FIELD OF INVENTION

The present invention relates to a heat exchanger, particularly, the present invention relates to a battery thermal management system for an electric vehicle.

BACKGROUND

Generally a conventional battery thermal management system 1 includes a base plate 2 and a channel plate 3 assembled to each other and collectively forming fluid flow passages of a plate heat exchanger subassembly 4. The battery thermal management system 1 further includes an inlet nozzle 4a and an outlet nozzle 4b formed on the base plate 2 for ingress and egress of fluid with respect to the fluid flow passages. The conventional battery thermal management system 1 still further includes at least one thermal pad 6 and elastic pads 8.

The base plate 2 supports thereon batteries b to be cooled. The channel plate 3 is disposed underneath and abutting the base plate 2 and is formed with interconnected channels 3a to define the fluid flow passages between the base plate 2 and the channel plate 3. The fluid flowing through the fluid flow passages defined by the channels 3a extract heat from the batteries b disposed over the base plate 2 to cause cooling of the batteries b that are inherently heated during operation thereon. The thermal pad 6 is /are disposed between the base plate 2 and the corresponding batteries b supported on the base plate 2 to improve thermal contact between the batteries b and the base plate 2 to improve thermal efficiency and battery cooling. The plate heat exchanger sub-assembly 4 is generally mounted over a casing 9 that at least partially encloses the plate heat exchanger subassembly 4 and is mounted over a vehicle frame. With such configuration, delicate components of the battery b and plate heat exchanger subassembly 4 are subject to vibration resulting in damage thereto. Particularly, the vibration may cause failure, reduced service life and reliability issues.

To prevent the problems associated with vehicle vibrations reaching the batteries b and the plate heat exchanger sub-assembly, vibration isolators in the form of elastic pads 8 are used. Generally, the elastic pads 8 of resilient material such as rubber disposed between the channel plate 3 and the casing 9 act as vibration isolators to protect the batteries and the plate heat exchanger sub-assembly 4 against the vehicle vibrations. However, the use of elastic pads 8 have other disadvantages associated therewith. For example, the positioning of the elastic pads 8 is problem. Particularly, the elastic pads 8 are required to be disposed aligned with respect to the batteries b and there are chances of dislocation and misalignment that may render the elastic pads 8 ineffective in isolating the batteries from vehicle vibrations. Further, it is difficult to confirm whether the elastic pads 8 are disposed between the channel plate 3 and the casing 9, after the assembly, during inspection. The elastic pads 8 are expensive and such arrangement of vibration isolation is cost ineffective. Further, the assembly of the elastic pads between the channel plate 3 and the casing 9 involves gluing that is time intensive and cumbersome operation, thereby substantially increasing the assembly time and manufacturing costs. More specifically, the curing of the glue for securing the elastic pads between the channel plate 3 and the casing 9 involves considerable time. Accordingly, there is a need for a battery thermal management system configured with vibration isolation arrangement disposed between a channel plate and a casing to protect the batteries and the plate heat exchanger sub-assembly against the vehicle vibrations. Further, there is a need for a battery thermal management system configured with vibration isolation arrangement that improves reliability and service life of the batteries and the plate heat exchanger sub-assembly. Furthermore, there is a need for a battery thermal management system that ensures detecting presence of vibration isolation arrangement, after assembly and during inspection. Further, there is a need for a battery thermal management system configured with vibration isolation arrangement that is effective but inexpensive. Further, there is a need for a battery thermal management system configured with vibration isolation arrangement that is convenient to assemble and reduces assembly time.

OBJECTS

An object of the present invention is to provide a battery thermal management system configured with vibration isolation arrangement that obviates the drawbacks such as misalignment and positioning issues associated with use of elastic pads for vibration isolation used in conventional battery thermal management systems.

Another object of the present invention is to provide a battery thermal management system configured with vibration isolation arrangement that effectively protects the batteries and the plate heat exchanger subassembly against the vehicle vibrations. Still another object of the present invention is to provide a battery thermal management system that ensures detecting presence of vibration isolation arrangement therein, after assembly and during inspection.

Yet another object of the present invention is to provide a battery thermal management system configured with vibration isolation arrangement that improves reliability and service life of the batteries and the plate heat exchanger sub-assembly.

Another object of the present invention is to provide a battery thermal management system configured with vibration isolation arrangement that is convenient to assemble and reduces assembly time.

SUMMARY

A battery thermal management system includes a base plate, a channel plate, a plurality of thermal pads, an inlet nozzle and an outlet nozzle. The base plate supports thereon batteries B to be cooled. The channel plate disposed underneath and abutting the base plate is formed with channels to define fluid flow passages between the base plate and the channel plate for configuring a plate heat exchanger sub-assembly. The plate heat exchanger sub-assembly is mounted over a casing that at least partially encloses the plate heat exchanger sub-assembly and is mounted over a vehicle frame. The inlet nozzle and the outlet nozzle for ingress and egress of fluid with respect to the fluid flow passages formed by the channels. The battery thermal management system further includes at least one, preferably, a plurality of spring elements. Each spring element forms at least one of snap fit engagement and locking engagement with a portion of the plate heat exchanger sub-assembly by virtue of cutouts formed on the plate heat- exchanger sub-assembly and is disposed between the channel plate and the casing to isolate a corresponding battery and plate heat exchanger sub-assembly from vehicle vibrations.

Generally, the spring element extends along lateral sides of the plate heat exchanger sub-assembly and forms at least one of snap fit engagement and locking engagement with at least one of the opposite longitudinal sides of the plate heat exchanger sub-assembly.

Specifically, each spring element includes a snap fit engagement element that engages with a first longitudinal side of the plate heat exchanger sub-assembly and a locking element that engages with a second longitudinal side opposite to the first longitudinal side.

Preferably, the snap fit engagement element is a spring clip connector that forms snap fit engagement with the first longitudinal side and the locking element is push male connector that forms locking engagement with the second longitudinal side of the plate heat exchanger sub-assembly.

In accordance with an embodiment, at least one of the snap fit engagement element and the locking element for a spring element is a spring clip connector.

Particularly, each of the spring clip connector includes spring-loaded arms under compression forming a respective cavity there between adapted to grip at least one of the base plate and the channel plate when pushed inside the cavity. Further, each of the spring clip connector further includes at least one gripping feature extending inwardly into the respective cavity to further enhance the gripping of the at least one of the base plate and the channel plate when pushed inside the cavity.

Preferably, the gripping feature is at least one protrusion extending from at least one of the inner walls of the spring clip connector into the respective cavity.

In accordance with an embodiment of the present invention, one protrusion is formed on a first spring-loaded arm and two protrusions are formed on a second spring-loaded arms of the spring clip connector.

In accordance with another embodiment of the present invention, the protrusions formed on the first spring-loaded arm extend substantially orthogonal to the protrusions formed on the second spring-loaded arm.

Further, at least one of the snap fit engagement element and the locking element for a spring element is a push male connector.

Particularly, each of the push male connector includes planar portions extending in different parallel planes that are received in and engages with a corresponding cutout formed on at least one of the base plate and the channel plate. Further, the battery thermal management system includes a plurality of thermal pads. Each thermal pad is disposed between the base plate and the corresponding battery B disposed on the base plate to improve thermal contact between the corresponding battery B and the base plate.

Also is disclosed a method of assembling battery thermal management system in accordance with an embodiment of the present invention. The method includes the steps of assembling a base plate to a channel plate to form a plate heat exchanger sub-assembly. The method further includes the step of mounting, at least one, preferably, a plurality of spring elements on underside of the plate heat exchanger sub-assembly. The step of mounting each spring element to the underside of the plate heat exchanger subassembly includes the steps of inserting a push male connector formed on one of the extreme ends of a spring element into a cutout formed on at least one of the base plate and the channel plate. The step of mounting each spring element to the underside of the plate heat exchanger sub-assembly further includes the step of receiving and gripping a first longitudinal side of the formed on other opposite extreme end of the spring element by pushing the same inside the cavity.

The method of assembling battery thermal management system further includes the step of mounting the plate heat exchanger sub-assembly with the spring elements secured to underside thereof over a casing mounted on a vehicle frame such that the spring element are disposed between the channel plate and the casing.

The method optionally includes the step of securely mounting thermal pads on the portions of the base plate supporting the batteries B such that at least one thermal pad is sandwiched between the base plate and a corresponding battery B.

BRIEF DESCRIPTION

Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

FIG. 1 illustrates a sectional view of a conventional battery thermal management system 1 for cooling of batteries, also is illustrated an enlarged sectional view depicting elastic pads disposed between channel plate and casing to isolate batteries and plate heat exchanger sub-assembly from vehicle vibrations;

FIG. 2 illustrates an exploded view of a battery thermal management system in accordance with an embodiment of the present invention using spring elements to isolate batteries and plate heat exchanger sub-assembly from vehicle vibrations;

FIG. 3 illustrates a top isometric view of the battery thermal management system of FIG. 2;

FIG. 4 illustrates a bottom isometric view of the battery thermal management system of FIG. 2; FIG. 5 illustrates a bottom view of a channel plate of the battery thermal management system of FIG. 2;

FIG. 6 illustrates a top isometric view of a spring element for isolating plate heat exchanger sub-assembly and batteries resting thereon from vehicle vibrations, also is illustrated an enlarged view of a snap fit engagement element formed on first end of the spring element;

FIG. 7 illustrates another isometric view of the spring element of FIG. 6, also is illustrated an enlarged view of a locking engagement element formed on a second end of the spring element opposite to the first end;

FIG. 8 illustrates a bottom isometric view of the spring element of FIG. 6 and FIG. 7, also are illustrated enlarged view of the snap fit engagement element and the locking engagement element;

FIG. 9 illustrates a sectional view of the battery thermal management system of FIG. 2 for cooling of batteries, also is illustrated an enlarged sectional view depicting spring elements used instead of elastic pads to isolate batteries and plate heat exchanger sub-assembly from vehicle vibrations;

FIG. 10 illustrates an enlarged sectional view depicting a spring clip connector receiving a first longitudinal side of a plate heat exchanger assembly; FIG. 11 illustrates an enlarged sectional view depicting a push male connector being received in a cavity formed on the plate heat exchanger sub-assembly; and

FIG. 12 depicts a block diagram depicting various steps of the method of assembling a battery thermal management system in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

Although the present invention is explained with one or more example of a battery thermal management system, wherein a plate heat exchanger sub-assembly is formed by assembling a base plate and a channel plate. The heat exchanger sub-assembly is mounted on casing enclosing at least a portion of the heat exchanger sub-assembly. The casing is mounted on a vehicle frame, whereas the batteries are supported on the base plate Further, a spring element forming at least one of snap fit engagement and locking engagement with a portion of the plate heat exchanger sub-assembly is disposed between the channel plate and the casing to isolate plate heat exchanger sub-assembly and corresponding battery B resting thereon from vehicle vibrations. However, the present invention is also applicable for any other application in vehicular and non- vehicular environment, where it is required to mount a first component on a second component while still isolating the first component from vibrations either emanating from the second component or reaching the second component.

FIG. 2 illustrates an exploded view of a battery thermal management system 100. FIG.3 and FIG. 4 illustrates isometric view of the battery thermal management system 100. The battery thermal management system 100 includes a base plate 10, a channel plate 20, a plurality of thermal pads 50, an inlet nozzle 12, an outlet nozzle 14 and at least one, preferably, a plurality of spring elements 60. The base plate 10 and the channel plate 20 collectively forms the plate heat exchanger assembly 30.

The base plate 10 supports thereon batteries B to be cooled by the plate heat exchanger assembly 30. The batteries are stacked in a spaced apart configuration with respect to each other on the base plate 10. Accordingly, the lateral dimension of the base plate is at least 1 .5 times the cumulative width of all the batteries B supported on the base plate 10. The base plate 10 is of metallic material. The base plate 10 further includes mounting holes 10a formed thereon. In accordance with an embodiment of the present invention, the inlet and the outlet nozzles 12 and 14 are formed on the base plate 10. The base plate 10 includes at least one of snap and locking features formed on first and second longitudinal sides 10b and 10c thereof. The base plate 10 further includes cutouts 16 formed along at least one longitudinal side 10b, 10c thereof to receive a corresponding push male connector 62c, 62d formed on at least one extreme end of the spring element 60 to lock the extreme end of the spring element 60 to the longitudinal side 10b, 10c of the base plate 10.

Further, the channel plate 20 is disposed underneath and abutting the base plate 10 is formed with channels 22 to define fluid flow passages between the base plate 10 and the channel plate 20 for configuring the plate heat exchanger sub-assembly 30. The fluid flowing through the fluid flow passages is generally a coolant for extracting heat from a heated body, for example, the batteries in this case that are disposed over the base plate 10. Preferably, the channel plate 20 is of same dimension and shape, as the base plate 10 and is disposed in an overlapping manner with respect to the base plate 10. FIG. 5 illustrates a bottom view of the channel plate 20. Preferably, the channel plate 20 includes a plurality of interconnected channels 22 extending along the longitudinal side of the channel plate 20. Particularly, the channels 22 formed on the channel plate 20 are interconnected channels with numerous torturous turns to increase length of the fluid flow passages and the time taken by the fluid to traverse through the channels 22 to improve the heat exchange. The channel plate 20 is of metallic material. The channel plate 20 further includes mounting holes 20a formed thereon. The base plate 10 and the channel plate 20 being of similar shape and size, the mounting holes 20a formed on the channel plate 20 are aligned to the mounting holes 10a formed on the base plate 10 for passage of mounting bolts there through. The bolted connection so formed is for mounting the plate heat exchanger sub-assembly 30 formed by the assembly of the base plate 10 and the channel plate 20 over a casing 40 that at least partially encapsulates the plate heat exchanger sub-assembly 30 and is mounted over a vehicle frame. With the plate heat exchanger subassembly 30 mounted over the casing 40 and the batteries supported over the base plate 10, the vehicle vibrations could reach the batteries to cause damage thereto, however, the spring element 60 disposed between the channel plate 20 and the casing 40 isolates the batteries and plate heat exchanger sub-assembly 30 from the vehicle vibrations. The channel plate 20 also includes cutouts 26 formed thereon that are aligned to the cutouts 16 formed on the base plate, accordingly, the plate heat exchanger subassembly 30 is formed with the cutouts 16, 26 that receive the push male connector 62c, 62d to form the locking engagement between the spring element 60 and the plate heat exchanger sub-assembly 30.

Each of the thermal pad 50 of the plurality of thermal pads is disposed between the base plate 10 and the corresponding battery B supported on the base plate 10 to improve thermal contact between the corresponding battery B and the base plate 10. The thermal pads 50 can be secured to the base plate 10 by using any means such as for example gluing. The number, spacing and the placement of the thermal pads 50 over the base plate 10 is based on the number and placement of the batteries over the base plate 10.

The inlet nozzle 12 and the outlet nozzle 14 are for ingress and egress of fluid with respect to the fluid flow channels. However, the present invention is not limited to any particular configuration, number and placement of the inlet and outlet nozzles 12 and 14 respectively as far as the inlet and outlet nozzles performs its function of ingress and egress of fluid with respect to the fluid flow channels.

FIG. 9 illustrates a sectional view of the battery thermal management system 100 for cooling of batteries B. Also is illustrated an enlarged sectional view depicting the spring elements 60 used instead of elastic pads to isolate batteries and the plate heat exchanger sub-assembly 30 from vehicle vibrations through the casing 40. Each spring element 60 of the plurality of spring elements 60 forms at least one of snap fit engagement and locking engagement with a portion of the plate heat exchanger subassembly 30 by virtue of cutouts 16, 26 formed on the plate heat exchanger sub-assembly 30. More specifically, the locking engagement between the spring element 60 and the plate heat exchanger sub-assembly 30 is by virtue of the cutout 16, 26. Specifically, the push male connector 62c, 62d of the spring element 60 is received in the cutout 16, 26 formed on the plate heat exchanger sub-assembly 30 to configure the locking engagement between the spring element 60 and the plate heat exchanger sub-assembly 30. Each of the spring element 60 is disposed between the channel plate 20 and the casing 40 to isolate the plate heat exchanger sub-assembly 30 and a corresponding battery B disposed thereon from vehicle vibrations. The spring element 60 extends along lateral sides of the plate heat exchanger sub-assembly 30 and forms at least one of snap fit engagement and locking engagement with at least one of the opposite longitudinal sides 30a and 30b of the plate heat exchanger sub-assembly 30. FIG. 6 illustrates an isometric view of the spring element 60. Preferably, each spring element 60 includes a snap fit engagement element 60a formed on a first extreme end thereof and a locking element 60b formed on a second extreme end thereof opposite to the first extreme end. The snap fit engagement element 60a engages with a first longitudinal side 30a of the plate heat exchanger sub-assembly 30 while the locking element 60b engages with a second longitudinal side 30b opposite to the first longitudinal side 30a.

The combination of snap fit engagement and locking engagement formed by the snap fit engagement element 60a and the locking element 60b forms a flexible connection between the spring element 60 and the underside of the channel plate 20, thereby preventing any induced stresses.

Generally, the snap fit engagement element 60a is a spring clip connector 62a, 62b that forms snap engagement with the first longitudinal side of the plate heat exchanger sub-assembly 30, while the locking element 60b is push male connector 62c, 62d that is received in the cutout 16, 26 formed on at least one of the base plate 10 and the channel plate 20 to form the locking engagement with the second longitudinal side of the plate heat exchanger sub-assembly 30. The spring clip connector formed on first extreme end of the spring element 60 is referred to as 62a and the spring clip connector formed on the second extreme end of the spring element 60 is referred to as 62b. Similarly, the push male connector formed on first extreme end of the spring element 60 is referred to as 62c and the push male connector formed on the second extreme end of the spring element 60 is referred to as 62b.

At least one of the snap fit engagement element 60a and the locking element 60b for a spring element 60 is the spring clip connector 62a and 62b.

FIG. 6 and FIG. 8 illustrates an enlarged view of the spring clip connector 62a formed on either one of the extreme ends of the spring element. Each of the spring clip connector 62a, 62b includes spring-loaded arms 64a, 66a and 64b, 66b respectively under compression forming a respective cavity 68a, 68b there between. The cavity 68a, 68b grips at least one of the base plate 10 and the channel plate 20 when pushed inside the cavity 68a, 68b as illustrated in FIG. 10. More specifically, the cavity 68a, 68b receives and grips either one of the opposite longitudinal sides 30a and 30b of the plate heat exchanger sub-assembly 30. The spring clip connector 62a, 62b further includes at least one gripping feature 70a, 70b extending inwardly into the respective cavity 68a, 68b to further enhance the gripping of the at least one of the base plate 10 and the channel plate 20 when pushed inside the cavity 68a, 68b. The gripping feature is at least one protrusion 70a, 70b extending from at least one inner wall of the spring clip connector 62a, 62b into the respective cavity 68a, 68b. Generally, the protrusions 70a, 70b can be formed on at least one of the spring-loaded arms 64a, 66a and 64b, 66b of the spring clip connector 62a, 62b. Referring to FIG. 6, a single protrusion is formed on the first spring-loaded arm 64a and two protrusions 70a are formed on the second spring-loaded arm 66a. The protrusions 70a formed on the second spring-loaded arm 66a is substantially larger than the protrusion 70a formed on the first spring-loaded arms 64a. Further, the protrusions 70a formed on the first spring-loaded arm 64a are substantially orthogonal to the protrusions 70a formed on the second spring-loaded arm 64a. However, the present invention is not limited to any particular configuration, number and placement of the protrusions 70a, 70b as far as the protrusions enable secure gripping of the longitudinal edge of the plate heat exchanger sub-assembly 30 by the spring clip connector 62a.

In accordance with another embodiment of the present invention, at least one of the snap fit engagement element 60a and the locking element 60b for a spring element 60 is a push male connector 62c and 62d. FIG. 8 illustrates an enlarged view of the push male connector 62c. Referring to the FIG. 1 1 , each of the push male connector 62c and 62d includes planar portions extending along different parallel planes. At least one of the planar portions is received in and engage with a corresponding cutout 16, 26 formed on at least one of the base plate 10 and the channel plate 20 to form the locking engagement between the spring element 60 and the plate heat exchanger sub-assembly 30.

Also, is disclosed a method 200 of assembling battery thermal management system 100 in accordance with an embodiment of the present invention. FIG. 12 illustrates a block diagram depicting the various steps of the method 200 for assembling the battery thermal management system 100. Particularly, the method 200 includes the step of mounting a spring element 60 underneath a plate heat exchanger sub-assembly 30 formed by assembly of a base plate 10 to a channel plate 20 to isolate the plate heat exchanger sub-assembly 30 and the batteries B disposed on the heat exchanger sub-assembly from vehicle vibrations. Although, the various steps of the method 200 are depicted by blocks in the flow diagram and any number of steps described as method blocks can be combined in any order or can be performed in parallel to employ the method 200, or an alternative method. Additionally, individual blocks may be deleted from the flow chart depicting the method without departing from the scope and ambit of the present invention. The method 200 is to be understood with reference to the following description along with the Fig. 12.

A method 200 of assembling battery thermal management system 100 includes the step 102 of assembling a base plate 10 to a channel plate 20 to form a plate heat exchanger sub-assembly 30. The method 200 further includes the step 104 of mounting at least one, preferably, a plurality of spring elements 60 on underside of the plate heat exchanger sub-assembly 30. The step 104 of mounting each spring element 60 to the underside of the plate heat exchanger sub-assembly 30 includes the step 104a of inserting a push male connector 62c, 62d formed on one of the extreme ends of a spring element 60 into a cutout 16, 26 formed on at least one of the base plate 10 and the channel plate 20. The step 104 further includes the step 104b of receiving and gripping a first longitudinal side 30a of the plate heat exchanger sub-assembly 30 in a cavity 68a, 68b of a spring clip connector 62a, 62b formed on other extreme end of the spring element 60 by pushing the same inside the cavity 68a, 68b.

The method 200 of assembling battery thermal management system 100 further includes the step 106 of mounting the plate heat exchanger subassembly 30 with the spring elements 60 secured to underside thereof, over the casing 40 mounted on a vehicle frame such that the spring elements 60 are disposed between the channel plate 20 and the casing 40. The method 200 optionally includes the step 108 of securely mounting thermal pads 50 on the portions of the base plate 10 supporting the batteries B such that at least one thermal pad 50 is sandwiched between the base plate 10 and a corresponding battery B supported on the based plate 10.

In any case, the invention cannot and should not be limited to the embodiments specifically described in this document, as other embodiments might exist. The invention shall spread to any equivalent means and any technically operating combination of means.