Description:BATTERY MODULE WITH A CELL HOLDER ASSEMBLY
TECHNICAL FIELD
[0001] The present subject matter relates to a battery module. More particularly, it pertains to heat dissipation in the battery module. The present application is a patent of addition with respect to the patent application number 202041017540.
BACKGROUND
[0002] In recent years, rechargeable energy storage devices have been widely used as an energy source for a number of electronic and electrical units, hybrid and electric vehicles. Commonly used rechargeable energy storage devices include, for example, nickel cadmium batteries, nickel hydrogen batteries, nickel zinc batteries, and lithium rechargeable batteries. Lithium rechargeable energy storage devices are widely used in electric and hybrid vehicles because they are rechargeable, they can be made in a compact size with large capacity, they have a high operation voltage, and they have a high energy density per unit weight.
[0003] An existing energy storage device comprises one or more energy storage cells, such as, lithium ion battery cells enclosed within a casing. The electrochemical reactions with the lithium ion battery cells are responsible for the voltage and the current generated by the energy storage device. Also, during charging of the energy storage device, electrochemical reactions occur within the lithium ion battery cells. These electrochemical reactions are highly exothermic and the lithium ion battery cells tend to heat up during the course of normal operation. The increased temperatures of the lithium ion battery cells degrade the electrical performance of the energy storage device and may lead to catastrophic failure of the energy storage devices.
[0004] The energy storage device comprising the lithium ion battery cells finds application as an energy source in electric vehicle or a hybrid electric vehicle. The energy storage device in the electric or hybrid electric vehicle requires cooling for continuous performance and durability with good health of the lithium ion battery cells. Range of the vehicle reduces due to temperature rise of the battery cells. There is probability of thermal runaway in the energy storage device, which may result in propagation of blasting of the cells. Further, charging immediately after riding/driving the vehicle may not be possible due to temperature rise in the battery module even by using fast charging chargers.
[0005] Thus, there is a need to effectively dissipate the generated heat and efficiently cool the lithium ion battery cells of the energy storage device for the safety and longevity of the energy storage device.
BRIEF DESCRIPTION OF DRAWINGS
[0006] The detailed description is described with reference to the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.
[0007] Fig. 1 exemplarily illustrates a top perspective view of a battery pack, as per an embodiment of the present invention;
[0008] Fig. 2 exemplarily illustrates an exploded perspective view of the battery pack illustrated in Fig. 1;
[0009] Fig. 3 exemplarily illustrates a top perspective view of a cell holder assembly holding cells of the battery pack as exemplarily illustrated in Fig. 2;
[0010] Fig. 4 exemplarily illustrates a partial exploded view of the cell holder assembly showing packaging members positioned in each of the cell holders;
[0011] Fig. 5 exemplarily illustrates an exploded view of the cell holder assembly of the battery pack illustrated in Fig. 2;
[0012] Figs. 6A-6B exemplarily illustrate a plan view and sectional view of the placeholder assembly showing flow path of the coolant from an inlet manifold to an outlet manifold;
[0013] Fig. 7 exemplarily illustrates a sectional view of the battery pack; and
[0014] Fig. 8 exemplarily illustrates a coolant system of a battery module comprising multiple battery packs, as per an embodiment of the present subject matter.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In an implementation for cooling of the energy storage device, and in turn the lithium ion battery cells, a heat exchange member in thermal contact with the casing of the energy storage device is used. The heat dissipated from the lithium ion battery cells has to traverse through air-filled gap between the cells and the casing. The heat transfer between the battery cells and the casing is not efficient since the air is a poor conductor of heat. In order to ensure that heat is effectively dissipated from the battery cells, it is essential to ensure that the heat generating battery cells are reliably secured to be in thermal contact with the heat exchange member proximal to the casing. Further, there is also a need to ensure that there is no air gap between an upper surface of the lithium ion battery cells and an inner surface of the outer casing, in order to ensure that heat is effectively transmitted to the metallic casing.
[0016] Currently, one of the implementations employs liquid cooling for thermal management in the energy storage device. The energy storage device as a whole may be immersed into a liquid coolant. However, the liquid coolant is stagnant and efficiency of cooling of the energy storage device is substantially less.
[0017] Another implementation of the energy storage device involves employing coolant tubes for a liquid coolant designed around individual battery cells or a cluster of battery cells in the energy storage device. However, insertion of modular coolant tubes within the casing of the energy storage devices makes the energy storage device bulky and no longer compact for space-constrained varied applications. The coolant tubes are to be made with a heat conductive material. Further, such an insert with coolant channels requires to be sealed efficiently, so as to prevent leakage of the liquid coolant into and outside the energy storage device.
[0018] Therefore, there exists a need for an improved design of an energy storage device that is light in weight with efficient and effective heat transfer from the battery cells which additionally provides ease and safety during assembly, use, maintenance, and servicing of the energy storage device overcoming all problems disclosed above as well as other problems of known art.
[0019] The present application is a patent of addition of the patent application number 202041017540. Henceforth patent application number 202041017540 is referred as “Main application” for the purpose of brevity.
[0020] The “Main application” discloses about an energy storage device, specifically a battery module with battery cells surrounded by a liquid coolant to dissipate heat generated by the cells and cool them for safety, longevity, and ease of use, maintenance, and servicing. The disclosed battery module comprises a casing, multiple cells positioned between a top cover and a bottom cover, and a cell holder assembly with inlet and outlet manifolds for the coolant to flow through the cell holders, extracting heat generated by the cells, and exiting through the outlet manifold. Further the “Main application” discloses about a method of assembly involving obtaining multiple cells, positioning them in the cell holders of the cell holder assembly, sealing each end of each cell in the cell holders with a packaging member, and positioning the casing with openings for the inlet and outlet manifold enclosing the cell holder assembly to obtain the battery module.
[0021] However, using multiple liquid coolant reservoirs in a battery module, to separately cool each of the battery present within the battery module can lead to several problems. Firstly, such system can increase the complexity of the overall coolant system of the battery module, which can result in incurring higher costs, increased maintenance requirements, and reduced reliability of the overall battery module. Further in such systems, each of the liquid coolant reservoir would require to be connected to the inlet of each of the battery, which can be challenging to manage and regulate.
[0022] Moreover, using multiple coolant reservoirs can result in an uneven distribution of coolant across the batteries. This can lead to some batteries being cooled more than others, which can cause imbalances in temperature and reduce the efficiency and lifespan of the batteries. Using multiple coolant reservoirs can also increase the risk of coolant leaks, which can damage the batteries and pose safety risks. The more liquid reservoirs there are, the higher the probability of coolant leaks occur, which can result in the loss of coolant and potential damage to the overall battery module.
[0023] Furthermore, if the flow of coolant is not regulated based on the usage of individual batteries, several issues can arise. First and foremost, the batteries that are not being used will continue to be cooled, which can waste energy and reduce the overall efficiency of the battery module. This can result in reduced driving ranges for electric vehicles and increase the frequency of battery replacements, which can be expensive and time-consuming. On the other hand, batteries that are being used heavily can overheat, which can cause several problems. Overheating can lead to degradation of the battery's performance and lifespan, reducing its storage capacity and ability to hold a charge. Additionally, overheating can pose safety risks such as fire and explosion. If the coolant system is not properly regulated, it can also lead to an imbalance in the temperature of the batteries. Some batteries may be cooler than others, which can cause uneven wear and tear, leading to premature failure. This can result in increased maintenance costs and reduce the overall reliability of the battery module.
[0024] Therefore, there exists a need for an improved design of an energy storage device which uses a single liquid coolant reservoir in the battery module. This would enable a battery module to be simpler and more manageable coolant system, thereby reducing costs, improving reliability, and ensuring an even distribution of coolant across the batteries.
[0025] Further, there exists a need for regulating the flow of coolant based on the usage of individual batteries to ensuring that the batteries remain within a safe temperature range, operate efficiently, and have a long lifespan. Failure to do so can result in wasted energy, reduced efficiency, increased maintenance costs, and safety risks.
[0026] As per an embodiment, the present subject matter discloses about a battery module comprising multiple batteries housed within a storage area.
[0027] Each of the battery with the battery module includes a cell holder assembly, top and bottom covers, and multiple cells arranged in a predetermined sequence. The cells are connected in series and/or parallel using interconnect sheets and electrically connected to a battery management system. The cell holder assembly contains multiple batteries, each of the battery comprises of an inlet opening and an outlet opening. The inlet opening and an outlet opening of each of the battery leads to an inlet and an outlet manifold that allow a liquid coolant to flow through the cells, extracting heat generated by the cells.
[0028] Packaging members act as coolant sealants to prevent leaking of the coolant from the collar portion of the cell holder. Placeholder assembly is divided into rows of cell holders, and the direction of the flow of coolant in the alternate rows is opposite due to the design of the opening in the common partition wall between the cell holders. The coolant reaches the cell holder and exits from the outlet manifold. A solitary coolant reservoir is linked to an inlet manifold of each battery through a pump unit.
[0029] As per an aspect of the present embodiment, the pump unit of the coolant reservoir is connected to a valve unit and a control unit. The control unit monitors battery usage and regulates the flow of the liquid coolant to the batteries accordingly, with the valve unit, to prevent cooling of idle batteries.
[0030] Upon being circulated through the battery packs, the liquid coolant absorbs the heat generated by the cells of each battery.
[0031] As per another aspect of the present embodiment, the heated liquid coolant is extracted from the outlet manifold of each battery and channeled to a dedicated heat exchanger. The heat exchanger eliminates the heat from the liquid coolant, which is then cooled and transferred back to the liquid coolant reservoir, thus perpetuating the cycle.
[0032] The present subject mattery discloses a battery module with improved battery performance. The use of liquid coolant ensures that the batteries remain at a consistent temperature, which can help to optimize their performance and extend their lifespan.
[0033] The present subject mattery discloses a battery module with increased safety. The use of liquid coolant and a dedicated heat exchanger helps to prevent the batteries from overheating, which can reduce the risk of fires or other safety hazards.
[0034] The present subject mattery discloses a battery module with efficient cooling. By using a single coolant reservoir and regulating the flow of coolant based on battery usage, the system can achieve efficient cooling while minimizing energy usage.
[0035] The present subject mattery discloses a battery module with a simple design and structure. The use of a single coolant reservoir and a valve unit to regulate the flow of liquid coolant simplifies the design of the overall battery module, which can reduce costs and improve reliability of the overall battery module.
[0036] The present subject mattery discloses a battery module with a better battery management. The vehicle control unit can monitor the usage of each battery and regulate the flow of coolant accordingly, which can help to manage the battery pack more effectively and optimize its overall performance.
[0037] The present subject mattery discloses a battery module with an increased flexibility. The design of the battery module can be adapted to suit different applications, which can increase its flexibility and make it suitable for a wider range of uses.
[0038] Exemplary embodiments detailing features of the battery module configured for improved cooling rate of the plurality of batteries contained therein in accordance with the present invention will be described hereunder. In an embodiment, the disclosed subject matter herein apply to a vehicle having a battery module with multiple batteries. Also, although the embodiments have been exemplified for a two-wheeled saddle-type vehicle, the present invention is applicable for all types of portable devices as well as products with mobility having a battery module. Each of or/and some of the battery pack may be composed of Li ion cells and the like.
[0039] Fig. 1 exemplarily illustrates a top perspective view of a battery pack 100, as per an embodiment of the present invention. As exemplarily illustrated in Fig. 1, the battery pack 100 comprises a casing 101. The casing 101 comprises a top cover 102 and a bottom cover 103. The casing 101 encloses multiple cells and other electrical and electronic components, such as, a battery management system (BMS) board of the battery pack 100. The bottom cover 103 further comprises an inlet opening 104 and an outlet opening 105 for a liquid coolant to flow around the enclosed cells. As exemplarily illustrated, the inlet opening 104 and the outlet opening 105 are at different elevations. That is, the inlet opening 104 is provided at a higher elevation compared to the outlet opening 105. In an alternate embodiment, the inlet opening 104 and the outlet opening 105 are at the same elevation. The inlet opening 104 and the outlet opening 105 are openings on the bottom cover 103 through which an inlet manifold and an outlet manifold extend from a cell holder assembly of the battery pack 100. The bottom cover 103 is a hollow container into which the cells are positioned. The top cover 102 acts as a lid to close the bottom cover 103. The top cover 102 and the bottom cover 103 protect the cells from external factors & environment like water and dust entry. The casing 101, further to the inlet opening 104 and the outlet opening 105, may comprise external electrical connections (not shown) of the battery pack 100 for charging and discharging of the battery pack 100.
[0040] Fig. 2 exemplarily illustrates an exploded perspective view of the battery pack 100 illustrated in Fig. 1. As exemplarily illustrated, the battery pack 100 comprises the top cover 102, the bottom cover 103, multiple cells 209, and a cell holder assembly 204. The cells 209 are disposed in the cell holder assembly 204. The cells 209 are cylindrical in shape as exemplarily illustrated. In an embodiment, the cells 209 may be rectangular, hexagonal, etc., in shape. The top cover 102 and the bottom cover 103 enclose the cells 209 in the cell holder assembly 204. The cells 209 are arranged in a predetermined sequence in the cell holder assembly 204. The cell holder assembly 204 comprises the inlet manifold 205 and the outlet manifold 206. The inlet manifold 205 and the outlet manifold 206 extend from the inlet opening 104 and the outlet opening 105 of the bottom cover 103. The cells 209 are electrically connected in series and/or parallel configuration to form an array of cells using one or more interconnect sheets, such as, 201 and 208. The ends 202a and 202b of each cell 202, identified as electrical terminals of the cell 202 are in contact with the interconnect sheets 201 and 208. The interconnect sheets 201 and 208 connect the cells 209 in series and/or parallel combination to deliver the desired current and voltage of the battery pack 100. In an embodiment, such arrays of cells 209 are electrically connected to the BMS (not shown) within the battery pack 100. Packaging members 203 and 207 are positioned at the ends of the cell 202a and 202b such that the packaging members are proximal to the electrical terminals. As per an aspect of the present invention, the packing members 203 & 207 act as coolant sealants for the cell holder 204 to hold the coolant effectively during usage of the battery pack 100.
[0041] The coolant flows from the inlet manifold 205 in the cell holder assembly 204 towards the outlet manifold 206. The coolant extracts heat generated by the cells 209 in the cell holder assembly 204. The coolant is a liquid coolant. In an embodiment, the coolant may be a phase changing material that changes phase at elevated temperatures and solidifies at lower temperatures. The inlet manifold 205 and the outlet manifold 206 extends from the cell holder assembly 204 through the inlet opening 104 and the outlet opening 105 respectively, external to the battery pack 100. In an additional embodiment, the outlet manifold 206 extending from the outlet opening 105 of the bottom cover 103 is connected to a radiator. At the radiator, the heated coolant from the outlet manifold 206 is cooled and stored in a reservoir for using in next cycle of extraction of heat from the cells 209. The reservoir may be connected to the inlet manifold 205 extending from the inlet opening 104 of the bottom cover 103.
[0042] Fig. 3 exemplarily illustrates a top perspective view of the cell holder assembly 204 holding the cells 209 of the battery pack 100 as exemplarily illustrated in Fig. 2. The cell holder assembly 204 comprises cell holders, such as, 301 for holding the cells 209. As disclosed earlier, the coolant flows through the inlet manifold 205, fills up the circumferential space surrounding the cells 209 in the cell holder 204, and exits from the outlet manifold 206. The coolant flows from the first cell holder 301, for example a first cell holder 301 of a cell 202 to the cell holder of another cell 202 and passes further sequentially to exit from the outlet manifold 206. The packaging member, such as, 203 seals the first cell holder 301 at a collar portion of each of the cells, such as, 202 to prevent leaking of the coolant from the collar portion at the top and bottom of the first cell holder 301.
[0043] Fig. 4 exemplarily illustrates a partial exploded view of the cell holder assembly 204 showing the packaging members 203 and 207 positioned in each of the individual cell holders, such as, 301. The cell holders, such as, 301, 302, 304 together form a placeholder assembly 303. As exemplarily illustrated, the first cell holder 301 is a hollow tubular structure that is open on both ends (not shown). The open ends allow the insertion of the cell, such as, 202 into it. As per an embodiment, the first cell holder 301 is hexagonal in shape on the outer periphery & circular in the inner periphery. In an embodiment, the first cell holder 301 may be of cylindrical or rectangular cross-section. The inlet manifolds 205 extends from the first cell holder 301 and the outlet manifold 206 extends from the last cell holder, for example a third cell holder 304. The coolant flows from the first cell holder 301 towards the third cell holder 304 in the cell holder assembly 204. A packaging member 203 and 207 is positioned proximal to the ends of each of the cell holders, such as, 301. The packaging members 203 and 207 are positioned at a collar portion of the ends 202a and 202b. Once, the cell, such as, 202 is inserted into the cell holder 301, a pocket or an empty space is formed around the cell 202 in the cell holder 301. The cells 209 are cylindrical in shape as exemplarily illustrated in Fig. 2 and the cell holder 301 is hexagonal in shape. The coolant fills the pocket in the cell holder 301. The ends 202a and 202b of the cells 209 protrude from the open ends of the cell holder 301. A collar region of the cell holder 301 proximal to the ends 202a and 202b of the cell 202 are sealed using the packaging members 203 and 207. The packaging members 203 and 207 seal the gap between the external surface of the cell 202 at the collar region proximal to the ends 202a and 202b and the cell holder 301. The coolant filled in the pocket is sealed from leaking at the ends by press fit seal joint formed at the collar region of the cells, i.e., 202a and 202b of the cells 209. In an embodiment, the packaging members 203 and 207 are elastic gaskets of C cross section profile, that sit in a groove formed at the collar region proximal to the ends 202a and 202b of the cell 202. In an embodiment, the packaging members 203 and 207 are O-ring gaskets. The packaging members 203 and 207 also arrest movement of the cell 202 in the cell holder 301 due to the flow of the coolant by holding the cell 202 tight in the cell holder 301.
[0044] Fig. 5 exemplarily illustrates an exploded view of the cell holder assembly 204 of the battery pack 100 illustrated in Fig. 2. The cell holder assembly 204 comprises the placeholder assembly 303 with cell locking members 501 and 503 at open ends 303a and 303b of the placeholder assembly 303. The open ends 301a and 301b of the cell holder, such as, 301 together form the open ends 303a and 303b of the placeholder assembly 303. The inlet manifolds 205 and the outlet manifold 206 extend from the first cell holder 301 and the third cell holder 304 of the placeholder assembly 303, respectively. In an embodiment, the cell locking members 501 and 503 may house the packaging members 203 and 207, respectively. In an embodiment, the cell locking members 501 and 503 are screwed or snap-fit to the open ends 303a and 303b of the placeholder assembly 303. The cell locking member 501 and 503 is a plate structure of a predetermined thickness with cut-outs, such as, 502 and 504 respectively to accommodate the ends 202a and 202b of the cells, such as, 202. The external profile of the cell locking members 501 and 503 matches the external profile of the placeholder assembly 303. As per an aspect of the present invention, the cell locking member 501 and 503 have a complimentary holding groove profile to enable press fit or self-alignment of the cell locking members 501, 503 onto the placeholder assembly 303. Such hexagonal shape of the placeholder assembly 303 and the cell locking members 501, 503 has advantages, such as, stable & secure joint, good mechanical properties, and easy manufacturing. The hexagonal shape of the cell holder 301, 302, 304 offers more room for the coolant in common pitch distance than the circular shape of cell holder 301, 302, 304. The cell holder assembly 204, when viewed from the top, replicates a honeycomb structure. In an embodiment, the packaging members 203 and 207 are integral part of the circular cut-outs 502 and 504 in the cell locking members 501 and 503 and thus, does not require the packaging members 203 and 207 to be inserted separately at the ends 202a and 202b of the cells 202 in the first cell holder 301. In another embodiment, the cell locking members 501, 503 and the packing members 203, 207 are integral part of the cell holder assembly 204.
[0045] From the inlet manifold 205, the coolant fills the first cell holder 301 surrounding the cell, such as, 202 in the first cell holder 301. The first cell holder 301 and the second cell holder 302 are consecutive cell holders. The first cell holder 301 and the second cell holder 302 share a common partition wall 305. The common partition wall 305 comprises an opening 306 for the coolant to flow from the first cell holder 301 to the second cell holder 302. The coolant now fills the pocket in the second cell holder 302 and flows further into the consecutive cell holder through the opening in the common partition wall of the cell holder. As per an embodiment, the opening 306 in the common partition wall 305 is formed proximal to a bottom location or a top location of the first cell holder 301. That is, the opening 306 is formed in the common partition wall 305 at a location proximal to one of the ends 301a and 301b of the first cell holder 301. In an embodiment, the opening 306 is formed in the common partition wall 305 centrally. The consecutive cell holders 301 and 302 have the opening 306 at the bottom location or the top location for the coolant to raise from the bottom to top in the pocket between the cell 202 and the walls of the first cell holder 301.
[0046] Figs. 6A-6B exemplarily illustrate a plan view and sectional view of the placeholder assembly 303 showing flow path of the coolant from the inlet manifold 205 to the outlet manifold 206. As exemplarily illustrated in Fig. 6A, the placeholder assembly 303 is divided into even number of rows, such as, six rows of cell holders, such as, 301, 302, 304. Each row of the cell holders witnesses the flow of coolant in one direction. In the alternate rows, the directions of flow of the coolant is opposite. The opposite direction of flow of the coolant in the alternate rows is due to design of the opening 306 in the common partition wall 305 between the cell holders. The flow of coolant in the cell holders is in the direction as illustrated in Fig. 6A with arrows. The coolant reaches the third cell holder 304 and exits from the outlet manifold 206. It can be seen that various permutations & combination of flow path can be designed to achieve an optimal cooling of the cells 209.
[0047] In Fig. 6B, the flow path of the coolant in the first row of the cell holders of the placeholder assembly 303. As illustrated, the coolant flows through the inlet manifold 205 into the first cell holder 301 at a top location, fills the pocket of the cell holder 301, and exits from the first cell holder 301 through an opening 306 at a bottom location of common partition wall 305 of the first cell holder 301. In the second cell holder 302, the coolant raises from bottom to top in the pocket and exits the second cell holder 302 from the opening at a bottom location to the subsequent cell holder.
[0048] Fig. 7 exemplarily illustrates a sectional view of the battery pack 100. As exemplarily illustrated, the cells 209 are positioned between the top cover 102 and the bottom cover 103. The cells 209 are located in the cell holder assembly 204. The packaging members 203 and 207 are positioned at collar region 212 proximal to the ends 202a and 202b of the cell 202 held in the cell holder assembly 204. The collar region 212 of the first cell holder 301 holds the packaging member 203 and 207, which in turn holds the cell 202 in a tight fit assembly to form a sealing. The packaging member 203 and 207 has the C shape cross section profile that abuttingly protrudes inside as well as outside of the collar region 212 of the first cell holder 301 & the mid portion of the packaging member 203 and 207 abuttingly holds the outer circumference of each respective cell 202 while the outer circumference of the packaging member 203 and 207 abuts the inner circumference of the collar region 212 of the first cell holder 301. The coolant surrounds each cell 202 in the cell holder assembly 204 in the pocket 213. The packaging members 203 and 207 seal the coolant from flowing out of the cell holder assembly 204. The coolant passes from one cell, such as 202 to another cell in the cell holder assembly 204 extracting heat from each of the cells 209 and exits from the outlet manifold 206 in the cell holder assembly 204. The electrical terminals of the cells 209 contact the interconnect sheets 201 and 208.
[0049] Fig. 8 exemplarily illustrates a coolant system 700 of a battery module (not shown) comprising multiple batteries (100a, 100b, 100c), as per an embodiment of the present subject matter. The battery module includes multiple batteries (100a, 100b, 100c) stored within a storage area (not shown) of the battery module.
[0050] Each of the battery packs (100a, 100b, 100c), or battery (100a, 100b, 100c) of the battery module includes a cell holder assembly 204, top 102 and bottom covers 103, and multiple cells 209 arranged in a predetermined sequence. The multiple cells 209 are connected in series and/or parallel using interconnect sheets 208 and electrically connected to a battery management system (not shown).
[0051] Each of the battery 100 comprises of an inlet opening 104 and an outlet opening 105. The inlet opening 104 and an outlet opening 105 of each of the battery 100 leads to inlet 205 and outlet 206 manifolds that allow a liquid coolant to flow through the cells 209, extracting heat generated by the cells 209.
[0052] Packaging members 203 act as coolant sealants to prevent leaking of the coolant from the collar region 212 of the cell holder assembly 204. The placeholder assembly 303 is divided into rows of cell holders (301, 302, 303), and the direction of the flow of coolant in the alternate rows of cell holders (301, 302, 303) is opposite due to the design of the opening in the common partition wall 305 between the cell holders (301, 302, 303). The coolant reaches the cell holders (301, 302, 303) and exits from the outlet manifold 206. A solitary coolant reservoir 701 is linked to an inlet manifold 205 of each battery through a pump unit 704.
[0053] The pump unit 704 of the coolant reservoir 701 is communicatively connected to a valve unit 705 and a control unit 702. In an example the control unit 702, being a vehicle control unit. The control unit 702 monitors battery 100 usage and regulates the flow of the liquid coolant to the batteries (100a, 100b, 100c) accordingly, with the valve unit 705, to prevent cooling of idle batteries (100a, 100b, 100c).
[0054] In an embodiment, the valve unit 705 is configured to communicatively connect the reservoir 701 to the inlet manifold 205 of each (100a, 100b, 100c) of the plurality of batteries 100. 702
[0055] The control unit 702 is connected to the valve unit 705. The control unit 702 being is configured for allowing the movement of the coolant from the reservoir 701 to the plurality of batteries 100 by means of the valve unit 705.
[0056] Herein in an example the multiple batteries (100a, 100b, 100c) include a first battery 100a, a second battery 100b, and a third battery 100c. Each of the first battery 100a, the second battery 100b, and the third battery 100c, include an inlet opening 104, being connected with the inlet manifold 205, and an outlet opening 105 being connected with the outlet manifold 206.
[0057] In an embodiment, the first battery 100a includes a first inlet opening 104a and a first outlet opening 105a. Similarly, the second battery 100b includes a second inlet opening 104b and a second outlet opening 105b. Similarly, the third battery 100c includes a third inlet opening 104c and a third outlet opening 105c.
[0058] The inlet opening (104a, 104b, 104c) of each of the plurality of batteries 100 leads to the inlet manifold 205 of each of the plurality of batteries 100. The outlet opening (105a, 105b, 105c) of each of the plurality of batteries 100 leads to the outlet manifold 206.
[0059] Upon being circulated through the batteries (100a, 100b, 100c) the liquid coolant absorbs the heat generated by the cells 209 of each battery (100a, 100b, 100c).
[0060] As per another aspect of the present embodiment, the heated liquid coolant is extracted from the outlet manifold 206 through the outlet opening 105 of each of the battery (100a, 100b, 100c) and channeled to a dedicated heat exchanger 708. In an embodiment, at least one heat exchanger 708 being configured to communicatively connect the outlet manifold 206 of each (100a, 100b, 100c) of the plurality of batteries 100 to the reservoir 701.
[0061] The heat exchanger 708 eliminates the heat from the liquid coolant, which is then cooled and transferred back to the liquid coolant reservoir 701, thus perpetuating the cycle.
[0062] The plurality of batteries 100, the reservoir 701, the valve unit 705, the at least one heat exchanger 708, and the pump unit 704 is connected together by means of plurality of connecting means.
[0063] In an embodiment, the reservoir 701 is communicatively connected to a pump unit 704 by means of a connecting means, herein called as a first connector 703. The pump unit 704 is connected with the valve unit 705 by means of another connecting means, herein called as a second connector 706. Further, valve unit 705 controls the flow of the coolant into each of the batteries (100a, 100b, 100c), herein referred as the first battery 100a, the second battery 100b, and the third battery 100c. Each of the first battery 100a, the second battery 100b, and the third battery 100c are connected with the valve unit 705 by means of separate dedicated connecting means, herein referred as a third connector 707. In the present embodiment, each of the first battery 100a, the second battery 100b, and the third battery 100c are connected with the valve unit 705 separately, with a dedicated third connector 707.
[0064] The liquid coolant is pumped through the pump unit 704 and the flow is regulated by the valve unit 705, and the liquid coolant enters each of the batteries (101a, 101b, 101c) through the inlet openings (104a, 104b, 104b) of each of the batteries (101a, 101b, 101c). The liquid coolant enters each of the batteries (101a, 101b, 101c) and extracts heat from the cells 209 of each of the batteries (101a, 101b, 101c). Post extraction of heat, the liquid coolant moves out of each of the batteries through the outlet openings (105a, 105b, 105c) of each of the batteries (101a, 101b, 101c). Herein the the first battery 100a and includes a first inlet opening 104a, and a first outlet opening 105a. Similarly, the second battery 100b includes a second inlet opening 104b, and a second outlet opening 105b. And the third battery 100c includes a third inlet opening 104c, and a third outlet opening 105c.
[0065] Once the heated liquid coolant exists through the dedicated outlet openings (105a, 105b, 105c) of each of the batteries (101a, 101b, 101c), the heated liquid coolant is transferred from the dedicated outlet openings (105a, 105b, 105c) to the heat exchanger 708, by means of one or more connecting means, herein at least one fourth connector 709 and/or a fifth connector 710. The heat exchanger 708 is used to cool down the heated liquid coolant and then the cooled liquid coolant is again transferred to the reservoir 701 by means of another connecting means, herein referred as a sixth connector 711.
[0066] The present subject mattery discloses a battery module with improved battery performance. The use of liquid coolant ensures that the batteries remain at a consistent temperature, which can help to optimize their performance and extend their lifespan.
[0067] The present subject mattery discloses a battery module with increased safety. The use of liquid coolant and a dedicated heat exchanger 708 helps to prevent the batteries (100a, 100b, 100c) from overheating, which can reduce the risk of fires or other safety hazards.
[0068] The present subject mattery discloses a battery module with efficient cooling. By using a single coolant reservoir 708 and regulating the flow of coolant based on battery usage, the cooling system 700 can achieve efficient cooling while minimizing energy usage.
[0069] The present subject mattery discloses a battery module with a simple design and structure. The use of the single coolant reservoir 708 and the valve unit 705 to regulate the flow of liquid coolant simplifies the design of the overall battery module, which can reduce costs and improve reliability of the overall battery module.
[0070] The present subject mattery discloses a battery module with a better battery management. The control unit 702, for example the vehicle control unit 702 can monitor the usage of each battery (100a, 100b, 100c) and regulate the flow of coolant accordingly, which can help to manage the battery (100a, 100b, 100c) more effectively and optimize its overall performance.
[0071] The present subject mattery discloses a battery module with an increased flexibility. The design of the battery module can be adapted to suit different applications, which can increase its flexibility and make it suitable for a wider range of uses.
[0072] The different embodiments of the battery module comprising multiple batteries (101a, 101b, 101c) with the coolant extracting the heat from the cells in the cell holder assembly provides technical advancements in the field of heat management in battery packs. Each of the battery (101a, 101b, 101c) uses the cell holders (301, 302) for containing the coolant and making it flow further towards the outlet manifold 206. The extraneous infrastructure of coolant channels around the cells 209 is avoided, thus making each of the battery (101a, 101b, 101c) lighter in weight, easy to assemble, maintain, and replace. Also, the difference in the elevation of the inlet manifold 205 and the outlet manifold 206 in the cell holder assembly 204 ensures the coolant is pushed further in the sequentially arranged cell holders, avoiding an external pumping force to push the coolant. The coolant is in direct contact with the cell 202 in the cell holder (301, 302) extracting heat by convection steadily. The efforts of packaging of the components of the battery module to ensure efficient cooling by coolant outside the casing, such as, in immersion cooling are avoided. Heat is extracted from each of the cells 209, thereby maintaining the temperature of the cells 209 at a desired temperature for longevity of the battery module.
[0073] The packaging member at the ends of the cells 209 arrests the flow of the coolant outside the cell holder. The packaging member contracts or expands to efficiently the pack the gap between the cell and the wall of the cell holder (301, 302). The packaging member prevents the contact of the coolant with the terminals of the cells 209. Also, the coolant is preferred to be a thermally conductive and electrically insulating in nature. The coolant may be a free-flowing liquid or a phase changing material that is chemically non-reactive with the cell holders (301, 302) for the longevity of the batteries (101a, 101b, 101c).
[0074] Such an assembly of the batteries (100a, 100b, 100c) ensures effective heat transfer between the cells 209 and the coolant. The heat dissipated effectively ensures thermal stability and durability of the battery module. The intact tight packaging of the cells 209 in the cell holder assembly 204 makes the battery module mechanically stable, impact resistant, and vibration proof. The resilient nature of the packaging member acts as a vibration absorber that is experienced by the cells 209 of the batteries (101a, 101b, 101c).
[0075] Improvements and modifications may be incorporated herein without deviating from the scope of the invention.

 
REFERENCE NUMERALS

100: Battery
100a: A first battery
100b: A second battery
100c: A third battery
101: casing
102: top cover
103: bottom cover
104: inlet opening
104a: first inlet opening
104b: second inlet opening
104c: third inlet opening
105: outlet opening
105a: first outlet opening
105b: second outlet opening
105c: third outlet opening
201: interconnect sheet
202: cell
202a: ends of each cell
202b: ends of each cell
203: packaging member
204: cell holder assembly
205: inlet manifold
206: outlet manifold
207: packaging member
208: interconnect sheet
209: multiple cells
212: collar region
213: pocket
301: first cell holder
302: second cell holder
303: placeholder assembly
303a, 303b: open ends of the place holder
304: third cell holder
305: partition wall
306: opening
501, 503: cell locking members
502, 504: Cut outs
700: Cooling system of a battery module
701: Reservoir
702: Control unit
703: First connector
704: Pump unit
705: Valve unit
706: Second connector
707: Third connector
708: Heat exchanger
709: Fourth connector
710: Fifth connector
711: Sixth connector

, Claims:I/We claim:
1. A battery module for a powered device, said battery module comprising:
a plurality of batteries (100),
each battery (100a, 100b, 100c) of said plurality of batteries (100) comprising a cell holder assembly (204), said cell holder assembly (204) including one or more cell holders (301, 302, 304) for accommodating a plurality of cells (209),
said cell holder assembly (204) comprising an inlet manifold (205) and an outlet manifold (206), for enabling a coolant to flow through said cell holders (301, 302, 304) sequentially from said inlet manifold (205) to said outlet manifold (206) for extracting heat generated by each of said plurality of cells (209);
a reservoir (701) accommodating said coolant;
a valve unit (705), said valve unit (705) configured to communicatively connect said reservoir (701) to said inlet manifold (205) of said each battery (100a, 100b, 100c) of said plurality of batteries (100); and
at least one heat exchanger (708) being configured to communicatively connect said outlet manifold (206) of said each battery (100a, 100b, 100c) of said plurality of batteries (100) to said reservoir (701),
wherein a control unit (702) being capable of controlling the flow of said coolant between said reservoir (701) and said plurality of batteries (100).
2. The battery module for a powered device, as claimed in claim 1, wherein said each battery (100a, 100b, 100c) of said plurality of batteries (100) include a casing (101), where said casing (101) including a top cover (102) and a bottom cover (103).
3. The battery module for a powered device, as claimed in claim 2, wherein said top cover (102) and said bottom cover (103) of said casing (101), encloses a plurality of cells (209).
4. The battery module for a powered device, as claimed in claim 1, wherein said control unit (702) being connected to a valve unit (705), wherein said control unit (702) being capable of controlling said flow of said coolant between said reservoir (701) and said plurality of batteries (100) by means of said valve unit (705).
5. The battery module for a powered device, as claimed in claim 1, wherein said control unit (702) being a vehicle control unit (702).
6. The battery module for a powered device, as claimed in claim 1, wherein said plurality of batteries (100), said reservoir (701), said valve unit (705), said at least one heat exchanger (708), and a pump unit (704) being connected together by means of plurality of connecting means.
7. The battery module for a powered device, as claimed in claim 6, wherein said plurality of connecting means includes a first connector (703), a second connector, (706) a third connector (707), a fourth connector (709), a fifth connector (710) and a sixth connector (711).
8. The battery module for a powered device, as claimed in claim 1, wherein an inlet opening (104a, 104b, 104c) of each of said plurality of batteries (100) leads to said inlet manifold (205) of each of said plurality of batteries (100) and an outlet opening (105a, 105b, 105c) of each of said plurality of batteries (100) leads to said outlet manifold (206).
9. The battery module for a powered device, as claimed in claim 1, wherein said battery module comprises a pump unit (704) being communicatively connected to said reservoir (701) on one side and to said valve unit (705) on another side, for enabling pumping of said coolant from said reservoir (701).
10. The battery module as claimed in claim 1, wherein each of said cell holders (301) comprises an opening (306) for said coolant to flow around one cell (202) of said plurality of cells (209) in each of said cell holders (301).
11. The battery module as claimed in claim 10, wherein said opening (306) of each of said cell holders (301) being configured at one of a bottom location and a top location of each of said cell holders (301).
12. The battery module as claimed in claim 11, wherein consecutive cell holders (301 and 302) of said cell holder assembly (204) comprises said opening (306) at said bottom location and said top location for enabling said coolant to rise from bottom to top in each of said consecutive cell holders (301 and 302).
13. The battery module as claimed in claim 10, wherein said opening (306) being configured on a common partition wall (305) between consecutive cell holders (301 and 302).
14. The battery module as claimed in claim 1, wherein said coolant flowing from said inlet manifold (205) into said cell holder assembly (204) through a plurality of openings (306) in said cell holders (301, 302), said cell holders (301, 302) being sequentially located in said cell holder assembly (204), wherein, said coolant extracts heat from said plurality of cells (209) in said cell holders (301), and said coolant flowing out through said outlet manifold (206) of said cell holder assembly (204).
15. The battery module as claimed in claim 1, wherein said cell holder assembly (204) comprises a cell locking member (501 and 503), said cell locking member (501, 503) being configured with openings (502, 504), said openings (502, 504) being configured at each end (301a and 301b) of said cell holders (301) of said cell holder assembly (204).
16. The battery module as claimed in claim 1, wherein said each battery (100a, 100b, 100c) of said plurality of batteries (100) comprising a packaging member (203 and 207), said packaging member (203, 207) being disposed at a collar region (212) at each end (202a and 202b) of each cell (202) of said plurality of cells (209), for sealing said coolant at said ends (202a and 202b) of each cell (202) of said plurality of cells (209).
17. The battery module as claimed claim 16, wherein said packaging member (203 and 207) being abuttingly disposed within a cell locking member (501 and 503).
18. The battery module as claimed in claim 16, wherein said packaging member (203 and 207) being integrally formed in a cell locking member (501 and 503).
19. The battery module as claimed in claim 1, wherein said each (100a, 100b, 100c) of said plurality of batteries (100) comprising an interconnect sheet (201, 208), said interconnect sheet (201, 208) being configured to be in contact with each end (202a, 202b) of said each cell (202) of said plurality of cells (209).
20. The battery module as claimed in claim 1, wherein said inlet manifold (204) and said outlet manifold (206) being disposed at one of a same elevation and a different elevation.
21. The battery module as claimed in claim 1, wherein an inner circumference of each of said cell holders (301) having a circular cross-section, and an outer circumference of each of said cell holders (301) having a geometrical shape.
22. The battery module as claimed in claim 10, wherein said opening (306) of each of said cell holders (301) being proximal to one of a bottom location and a top location of each of said cell holders (301), wherein consecutive cell holders (301, 302) of said cell holder assembly (204) comprises said opening (306) at said bottom location and said top location for said coolant to rise from bottom to top in each of said consecutive cell holders (301, 302), and wherein said opening (306) being formed in a common partition wall (305) between said consecutive cell holders (301, 302).
23. The battery module as claimed in claim 16, wherein said packaging member (203 and 207) of a C cross section profile sits in a groove at said collar region (212) proximal to said ends (202a and 202b) of each of said plurality of cells (209) to form a sealing joint.