Description:FIELD OF THE INVENTION

[0001] The present invention relates to the field of EV charging technology. More specifically, the present invention is focused towards a thermal management system for charging of electric vehicles that reduces cell charging time by efficiently dissipating heat, thereby preventing overheating and ensuring the longevity and safety of the battery cells.

BACKGROUND OF THE INVENTION

[0002] In modern electric vehicles (EVs), managing the thermal performance of battery cells is crucial for maintaining efficiency, safety, and longevity. Existing cooling systems typically rely on traditional methods such as air cooling or liquid cooling through simple heat exchange mechanisms. Air cooling systems often struggle to provide adequate thermal management under high power conditions, leading to inefficiencies and potential overheating due to limited heat dissipation capacity and uneven airflow distribution. This results in thermal hotspots and reduced battery performance.

[0003] Liquid cooling systems offer better thermal management by using coolant to absorb and transfer heat away from the battery cells. However, these systems generally use straightforward channel designs and standard heat exchangers, which might not fully optimize heat dissipation. These designs often lack the flexibility to adapt dynamically to varying thermal loads, leading to suboptimal cooling performance during periods of rapid charging or high-power output. Additionally, conventional liquid cooling systems may not fully address issues like localized overheating or uneven cooling across the battery pack.

[0004] In current technology, DCFC (Direct Current Fast Charging) and UFC (Ultra-Fast Charging) are employed to greatly reduce the time required to charge batteries in electric vehicles (EVs). While these methods have significantly accelerated the charging process, they also give rise to a challenge known as "battery superheating." This phenomenon occurs as a result of the high energy transfer rates during rapid charging, which causes the battery cells to heat up significantly. The term "battery superheating" refers to this excessive heat generation that impacts battery performance. The rapid energy transfer during fast charging creates thermal stress within the battery cells, leading to uneven temperature distribution across the battery pack. This results in the development of hot spots, where localized heating can degrade battery efficiency and shorten its lifespan. As the cells heat up unevenly, some areas of the battery pack experience higher temperatures than others, potentially causing reduced performance and accelerated wear of the battery. To address these issues, advanced cooling solutions are required to effectively manage and mitigate the heat generated during fast charging. The current technologies often lack the capability to dynamically adapt to varying thermal loads, which exacerbates the problem of heat management.

[0005] US20200338998A1 discloses a vehicle battery charging system includes a battery charger for charging a battery module of a vehicle. A first coolant circuit conveys a first cooling fluid therethrough. The first coolant circuit includes a chiller unit separate from the vehicle. The chiller unit and the first cooling fluid exchange heat therebetween. A second coolant circuit conveys a second cooling fluid therethrough. The second coolant circuit includes a battery module. The battery module and the second cooling fluid exchange heat therebetween. A heat exchanger exchanges heat between the first cooling fluid and the second cooling fluid.

[0006] US10814734B2 discloses embodiments described and claimed herein are apparatus, systems, and methods for charging an electric vehicle at a stationary service station. In one embodiment, the service station includes a power generation component including at least one fuel cell, a fuel supply component for supplying fuel to the power generation component, a charging component including at least one customer charging station, and a control component for controlling and monitoring the other components and for providing accounting and billing functions.

[0007] Having reference to the above disclosed technologies, i.e., it shall be apparent to a person skilled in the art that the existing systems and embodiments are more focused towards usage of multiple cooling fluids for heat exchange during charging of the batteries and also reveals usage of water-based cooling system to cool down the fuel cells. The document US’998 is focused towards usage of multiple cooling fluids for heat exchange during charging of the batteries & US’ 734 discloses about water-based cooling system to cool down the fuel cells. to the advancement in existing sirens. It is pertinent to note that the existing advancement are using more than one cooling fluid and water-based cooling system, respectively to cool down the batteries. Therefore, the existing technologies possess some major drawbacks due to which the current requirements are not met. As highlighted hereinbefore, the existing technologies are incapable of effectively carrying out the process of heat-exchange by dissipating the heat from the batteries at optimal level while charging, as water-based cooling system pose leakage risks, which leads to short circuits and safety hazards.

[0008] Thus, having regard to such limitations/drawbacks, there is a critical need for a system that utilized only a single cooling fluid for proper heat-exchange of the heat generated from the cells while being charged, thereby preventing overheating conditions which in turn assures longevity and safety of the battery cells.

OBJECTS OF THE INVENTION

[0009] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0010] An object of the present invention is to develop a system that is capable of charging numerous numbers of cells of an electric vehicle in a single go.

[0011] Another object of the present invention is to develop a system that ensures rapid heat dissipation from the cells, thereby maintaining an optimal temperature and preventing overheating which in turn assures longevity and safety of the battery cells, as excessive heat leads to degradation or even failure.

[0012] Another object of the present invention is to develop a system that minimizes the charging time of the cells significantly by constantly dissipating the heat from the cells.

[0013] Another object of the present invention is to develop a system that provides a means for absorption of mechanical shocks during movement of the vehicle, thereby protecting the accommodated cells from potential damage.

[0014] Another object of the present invention is to develop a system that measures temperature difference and flow rate of cooling fluid circulated within the system for immediate detection of thermal anomalies or flow issues in view of maintaining proper dissipation of heat from the cells while being charged.

[0015] Yet another object of the present invention is to develop a system that generates alerts for flow discrepancies of cooling fluid and ensures timely identification and resolution of leaks or blockages, enhancing system reliability and safety.

[0016] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0017] The present invention pertains to a thermal management system for charging of electric vehicles, designed to significantly reduce the charging time of the cells by efficiently dissipating heat. By continuously removing heat from the cells, the system maintains an optimal temperature range, preventing the cells from overheating, thus ensuring safety of the battery cells and extension of their lifespan.

[0018] According to an embodiment of the present invention, a thermal management system for charging of electric vehicles, comprises a tubular channel designed in a sinusoidal shape is installed in a three-wheeler electric vehicle. One side of the channel is flat, while the other side features lateral contours along its length to hold multiple vehicle cells in a charged state. A cylindrical tube runs longitudinally along the channel, specifically for the circulation of nanofluid. The nanofluid enters the tube through an inlet connected between the channel and an outlet port of a radiator containing the fluid. Numerous fins are attached to the tube, extending radially towards the inner surface of the channel to improve heat transfer. The heat released from the cells during charging is transferred to a material that changes from a solid to a liquid state via latent heat. The absorbed heat is then transmitted to the nanofluid through conduction, followed by convection. A temperature sensor, positioned at the inlet and outlet of the channel, detects the temperature difference of the nanofluid entering and exiting the channel. A microcontroller, interfaced with these sensors, processes the temperature data and, if the difference exceeds a threshold, sends a command. An electronically controlled valve at the inlet responds to this command by adjusting to a predefined extent, allowing optimal fluid entry into the tube to maximize heat absorption from the material.

[0019] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates a perspective view of a thermal management system for charging of electric vehicles;
Figure 2 illustrates an internal view of a channel depicting a tube associated with the proposed system;
Figure 3 illustrates an internal view of the channel showcasing phase changing material;
Figure 4 illustrates an isometric view of a contoured region developed on channel, associated with the proposed system; and
Figure 5 illustrates a cross-sectional view of the channel.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0022] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0023] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0024] The present invention is envisioned towards a thermal management system for charging of electric vehicles that minimizes the charging time of the cells significantly by constantly dissipating the heat from the cells. The rapid heat dissipation from the cells maintains an optimal temperature and prevents the cells from being overheated which in turn assures longevity and safety of the battery cells.

[0025] Referring to Figure 1 and 2, a perspective view of a thermal management system for charging of electric vehicles and an internal view of a channel depicting a tube associated with the proposed system are illustrated, respectively, comprising a tubular channel 101 in a three-wheeler electric vehicle, one of the sides of the channel 101 is flat and the other side forms a contoured region 401, multiple cells 102 accommodated within the contoured region 401, a cylindrical tube 103 longitudinally disposed along the length of the channel 101, an inlet 105 and outlet 106 constructed on the channel 101.

[0026] Figure 1 and 2 further illustrates multiple fins 201 fused on the tube 103 radially projected towards inner peripheral surface of the channel 101, a phase changing material 301 embedded in between each of the fins 201, a temperature sensor 108 configured with the inlet 105 and outlet 106, electronically controlled valve 111 integrated with the inlet 105, and inlet port 109 and outlet port 110 installed on a radiator 107 configured with the vehicle, a centrifugal pump 113 installed on the radiator 107 and an upper and lower sections of contoured regions 401 of the channel 101 are arranged with a thermal-resistant rubber pad.

[0027] In the existing technology, DCFC (Direct Current Fast Charging) and UFC (Ultra-Fast Charging) are particularly used to fast charge batteries/cells installed in EV (Electric Vehicles). They have been developed to significantly reduce the charging time. However, these technologies lead to a phenomenon known as "battery superheating," which negatively impacts battery efficiency and lifespan. The term “battery superheating” as mentioned herein is caused due to rapid charging process which results in heating up the battery cells due to high rate of energy transfer. This thermal stress leads to uneven temperature distribution within the battery pack, resulting in formation of hot-spots.

[0028] The system as disclosed herein is focused towards efficient thermal management of battery cells installed in a three-wheeler electric vehicle in a charging condition to mitigate the risks of cells 102 damage or, in extreme cases, fire hazards. The cells 102 as mentioned herein are LFP (Lithium Iron Phosphate) cells 102. The system includes a tubular channel 101 that is structured sinusoidally, more precisely in a wavy-form, developed to be installed in the three-wheeler EV in a secured manner.

[0029] In an embodiment of the present invention, the system also offers charging of other types of cells other than LPF cells, that are Lithium Nickel Manganese Cobalt Oxide (NMC) cells, Lithium Nickel Cobalt Aluminum Oxide (NCA) cells, Lithium Manganese Oxide cells, Lithium Titanate (LTO) cells, Lithium Cobalt Oxide cells, Solid-State Batteries and Sodium-Ion Batteries.

[0030] In an embodiment of the present invention, the dimensions of the tubular channel 101 may be adjusted based on the number of cells 102 required for fast charging. This adaptability allows for the efficient accommodation of various cell configurations, optimizing the system's performance. The tubular channel 101 is designed with a flat side and a contoured side 401, which runs along its length. The lateral contouring 401creates a series of barrel-like spaces. These spaces are specifically shaped to securely house multiple cells 102, ensuring they are held in place during operation.

[0031] The contouring not only provides structural support but also enhances thermal management. This design is crucial for maintaining the optimal temperature of the cells 102, thereby extending their lifespan and improving overall efficiency. The cells 102 positioned along the contoured side 401 of the casing maintain proper contact with the inner walls of these formed spaces i.e. surface to surface contact, ensuring efficient heat dissipation and electrical connectivity. Additionally, the channel’s 101 structure can be modified to accommodate different cell sizes, providing a versatile solution for various vehicle applications. This customized approach ensures that the energy storage system is both compact and effective, meeting the specific needs of the vehicle's power requirements.

[0032] The contoured region 401 described above consists of an upper and lower section, both of which are lined with thermal-resistant rubber pads. These pads serve a crucial role in absorbing mechanical shocks during the movement of the three-wheeler vehicle, thereby protecting the accommodated cells 102 from potential damage. The rubber used in these pads is an elastic material that stretch and compress, effectively cushioning the cells 102 against any jarring forces encountered when the vehicle traverse potholes or other road irregularities, as illustrated in figure 4.

[0033] The elastic nature of the rubber allows it to deform under pressure and then return to its original shape, maintaining the integrity of the cell arrangement. This characteristic is essential for safeguarding the orientation and alignment of the cells 102, preventing them from shifting or sustaining impact damage. When the vehicle experiences a sudden impact or vibration, the force generated is absorbed by the rubber pads through compression. This process involves the temporary deformation of the rubber, which dissipates the energy over time, thereby significantly reducing the force or shocks transmitted to the cells 102.

[0034] Furthermore, the thermal-resistant properties of the rubber pads contribute to the overall thermal management of the system, ensuring that heat generated during operation does not adversely affect the pads elasticity or performance. The design of the contoured region 401, along with the strategically placed rubber pads, not only enhances the safety and durability of the cells 102 but also contributes to the smooth operation of the vehicle by minimizing the transmission of vibrations.

[0035] The channel 101 includes a cylindrical tube 103 that is longitudinally positioned along its length, serving as a critical component for thermal management. This cylindrical tube 103 is made of metal, specifically selected from materials like copper and aluminum, though other metals with similar properties could also be used. The primary function of the tube 103 is to facilitate the circulation of a nano-fluid 104, which is specially chosen for its superior thermal conductivity. This circulation system is essential for efficient heat transfer, especially during the fast-charging process when the cells 102 generate a significant amount of heat.

[0036] The choice of materials for the tube 103 is deliberate and strategic. Copper, known for its excellent thermal conductivity, ensures rapid heat dissipation from the cells 102, thereby maintaining an optimal temperature and preventing overheating. This property is crucial for the longevity and safety of the battery cells 102, as excessive heat leads to degradation or even failure. On the other hand, aluminum is selected for its lightweight nature and corrosion-resistant properties. The use of aluminum helps in reducing the overall weight of the channel 101, which is particularly beneficial for electric vehicles where weight savings enhance efficiency and range.

[0037] The use of a nano-fluid 104 further enhances the system's efficiency. These fluids 104, often engineered with nanoparticles, have a higher thermal conductivity than conventional cooling fluids, allowing for more effective heat transfer. The integration of this cooling mechanism ensures that the cells 102 are maintained within a safe temperature range even under high-power operations, such as fast charging.

[0038] The nano-fluid 104 as described above is selected from but not limited to ethylene glycol based nano-fluid 104, water-based nano-fluid fluids 104 and oil based nano-fluid fluids 104. Ethylene glycol has good thermal conductivity, which is enhanced by adding nanoparticles, it is commonly used in cooling systems, including automotive radiators and industrial coolants, due to its low freezing point and ability to handle a wide temperature range. Similarly, in place of ethylene glycol, water is also used for its thermal conductivity. It is widely used in heat exchangers, cooling systems, and heat transfer applications. The oil based nano-fluid 104 have lower thermal conductivity compared to water-based nanofluid fluids 104, but is used in specific applications where oils are preferred.

[0039] The nano-fluid 104 is introduced into the cylindrical tube 103 via an inlet 105 arranged on the channel 101. This inlet 105 is connected to an outlet port 110 of the radiator 107 already installed in the vehicle. The radiator 107 is generally equipped with advanced thermal management capabilities, it is designed to work in conjunction with the nano-fluid 104 to enhance the cooling efficiency of the system. The nano-fluid 104 itself is stored in a dedicated coolant reservoir positioned near the radiator 107. This reservoir is specifically designed to hold excess coolant and accommodate the thermal expansion of the fluid 104 as it heats up during operation.

[0040] To ensure the efficient circulation of the nano-fluid 104, a centrifugal pump is connected with the coolant reservoir of the radiator 107 and is responsible for moving the nano-fluid 104 through the system. Upon activation, the centrifugal pump draws the nano-fluid 104 from the reservoir and propels it through the outlet port 110 of the radiator 107. The fluid 104 then flows into the inlet 105 of the channel 101, where it enters the cylindrical tube 103. This consistency is crucial for ensuring uniform cooling across all cells 102, preventing hotspots and ensuring the longevity of the battery pack.

[0041] The tube 103 includes multiple fins 201 fused onto its surface, which are radially projected towards the inner peripheral surface of the channel 101 i.e. radially outwards. These fins 201 play a critical role in enhancing the heat transfer rate by significantly increasing the surface area available for heat dissipation. The design of the fins 201 is carefully optimized to maximize the efficiency of the cooling system. They are made longer and more numerous to provide greater surface contact with the nano-fluid 104 circulating through the tube 103, thereby facilitating more effective thermal exchange. The number of fins 201 fused on the tube 103 is directly proportional to diameter of said tube 103, as illustrated in figure 5.

[0042] The increased number of fins 201 ensures that a larger volume of nano-fluid 104 comes into contact with the surfaces, allowing for more heat to be absorbed and carried away from the cells 102. Additionally, the fins 201 are kept thinner, as thinner fins 201 are more effective at enhancing heat transfer. This is because thinner fins 201 reduce the thermal resistance between the tube’s 103 surface and the fluid 104, allowing heat to move more quickly and efficiently. The reduced thermal resistance ensures that the heat generated by the cells 102 during operation is rapidly conducted away, minimizing the risk of overheating and maintaining the system's thermal stability.

[0043] The spaces between each of the fins 201 are filled with a phase-changing material that received heat dissipated from the cells 102 during fast charging, as illustrated in figure 3. These phase-changing materials (PCMs), possess unique properties that allow them to undergo a phase transition from solid to liquid at specific temperatures. This phase transition is crucial for managing thermal loads within the system. The phase changing materials 301 as utilized in the present invention is selected from but not limited to Paraffin wax, Salt Hydrates and Organic compounds.

[0044] PCMs are strategically placed between the fins 201 to absorb the excess heat generated by the cells 102. The phase changing material 301 is closely packed in between the fins 201 with minimum tolerance to allow phase transition of the material. As the temperature of the system rises, the PCM begins to absorb heat, causing it to transition from a solid state to a liquid state. This process is governed by the phenomenon of latent heat, where a significant amount of energy is absorbed by the material without a corresponding rise in temperature. The absorbed energy, known as latent heat, is stored within the PCM as it changes phase, effectively mitigating the temperature rise to the fins 201 outer periphery of the tube 103. This phase change is particularly beneficial because it provides a high capacity for heat absorption over a relatively narrow temperature range. As a result, the PCMs can stabilize the temperature of the cells 102, preventing overheating and maintaining optimal operating conditions.

[0045] The heat absorbed by the phase changing material 301 is further transmitted to the nano-fluid 104 via conduction followed by convection phenomena. Initially, when the heat is dissipated from the cells 102 to phase changing material 301 and the same heat when simultaneously exchanged in between the wall and fins 201 of the tube 103, then the heat transferred is through conduction phenomena and when the phase changing material 301 gradually gets converted to liquid state, then the heat transferred from the liquid state phase changing material 301 to the wall and fins 201 of the tube 103 is also via conduction phenomena. The heat sustained with the wall and fins 201 of the tube 103 when dissipated to the nano-fluid fluids 104, then this heat exchange phenomenon is though convection.

[0046] The channel 101, equipped with the inlet 105 and an outlet 106, is fitted with temperature sensors 108 at both points to monitor the thermal state of the nano-fluid 104 circulating through the tube 103. These temperature sensors 108 play a critical role in maintaining the optimal thermal management of the vehicle's battery cells 102. The temperature sensor 108 at the inlet 105 measures the temperature of the nano-fluid 104 as it enters the channel 101, providing a baseline reading of the fluid 104's initial thermal condition. Simultaneously, the sensor at the outlet 106 captures the temperature of the nano-fluid 104 as it exits the channel 101, offering a precise measurement of the fluid’s 104 temperature gradient after it has absorbed heat from the cells 102.

[0047] The data collected by these sensors are transmitted to a microcontroller, which is programmed to analyse the temperature readings. The microcontroller processes the information in real-time, calculating the temperature difference (?T) between the inlet 105 and outlet 106. This temperature differential is a key indicator of the heat absorbed by the nano-fluid 104 from the battery cells 102, thus reflecting the overall efficiency of the cooling system. The microcontroller is equipped with protocols to determine whether the temperature difference falls within a pre-defined safe range. If the temperature difference exceeds a predetermined threshold limit, it indicates that the cooling system may not be functioning efficiently or that the cells 102 are generating excessive heat, potentially leading to thermal runaway or degradation. In such cases, the microcontroller immediately generates a corresponding command.

[0048] The generated command from the microcontroller is received by an electronically controlled valve 111 integrated with the inlet 105 of the channel 101. This valve 111, upon receiving the command, adjusts its opening to a pre-defined extent, allowing the optimal flow of nano-fluid 104 into the tube 103. The purpose of this adjustment is to maximize the heat absorption capability of the nano-fluid 104 from the phase-changing material and the cells 102 themselves. The electronically controlled valve 111, also known as a motorized valve 111, employs electrical signals to precisely regulate the flow of nano-fluid 104. This motorized valve 111 is equipped with an electric motor, which drives the opening and closing mechanism. The motor can be of various types, including stepper motors and DC motors, each selected based on the specific requirements of the system.

[0049] Upon receiving the command, the motor actuates the valve 111 to regulate the amount of nano-fluid 104 circulating within the tube 103. This regulation is critical for maintaining an efficient thermal management system. The amount of nano-fluid 104 allowed to enter the inlet 105 is directly proportional to the rate of heat transfer within the system. Specifically, an increased flow of nano-fluid 104 enhances the heat transfer rate, as a greater volume of fluid 104 can absorb and dissipate more heat. This relationship ensures that the system can effectively manage high thermal loads, particularly during peak operational periods such as fast charging.

[0050] By precisely controlling the valve 111 opening, the system can dynamically adjust the nano-fluid 104 flow based on real-time temperature data. If the temperature difference between the inlet 105 and outlet 106 exceeds the threshold, indicating insufficient cooling, the microcontroller signals the valve 111 to open wider, thereby increasing the flow rate of nano-fluid 104. This increased flow rate accelerates heat dissipation, helping to bring the system's temperature back within the desired range. Conversely, if the system is operating within safe temperature limits, the valve 111 can remain partially closed to conserve energy and minimize unnecessary fluid 104 circulation.

[0051] Simultaneously, the centrifugal pump installed with the radiator’s 107 coolant reservoir is directed by the microcontroller to pump larger amount of nano-fluid 104 at a faster rate for allowing faster administration of the nano-fluid 104 within the inlet 105 of the channel 101 in view of balancing the temperature difference resulted due to fast charging of cells 102. The centrifugal pump as used herein is capable of handling large volumes of nano-fluid 104 efficiently. The pump provides a smooth and continuous flow of the nano-fluid 104.

[0052] After carrying the heat dissipated from the cells 102, the nano-fluid 104 exits the channel 101 through the outlet 106. This heated nano-fluid 104 then flows through an intake port of the radiator 107, which is an essential component of the vehicle's cooling system. The radiator 107 is designed to facilitate effective heat exchange, ensuring that the temperature of the nano-fluid 104 is significantly reduced before it is recirculated back into the system.

[0053] The radiator 107 consists of a network of thin tubes and flaps 112. As the hot nano-fluid 104 flows through this tube, it releases the absorbed heat to the metal flaps 112 attached to the tube. The design of the radiator 107 maximizes the surface area exposed to the air, which is crucial for efficient heat dissipation. The metal flaps 112, typically made from materials with high thermal conductivity like aluminum or copper, effectively transfer heat from the nano-fluid 104 to the surrounding air. The large surface area provided by the numerous flaps 112 ensures that a significant amount of heat is dissipated, lowering the temperature of the nano-fluid 104 as it passes through the radiator 107.

[0054] To further enhance the cooling process, the radiator 107 is equipped with a fan. This fan plays a critical role in increasing airflow through the radiator 107, which helps to accelerate the heat exchange process. By forcing cooler air over the heated flaps 112 and tube, the fan facilitates the rapid removal of heat from the nano-fluid 104. The increased airflow not only improves the efficiency of the radiator 107 but also ensures that the system manages high thermal loads, such as those encountered during prolonged fast charging.

[0055] In an embodiment of the present invention, the inlet 105 and outlet 106 of the channel 101 are equipped with flow meters 114 designed to measure the flow rate of the nano-fluid 104 entering and exiting the tube 103. These flow meters 114 provide critical data regarding the volume and velocity of the nano-fluid 104. The microcontroller, linked to the flow meters 114, continuously processes the flow rate measurements from both the inlet 105 and outlet 106. By comparing these values, the microcontroller detects any significant fluctuations or discrepancies in the flow rates. Such fluctuations might indicate potential issues within the cooling system, such as leaks in the tube 103 or casing, or obstructions that impede the proper flow of the nano-fluid 104. If the microcontroller identifies a considerable deviation between the inlet and outlet flow rates, it generates an alert notification. This notification is sent to the instrument cluster of the three-wheeler electric vehicle, where it is displayed to the driver or operator. The alert may provide specific information about the nature of the issue, such as indicating the presence of a leak or suggesting a possible blockage within the tube 103.

[0056] The technical advantage of the present invention over the existing systems are listed below:

• Enhanced Thermal Management: The combination of nano-fluid, phase-changing materials, and finned provides heat dissipation, maintaining optimal cell temperatures during high-demand conditions.
• Dynamic Flow Control: The electronically controlled valve and flow meters enable precise regulation of nano-fluid flow, ensuring efficient heat absorption and transfer.
• Real-Time Monitoring: Temperature sensors and flow meters continuously monitor system performance, allowing for immediate detection of thermal anomalies or flow issues.
• Automatic Alerts: The microcontroller’s ability to generate alerts for flow discrepancies ensures timely identification and resolution of leaks or blockages, enhancing system reliability and safety.

[0057] The system as disclosed above offers significant improvements over traditional systems by integrating real-time monitoring, dynamic control, and enhanced thermal management, leading to better performance, safety, and reliability.

[0058] The invention works best in the following manner, where the tubular channel 101 as disclosed in the invention is designed with a sinusoidal shape and installed in a three-wheeler electric vehicle. One side of the channel 101 is flat, while the other side features lateral contours 401 along its length to accommodate multiple vehicle cells 102 during charging. Inside the channel 101, the cylindrical tube 103 runs longitudinally for circulating nanofluid 104. The nanofluid 104 flows into the tube 103 through an inlet 105 connected between the channel 101 and the outlet port 110 of the radiator 107 containing the fluid 104. The cylindrical tube 103 is equipped with numerous fins 201 extending radially towards the channel 101 inner surface to enhance heat transfer. The heat released by the cells 102 during charging is absorbed by a material that transitions from a solid to a liquid state via latent heat. This absorbed heat is then conducted to the nanofluid 104 and further transferred through convection. Temperature sensors 108 at both the inlet 105 and outlet 106 of the channel 101 measure the nanofluid 104’s temperature difference. The microcontroller, connected to these sensors, analyses the temperature data. If the temperature difference exceeds threshold limit, the microcontroller sends a command to an electronically controlled valve 111 at the inlet 105. This valve 111 adjusts to a predefined extent, optimizing the flow of nanofluid 104 into the tube 103 to maximize heat absorption from the material.

NOVELTY AND INVENTIVE STEP

[0059] The novelty and inventive step of the present invention mainly lies in configuration of the system. The setup of the components within the system are organized and structured in a manner that they work collectively and functioning of one component is dependent upon the other. The tubular channel 101 as disclosed in the invention is designed in a sinusoidal shape for accommodating numerous numbers of cells 102 in a compact orientation which are to be charged. The contoured region 401 developed over one of the sides of the channel 101 facilitates secured accommodation of the cells 102. The channel 101 is embodied with the cylindrical tube 103 that runs longitudinally along the length of channel 101, for circulation of nanofluid 104 which is introduced to the tube 103 from the vehicle’s radiator 107. Numerous fins 201 are attached to the tube 103, extending radially towards the inner surface of the channel 101 to improve heat transfer that is dissipated from the cells 102 while they are being charged. Heat released from the cells 102 during charging is transferred to a phase changing material 301 embedded in between each of the fins 201 which undergoes phase change solid to a liquid and the heat absorbed by the material is further transmitted to the nano-fluid 104. The set-up includes incorporation of temperature sensors 108 and flow meters 114 on inlet 105 and outlet 106 of the channel 101 for real-time monitoring of the temperature and flow rate of the fluid 104 circulating within the tube 103 for immediate detection of thermal anomalies or flow issues.

[0060] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A thermal management system for charging of electric vehicles, comprising:

i) a tubular channel 101 arranged in a sinusoidal form installed in a three-wheeler electric vehicle, wherein one of the sides of said channel 101 is flat in nature and the other side is laterally contoured along the length of said channel 101 to accommodate multiple cells 102 of said vehicle in a charged state;
ii) a cylindrical tube 103 longitudinally disposed along the length of said channel 101 that is dedicated towards circulation of nano-fluid 104, wherein said nano-fluid 104 is introduced to said tube 103 via an inlet 105 connected in between said channel 101 and an outlet port 110 of a radiator 107 of said vehicle stored with said fluid 104;
iii) plurality of fins 201 fused on said tube 103 radially projected towards inner peripheral surface of said channel 101 to enhance heat transfer rate, wherein heat dissipated from said cells 102 while being charged is transferred to a phase changing material 301 embedded in between each of said fins 201, that in turn change phase of said material which is initially in a solid state into liquid state via latent heat phenomenon and heat absorbed by said material is further transmitted to said nano-fluid 104 via conduction followed by convection phenomena;
iv) a temperature sensor 108 configured with said inlet 105 and an outlet 106 attached with said channel 101 for detecting temperature difference in between flow of nano-fluid 104 while entering and exiting said channel 101, wherein a microcontroller interfaced with said temperature sensors 108 processes said detected temperature difference and in case evaluates said difference to be exceeding a threshold limit, then said microcontroller generates a relative command; and
v) an electronically controlled valve 111 integrated with said inlet 105 upon receiving said generated command opens up to a pre-defined extent for allowing optimal entrance of said fluid 104 within said tube 103 to maximize the heat absorption by said fluid 104 from said material.

2) The system as claimed in claim 1, wherein said nano-fluid 104 as mentioned herein is selected from but not limited to ethylene glycol-based nano-fluid 104, water-based nano-fluids 104 and oil-based nano-fluids 104.

3) The system as claimed in claim 1, wherein heated nano-fluid 104 circulated inside said tube 103 exits out via outlet 106 of said channel 101 and goes within an intake port of said radiator 107 to be flown through flaps 112 installed in said radiator 107 for heat exchange.

4) The system as claimed in claim 1, wherein a centrifugal pump is installed on said radiator 107 for pumping said nano-fluid 104 based on said detected temperature difference and determined flow rates in view of attaining proper heat management during fast charging of said cells 102.

5) The system as claimed in claim 1, wherein said cells 102 as mentioned herein are LFP (Lithium Iron Phosphate) cells 102.

6) The system as claimed in claim 1, wherein upper and lower sections of contoured regions 401 of said channel 101 are arranged with a thermal-resistant rubber pad for absorbing mechanical shocks while movement of said vehicle in order to prevent said cells 102 from any type of damages.

7) The system as claimed in claim 1, wherein said phase changing material 301s as disclosed herein is selected from but not limited to Paraffin wax, Salt Hydrates and Organic compounds.

8) The system as claimed in claim 1, wherein said material is closely packed in between said fins 201 with minimum tolerance to allow phase transition of said material.

9) The system as claimed in claim 1, wherein number of fins 201 fused on said tube 103 is directly proportional to diameter of said tube 103.

10) The system as claimed in claim 1, wherein said valve 111 as mentioned herein is a motor operated valve 111.