Description:FORM 2
THE PATENTS ACT 1970
39 OF 1970
&
THE PATENT RULES 2003
COMPLETE SPECIFICATION
(SEE SECTIONS 10 & RULE 13)
1. TITLE OF THE INVENTION

“AN ELECTRIC VEHICLE BATTERY COOLING SYSTEM AND A METHOD THEREOF”
2. APPLICANTS (S)
NAME NATIONALITY ADDRESS

MARUTI SUZUKI INDIA LIMITED

Indian
Maruti Suzuki India Limited
1, Nelson Mandela Road, Vasant Kunj,
New Delhi - 110070
India
3. PREAMBLE TO THE DESCRIPTION

COMPLETE SPECIFICATION

The following specification particularly describes the invention and the manner in which it is to be performed.

AN ELECTRIC VEHICLE BATTERY COOLING SYSTEM AND A METHOD THEREOF

TECHNICAL FIELD
[0001] The present disclosure relates to an electric vehicle cooling system and a method thereof. In particular, the present disclosure relates to the electric vehicle battery cooling system operated using principle of either an air cooling or a liquid cooling individually, or a combination of both the air cooling and the liquid cooling in a step wise manner depending on requirement.
BACKGROUND
[0002] There is no denying the fact that electric vehicles are the near future owing to their smart technology, eco-friendliness and zero dependency on expensive fuels. Unlike conventional vehicles, electric vehicles depend on rechargeable batteries for mobility. However, while supplying electric power to the electric motors present in electric vehicles, these batteries eventually get heated and therefore some thermal management system is required to regulate temperature of the batteries. In case there is no proper thermal management system, the batteries may get overheated.
[0003] The effects of overheating include accelerated rate of degradation of state of health (SOH) of batteries, also impacting performance of the electric vehicle in terms of mileage, driveability, etc. Moreover, overheating of the batteries may invite issues like thermal runaway thereby damaging entire battery pack of the electric vehicle and subsequently leading to fatal accidents.
[0004] In an existing arrangement, temperature of batteries of the electric vehicle are regulated following principle of air cooling and liquid cooling. Herein, in operation, the air cooling technique uses air from the outdoor or from the cabin to control temperature of the battery. The air may also be drawn from an air conditioner of the electric vehicle which in turn may reduce temperature of the overheated batteries.
[0005] The principle of liquid cooling, on the other hand, involves usage of suitable cooling agents in order to cool the battery. The liquid goes through modules of the battery pack and transmits heat outside through radiator present in the electric vehicle.
[0006] But a common disadvantage of the above mentioned existing cooling principle is that both the air cooling and liquid cooling methodologies are non-uniform in nature and are not able overcome the issue related to thermal runaway. Moreover, these techniques are not individual battery cell specific and are directed to regulate temperature of the battery pack as a whole, even if some cells maintain the desired temperature. This creates a difference in temperature between cells of the battery pack, eventually damaging overall performance of the electric vehicle.
[0007] Towards this direction, the present disclosure is intended to design and develop a suitable cooling system that is not only able to address the issue of thermal runaway but also can ensure homogenized cooling of the entire battery pack.
OBJECTS OF THE INVENTION
[0008] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0009] It is an object of the present subject matter to overcome the aforementioned and other drawbacks existing in the prior art systems and methods.
[0010] It is a significant object of the present subject matter to develop a cooling system that is capable of providing a regulatory mechanism in order to cool cell of the battery pack of an electric vehicle at an individual level.
[0011] It is another object of the present subject matter to develop the cooling system that is able to facilitate homogenized cooling of cells in the battery pack of the electric vehicle.
[0012] It is another object of the present subject matter to develop the cooling system that is able to address issues of thermal runaway caused otherwise due to overheating of the batteries in the electric vehicle.
[0013] It is another object of the present disclosure to develop the cooling system that is able to enhance mileage of the electric vehicle.
[0014] It is yet another object of the present disclosure to develop the cooling system that is easy to implement and simple to operate.
[0015] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description, taking into consideration the accompanied drawings in which preferred embodiments of the present subject matter are illustrated.

SUMMARY OF THE INVENTION
[0016] This summary is provided to introduce concepts related to an electric vehicle battery cooling system that 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.
[0017] According to an embodiment of the present disclosure, there is provided an electric vehicle battery cooling system and associated methods. In an embodiment, the electric vehicle battery cooling system comprises of an air cooling system, where air vents are controlled by motor and each motorized vent of a plurality of motorized vents are connected to each battery module of the plurality of battery module in one to one manner. Herein, temperature of each battery module of the plurality of battery modules is sensed by a temperature sensing unit and is fetched to the electric vehicle control unit (EVCU), which further instruct the corresponding motorized vent to direct air flow towards heated battery module of the plurality of battery modules. The battery module is said to be heated when temperature of same exceeds from a threshold temperature. The air flow is directed by angular deflection of the corresponding motorized vent from a predefined value. This forced air with directed motorized vents throw the cold air from the cabin of the electric vehicle towards the plurality of battery modules and exits from the other end.
[0018] In another embodiment of the present disclosure, there is provided a liquid cooling system, where each battery module of the plurality of battery modules are cooled separately with their respective cooling circuits. Herein, each battery module of the plurality of battery modules is connected to a two position two-way solenoid servo valve in one to one manner, where solenoid of normally closed servo valve is energized by control voltage by an embedded battery management system controller (EBMSC) when temperature of the corresponding battery module of the plurality of battery module exceeds from a threshold temperature. The temperature is determined by a temperature sensing unit connected to each battery module of the plurality of battery modules. The embedded battery management system controller (EBMSC) de-energizes the solenoid of the servo valve whenever there is no cooling requirement for a particular battery module of the plurality of battery modules. The spring in the solenoid servo valve aids in returning spool land of the servo valve to its closed position thereby closing the valve and enhancing flow cut off to a particular module of the plurality of battery modules.
[0019] In another embodiment, there is provided an electric vehicle cooling system, which is a combination of both air cooling system and liquid system as mentioned above. Herein, the system operates following principle of air cooling when the temperature of each module of the plurality of battery modules exceed from a first predefined threshold value. Further, the system operates following principle of liquid cooling when temperature of each module of the plurality of battery modules exceed from a second predefined threshold value. The principle of cooling operation for both the system remains same as already mentioned.
[0020] In all the embodiments, the electric vehicle cooling system is provided with a compressor control unit, where the compressor control unit is operated to determine rpm of the compressor by receiving inputs from the temperature sensing unit about temperature of each battery module of the plurality of battery modules, determining a range of temperature based on inputs received from the temperature sensing unit and determining rpm of the compressor based on determined range of temperature.
[0021] 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.
[0022] 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 numerals represent like components.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING(S)
[0023] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which
[0024] Figure 1 depicts an exemplary overall system responsible for cooling of an electric vehicle battery in accordance with an exemplary embodiment of the present disclosure;
[0025] Figure 2 depicts the exemplary architectural layout of the system for electric vehicle’s battery cooling accordance with an exemplary embodiment of the present disclosure;
[0026] Figure 3 (a)-(b) depicts an example method of air cooling operation of the electric vehicle battery cooling system in accordance with an exemplary embodiment of the present disclosure;
[0027] Figure 4 (a)-(b) depicts an example method of liquid cooling operation of the electric vehicle battery cooling system in accordance with an exemplary embodiment of the present disclosure; and
[0028] Figure 5 (a)-(b) depicts an example method of combination of air cooling and liquid cooling operation of the electric vehicle battery cooling system in accordance with an embodiment of the present disclosure.
[0029] 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
[0030] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0031] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.
[0032] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.
[0033] The present disclosure relates to an electric vehicle battery cooling system and associated methods to prevent overheating of localized battery module and thermal runaway. The electric vehicle battery cooling system discussed in the present disclosure delineates structural layouts and operation of the system for air cooling, liquid cooling and an integration of both air cooling and liquid cooling depending on temperature of each battery module. The electric vehicle battery cooling system is also enabled with a feature of enhancing range (mileage) of the electric vehicle. The structural attributes of the present system are discussed in the subsequent sections.
[0034] Figure 1 depicts an exemplary overall system (112) responsible for cooling of an electric vehicle battery in accordance with an exemplary embodiment of the present disclosure. An exemplary architectural layout of the system for electric vehicle’s battery cooling is depicted in Figure 2 in accordance with an exemplary embodiment of the present disclosure
[0035] In an embodiment, as can be observed from Figure 1 and Figure 2, an electric vehicle battery cooling system (100) comprises of a plurality of battery modules (102) having an inlet port (C) and an outlet port (D), a temperature sensing unit (106) connected to the plurality of battery modules, a compressor control unit (108) connected to the temperature sensing unit (106).
[0036] In an aspect, the temperature sensing unit (106) is configured to determine temperature of each battery module of the plurality of battery modules (102) and the compressor control unit (108) is operated to change rpm of the compressor based on temperature of the plurality of battery modules (102) determined by the temperature sensing unit (106).
[0037] In an aspect, a plurality of motorized vents (104) is connected across the plurality of battery modules (102) in a one-to-one manner to direct flow of air across each vent of the plurality of motorized vents (104) for air cooling operation of the electric vehicle battery cooling system (100).
[0038] In an aspect, herein each motorized vent of the plurality of motorized vents (104) is operated to undergo an angular deflection from a pre-defined value to direct air flow towards one or more battery module of the plurality of battery modules (102) in case temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106) increases from a threshold value.
[0039] In an aspect, each motorized vent of the plurality of motorized vents (104) is operated to undergo angular deflection from a pre-defined value by an electric vehicle control unit (EVCU) (112-1) upon receiving inputs from the temperature sensing unit (106). The angular deflection of each vent of the plurality of motorized vents (104) is controlled by the electric vehicle control unit (EVCU) (112-1) using PWM/LIN/CAN signals. In this manner, cold air from cabin HVAC system is transferred to the specific battery module of the plurality of battery modules (102) and exits from the other end of the motorized vent.
[0040] In an aspect, each battery module of the plurality of battery modules (102) is cooled by flow of normal blower air in case the cooling requirement is very less. Herein, a blower fan circulates the air for homogenization purpose.
[0041] In an aspect, in the electric vehicle battery cooling system (100), herein the threshold temperature is a normal ambient temperature.
[0042] In an aspect, the electric vehicle battery cooling system (100) operates using the principle of motorized vent based air cooling when range of temperature of one or more battery module of the plurality of battery modules (102) lies between 27 ºC to 35 ºC.
[0043] In another embodiment of the present invention, there is provided an electric vehicle battery cooling system (100), where the electric battery cooling system (100) operates by means of liquid cooling.
[0044] Herein, in an aspect, the electric vehicle cooling system (100) comprises of a plurality of battery modules (100) along with the temperature sensing unit (106) and the compressor control unit (108) as mentioned above. Herein, a plurality of two position-two-way solenoid servo valves (202) are connected across the plurality of battery modules (102) in a one-to-one manner.
[0045] In an aspect, the plurality of two position-two-way solenoid servo valves (202) are having an inlet port (A) and an outlet port (B), respectively. The two-way of the plurality of two position-two-way solenoid servo valves (202) corresponds to two position (open/closed) of a spool land of the servo valve, which is changed based on heating requirement of each battery module of the plurality of battery modules (102).
[0046] In an aspect, solenoid of each two-position two-way solenoid servo valve of the plurality of two-position-two-way solenoid servo valves (104) is operated to be energized and opened by a control voltage in case temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106) exceeds from a threshold value, to allow flow of a coolant to one or more battery module of the plurality of battery modules (102) via corresponding two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202).
[0047] In an aspect, in order to cool one or more battery module of the plurality of battery modules (102), the coolant is forced to flow through a chiller (206) by a pump, where heat from the coolant is absorbed by a refrigerant in the refrigerant circuit thereby chilling the coolant. The chilled coolant flows through one or more battery module of the plurality of battery modules (102) as per cooling requirement.
[0048] In an aspect, each of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202) is further operated to be de-energized and closed in case temperature of one or more battery module of the plurality of battery modules (102) is maintained at the threshold value.
[0049] In an aspect, each two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid valves (202) is provided with a spring to enable return of spool of each two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid valves (202) to closed position in order to de-energize the solenoid during an event of coolant flow cut off to one or more battery module of the plurality of battery modules (102).
[0050] In an aspect, in the electric vehicle battery cooling system (100), the coolant enters from the inlet port (A) of each of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202) to the inlet port (C) of one or more battery module of the plurality of battery modules (102) via the outlet port (B) and exits into a tank line through a non-return valve (204) via the outlet port (D) of one or more battery module of the plurality of battery modules (102). The non-return valve (204) is used to prevent back flow of heated coolant exiting from one or more battery modules to outlet of other modules or from the coolant tank under any situation.
[0051] In an aspect, each two-position two-way solenoid servo valves of the plurality of two-position-two-way solenoid valves (202) is energized or de-energized by the embedded battery management system controller (EBMSC) on receiving instructions from an electric vehicle control unit (EVCU) (112-1) based on temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106). The embedded battery management system controller (EBMSC) is installed inside the electric vehicle control unit (EVCU) (112-1).
[0052] In an aspect, the electric vehicle battery cooling system (100) operates for liquid cooling when range of temperature of each battery module of the plurality of battery modules lies between 36 ºC to 45ºC subject to environmental conditions.
[0053] In yet another embodiment of the present disclosure, there is provided an electric vehicle battery cooling system (100) operated using principle of both air cooling and liquid cooling in a step wise manner.
[0054] In an aspect, the electric vehicle battery cooling system (100) comprises the plurality of battery modules (102), where each battery module of the plurality of battery modules is having an inlet port (C) and an outlet port (D), a plurality of motorized vents connected across the plurality of battery modules (102) in a one-to-one manner, a plurality of two position-two-way solenoid servo valves having an inlet port (A) and an outlet port (B), where the plurality of two position-two-way solenoid servo valves are connected across the plurality of battery modules (102) in a one-to-one manner via the outlet port (B).
[0055] In an aspect, the electric vehicle battery cooling system (100) also comprises of a temperature sensing unit (106) and a compressor control unit (108). The temperature sensing unit (106) is having similar functions as discussed above.
[0056] In an aspect, each motorized vent of the plurality of motorized vents (104) is operated to undergo an angular deflection from a pre-defined value to direct air flow towards one or more battery module of the plurality of battery modules (102) in case temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106) exceed from a first threshold value.
[0057] In an aspect, each two-position two-way solenoid servo valve of the plurality of two-position-two-way solenoid servo valves (202) is operated to be energized and opened by a control voltage in case temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106) exceeds from a second threshold value, to allow flow of chilled coolant to one or more battery module of the plurality of battery modules (102) via corresponding two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202).
[0058] In an aspect, as mentioned before, each of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202) is operated to be de-energized and closed similarly in case temperature of one or more battery module of the plurality of battery modules (102) is maintained at the second threshold value.
[0059] In an aspect, as mentioned before, the energization and de-energization signals are sent by the embedded battery management controller installed inside the electric vehicle control unit (EVCU) (112-1).
[0060] In an aspect, in the electric vehicle battery cooling system (100), the first threshold value ranges between 27 ºC to 35 ºC and the second threshold value ranges between 36 ºC to 45 ºC.
[0061] In an aspect, in all of the cooling operations viz., air cooling, liquid cooling and combination cooling, there is also provided a compressor control unit (108) connected to the temperature sensing unit (106), where the compressor control unit (108) is operated to change rpm of the compressor based on temperature of the plurality of battery modules (102) as determined by the temperature sensing unit (106).
[0062] In an aspect, the compressor control unit (108) is operated to change rpm of a compressor (110) based on a range of temperature of the plurality of battery modules (102) on receiving inputs from the temperature sensing unit (106).
[0063] In an aspect, the temperature sensing unit (106) may include a thermal sensor, a thermocouple, an infra-red sensor or a thermal imager.
[0064] In an aspect, the engine control unit (ECU) (112-1) may be equipped with processing devices(s). The processing device(s) may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, logic circuitries, and/or any devices that manipulate data based on operational instructions received from the temperature sensing unit (106) present in the system (100). Among other capabilities, the one or more processor(s) present in the engine control unit (ECU) are configured to fetch and execute computer-readable instructions stored in the memory of the system (100). The memory may store one or more computer-readable instructions or routines, which may be fetched and executed to create or share the data units over a network service. The memory may include any non-transitory storage device including, for example, volatile memory such as RAM, or non-volatile memory such as EPROM, flash memory, and the like.
[0065] Figure 3 (a)-(b) depicts an example method of air cooling operation of the electric vehicle battery cooling system (100) in accordance with an exemplary embodiment of the present disclosure. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the methods, or an alternative method.
[0066] At block (302), the method includes receiving input by the temperature sensing unit (106) from one or more battery module of the plurality of battery modules (102).
[0067] At block (304), the method includes fetching temperature of the plurality of battery modules (102) by the temperature sensing unit (106) to an electric vehicle control unit (EVCU) (112-1).
[0068] At block (306), the method includes determining angular deflection of each motorized vent of the plurality of motorized vents (104) from a pre-defined value by the electric vehicle control unit (EVCU) (112-1) based on temperature of the plurality of battery modules (102) as received from the temperature sensing unit (106).
[0069] At block (308), the method includes allowing entry of cold air through angularly deflected motorized vent of the plurality of motorized vents (104) from the cabin to one or more battery module of the plurality of battery modules (102) in case temperature of one or more battery module exceeds a threshold value.
[0070] Referring to Figure 3 (b), at block (402), the method includes simultaneous operation of the compressor control unit (108) to determine rpm of the compressor (110) by receiving inputs from the temperature sensing unit (106) about temperature of one or more battery module of the plurality of battery modules (102).
[0071] At block (404), the method includes determining a range of temperature based on inputs received from the temperature sensing unit (106).
[0072] At block (406), the method includes determining rpm of the compressor (110) based on determined range of temperature. Herein the compressor control unit (108) receives change in range of temperature of each battery module of the plurality of battery modules (102), and change rpm of the compressor (110) by comparing the change in temperature with the pre-fetched temperature ranges. The rpm of the compressor (110) is always changed in accordance to maximum temperature range of each battery module of the plurality of battery modules (102).
[0073] Figure 4 (a)-(b) depicts an example method of liquid cooling operation of the electric vehicle battery cooling system (100) in accordance with an exemplary embodiment of the present disclosure. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the methods, or an alternative method.
[0074] At block (502), the method includes receiving input by a temperature sensing unit (106) of the plurality of battery modules (102).
[0075] At block (504), the method includes fetching temperature of the plurality of battery modules (102) by the temperature sensing unit (106) to the electric vehicle control unit (EVCU) (112-1).
[0076] At block (506), the method includes energizing corresponding two-position two-way solenoid servo valve of the plurality of two-position two-way servo valves (202) by a control voltage in case temperature of one or more battery module of the plurality of battery modules (102) is greater than a threshold value, allowing flow of chilled coolant from an inlet port (A) of two-position two-way solenoid valve of the plurality of two-position two-way solenoid valves to an inlet port (C) of the corresponding battery module of the plurality of battery modules (102) via an outlet port (B) of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202).
[0077] At block (508), the method includes allowing exit of coolant from an outlet port (D) of each battery module of the plurality of battery modules (102) into a tank line via a non-return valve (204).
[0078] In an aspect, herein the method includes enabling return of spool of each two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid valves (202) to closed position during an event of coolant flow cut off to one or more battery module of the plurality of battery modules (102).
[0079] In an aspect, referring to Figure 4 (b), the method includes simultaneous operation by a compressor control unit to determine rpm of a compressor and the blocks (602), (604) and (606) perform similar operation as discussed with respect to block (402), (404) and (406), respectively.
[0080] Figure 5 (a)-(b) depicts an example method of step wise air cooling and liquid cooling operation of the electric vehicle battery cooling system (100) in accordance with an exemplary embodiment of the present disclosure. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the methods, or an alternative method.
[0081] At block (702), the method includes receiving input by a temperature sensing unit (106) of the plurality of battery modules (102).
[0082] At block (704), the method includes fetching temperature of the plurality of battery modules (102) by the temperature sensing unit (106) to the electric vehicle control unit (EVCU) (112-1).
[0083] At block (706), the electric vehicle control unit (EVCU) (112-1) is configured to determine angular deflection of each motorized vent of the plurality of motorized vents (104) from a pre-defined value when temperature of one or more battery module of the plurality of battery module exceeds from a first threshold value,
[0084] At block (708), the method includes configuring of the electric vehicle control unit (EVCU) (112-1) to allow entry of cold air through angularly deflected motorized vent of the plurality of motorized vents (104) from the cabin to one or more battery module of the plurality of battery modules (102) in case temperature of one or more battery module exceeds the first threshold value.
[0085] At block (710), the method includes configuring of the electric vehicle control unit (EVCU) (112-1) to alternatively energize corresponding two-position two-way solenoid servo valve of the plurality of two-position two-way servo valves (202) by a control voltage in case temperature of one or more battery module of the plurality of battery modules (102) is greater than a second threshold value.
[0086] At block (712), the method includes configuring of the electric vehicle control unit (EVCU) (112-1) to allow flow of coolant from an inlet port (A) of two-position two-way solenoid valve of the plurality of two-position two-way solenoid valves (202) to an inlet port (C) of the corresponding battery module of the plurality of battery modules (102) via an outlet port (B) of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202).
[0087] At block (712), the method includes configuring of the electric vehicle control unit (EVCU) (112-1) to allow exit of coolant from an outlet port (D) of each battery module of the plurality of battery modules (102) into a tank line via a non-return valve (204) when temperature of each battery module of the plurality of battery modules (102) reaches the second threshold value. Herein, the method includes enabling return of spool of each two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid valves to closed position during an event of coolant flow cut off to one or more battery module of the plurality of battery modules (102).
[0088] In an aspect, as can be observed from Figure 5 (b), the method includes simultaneous operation by a compressor control unit (108) to determine rpm of a compressor and the blocks (802), (804) and (806) perform similar operation as discussed with respect to block (402), (404) and (406), respectively.
[0089] For an example, say if a first threshold temperature is t1 and a second threshold temperature is t2, the proposed electric vehicle battery cooling system (100) cools one or more battery module of the plurality of battery modules (102) following an operation of air cooling when temperature of one or more battery module of the plurality of battery modules (102) is greater than t1 but less than t2.
[0090] Alternatively, if temperature of one or more battery module of the plurality of battery modules (102) exceeds beyond t2, the proposed electric vehicle battery cooling system (100) cools one or more battery module of the plurality of battery modules (102) following an operation of liquid cooling. The temperature is determined by the temperature sensing unit (106) and the corresponding cooling instructions are provided by the electric vehicle control unit (EVCU) (112-1) on receiving inputs from the temperature sensing unit (106).
[0091] Therefore, in this manner step wise cooling is facilitated as per requirement which also lessens power requirement of the electric vehicle battery cooling system (100) as well.
[0092] Technical Advantages
All in all, the invention described in the present disclosure is having the following advantages:
a) The present system (100) helps in homogenization of temperature of the plurality of battery modules (102) of the electric vehicle
b) The present system (100) helps in level wise cooling of the plurality of battery modules (102) of the electric vehicle by enabling a suitable cooling system
c) The present system (100) ensures better battery life of the electric vehicle in comparison to the existing arrangements
d) The present system (100) helps to enhance range (mileage) of the electric vehicle by enabling the compressor to function as per requirement
e) The present system (100) is easy to implement and is simple to operate
f) The present system (100) consumes less power compared to the existing arrangements

[0093] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various systems that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
[0094] Although embodiments for the present subject matter have been described in language specific to package features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/device of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter.
[0095] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0096] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.

, Claims:We Claim:
1. An electric vehicle battery cooling system (100), comprising:
- a plurality of battery modules (102);
- a plurality of motorized vents (104) connected across the plurality of battery modules (102) in a one-to-one manner;
- a temperature sensing unit (106) connected to the plurality of battery modules (102), wherein the temperature sensing unit (106) is configured to determine temperature of the plurality of battery modules (102),
- wherein each motorized vent of the plurality of motorized vents (104) is operated to undergo an angular deflection from a pre-defined value by an electric vehicle control unit (EVCU) to direct air flow towards one or more battery module of the plurality of battery modules (102) in case temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106) exceeds from a threshold value; and
- a compressor control unit (108) connected to the temperature sensing unit (106), wherein the compressor control unit (108) is operated to change rpm of the compressor based on temperature of the plurality of battery modules (102) determined by the temperature sensing unit (106).

2. The electric vehicle battery cooling system (100) as claimed in claim 1, wherein the electric vehicle battery cooling system (100) operates when range of temperature of one or more battery module of the plurality of battery modules (102) lies between 27 ºC to 35 ºC.

3. A method of operating an electric vehicle battery cooling system (100), the method comprising:
- receiving (302) input by a temperature sensing unit (106) from one or more battery module of the plurality of battery modules (102);
- fetching (304) temperature of the plurality of battery modules (102) by the temperature sensing unit (106) to an electric vehicle control unit (EVCU);
- determining angular deflection of each motorized vent of the plurality of motorized vents (104) from a pre-defined value by the electric vehicle control unit (EVCU) based on temperature of the plurality of battery modules (102) as received from the temperature sensing unit (106); and
- allowing entry of cold air through angularly deflected motorized vent of the plurality of motorized vents (104) from the cabin to one or more battery module of the plurality of battery modules (102) in case temperature of one or more battery module exceeds a threshold value.

4. An electric vehicle battery cooling system (100), comprising:
- a plurality of battery modules (102), wherein each battery module of the plurality of battery modules (102) is having an inlet port (C) and an outlet port (D);
- a plurality of two position-two-way solenoid servo valves (202) connected across the plurality of battery modules (102) in a one-to-one manner, wherein the plurality of two position-two-way solenoid servo valves (202) are having an inlet port (A) and an outlet port (B), respectively;
- a temperature sensing unit (106) connected to the plurality of battery modules (102), wherein the temperature sensing unit (106) is configured to determine temperature of each battery module of the plurality of battery modules (102),
- wherein each two-position two-way solenoid servo valve of the plurality of two-position-two-way solenoid servo valves (202) is operated to be energized and opened by a control voltage in case temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106), exceeds from a threshold value, to allow flow of chilled coolant to one or more battery module of the plurality of battery modules (102) via corresponding two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202),
- and wherein each of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202) is operated to be de-energized and closed in case temperature of one or more battery module of the plurality of battery modules (102) is maintained at the threshold value; and
- a compressor control unit (108) connected to the temperature sensing unit (106), wherein the compressor control unit (108) is operated to change rpm of the compressor based on temperature of the plurality of battery modules (102) as determined by the temperature sensing unit (106).

5. The electric vehicle battery cooling system (100) as claimed in claim 4, wherein the electric vehicle battery cooling system (100) operates when range of temperature of each battery module of the plurality of battery modules (102) lies between 27 ºC to 35 ºC.

6. A method of operating an electric vehicle battery cooling system (100), the method comprising:
- receiving (502) input by a temperature sensing unit (106) of a plurality of battery modules (102);
- fetching (504) temperature of the plurality of battery modules (102) by the temperature sensing unit (106) to an electric vehicle control unit (EVCU);
- energizing (506) corresponding two-position two-way solenoid servo valve of a plurality of two-position two-way servo valves (202) by a control voltage in case temperature of one or more battery module of the plurality of battery modules (102) is greater than a threshold value of ambient temperature;
- allowing flow (508) of coolant from an inlet port (A) of two-position two-way solenoid valve of the plurality of two-position two-way solenoid valves (202) to an inlet port (C) of the corresponding battery module of the plurality of battery modules (102) via an outlet port (B) of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202); and
- allowing exit (510) of coolant from an outlet port (D) of each battery module of the plurality of battery modules (102) into a tank line via a non-return valve (204).

7. An electric vehicle battery cooling system (100), comprising:
a plurality of battery modules (102), wherein each battery module of the plurality of battery modules (102) is having an inlet port (C) and an outlet port (D);
a plurality of motorized vents (104) connected across the plurality of battery modules (102) in a one-to-one manner;
a plurality of two position-two-way solenoid servo valves (202) having an inlet port (A) and an outlet port (B), wherein the plurality of two position-two-way solenoid servo valves (202) are connected across the plurality of battery modules (102) in a one-to-one manner via the outlet port (B);
a temperature sensing unit (106) connected to the plurality of battery modules (102), wherein the temperature sensing unit (106) is configured to determine temperature of the plurality of battery modules (102),
wherein each motorized vent of the plurality of motorized vents (104) is operated to undergo an angular deflection by an electric vehicle control unit (EVCU) from a pre-defined value by to direct air flow towards one or more battery module of the plurality of battery modules (102) in case temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106) exceeds from a first threshold value,
wherein each two-position two-way solenoid servo valve of the plurality of two-position-two-way solenoid servo valves (202) is operated to be energized and opened by a control voltage in case temperature of one or more battery module of the plurality of battery modules (102) as determined by the temperature sensing unit (106) exceeds from a second threshold value, to allow flow of a coolant to one or more battery module of the plurality of battery modules (102) via corresponding two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202),
and wherein each of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202) is operated to be de-energized and closed in case temperature of one or more battery module of the plurality of battery modules is maintained at the second threshold value; and
a compressor control unit (108) connected to the temperature sensing unit (106), wherein the compressor control unit (108) is operated to change rpm of the compressor based on temperature of the plurality of battery modules (102) determined by the temperature sensing unit (106).

8. The electric vehicle battery cooling system (100) as claimed in claim 1, 4 and 7, wherein the threshold temperature is a normal ambient temperature.

9. The electric vehicle battery cooling system (100) as claimed in claim 7, wherein the first threshold value ranges between 27 ºC to 35 ºC and the second threshold value ranges between 36 ºC to 45 ºC.

10. The electric vehicle battery cooling system (100) as claimed in claim 1, 4 and 7, wherein the temperature sensing unit (106) includes a thermal sensor, a thermocouple, an infra-red sensor or a thermal imager.

11. The electric vehicle battery cooling system (100) as claimed in claim 4 and 7, wherein each two-position two-way solenoid servo valves of the plurality of two-position-two-way solenoid valves (202) is energized or de-energized by an embedded battery management system controller (EBMSC) on receiving instructions from the electric vehicle control unit (EVCU) when temperature of one or battery module of the plurality of battery modules (102) exceed the second threshold value.

12. A method of operating an electric vehicle cooling system (100), the method comprising:
- receiving (702) input by a temperature sensing unit (106) of the plurality of battery modules (102); and
- fetching (704) temperature of the plurality of battery modules (102) by the temperature sensing unit (106) to an electric vehicle control unit (EVCU), wherein the electric vehicle control unit (EVCU) is configured to:
determine angular deflection of each motorized vent of the plurality of motorized vents (104) from a pre-defined value when temperature of one or more battery module of the plurality of battery module (102) exceeds from a first threshold value,
allowing entry of cold air through angularly deflected motorized vent of the plurality of motorized vents (104) from the cabin to one or more battery module of the plurality of battery modules (102) in case temperature of one or more battery module exceeds the first threshold value,
alternatively energizing (506) corresponding two-position two-way solenoid servo valve of the plurality of two-position two-way servo valves (202) by a control voltage in case temperature of one or more battery module of the plurality of battery modules (102) is greater than a second threshold value,
alternatively allowing flow (508) of coolant from an inlet port (A) of two-position two-way solenoid valve of the plurality of two-position two-way solenoid valves (202) to an inlet port (C) of the corresponding battery module of the plurality of battery modules (102) via an outlet port (B) of two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid servo valves (202),
allowing exit (510) of coolant from an outlet port (D) of each battery module of the plurality of battery modules (102) into a tank line via a non-return valve (204) when temperature of each battery module of the plurality of battery modules (102) reaches the second threshold value.

13. The method as claimed in claim 6 and 12, wherein the method includes enabling return of spool of each two-position two-way solenoid servo valve of the plurality of two-position two-way solenoid valves (202) to closed position during an event of coolant flow cut off to one or more battery module of the plurality of battery modules (102).

14. The method as claimed in claim 3, 6 and 12, wherein simultaneously a compressor control unit (108) is operated to determine rpm of a compressor by:
- receiving (402), (602), (702) inputs from the temperature sensing unit (106) about temperature of each battery module of the plurality of battery modules (102);
- determining (404), (604), (704) a range of temperature based on inputs received from the temperature sensing unit (106); and
- determining (406), (606), (706) rpm of the compressor based on determined range of temperature.

15. The method as claimed in claim 12, wherein the first threshold temperature 27 ºC to 35 ºC and the second threshold temperature ranges from 36 ºC to 45 ºC and respectively.
Dated this 28th day of March, 2023

AMIT JAIN
PATENT AGENT
IN/PA – 2189
OF L. S. DAVAR & CO.