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 SYSTEM AND A METHOD FOR ASSEMBLING A BATTERY PACK WITH A POWER PATH STRUCTURE
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 202341021848, filed on 27th March 2023, incorporated herein by a reference.

FIELD OF INVENTION
The present disclosure relates to the field of batteries and battery modules. More specifically, the present specification relates to a battery assembly architecture. More particularly, the present application discloses a battery assembly comprising a power path mounting structure 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 cooling 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 cooling 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, module to pack and cell to module. 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 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.
Further, in the field of battery assembly architecture, specifically for electric vehicles (EVs), a fast-charging mechanism is implemented at the EV charging stations. During fast charging, the battery assembly architecture and the internal components are susceptible for overheating and thereby affecting their work capacity. Therefore, the battery assembly requires mechanism for heat control and avoid searing for the prolonged durability of the battery assembly. A conventionally implemented cooling method involves passive cooling and/or active cooling.
The passive cooling methods involve where the battery assembly is cooled with help of air or water through internal components such as heat exchanger unit, heat sink, or cooling pane. The coolant is already present in the battery pack. The passive cooling can lead to an increase in weight of the battery assembly. The increased weight of the battery assembly contributes to the outsize mass of the EV vehicles consuming more resources. The active cooling method involves techniques such as pumping the conditioning fluid from resources external to the battery pack. Therefore, for maintaining a battery assembly’s efficient peak performance without increasing the overall battery assembly load, 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.
Existing battery structures require different systems to take care of each individually for positioning and conditioning of microchannel circuitry, and power path circuitry. Generally, the power path circuitry is placed on the sides of the battery modules with the help of side walls. The side positioning of power path modules requires a separate housing/casing. Therefore, the placement of other battery components such as power path panels with an efficient thermal management becomes challenging when active cooling is implemented. The overall size of the battery assembly may increase due to stacking and stationing of the plurality of components making the assembly bulky, and unhandy.
Further, the modern developments as described above lack a well-designed, and compact, thermal management mechanism for the battery assembly. Thus, aforementioned conventional systems and methods for circulation of conditioning fluid for the thermal management of the battery are not efficient, both practically and commercially.
Thus, there is a long-standing need for a combined battery architecture with a compact and effective mounting of the power path circuitry, and protected cooling mechanism for a battery assembly so as to preserve and improve the durability, serviceability, and efficacy of the conditioning of the battery assembly so that an optimum temperature 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 an improved battery assembly that features better cell orientations for superior conditioning of the battery pack, resulting in improved conditioning capacity and efficiency 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 present disclosure, a battery pack assembly with a power path structure is disclosed. The battery pack assembly may comprise a battery management system (BMS), a plurality of power path, and a power path base plate. The BMS and the plurality of power path may be coupled with the power path base plate to form a power path assembly. Further, the battery pack assembly may include a power path mounting structure and a plurality of conditioning manifolds. Furthermore, the power path assembly may be placed on the top side of the power path mounting structure. Additionally, the plurality of conditioning manifolds may be attached to the power path assembly, for conditioning the power path assembly.
In another implementation, a method for assembling a battery pack with a power path structure is disclosed. The method may include a step of arranging a plurality of battery modules in a predetermined manner to form the battery pack. Further, the method may include a step of attaching the battery management system (BMS) and the plurality of power path to the power path base plate to form the power path assembly. Further, the method may include a step of placing the power path assembly on top side of the power path mounting structure. Further, the method may include a step of arranging the power path mounting structure on top side of the plurality of battery modules. Further, the method may include a step of attaching the plurality of conditioning manifolds on the power path assembly for conditioning the power path assembly. Furthermore, the plurality of conditioning manifolds may comprise an inlet conditioning manifold and an outlet conditioning manifold. The method may further include a step of connecting the inlet conditioning manifold and the outlet conditioning manifold to a conditioning station, via a fluid connector, for exchanging conditioning fluid with the condition station. Further, the method may include a step of attaching the plurality of battery modules and the power path mounting structure to a base plate through one or more fastening means. Additionally, the method may include a step of attaching a battery assembly cover to the base plate for covering the plurality of battery modules, the power path mounting structure, the plurality of conditioning manifolds and the power path assembly.
In one embodiment, the battery pack assembly may comprise the plurality of battery modules and a plurality of conditioning channels for conditioning the plurality of battery modules. Further, each conditioning channel from the plurality of conditioning channels may comprise an inlet port and an outlet port. Further, the inlet port of each conditioning channel, from the plurality of conditioning channels, may be connected to one or more inlet manifold output ports of the inlet conditioning manifold. Furthermore, the outlet port of each conditioning channel, from the plurality of conditioning channels, may be connected to one or more outlet manifold input ports of the outlet conditioning manifold.
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 an exploded diagram describing a battery pack assembly (100) with a power path structure (200), in accordance with an embodiment of a present subject matter.
Figure 2 illustrates a diagram describing a power path structure (200) of the battery pack assembly (100), in accordance with an embodiment of a present subject matter.
Figure 3 illustrates a diagram describing a power path assembly (102) of the battery pack assembly (100), in accordance with an embodiment of a present subject matter.
Figure 4 illustrates a flowchart describing a method (400) for assembling a battery pack with a power path structure (200), 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 particular 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.
Now referring to Figure 1, an exploded diagram describing a battery pack assembly (100) with a power path structure (200), is illustrated in accordance with an embodiment of a present subject matter. In an embodiment, the battery back assembly (100) may include a battery assembly cover (101), a power path assembly (102), a plurality of conditioning manifolds (103, 104), a plurality of battery modules (105), a base plate (106), and a power path mounting structure (107).
In one embodiment, the power path assembly (102) (as shown in Figure 3) may include a battery management system (BMS) (303), a plurality of power path (302), a power path base plate (301). More specifically, the BMS (303) and the plurality of power path (302) may be attached with the power path base plate (301), via an adhesive to form the power path assembly (102). Further, the power path assembly (102) may be placed on the top side of the power path mounting structure (107). In an embodiment, the power path assembly (102) may be attached to the power path mounting structure (107) using one or more fastening means.
In another embodiment, the plurality of conditioning manifolds (103, 104) may be attached to the power path assembly (102) using one or more fastening means. Furthermore, a thermal pad may be placed between the plurality of conditioning manifolds (103, 104) and the power path assembly (102) for thermal conduction between the plurality of conditioning manifolds (103, 104) and the power path assembly (102). Furthermore, the plurality of conditioning manifolds (103, 104) may include an inlet conditioning manifold (104) and an outlet conditioning manifold (103). Further, each conditioning manifold from the plurality of conditioning manifolds (103, 104) may include one or more input ports and one or more output ports. More specifically, the inlet conditioning manifold (104) may include an inlet manifold input port and one or more inlet manifold output ports, and the outlet conditioning manifold (103) may include one or more outlet manifold input ports and an outlet manifold output port. Moreover, the inlet manifold input port of the inlet conditioning manifold (104) may be designed to connect with a conditioning station, via a fluid connector, for receiving the conditioning fluid from the conditioning station. Similarly, the outlet manifold output port of the outlet conditioning manifold (103) may be designed to connect with the conditioning station, via the fluid connector, for transmitting the conditioning fluid to the conditioning station. The conditioning station may include one or more fluid reservoirs for storing the conditioning fluid. Additionally, the plurality of conditioning manifolds (103, 104) may be attached to the power path assembly (102), for conditioning of the power path assembly (102).

In yet another embodiment, a plurality of cells may be arranged together to form a battery module. Further, the plurality of battery modules (105) may be arranged in a predetermined manner to form a battery pack. Furthermore, the battery pack assembly (100) may include a plurality of conditioning channels for conditioning the plurality of battery modules (105). Each conditioning channel from the plurality of conditioning channels comprises an inlet port and an outlet port. In an implementation, the inlet port of each conditioning channel, from the plurality of conditioning channels, is connected to one or more inlet manifold output ports of the inlet conditioning manifold (104) and the outlet port of each conditioning channel, from the plurality of conditioning channels, is connected to one or more outlet manifold input ports of the outlet conditioning manifold (103).
Further, each battery module from the plurality of battery modules (105) may be attached with the plurality of conditioning channels on either side of the battery module. Moreover, the plurality of conditioning channels may be attached to the plurality of battery modules (105) through the adhesive.
In a related embodiment, the conditioning fluid may be any fluid, preferably a liquid. In one exemplary embodiment, the conditioning fluid may either be a cold fluid or a hot fluid, depending on thermal requirements of the battery. A conditioning station/vehicle charging station may be allowed to flow the conditioning fluid into the battery pack assembly, via the fluid connector, while performing the conditioning/charging of the battery assembly. Further, the plurality of conditioning channels and the plurality of battery modules (105) may be fixed by bonding with a thermally uniform conductive structural adhesive/glue.
In an exemplary embodiment, the adhesive may correspond to a thermally conductive, electrically insulated, and structural member adhesive. More specifically, the adhesive may correspond to Polyurethane acrylate adhesive. The thermally conductive adhesive may be configured to maintain the electrical isolation from the plurality of battery modules, to protect battery modules during automotive vibrations caused from the road, and to keep the battery modules under the right operating condition. Further, a well- maintained electrical isolation between the body of each battery module and the plurality of conditioning channels. This electrical isolation is consistent across the battery packs of the battery assembly.
More specifically, each battery module from the plurality of battery modules (105) may be attached with a first conditioning channel, from the plurality of conditioning channels, on a first side of the battery module, and further may be attached with a second conditioning channel, from the plurality of conditioning channels, on a second side, opposite to the first side, of the battery module. Moreover, each conditioning channel from the plurality of conditioning channels may include an inlet port and an outlet port. More specifically, the first conditioning channel may include a first inlet port and a first outlet port, and simultaneously, the second conditioning channel may include a second inlet port and a second outlet port. Moreover, the conditioning fluid flows inside the plurality of conditioning channels in a serpentine manner.
Furthermore, the inlet port of each conditioning channel, from the plurality of conditioning channels, may be connected to one or more inlet manifold output ports of the inlet conditioning manifold (104). On the other hand, the outlet port of each conditioning channel, from the plurality of conditioning channels, may be connected to one or more outlet manifold input ports of the outlet conditioning manifold (103). More specifically the first inlet port of the first conditioning channel and the second inlet port of the second conditioning channel may be connected to one or more inlet manifold output ports of the inlet conditioning manifold (104). On the other hand, the first outlet port of the first conditioning channel and the second outlet port of the second conditioning channel are connected to one or more outlet manifold input ports of the outlet conditioning manifold (103).
Alternatively, the first outlet port of the first conditioning channel may be connected to the second inlet port of the second conditioning channel, via a conditioning channel connector. Moreover, the first inlet port of the first conditioning channel, for each battery module from the plurality of battery modules (105), may be connected to one or more inlet manifold output ports of the inlet conditioning manifold (104). Simultaneously, the second outlet port of the second conditioning channel, for each battery module from the plurality of battery modules (105), may be connected to one or more outlet manifold input ports of the outlet conditioning manifold (103). Moreover, the battery pack assembly may include a plurality of connectors including the conditioning channel connector along with inlet manifold connectors (104a, 104b) and outlet manifold connectors (103a, 103b) (as shown in Figure 2).
In yet another embodiment, the battery pack assembly (100) may include the base plate (106). Further, the plurality of battery modules (105) may be connected to the base plate (106) using one or more fastening means. Simultaneously, the power path mounting structure (107) may be connected to the base plate (106) using one or more fastening means. Similarly, the power path mounting structure (107) may be connected to the plurality of battery modules (105) using one or more fastening means.
In an exemplary embodiment, the base plate (106) of the battery pack assembly (100) may have a plurality of mounting holes for fixing the battery assembly to a rigid support. The rigid support may be an automobile floor. The battery assembly acts as a unibody where everything is bonded together ensuring that the complete battery assembly architecture acts as a single unit during an automotive vibration scenario. Such unibody architecture may create better stiffness than a conventional architecture and may use the structural strength of each battery cell as a battery assembly structure.
In yet another embodiment, the battery pack assembly (100) may include the power path mounting structure (107) (as shown in Figure 2). Further, the power path mounting structure (107) may be arranged on the top side of the plurality of battery modules (105). Moreover, the power path assembly (102) may be placed on the top side of the power path mounting structure (107). Additionally, the power path mounting structure (107) may be connected to the base plate (106) and the plurality of battery modules (105), and the power path assembly (102), using one or more fastening means.
In an exemplary embodiment, the fastening means may correspond to one of bolts, brackets and a combination of the same.
In yet another embodiment, the battery pack assembly (100) may include the battery assembly cover (101). Furthermore, the battery assembly cover (101) may be designed to cover various components of the battery pack assembly (101). More specifically, the battery assembly cover (101) may cover the plurality of battery modules (105), the plurality of conditioning channels, the plurality of conditioning manifolds (103, 104), the plurality of connectors, the power path assembly (102), and the power path mounting structure (107). Furthermore, the battery assembly cover (101) may be attached to the base plate (106) using the fastening means. Moreover, the plurality of conditioning manifolds (103, 104) may be connected to the fluid reservoirs of the conditioning station, through the battery assembly cover (101).
In an exemplary embodiment, the plurality of battery modules (105) including the plurality of cells may be arranged in a fixture, like a battery module case, or by using the plurality of spacers. The plurality of spacers may be utilized for ensuring an equal spacing between the plurality of cells. The fixture may also be configured to ensure equal spacing of the plurality of battery cells via the fixture tolerances.
In another exemplary 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.
Now, referring to Figure 2, a diagram describing a power path structure (200) of the battery pack assembly (100), is illustrated in accordance with an embodiment of a present subject matter. The power path structure (200) may include the power path assembly (102), the plurality of conditioning manifolds (103, 104), the plurality of connectors and the power path mounting structure (107).
In one embodiment, the power path assembly (102) including the battery management system (BMS) (303), the plurality of power path (302), and the power path base plate (301) may be placed on the top side of the power path mounting structure (107). Furthermore, the power path assembly (102) may be attached to the power path mounting structure (107) using one or more fastening means. Also, the plurality of conditioning manifolds (103, 104) may be attached to the power path assembly (102) using one or more fastening means, thereby forming the power structure providing protective conditioning for the battery pack assembly.
In yet another embodiment, the battery pack assembly (100) may include the plurality of connectors. Further, the plurality of connectors may include the conditioning channel connector, the inlet manifold connectors (104a, 104b) and the outlet manifold connectors (103a, 103b). Further, the conditioning channel connector may be designed to connect the inlet port of one conditioning channel to the outlet port of another conditioning channel in the same battery module. Furthermore, an inlet manifold connector (104a) may be designed to connect the inlet manifold input port of the inlet conditioning manifold (104) with the fluid connector, for receiving the conditioning fluid from the conditioning station. Simultaneously, inlet manifold connectors (104b) may be designed to connect inlet manifold output ports of the inlet conditioning manifold (104) with the inlet ports of the plurality of conditioning channels, for distributing the conditioning fluid into the inlet ports of each conditioning channel.
Similarly, an outlet manifold connector (103a) may be designed to connect the outlet manifold output port of the outlet conditioning manifold (103) with the fluid connector, for transmitting the conditioning fluid to the conditioning station. Further, outlet manifold connectors (103b) may be designed to connect outlet manifold input ports of the outlet conditioning manifold (103) with the outlet ports of the plurality of conditioning channels, for receiving the conditioning fluid from each of the conditioning channel to the outlet conditioning manifold (103).
In an exemplary embodiment, the plurality of connectors may correspond to one of the poly hose connectors, vertical and angular connectors, flexible connectors, and a combination of the same.
In a related embodiment, a compact and strong structure of the power path mounting structure (107) may be attributed to place the power path assembly (102) above the plurality of battery modules (105) and eliminate requirement positioning of the power path assembly beside the side walls affixed by the adhesive.
Now, referring to Figure 3, a diagram describing a power path assembly (102) of the battery pack assembly (100), is illustrated in accordance with an embodiment of a present subject matter. The power path assembly (102) may include the battery management system (BMS) (303) and the plurality of power path (302) attached with the power path base plate (301). Further, the plurality of power path (302) and the BMS (303) may be attached to the power path base plate (301). Further, the power path assembly (102) may be arranged on the top side of the power path mounting structure (107) and connected using one or more fastening means.
In an exemplary embodiment, the battery management system (303) may further comprise a plurality of bus bars and power paths. Further, the plurality of bus bars and power paths may be pre-bonded with the power path base plate and other electrical components of the battery management system (303), via the adhesive.
Now referring to Figure 4, a flowchart describing a method (400) for assembling the battery pack with the power path structure (200), in accordance with an embodiment of the present subject matter. The method (400) may involve a variety of steps for arranging an improved battery pack assembly (100). The method (400) may involve a step (401) for arranging the plurality of battery modules (105) in a predetermined manner to form a battery pack.
Further, the method (400) may involve a step (402) for attaching the battery management system (BMS) (303) and the plurality of power path (302) to the power path base plate (301) to form the power path assembly (102).
Further, the method (400) may involve a step (403) for placing the power path assembly (102) on top side of a power path mounting structure (107).
Further, the method (400) may involve a step (404) for arranging the power path mounting structure (107) on top side of the plurality of battery modules (105).
Further, the method (400) may involve a step (405) for attaching the plurality of conditioning manifolds (103, 104) on the power path assembly (102) for conditioning the power path assembly (102). The plurality of conditioning manifolds (103, 104) further may include the inlet conditioning manifold (104) and the outlet conditioning manifold (103).
Further, the method (400) may involve a step (406) for connecting the inlet conditioning manifold (104) and the outlet conditioning manifold (103) to the conditioning station, via the fluid connector, for exchanging conditioning fluid with the condition station.
Further, the method (400) may involve a step (407) for attaching the plurality of battery modules (105) and the power path mounting structure (107) to the base plate (106) through one or more fastening means.
Furthermore, the method (400) may involve a step (408) for attaching the battery assembly cover (101) to the base plate (106) for covering the plurality of battery modules (105), the power path mounting structure (107), the plurality of conditioning manifolds (103, 104) and the power path assembly (102).
The presently disclosed battery pack assembly (100) with the power path structure (200) comprising the power path assembly (102), power path mounting structure (107), and the plurality of conditioning manifolds (103, 104) for conditioning of the power path assembly (102) and thereby the battery pack assembly (100) may have the following advantageous functionalities over the conventional art:
• Simultaneous conditioning of the power path assembly and the battery module, using the plurality of conditioning manifolds.
• Active conditioning technique enables reduction in busbar power path condition more effectively.
• Reduction in addition mass/weight of the battery assembly due to simultaneous conditioning of power path assembly and the battery modules.
• Elimination of heavy side walls by introducing a mounting structure for power path circuitry resulting in weight cost reduction.
• Single Plastic cover from top to bottom, eliminates the problem of outsizing and weight.
• Easy serviceability of the battery assembly in case of maintenance activity
• 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:I/WE CLAIM:
1. A battery pack assembly (100) with a power path structure, characterized in that, the battery pack assembly (100) comprises:
a battery management system (BMS) (303);
a plurality of power path (302); and
a power path base plate (301), wherein the BMS (303) and the plurality of power path (302) are coupled with the power path base plate (301) to form a power path assembly (102);
a power path mounting structure (107), wherein the power path assembly (102) is placed on top side of the power path mounting structure (107); and
a plurality of conditioning manifolds (103, 104), wherein each conditioning manifold from the plurality of conditioning manifold (103, 104) comprise one or input ports and one or more output ports;
wherein the plurality of conditioning manifolds (103, 104) is attached to the power path assembly (102), for conditioning the power path assembly (102).
2. The battery pack assembly (100) as claimed in claim 1, wherein the plurality of conditioning manifolds (103, 104) is attached to the power path assembly (102) using one or more fastening means; wherein a thermal pad is placed between the plurality of conditioning manifolds (103, 104) and the power path assembly (102) for thermal conduction between the plurality of conditioning manifolds (103, 104) and the power path assembly (102).
3. The battery pack assembly (100) as claimed in claim 1, wherein the plurality of power path (302) and the BMS (303) are attached to the power path base plate (301), through an adhesive; wherein the power path assembly (102) is attached to the power path mounting structure (107) using one or more fastening means.
4. The battery pack assembly (100) as claimed in claim 1, wherein the plurality of conditioning manifolds (103, 104) comprises an inlet conditioning manifold (104) and an outlet conditioning manifold (103), wherein the inlet conditioning manifold (104) comprises an inlet manifold input port and one or more inlet manifold output ports, wherein the outlet conditioning manifold (103) comprises one or more outlet manifold input ports and an outlet manifold output port.
5. The battery pack assembly (100) as claimed in claim 4, wherein the battery pack assembly (100) comprises:
a plurality of battery modules (105);
a plurality of conditioning channels for conditioning the plurality of battery modules (105), wherein each conditioning channel from the plurality of conditioning channels comprises an inlet port and an outlet port;
wherein the inlet port of each conditioning channel, from the plurality of conditioning channels, is connected to one or more inlet manifold output ports of the inlet conditioning manifold (104) and the outlet port of each conditioning channel, from the plurality of conditioning channels, is connected to one or more outlet manifold input ports of the outlet conditioning manifold (103).
6. The battery pack assembly (100) as claimed in claim 5, wherein each battery module from the plurality of battery modules (105) is attached with a first conditioning channel, from the plurality of conditioning channels, on a first side of the battery module and is attached with a second conditioning channel, from the plurality of conditioning channels, on a second side, opposite to the first side, of the battery module.
7. The battery pack assembly as claimed in claims 4 and 6, wherein the first conditioning channel comprises a first inlet port and a first outlet port; wherein the second conditioning channel comprises a second inlet port and a second outlet port;
wherein the first inlet port of the first conditioning channel and the second inlet port of the second conditioning channel are connected to one or more inlet manifold output ports of the inlet conditioning manifold (104);
wherein the first outlet port of the first conditioning channel and the second outlet port of the second conditioning channel are connected to one or more outlet manifold input ports of the outlet conditioning manifold (103).
8. The battery pack assembly (100) as claimed in claims 4 and 6, wherein the first outlet port of the first conditioning channel is connected to the second inlet port of the second conditioning channel, via a conditioning channel connector;
wherein the first inlet port of the first conditioning channel, for each battery module from the plurality of battery modules (105), is connected to one or more inlet manifold output ports of the inlet conditioning manifold (104);
wherein the second outlet port of the second conditioning channel, for each battery module from the plurality of battery modules (105), is connected to one or more outlet manifold input ports of the outlet conditioning manifold (103).
9. The battery pack assembly (100) as claimed in claim 4, wherein the inlet manifold input port of the inlet conditioning manifold (104) is designed to connect with a conditioning station, via a fluid connector, for receiving the conditioning fluid from the conditioning station;
wherein the outlet manifold output port of the outlet conditioning manifold (103) is designed to connect with the conditioning station, via the fluid connector, for transmitting the conditioning fluid to the conditioning station;
wherein the conditioning station comprises one or more fluid reservoirs for storing the conditioning fluid.
10. The battery pack assembly (100) as claimed in claim 9, wherein the battery pack assembly (100) comprises a plurality of connectors,
wherein the plurality of connectors comprises the conditioning channel connector, inlet manifold connectors (104a, 104b) and outlet manifold connectors (103a, 103b);
wherein the conditioning channel connector is designed to connect an inlet port of one conditioning channel to an outlet port of another conditioning channel in a same battery module;
wherein inlet manifold connector (104a) is designed to connect inlet manifold input port of the inlet conditioning manifold (104) with the fluid connector, for receiving the conditioning fluid from the conditioning station;
wherein inlet manifold connectors (104b) are designed to connect inlet manifold output ports of the inlet conditioning manifold (104) with the inlet ports of the plurality of conditioning channels, for distributing the conditioning fluid into the inlet ports of each conditioning channel;
wherein outlet manifold connector (103a) is designed to connect outlet manifold output port of the outlet conditioning manifold (103) with the fluid connector, for transmitting the conditioning fluid to the conditioning station;
wherein outlet manifold connectors (103b) are designed to connect outlet manifold input ports of the outlet conditioning manifold (103) with the outlet ports of the plurality of conditioning channels, for receiving the conditioning fluid from each of the conditioning channel to the outlet conditioning manifold (103);
wherein the plurality of connectors corresponds to one of the poly hose connectors, vertical and angular connectors, flexible connectors, and a combination thereof.
11. The battery pack assembly (100) as claimed in claim 1, wherein the battery pack assembly (100) comprises a base plate (106); wherein the plurality of battery modules (105) is connected to the base plate (106) through one or more fastening means; wherein the power path mounting structure (107) is connected to the base plate (106) through one or more fastening means; wherein the power path mounting structure (107) is connected to the plurality of battery modules (105) through one or more fastening means; wherein the fastening means corresponds to one of bolts, brackets and a combination thereof.
12. The battery pack assembly (100) as claimed in claims 5, 10 and 11, wherein the battery pack assembly (100) comprises a battery assembly cover (101); wherein the battery assembly cover (101) is attached to the base plate (106) through the fastening means; wherein the battery assembly cover (101) is designed to cover the plurality of battery modules (105), the power path mounting structure (107), the plurality of conditioning manifolds (103, 104), the plurality of conditioning channels, the plurality of connectors and the power path assembly (102); wherein the plurality of conditioning manifolds (103, 104) are connected to the fluid reservoirs of the conditioning station, through the battery assembly cover (101).
13. The battery pack assembly (100) as claimed in claim 5, wherein the plurality of conditioning channels is attached to the plurality of battery modules (105) through the adhesive; wherein the adhesive corresponds to a thermally conductive, electrically insulated, and structural member adhesive, wherein the adhesive corresponds to Polyurethane acrylate adhesive.
14. The battery pack assembly (100) as claimed in claim 9, wherein the conditioning fluid corresponds to one of, cold fluid, hot fluid, and a combination thereof; wherein the conditioning fluid flows inside the plurality of conditioning channels in a serpentine manner.
15. A method (400) for assembling a battery pack with a power path structure, characterized in that, the method (400) comprising:
arranging (401) a plurality of battery modules (105) in a predetermined manner to form a battery pack;
attaching (402) a battery management system (BMS) (303) and a plurality of power path (302) to a power path base plate (301) to form a power path assembly (102);
placing (403) the power path assembly (102) on top side of a power path mounting structure (107);
arranging (404) the power path mounting structure (107) on top side of the plurality of battery modules (105);
attaching (405) a plurality of conditioning manifolds (103, 104) on the power path assembly (102) for conditioning the power path assembly (102), wherein the plurality of conditioning manifolds (103, 104) comprises an inlet conditioning manifold (104) and an outlet conditioning manifold (103);
connecting (406) the inlet conditioning manifold (104) and the outlet conditioning manifold (103) to a conditioning station, via a fluid connector, for exchanging conditioning fluid with the condition station;
attaching (407) the plurality of battery modules (105) and the power path mounting structure (107) to a base plate (106) through one or more fastening means; and
attaching (408) a battery assembly cover (101) to the base plate (106) for covering the plurality of battery modules (105), the power path mounting structure (107), the plurality of conditioning manifolds (103, 104) and the power path assembly (102).
Dated this 27th day of March 2024