DESC:COOLING PLATE INTEGRATED CELL HOLDER FOR BATTERY MODULE
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202221041608 filed on 20/07/2022, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to a cell holder for battery module. The present disclosure specifically relates to a cell holder for battery module with integrated cooling plate. Furthermore, the present disclosure relates to a battery module with cooling plate integrated cell holder.
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 cell holder with integrated cooling plate for battery modules.
Another object of the present disclosure is to provide a compact and light-weight battery module having at least one cell holder with integrated cooling plate for efficient heat dissipation capabilities.
In accordance with first aspect of the present disclosure, there is provided a cell holder for battery module comprising a base frame and a top frame. The base frame comprises a cell holding structure, a cooling plate and a plurality of channels. The cell holding structure comprises a plurality of grooves to hold a plurality of battery cell. The cooling plate is integrated below the cell holding structure, wherein the cooling plate is configured to create a physical contact with the plurality of battery cells. The plurality of channels are integrated below the cooling plate and configured to create a coolant flow path. The top frame comprises a cell holding structure configured to be fixed on top of the base frame to securely hold the plurality of battery cells.
The present disclosure provides a cell holder for a battery module with integrated cooling plate. The cell holder, as disclosed in the present disclosure is advantageous in terms of compactness of size. Furthermore, the cell holder of the present disclosure is lesser in weight compared to conventional cell holders with cooling mechanisms. Furthermore, the cell holder of the present disclosure is advantageous in terms of providing better heat dissipation leading to improved battery module health and longer operational life.
In accordance with second aspect of the present disclosure, there is provided a battery module comprising a plurality of battery cells and a pair of cell holders. Each of the cell holder comprises a base frame and a top frame. The base frame comprises a cell holding structure, a cooling plate and a plurality of channels. The cell holding structure comprises a plurality of grooves to hold a plurality of battery cells. The cooling plate is integrated below the cell holding structure, wherein the cooling plate is configured to create a physical contact with the plurality of battery cells. The plurality of channels are integrated below the cooling plate and configured to create a coolant flow path. The top frame comprises a cell holding structure configured to be fixed on top of the base frame to securely hold the plurality of battery cells. The pair of cell holders are joined together at the base frames with the top frames facing mutually opposite directions.
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 1a illustrates an exploded view of a cell holder for a battery module, in accordance with an aspect of the present disclosure.
Figure 1b illustrates a top perspective view of a base frame of the cell holder, in accordance with an embodiment of the present disclosure.
Figure 1c illustrates a bottom perspective view of the base frame of the cell holder, in accordance with an embodiment of the present disclosure.
Figure 1d illustrates a side view of the base frame of the cell holder, in accordance with an embodiment of the present disclosure.
Figure 2 illustrates an exploded view of a battery module with a pair of cooling plate integrated cell holders, in accordance with an aspect of the present disclosure.
Figure 3a illustrates an exploded view of the two base frames of the pair of cell holders of the battery module, in accordance with an embodiment of the present disclosure.
Figure 3b illustrates a perspective view of the two base frames joined together, in accordance with an embodiment 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.
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 “battery module” refers to an assembled unit of a plurality of cylindrical battery cells that are connected together physically and electrically to form a larger energy storage system. Each cell within the battery module is typically a discrete unit capable of storing electrical energy. The battery modules can 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 pack 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 “battery cell”, “cells” and “battery-cell” are used interchangeably and refer to basic unit that generates and stores electrical energy. A battery 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 holder” and “holder” are used interchangeably and refer to a component of the 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 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 cell holder may comprise a “base frame” and a “top frame”. The base frame refers to a component of the cell holder that is used as a base for mounting plurality of battery cells. Similarly, the top frame refers to a component of the cell holder that is mounted on top of the plurality of battery cells once the plurality of battery cells are assembled in the base frame.
As used herein, the term “cell holding structure” refers to the component of the base frame and the top frame that physically holds each of the battery cell of the plurality of battery cells.
As used herein, the terms “plurality of channels” “channels” and “channels” are used interchangeably and refer to structure in the cell holder 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 “bus bar” and “bus bar 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 bus bar plate serves as a common electrical connection point for multiple battery cells.
As used herein, the term “thermal cooling plate” and “cooling plate” are used interchangeably and refers to a structure that is used to dissipate heat generated during the operation of the battery cells in the cell array. It would be understood that the cooling plate is designed to maintain optimal temperature levels within the cell array, preventing excessive heat build-up that can affect the performance, lifespan, and safety of the cells. The cooling plate 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 1a, in accordance with an embodiment describes an exploded view of a cell holder 100 for battery module comprising a base frame 102 and a top frame 104. The base frame 102 comprises a cell holding structure 106, a cooling plate 110 and a plurality of channels 112. The cell holding structure 106 comprises a plurality of grooves 108 to hold a plurality of battery cells. The cooling plate 110 is integrated below the cell holding structure 106 and configured to create a physical contact with the plurality of battery cells. The plurality of channels 112 are integrated below the cooling plate 110 and configured to create a coolant flow path. The top frame 104 comprises a cell holding structure 114 configured to be fixed on top of the base frame 102 to securely hold the plurality of battery cells.
The cell holder 100, as disclosed in the present disclosure is advantageous in terms of compactness of size. It is to be understood that the cell holder 100 eliminates the need of any external cooling jacket for cooling of the plurality of battery cells, thus reducing the size of battery module assembled using the cell holder 100. Furthermore, the cell holder 100 of the present disclosure is lesser in weight compared to conventional cell holders with cooling mechanisms to cool the plurality of battery cells. Furthermore, the cell holder 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.
In an embodiment, the cell holding structure 114 of the top frame 104 is same as the cell holding structure 106 of the base frame 102. It is to be understood that the cell holding structure 114 and the cell holding structure 106 are identical in shape and size to securely hold the plurality of battery cells. Beneficially, the cell holding structure 114 and the cell holding structure 106 are designed such that the plurality of battery cells snugly fit into the plurality of grooves 108.
In an embodiment, the top frame 104 comprises arrangement for accommodating a busbar plate. The busbar plate is accommodated over the cell holding structure 114. Beneficially, the busbar plate electrically connects the plurality of battery cells.
In an embodiment, the plurality of channels 112 emerges from an inlet channel 112a and converge into an outlet channel 112b of the cell holder 100. It is to be understood that the plurality of channels 112 forms a coolant flow path when enclosed. Optionally, the plurality of channels 112 emerges from the inlet channel 112a from which a coolant enters into the plurality of channels 112. Optionally, the plurality of channels 112 converge into an outlet channel 112b through which the coolant exits the cell holder 100 after absorbing heat from the plurality of battery cells. Beneficially, the inlet channel 112a and the outlet channel 112b are design in such a way that it complements an inlet channel and an outlet channel of another cell holder identical to cell holder 100. In other words, the inlet channel 112a is designed to such that it forms enclosed inlet when complemented with another inlet channel of another cell holder identical to cell holder 100. Similarly, the outlet channel 112b is designed to such that it forms enclosed outlet when complemented with another outlet channel of another cell holder identical to cell holder 100.
Figure 1b illustrates a top perspective view of the base frame 102 of the cell holder 100, in accordance with an embodiment of the present disclosure. The base frame 102 comprises the cell holding structure 106, wherein the cell holding structure 106 comprises a plurality of grooves 108 to hold a plurality of battery cells at the top.
Figure 1c illustrates a bottom perspective view of the base frame 102 of the cell holder 100, in accordance with an embodiment of the present disclosure. The base frame 102 comprises the cooling plate 110 integrated below the cell holding structure 106, wherein the cooling plate 110 is configured to create a physical contact with the plurality of battery cells. The plurality of channels 112 integrated below the cooling plate 110 configured to create a coolant flow path.
Figure 1d illustrates a side view of the base frame 102 of the cell holder 100, in accordance with an embodiment of the present disclosure. The base frame 102 comprises a cell holding structure 106, a cooling plate 110 and a plurality of channels 112.
Figure 2, in accordance with an embodiment describes battery module 200 comprising a plurality of battery cells 216 and a pair of cell holders 100. Each of the cell holder 100 comprises a base frame 102 and a top frame 104. The base frame 102 comprises a cell holding structure 106, a cooling plate 110 and a plurality of channels 112. The cell holding structure 106 comprises a plurality of grooves 108 to hold a plurality of battery cells 216. The cooling plate 110 is integrated below the cell holding structure 106 and configured to create a physical contact with the plurality of battery cells 216. The plurality of channels 112 are integrated below the cooling plate 110 and configured to create a coolant flow path. The top frame 104 comprises a cell holding structure 114 configured to be fixed on top of the base frame 102 to securely hold the plurality of battery cells 216. The pair of cell holders 100 are joined together at the base frames 102 with the top frames 104 facing mutually opposite directions.
It is to be understood that the pair of base frames 102 are joined together facing their plurality of channels 112 towards each other. The pair of base frames 102 are aligned with each other such that the plurality of channels 112 of both the base frames 102 are overlapping each other. The overlapping plurality of channels 112 of the pair of base frames 102 are joined together.
Beneficially, the battery module 200 provides efficient cooling of the plurality of battery cells 216. Furthermore, the battery module 200 is compact in size. Furthermore, the battery module 200 is light-weight. Moreover, the battery module 200 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 200.
In an embodiment, the plurality of channels 112 of the joined base frames 102 forms a concealed coolant flow path for cooling of the battery module 200. Beneficially, the coolant flows in the concealed coolant flow path absorbing the heat generated from the plurality of battery cells 216. The heat absorbed coolant flows out of the concealed coolant flow path resulting into the cooling of the battery module 200.
In an embodiment, the battery module 200 comprises a sealant lining on the plurality of channels 112 to conceal the coolant flow path in the battery module 200. Beneficially, the sealant lining on the plurality of channels 112 ensures that the coolant does not leak within the plurality of channels 112. Furthermore, the sealant lining ensures that the coolant does not leak from the joints between the joined plurality of channels 112 of both the base frames 102.
In an embodiment, the plurality of channels 112 forming the concealed coolant flow path emerges from an inlet channel 112a and converge into an outlet channel 112b of the battery module 200. Beneficially, the concealed coolant flow path emerges from the inlet channel 112a from which the coolant enters into the plurality of channels 112. Furthermore, the concealed coolant flow path converges into the outlet channel 112b through which the coolant exits the cell holder 100 after absorbing heat from the plurality of battery cells 216. It is to be understood that the inlet channel 112a and the outlet channel 112b are concealed due to the joining of the plurality of channels 112 of both the base frames 102.
In an embodiment, the battery module 200 comprises a pair of busbar plates, and wherein each of the busbar plate is accommodated in each of the top frame 104 of the battery module 200 to electrically connect the plurality of battery cells 216. Each of the busbar plate of the pair of the busbar plate is accommodated over the cell holding structure 114 of the pair of the top frame 104. Beneficially, the pair of the busbar plates electrically connects the plurality of battery cells 216.
In an embodiment, the battery module 200 comprises a pair of thermal cooling pads, and wherein each of the thermal cooling pad is mounted over each of the busbar plate to create thermal cooling of the busbar plates and terminals of the plurality of battery cells 216. Beneficially, the pair of thermal cooling pads enables the cooling of the busbar plates and terminals of the plurality of battery cells 216.
Beneficially, in the presently disclosed battery module 200, the plurality of battery cells 216 are efficiently cooled at both the ends, wherein one end of the plurality of battery cells 216 is cooled by the cooling plate and other end of the plurality of battery cells 216 is cooled by the thermal cooling pads.
Figure 3a, in accordance with an embodiment illustrates a pair of base frames 102 aligned to be joined together to form the concealed coolant flow path. The pair of base frames 102 are aligned over each other such that the plurality of channels 112 of the pair of base frames 102 are overlapping each other.
Figure 3b, in accordance with an embodiment illustrates a pair of base frames 102 joined together to form the concealed coolant flow path. In an embodiment, the pair of base frames 102 are joined together using ultrasonic welding. In an alternative embodiment, the pair of base frames 102 are joined together using other suitable techniques.
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 cell holder (100) for battery module comprising:
- a base frame (102), wherein the base frame (102) comprises:
- a cell holding structure (106), wherein the cell holding structure (106) comprises a plurality of grooves (108) to hold a plurality of battery cells;
- a cooling plate (110) integrated below the cell holding structure (106), wherein the cooling plate (110) is configured to create a physical contact with the plurality of battery cells; and
- a plurality of channels (112) integrated below the cooling plate (110) configured to create a coolant flow path;
- a top frame (104) comprising a cell holding structure (114) configured to be fixed on top of the base frame (102) to securely hold the plurality of battery cells.
2. The cell holder (100) as claimed in claim 1, wherein the cell holding structure (114) of the top frame (104) is same as the cell holding structure (106) of the base frame (102).
3. The cell holder (100) as claimed in claim 1 and 2, wherein the top frame (104) comprises arrangement for accommodating a busbar plate.
4. The cell holder (100) as claimed in claim 1 to 3, wherein the plurality of channels (112) emerges from an inlet channel (112a) and converge into an outlet channel (112b) of the cell holder (100).
5. A battery module (200) comprising:
- a plurality of battery cells (216); and
- a pair of cell holders (100) wherein each of the cell holder (100) comprises:
- a base frame (102), wherein the base frame (102) comprises:
- a cell holding structure (106), wherein the cell holding structure (106) comprises a plurality of grooves (108) to hold a plurality of battery cells (216);
- a cooling plate (110) integrated below the cell holding structure (106), wherein the cooling plate (110) is configured to create a physical contact with the plurality of battery cells (216); and
- a plurality of channels (112) integrated below the cooling plate (110) configured to create a coolant flow path; and
- a top frame (104) comprising a cell holding structure (114) configured to be fixed on top of the base frame (102) to securely hold the plurality of battery cells (216),
wherein the pair of cell holders (100) are joined together at the base frames (102) with the top frames (104) facing mutually opposite directions.
6. The battery module (200) as claimed in claim 5, wherein the plurality of channels (112) of the joined base frames (102) forms a concealed coolant flow path for cooling of the battery module (200).
7. The battery module (200) as claimed in claim 5 and 6, wherein the battery module (200) comprises a sealant lining on the plurality of channels (112) to conceal the coolant flow path in the battery module (200).
8. The battery module (200) as claimed in claim 5 to 7, wherein the plurality of channels (112) forming the concealed coolant flow path emerges from an inlet channel (112a) and converge into an outlet channel (112b) of the battery module (200).
9. The battery module (200) as claimed in claim 5 to 8, wherein the battery module (200) comprises a pair of busbar plate, and wherein each of the busbar plate is accommodated in each of the top frame (104) of the battery module (200) to electrically connect the plurality of battery cells (216).
10. The battery module (200) as claimed in claim 5 to 9, wherein the battery module (200) comprises a pair of thermal cooling pads, and wherein each of the thermal cooling pad is mounted over each of the busbar plate to create thermal cooling of the busbar plates and terminals of the plurality of battery cells (216).