TECHNICAL FIELD

[0001] The present disclosure in general relates to the system and method for battery thermal management. More particularly, the present disclosure relates to a thermal management system for heat rejecting devices, especially vehicle batteries, wherein the system facilitates direct internal cooling of batteries.

BACKGROUND

[0002] Many of the components used in a circuit, such as, battery, electronic equipment, motor etc. come in the category of heat rejecting devices. The heat rejecting devices extract heat while in operation, and accumulation of the extracted heat may cause overheating of the heat rejecting devices. The overheating of the heat rejecting devices may result in fire accidents, which may prove to be fatal. Therefore, time-to-time removal of the extracted heat and cooling of the heat rejecting devices is important.

[0003] The heat rejecting devices generally get heated up due to ohmic losses and impedance factors. Especially, in case of vehicles, overheating of the batteries of the vehicles may trigger fire, and whole of the vehicle may catch the fire.

[0004] A number of techniques have been evolved to overcome the issue of overheating of the heat rejecting devices, such as, incorporating fan in the vehicle, and other such cooling methods and systems. However, there is still a need in the art to provide an efficient system that facilitates cooling of the heat rejecting devices by removing heat from said devices.

OBJECTS OF THE PRESENT DISCLOSURE

[0005] A general object of the present disclosure is to provide a system for thermal management of batteries of a vehicle.

[0006] An object of the present disclosure is to provide a thermal management system that facilitates enhanced removal of heat from the batteries, heat rejecting devices, and auxiliary electronic components of the vehicle.

[0007] Another object of the present disclosure is to provide a system having higher thermal efficiency.

[0008] Yet another object of the present disclosure is to provide a thermal management system with high power output. [0009] Still another object of the present disclosure is to provide a safe thermal management system facilitating a uniform and predictable distribution of heat.

SUMMARY

[0010] Aspects of the present disclosure in general relate to the system and method for battery thermal management. More particularly, the present disclosure relates to a thermal management system for heat rejecting devices, especially vehicle Lithium-ion batteries, wherein the system facilitates direct internal cooling of batteries through a looped heat exchange mechanism and establishes efficient cooling.

[0011] An aspect of the present disclosure pertains to a thermal management system can be implemented in a vehicle for cooling heat rejecting devices of the vehicle, for instance, batteries, auxiliary electronic components, and motor of the vehicle. The thermal management system includes a thermally insulated structure, a thermally conductive heat sink, and one or more fluid displacement modules. Further, the thermally insulated structure is adapted to accommodate the one or more heat rejecting devices, and the thermally conductive heat sink is coupled to the thermally insulated structure via a fluid channel comprising a dielectric, anti-corrosive, and thermally conductive fluid, where the heat sink is configured to absorb heat from the fluid. The one or more fluid displacement modules are disposed in one or more configurations in the fluid channel, such that at least one portion of each of the one or more fluid displacement modules is in contact with the thermally insulated structure. The one or more fluid displacement modules are configured to create one or more vortex by actuating circulation of the fluid in between the thermally insulated structure and the thermally conductive heat sink via the fluid channel. The one or more vortex have predefined temporal attributes, such as, speed, height, radius, circumference, angular velocity, and height-to-radius ratio. Further, the created one or more vortex of the circulating fluid transfers heat in between the thermally insulated structure and the thermally conductive heat sink, thereby facilitate in maintaining temperature of the one or more heat rejecting devices at a pre-defined temperature.

[0012] In an aspect, the system may be configured to operate safely using pull mode and/ or push mode for facilitating a uniform and predictable distribution of heat. The one or more fluid displacement modules are configured to induce variation, by controlling the temporal attributes, in the created one or more vortex on the basis of the pull mode and the push mode. Further, the variation induced by one or more fluid displacement modules may result in creation of an additional vortex. Moreover, operation of the system in both modes, the pull mode and the push mode, reduces pumping losses and enhances flow speed of the fluid.

[0013] In another aspect, the thermally insulated structure may accommodate the one or more heat rejecting devices such that the fluid flows inside the thermally insulated structure through more than one dedicated paths removing heat from the one or more heat rejecting devices. During the push mode, the one or more fluid displacement modules can push the fluid inside the thermally insulated structure, whereas, during the pull mode, the one or more fluid displacement modules can pull the fluid out from the thermally insulated structure towards the heat sink.

[0014] In another aspect, the system may include a single fluid displacement module, which can be configured at any of the top, bottom, left, and right portion of the thermally insulated structure. The system may also include mid mounted fluid displacement module and central fluid displacement module.

[0015] In one aspect, when the fluid displacement module is disposed in central configuration or is mid-mounted on the thermally insulated structure, the fluid displacement module may generate radial effect providing enhanced flow distribution of the fluid and hence increased cooling rate of the heat rejecting devices.

[0016] In another aspect, when two of the one or more fluid displacement modules are disposed in diagonal configuration on a tubular thermally insulated structure, the diagonally configured fluid displacement modules create more than one vortex, thereby enhancing heat exchange and cooling. Further, the one or more fluid displacement modules are configured to create a horizontal vortex or a vertical vortex; wherein, the vertical vortex produces pulsated flow of the fluid, which in turn results in increased heat transfer coefficient.

[0017] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. [0019] FIGs. 1A to ID illustrate exemplary diagrams representing architecture of the proposed thermal management system having single fluid displacement module, in order to elaborate its overall working, in accordance with an embodiment of the present invention.

[0020] FIG. 2 illustrates an exemplary diagram representing the proposed thermal management system having two fluid displacement modules, in accordance with an embodiment of the present invention.

[0021] FIGs. 3A and 3B illustrate exemplary diagrams representing the proposed thermal management system having a mid-mounted fluid displacement module, in accordance with an embodiment of the present invention.

[0022] FIGs. 4A and 4B illustrate exemplary diagrams representing the proposed thermal management system including diagonally configured fluid displacement modules, in accordance with an embodiment of the present disclosure.

[0023] FIG. 5 illustrates an exemplary diagram representing operation of the proposed system in pull mode and push mode, in accordance with an embodiment of the present disclosure.

[0024] FIG. 6 illustrates an exemplary diagram representing creation of horizontal vortex by the proposed system, in accordance with an embodiment of the present disclosure.

[0025] FIGs. 7A and 7B illustrate exemplary diagrams representing the proposed thermal management system having a central fluid displacement module, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

[0026] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such details as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosures as defined by the appended claims.

[0027] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0028] Embodiments explained herein relate to the system and method for battery thermal management. More particularly, embodiments of the present disclosure relate to a thermal management system for batteries of a vehicle, especially Lithium-ion batteries, wherein the system can facilitate direct internal cooling of batteries through a looped heat exchange mechanism and may establish efficient cooling.

[0029] Referring to FIGs. 1A to ID, the proposed thermal management system 100 (also, referred to as system 100, herein) can include a thermally insulated structure 102, a thermally conductive heat sink 104, and one or more fluid displacement modules 106.

[0030] In an embodiment, the thermally insulated structure 102 can be adapted to accommodate one or more heat rejecting devices. In an exemplary embodiment, the thermally insulated structure 102 can be made using elements such as, glasswool, earthwool, polyester, reflective foil, and the like.

[0031] In other embodiment, the thermally conductive heat sink 104 can be coupled to the thermally insulated structure 102, preferably through a fluid channel 108, which may include a dielectric, anti-corrosive, and thermally conductive fluid 110. The heat sink 104 can be configured to absorb heat from the fluid 110. In a preferred embodiment, the fluid 110 is in liquid state.

[0032] In an exemplary embodiment, the thermally insulated structure 102 may accommodate the one or more heat rejecting devices such that the fluid 110 can flow inside the thermally insulated structure 102 through more than one dedicated paths removing heat from the one or more heat rejecting devices. Also, a fluid resistant cover may be provided in the thermally insulated structure 102, such that the one or more heat rejecting devices are placed within the fluid resistant cover in order to avoid direct contact of said heat rejecting devices with the fluid, thereby preventing short-circuiting.

[0033] In another embodiment, the one or more fluid displacement modules 106 can be disposed in one or more configurations in the fluid channel 108, such that at least one portion of each of the one or more fluid displacement modules 106 may be in contact with the thermally insulated structure 102. In an exemplary embodiment, the one or more fluid displacement modules 106 can be configured with respect to the thermally insulated structure 102 in various configurations including, but not limited to, top, bottom, both top and bottom, central, mid mounted, and diagonal configuration.

[0034] In one embodiment, the one or more fluid displacement modules 106 can be configured to actuate circulation of the fluid 110 in between the thermally insulated structure 102 and the thermally conductive heat sink 104 via the fluid channel 108. Further, the circulation of the fluid 110 may create one or more vortex having pre -defined temporal attributes, wherein the created one or more vortex of the circulating fluid 110 may transfer heat in between the thermally insulated structure 102 and the thermally conductive heat sink 104, thereby facilitate in maintaining temperature of the one or more heat rejecting devices at a user-defined temperature. In an exemplary embodiment, the pre-defined temporal attributes can include speed, height, angular velocity, radius, circumference, height-to-width ratio of the vortex, and the like.

[0035] In an implementation, the one or more fluid displacement modules 106 may push the fluid 110 to extract heat from the thermally insulated structure 102, and then can force the fluid 110 towards the heat sink 104, wherein forced conduction and pressure makes the fluid 110 reject heat at the heat sink 104.

[0036] In an embodiment, the system 100 configured to operate in any or a combination of a pull mode and a push mode, wherein, the one or more fluid displacement modules 106 may induce variation, by controlling the temporal attributes, in the created one or more vortex on the basis of the pull mode and the push mode. In an exemplary embodiment, during the push mode, the one or more fluid displacement modules 106 can push the fluid 110 inside the thermally insulated structure 102, whereas, during the pull mode, the one or more fluid displacement modules 106 can pull the fluid 110 out from the thermally insulated structure 102 towards the heat sink 104.

[0037] In one embodiment, as illustrated in FIG. 1A, the system 100 can include a single fluid displacement module 106 (also, referred to as FDM 106, herein) configured at a bottom portion of the thermally insulated structure 102 (also, referred to as TIS 102, herein). The fluid displacement module 106 can uniformly distribute the fluid 110 within the TIS 102 consisting the one or more heat rejecting devices. Inside the TIS 102, the fluid 110 may absorb heat from the one or more heat rejecting devices, and further may flow out towards the heat sink 104 through the more than one dedicated paths. Further, the forced conduction and pressure, generated by the FDM 106, can make the fluid 110 reject heat at the heat sink 104, hence resulting in heat rejection in an efficient manner and cooling down of the one or more heat rejecting devices, for instance, batteries, auxiliary electronic components, motor, and the like.

[0038] In other embodiment, as illustrated in FIG. IB, the system 100 can include a single FDM 106 configured at a top portion of the TIS 102. Placing the FDM 106 at the top portion can provide a unique fluid distribution, which may improve efficiency of the overall system 100.

[0039] In an exemplary embodiment, said configuration of the FDM 106 may increase cooling rate of Lithium-ion batteries associated with a vehicle and improve efficiency of the overall system 100 by 5 percent (%). Further, when the system 100 operates in the push mode, variations induced by the FDM 106 may aid in creating at least one additional vortex, where the additional vortex can be utilized for cooling the auxiliary electronic components, for instance, electronic components associated with engine assembly, wheel assembly, and motor of the vehicle in which the system 100 is implemented.

[0040] In another embodiment, as illustrated in FIGs. 1C and ID, the FDM 106 can also be configured at either of the left portion and the right portion of the TIS 102, where the FDM 106 can facilitate heat rejection from the one or more array of batteries and hence cooling down of said batteries in an efficient manner.

[0041] Referring to FIG. 2, the system 100 can include two FDM 106-1 and 106-2, such that the FDM 106-1 can be configured at the top portion of the TIS 102, and the FDM 106-2 can be configured at the bottom portion of the TIS 102. In an embodiment, said configuration of the FDM 106-1 and 106-2 can be referred to as top plus bottom FDM configuration. In another embodiment, said configuration of the FDM 106-1 and 106-2 can improve heat removal efficiency of the system 100 by 30%. In an exemplary embodiment, the FDM 106-1 and 106-2 can be identical to each other.

[0042] In another embodiment, said configuration of the FDM 106-1 and 106-2 can facilitate the system 100 to operate in the pull mode and/ or push mode, thereby enhancing the rate of cooling. In yet another embodiment, in case any failure or short-circuit in the electronic components of the vehicle, both the FDM 106-1 and 106-2 can work in synchronization with each other for rejecting maximum possible heat, thereby ensuring safety such cases.

[0043] Referring to FIGs. 3A and 3B, the system 100 can include a mid-mounted FDM 106, which may assist the system 100 in operating in the pull mode and/ or push mode. In one embodiment, the FDM 106 can be placed horizontally with respect to the TIS 102, as illustrated in the FIG. 3A. In other embodiment, the FDM 106 can be placed vertically with respect to the TIS 102, as illustrated in the FIG. 3B. In an implementation, the mid-mounted configuration of the FDM 106 can provide advantages similar to as that of the top plus bottom FDM configuration, as illustrated in the FIG. 2.

[0044] In an embodiment, the mid-mounted FDM 106 may utilize a larger space, which may facilitate increased flow of the fluid, which in turn can result enhanced heat removal efficiency.

[0045] Referring to FIGs. 4A and 4B, the system 100 can include FDM 106 configured at one of the diagonals of the TIS 102, and can result in enhanced heat removal rates. In one embodiment, the FDM 106 can be configured at one of the diagonals on the top portion of the TIS 102, as illustrated in the FIG. 4A. In other embodiment, the FDM 106 can be configured at one of the diagonals on the bottom portion of the TIS 102, as illustrated in the FIG. 4B.

[0046] Referring to FIG. 5, the system 100 can include FDM 106-1 and 106-2 configured diagonally with respect to each other on tubular TIS 102, where the diagonally configured FDM 106-1 and 106-2 can create more than one vortex, thereby enhancing heat exchange and cooling. In a preferred embodiment, the diagonally configured FDM 106-1 and 106-2 can create synchronous internal vortex and external vortex in the fluid channel 108. In an embodiment, the internal vortex pertains to vortex created within the TIS 102 and the external vortex pertains to vortex created outside the TIS 102. Further, the variation induced in the created synchronous internal vortex and external vortex can result in enhanced heat removal rates.

[0047] In an exemplary embodiment, creation of the vortex and induced variation therein are advantageous for high powered devices as it may result in enhance heat removal and cooling of said devices. Hence, the system can facilitate direct cooling of heat rejecting devices including high powered devices, electronic components, super capacitors, and batteries through a looped heat exchange mechanism and may establish efficient cooling.

[0048] In an implementation, as illustrated in the FIG. 5, operation of the system 100 in push-pull modes may reduce pumping losses of the system 100 and can enhance flow speeds of the fluid 110.

[0049] Referring to FIG. 6, creation of horizontal vortex by the proposed system 100 can help in implementation of pulsated flow of the fluid which results in improving heat transfer coefficient. In an exemplary embodiment, the horizontal vortex can remove 5% excess heat in comparison to the vertical vortex.

[0050] Referring to FIGs. 7A and 7B, when the FDM 106 is disposed in central configuration, said FDM 106 can generate radial effect providing enhanced flow distribution of the fluid 110. The radial effect provides better flow distribution, for instance approximately 5% improvement over all the other configurations.

[0051] In an embodiment, a variation in the radial flow of the fluid 110 helps in implementation of the pulsed flow in order to improve the heat transfer coefficient. A horizontal radial effect, as illustrated in the FIG. 7B, may have an improved heat transfer coefficient, which may facilitate in removal of 5% excess heat compared to vertical radial effect, as illustrated in the FIG. 7A. [0052] It should be appreciated that the proposed system 100 can be utilized for batteries and battery packs of almost all sizes, motors, super capacitors, and the like.

[0053] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0054] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0055] Moreover, in interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a nonexclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C....and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

[0056] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE

[0057] The present disclosure provides a system for thermal management of batteries of a vehicle.

[0058] The present disclosure provides a thermal management system that facilitates enhanced removal of heat from the batteries, heat rejecting devices, and auxiliary electronic components of the vehicle.

[0059] The present disclosure provides a system having higher thermal efficiency.

[0060] The present disclosure provides a thermal management system with high power output. [0061] The present disclosure provides a safe thermal management system facilitating a uniform and predictable distribution of heat.