DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

TITLE OF INVENTION:
A CONDITIONING SYSTEM FOR A BATTERY ASSEMBLY AND A METHOD THEREOF

APPLICANT:
EXPONENT ENERGY PRIVATE LIMITED
An Indian Entity having address as:
No.76/2, Site No.16, Khatha No.69, Singasandra Village, Bengaluru (Bangalore) Urban, BENGALURU, KARNATAKA (IN) - 560068

The following specification particularly describes the invention and the manner in which it is to be performed.
CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application claims priority from the Indian provisional patent application, having application number 202341018075, filed on 17th March 2023, incorporated herein by a reference.

FIELD OF INVENTION
The present invention relates to the field of batteries and battery modules. More specifically, the present specification relates to a battery assembly architecture. More particularly, the present invention discloses a battery assembly comprising a conditioning system that can be combined with the battery architecture and that may be used in the context of electric vehicles and other energy storage/consumption applications.

BACKGROUND OF THE INVENTION
This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure that are described or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements in this background section are to be read in this light, and not as admissions of prior art. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
In the field of battery assembly architecture, specifically for electric vehicles (EVs), efficient thermal management by an effective conditioning system plays an important role, to ensure consistent performance of a battery pack. Excessive temperature will negatively affect the EV's battery and its performance. Improper thermal management of the battery pack may lead to impacting the electrochemical system, charge acceptance, power output, safety and life cycle/replacement cost and the vehicle’s driving distance. The conditioning of the battery while charging at EV charging stations relies on a packaging architecture of the battery.
Generally, the electric vehicle battery consists of mainly two different types of assembly architecture, which can be categorized as cell to pack and module to pack. In a cell to pack category, the cells are directly placed on the battery casing and connected electrically as well as mechanically to make the battery pack.
The main function of such packaging architecture is to maintain the electrical isolation from cells, structural methods to protect the cells during automotive vibrations caused from the road. and to take care of thermals and to keep the cells under right operating temperature. The existing battery structures require different systems to take care of each individually.
The existing battery modular architecture uses sheet metal welded with foam pads between cells and the battery structure. Other existing designs like the VDA module can only be cooled using a bottom cooling method which requires large bottom cooling plates, or heat sinks. The conventional design uses extruded cooling channels welded to each other or by brazed heat sinks. All methods known in the state of art use separate systems for thermal management, module isolation, and structural mounting.
In the field of battery architecture, preferably for electric vehicles (EVs), an efficient and effective thermal management is the key to improve the performance and durability of a battery cell as well as a battery assembly (also termed as, a battery pack/module or an energy storage system). This also results in an optimum power performance throughout the shelf life of the battery assembly. Thus, there is an enhancement in the performance of the electric vehicle. Therefore, for maintaining a battery assembly’s efficient peak performance, separately or for an EV, the modern conditioning stations have been embedded with a conditioning fluid circuit that maintains the optimum working temperature of the battery assembly while charging and/or conditioning.
However, modern developments as described above lack a well-designed damage-proof conditioning mechanism for the battery assembly. Thus, the aforementioned conventional systems and methods for conditioning the battery assembly are not efficient, both practically and commercially.
The EV charging stations are also configured with a conditioning fluid circulation pump to condition the battery pack. The battery assembly of the EV comprises an inlet for electric charging and a separate inlet-outlet system for conditioning fluid circulation protruded in the outer direction and positioned on one or more conditioning plate(s). The protrusions positioned on the outer periphery of conventional batteries are weak members and prone to damage easily. Particularly, the damages in the conditioning fluid circulating inlet-outlet system often leads to damage of the conditioning plates. Also, the serviceability of these damaged members is difficult, and often prone to replacement of the overall conditioning system or in some cases the complete battery pack.
Thus, there is a long-standing need for a combined battery architecture with an efficient mounting and protected conditioning mechanism for a battery assembly so as to preserve and improve the durability, serviceability, and efficacy of the conditioning mechanism in conditioning the battery assembly so that an optimum condition of the battery assembly is maintained.
SUMMARY OF THE INVENTION
The present disclosure overcomes one or more shortcomings of the prior art and provides additional advantages discussed throughout the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. This summary is not intended to identify the essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
The present disclosure has been made in order to solve the problems, and it is an object of the present disclosure to provide a battery assembly that features an efficient mounting of conditioning mechanism, resulting in improved conditioning capacity, durability, serviceability and efficiency of the conditioning mechanism of the battery assembly. In one non-limiting embodiment of the present disclosure, the conditioning may comprise temperature conditioning, pressure conditioning, electrical charging, or other parameter conditioning of cell/module/Battery Pack.
In one implementation of the present disclosure, a conditioning system for a battery assembly is disclosed. Further, the conditioning system may include a battery module case. The battery module case may include a case portion. Further, the case portion may include a main inlet port and a main outlet port. Further, the conditioning system may include a plurality of conditioning plates arranged in one or more sides of a plurality of cells. Furthermore, the plurality of conditioning plates may include a first conditioning plate arranged on a first side of the plurality of cells and a second conditioning plate arranged on a second side of the plurality of cells. The first side of the plurality of cells is opposite to the second side of the plurality of cells. Moreover each conditioning plate from the plurality of conditioning plates may include an inlet port and an outlet port. Furthermore, the conditioning system may include a plurality of connectors. In an exemplary embodiment, the plurality of connectors comprises a first connector, a second connector and a third connector. In one embodiment, a first inlet port of the first conditioning plate may be connected with the main inlet port via the first connector from the plurality of connectors. In another embodiment, a second outlet port of the second conditioning plate may be connected with the main outlet port via the second connector from the plurality of connectors. Furthermore, a first outlet port of the first conditioning plate may be connected to a second inlet port of the second conditioning plate via the third connector from the plurality of connectors. Additionally, the battery module case may be designed to cover the plurality of conditioning plates, the inlet port and the outlet port of the plurality of conditioning plates, the plurality of cells and the plurality of connectors including the first connector, second connector and the third connector.
In one embodiment, each cell from the plurality of cells may include one or more terminals, and each terminal from the one or more terminals may include a terminal axis. Furthermore, the plurality of cells may be arranged according to a coordinate system in a three-dimensional space. Further, the coordinate system may include a X-orientation, a Y-orientation, and a Z-orientation. Further, in a three-dimensional coordinate system, the X-orientation may represent a horizontal axis, the Z-orientation may represent a vertical axis, and the Y-orientation may represent an axis perpendicular to both the X-orientation and the Z-orientation. In a related embodiment, the plurality of cells is positioned in a way that the terminal axis of each cell may be parallel to either the X-orientation, the Y-orientation, or a combination of both. The terminal axis may refer to an axis passing through the terminals of the cells. The plurality of conditioning plates of the system may be arranged around the cells. In another embodiment, the conditioning plates may be positioned perpendicular to the Z-orientation and parallel to the terminal axis of the cells.
In another embodiment, the conditioning system includes the plurality of cells which may be arranged together to form a battery module, and a size of each conditioning plate from the plurality of conditioning plates may be greater than the size of the battery module. In an exemplary embodiment, the length of each conditioning plate from the plurality of conditioning plates is greater than the length of the battery module. Furthermore, the system may comprise a safety cover for protecting the case portion of the battery module case. Further, the safety cover may be utilized to cover the main inlet port and the main outlet port. Specifically, the case portion may be detachably coupled with the battery module case and may be arranged on one side of the battery module case. Further, the main inlet port and the main outlet port may be designed to be connected with a conditioning station via a fluid connector. Furthermore, the first conditioning plate from the plurality of conditioning plates may be arranged on the bottom side of the plurality of cells and the second conditioning plate from the plurality of conditioning plates may be arranged on the top side of the plurality of cells and vice versa. Moreover, the first inlet port and the first outlet port of the first conditioning plate may be inwardly protruded towards the second inlet port and the second outlet port of the second conditioning plate inside the battery module case.
In yet another embodiment, the plurality of conditioning plates may be connected with the battery module case and the plurality of cells by an adhesive. Furthermore, the adhesive may correspond to a thermally conductive, electrically insulated and structural member adhesive. Additionally, the battery assembly may comprise a battery management system (BMS) and a plurality of power path electrical circuitry attached to one side of the second conditioning plate from the plurality of conditioning plates via the adhesive. Further, the plurality of connectors may be designed to attach with the inlet port and the outlet port of the plurality of conditioning plates and also may be designed to attach with the main inlet port and the main outlet port of the case portion. Further, the plurality of connectors may correspond to one of the poly hose connectors, vertical and angular connectors, flexible connectors, and a combination thereof. Furthermore, the plurality of conditioning plates may comprise a plurality of micro-channels for a conditioning fluid to flow in a serpentine manner. The conditioning fluid may correspond to one of cold fluid, hot fluid and a combination thereof depending on thermal requirements of the battery assembly.
In another implementation of the present disclosure, a method for assembling a conditioning system of a battery assembly is disclosed. Further, the method may comprise a step of arranging the plurality of cells to form a battery module. Further, the method may comprise a step of arranging the plurality of conditioning plates in one or more sides of the battery module. The first conditioning plate may be arranged on the first side of the battery module and the second conditioning plate may be arranged on the second side of the battery module. The first side of the battery module is opposite to the second side of the battery module. Each conditioning plate from the plurality of conditioning plates may comprise an inlet port and an outlet port. Furthermore, the method may comprise a step of connecting the first inlet port of the first conditioning plate with the main inlet port of the case portion via a first connector from the plurality of connectors. Further, the case portion may be detachably connected to the battery module case. Further, the method may comprise a step of connecting the second outlet port of the second conditioning plate with the main outlet port of the case portion via a second connector from the plurality of connectors. Furthermore, the method may comprise a step of connecting the first outlet port of the first conditioning plate to the second inlet port of the second conditioning plate via a third connector from the plurality of connectors. Moreover, the method may comprise a step of covering the plurality of conditioning plates, the inlet port and the outlet port of the plurality of conditioning plates, the plurality of cells and the plurality of connectors, including the first connector, the second connector and the third connector, within the battery module case.
In one embodiment, the method may comprise a step for arranging the first conditioning plate from the plurality of conditioning plates on the bottom side of the plurality of cells. Moreover, the method may further comprise a step of arranging the second conditioning plate from the plurality of conditioning plates on top side of the plurality of cells. Additionally, the method may comprise a step of arranging the first conditioning plate and the second conditioning plate such that the first inlet port and the first outlet port of the first conditioning plate are inwardly protruded towards the second inlet port and the second outlet port of the second conditioning plate inside the battery module case.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF DRAWINGS
The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.
Figure 1 illustrates a diagram describing a conditioning system (100) for a battery assembly, in accordance with an embodiment of a present subject matter.
Figure 2 illustrates a diagram describing an overview (200) of one side of a second conditioning plate (102), in accordance with an embodiment of a present subject matter.
Figure 3 illustrates a flowchart describing a method (300) for assembling a conditioning system (100) for a battery assembly, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION OF THE INVENTION

Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items. It must also be noted that, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary methods are described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
In the various embodiments disclosed herein, ‘a battery assembly’ may be interchangeably read and/or interpreted as ‘a battery module’, ‘a battery pack’, ‘a battery assembly’, ‘an energy storage system’ or ‘an energy storage apparatus’ or the like. Further, ‘an adhesive’ may be interchangeably read and/or interpreted as ‘a glue’ or ‘a sealant’ or the like. A ‘a battery cell’ may further be interchangeably read and/or interpreted as a ‘cell’ or a ‘storage cell’ or an ‘energy storage cell’ or an ‘energy storage device’ or the like.
In one non-limiting implementation, a conditioning system for assembly of a battery is disclosed. Further, an assembly of the battery assembly may involve several components such as a plurality of cells, a plurality of spacers, a plurality of conditioning plates, a battery module case, an adhesive, a battery management system (BMS), a pre-bonded busbar and a power path electrical circuitry. Further, the conditioning system may include an assembly of conditioning path, arrangement of inlet ports and outlet ports via connectors and arrangement of the plurality of conditioning plates for conditioning wherein each conditioning plates from the plurality of conditioning plates may be placed opposite to the plurality of cells to either absorb or transfer energy, during charging time.
Now referring to Figure 1, a diagram describing a conditioning system (100) for a battery assembly, is illustrated in accordance with an embodiment of a present subject matter. The conditioning system (100) may include a battery module case (108) for covering the battery assembly. The battery module case (108) may include a case portion (109) arranged on one side of the battery module case (108). In one embodiment, the case portion (109) may be detachably coupled with the battery module case (108). The case portion (109) may include a main inlet port (109a) and a main outlet port (109b). The main inlet port (109a) is designed to enter the conditioning fluid inside the conditioning system (100) of the battery assembly, and the main outlet port (109b) is designed to exit the conditioning fluid from the conditioning system (100) of the battery assembly. Both the main inlet port (109a) and the main outlet port (109b) are designed to be connected with a conditioning station via a fluid connector. Further, the conditioning station may be allowed to flow the conditioning fluid into the battery assembly, via the fluid connector, while performing the conditioning/charging of the battery. Conditioning fluid from the conditioning station may enter into the conditioning system (100) via the main inlet port (109a) of the case portion (109) and the conditioning fluid may exit from the conditioning system (100) via the main outlet port (109b) of the case portion (109).
Further, the conditioning system (100) may include a plurality of conditioning plates (102, 103) arranged in one or more sides of the plurality of cells (110). In one embodiment, the plurality of conditioning plates (102, 103) may include a first conditioning plate (103) arranged on a first side of the plurality of cells (110) and a second conditioning plate (102) arranged on a second side, opposite to the first side, of the plurality of cells (110). In an exemplar embodiment, the first conditioning plate (103) from the plurality of conditioning plates (102, 103) is arranged on bottom side of the plurality of cells (110) and the second conditioning plate (102) from the plurality of conditioning plates (102, 103) is arranged on top side of the plurality of cells (110) and vice versa. Furthermore, each conditioning plate from the plurality of conditioning plates (102, 103) may include an inlet port and an outlet port. In an implementation, a first inlet port and a first outlet port of the first conditioning plate (103) are inwardly protruded towards a second inlet port and a second outlet port of the second conditioning plate (102) inside the battery module case (108). The main objective of designing the inlet and outlet ports of the plurality of conditioning plates inwardly protruded to protect from outside interference which may cause due to any direct hit during an accident or due to roadside vibration. Furthermore, the conditioning system (100) may include a plurality of connectors (105, 106, 107). In an embodiment of the present disclosure, the plurality of connectors (105, 106, 107) are designed to attach with the inlet port and the outlet port of the plurality of conditioning plates (102, 103). In another embodiment, the plurality of connectors (105, 106, 107) are designed to attach with the main inlet port (109a) and the main outlet port (109b) of the case portion (109). The plurality of connectors (105, 106, 107) may correspond to one of a poly hose connector, vertical and angular connectors, flexible connectors, and a combination thereof.
In one embodiment of the conditioning system (100), a first inlet port of the first conditioning plate (103) is connected with the main inlet port (109a) via a connector (106) from the plurality of connectors (105, 106, 107) and a second outlet port of the second conditioning plate (102) may be connected with the main outlet port (109b) via a connector (105) from the plurality of connectors (105, 106, 107). Further, a first outlet port of the first conditioning plate (103) may be connected to a second inlet port of the second conditioning plate (102) via a connector (107) from the plurality of connectors (105, 106, 107). In one embodiment, the battery module case (108) is designed to cover the plurality of conditioning plates (102, 103), the inlet port and the outlet port of the plurality of conditioning plates (102, 103), the plurality of cells (110) and the plurality of connectors (105, 106, 107).
In yet another embodiment, the conditioning system (100) for the battery assembly is arranged with a plurality of cells (110). Further, the plurality of cells (110) may be arranged in a predetermined order to form an ESS module. These cells may serve as the fundamental building blocks of the ESS. In an embodiment, each cell from the plurality of cells (110) comprises one or more terminals, more specifically a positive terminal (cathode) and a negative terminal (anode). Each terminal from one or more terminals may comprise a terminal axis. The terminal axis refers to an axis passing through one or more terminals of the cell. Further, the plurality of cells (110) may be arranged according to a coordinate system in a three-dimensional space. Furthermore, the coordinate system in the three-dimensional space may include a X-orientation, a Y-orientation, and a Z-orientation. Furthermore, in the three-dimensional coordinate system, the X-orientation represents a horizontal axis, the Z-orientation represents a vertical axis, and the Y-orientation represents an axis perpendicular to both the X-orientation and the Z-orientation. Additionally, the plurality of cells (110) may be positioned in a way such that the terminal axis of each cell, from the plurality of cells (110), is parallel to either the X-orientation, the Y-orientation, or a combination of both. Moreover, the terminal axis refers to an axis passing through one or more terminals of each cell from the plurality of cells (110). Furthermore, the plurality of conditioning plates (102, 103) may be arranged in a direction perpendicular to the Z-orientation of the coordinate system.
In yet another embodiment, the plurality of cells (110) may be arranged together to form a battery module. Further, the size of each conditioning plate from the plurality of conditioning plates (102, 103) may be greater than the size of the battery module. In an exemplary embodiment, the length of each conditioning plate from the plurality of conditioning plates (102, 103) is greater than the length of the battery module. Furthermore, the battery module along with the plurality of conditioning plates (102, 103), and the inlet port and the outlet port of each conditioning plate from the plurality of conditioning plates (102, 103) may be placed in the battery module case (108).
Furthermore, the plurality of conditioning plates (102, 103) may be connected with the battery module case (108) and the plurality of cells (110) by an adhesive (104). Moreover, the adhesive (104) may correspond to a thermally conductive, electrically insulated, and structural member adhesive. In an exemplary, but non-limited embodiment, the adhesive (104) may correspond to Polyurethane acrylate adhesive.
Additionally, the conditioning system (100) may include a safety cover for protecting the case portion (109) of the battery module case (108). The safety cover is utilized to cover the main inlet port (109a) and the main outlet port (109b). In one embodiment, the battery assembly may comprises a battery management system (BMS) (201) (as illustrated in Figure 2) and a plurality of power path electrical circuitry (202) (as illustrated in Figure 2) attached to one side of the second conditioning plate (102) from the plurality of conditioning plates (102, 103) via the adhesive (104).
In an exemplary embodiment of the present disclosure, the conditioning may comprise temperature conditioning, pressure conditioning, electrical charging, or other parameter conditioning of the battery assembly.
In another exemplary embodiment, the adhesive may be a thermally conductive and electrically insulative adhesive. The adhesive may further be selected as a fast-curing adhesive. The adhesive, being thermally conductive and electrically insulative, may act as an energy transfer medium for the battery assembly.
In yet another embodiment, the plurality of spacers may form a spacers assembly which may be used between each cell and the conditioning plate. The spacers assembly may consist of a plastic sheet bonded with a double-sided tape, which may be either silicone based or acrylic based adhesive. Further, this double-sided tape may be applied to the body of each cell. In this case, the thickness of the plastic sheet may be maintained and designed to have multiple isolation values as required by the battery assembly to be manufactured. At least two spacers may be used for each cell.
In yet another embodiment, the plurality of cells (110) may be arranged in a fixture, like the battery module case (108), or by using the plurality of spacers. The plurality of spacers may be utilized for ensuring an equal spacing between the plurality of cells (110). The fixture may also be configured to ensure equal spacing of the plurality of battery cells via the fixture tolerances.
In yet another embodiment, the thermally conductive and electrically insulative adhesive may be applied to a minor face (top and bottom faces) of each cell from the plurality of cells (110). Then, the plurality of conditioning plates (102, 103) may be glued to the minor faces of the plurality of cells (110). As soon as the adhesive gets cured, the battery assembly with structurally bonded plurality of cells (110) may be formed. Also, the battery assembly may be formed as a thermally conductive battery assembly. This battery assembly may be configured for maintaining an electrical isolation between the plurality of cells (110) and the plurality of conditioning plates (102, 103).
In yet another embodiment, the plurality of spacers may also be applied on to the body of each cell from the plurality of cells (110). The plurality of spacers may be applied for ensuring the plurality of conditioning plates (102, 103) may be positioned at a predefined thickness/distance from the module or the minor faces of each cell from the plurality of cells (110).
In yet another embodiment, each spacer from the plurality of spacers may be made of plastic or glass beads. Each spacer may also ensure an equal thickness of the adhesive being applied between the conditioning plates and each battery cell. This uniform adhesive thickness may create a uniform stiffness across the battery assembly which is absent in the conventional battery module designs. Each spacer may also ensure an equal spacing between the plurality conditioning plates (102, 103) and each cell, when each cell is pressurized towards the plurality of conditioning plates (102, 103).
The battery assembly, as disclosed, may comprise a well- maintained electrical isolation between the body of each battery cell and the plurality of conditioning channels. This electrical isolation is consistent across the battery packs of the battery assembly.
Such battery assembly architecture may result in building the battery assembly using a single adhesive. This may also ensure that the battery assembly is thermally stable and structurally effective for any kind of mechanical vibrations. This may further confirm an electrical insulation of the plurality of cells (110) from the battery assembly. The mechanical vibrations exerted on the battery assembly may be any mechanical/frictional vibrations while the battery assembly may be used in an automobile.
Now, referring to Figure 2, a diagram describing an overview (200) of one side of the second conditioning plate (102), is illustrated in accordance with an embodiment of a present subject matter. The second conditioning plate (102) may include a battery management system (BMS) (201) and a plurality of power path electrical circuitry (202). The BMS (201) and a plurality of power path electrical circuitry (202) may be attached to the top side of the second conditioning plate (102) from the plurality of conditioning plates (102, 103) via the adhesive (104). In one embodiment, the second conditioning plate (102) from the plurality of conditioning plates (102, 103) may include a plurality of micro-channels (203) for a conditioning fluid to flow in a serpentine manner. The conditioning fluid may correspond to one of cold fluid, hot fluid and a combination of the same, depending on thermal requirements of the battery assembly.
In another embodiment, the plurality of conditioning plates (102, 103) may be placed opposite to the plurality of cells (110) to either absorb or transfer energy, during charging time. Further, the transfer energy may correspond to either transfer heat from the conditioning fluid to the plurality of cells (110) or extract heat from the plurality of cells (110) or the battery management system (BMS) (201) or the power path electrical circuitry (202).
In another non-limiting implementation, a method (300) for assembling the conditioning system (100) for the battery assembly is disclosed. Now referring to Figure 3, a flowchart describing the method (300) for assembling the conditioning system (100) for the battery assembly, is illustrated in accordance with an embodiment of the present subject matter. The method (300) involves various steps for assembling the conditioning system for the battery assembly. Further, the method (300) may involve the step (301) of arranging the plurality of cells (110) to form a battery module. Further, the method (300) may involve a step (302) of arranging a plurality of conditioning plates (102, 103) in one or more sides of the battery module. Furthermore, the first conditioning plate (103) may be arranged on a first side of the battery module and the second conditioning plate (102) may be arranged on a second side, opposite to the first side, of the battery module. Furthermore, each conditioning plate from the plurality of conditioning plates (102, 103) may include the inlet port and the outlet port.
Additionally, the method (300) may involve a step (303) of connecting (303) a first inlet port of the first conditioning plate (103) with the main inlet port (109a) of the case portion (109) via a connector (106) from the plurality of connectors (105, 106, 107). The case portion (109) may be detachably connected to the battery module case (108).
Further, the method (300) may involve a step (304) of connecting a second outlet port of the second conditioning plate (102) with a main outlet port (109b) of the case portion (109) via a connector (105) from the plurality of connectors (105, 106, 107).
Furthermore, the method (300) may involve the step (305) of connecting the first outlet port of the first conditioning plate (103) to the second inlet port of the second conditioning plate (102) via the connector (107) from the plurality of connectors (105, 106, 107).
Moreover, the method (300) may involve the step (306) of covering the plurality of conditioning plates (102, 103), the inlet port and the outlet port of the plurality of conditioning plates (102, 103), the plurality of cells (110) and the plurality of connectors (105, 106, 107) within the battery module case (108).
In one embodiment, the method (300) may involve a step for arranging the first conditioning plate (103) from the plurality of conditioning plates (102, 103) on the bottom side of the plurality of cells (110). Furthermore, the method (300) may involve the step of arranging the second conditioning plate (102) from the plurality of conditioning plates (102, 103) on top side of the plurality of cells (110).
In another embodiment, the method (300) may involve a step of arranging the first conditioning plate (103) and the second conditioning plate (102) such that the first inlet port and the first outlet port of the first conditioning plate (103) are inwardly protruded towards the second inlet port and the second outlet port of the second conditioning plate (102) inside the battery module case (108).
The present invention discloses the conditioning system and method for assembling the conditioning system of the battery providing an improved protection to the battery assembly architecture, and may have the following advantageous functionalities over the conventional art:
? Protected positioning of inlet/outlet connectors and other protruded components of the battery assembly, to prevent from external damages
? Easy serviceability of the conditioning plates in case of maintenance activity
? Protected positioning of the inlet/outlet of conditioning plates
? Structural isolation of the battery assembly components
? Provides better structural integrity to the battery assembly.
? Uniform thermal control while charging the battery assembly at the charging station.
? Provides improved battery life.
The embodiments, examples and alternatives of the preceding paragraphs, the description, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
Although implementations of the system and method for conditioning assembly of the battery have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described.
The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.
,CLAIMS:WE CLAIM:
1. A conditioning system (100) for a battery assembly, characterized in that, wherein the system (100) comprises:
a battery module case (108), wherein the battery module case (108) comprises a case portion (109), wherein the case portion (109) comprises a main inlet port (109a) and a main outlet port (109b);
a plurality of conditioning plates (102, 103) arranged in one or more sides of a plurality of cells (110), wherein the plurality of conditioning plates (102, 103) comprises a first conditioning plate (103) arranged on a first side of the plurality of cells (110) and a second conditioning plate (102) arranged on a second side, opposite to the first side, of the plurality of cells (110), wherein each conditioning plate from the plurality of conditioning plates (102, 103) comprises an inlet port and an outlet port; and
a plurality of connectors (105, 106, 107),
wherein a first inlet port of the first conditioning plate (103) is connected with the main inlet port (109a) via a connector (106) from the plurality of connectors (105, 106, 107) and a second outlet port of the second conditioning plate (102) is connected with the main outlet port (109b) via a connector (105) from the plurality of connectors (105, 106, 107),
wherein a first outlet port of the first conditioning plate (103) is connected to a second inlet port of the second conditioning plate (102) via a connector (107) from the plurality of connectors (105, 106, 107),
wherein the battery module case (108) is designed to cover the plurality of conditioning plates (102, 103), the inlet port and the outlet port of the plurality of conditioning plates (102, 103), the plurality of cells (110) and the plurality of connectors (105, 106, 107).

2. The system (100) as claimed in claim 1, wherein each cell from the plurality of cells (110) comprises one or more terminals, wherein each terminal from the one or more terminals comprises a terminal axis.

3. The system (100) as claimed in claim 2, wherein the plurality of cells (110) is arranged according to a coordinate system in a three-dimensional space, wherein:
the coordinate system comprises X-orientation, Y-orientation and Z-orientation, wherein the X-orientation corresponds to a horizontal axis, the Z-orientation corresponds to a vertical axis, and the Y-orientation corresponds to an axis perpendicular to the X-orientation and the Z-orientation; and
wherein each cell from the plurality of cells (110) is placed in a way such that the terminal axis of each cell is parallel to one of, the X-orientation, the Y-orientation, and a combination thereof.

4. The system (100) as claimed in claim 3, wherein the plurality of conditioning plates (102, 103) is arranged in a direction perpendicular to the Z-orientation of the coordinate system.

5. The system (100) as claimed in claim 1, wherein the plurality of cells (110) arranged together to form a battery module, wherein a size of each conditioning plate from the plurality of conditioning plates (102, 103) is greater than a size of the battery module.

6. The system (100) as claimed in claim 1, wherein the conditioning system (100) comprises a safety cover for protecting the case portion (109) of the battery module case (108), wherein the safety cover is utilized to cover the main inlet port (109a) and the main outlet port (109b).

7. The system (100) as claimed in claim 1, wherein the case portion (109) is detachably coupled with the battery module case (108) and arranged on one side of the battery module case (108).

8. The system (100) as claimed in claim 1, wherein the main inlet port (109a) and the main outlet port (109b) are designed to be connected with a conditioning station via a fluid connector.

9. The system (100) as claimed in claim 1, wherein the first conditioning plate (103) from the plurality of conditioning plates (102, 103) is arranged on bottom side of the plurality of cells (110) and the second conditioning plate (102) from the plurality of conditioning plates (102, 103) is arranged on top side of the plurality of cells (110) and vice versa.

10. The system (100) as claimed in claim 1, wherein the first inlet port and the first outlet port of the first conditioning plate (103) are inwardly protruded towards the second inlet port and the second outlet port of the second conditioning plate (102) inside the battery module case (108).

11. The system (100) as claimed in claim 1, wherein the plurality of conditioning plates (102, 103) is connected with the battery module case (108) and the plurality of cells (110) by an adhesive (104), wherein the adhesive (104) corresponds to a thermally conductive, electrically insulated and structural member adhesive.

12. The system (100) as claimed in claim 1, wherein the battery assembly comprises a battery management system (BMS) (201) and a plurality of power path electrical circuitry (202) attached to one side of the second conditioning plate (102) from the plurality of conditioning plates (102, 103) via the adhesive (104).

13. The system (100) as claimed in claim 1, wherein the plurality of connectors (105, 106, 107) are designed to attach with the inlet port and the outlet port of the plurality of conditioning plates (102, 103) and are designed to attach with the main inlet port (109a) and the main outlet port (109b) of the case portion (109); wherein the plurality of connectors (105, 106, 107) corresponds to one of poly hose connector, vertical and angular connectors, flexible connectors, and a combination thereof.

14. The system (100) as claimed in claim 1, wherein the plurality of conditioning plates (102, 103) comprises a plurality of micro-channels (203) for a conditioning fluid to flow in a serpentine manner, wherein the conditioning fluid corresponds to one of cold fluid, hot fluid and a combination thereof depending on thermal requirements of the battery assembly.

15. A method (300) for assembling a conditioning system (100) of a battery assembly, characterized in that, wherein the method (300) comprises:
arranging (301) a plurality of cells (110) to form a battery module;
arranging (302) a plurality of conditioning plates (102, 103) in one or more sides of the battery module, wherein a first conditioning plate (103) arranged on a first side of the battery module and a second conditioning plate (102) arranged on a second side, opposite to the first side, of the battery module, wherein each conditioning plate from the plurality of conditioning plates (102, 103) comprises an inlet port and an outlet port;
connecting (303) a first inlet port of the first conditioning plate (103) with a main inlet port (109a) of a case portion (109) via a connector (106) from the plurality of connectors (105, 106, 107), wherein the case portion (109) is detachably connected to a battery module case (108);
connecting (304) a second outlet port of the second conditioning plate (102) with a main outlet port (109b) of the case portion (109) via a connector (105) from the plurality of connectors (105, 106, 107);
connecting (305) a first outlet port of the first conditioning plate (103) to a second inlet port of the second conditioning plate (102) via a connector (107) from the plurality of connectors (105, 106, 107), and
covering (306) the plurality of conditioning plates (102, 103), the inlet port and the outlet port of the plurality of conditioning plates (102, 103), the plurality of cells (110) and the plurality of connectors (105, 106, 107) within the battery module case (108).

16. The method (300) as claimed in claim 15, wherein the method (300) comprises a step for arranging the first conditioning plate (103) from the plurality of conditioning plates (102, 103) on bottom side of the plurality of cells (110), wherein the method (300) comprises a step of arranging the second conditioning plate (102) from the plurality of conditioning plates (102, 103) on top side of the plurality of cells (110).

17. The method (300) as claimed in claim 15, wherein the method (300) comprises a step of arranging the first conditioning plate (103) and the second conditioning plate (102 such that the first inlet port and the first outlet port of the first conditioning plate (103) are inwardly protruded towards the second inlet port and the second outlet port of the second conditioning plate (102) inside the battery module case (108).

Dated this 17th day of March 2023

Deepak Pawar
Agent for the Applicant
IN/PA-2052