The present disclosure relates generally to a vehicle battery pack and in particular relates to an electric or a hybrid vehicle battery pack which is capable of efficiently removing heat dissipated by rechargeable battery modules.
BACKGROUND
[0002] Electric vehicles (EVs) and hybrid vehicles are powered by onboard rechargeable battery modules. The rechargeable battery modules are provided in a battery pack. To drive a vehicle huge amount of power is needed which is fulfilled by the battery pack containing multiple rechargeable battery modules. While charging or discharging during vehicle operation, the rechargeable battery modules generate heat that needs to be removed from the battery pack for proper functioning of the rechargeable battery modules. Any failure in efficiently removing of heat from the battery pack may damage the rechargeable battery module. Further, it is desired to uniformly maintain the temperature of the rechargeable battery modules for proper functioning.
[0003] For removal of heat from the battery pack, a cooling module is provided in the battery pack. The rechargeable battery modules are usually placed over the cooling module to remove heat.
[0004] FIG. 1 illustrates a cooling module of a battery pack in accordance with the existing art. The cooling module 100 comprises cooling channels 101 having coolant inlet header 102 on one side and the coolant outlet header 103 on the other side. Rechargeable battery modules are placed over the cooling channels 101. The coolant inside the cooling channels 101 flows from the coolant inlet header 102 to the coolant outlet header 103. As the coolant inlet header 102 and the coolant outlet header 103 are provided at different ends of the cooling channels 101, a temperature gradient is created along the length of the cooling channels 101. The region of

cooling channels 101 which is in the vicinity of coolant inlet header 102 has low temperature whereas the region of cooling channels 101 which is in the vicinity of the coolant outlet header 103 has high temperature. This creates problem in maintaining uniform temperature of the rechargeable battery modules. Further, the inlet and outlet headers on both sides inside battery takes more space. Thus, reducing the volumetric efficiency.
[0005] To overcome the drawbacks of generation of temperature gradient in the cooling channels 101, a very thick cooling plate is suggested wherein the flow of coolant is maintained in the top and bottom side of cooling plate. However, the problem of poor volumetric efficiency is still maintained due to limited space inside the battery pack and increased thickness of the cooling plate.
[0006] Another embodiment of existing cooling modules uses multiple quick connectors to connect the cooling channels 101 with the coolant inlet header 102 for introducing coolant in the channels. Further, separate multiple quick connectors are used to connect the cooling channels 101 with the coolant outlet header 103 for evacuating the coolant from the cooling channels. However, using of multiple quick connectors increase the risk of leakage of the coolant which is a fire hazard.
[0007] Accordingly, there is a need for a vehicle battery pack which is capable of efficiently removing heat from the battery pack while maintaining good volumetric efficiency and reduce the risk of leakage of the coolant.
SUMMARY
[0008] This summary is provided to introduce concepts related to a vehicle battery pack. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0009] The present subject matter relates to a vehicle battery pack. The vehicle battery pack comprises a plurality of rechargeable battery modules and a battery

cooling module. The battery cooling module is provided in contact with the plurality of rechargeable battery modules. The battery cooling module comprises an upper plate, a lower plate and a separator plate. The upper plate is in contact with the plurality of rechargeable battery modules. The upper plate has a coolant inlet. The lower plate is provided below the upper plate. The lower plate has a coolant outlet. The separator plate is provided in between the upper plate and the lower plate creating a thermal barrier between the upper plate and the lower plate of the battery cooling module.
[0010] In an aspect, the upper plate comprises a coolant inlet header, a plurality of extended cooling channels and a plurality of isolated cooling channels. The coolant inlet header has an inlet hole for introducing coolant into the battery cooling module. The plurality of extended cooling channels are branching from the coolant inlet header. Each of the plurality of extended cooling channels has an inlet in connection with the coolant inlet header and an outlet. Each of the plurality of isolated cooling channels have an inlet and an outlet without any linkage with the coolant inlet header.
[0011] In an aspect, the lower plate comprises a coolant outlet header and a plurality of connecting channels. The coolant outlet header is provided for evacuation of coolant from the battery cooling module. The plurality of connecting channels is provided to connect the isolated cooling channels with the adjacent extended cooling channels.
[0012] In an aspect, the separator plate comprises a plurality of vent holes, a plurality of duct holes, a plurality of passage holes and an outlet hole. The plurality of vent holes are provided to create a connection between the outlet of the extended cooling channels of the upper plate and the coolant outlet header of the lower plate. The plurality of duct holes are provided to create a connection between the outlet of the extended cooling channels of the upper plate and the inlet of the adjacent isolated cooling channels of the upper plate. The plurality of passage holes are provided to create a connection between the outlet of the isolated cooling channels of the upper plate and the coolant outlet header of the lower plate. The outlet hole

is provided in connection with the coolant outlet header for evacuation of coolant from the battery cooling module.
[0013] In an aspect, the plurality of connecting channels of the lower plate facilitates connection between the outlets of the plurality of extended cooling channels of the upper plate and the inlets of the corresponding adjacent isolated cooling channels of the upper plate using duct holes of the separation plate.
[0014] In an aspect, the upper plate is securely attached to upper surface of the separator and the lower plate is securely attached to the lower surface of the separator in such a manner that the placement of the coolant inlet header with respect to the separator is identical to the placement of the coolant outlet header with respect to the separator.
[0015] In an aspect, the upper plate is made of thermally conductive material.
[0016] In an aspect, the separator and the lower plate are made up of thermally insulating materials.
[0017] In an aspect, thickness of the battery cooling module in the coolant inlet header region and the coolant outlet header region is more than the thickness of the battery cooling module in any other region.
[0018] In an aspect, the vehicle battery pack further comprises a battery upper cover and a battery lower cover together forming a compartment.
[0019] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.
[0020] 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 FIGURES
[0021] The illustrated embodiments of the present disclosure will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of the vehicle side body structure that are consistent with the subject matter as claimed herein, wherein:
[0022] FIG. 1 illustrates a cooling module of a battery pack in accordance with the existing art;
[0023] FIG. 2 illustrates an exploded view of exemplary vehicle battery pack that can be utilized to implement one or more exemplary embodiments of the present disclosure;
[0024] FIG. 3 illustrates an exploded view of exemplary battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure;
[0025] FIG. 4 illustrates a top view of the exemplary upper plate of the battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure;
[0026] FIG. 5 illustrates top view of the exemplary lower plate of the battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure;
[0027] FIG. 6 illustrates a top view of the exemplary separator of the battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure; and
[0028] FIG. 7 a and 7b illustrates sectional views of the exemplary battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure and

[0029] FIG. 8 illustrates working of the exemplary battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure.
[0030] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
[0031] A few aspects of the present disclosure are explained in detail below with reference to the various figures. Example implementations are described to illustrate the disclosed subject matter, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations of the various features provided in the description that follows.
EXEMPLARY EMBODIMENTS
[0032] While the present disclosure may be embodied in various forms, there are shown in the drawings, and will hereinafter be described, some exemplary and non-limiting embodiments, with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. Not all of the depicted components described in this disclosure may be required, however, and some implementations may include additional, different, or fewer components from those expressly described in this disclosure. Variations in the arrangement and type of the components may be made without departing from the scope of the claims as set forth herein.
[0033] Electric vehicles and hybrid vehicles are equipped with rechargeable battery modules which are stacked inside a battery cover together forming a battery

pack. These rechargeable battery modules dissipate heat while charging and discharging which raises temperature inside the battery pack. To remove heat from the battery pack, a battery cooling module is provided. The rechargeable battery modules are placed over the battery cooling module to efficiently remove the heat. Existing battery cooling modules have poor volumetric efficiency and high risk of leakage of coolant from the battery cooling module. Further, the existing battery cooling module are not capable of uniformly maintaining the temperature of rechargeable battery modules.
[0034] To solve the problem, a vehicle battery pack which is capable of efficiently removing heat from the battery pack while maintaining good volumetric efficiency and reduce the risk of leakage of the coolant, is needed.
[0035] In order to achieve these goals of efficiently removing of heat, good volumetric efficiency and low risk of leakage of coolant, a vehicle battery pack may be utilized. The features of the vehicle battery pack are described in more detail below.
[0036] FIG. 2 illustrates an exploded view of exemplary vehicle battery pack that can be utilized to implement one or more exemplary embodiments of the present disclosure. The vehicle battery pack 200 comprises a plurality of rechargeable battery modules 202 and a battery cooling module 203. A battery upper cover 201 and a battery lower cover 204 together form a compartment to accommodate the plurality of rechargeable battery modules 202 and the battery cooling module 203. The rechargeable battery modules 202 are stacked inside the compartment. The battery cooling module 203 is provided between the plurality of rechargeable battery modules 202 and the battery lower cover 204. While charging and discharging of the plurality of rechargeable battery modules 202, the heat generated by the plurality of rechargeable battery modules 202 are removed by the battery cooling module 203. A liquid coolant is made to flow through the battery cooling module 203. A coolant reservoir (not shown) is provided and provisions are provide in the vehicle battery pack 200 for inlet and outlet of coolant. The coolant reservoir is provided outside the vehicle battery pack (200).

[0037] FIG. 3 illustrates an exploded view of exemplary battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure. The battery cooling module 203 comprises an upper plate 301, a lower plate 303 and a separator plate 302. The separator plate 302 is provided between the upper plate 301 and the lower plate 303 to thermally isolate the upper plate 301 with the lower plate 303. The upper plate 301 is provided with a coolant inlet header 304. The liquid coolant from the coolant reservoir is introduced in the battery cooling module 203 through the coolant inlet header 304 provided in the upper plate 301 of the battery cooling module 203. The upper plate 301 is arranged in contact with the lower surface of the plurality of rechargeable battery modules 202. For the purpose of efficient heat removing from the plurality of rechargeable battery modules 202, the upper plate 301 of the battery cooling module 203 is made up of thermally conductive material. Thus, the upper plate 301 of the battery cooling module 203 is responsible for removal of heat from the plurality of rechargeable battery modules 202.
[0038] The lower plate 303 of the battery cooling module 203 is provided with a coolant outlet header 305. The liquid coolant from the upper plate 301 is evacuated from the battery cooling module 203 through the coolant outlet header 305 provided in the lower plate 303. The lower plate 303 is arranged in contact with the battery lower cover 204. For the purpose of thermal isolation from the battery lower cover 204, the lower plate 303 of the battery cooling module 203 is made up of thermally insulating material. The separator plate 302 is also made up of thermally insulating material to create a thermal barrier between the upper plate 301 and the lower plate 303 of the battery cooling module 203. Thus, the lower plate 303 and the separator 302 is responsible for evacuating the coolant from the battery cooling module 203 without it affecting the cooling efficiency of the coolant flowing in the upper plate 301.
[0039] FIG. 4 illustrates a top view of the exemplary upper plate of the battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure. As already disclosed, the upper plate 301 of

the battery cooling module 203 is responsible for removal of heat from the plurality of rechargeable battery modules 202. The upper plate 301 of the battery cooling module 203 is purposefully designed to efficiently remove the heat from the plurality of rechargeable battery modules 202 and uniformly maintain the temperature of the plurality of rechargeable battery modules 202. The upper plate 301 of the battery cooling module comprises a coolant inlet header 304, a plurality of extended cooling channels 401a, 401b, 401c, 40Id, 40le and a plurality of isolated cooling channels 402a, 401b. The cooling inlet header 304, the plurality of extended cooling channels 401a, 401b, 401c, 40Id, 40le and the plurality of isolated cooling channels 402a, 402b are formed on the upper plate 301 through sheet metal forming process or stamping process. The coolant inlet header 304 is the main channel in which the coolant is introduced initially. The coolant inlet header 304 is provided with an inlet hole 403 which facilitates the introduction of coolant into the battery cooling module 203, particularly, the upper plate 301.
[0040] The plurality of extended cooling channels 401a, 401b, 401c, 40Id, 401e are directly connected with the coolant inlet header 304. In other words, the plurality of extended cooling channels 401a, 401b, 401c, 40Id, 401 e are branching from the coolant inlet header 304. Each of the plurality of extended cooling channels 401a, 401b, 401c, 40Id, 401ehas an inlet 401 ai, 401bi, 40lei, 401di, 40lei and an outlet 401ao, 401bo, 401co, 401 do, 401eo. The inlet 401ai, 401bi, 40lei, 401di, 40 lei of each of the plurality of extended cooling channels 401a, 401b, 401c, 401d, 401e are connected with the coolant inlet header 304. In an aspect, the plurality of extended cooling channels 401a, 401b, 401c, 401d, 401e are provided on both sides of the coolant inlet header 304. Since the coolant is introduced in the plurality of extended cooling channels 401a, 401b, 401c, 40Id, 40le through same coolant inlet header 304, the heat is uniformly removed from the plurality of rechargeable battery modules 202 placed over the upper plate 301 of the battery cooling module 203.
[0041] In an aspect, the orientation of the coolant inlet header 304 is maintained along the breadth of the upper plate 301 and the orientation of the plurality of the

extended cooling channels 401a, 401b, 401c, 40Id, 40le are maintained along the length of the upper plate 301.
[0042] In addition to the plurality of extended cooling channels 401a, 401b, 401c, 40Id, 40le a plurality of isolated cooling channels 402a, 402b are also provided on the upper plate 301 of the battery cooling module 203. Each of the plurality of isolated cooling channels 402a, 402b also have an inlet 402ai, 402bi and an outlet 402ao, 402bo. However, contrary to the inlets 401ai, 401bi, 40lei, 401di, 40lei of the plurality of extended cooling channels 401a, 401b, 401c, 40Id, 40le being directly connected to the coolant inlet header 304, the inlets 402ai, 402bi of the plurality of isolated cooling channels 402a, 402b have no direct linkage with the coolant inlet header 304. Each of the inlet 402ai, 402bi of the plurality of isolated cooling channels 402a, 402b are connected to the outlet 401ao, 401bo of the extended cooling channels 401a, 401b which are present adjacent to the corresponding isolated cooling channels 402a, 402b. The linkage between the inlet 402ai, 402bi of the plurality of isolated cooling channels 402a, 402b with the outlet 401ao, 401bo of the adjacent extended cooling channel 401a, 401b is discussed in detail while discussing the lower plate 303 shown in FIG. 5.
[0043] FIG. 5 illustrates top view of the exemplary lower plate of the battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure. As already disclosed, the lower plate 303 of the battery cooling module 203 is responsible for evacuating coolant from the battery cooling module 203. The lower plate 303 of the battery cooling module 203 is purposefully designed to efficiently evacuate the coolant from the battery cooling module 203 without exchanging heat from the surrounding. The lower plate 303 of the battery cooling module 203 comprises a coolant outlet header 305 and a plurality of connecting channels 501a, 501b. The coolant outlet header 305 and the plurality of connecting channels 501a, 501b are formed on the lower plate 303 through sheet metal forming process or stamping process. The coolant outlet header 305 is the main channel in which the coolant is received after circulation in the upper plate 301 of the battery cooling module 203. The plurality of connecting

channels 501a, 501b are provided in the lower plate 303 to create a connection between the isolated cooling channels 402a, 402b and the adjacent cooling channels 401a, 401b. In particular, the plurality of connecting channels 501a, 501b are provided to connect the inlet 402ai, 402bi of the plurality of isolated cooling channels 402a, 402b with the outlet 401ao, 401bo of the adjacent extended cooling channel 401a, 401b. Thus, the plurality of connecting channels 501a, 501b are provided below the pair of the isolated cooling channel 402a, 402b and the corresponding adjacent extended cooling channels 401a, 401b.
[0044] In an aspect, the outlet 401 ao, 40 lbo of the plurality of extended cooling channel 401a, 401b of the upper plate 301 is connected to the inlet 402ai, 402bi of the adjacent isolated cooling channels 402a, 402b of the upper plate 301. When there is no adjacent isolated cooling channel available on the upper plate 301, the outlet 401 co, 401 do, 401eo of the plurality of extended cooling channels 401c, 40 Id, 40 le of the upper plate 301 are connected to the coolant outlet header 305 of the lower plate 303.
[0045] The connections between the cooling channels 401a, 401b, 401c, 40Id, 401e, 402a, 402b of the upper plate 301 and the channels 305, 501a, 501b (coolant outlet header and connection channel) of the lower plate 303 is facilitated by the separator plate 302.
[0046] FIG. 6 illustrates a top view of the exemplary separator of the battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure. As already disclosed, the separator plate 302 of the battery cooling module 203 is responsible for creating a thermal barrier between the upper plate 301 and the lower plate 303 of the battery cooling module 203. The separator plate 302 of the battery cooling module 203 is purposefully designed to stop heat exchange between the coolant flowing in the upper plate 301 and the coolant flowing in the lower plate 303 of the battery cooling module 203. The separator plate 302 comprises a plurality of vent holes 601a, 601b, 601c, a plurality of duct holes 602a, 602b, 602c, 602d, a plurality of passage holes 603a, 603b and an outlet hole 604. The plurality of vent holes 601a, 601b, 601c are

provided to create a connection between the outlet 401co, 401 do, 401eo of the extended cooling channels 401c, 40 Id, 40 le of the upper plate 301 and the coolant outlet header 305 of the lower plate 303. The plurality of vent holes 601a, 601b, 601 c ensures that the coolant from the extended cooling channels 401 c, 401 d, 401 e, which does not have any adjacent isolated cooling channels, gets evacuated via coolant outlet header 305.
[0047] The plurality of duct holes 602a, 602b, 602c, 602d are provided to create a connection between the outlet 401ao, 401bo of the extended cooling channels 401a, 401b of the upper plate 301 and the inlet 402ai, 402bi of the adjacent isolated cooling channels 402a, 402b of the upper plate 301. The plurality of duct holes 602a, 602b, 602c, 602d ensures that the coolant from the extended cooling channels 401a, 401b flows through the adjacent isolated cooling channels 402a, 402b.
[0048] The plurality of passage holes 603a, 603b are provided to create a connection between the outlet 402ao, 402bo of the isolated cooling channels 402a, 402b of the upper plate 301 and the coolant outlet header 305 of the lower plate 303. The plurality of passage holes 603a, 603b ensures that the coolant from the isolated cooling channels 402a, 402b gets evacuated via coolant outlet header 305.
[0049] The outlet hole 604 is provided on the separator plate 302 as an exit point of the coolant from the battery cooling module 203. The outlet hole 604 is provided in connection with the coolant outlet header 305 of the lower plate 303.
[0050] The upper plate 301 is securely attached to the upper surface of the separator plate 302 and the lower plate 303 is securely attached to the lower surface of the separator plate 302. The placement of the coolant inlet header 304 with respect to the separator plate 302 is made identical to the placement of the coolant outlet header 305 with respect to the separator plate 302. In other words, the coolant outlet header 305 is placed below the coolant inlet header 304 with separator plate 302 in between the coolant outlet header 305 and the coolant inlet header 304. This optimize the packing volume of the battery cooling module 203.

[0051] Packing volume of the battery cooling module 203 is kept lower than the existing designs. Instead of making the entire battery cooling module thicker, just a small area is kept thicker. In particular, thickness of the battery cooling module 203 in the coolant inlet header 304 region and the coolant outlet header 305 region is more than the thickness of the battery cooling module 203 in any other region. In an aspect, thickness of the battery cooling module 203 in the coolant inlet header 304 region and the coolant outlet header 305 region is maintained under 18 mm. Thickness of the battery cooling module 205 in other regions are maintained under 7 mm.
[0052] FIG. 7 a and 7b illustrates sectional views of the exemplary battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure. FIG. 7a shown sectional view of the battery cooling module 203 from the front end. The coolant introduced in the battery cooling module 203 through the coolant inlet header 304 is further introduced in the extended cooling channel 401e branching from the coolant inlet header 304. FIG. 7b shows section view of the battery cooling module 203 from the rear end. The coolant from the cooling channel 402a of the upper plate 301 is diverted towards the coolant outlet header 305 for evacuation.
WORKING OF THE EXAMPLARY EMBODIMENT
[0053] FIG. 8 illustrates working of the exemplary battery cooling module that can be utilized to implement one or more exemplary embodiments of the present disclosure. To provide better understanding of the working of the battery cooling module, flow of coolant is shown using arrows. In the assembled condition, the plurality of rechargeable battery modules are placed over the battery cooling module 203. For clarity, the plurality of rechargeable battery modules 202 are not shown. The coolant from the coolant reservoir is introduced into the coolant inlet header 304 through the inlet hole 403. Coolant from the coolant inlet header 304 is then introduced into the extended cooling channels 401a, 401b, 401c, 40Id, 40le through their corresponding inlets 401ai, 401bi, 401ci, 401di, 401ei. The coolant flows through the plurality of extended cooling channels 401a, 401b, 401c, 401d,

40le and exit the extended cooling channels 401a, 401b, 401c, 40Id, 40le from the corresponding outlets 401ao, 401bo, 401co, 401 do, 401eo. The coolant from the outlet 401ao, 401bo of the extended cooling channels 401a, 401b are then introduced into the adjacent isolated cooling channels 402a, 402b through the connecting channels 501a, 501b provided on the lower plate 303. The outlets 401ao, 401bo of the extended cooling channels 401a, 401b of the upper plate 301 are connected to one end of the connecting channel 501a, 501b in the lower plate 303 through duct hole 602b, 602c. Similarly, the inlet 402ai, 402bi of the adjacent isolated cooling channels 402a, 402b of the upper plate 301 is connected to other end of the connecting channel 501a, 501b in the lower plate 303 thought duct hole 602a, 602d. The connecting channels 501a, 501b bridge the gap between the outlet 401ao, 401bo of the extended cooling channels 401a, 401b and the inlet 402ai, 402bi of the adjacent isolated cooling channels 402a, 402b. The coolant then flow through the isolated cooling channels 402a, 402b and exit the isolated cooling channels 402a, 402b from their corresponding outlets 402ao, 402bo. The outlets 402ao, 402bo of the isolated cooling channels 402a, 402b in the upper plate 301 are connected to the coolant outlet header 305 in the lower plate 303 through passage holes 603a, 603b. For the plurality of extended cooling channels 401c, 401d, 401e which does not have adjacent isolated cooling channels, the coolant flow through the extended cooling channels 401c, 40Id, 40le and exit the extended cooling channels 401c, 40Id, 40le from their corresponding outlets 401co, 401 do, 401eo. The outlets 401co, 401 do, 401eo of such extended cooling channels of the upper plate are connected to the coolant outlet header 305 of the lower plate 303 though vent holes 601a, 601b, 601c.
[0054] Accordingly, the coolant outlet header 305 receives the coolant from the outlet 402ao, 402bo of the plurality of isolated cooling channels 402a, 402b and the plurality of the extended cooling channels 401c, 40Id, 40le which does not have adjacent isolated cooling channels. The coolant then flow though the coolant outlet header 305 and gets evacuated from the outlet hole 604 provided on the separator plate 302.

ADVANTAGES
[0055] Thus, the proposed vehicle battery pack ensures to efficiently remove the heat dissipated from the plurality of rechargeable battery modules. Further, the vehicle battery pack maintains a good volumetric efficiency as the temperature of the battery cooling module over its entire upper surface is uniformly maintained. This results in good packing efficiency/ volumetric efficiency as plurality of rechargeable battery modules can be stacked all over the battery cooling module. Furthermore, the use of plurality of quick connectors are completely eliminated in the proposed design of the battery cooling module. This results in low risk of leakage of coolant.
[0056] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0057] Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0058] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.

[0059] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.


We Claim:

1. A vehicle battery pack (200), comprising:
a plurality of rechargeable battery modules (202); and
a battery cooling module (203) provided in contact with the plurality of rechargeable battery modules (202), wherein the battery cooling module (203) comprises:
an upper plate (301) in contact with the plurality of rechargeable battery modules (202), wherein the upper plate (301) has a coolant inlet;
a lower plate (303) provided below the upper plate (301), wherein the lower plate (303) has a coolant outlet; and
a separator plate (302) provided in between the upper plate and the lower plate (303) creating a thermal barrier between the upper plate (301) and the lower plate (303) of the battery cooling module (203).
2. The vehicle battery pack (200) as claimed in claim 1, wherein the upper
plate (301) comprises:
a coolant inlet header (304) having an inlet hole (403) for introducing coolant into the battery cooling module (203);
a plurality of extended cooling channels (401a, 401b, 401c, 40Id, 40 le) branching from the coolant inlet header (304), each having an inlet (401ai, 401bi, 401ci, 401di, 401ei) in connection with the coolant inlet header (304) and an outlet (401ao, 401bo, 401co, 401do, 401eo); and
a plurality of isolated cooling channels (402a, 402b), each having an inlet (402ai, 402bi) and an outlet (402ao, 402bo), without any linkage with the coolant inlet header (304).

The vehicle battery pack (200) as claimed in claim 1, wherein the lower plate (303) comprises:
a coolant outlet header (305) for evacuation of coolant from the battery cooling module (203); and
a plurality of connecting channels (501a, 501b) to connect the isolated cooling channels (402a, 402b) with the adjacent extended cooling channels (401a, 401b, 401c, 40Id, 40le).
The vehicle battery pack (200) as claimed in claims 1 to 3, wherein the separator plate (302) comprises:
a plurality of vent holes (601a, 601b, 601c) to create a connection between the outlet (401co, 401 do, 401eo) of the extended cooling channels (401c, 40 Id, 40 le) of the upper plate and the coolant outlet header (305) of the lower plate (303);
a plurality of duct holes (6023a, 602b, 602c, 602d) to create a connection between the outlet (401ao, 401bo) of the extended cooling channels (401a, 401b) of the upper plate (301) and the inlet (402ai, 402bi) of the adjacent isolated cooling channels (402a, 402b) of the upper plate (301);
a plurality of passage holes (603a, 603b) to create a connection between the outlet (402ao, 402bo) of the isolated cooling channels (402a, 402b) of the upper plate (301) and the coolant outlet header (305) of the lower plate (303); and
an outlet hole (604) in connection with the coolant outlet header (305) for evacuation of coolant from the battery cooling module (203).
The battery pack (200) as claimed in claims 1 to 4, wherein the plurality of connecting channels (501a, 501b) of the lower plate (303) facilitates

connection between the outlets (401ao, 401bo) of the plurality of extended cooling channels (401a, 401b) of the upper plate (301) and the inlets (402ai, 402bi) of the corresponding adjacent isolated cooling channels (402a, 402b) of the upper plate (301) using duct holes (602a, 602b, 602c, 602d) of the separation plate (302).
6. The vehicle battery pack (200) as claimed in claim 1, wherein the upper plate (301) is securely attached to upper surface of the separator plate (302) and the lower plate (303) is securely attached to the lower surface of the separator plate (302) in such a manner that the placement of the coolant inlet header (304) with respect to the separator plate (302) is identical to the placement of the coolant outlet header (305) with respect to the separator plate (302).
7. The vehicle battery pack (200) as claimed in claim 1, wherein the upper plate (301) is made of thermally conductive material.
8. The vehicle battery pack (200) as claimed in claim 1, wherein the separator plate (302) and the lower plate (303) are made up of thermally insulating materials.
9. The vehicle battery pack (200) as claimed in claim 1, wherein thickness of the battery cooling module (203) in the coolant inlet header (304) region and the coolant outlet header (305) region is more than the thickness of the battery cooling module (203) in any other region.

10. The vehicle battery pack (200) as claimed in claim 1, wherein the vehicle battery pack (200) further comprises a battery upper cover (201) and a battery lower cover (204) together forming a compartment.