Description:TECHNICAL FIELD
[0001] The present disclosure relates to the technical field of thermal management system for battery packs. In particular, the present disclosure pertains to an improved battery pack with integrated plurality of fans for maintaining temperature uniformity inside the battery pack.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Designing an effective cooling system for a battery pack is crucial for ensuring optimal performance, safety, and longevity of the batteries. A well-designed cooling system helps manage heat generated by the battery cells, prevents overheating, and maintains the battery within its ideal operating temperature range.
[0004] Existing technologies in the field of battery cooling are active refrigerant air-based cooling, direct expansion based liquid cooling, water ethylene glycol based secondary liquid cooling, immersion cooling, Peltier cooling and phase change material-based cooling. The refrigerant based active air cooling has a limitation in terms of heat transfer rate and unequal cooling of cell modules of the battery. An active liquid cooling system is another type of thermal management system, which is further classified as Direct Expansion (DX) Liquid cooling system, and Secondary Liquid Cooling (SLC) system. Most of the automobile application involves the use of the SLC system, where the refrigerant is a primary coolant, and water-ethylene glycol is a secondary coolant which flows through coolant pipes to remove heat from the battery pack. However, there are certain limitations associated with the SLC system such as increase in weight of the overall system as it requires a permanent stationing of the secondary coolant storage tank and also use of additional heat exchangers for heat transfer between the refrigerant and water-ethylene glycol mixture. Since, three-wheeler vehicles have a very limited volume available for the battery pack integration and placement. Thus, bulky nature of the SLC system acts as a major hindrance. Other cooling technologies involve the use of Phase Change Material (PCM) and the Peltier. The phase change material cooling is a passive cooling system because the heat absorbed by the PCM needs to be eventually removed. This heat removal is done by using air cooling and liquid cooling methods. The PCM has a viable cooling strategy and is limited for stationary storage application, where the heat generation rate is low. The Peltier is also a promising option for compact cooling, however due to extremely low coefficient of performance, high price, and brittle nature makes the Peltier unsuitable for automobile application.
[0005] Therefore, it would be advantageous to have an improved cooling system for the battery pack for effective heat-dissipation and maintain temperature uniformity across cells of the battery pack with enhanced usable cycle life of the battery pack.
[0006] There is, therefore, a need to overcome the above-mentioned drawbacks, shortcomings, and limitations associated with the existing cooling systems by providing a simple, versatile and improved a battery pack with integrated plurality of fans, which facilitate effective heat dissipation and maintaining temperature uniformity across battery cells of the battery pack.

OBJECTIVESS OF THE INVENTION
[0007] A general objective of the present disclosure is to provide a battery pack with integrated plurality of fans for maintaining temperature uniformity inside the battery pack, which overcomes above-mentioned limitations of the existing thermal management systems for battery packs.
[0008] An objective of the present disclosure is to provide an enhanced layout design of the battery pack that can facilitate effective heat dissipation and maintain thermal uniformity across battery cells of the battery pack.
[0009] Another objective of the present disclosure is to provide an improved battery pack that can ensure minimum pressure losses during airflow.
[0010] Yet another objective of the present disclosure is to provide an optimized design of the battery pack which can enhance usage cycle life of the battery pack.
[0011] Yet another objective of the present disclosure is to provide a design of components of the battery pack to enable increase in overall effective area for heat transfer with a coolant.

SUMMARY
[0012] Aspects of the present disclosure relate generally to the technical field of thermal management systems for battery packs. In particular, the present disclosure pertains to a battery pack with integrated plurality of fans for maintaining temperature uniformity inside the battery pack.
[0013] According to an aspect, the present disclosure pertains to an improved battery pack for a vehicle. The battery pack comprises a casing. Further, the battery pack comprises a plurality of cell modules arranged within the casing. Each of the plurality of cell modules comprises a plurality of battery cells. Furthermore, the battery pack comprises a plurality of cooling passages configured between each of the plurality of cell modules to define a pathway for coolant flow. Moreover, the battery pack comprises a reservoir coupled to the casing. The reservoir is configured to store a coolant received from a thermal management unit associated with the vehicle.
[0014] In addition, the reservoir comprises a plurality of fans configured corresponding to the plurality of cooling passages, The plurality of fans direct flow of the coolant towards the plurality of cooling passages to uniformly circulate the coolant within the battery pack and for maintaining temperature uniformity within the plurality of cell modules associated with the battery pack.
[0015] In an aspect, the reservoir may comprise a plurality of inlet ports configured at a first opposite plate and/or at a second opposite plate of the reservoir. The plurality of inlet ports may be configured to receive the coolant from an evaporator of the thermal management unit.
[0016] In an aspect, the coolant flowing across the plurality of cooling passages may absorb heat from surfaces of each of the plurality of cell modules coming in contact with the coolant, for effective heat dissipation and maintaining temperature uniformity within the battery pack.
[0017] In an aspect, a plurality of outlet ports may be disposed at a first side surface and/ or a second side surface of the casing. The plurality of outlet ports may be configured to extract the coolant with absorbed heat from the battery pack and may recirculate the coolant with absorbed heat to the evaporator of the thermal management unit.
[0018] In an aspect, the plurality of cooling passages may include a plurality of first tubular spacers configured along each of the cell modules, in a direction perpendicular to a central axis of the plurality of fans.
[0019] In an aspect, the plurality of cooling passages may comprise a plurality of second tubular spacers configured between adjacent battery cells of each of the cell modules, along a direction of the central axis of the plurality of fans, to enhance effective area for heat transfer with the coolant.
[0020] In an aspect, a shape of each of the plurality of first and second spacers may be selected from a group consisting of: rectangular tubular spacers, or circular tubular spacers.
[0021] In an aspect, the plurality of first and second tubular spacers (108) may be made of material selected from a group consisting of: copper, aluminium, stainless steel, polymer composites, and titanium.
[0022] In an aspect, the battery pack may comprise a control unit. The control unit may comprise a processor which may be configured to receive, from one or more sensors, provided in the casing. The processor may be configured to a current temperature of the plurality of cell modules. The control unit may be configured to operate the thermal management unit to enable a suitable flow of the coolant from the plurality of inlet ports to the reservoir. Further, the control unit may actuate the plurality of fans to direct the flow of the coolant through the plurality of cooling passages to facilitate uniform circulate the coolant within the battery pack and maintain temperature uniformity within the plurality of cell modules.
[0023] In an aspect, the coolant circulated through the plurality of cooling passages may comprise air or a liquid coolant selected from water, ethylene glycol, propylene glycol, or a mixture thereof.
[0024] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0026] FIG. 1A illustrates an exploded view of an exemplary battery pack with integrated plurality of fans, in accordance with an embodiment of the present disclosure.
[0027] FIG. 1B illustrates an exemplary top view of the battery pack of FIG.1A, in accordance to an embodiment of the present disclosure.
[0028] FIG. 1C illustrates an exemplary top view of the battery pack of FIG.1 A showing flow of coolant, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0029] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such details as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0030] Embodiments explained herein relate to the technical field of thermal management system for battery packs. In particular, the present disclosure pertains to an improved battery pack with integrated plurality of fans for maintaining temperature uniformity inside the battery pack.
[0031] Existing technologies in the field of battery cooling have certain limitations such as low heat transfer rate, high pressure losses during airflow, and high temperature non-uniformity across cell modules.
[0032] The proposed battery pack overcomes the abovementioned problems associated with the existing technologies by design optimization of a plurality of air ports, layout of the plurality of cooling passages inside the battery pack as well as placement and positioning of a plurality of fans inside the battery pack.
[0033] In an aspect, the present disclosure relates to an improved battery pack for a vehicle. The battery pack comprises a casing. Further, the battery pack comprises a plurality of cell modules arranged within the casing. Each of the plurality of cell modules comprises a plurality of battery cells. Furthermore, the battery pack comprises a plurality of cooling passages configured between each of the plurality of cell modules to define a pathway for coolant flow. Moreover, the battery pack comprises a reservoir coupled to the casing. The reservoir is configured to store a coolant received from a thermal management unit associated with the vehicle.
[0034] In addition, the reservoir comprises a plurality of fans configured corresponding to the plurality of cooling passages, The plurality of fans direct flow of the coolant towards the plurality of cooling passages to uniformly circulate the coolant within the battery pack and, for maintaining temperature uniformity within the plurality of cell modules associated with the battery pack.
[0035] Referring to FIGs. 1A to 1C, the proposed battery pack 100 for a vehicle is disclosed. The vehicle can include but not limited to an electric vehicle, a hybrid electric vehicle, and a plug-in hybrid electric vehicle. The vehicle can be selected from but not limited to two-wheeler vehicle, three wheeler vehicle, four wheeler vehicles, and the like. The battery pack 100 includes a casing 102 configured to accommodate one or more components of the battery pack 100. The one or more components can include but not limited to protection circuitry such as fuses, circuit breakers, and the like, structural components such as brackets, mounts and frames, without limitations. Further, the battery pack 100 includes a plurality of cell modules 104-1, 104-2, 104-3, 104-4 (collectively referred herein as 104) arranged within the casing 102. Each of the plurality of cell modules 104 includes a plurality of battery cells 106-1, 106-2, 106-3,…106-16 (collectively referred herein as 106). Furthermore, the battery pack 100 includes a plurality of cooling passages 108-1, 108-2, 108-3, 108-4….108-20 (collectively referred herein as 108) configured between each of the plurality of cell modules 104 to define a pathway for coolant flow. Moreover, the battery pack 100 includes a reservoir 110 coupled to the casing 102. The reservoir 110 is configured to store a coolant received from a thermal management unit associated with the vehicle. The reservoir 110 includes a plurality of fans 112-1, 112-2, 112-3 (collectively referred herein as 112) configured corresponding to the plurality of cooling passages 108. The plurality of fans 112 direct flow of the coolant towards the plurality of cooling passages 108 to uniformly circulate the coolant within the battery pack 100 and for maintaining temperature uniformity within the plurality of cell modules 104. The fans 112 can improve cooling efficiency by increasing airflow rates, thereby enhancing heat transfer away from the battery cells 106.
[0036] In an embodiment, the battery pack 100 includes a plurality of cooling passages 108 configured between each of the plurality of cell modules 104 to define a pathway for coolant flow. The plurality of cooling passages 108 can include a plurality of first tubular spacers configured along each of the cell modules 104, in a direction perpendicular to a central axis of the plurality of fans 112. Further, the plurality of cooling passages 108 can include a plurality of second tubular spacers configured between adjacent battery cells 106 of each of the cell modules 104, along a direction of the central axis of the plurality of fans 112, to enhance effective area for heat transfer with the coolant. The coolant flowing across the plurality of cooling passages 108 can absorb heat from surfaces of each of the plurality of cell modules 104 coming in contact with the coolant for effective heat dissipation and maintaining temperature uniformity within the battery pack 100.
[0037] In an embodiment, a shape of each of the plurality of first and second spacers is selected from but not limited to a group consisting of: rectangular tubular spacers, or circular tubular spacers. The plurality of first and second tubular spacers can be made of material selected from but not limited to a group consisting of: copper, aluminium, stainless steel, polymer composites, and titanium.
[0038] In an embodiment, the reservoir 110 can include a plurality of inlet ports 114-1, 114-2, 114-3, 114-4 (collectively referred herein as 114) configured at a first opposite plate 110-1 and/or at a second opposite plate 110-2 of the reservoir 110, to receive the coolant from an evaporator of the thermal management unit. The plurality of inlet ports 114 can have a cross-sectional shape selected from but not limited to circular, square, ellipse, triangle, and the like. Most preferably, the cross-sectional shape of each of the plurality of inlet ports 114 can be circular.
[0039] In an embodiment, the battery pack 100 can include a plurality of outlet ports 116-1, 116-2, 116-3 (collectively referred herein as 116) disposed at a first side surface 102-1 and/ or a second side surface 102-2 of the casing 102. The plurality of outlet ports 116 can be configured to extract the coolant with absorbed heat from the battery pack 100 and recirculate the coolant with absorbed heat to the evaporator of the thermal management unit. The plurality of outlet ports 116 can have a cross-sectional shape selected from but not limited to circular, square, ellipse, triangle, and the like. Most preferably, the cross-sectional shape of each of the plurality of outlet ports 116 can be circular.
[0040] In an embodiment, the battery pack 100 can include a control unit (not shown). The control unit can include a processor which can be configured to receive, from one or more sensors (not shown), provided in the casing 102. The processor can be configured to a current temperature of the plurality of cell modules 104. The control unit can be configured to operate the thermal management unit to enable a suitable flow of the coolant from the plurality of inlet ports 114 to the reservoir 110. Further, the control unit can actuate the plurality of fans 112 to direct the flow of the coolant through the plurality of cooling passages 108 to facilitate uniform circulate the coolant within the battery pack 100 and maintain temperature uniformity within the plurality of cell modules 104.
[0041] Furthermore, the one or more sensors can be selected from but not limited to thermocouples, resistance temperature detectors (RTDs), thermistors, Infrared (IR) sensors, Integrated circuit (IC) temperature sensors, and fibre optic sensors. The one or more sensors can be strategically placed within the casing 102 of the battery pack 100 to ensure accurate readings of the temperature of the plurality of battery cells 106.
[0042] In an embodiment, the control unit may comprise one or more processor(s) (interchangeably referred to as processor, hereinafter), a memory and one or more interface(s). The one or more processors may be implemented as one or more microprocessors, microcomputers, microcontrollers, edge or fog microcontrollers, digital signal processors, central processing units, logic circuitries, and/or any devices that process data, based on operational instructions. Among other capabilities, the processor) may be configured to fetch and execute computer-readable instructions stored in a memory of the control unit. The memory may be configured to store one or more computer-readable instructions or routines in a non-transitory computer readable storage medium, which may be fetched and executed to collect a plurality of data associated with temperature of the plurality of battery cells 106 from the one or more sensors. The memory may comprise any non-transitory storage device including, for example, volatile memory such as Random Access Memory (RAM), or non-volatile memory such as Erasable Programmable Read-Only Memory (EPROM), flash memory, and the like.
[0043] In an embodiment, the control unit may also include the one or more interface(s). The interface(s) may include a variety of interfaces, for example, interfaces for data input and output devices referred to as I/O devices, storage devices, and the like. The interface(s) may facilitate communication of the control unit with various components coupled to the control unit. In an embodiment, the control unit may feature a user interface for local interaction. The user interface can include status indicators (LEDs), switches, or a display to provide feedback on battery pack 100 status and allow for manual control or configuration adjustments.
[0044] As can be seen, the proposed solution overcomes the problems associated with the refrigerant based air-cooling systems such as low heat transfer rate, high pressure losses during airflow, and high temperature non-uniformity across cell modules 104, by providing design optimization of a plurality of ports, layout of the plurality of cooling passages 108 inside the battery pack 100 as well as placement and positioning of a plurality of fans 112 inside the battery pack 100.
[0045] It is to be appreciated by a person skilled in the art that while various embodiments of the present disclosure have been elaborated for the disclosed battery pack 100. However, the teachings of the present disclosure are also applicable for other types of applications as well, and all such embodiments are well within the scope of the present disclosure. However, the improved battery pack 100 with integrated plurality of fans 112 is also equally implementable in other industries as well, and all such embodiments are well within the scope of the present disclosure without any limitation.
[0046] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0047] The present invention provides a battery pack with integrated plurality of fans for maintaining temperature uniformity inside the battery pack.
[0048] The present invention provides an enhanced layout design of the battery pack that facilitates effective heat dissipation and maintain thermal uniformity across battery cells of the battery pack.
[0049] The present invention provides an improved battery pack that can ensure minimum pressure losses during airflow.
[0050] The present invention provides an optimized design of the battery pack which can enhance usage cycle life of the battery pack.
[0051] The present invention provides a design of components of the battery pack to enable increase in overall effective area for heat transfer with a coolant.
, Claims:1. An improved battery pack (100) for a vehicle, wherein the battery pack (100) comprising:
a casing (102);
a plurality of cell modules (104) arranged within the casing (102), wherein each of the plurality of cell modules (104) comprises a plurality of battery cells (106);
a plurality of cooling passages (108) configured between each of the plurality of cell modules (104) to define a pathway for coolant flow;
a reservoir (110) coupled to the casing (102), wherein the reservoir (110) is configured to store a coolant received from a thermal management unit associated with the vehicle,
wherein the reservoir (110) comprises a plurality of fans (112) configured corresponding to the plurality of cooling passages (108), the plurality of fans (112) direct flow of the coolant towards the plurality of cooling passages (108) to uniformly circulate the coolant within the battery pack (100) and for maintaining temperature uniformity within the plurality of cell modules (104).

2. The battery pack (100) as claimed in claim 1, wherein the reservoir (110) comprises a plurality of inlet ports (114) configured at a first opposite plate (110-1) and/or at a second opposite plate (110-2) of the reservoir (110), to receive the coolant from an evaporator of the thermal management unit.

3. The battery pack (100) as claimed in claim 1, wherein the coolant flowing across the plurality of cooling passages (108) absorbs heat from surfaces of each of the plurality of cell modules (104) coming in contact with the coolant for effective heat dissipation and maintaining temperature uniformity within the battery pack (100).

4. The battery pack (100) as claimed in claim 1, comprising a plurality of outlet ports (116) disposed at a first side surface (102-1) and/ or a second side surface (102-2) of the casing (102), to extract the coolant with absorbed heat from the battery pack (100) and recirculate the coolant with absorbed heat to the evaporator of the thermal management unit.

5. The battery pack (100) as claimed in claim 1, wherein the plurality of cooling passages (108) comprise a plurality of first tubular spacers configured along each of the cell modules (104), in a direction perpendicular to a central axis of the plurality of fans.

6. The battery pack (100) as claimed in claim 1, wherein the plurality of cooling passages (108) comprise a plurality of second tubular spacers configured between adjacent battery cells (106) of each of the cell modules (104), along a direction of the central axis of the plurality of fans, to enhance effective area for heat transfer with the coolant.

7. The battery pack (100) as claimed in claim 5 and 6, wherein a shape of each of the plurality of first and second spacers is selected from a group consisting of: rectangular tubular spacers, or circular tubular spacers.

8. The battery pack (100) as claimed in claim 5 and 6, wherein the plurality of first and second tubular spacers (108) are made of material selected from a group consisting of: copper, aluminium, stainless steel, polymer composites, and titanium.

9. The battery pack (100) as claimed in claim 1, wherein the battery pack (100) comprises a control unit comprises a processor, wherein the processor is configured to:
receive, from one or more sensors, provided in the casing (102); and
a current temperature of the plurality of cell modules (104),
wherein the control unit is configured to operate the thermal management unit to enable a suitable flow of the coolant from the plurality of inlet ports (114) to the reservoir (110), and actuate the plurality of fans (112) to direct the flow of the coolant through the plurality of cooling passages (108) to facilitate uniform circulate the coolant within the battery pack (100) and maintain temperature uniformity within the plurality of cell modules (104).

10. The battery pack (100) as claimed in claim 1, wherein the coolant circulated through the plurality of cooling passages (108) comprises air or a liquid coolant selected from water, ethylene glycol, propylene glycol, or a mixture thereof.