells 106 in contact with the air, thereby increasing the heat transfer rate. The design layout of the plurality of cooling tubes 108 can ensure uniform heat dissipation from all the exposed surfaces of the battery cells 106, and avoid presence of high temperature hotspots on the battery cells 106 and across the battery cells 106, thereby maintaining good health of the battery pack 100.
[0065] Thus, the present disclosure overcomes the drawbacks, shortcomings, and limitations associated with the existing battery packs, by providing a battery pack 100 with integrated thermal management system for maintaining temperature uniformity inside the battery pack.
[0066] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention 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 invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0067] The present invention overcomes the problems associated with the existing battery assemblies.
[0068] The present invention provides a battery pack with integrated plurality of cooling channels for maintaining temperature uniformity inside the battery.
[0069] The present invention provides a simple and improved battery pack which ensure that each battery cell within the battery pack receives adequate cooling.
[0070] The present invention provides an efficient battery pack which maximizes performance of the battery.
[0071] The present invention provides a battery pack that ensures safe operation of the battery during its operation.
[0072] The present invention provides a battery pack having an integrated thermal management system for use in three-wheeler automotive applications, and which provides high thermal response time thereby keeping the battery temperature within desired range under all operating conditions.
[0073] The present invention provides a battery pack that is cost-effective.
, Claims:1. A battery pack (100) for a vehicle, the battery pack (100) comprising:
a casing (102) configured to accommodate one or more components of the battery pack (100);
a plurality of cell modules (104) secured within the casing (102), wherein each cell module (104) housing a plurality of battery cells (106); and
a plurality of cooling channels (108) configured within the plurality of cell modules (104), and between each battery cell (106) in each cell module (104),
wherein the plurality of cooling channels (108) provide an increased exposed surface area of the plurality of battery cells (106) in contact with a coolant flowing through the plurality of cooling channels (108) to enhance thermal management by optimizing heat dissipation and maintaining uniform operating temperature across the battery pack (100), wherein the coolant is adapted to exchange heat or thermal energy with the plurality of cell modules (104).
2. The battery pack (100) as claimed in claim 1, wherein the plurality of cooling channels (108) comprise a plurality of first cooling channels (108-1, 108-2, 108-3, 108-4, 108-5) configured within the plurality of cell modules (104), to extract heat from side surfaces of the cell module (104).
3. The battery pack (100) as claimed in claim 1, wherein the plurality of cooling channels comprise a plurality of second cooling channels (108-6, 108-7, 108-8, ….108-21) that are configured between adjacent battery cells (106) in each battery module (104), to extract heat from a surface area of each battery cell (106).
4. The battery pack (100) as claimed in claim 1, wherein the plurality of cooling channels within each battery cell (106) of the battery module (104) are configured in a parallel arrangement to enhance flow efficiency of the coolant.
5. The battery pack (100) as claimed in claim 1, wherein the plurality of cooling channels (108) comprise a plurality of cooling tubes (108-1, 108-2, ….108-21) arranged between the plurality of cell modules (104) are integrated into a structural frame of the battery pack (100) to provide mechanical support and thermal management.
6. The battery pack (100) as claimed in claim 1, wherein the battery pack (100) comprises a control unit comprises a processor, wherein the processor is configured to:
receive, from one or more sensors, provided in the casing (102), a current temperature of the plurality of cell modules (104),
wherein the control unit is configured to operate a cooling mechanism to enable a suitable flow rate of the cooling fluid in the plurality of cooling channels (108) to facilitate a corresponding thermal energy exchange with the cell module (104) to enable limiting operating temperature of the cell module (104) to within a desired range.
7. The battery pack (100) as claimed in claim 1, wherein the plurality of battery cells (106) within each cell module (104) are electrically interconnected to form a series or parallel configuration, wherein the plurality of battery cells (106) are lithium-ion energy cells.
8. The battery pack (100) as claimed in claim 1, wherein the coolant circulated through the plurality of cooling tubes (108) comprises air or a liquid coolant selected from water, ethylene glycol, propylene glycol, or a mixture thereof.
9. The battery pack (100) as claimed in claim 5, wherein a cross-sectional shape of each of the plurality of cooling tubes (108) is selected from a group consisting of: rectangular, circular, ellipse or square.
10. The battery pack (100) as claimed in claim 5, wherein the plurality of cooling tubes (108) are made of material selected from a group consisting of: copper, aluminium, stainless steel, polymer composites, and titanium.