DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
AN OPTIMAL CONDITIONING SYSTEM FOR HIGH VOLTAGE BATTERY PACK

APPLICANT:
EXPONENT ENERGY PVT. LTD.
An Indian entity having address as:
No.76/2, Site No.16,
Khatha, No 69, Singasandra Village,
Begur Hobli, Bengaluru Urban,
Karnataka (IN) - 560068

The following specification particularly describes the invention and the manner in which it is to be performed.
CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application claims priority from the Indian provisional patent application, having application number 202341021849, filed on 27th March 2023, incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure relates to the field of batteries and battery modules. More specifically, the present specification relates to a battery assembly architecture. More particularly, the present application discloses a battery assembly comprising a plurality of conditioning channels for high voltage battery packs that may be used in the context of electric vehicles and other conditioning systems for high voltage batteries.
BACKGROUND
This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure that are described or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements in this background section are to be read in this light, and not as admissions of prior art. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
In the field of battery architecture, a battery pack assembly has a wide range of applications in the automobile industry. Specifically in the electric vehicles (EV) market, battery technology has evolved to a great extent in order to produce safe, green, and efficient electric vehicles. The EV market drives on the motto of an alternative eco-friendly solution to crude the fuel-based automotive industry.
In the field of battery assembly architecture, specifically for electric vehicles (EVs), the batteries are prone to have a high probability of an outburst of flames due to overheating of the cells. Thus, efficient thermal management by an effective cooling system plays an important role in ensuring the consistent performance of a battery pack. Excessive temperature will negatively affect the EV's battery and its performance. Improper thermal management of the battery pack may lead to impacting the electrochemical system, charge acceptance, power output, safety and life cycle/replacement cost and the vehicle’s driving distance. Hence, batteries are bound to have thermal management systems to efficiently cool down the battery. The cooling of the battery while charging at EV charging stations relies on the packaging architecture of the battery.
Further, in the field of battery charging architecture, a fast charging mechanism is implemented at the EV charging stations. During fast charging, the battery assembly architecture and the internal components are susceptible to overheating and thereby affecting their work capacity. Therefore, the battery assembly requires mechanism for heat control and avoid searing for the prolonged durability of the battery assembly. A conventionally implemented cooling method involves passive cooling and/or active cooling.
The passive cooling methods involve where the battery assembly is cooled with help of air or water through internal components such as heat exchanger unit, heat sink, or cooling pane. The coolant is already present in the battery pack. The passive cooling can lead to an increase in weight of the battery assembly. The increased weight of the battery assembly contributes to the outsize mass of the EV vehicles consuming more resources. The active cooling method involves techniques such as pumping the conditioning fluid from resources external to the battery pack such as the air conditioning system. Therefore, for maintaining a battery assembly’s efficient peak performance without increasing the overall battery assembly load, separately or for an EV, the modern conditioning stations have been embedded with a conditioning fluid circuit that maintains the optimum working temperature of the battery assembly while charging and/or conditioning.
Further in the application of high voltage battery packs, a large number of battery modules are connected to operate as a high voltage battery pack. Existing battery assembly architecture involves connecting a large number of battery modules through a busbar of very large length depending on the number of battery modules connected. Operating the high voltage battery pack along with the lengthy busbar may lead to an increase in resistance, which thereby drops the overall voltage of the battery pack. Further, using the lengthy busbar in the battery pack may involve connection complexity and may increase size of the battery assembly, making the assembly bulky, and unhandy. Further, fast charging the high voltage battery pack may lead to overheating of the internal components of the battery pack, thereby affecting their work capacity and operating condition.
Further, the modern developments as described above lack a well-designed, and compact, thermal management mechanism for the battery assembly. Thus, the aforementioned conventional systems and methods for the circulation of conditioning fluid for the thermal management of the battery are not efficient, both practically and commercially.
Thus, there is a long-standing need for a combined battery architecture with a compact and effective conditioning mechanism for high-voltage battery pack assembly so as to preserve and improve the durability, serviceability, and efficacy of the conditioning of the battery assembly so that an optimum temperature of the high voltage battery assembly is maintained.
SUMMARY
This summary is provided to introduce concepts related to the field of battery assembly architecture comprising a plurality of conditioning channels and more particularly, for conditioning of the battery cells of high voltage battery packs. This summary is not intended to identify the essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
The present disclosure relates to a battery pack assembly for conditioning of high voltage batteries, using a plurality of conditioning channels. In one non-limiting embodiment of the present disclosure, the conditioning system may be configured for internal conditioning of cell/module/Battery Pack.
In one embodiment a battery pack assembly with an optimized conditioning system is disclosed. The battery pack assembly may comprise a plurality of battery modules, a plurality of conditioning channels, each with one or more input ports and one or more output ports, and a plurality of conditioning plates for conditioning the plurality of battery modules. In one embodiment, the plurality of conditioning channels may comprise an inlet conditioning channel and an outlet conditioning channel, with the former featuring an inlet channel input port and one or more inlet channel output ports, and the latter comprising one or more outlet channel input ports and an outlet channel output port. In one embodiment the plurality of conditioning plates may be utilized to condition the battery modules, with each plate may be equipped with an inlet and an outlet port. The inlet ports of each of the plurality of conditioning plates may connect to the inlet channel output ports, while the outlet ports of each of the plurality of conditioning plates may link to the outlet channel input ports. Each battery module from the plurality of battery modules may be attached with a first conditioning plate on one side and a second conditioning plate on the opposite side, potentially ensuring comprehensive conditioning. In one embodiment, the battery pack assembly may comprise a first conditioning plate featuring a first inlet port and a first outlet port. Similarly, a second conditioning plate may be equipped with a second inlet port and a second outlet port. In one embodiment, the plurality of battery modules may be arranged in a series to form a required voltage battery pack. In a related embodiment, the plurality of battery modules may be arranged in a series to form a high voltage battery pack. In another embodiment, the plurality of battery modules may be arranged in a rotating manner to form the battery pack. The rotating manner may correspond to placing positive and negative terminals of the plurality of battery modules in an alternative fashion. In one embodiment, each battery module from the plurality of battery modules may comprise the first conditioning plate and the second conditioning plate. In one embodiment, each of the first conditioning plate and the second conditioning plate may comprise an inlet and an outlet. In one embodiment, the inlet of each of the first conditioning plate and the second conditioning plate may be configured to receive conditioning fluid from the inlet conditioning channel. In another embodiment, the outlet of each of the first conditioning plate and the second conditioning plate may be configured to provide conditioning fluid to the outlet conditioning channel. In another embodiment, the inlet of the first conditioning plate may be configured to receive conditioning fluid from the inlet conditioning channel and the outlet of the second conditioning plate may be configured to provide conditioning fluid to the outlet conditioning channel. In a related embodiment, the outlet of the first conditioning plate may be connected to the inlet of the second conditioning plate.
In one embodiment a method for assembling a battery pack with an optimized conditioning system is disclosed. The method may be an arrangement of multiple battery modules in a predetermined manner to form the battery pack. Specifically, a positive terminal of one battery module aligns with a negative terminal of another battery module in an alternating fashion. This arrangement may optimize the space and electrical connections within the battery pack. Further, the method may comprise a step of attaching a plurality of conditioning plates to one or more sides of the battery modules. Each conditioning plate may feature an inlet port and an output port to facilitate the flow of conditioning fluid. Further, the method may comprise a step of arranging a network of conditioning channels in between the plurality of battery modules. These channels consist of an inlet conditioning channel and an outlet conditioning channel. The inlet channel may include an inlet channel input port connected to a conditioning station via a fluid connector for receiving conditioning fluid. The inlet conditioning station may comprise one or more inlet channel output ports. The outlet channel may comprise one or more outlet channel input ports and an outlet channel output port for fluid exit. The method may involve connecting the inlet channel input port to a conditioning station, and then linking the one or more inlet channel outlet ports of the inlet conditioning channel to the inlet ports of each conditioning plate. This setup may enable the circulation of conditioning fluid throughout the battery pack. Furthermore, the method may comprise a step of connecting the outlet ports of the conditioning plates to the one or more outlet conditioning inlet ports of the outlet conditioning channel. Further, the method may comprise a step of connecting the outlet channel output port of the outlet conditioning channel to the conditioning station, via the fluid connector, for exiting the conditioning fluid from the outlet conditioning channel. Further, the method may comprise a step of connecting the battery modules and conditioning channels to a base plate using fastening means. This secures the components in place and provides structural integrity to the assembled battery pack.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF DRAWINGS
The detailed description is described with reference to the accompanying Figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.
Figure 1 illustrates an exploded view of a battery pack assembly (100), in accordance with an embodiment of the present disclosure.
Figure 2a, 2b and 2c illustrates isometric view of various arrangements of battery pack along with plurality of conditioning channels, in accordance with various embodiments of the present disclosure.
Figure 3 illustrates a block diagram of battery pack assembly (100) in accordance with an embodiment of the present disclosure.
Figure 4A and 4B illustrates a flowchart describing a method (400) for assembling a battery pack with an optimized conditioning system, in accordance with the embodiment of the present disclosure.
DETAILED DESCRIPTION
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
The present disclosure relates to a battery pack assembly with an optimized conditioning system for the conditioning of high voltage batteries, using a plurality of conditioning channels. In one non-limiting embodiment of the present disclosure, the conditioning system may be configured for internal conditioning of cell/module/Battery Pack.
Referring to Figure1, a battery pack assembly (100) with an optimized conditioning system is disclosed. The battery pack assembly (100) may comprise a battery assembly cover (101), a power path assembly (102), a plurality of conditioning channels (103, 104), a plurality of battery modules (105), and a base plate (106).
In one embodiment, the battery assembly cover (101) may be configured to be attached to the base plate (106) using one or more fastening means. In one embodiment, the battery assembly cover (101) may be configured to cover the plurality of battery cells/modules (105), the power path assembly (102), and the plurality of conditioning channels (103,104).
In another embodiment, the power path assembly (102) comprises a plurality of power path electrical circuitry, power path base plate and a battery management system (BMS). In one embodiment, the power path circuitry may comprise at least Bus bar, Printed Circuit Board (PCB), connectors or more. The plurality of power path electrical circuitry along with the BMS may be attached to the power path base plate to form the power path assembly (102), In one embodiment, the power path electrical circuitry and BMS are attached to the power path base plate using an adhesive. In another embodiment, the power path electrical circuitry and the BMS are attached to the power path base plate using one or more fastening means. In one embodiment, the power path assembly (102) with reduced length of bus bar may correspond to a shorter power path assembly. In one embodiment, the adhesive may comprise a thermally conductive and electrically insulative adhesive. In a related embodiment, the adhesive corresponds to Polyurethane acrylate adhesive. In another embodiment, the power path electrical circuitry and the BMS may be attached using a bolting means. In one embodiment, the power path assembly (102) may be configured to be attached to the base plate (106), wherein the power path assembly (102) is attached to the base plate (106) using one or more fastening means.
In one embodiment, the plurality of battery modules (105) may be connected to the base plate (106) using one or more fastening means. In another embodiment, the plurality of conditioning channels (103,104) may be attached to the base plate (106) using one or more fastening means. In an exemplary embodiment, the fastening means corresponds to one of bolts, brackets and a combination thereof. The attachment of the plurality of conditioning channels (103,104) to the base plate (106) using brackets and bolts may enable the structural holding of the battery pack (106). In another embodiment, the plurality of conditioning channels (103,104) may be placed between the plurality of battery modules (105) for distributing conditioning fluid to the plurality of battery modules (105) and receiving conditioning fluid from the plurality of battery modules (105). In one embodiment, the plurality of conditioning channels (103,104) may comprise an inlet conditioning channel (104) and an outlet conditioning channel (103). The inlet conditioning channel (104) is used to receive the conditioning fluid from a conditioning station fluid reservoir and to distribute the conditioning fluid to one or more conditioning plates associated with the plurality of battery modules (105). In contrast, the outlet conditioning channel (103) is used to receive the conditioning fluid from one or more conditioning plates associated with the plurality of battery modules (105) and to exit the conditioning fluid from the outlet conditioning channel (103) to the conditioning station.
In another embodiment, the battery pack assembly (100) may comprise a plurality of battery cells. Each cell from the plurality of cells comprises one or more terminals. Each terminal from the one or more terminals comprises a terminal axis passing through the one or more terminals of the plurality of cells. The plurality of battery cells may be arranged in a predefined manner to form a battery module (105). In an implementation, the plurality of cells in each battery module is arranged in a predetermined manner to place one or more terminals of the plurality of cells in the same direction. Each battery module from the plurality of battery modules (105) comprises a plurality of module terminals. The plurality of module terminals may comprise a positive module terminal and a negative module terminal. A plurality of battery modules (105) may further be arranged in a predetermined manner to form a battery pack. In one embodiment, the plurality of battery modules (105) may be arranged in a series to form a required high voltage battery pack. In a related embodiment, the plurality of battery modules (105) may be arranged in a rotating manner to form a compact battery pack. The rotating manner may correspond to placing the positive module terminal and the negative module terminals of the plurality of battery modules (105) in an alternative fashion. In a related embodiment, the arrangement of the plurality of battery modules (105) in the rotating manner may enable the reduction in length of the Bus bar.
Referring to Fig 2a, 2b and 2c various views of a battery pack assembly (100) along with plurality of conditioning channels, is illustrated in accordance with various embodiments of the present disclosure.
Referring to Fig. 2.c according to one embodiment, the plurality of conditioning channels (103,104) may comprise one or more inlet conditioning connectors (104a, 104b) and one or more outlet conditioning connectors (103a, 103b). In one embodiment, the inlet conditioning channel (104) comprises an inlet channel input port (301) (as shown in Figure 3) and one or more inlet channel output ports. In a similar embodiment, the outlet conditioning channel (103) comprises one or more outlet channel input ports and an outlet channel output port (303) (as shown in Figure 3). The inlet channel input port (301) is connected with an inlet channel connector (104a). One or more inlet channel output ports are connected with one or more inlet channel connectors (104b). Further, one or more outlet channel input ports are connected with one or more outlet channel connectors (103b). Further, outlet channel output port is connected with an outlet channel connector (103a).
Referring to Figure 3 a block diagram of battery pack assembly (100), is illustrated in accordance with an embodiment of the present disclosure. According to one embodiment, the battery pack assembly (100) comprises each of an inlet conditioning channel (104) and an outlet conditioning channel (103). Further, each of the inlet conditioning channel (104) and the outlet conditioning channel (103) may comprise a fluid supply inlet and a fluid supply outlet. In one embodiment, the fluid supply inlet of the inlet conditioning channel may be configured to receive conditioning fluid into the inlet conditioning channel (104) and the fluid supply outlet of the inlet conditioning channel (104) may be configured to exit conditioning fluid from the inlet conditioning channel (104). In a related embodiment, the fluid supply inlet of the outlet conditioning channel (103) may be configured to receive conditioning fluid into the outlet conditioning channel (103) and the fluid supply outlet of the outlet conditioning channel (103) may be configured to exit conditioning fluid from the outlet conditioning channel (103). In one embodiment, the fluid supply outlet of the inlet conditioning channel (104) may be connected to the fluid supply inlet of the outlet conditioning channel (103) and vice versa. In one embodiment, the fluid supply inlet of the inlet conditioning channel (104) may be connected to a main inlet reservoir connector and the fluid supply outlet of the outlet conditioning channel (103) may be connected to a main outlet reservoir connector. In an embodiment, the fluid supply inlet of the inlet conditioning channel (104) may be connected to the main inlet reservoir connector through the battery assembly cover (101). In another embodiment, the fluid supply outlet of the outlet conditioning channel (103) may be connected to the main outlet reservoir connector through the battery assembly cover (101).
According to an exemplary embodiment, the battery pack assembly (100) comprises a plurality of conditioning plates (304a, 304b) may comprise a first conditioning plate (304a) and a second conditioning plate (304b) positioned opposite to one or more battery module (105). In present embodiment, the first conditioning plate (304a) may be configured to be attached to a first side of the plurality of cells and the second conditioning plate (304b) may be configured to be attached to the other side of the plurality of cells, different from the first side. In a related embodiment, the first conditioning plate (304a) and the second conditioning plate (304b) may be placed on the longitudinal sides of the battery module (105), different from the terminal side of the cells. In one embodiment, each battery module from the plurality of battery modules (105) may comprise the first conditioning plate (304a) and the second conditioning plate (304b). In one embodiment, the plurality of conditioning plates (304a, 304b), may comprise a plurality of microchannels, wherein the plurality of microchannels may be configured to enable the flowing of conditioning fluid inside the plurality of conditioning plates (304a, 304b). In another embodiment, the plurality of conditioning plates (304a, 304b), may comprise serpentine fluid channels, wherein the conditioning fluid in the plurality of conditioning plates may flows in a serpentine fluid flow. In one embodiment, each of the first conditioning plate (304a) and the second conditioning plate (304b) may comprise an inlet and an outlet. In one embodiment, the inlet of each of the first conditioning plate (304a) and the second conditioning plate (304b) may be configured to receive conditioning fluid from the inlet conditioning channel (104). In another embodiment, the outlet of each of the first conditioning plate (304a) and the second conditioning plate (304b) may be configured to provide conditioning fluid to the outlet conditioning channel (103). In an embodiment, the inlet port of each conditioning plate, from the plurality of conditioning plates (304a, 304b), is connected to the one or more inlet channel output ports of the inlet conditioning channel (104) and the outlet port of each conditioning plate, from the plurality of conditioning plates (304a, 304b), is connected to one or more outlet channel input ports of the outlet conditioning channel (103).
In an exemplary embodiment, the first conditioning plate (304a) comprises a first inlet port and a first outlet port. Similarly, the second conditioning plate (304b) comprises a second inlet port and a second outlet port. The first inlet port of the first conditioning plate (304a) and the second inlet port of the second conditioning plate (304b) are connected to one or more inlet channel output ports of the inlet conditioning channel (104). Further, the first outlet port of the first conditioning plate (304a) and the second outlet port of the second conditioning plate (304b) are connected to one or more outlet channel input ports of the outlet conditioning channel (103).
In a related embodiment, the first outlet port of the first conditioning plate (304a) may be connected to the second inlet port of the second conditioning plate (303b), via a conditioning plate connector. In an embodiment, the first inlet port of the first conditioning plate (304a) is connected to one or more inlet channel output ports of the inlet conditioning channel (104) and the second outlet port of the second conditioning plate (304b) is connected to one or more outlet channel input ports of the outlet conditioning channel (103).
In a related embodiment, an inlet channel input port (301) of the inlet conditioning channel (104) may connect with a conditioning station (302), via a fluid connector, for receiving the conditioning fluid into the inlet conditioning channel (104). Further, an outlet channel output port (303) of the outlet conditioning channel (103) may connect with the conditioning station (302), via the fluid connector, for exiting the conditioning fluid from the outlet conditioning channel (103). In another embodiment a conditioning station (302) may comprise one or more fluid reservoirs for storing the conditioning fluid. Further, battery pack assembly (100) may comprise a plurality of connectors. Further, the plurality of connectors may comprise the conditioning plate connector, inlet channel connectors (104a, 104b) and outlet channel connectors (103a, 103b). The conditioning plate connector may connect the inlet port of one conditioning plate to the outlet port of another conditioning plate in the same battery module. The inlet channel connector (104a) may connect the inlet channel input port (301) of the inlet conditioning channel (104) with the fluid connector, for receiving the conditioning fluid into the inlet conditioning channel (104).
In another embodiment an inlet channel connector (104b) is designed to connect inlet channel output ports of the inlet conditioning channel (104) with the inlet ports of the plurality of conditioning plates (304a, 304b), for distributing the conditioning fluid into the inlet ports of each conditioning plate. In another embodiment an outlet channel connector (103a) is designed to connect outlet channel output port (303) of the outlet conditioning channel (103) with the fluid connector, for exiting the conditioning fluid from the outlet conditioning channel (103). Further outlet channel connectors (103b) are designed to connect outlet channel input ports of the outlet conditioning channel (103) with the outlet ports of the plurality of conditioning plates (304a, 304b), for exiting the conditioning fluid from each of the conditioning plate to the outlet conditioning channel (103). In one embodiment, the plurality of connectors may correspond to one of the poly hose connectors, vertical and angular connectors, flexible connectors, and a combination thereof. In one embodiment, the inlet conditioning connector (104a) and the outlet conditioning connector (103b) may comprise a plurality of poly hose connectors, wherein the plurality of poly hose connectors may be configured to connect to the inlet or the outlet of the plurality of conditioning plates (304a, 304b). In one embodiment, the plurality of poly hose connectors of the inlet conditioning channel (104) may be connected to the inlet port of the plurality of conditioning plates (304a, 304b) of the plurality of battery modules (105). In a related embodiment, the plurality of poly hose connectors of the inlet conditioning channel (104) may be configured to distribute conditioning fluid to the plurality of conditioning plates (304a, 304b) of the plurality of battery modules (105). In another embodiment, the plurality of poly hose connectors of the outlet conditioning channel (103) may be connected to the outlet of the plurality of conditioning plates (304a, 304b) of the plurality of battery modules (105). In a related embodiment, the plurality of poly hose connectors of the outlet conditioning channel (103) may be configured to receive conditioning fluid from the plurality of conditioning plates (304a, 304b) of the plurality of battery modules (105).
In an embodiment of the present disclosure, the conditioning fluid may be any fluid, preferably a liquid. In one exemplary embodiment, the conditioning fluid may either be a cold fluid or a hot fluid, depending on thermal requirements of the battery. A conditioning station (302)/vehicle charging station may be allowed to flow the conditioning fluid into the battery assembly, via a connector, while performing the conditioning/charging of the battery assembly. Further, the plurality of conditioning plates (304a, 304b) and the battery cell structure may be fixed by bonding with a thermally uniform conductive structural adhesive/glue. The thermally conductive adhesive may be configured to maintain the electrical isolation from the battery cells, to protect cells during automotive vibrations caused from the road, and to keep the cells under the right operating condition.
Referring to Figure 4 a method (400) for assembling a battery pack with an optimized conditioning system is illustrated in accordance with the embodiment of the present disclosure. In the method (400), the following steps could be involved:
Arranging Battery Modules: The process may start with arranging (401) multiple battery modules (105) in a predetermined manner. This arrangement might involve placing the positive terminal of one battery module and the negative terminal of another in an alternating fashion, optimizing space utilization and electrical connections within the battery pack.
Attaching Conditioning Plates: Next, a plurality of conditioning plates (304a, 304b) may be attached (402) on one or more sides of the battery modules. Each conditioning plate could feature an inlet port and an output port, facilitating the flow of conditioning fluid.
Arranging Conditioning Channels: A network of conditioning channels (103, 104) may be arranged (403) between the battery modules. These channels could include an inlet conditioning channel (104) and an outlet conditioning channel (103). The inlet conditioning channel might comprise an inlet channel input port (301) and one or more inlet channel output ports, while the outlet conditioning channel could feature one or more outlet channel input ports and an outlet channel output port (303).
Connecting Inlet Conditioning Channel to Conditioning Station: The inlet channel input port (301) of the inlet conditioning channel (104) might be connected (404) to a conditioning station (302) via a fluid connector. This connection could enable the receiving of conditioning fluid into the inlet conditioning channel.
Connecting Conditioning Plates to Inlet Ports: One or more inlet channel output ports of the inlet conditioning channel (104) could be connected (405) to the inlet port of each conditioning plate from the plurality of conditioning plates (304a, 304b). This connection may ensure that conditioning fluid is directed to each conditioning plate.
Connecting Conditioning Plates to Outlet Conditioning Channel: The outlet port of each conditioning plate from the plurality of conditioning plates (304a, 304b) may be connected (406) to one or more outlet channel input ports of the outlet conditioning channel (103). This linkage could facilitate the flow of conditioned fluid through the battery pack.
Connecting Outlet Conditioning Channel to Conditioning Station: The outlet channel output port (303) may be connected (407) to the conditioning station (302) via the fluid connector, allowing for the exit of conditioning fluid from the outlet conditioning channel.
Attaching to Base Plate: Finally, the plurality of battery modules (105) and the plurality of conditioning channels (103, 104) may be attached (408) to a base plate (106) through one or more fastening means. This attachment may provide stability and structural integrity to the assembled battery pack.
In one embodiment, the fluid supply outlet of the inlet conditioning channel may be connected to the fluid supply inlet of the outlet conditioning channel and vice versa. In one embodiment, the fluid supply inlet of the inlet conditioning channel may be connected to a main inlet reservoir connector and the fluid supply outlet of the outlet conditioning channel may be connected to a main outlet reservoir connector. In an embodiment, the fluid supply inlet of the inlet conditioning channel may be connected to the main inlet reservoir connector through the battery assembly cover. In another embodiment, the fluid supply outlet of the outlet conditioning channel may be connected to the main outlet reservoir connector through the battery assembly cover.
In one embodiment, a single battery assembly cover (101) may be configured to cover the plurality of battery cells/modules (105), power path assembly (102), the plurality of conditioning plates (304a, 304b) and the plurality of conditioning channels (103,104). In one embodiment, the battery assembly cover (101) may be formed using a lightweight material, wherein the lightweight material may comprise a plastic material.
In an exemplary embodiment, the base plate (106) of the battery assembly may have a plurality of mounting holes for fixing the battery assembly to a rigid support. The rigid support may be an automobile floor. The battery assembly acts as a unibody where everything is bonded together ensuring that the complete battery assembly architecture acts as a single unit during an automotive vibration scenario. Such unibody architecture may create better stiffness than a conventional architecture and may use the structural strength of each battery cell as a battery assembly structure.
In a non-limiting embodiment of the present disclosure, the plurality of battery cells may be arranged in a fixture, like the battery module case, or by using the plurality of spacer elements. The plurality of spacer elements may be utilized for ensuring an equal spacing between the plurality of battery cells. The fixture may also be configured to ensure equal spacing of the plurality of battery cells via the fixture tolerances.
In another non-limiting embodiment, the thermally conductive and electrically insulative adhesive may be applied to the side faces of each battery cell from the plurality of battery cells. Then, the plurality of conditioning plates may be glued to the side faces of the plurality of battery cells. As soon as the adhesive gets cured, a battery assembly with structurally bonded plurality of battery cells may be formed. Also, the battery assembly may be formed as a thermally conductive battery assembly. This battery assembly may be configured for maintaining an electrical isolation between the plurality of battery cells and the plurality of conditioning plates.
In an embodiment, the plurality of spacers may form a spacers assembly which may be used between each battery cell and the conditioning plates. The spacers assembly may consist of a plastic sheet bonded with a double-sided tape, which may be either silicone based or acrylic based adhesive. Further, this double-sided tape may be applied to the body of each battery cell. In this case, the thickness of the plastic sheet may be maintained and designed to have multiple isolation values as required by the battery assembly to be manufactured. At least two spacers may be used for each battery cell.
The battery assembly, as disclosed, may comprise a well- maintained electrical isolation between the body of each battery cell and the plurality of conditioning plates. This electrical isolation is consistent across the battery packs of the battery assembly.
Such battery assembly architecture may result in building the battery assembly using a single adhesive. This may also ensure that the battery assembly is thermally stable and structurally effective for any kind of mechanical vibrations. This may further confirm an electrical insulation of the plurality of battery cells from the battery pack or the battery assembly. The mechanical vibrations exerted on the battery assembly may be any mechanical/frictional vibrations while the battery assembly may be used in an automobile.
In a non-limiting embodiment, each spacer from the plurality of spacers may be made of plastic or glass beads. Each spacer may also ensure an equal thickness of the adhesive being applied between the plurality of conditioning plates and each battery cell. This uniform adhesive thickness may create a uniform stiffness across the battery assembly which is absent in the conventional battery module designs. Each spacer may also ensure an equal spacing between the plurality of conditioning plates and each battery cell when each battery cell is pressurized towards the plurality of conditioning plates.
In an embodiment, the disclosed battery assembly architecture may ensure that the load is equally distributed among the plurality of battery cells. The equal load distribution may be able to create uniform stiffness across the battery assembly.
In another embodiment, the battery management system may further comprise a plurality of bus bars and power paths. The plurality of bus bars and power paths may be pre-bonded with the power path base plate and other electrical components of the battery management system via the adhesive.
The presently disclosed battery assembly comprising the conditioning channels for high voltage battery pack may have the following advantageous functionalities over the conventional art:
1. Busbar is optimized with reduced length by placing the plurality of battery modules in a rotating manner.
2. Optimized conditioning channel by enabling all the inlet and outlet of the battery modules to connect to nearby inlet/outlet conditioning channels.
3. Enables better structural integrity, also in case of lengthy battery packs.
4. Inlet and outlet conditioning channels also act as structural members for holding the battery pack assembly.
5. Reducing voltage drop of the optimized busbar with reduced busbar length.
6. Less resistance due to reduced busbar length while charging.
7. Reduced weight and size of the battery assembly.
8. Easy serviceability of the battery assembly in case of maintenance activity
9. The battery assembly is formed as a unibody architecture.
10. Provides better structural integrity and stiffness of the battery assembly.
11. Efficient conditioning of the battery cells according to the thermal requirements of a fast-charging battery pack.
12. Equal spacing between the battery cells is maintained due to the use of spacers in the fixture.
13. Compact and concise arrangement in the battery for avoiding poor use of space or storage.
14. The battery assembly acts as a cage for equal load distribution throughout the battery cells.
15. Prolonged shelf life of the battery cells, and thus, the battery assembly.
The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure.
The embodiments, examples, and alternatives of the preceding paragraphs or the description, including any of their various aspects or respective individual feature(s), may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.

,CLAIMS:I/WE CLAIM
1. A battery pack assembly (100) with an optimized conditioning system, characterized in that, the battery pack assembly (100) comprises:
a plurality of battery modules (105);
a plurality of conditioning channels (103, 104), wherein each conditioning channel from the plurality of conditioning channels (103, 104) comprise one or input ports and one or more output ports;
wherein the plurality of conditioning channels (103, 104) comprises an inlet conditioning channel (104) and an outlet conditioning channel (103), wherein the inlet conditioning channel (104) comprises an inlet channel input port (301) and one or more inlet channel output ports, wherein the outlet conditioning channel (103) comprises one or more outlet channel input ports and an outlet channel output port (303);
a plurality of conditioning plates (304a, 304b) for conditioning the plurality of battery modules (105), wherein each conditioning plate from the plurality of conditioning plates (304a, 304b) comprises an inlet port and an outlet port;
wherein the inlet port of each conditioning plate, from the plurality of conditioning plates (304a, 304b), is connected to the one or more inlet channel output ports of the inlet conditioning channel (104) and the outlet port of each conditioning plate, from the plurality of conditioning plates (304a, 304b), is connected to one or more outlet channel input ports of the outlet conditioning channel (103).
2. The battery pack assembly (100) as claimed in claim 1, wherein each battery module from the plurality of battery modules (105) is attached with a first conditioning plate (304a), from the plurality of conditioning plates (304a, 304b), on a first side of the battery module and is attached with a second conditioning plate (304b), from the plurality of conditioning plates (304a, 304b), on a second side, opposite to the first side, of the battery module.
3. The battery pack assembly as claimed in claim 2, wherein the first conditioning plate (304a) comprises a first inlet port and a first outlet port; wherein the second conditioning plate (304b) comprises a second inlet port and a second outlet port.
4. The battery pack assembly as claimed in claim 3,
wherein the first inlet port of the first conditioning plate (304a) and the second inlet port of the second conditioning plate (304b) are connected to one or more inlet channel output ports of the inlet conditioning channel (104);
wherein the first outlet port of the first conditioning plate (304a) and the second outlet port of the second conditioning plate (304b) are connected to one or more outlet channel input ports of the outlet conditioning channel (103).
5. The battery pack assembly (100) as claimed in claim 3,
wherein the first outlet port of the first conditioning plate (304a) is connected to the second inlet port of the second conditioning plate (304b), via a conditioning plate connector;
wherein the first inlet port of the first conditioning plate (304a), for each battery module from the plurality of battery modules (105), is connected to one or more inlet channel output ports of the inlet conditioning channel (104);
wherein the second outlet port of the second conditioning plate (304b), for each battery module from the plurality of battery modules (105), is connected to one or more outlet channel input ports of the outlet conditioning channel (103).
6. The battery pack assembly (100) as claimed in claim 1,
wherein the inlet channel input port (301) of the inlet conditioning channel (104) is designed to connect with a conditioning station (302), via a fluid connector, for receiving the conditioning fluid into the inlet conditioning channel (104);
wherein the outlet channel output port (303) of the outlet conditioning channel (103) is designed to connect with the conditioning station (302), via the fluid connector, for exiting the conditioning fluid from the outlet conditioning channel (103);
wherein the conditioning station (302) comprises one or more fluid reservoirs for storing the conditioning fluid.
7. The battery pack assembly (100) as claimed in claim 1,
wherein the battery pack assembly (100) comprises a plurality of connectors,
wherein the plurality of connectors comprises the conditioning plate connector, inlet channel connectors (104a, 104b) and outlet channel connectors (103a, 103b);
wherein the conditioning plate connector is designed to connect inlet port of one conditioning plate to an outlet port of another conditioning plate in a same battery module;
wherein inlet channel connector (104a) is designed to connect inlet channel input port (301) of the inlet conditioning channel (104) with the fluid connector, for receiving the conditioning fluid into the inlet conditioning channel (104);
wherein inlet channel connectors (104b) are designed to connect inlet channel output ports of the inlet conditioning channel (104) with the inlet ports of the plurality of conditioning plates (304a, 304b), for distributing the conditioning fluid into the inlet ports of each conditioning plate;
wherein outlet channel connector (103a) is designed to connect outlet channel output port (303) of the outlet conditioning channel (103) with the fluid connector, for exiting the conditioning fluid from the outlet conditioning channel (103);
wherein outlet channel connectors (103b) are designed to connect outlet channel input ports of the outlet conditioning channel (103) with the outlet ports of the plurality of conditioning plates (304a, 304b), for exiting the conditioning fluid from each of the conditioning plate to the outlet conditioning channel (103);
wherein the plurality of connectors corresponds to one of the poly hose connectors, vertical and angular connectors, flexible connectors, and a combination thereof.
8. The battery pack assembly (100) as claimed in claim 1, wherein the battery pack assembly (100) comprises a base plate (106); wherein the plurality of battery modules (105) is connected to the base plate (106) through one or more fastening means; wherein the plurality of conditioning channels (103, 104) is connected to the base plate (106) through one or more fastening means, wherein the fastening means corresponds to one of bolts, brackets and a combination thereof.
9. The battery pack assembly (100) as claimed in claim 8, wherein the battery pack assembly (100) comprises a plurality of power path electrical circuitry, a power path base plate, and a battery management system (BMS);
wherein the plurality of power path electrical circuitry and the BMS are attached to the power path base plate, through an adhesive, to form a power path assembly (102);
wherein the power path assembly (102) is connected to the base plate (106) through the fastening means.
10. The battery pack assembly (100) as claimed in claims 6 and 9, wherein the battery pack assembly (100) comprises a battery assembly cover (101); wherein the battery assembly cover (101) is attached to the base plate (106) through the fastening means; wherein the battery assembly cover (101) is designed to cover the plurality of battery modules (105), the plurality of conditioning channels (103, 104), the plurality of conditioning plates (304a, 304b), the plurality of connectors and the power path assembly (102); wherein the plurality of conditioning channels (103, 104) are connected to the fluid reservoirs of the conditioning station (302), through the battery assembly cover (101).
11. The battery pack assembly (100) as claimed in claim 1,
wherein each battery module from the plurality of battery modules (105) comprises a plurality of cells;
wherein each cell from the plurality of cells comprises one or more terminals;
wherein each terminal from the one or more terminals comprises a terminal axis passing through the one or more terminals of the plurality of cells;
wherein the plurality of cells, in each battery module, is arranged in a predetermined manner to place one or more terminals of the plurality of cells in the same direction.
12. The battery pack assembly (100) as claimed in claim 1, wherein each battery module from the plurality of battery modules (105) comprises a plurality of module terminals; wherein the plurality of module terminals comprises a positive module terminal and a negative module terminal.
13. The battery pack assembly (100) as claimed in claim 12,
wherein the plurality of battery modules (105) is arranged in a predetermined manner to form a battery pack;
wherein the plurality of battery modules (105) is arranged in series to form a high voltage battery pack;
wherein the plurality of battery modules (105) is arranged in a rotating manner to form a compact battery pack, wherein the rotating manner corresponds to placing the positive module terminal and the negative module terminals of the plurality of battery modules (105) in an alternative fashion.
14. The battery pack assembly (100) as claimed in claim 1, wherein the plurality of conditioning plates (304a, 304b) is attached to the plurality of battery modules (105) through the adhesive; wherein the adhesive corresponds to a thermally conductive, electrically insulated, and structural member adhesive, wherein the adhesive corresponds to Polyurethane acrylate adhesive.
15. The battery pack assembly (100) as claimed in claim 6, wherein the conditioning fluid corresponds to one of, cold fluid, hot fluid, and a combination thereof; wherein the conditioning fluid flows inside the plurality of conditioning plates (304a, 304b) in a serpentine manner.
16. A method (400) for assembling a battery pack with an optimized conditioning system, characterized in that, the method (400) comprising:
arranging (401) a plurality of battery modules (105) in a predetermined manner to form a compact battery pack, wherein the predetermined manner corresponds to placing a positive module terminal of one battery module and a negative module terminal of another battery module in an alternative fashion;
attaching (402) a plurality of conditioning plates (304a, 304b) on one or more sides of a plurality of battery modules (105), wherein each conditioning plate from the plurality of conditioning plates comprises an inlet port and an output port;
arranging (403) a plurality of conditioning channels (103, 104) between the plurality of battery modules (105), wherein the plurality of conditioning channels (103, 104) comprises an inlet conditioning channel (104) and an outlet conditioning channel (103), wherein the inlet conditioning channel (104) comprises an inlet channel input port (301) and one or more inlet channel output ports, wherein the outlet conditioning channel (103) comprises one or more outlet channel input ports and an outlet channel output port (303);
connecting (404) the inlet channel input port (301) of the inlet conditioning channel (104) to a conditioning station (302), via a fluid connector, for receiving the conditioning fluid into the inlet conditioning channel (104);
connecting (405) one or more inlet channel output ports of the inlet conditioning channel (104) to the inlet port of each conditioning plate, from the plurality of conditioning plates (304a, 304b);
connecting (406) the outlet port of each conditioning plate, from the plurality of conditioning plates (304a, 304b) to one or more outlet channel input ports of the outlet conditioning channel (103);
connecting (407) the outlet channel output port (303) to the conditioning station (302), via the fluid connector, for exiting the conditioning fluid from the outlet conditioning channel (103), and attaching (408) the plurality of battery modules (105) and the plurality of conditioning channels (103, 104) to a base plate (106) through one or more fastening means.
Dated this 27th day of March 2024


Deepak Pawar
Agent for the Applicant
IN/PA- 2052