DESC:BATTERY MODULE FOR ELECTRIC VEHICLE
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202221041753 filed on 21/07/2022, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to a battery module. Specifically, the present disclosure specifically relates to a compact battery module with efficient cooling for electric vehicle.
BACKGROUND
Recently, there have been a rapid development in battery packs because of their use as energy storage solution for various uses ranging from domestic use to transportation use. The battery pack comprises a set of any number of identical batteries or individual battery cells. The battery cells are assembled as cell arrays and multiple cell arrays are combined to form the battery module.
Each battery module comprises a plurality of cells and cell holders for securing the plurality of cells. These battery cells are electrically connected to form a cell arrays and multiple cell arrays can be stacked together to form a battery module, being used as a single unit for meeting high voltage and current requirements. However, the battery module generates a large amount of heat during a charging and discharging process. If heat generated during the charging and discharging process is not effectively eliminated, heat accumulation may occur, which results in accelerated deterioration of the battery cells. Moreover, in some conditions such heat accumulation may even lead to thermal runaway which would permanently damage the battery module. The thermal runaway may lead to fire and/or explosion.
Generally, to eliminate the heat and preventing resultant damages, from the plurality of battery module being stacked together, a cooling structure is placed on the outer surfaces such as casing of the battery module. Such cooling structure can only extract heat from the outer portions of the battery module, as a result of which inner portions remain at a higher temperature. Thus, a temperature gradient is formed between the inner and outer portion of the battery module which leads to poor cell performance and higher degradation rate. In some cases, an external cooling plate can be used to minimise the temperature gradient or submerged cooling technique wherein the cells of the whole battery module are submerged in a coolant. However, use of such cooling techniques will lead to increase in weight, size and cost of the battery module. Such cooling techniques add unnecessary bulk to the already bulky battery module. Furthermore, the added weight affects the performance of the battery module in mobile application such as electric vehicles.
Thus, there exists a need for a battery module with efficient cooling mechanism capable of quickly dissipating heat generated during the charging and discharging operation.
SUMMARY
An object of the present disclosure is to provide a battery module for powerpack of an electric vehicle.
In accordance with first aspect of the present disclosure, there is provided a battery module for powerpack of an electric vehicle, the battery module comprising a first cell array, a first enclosure tub, a second cell array, a second enclosure tub and a cooling chamber. The first cell array comprises a first set of battery cells. The first enclosure tub holds the first cell array. The second cell array comprises a second set of battery cells. The second enclosure tub holds the second cell array. The cooling chamber is configured between the first cell array and the second cell array such that the first cell array and the second cell array are in physical contact with the cooling chamber.
The present disclosure provides a battery module with common cooling chamber for the first cell array and the second cell array. The battery module, as disclosed in the present disclosure is advantageous in terms of compactness of size. Furthermore, the battery module of the present disclosure is lesser in weight compared to conventional battery modules with cooling mechanisms. Furthermore, the battery module of the present disclosure is advantageous in terms of providing better heat dissipation leading to improved battery module health and longer operational life.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figure 1 illustrates an exploded view of a battery module for powerpack of an electric vehicle, in accordance with an aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a cell holder and a battery module and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms ‘electric vehicle’, ‘EV’, and ‘EVs’ are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries which are exclusively charged from an external power source, as well as hybrid-vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheeler, electric three-wheeler, electric four-wheeler, electric pickup trucks, electric trucks and so forth.
A used herein, the terms “battery pack”, “battery”, and “power pack” are used interchangeably and refer to multiple individual battery module connected together to provide a higher combined voltage or capacity than what a single battery module can offer. The battery pack is designed to store electrical energy and supply it as needed to various devices or systems. Battery pack, as referred herein may be used for various purposes such as power electric vehicles and other energy storage applications. Furthermore, the battery pack may include additional circuitry, such as a battery management system (BMS), to ensure the safe and efficient charging and discharging of the battery cells. The battery pack comprises a plurality of battery modules which in turn comprises a plurality of battery cells.
As used herein, the term “cell array”, “first cell array” and “second cell array” may be used interchangeably and refer to an assembled unit of a plurality of battery cells that are connected together electrically to form a larger energy storage system. It is to be understood that multiple cell arrays may be connected as per the required configuration to form a battery module. Furthermore, the cell arrays may be arranged in series or parallel configuration depending on the desired voltage and capacity requirements. It is understood that connecting cell arrays in series increases the overall voltage of the battery pack, while connecting the cell arrays in parallel increases the capacity.
As used herein, the term “battery module” refers to an assembled unit of a plurality of cell arrays that are connected together electrically to form a larger energy storage system capable of delivering required amount of energy for high power applications. The battery modules may be arranged in series or parallel configuration depending on the desired voltage and capacity requirements. It is understood that connecting battery modules in series increases the overall voltage of the battery pack, while connecting them in parallel increases the capacity. The electrical connections in the battery module are formed by connecting the terminals of the battery cells with bus bars. Furthermore, in addition to the individual cells, a battery module may also include circuitry for balancing the charge levels of the cells, managing the charging and discharging processes, and providing safety features such as overcharge and over-discharge protection. The battery module, along with the associated electronics and packaging, forms the core component of a battery pack, enabling the efficient and reliable storage and delivery of electrical energy.
As used herein, the terms “plurality of battery cells”, “cells” “first set of battery cells”, “second set of battery cells” and “battery-cell” are used interchangeably and refer to basic unit that generates and stores electrical energy. A battery module is typically composed of one or more individual cells connected together. The cells may be comprised of different chemistry including lithium-ion cells, solid state cells, zinc-carbon and alkaline cells, nickel metal hydride, nickel cadmium and so forth. Furthermore, the battery cells may include various types of cells including cylindrical cells, prismatic cells, pouch cells, coin cells or any customised shape cells.
As used herein, the term “cell enclosure tub”, “cell tub” and “enclosure tub” are used interchangeably and refer to a protective housing of the battery module that is used to securely enclose the cell arrays of the battery module. The cell enclosure tub physically encloses the cell arrays and protects the plurality of cells from any mechanical damage. It is to be understood that cell enclosure tub is designed to provide physical protection, electrical insulation, and thermal management for the battery module. Furthermore, the cell enclosure tub beneficially provides protection against physical damage, ingress of moisture or foreign objects. Beneficially, the cell enclosure tub may comprise shock absorption capabilities, sealing gaskets, venting mechanisms, and fire-resistant materials to enhance safety.
As used herein, the term “cell-holding structure”, “cell-holder” and “holder” are used interchangeably and refer to a component of the cell enclosure tub used to securely hold and position individual battery cells within the battery module. The primary purpose of a cell holder is to provide mechanical support and protection for the battery cells. It helps to maintain the structural integrity of the battery module, preventing cells from shifting or coming into contact with each other, which could cause damage or safety hazards. It would be appreciated that the cell holders are crucial in ensuring the proper assembly, alignment, and electrical connectivity of battery cells within the cell array. They contribute to the overall reliability, safety, and performance of the battery system by preventing cell damage, maintaining consistent contact, and facilitating efficient power transfer.
As used herein, the terms “plurality of channels” “channels” and “channels” are used interchangeably and refer to structure in the cooling chamber that forms a pathway for flow of coolant. The flow of coolant is used to dissipate the heat from the plurality of battery cells and ensuring optimum operation.
As used herein, the terms “busbar” and “busbar plates” are used interchangeably and refer to a conductive metal strip or plate used to facilitate the distribution of electrical power or signals within the cell array. The busbar plate serves as a common electrical connection point for plurality of battery cells.
As used herein, the term “cooling chamber” refers to a structure that is used to dissipate heat generated during the operation of the battery cells in the battery module. It would be understood that the cooling chamber is designed to maintain optimal temperature levels within the battery module, preventing excessive heat build-up that can affect the performance, lifespan, and safety of the battery cells. The cooling chamber may include metal heat spreader, liquid cooling plate, finned cooling plate and so forth.
As used herein, the term “thermal cooling pad” and “cooling pad” are used interchangeably and refers to a soft, compressible material used to enhance heat transfer between two surfaces. It is to be understood that the thermal cooling pad fills in microscopic air gaps and uneven surfaces between the heat source and the heat sink, ensuring efficient heat transfer and minimizing thermal resistance. By improving the contact between the two surfaces, the thermal cooling pad enhances the conduction of heat from the heat-generating component to the heat sink, allowing for more effective cooling.
Figure 1, in accordance with an embodiment describes an exploded view of a battery module 100 for powerpack of an electric vehicle, the battery module 100 comprising a first cell array 102, a first enclosure tub 104, a second cell array 106, a second enclosure tub 108 and a cooling chamber 110. The first cell array 102 comprises a first set of battery cells. The first enclosure tub 104 holds the first cell array 102. The second cell array 106 comprises a second set of battery cells. The second enclosure tub 108 holds the second cell array 106. The cooling chamber 110 is configured between the first cell array 102 and the second cell array 106 such that the first cell array 102 and the second cell array 106 are in physical contact with the cooling chamber 110.
The battery module 100, as disclosed in the present disclosure is advantageous in terms of compactness of size. It is to be understood that the battery module 100 eliminates the need of any external cooling jacket for cooling of the plurality of battery cells, thus reducing the size of battery module 100. Furthermore, the battery module 100 of the present disclosure is lesser in weight compared to conventional battery modules with cooling mechanisms to cool the plurality of battery cells. Furthermore, the battery module 100 of the present disclosure is advantageous in terms of providing better heat dissipation leading to improved health and longer operational life of the plurality of battery cells. Moreover, the battery module 100 is cost-effective to manufacture as it eliminates the requirement of various cooling associated components such as cooling jackets and covers for cooling of the battery module 100.
In an embodiment, the first enclosure tub 104 and the second enclosure tub 108 comprise a cell-holding structure. Furthermore, in an embodiment, the cell-holding structure comprises plurality of grooves to receive the plurality of battery cells. Beneficially, the cell-holding structure is designed such that the plurality of battery cells snugly fit into the plurality of grooves of the cell-holding structure. It is to be understood that the first enclosure tub 104 and the second enclosure tub 108 have an open surface on one side and a closed surface on the other side. A person skilled in the art would understand that the plurality of battery cells are inserted into the first enclosure tub 104 and the second enclosure tub 108 from the side having open surface. Furthermore, it is to be understood that the plurality of battery cells inserted into the first enclosure tub 104 and the second enclosure tub 108 fits into the cell-holding structure.
In an embodiment, the battery module 100 comprises a first busbar plate 112 for electrically connecting the first set of battery cells with each other within the first cell array 102 and a second busbar plate 114 for electrically connecting the second set of battery cells with each other within the second cell array 106. Beneficially, the first busbar plate 112 and the second busbar plate 114 may be welded on terminals of the plurality of battery cells. Alternatively, the first busbar plate 112 and the second busbar plate 114 may be removably fixed on the terminals of the plurality of battery cells.
In an embodiment, the first enclosure tub 104 and the second enclosure tub 108 comprise busbar holding structures to hold the first busbar plate 112 and the second busbar plate 114, respectively. Beneficially, the busbar holding structures accommodate the busbar plates inside the first enclosure tub 104 and the second enclosure tub 108. Furthermore, the busbar holding structures securely hold the busbar plates 112, 114 in place and restrict any movement of the busbar plates 112, 114 during the operation of the battery module 100.
In an embodiment, the cooling chamber 110 comprises a plurality of channels forming a coolant flow path. Specifically, in an embodiment, the cooling chamber 110 comprises an inlet channel 116 and an outlet channel 118 for inflow and outflow of a coolant through the cooling chamber 110. Beneficially, the coolant flows through the coolant flow path formed by the plurality of channels to reduce the temperature of the plurality of battery cells during the operation of the battery module 100. It is to be understood that the coolant enters into the plurality of channels through the inlet channel 116 and exits the plurality of channels through the outlet channel 118.
In an embodiment, the first enclosure tub 104 and the second enclosure tub 108 comprise a locking mechanism to join the first enclosure tub 104 and the second enclosure tub 108 to enclose the battery module 100. It is to be understood that the first enclosure tub 104 and the second enclosure tub 108 may be arranged together with their open sides facing each other. The cooling chamber 110 may be placed between the first enclosure tub 104 and the second enclosure tub 108 and the first enclosure tub 104 and the second enclosure tub 108 may be then joined to close the battery module 100. Beneficially, the locking mechanism securely keep the first enclosure tub 104 and the second enclosure tub 108 joined together forming the enclosed battery module 100. In an embodiment, the locking mechanism may comprise nut-bolt, screws, rivets and so forth.
In an embodiment, the first enclosure tub 104 and the second enclosure tub 108 comprise a filler material filled in empty spaces between plurality of cells of the first set of battery cells and plurality of cells of the second set of battery cells. Beneficially, the filler material absorbs vibrations occurring during the operation of the battery module 100. More beneficially, the filler material prevents any movement of the plurality of battery cells in the first enclosure tub 104 and the second enclosure tub 108. Furthermore, the filler material is electrically insulating. Moreover, the filler material may prevent thermal runaway in the battery module 100. In an embodiment, the filler material may be a foam. In an alternative embodiment, the filler material may be a gel or any other suitable material.
In an embodiment, the first enclosure tub 104 and the second enclosure tub 108 are made of an electrically insulating and thermally conducting material. Beneficially, the first enclosure tub 104 and the second enclosure tub 108 transfers the heat generated by the plurality of battery cells towards outer surface of the battery module 100. Beneficially, the heat transferred towards the outer surface of the battery module 100 may propagate into surrounding atmosphere resulting in the cooling of the plurality of battery cells.
In an embodiment, the battery module 100 comprises a pair of thermal cooling pads mounted over the first enclosure tub 104 and the second enclosure tub 108. Beneficially, the pair of thermal cooling pads enables the cooling of the busbar plates and terminals of the plurality of battery cells.
In an embodiment, the battery module 100 comprises a pair of auxiliary cell-holding structure, wherein one auxiliary cell-holding structure is configured between the cooling chamber 110 and the first enclosure tub 104, and wherein another auxiliary cell-holding structure is configured between the cooling chamber 110 and the second enclosure tub 108. In an embodiment, the auxiliary cell-holding structure comprises plurality of grooves to receive the plurality of battery cells. It is to be understood that the cell-holding structure and the auxiliary cell-holding structure are identical in shape and size to securely hold the plurality of battery cells. Beneficially, the auxiliary cell-holding structure is designed such that the plurality of battery cells snugly fit into the plurality of grooves of the auxiliary cell-holding structure.
Beneficially, in the presently disclosed battery module 100, the plurality of battery cells are efficiently cooled at both the ends, wherein one end of the plurality of battery cells is cooled by the cooling chamber 110 and other end of the plurality of battery cells is cooled by the thermal cooling pads. Beneficially, the battery module 100 takes advantage of sharing cooling chamber 110 between the first cell array 102 and the second cell array 106 for cooling the first cell array 102 and the second cell array 106 simultaneously using single cooling chamber resulting into efficient space utilization of space inside the battery module 100.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A battery module (100) for powerpack of an electric vehicle, the battery module (100) comprising:
- a first cell array (102) comprising a first set of battery cells;
- a first enclosure tub (104) for holding the first cell array (102);
- a second cell array (106) comprising a second set of battery cells;
- a second enclosure tub (108) for holding the second cell array (106);
- a cooling chamber (110) configured between the first cell array (102) and the second cell array (106) such that the first cell array (102) and the second cell array (106) are in physical contact with the cooling chamber (110).
2. The battery module (100) as claimed in claim 1, wherein the first enclosure tub (104) and the second enclosure tub (108) comprise a cell-holding structure.
3. The battery module (100) as claimed in claim 1, wherein the battery module (100) comprises a first busbar plate (112) for electrically connecting the first set of battery cells with each other within the first cell array (102) and a second busbar plate (114) for electrically connecting the second set of battery cells with each other within the second cell array (106).
4. The battery module (100) as claimed in claim 1 to 3, wherein the first enclosure tub (104) and the second enclosure tub (108) comprise busbar holding structures to hold the first busbar plate (112) and the second busbar plate (114), respectively.
5. The battery module (100) as claimed in claim 1 to 4, wherein the cooling chamber (110) comprises a plurality of channels forming a coolant flow path.
6. The battery module (100) as claimed in claim 1 to 5, wherein the cooling chamber (110) comprises an inlet channel (116) and an outlet channel (118) for inflow and outflow of a coolant through the cooling chamber (110).
7. The battery module (100) as claimed in claim 1 to 6, wherein the first enclosure tub (104) and the second enclosure tub (108) comprise a locking mechanism to join the first enclosure tub (104) and the second enclosure tub (108) to enclose the battery module (100).
8. The battery module (100) as claimed in claim 1 to 7, wherein the first enclosure tub (104) and the second enclosure tub (108) comprise a filler material filled in empty spaces between plurality of cells of the first set of battery cells and plurality of cells of the second set of battery cells.
9. The battery module (100) as claimed in claim 1 to 8, wherein the first enclosure tub (104) and the second enclosure tub (108) are made of an electrically insulating and thermally conducting material.
10. The battery module (100) as claimed in claim 1 to 9, wherein the battery module (100) comprises a pair of thermal cooling pads mounted over the first enclosure tub (104) and the second enclosure tub (108).
11. The battery module (100) as claimed in claim 1 to 10, wherein the battery module (100) comprises a pair of auxiliary cell-holding structure, wherein one auxiliary cell-holding structure is configured between the cooling chamber (110) and the first enclosure tub (104), and wherein another auxiliary cell-holding structure is configured between the cooling chamber (110) and the second enclosure tub (108).