[001] The present disclosure generally relates to thermal management systems for use
in power battery applications in automobiles. More particularly, the present disclosure relates
to an improved battery assembly having an integrated thermal management system for use in
three-wheeler automotive applications.
BACKGROUND
[002] Background description includes information that can 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.
[003] As can be appreciated, one determining factor for battery system efficiency is
the factor of thermal efficiency of the battery system. As per existing conventional cooling
strategies for battery pack cooling (in particular, Li-ion or Lithium Ion based batteries), the
most commonly used is air cooling wherein the ambient air is passed over the battery pack to
transfer the heat generated by Li-ion cells. However, the limitations associated with this method
is that it is applicable only when the ambient temperature is lower than the battery pack
temperature and furthermore the heat transfer rate is extremely low.
[004] The limitations associated with air cooling may be overcome by using active
liquid cooling. Most of the automotive application involves the use of Secondary Liquid
Cooling System (SLC) wherein the refrigerant is the primary coolant and water-ethylene glycol
is the secondary coolant which flows through the coolant pipes to remove heat from the battery
pack. The limitations associated with SLC is the increase in weight of the overall system as it
requires a permanent stationing of the secondary coolant storage tank and also use of additional
components such as heat exchangers for heat transfer between the refrigerant and waterethylene glycol mixture and pump for pushing this mixture.
[005] In case of air cooled thermal management systems the thermal response is very
slow, because this low heat transfer rate having a control over Li-ion cell temperature becomes
complex and the heat exchanging efficiency is comparatively less with respect to Liquid
Cooled Systems. Apart from the drawbacks of SLC mentioned above, the SLC System is better
than air cooling in terms of efficiency, heat exchange effectiveness and heat transfer rate
3
however it still involves two cooling mediums i.e. the refrigerant as a primary coolant and
water ethylene glycol mixture as a secondary coolant which may be undesirable.
[006] A significant market share in the automotive industry is occupied by threewheeler automotive applications, in Asian countries such as India, Sri Lanka, Nigeria, Kenya,
Philippines, Thailand, etc. Since the three wheeler vehicles have a very limited volume
available for battery pack integration and placement, such bulky nature of SLC acts as a major
hindrance.
[007] Other cooling technologies extant in the art involve the use of phase change
material (hereinafter interchangeably used as “PCM”) and Peltier Chips. PCM cooling is a
passive cooling system because heat absorbed by the PCM needs to be eventually removed.
This heat removal is performed by means of air cooling and liquid cooling methods. On its
own, PCM may be a viable cooling strategy, but it is limited for stationary storage application
where the heat generation rate is low.
[008] Peltier chips can also be an option for compact cooling. However due to its
extremely low coefficient of performance, high price, and brittle nature, they are undesirable
and unsuitable for automotive applications.
[009] Therefore, there is a need in the art to provide an improved battery assembly
that has an integrated thermal management system for use in three-wheeler automotive
applications, and which can overcome the above-mentioned limitations of other thermal
management systems.
[0010] All publications herein are incorporated by reference to the same extent as if
each individual publication or patent application were specifically and individually indicated
to be incorporated by reference. Where a definition or use of a term in an incorporated reference
is inconsistent or contrary to the definition of that term provided herein, the definition of that
term provided herein applies and the definition of that term in the reference does not apply.
[0011] In some embodiments, the numbers expressing quantities or dimensions of
items, and so forth, used to describe and claim certain embodiments of the invention are to be
understood as being modified in some instances by the term “about.” Accordingly, in some
embodiments, the numerical parameters set forth in the written description and attached claims
are approximations that may vary depending upon the desired properties sought to be obtained
by a particular embodiment. In some embodiments, the numerical parameters should be
construed in light of the number of reported significant digits and by applying ordinary
rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth
the broad scope of some embodiments of the invention are approximations, the numerical
4
values set forth in the specific examples are reported as precisely as practicable. The numerical
values presented in some embodiments of the invention may contain certain errors necessarily
resulting from the standard deviation found in their respective testing measurements.
[0012] As used in the description herein and throughout the claims that follow, the
meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates
otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on”
unless the context clearly dictates otherwise.
[0013] Groupings of alternative elements or embodiments of the invention disclosed
herein are not to be construed as limitations. Each group member can be referred to and claimed
individually or in any combination with other members of the group or other elements found
herein. One or more members of a group can be included in, or deleted from, a group for
reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the
specification is herein deemed to contain the group as modified thus fulfilling the written
description of all groups used in the appended claims.
OBJECTS OF THE PRESENT DISCLOSURE
[0014] Some of the objects of the present disclosure, which at least one embodiment
herein satisfies are as listed herein below.
[0015] It is an object of the present disclosure to provide an improved battery assembly
having an integrated thermal management system for use in three-wheeler automotive
applications.
[0016] It is another object of the present disclosure to provide a simple and cost
effective battery assembly having an integrated thermal management system for use in threewheeler automotive applications.
[0017] It is another object of the present disclosure to provide a reliable and efficient
battery assembly having an integrated thermal management system for use in three-wheeler
automotive applications.
[0018] It is another object of the present disclosure to provide a robust battery assembly
having an integrated thermal management system for use in three-wheeler automotive
applications.
[0019] It is another object of the present disclosure to provide a battery assembly having
an integrated thermal management system for use in three-wheeler automotive applications,
and which provides high thermal response time thereby keeping the battery temperature within
desired range under all operating conditions.
5
SUMMARY
[0020] The present disclosure generally relates to thermal management systems for use
in traction battery applications in automobiles. More particularly, the present disclosure relates
to an improved battery assembly having an integrated thermal management system for use in
three-wheeler automotive applications.
[0021] This summary is provided to introduce simplified concepts of a system for time
bound availability check of an entity, which are further described below in the detailed
description. This summary is not intended to identify key or essential features of the claimed
subject matter, nor is it intended for use in determining/limiting the scope of the claimed subject
matter.
[0022] An aspect of the present disclosure pertains to an energy storage assembly. The
energy storage assembly includes a housing. The housing can include one or more energy
storage module(s) and one or more roll bond evaporator plate. The one or more energy storage
modules disposed on any of one or more inner walls of the housing. The roll bond evaporator
plate(s) has a first face thermally coupled to at least one of the one or more energy storage
module, and a second face coupled with any of one or more inner walls of the housing. Each
roll bond evaporator includes a path adapted for flow of a cooling fluid.
[0023] In an aspect, the housing can include one or more energy storage modules.
[0024] In an aspect, the cooling fluid is introduced at an inlet to the path and the cooling
fluid exits at an outlet to the path, the inlet and outlet provided on the roll bond evaporator
plate.
[0025] In an aspect, the cooling fluid is adapted to exchange thermal energy at least one
of the one or more energy storage module.
[0026] In an aspect, a suitable flow rate of the cooling fluid in the roll bond evaporator
facilitates corresponding thermal energy exchange with at least one of the one or more energy
storage module to limit operating temperature of the at least one of the one or more energy
storage module to be within a desired range.
[0027] In an aspect, the energy storage assembly is used in three-wheeler automotive
applications.
[0028] In an aspect, the energy storage module comprises lithium-ion energy cells.
[0029] In an aspect, the battery assembly comprises a reservoir adapted for storage of
the cooling fluid, wherein a pump fluidically coupled with the reservoir facilitates flow of the
cooling fluid in the roll bond evaporator plate.
6
[0030] In an aspect, the battery assembly includes a control unit having a digital
processor or any other element of control which may be pneumatic, electronic or any other
methodology by which it can receive signals from multiple sensors. This can be the control
unit. The control unit is configured to receive signals from one or more sensors providing, the
present temperature of at least one of the one or more energy storage module, the ambient
temperature and the present remaining capacity of at least one of the one or more energy storage
module. The Control Unit can optimize the temperature at which the at least one of the one or
more energy storage module is maintained so as to maximise the life of the energy storage
module.
[0031] In an aspect, the control unit is configured to operate the pump to enable a
suitable flow rate of the cooling fluid in the roll bond evaporator to facilitate a corresponding
thermal energy exchange with at least one of the one or more energy storage module to enable
limiting operating temperature of the energy storage module to within a desired range.
[0032] In an aspect, the battery assembly is provided with a heat exchange apparatus
fluidically coupled with the inlet and outlet of the roll bond evaporator plate, the heat exchanger
adapted to facilitate exchange of thermal energy between the cooling fluid flowing through
said heat exchanger and an ambient atmosphere.
[0033] In an aspect, the housing comprises one or more insulation pads provided on
any one or more of the inner walls of the housing to enable restriction of flow of thermal energy
from external atmosphere.
[0034] Another aspect of the present disclosure pertains to a system for an energy
storage assembly. The system includes a housing and the housing further includes one or more
energy storage module and one or more roll bond evaporator plate(s). The one or more energy
storage module is disposed on any of one or more inner walls of the housing. The roll bond
evaporator plate(s) has a first face thermally coupled to at least one of the one or more energy
storage module, and a second face coupled with any of one or more inner walls of the housing.
The roll bond evaporator plates(s) is provided with a path adapted for flow of a cooling fluid.
[0035] In an aspect, the cooling fluid is introduced at an inlet to the path and the cooling
fluid exits at an outlet to the path, the inlet and outlet provided on the roll bond evaporator
plate.
[0036] In an aspect, a pump fluidically coupled to a reservoir is adapted for storage of
the cooling fluid, said pump configured to facilitate flow of the cooling fluid in the roll bond
evaporator plate.
7
[0037] In an aspect, a control unit is present which includes a digital processor or any
other element of control which may be pneumatic, electronic or any other methodology by
which it can receive signals from multiple sensors.
[0038] In an aspect, the Control Unit is configured to receive, from one or more sensors
provided in the housing signals of, current temperature of the energy storage module.
[0039] In an aspect, the Control Unit is configured to operate the pump to enable a
suitable flow rate of the cooling fluid in the roll bond evaporator plates(s) to facilitate a
corresponding thermal energy exchange with at least one of the one or more energy storage
module to enable limiting operating temperature of at least one of the one or more energy
storage module to within a desired range.
[0040] 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
[0041] The diagrams are for illustration only, which thus is not a limitation of the
present disclosure, and wherein:
[0042] FIG. 1 illustrates an exploded view of an exemplary energy storage assembly
having a thermal management system, in accordance with an embodiment of the present
disclosure.
[0043] FIG. 2 illustrates the exemplary energy storage assembly having the thermal
management system, in accordance with an embodiment of the present disclosure.
[0044] FIG. 3 illustrates a roll bond evaporator plate implemented on exemplary energy
storage assembly, in accordance with an embodiment of the present disclosure.
[0045] FIG. 4 shows a schematic representation of the functions of the energy storage
assembly having the thermal management system, in accordance with an embodiment of the
present disclosure.
[0046] FIG. 5 illustrates a roll bond evaporator plate associated with the energy storage
assembly, in accordance with the present disclosure.
DETAILED DESCRIPTION
[0047] 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
8
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.
[0048] In the following description, numerous specific details are set forth in order to
provide a thorough understanding of embodiments of the present invention. It will be apparent
to one skilled in the art that embodiments of the present invention may be practiced without
some of these specific details.
[0049] Embodiments of the present invention include various steps, which will be
described below. The steps may be performed by hardware components or may be embodied
in machine-executable instructions, which may be used to cause a general-purpose or specialpurpose processor programmed with the instructions to perform the steps. Alternatively, steps
may be performed by a combination of hardware, software, and firmware and/or by human
operators.
[0050] Various methods described herein may be practiced by combining one or more
machine-readable storage media containing the code according to the present invention with
appropriate standard computer hardware to execute the code contained therein. An apparatus
for practicing various embodiments of the present invention may involve one or more
computers (or one or more processors within a single computer) and storage systems containing
or having network access to computer program(s) coded in accordance with various methods
described herein, and the method steps of the invention could be accomplished by modules,
routines, subroutines, or subparts of a computer program product.
[0051] If the specification states a component or feature “may”, “can”, “could”, or
“might” be included or have a characteristic, that particular component or feature is not
required to be included or have the characteristic.
[0052] As used in the description herein and throughout the claims that follow, the
meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates
otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on”
unless the context clearly dictates otherwise.
[0053] Exemplary embodiments will now be described more fully hereinafter with
reference to the accompanying drawings, in which exemplary embodiments are shown. These
exemplary embodiments are provided only for illustrative purposes and so that this disclosure
will be thorough and complete and will fully convey the scope of the invention to those of
ordinary skill in the art. The invention disclosed may, however, be embodied in many different
9
forms and should not be construed as limited to the embodiments set forth herein. Various
modifications will be readily apparent to persons skilled in the art. The general principles
defined herein may be applied to other embodiments and applications without departing from
the spirit and scope of the invention. Moreover, all statements herein reciting embodiments of
the invention, as well as specific examples thereof, are intended to encompass both structural
and functional equivalents thereof. Additionally, it is intended that such equivalents include
both currently known equivalents as well as equivalents developed in the future (i.e., any
elements developed that perform the same function, regardless of structure). Also, the
terminology and phraseology used is for the purpose of describing exemplary embodiments
and should not be considered limiting. Thus, the present invention is to be accorded the widest
scope encompassing numerous alternatives, modifications and equivalents consistent with the
principles and features disclosed. For purpose of clarity, details relating to technical material
that is known in the technical fields related to the invention have not been described in detail
so as not to unnecessarily obscure the present invention.
[0054] Furthermore, embodiments may be implemented by hardware, software,
firmware, middleware, microcode, hardware description languages, or any combination
thereof. When implemented in software, firmware, middleware or microcode, the program
code or code segments to perform the necessary tasks (e.g., a computer-program product) may
be stored in a machine-readable medium. A processor(s) may perform the necessary tasks.
[0055] Systems depicted in some of the figures may be provided in various
configurations. In some embodiments, the systems may be configured as a distributed system
where one or more components of the system are distributed across one or more networks in a
cloud computing system.
[0056] Each of the appended claims defines a separate invention, which for
infringement purposes is recognized as including equivalents to the various elements or
limitations specified in the claims. Depending on the context, all references below to the
"invention" may in some cases refer to certain specific embodiments only. In other cases, it
will be recognized that references to the "invention" will refer to subject matter recited in one
or more, but not necessarily all, of the claims.
[0057] All methods described herein may be performed in any suitable order unless
otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all
examples, or exemplary language (e.g., “such as”) provided with respect to certain
embodiments herein is intended merely to better illuminate the invention and does not pose a
limitation on the scope of the invention otherwise claimed. No language in the specification
10
should be construed as indicating any non-claimed element essential to the practice of the
invention.
[0058] Various terms as used herein are shown below. To the extent a term used in a
claim is not defined below, it should be given the broadest definition persons in the pertinent
art have given that term as reflected in printed publications and issued patents at the time of
filing.
[0059] The present disclosure generally relates to thermal management systems for use
in power battery applications in automobiles. More particularly, the present disclosure relates
to an improved battery assembly having an integrated thermal management system for use in
three-wheeler automotive applications.
[0060] An aspect of the present disclosure pertains to an energy storage assembly. The
energy storage assembly includes a housing. The housing can include one or more energy
storage module(s) and one or more roll bond evaporator plate. The one or more energy storage
modules disposed on any of one or more inner walls of the housing. The roll bond evaporator
plate(s) has a first face thermally coupled to at least one of the one or more energy storage
module, and a second face coupled with any of one or more inner walls of the housing. Each
roll bond evaporator includes a path adapted for flow of a cooling fluid.
[0061] In an aspect, the housing can include one or more energy storage modules.
[0062] In an aspect, the cooling fluid is introduced at an inlet to the path and the cooling
fluid exits at an outlet to the path, the inlet and outlet provided on the roll bond evaporator
plate.
[0063] In an aspect, the cooling fluid is adapted to exchange thermal energy at least one
of the one or more energy storage module.
[0064] In an aspect, a suitable flow rate of the cooling fluid in the roll bond evaporator
facilitates corresponding thermal energy exchange with at least one of the one or more energy
storage module to limit operating temperature of the at least one of the one or more energy
storage module to be within a desired range.
[0065] In an aspect, the energy storage assembly is used in three-wheeler automotive
applications.
[0066] In an aspect, the energy storage module comprises lithium-ion energy cells.
[0067] In an aspect, the battery assembly comprises a reservoir adapted for storage of
the cooling fluid, wherein a pump fluidically coupled with the reservoir facilitates flow of the
cooling fluid in the roll bond evaporator plate.
11
[0068] In an aspect, the battery assembly includes a control unit having a digital
processor or any other element of control which may be pneumatic, electronic or any other
methodology by which it can receive signals from multiple sensors. This can be the control
unit. The control unit is configured to receive signals from one or more sensors providing, the
present temperature of at least one of the one or more energy storage module, the ambient
temperature and the present remaining capacity of at least one of the one or more energy storage
module. The Control Unit can optimize the temperature at which the at least one of the one or
more energy storage module is maintained so as to maximise the life of the energy storage
module.
[0069] In an aspect, the control unit is configured to operate the pump to enable a
suitable flow rate of the cooling fluid in the roll bond evaporator to facilitate a corresponding
thermal energy exchange with at least one of the one or more energy storage module to enable
limiting operating temperature of the energy storage module to within a desired range.
[0070] In an aspect, the battery assembly is provided with a heat exchange apparatus
fluidically coupled with the inlet and outlet of the roll bond evaporator plate, the heat exchanger
adapted to facilitate exchange of thermal energy between the cooling fluid flowing through
said heat exchanger and an ambient atmosphere.
[0071] In an aspect, the housing comprises one or more insulation pads provided on
any one or more of the inner walls of the housing to enable restriction of flow of thermal energy
from external atmosphere.
[0072] Another aspect of the present disclosure pertains to a system for an energy
storage assembly. The system includes a housing and the housing further includes one or more
energy storage module and one or more roll bond evaporator plate(s). The one or more energy
storage module is disposed on any of one or more inner walls of the housing. The roll bond
evaporator plate(s) has a first face thermally coupled to at least one of the one or more energy
storage module, and a second face coupled with any of one or more inner walls of the housing.
The roll bond evaporator plates(s) is provided with a path adapted for flow of a cooling fluid.
[0073] In an aspect, the cooling fluid is introduced at an inlet to the path and the cooling
fluid exits at an outlet to the path, the inlet and outlet provided on the roll bond evaporator
plate.
[0074] In an aspect, a pump fluidically coupled to a reservoir is adapted for storage of
the cooling fluid, said pump configured to facilitate flow of the cooling fluid in the roll bond
evaporator plate.
12
[0075] In an aspect, a control unit is present which includes a digital processor or any
other element of control which may be pneumatic, electronic or any other methodology by
which it can receive signals from multiple sensors.
[0076] In an aspect, the Control Unit is configured to receive, from one or more sensors
provided in the housing signals of, current temperature of the energy storage module.
[0077] In an aspect, the Control Unit is configured to operate the pump to enable a
suitable flow rate of the cooling fluid in the roll bond evaporator plates(s) to facilitate a
corresponding thermal energy exchange with at least one of the one or more energy storage
module to enable limiting operating temperature of at least one of the one or more energy
storage module to within a desired range.
[0078] FIG. 1 illustrates an exploded view of an exemplary energy storage assembly 12
having a thermal management system, in accordance with an embodiment of the present
disclosure. The energy storage assembly 12 shown in FIG. 1 can typically be used in
automotive applications but in particular, it may well-suited for use with three wheeler
automotive applications. The energy storage assembly 12 is typically based on a direct
expansion cooling system but can be based on other systems known in the art in other
embodiments. The thermal management system can be based on a direct expansion liquid
cooling system (DXLC). In some embodiments, it can be based on other cooling systems
known in the art.
[0079] As shown in FIG. 1, the energy storage assembly 12 can include a series of
energy storage modules (comprising of individual cells; i.e. a plurality of battery cells, or a
plurality of energy storage modules, or “energy storage module” for brevity, unless otherwise
mentioned) 35 and 20, a roll bond evaporator plate 11. The energy storage module can be based
on lithium ion (or “Li-ion” as is herein provided) battery cells known in the art. The roll bond
evaporator plate 11 can be a plate that has been roll-bonded onto a bottom plate (not indicated;
but can be seen in FIG. 3) of the energy storage assembly 12 as is more clearly shown in FIG.
3.
[0080] Referring again to FIG. 3 which illustrates the roll bond evaporator plate 11
implemented on the energy storage assembly 12, the roll bond evaporator plate 11 can include
a inlet 15 and a outlet 16. The sections 15, 16 can be located adjacent to each other as shown.
The sections 15, 16 can also be located adjacent the roll bond evaporator plate 11 as shown in
a planar perspective. Typically, they may be arranged such that there is no hindrances between
their respective fluid flow directions. As can be seen, the roll bond evaporator plate 11 can
be arranged, in a planar perspective on the surface of the bottom plate of the energy storage
13
assembly 12. The inlet 15 is a typical inlet known in the art capable of receiving a refrigerant
or a coolant or a cooling fluid and the outlet 16 is a typical outlet known in the art capable of a
discharge function. The roll bond evaporator plate 11 is in communication with sections 15, 16
with a fluid flow direction emanating from section 15 towards section 16.
[0081] The roll bond evaporator plate 11 can have a first face (not shown) thermally
coupled to the energy storage module, and a second face coupled with any of one or more inner
walls of a housing, the roll bond evaporator plate 11 provided with a path adapted for flow of
a cooling fluid (not shown). The cooling fluid can be introduced at the inlet 15 to the path and
the cooling fluid exits at the outlet 16 to the path. The inlet and outlet 15, 16 are provided on
the roll bond evaporator plate 11. The cooling fluid is typically adapted to exchange thermal
energy with the energy storage module and a suitable flow rate of the cooling fluid in the roll
bond evaporator plate 11 facilitates corresponding thermal energy exchange with the energy
storage module to limit operating temperature of the energy storage module to be within a
desired range. The desired range can be based on any range known in the art associated in
particular with three wheeler automotive applications, as is herein mentioned.
[0082] The battery assembly can also include a reservoir that can be adapted for storage
of the cooling fluid and a pump that is fluidically coupled with the reservoir which can facilitate
flow of the cooling fluid in the roll bond evaporator plate 11.
[0083] The energy storage assembly 12 can be based on Li-ion energy storage modules
35 and 20 as already mentioned. These modules are electrically connected to each other and
can be arranged in any feasible manner known in the art and which can be appreciated by a
person skilled in the art. Further, each of the energy storage modules 35 and 20 can include
battery cells 21 which are further electrically connected to each other. The battery cells 21 of
each energy storage module 35 and 20 are tightly adhered to the roll bonded evaporator plate
11 from the bottom side of the energy storage assembly 12 to dissipate heat generated from the
battery cells 21.
[0084] Referring now to FIG. 5 which shows the roll bond evaporator plate 11, the roll
bond evaporator plate 11 can be designed based on thermal points associated with the energy
storage modules 35 and 20, the thermal points being the source of thermal dissipation
associated with the energy storage modules 35 and 20. Therefore, in some embodiments, the
roll bond evaporator plate 11 can take the form associated with the thermal points of respective
energy storage modules 35 and 20. In some embodiments, the roll bond evaporator plate 11
can take the form associated with the thermal points of the battery cells 21. The inlet 15 and
14
the outlet 16 and their routing inside the evaporator plate 11 can ensure high thermal heat
transfer rate and minimum temperature non uniformity across the cells.
[0085] Referring now to FIG. 1, the energy storage assembly 12 can include an
insulation layer 10 which can be added to the bottom surface of the roll bond evaporator plate
11 to ensure that no leakage of heat flux is caused from the lower end of the energy storage
assembly 12 and heat generated by a cell 21 associated with the energy storage modules 35 and
20 is transferred into the roll bond evaporator plate 11. As can be seen, the energy storage
assembly 12 can include insulation pads 17 and 18 that can be placed at the walls of energy
storage modules 35 and 20, and the energy storage assembly 12. In an embodiment, the housing
can include one or more insulation pads provided on any one or more of the inner walls of the
housing to enable restriction of flow of thermal energy from external atmosphere.
[0086] FIG. 2 illustrates the exemplary energy storage assembly 12 having the thermal
management system, in accordance with an embodiment of the present disclosure. Thermal
subsystem 36 (shown in FIG. 1) components can include a condenser 6, a fan 5 (i.e. a fin or
like device that can cause air to move), a fan box 4, a compressor 6, a controller 9, and a direct
expansion (DX) coil 1. The condenser 6 is air cooled by means of fan 5. The heat from the
condenser 6 is rejected into the atmosphere through the exhaust section.
[0087] FIG. 4 shows a schematic representation of the functions of the energy storage
assembly 12 having the thermal management system. As can be seen, the energy storage
assembly 12, in a typical three wheeler automotive application, is in communicative connection
with a condensing unit 404. The condensing unit 404 can include a compressor 406, a
condenser coil 408, and a drier 412. As can be appreciated, the condensing unit 404 can have
two fluid flow trajectory, a hose pipe 414 fluid flow trajectory configured for a coolant or a
refrigerant associated with the energy storage assembly 12, and an NRV 416 fluid flow
trajectory.
[0088] During the charge and discharge process each cell temperature is monitored
using thermistors. The temperature values are logged in a Control Unit. A threshold set point
temperature value of Li-ion cell is programmed in the Control Unit. As soon as the temperature
of Li-ion cell crosses above a set point temperature, the DX System gets activated. The
refrigerant flows through the roll bond evaporator plate 11 absorb the heat generated by the
energy storage modules. Once the refrigerant has absorbed heat energy it is further passed
inside the compressor 6 where its pressure and temperature is increased to pass it in the
discharge line into the condenser 9 wherein the heat is rejected outside the energy storage
assembly 12 by fan 5.
15
[0089] The Control Unit can be configured to receive, from one or more sensors (not
shown) provided in the housing, a current temperature of the energy storage module. The
current temperature refers to the temperature of the energy storage assembly 12 during its
operation. In an embodiment, the control unit can be configured to operate the pump to enable
a suitable flow rate of the cooling fluid in the roll bond evaporator plate 11 to facilitate a
corresponding thermal energy exchange with the energy storage module to enable limiting
operating temperature of the energy storage module to within a desired range as previously
provided.
[0090] In an embodiment, the battery assembly can be provided with a heat exchange
apparatus fluidically coupled with the inlet 15 and outlet 16 of the roll bond evaporator plate
11 with the heat exchange apparatus (not shown) being adapted to facilitate exchange of
thermal energy between the cooling fluid flowing through the heat exchange apparatus and an
ambient atmosphere.
[0091] The active liquid cooling system in the instant disclosure is catered to through a
Direct Expansion Liquid Cooling (DXLC) System. The sizing aspect of the DXLC
system(associated with the energy storage assembly 12) involves a comprehensive
computation of heat generation at any Li-ion cell and energy storage assembly 12 level with
the predicted driving cycle. Heat generation inside each Li-ion cell can be calculated by
considering the Ohmic irreversible heat generation and entropic heat generation. The ambient
heat flux from the high ambient temperature into the energy storage assembly 12 also plays a
considerable role in the sizing of compressor specifications. For example, the rated capacity of
compressor selected for a 10 KWH Li-ion battery pack is 350W. Accordingly, the compressor’s
specifications can depend upon the specification of a given DXLC system associated with the
energy storage assembly 12. Further, instantaneous heat loads arising due to high current
discharge during gradient climb are absorbed by the DXLC system with a selected compressor.
[0092] The equation considered for capacity computations can be:
Where Qjou represents Ohmic Heat and Qre represents reversible entropic heat. Uocv denotes
the open circuit voltage while Ut denotes the terminal voltage of a Li-ion cell or the energy
storage module as is herein mentioned. The reaction heat is determined by the battery
operating current and the effective entropic potential.
[0093] The Li-ion cell’s internal resistance Rin can be calculated as follows.
16
Where Rin is a function of temperature and SOC (State of Charge), a lookup table with
internal resistance as a function SOC and Temperature is given as an input to the heat
generation model and heat generation at all points within the drive cycle can be calculated.
This ensures that all operating design points are covered by the DXLC system thus making it
versatile to use in geographies with varied ambient temperatures and driving topologies.
[0094] Thus, the cooling strategy and Control Unit used for compressor drive ensures
optimized energy usage of the compressor to ensure a balance between the battery state of
health (SOH) and state of charge (SOC). This is achieved by real time monitoring of ambient
temperature data around the battery pack. The algorithm computes an estimated threshold
temperature limit based on ambient temperatures associated with specific geographical location
and the Li-ion cell temperature. This estimated threshold limit can be based on real time data
collection, thereby regulating the triggering of compressor. Thus the control strategy allows
the optimised use of energy consumption by the compressor with simultaneously fulfilling the
core objective of maintaining the Li ion cell temperature within the desired temperature limits.
For example, in a place like Delhi, India where in the temperature is 40°C (average temperature
in May) the control algorithm calculates the threshold temperature at which the compressor is
triggered at 32°C thereby arresting the Li-ion cell temperature within 35°C. Also for instances
when average temperature is 30°C (average temperature in March), the control algorithm can
calculate the compressor trigger temperature as 28.5°C and thereby arresting the temperature
of Li-ion cell within 32°C. The control strategy also considers the nature of the driving cycle
behaviour along with the ambient temperature in determining the compressor triggering
temperature. For example as discussed above when the ambient temperature is 40°C and if the
driving profile is very aggressive with high current discharge rate, the compressor triggering
temperature is calculated to be 29°C, thereby giving an extra temperature bandwidth for
operating the DXLC system to keep the Li-ion cell temperature within 35°C limit.
[0095] The present limitations like low heat transfer rate, needs of additional
components to accommodate water-Ethylene Glycol storage compartment leading to weight
and volume increase, high operational cost are often associated with the SLC system. The
present disclosure involves a thermal subsystem and architecture design of DXLC hybrid
system for use in a three wheeler automotive application.
17
[0096] The present disclosure also pertains to a system for an energy storage assembly.
The system includes a housing and the housing further includes an energy storage module and
a roll bond evaporator plate. The energy storage module disposed on any of one or more inner
walls of the housing. The roll bond evaporator plate has a first face thermally coupled to the
energy storage module, and a second face coupled with any of one or more inner walls of the
housing. The roll bond evaporator is provided with a path adapted for flow of a cooling fluid.
The cooling fluid is introduced at an inlet to the path and the cooling fluid exits at an outlet to
the path, the inlet and outlet provided on the roll bond evaporator plate. A pump fluidically can
be coupled to a reservoir is adapted for storage of the cooling fluid, said pump configured to
facilitate flow of the cooling fluid in the roll bond evaporator plate. A Control Unit is present.
The Control Unit is configured to receive, from one or more sensors provided in the housing,
a current temperature of the energy storage module. The control unit can have a digital
processor or any other element of control which may be pneumatic, electronic or any other
methodology by which it can receive signals from multiple sensors. This can be the control
unit. The control unit is configured to receive signals from one or more sensors providing, the
present temperature of the energy storage module, the ambient temperature and the present
remaining capacity of the energy storage module. The Control Unit can optimize the
temperature at which the energy storage module is maintained so as to maximise the life of the
energy storage module. The control unit is also configured to operate the pump to enable a
suitable flow rate of the cooling fluid in the roll bond evaporator to facilitate a corresponding
thermal energy exchange with the energy storage module to enable limiting operating
temperature of the energy storage module to within a desired range.
[0097] The present disclosure involves design of DXLC system with enhanced roll
bonded evaporator which ensures maximum surface contact with the cells thereby enhancing
the heat transfer rate with rapid thermal response time. The micro channels within the roll
bonded evaporator are routed such that temperature non uniformity is minimized thereby
cooling all Li-ion cells equally. The fitment mechanism of evaporator plate and energy storage
modules is designed to ensure tight adherence with each other. Due to this tight bonding, the
air cavities between the heat exchanging surfaces are minimized thereby further enhancing the
heat transfer rate. The compact battery pack assembly along with DXLC thermal management
system is mounted in the volume available below the driver’s seat or the loading bay or
passenger seats (based on customer application) in the three wheeler.
[0098] The other aspect of the invention involves the restriction of incoming heat flux
from high ambient temperature into the battery pack using high insulation pads or PCM along
18
the inner surface of the battery pack. As discussed above the DXLC cooling takes care of the
heat generated by the battery pack during the operating conditions. However, when the battery
is not under operation i.e. the vehicle is at rest, due to high ambient temperature there is high
convective heat influx into the battery pack from ambience. This leads to rising Li-ion cell
temperature and the thermal management system needs to be triggered to restrict the rise in
temperature. This frequent triggering of DXLC System while the battery pack is at rest is not
desirable as it increases the energy utilization of the battery pack, thereby adding additional
operating cost of the DXLC system. This major limitation is solved by the design of insulation
pads or PCM placed along the Li-ion cell surface inside the battery pack. Thus, the temperature
rise of Li-ion cells due to high ambient temperature when the battery pack is at rest is restricted
without adding any additional load on the DXLC system. Also in case when the ambient
temperature drops to a significantly low value the insulation pads or PCM inside the battery
pack prevents the convective heat outflux from the battery pack to cool ambient surrounding.
Thus this invention assures that the temperature control of Li-ion cell is maintained over wide
range of surrounding temperatures.
[0099] Another important aspect of this invention is the cost competitiveness as the
value involved in incorporating the DXLC system in the battery pack justifies the increase in
the cycle life of Li-ion cells and also the overall safety aspects associated with the battery pack.
[00100] While this disclosure pertains to an improved energy storage assembly 12
having an integrated thermal management system for use in three-wheeler automotive
applications, other variations are possible as can be appreciated by a person skilled in the art.
[00101] The present disclosure pertains to an energy storage assembly. The energy
storage assembly includes a housing. The housing includes an energy storage module and a
roll bond evaporator plate. The energy storage module is disposed on any of one or more inner
walls of the housing. The roll bond evaporator plate has a first face thermally coupled to the
energy storage module, and a second face coupled with any of one or more inner walls of the
housing. The roll bond evaporator plate includes a path adapted for flow of a cooling fluid. A
compressor pumps the cooling fluid into the roll bond evaporator plate and a condenser
conducts a successive cooling of the cooling fluid after the cooling fluid exits the roll bond
evaporator plate.
[00102] It would be appreciated that although the proposed system has been elaborated
as above to include all the main units, it is conceivable that actual implementations are well
within the scope of the present disclosure, which can include without any limitation, only a
part of the proposed units or a combination of those or a division of those into sub-units in
19
various combinations across multiple devices that can be operatively coupled with each other,
including in the cloud. Further, the units can be configured in any sequence to achieve
objectives elaborated. Also, it can be appreciated that proposed system can be configured in a
computing device or across a plurality of computing devices operatively connected with each
other, wherein the computing devices can be any of a computer, a laptop, a smart phone, an
Internet enabled mobile device and the like. Therefore, all possible modifications,
implementations and embodiments of where and how the proposed system 100 is configured
are well within the scope of the present invention.
[00103] While embodiments of the present invention have been illustrated and
described, it will be clear that the invention is not limited to these embodiments only. Numerous
modifications, changes, variations, substitutions, and equivalents will be apparent to those
skilled in the art, without departing from the spirit and scope of the invention, as described in
the claim.
[00104] In the foregoing description, numerous details are set forth. It will be apparent,
however, to one of ordinary skill in the art having the benefit of this disclosure, that the present
invention can be practiced without these specific details. In some instances, well-known
structures and devices are shown in block diagram form, rather than in detail, to avoid
obscuring the present invention.
[00105] As used herein, and unless the context dictates otherwise, the term "coupled to"
is intended to include both direct coupling (in which two elements that are coupled to each
other contact each other)and indirect coupling (in which at least one additional element is
located between the two elements). Therefore, the terms "coupled to" and "coupled with" are
used synonymously. Within the context of this document terms "coupled to" and "coupled
with" are also used euphemistically to mean “communicatively coupled with” over a network,
where two or more devices are able to exchange data with each other over the network, possibly
via one or more intermediary device.
[00106] It should be apparent to those skilled in the art that many more modifications
besides those already described are possible without departing from the inventive concepts
herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the
appended claims. Moreover, in interpreting both the specification and the claims, all terms
should be interpreted in the broadest possible manner consistent with the context. In particular,
the terms “comprises” and “comprising” should be interpreted as referring to elements,
components, or steps in a non-exclusive manner, indicating that the referenced elements,
components, or steps can be present, or utilized, or combined with other elements, components,
20
or steps that are not expressly referenced. Where the specification claims refers to at least one
of something selected from the group consisting of A, B, C …. and N, the text should be
interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
[00107] While the foregoing describes various embodiments of the invention, other and
further embodiments of the invention can 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 PRESENT DISCLOSURE
[00108] The present disclosure provides an improved battery assembly having an
integrated thermal management system for use in three-wheeler automotive applications.
[00109] The present disclosure provides a simple and cost effective improved battery
assembly having an integrated thermal management system for use in three-wheeler
automotive applications.
[00110] The present disclosure provides a reliable and efficient battery assembly having
an integrated thermal management system for use in three-wheeler automotive applications.
[00111] The present disclosure provides a robust battery assembly having an integrated
thermal management system for use in three-wheeler automotive applications.
[00112] The present disclosure provides a battery assembly having an integrated thermal
management system for use in three-wheeler automotive applications, and which provides high
thermal response time thereby keeping the battery temperature within desired range under all
operating conditions.
[00113] The present disclosure provides a battery assembly having an integrated thermal
management system for use in three-wheeler automotive applications that offers a substantial
increase in battery life.
21
[00114] The present disclosure provides a battery assembly having an integrated thermal
management system for use in three-wheeler automotive applications that can prevent thermal
runaway of li-ion cells or energy storage module, thereby preventing any fire hazard, which
are common in high temperature operation zones.

We Claim:

1. An energy storage assembly comprising:
a housing comprising:
an energy storage module disposed on any of one or more inner walls of the housing;
and
a roll bond evaporator plate having a first face thermally coupled to the energy storage
module, and a second face coupled with any of one or more inner walls of the housing, the roll
bond evaporator provided with a path adapted for flow of a cooling fluid;
wherein the cooling fluid is introduced at an inlet to the path and the cooling fluid exits
at an outlet to the path, the inlet and outlet provided on the roll bond evaporator plate;
wherein the cooling fluid is adapted to exchange thermal energy with the energy storage
module;
wherein a suitable flow rate of the cooling fluid in the roll bond evaporator facilitates
corresponding thermal energy exchange with the energy storage module to limit operating
temperature of the energy storage module to be within a desired range; and
wherein the energy storage assembly is used in three-wheeler automotive applications.
2. The energy storage assembly as claimed in claim 1, wherein the energy storage module
comprises lithium-ion energy cells.
3. The energy storage assembly as claimed in claim 1, wherein the battery assembly
comprises a reservoir adapted for storage of the cooling fluid, wherein a pump fluidically
coupled with the reservoir facilitates flow of the cooling fluid in the roll bond evaporator plate.
4. The energy storage assembly as claimed in claim 3, wherein the battery assembly
comprises a control unit comprising a processor, the processor configured to:
receive, from one or more sensors provided in the housing, a current temperature of the
energy storage module,
wherein the control unit is configured to operate the pump to enable a suitable flow rate
of the cooling fluid in the roll bond evaporator to facilitate a corresponding thermal energy
exchange with the energy storage module to enable limiting operating temperature of the
energy storage module to within a desired range.
5. The energy storage assembly as claimed in claim 1, wherein the battery assembly is
provided with a heat exchange apparatus fluidically coupled with the inlet and outlet of the roll
bond evaporator plate, the heat exchanger adapted to facilitate exchange of thermal energy
between the cooling fluid flowing through said heat exchanger and an ambient atmosphere.
23
6. The energy storage assembly as claimed in claim 1, wherein the housing comprises one
or more insulation pads provided on any one or more of the inner walls of the housing to enable
restriction of flow of thermal energy from external atmosphere.
7. A system for an energy storage assembly, said system comprising:
a housing comprising:
an energy storage module disposed on any of one or more inner walls of the housing;
a roll bond evaporator plate having a first face thermally coupled to the energy storage
module, and a second face coupled with any of one or more inner walls of the housing, the roll
bond evaporator provided with a path adapted for flow of a cooling fluid, wherein the cooling
fluid is introduced at an inlet to the path and the cooling fluid exits at an outlet to the path, said
inlet and outlet provided on the roll bond evaporator plate;
a pump fluidically coupled to a reservoir adapted for storage of the cooling fluid, said
pump configured to facilitate flow of the cooling fluid in the roll bond evaporator plate; and
a control unit comprising a processor, said processor configured to:
receive, from one or more sensors provided in the housing, a current
temperature of the energy storage module,
wherein the control unit is configured to operate the pump to enable a suitable flow rate of the
cooling fluid in the roll bond evaporator to facilitate a corresponding thermal energy exchange
with the energy storage module to enable limiting operating temperature of the energy storage
module to within a desired range.