BATTERY ARRAY

TECHNICAL FIELD

The present disclosure relates to cover elements. The present disclosure also relates to cover units for plurality of lids of battery arrays.

BACKGROUND

As the world moves toward emissions-free electrification, the demand for batteries is now expanding dramatically over time. Typically, the battery is a significant component of several electrical and electronic devices and devices that are regularly utilised in all facets of daily life. Herein, the battery is an electrochemical device that performs chemical reactions inside the battery and causes electrons to flow in a closed circuit of the electrical, and electronic equipment or devices. Operatively, the battery stores and converts chemical energy to electricity. When in use, the battery is electrically connected to a load that drains the battery by drawing a current. A battery-powered torch may experience minimal, constant current flow, whereas a power tool may experience irregular, rapid discharges of current. The battery's temperature can change after a prolonged discharge, which can have an impact on the battery's functionality and lifespan as well as other physical and environmental aspects.

Notably, the battery's temperature needs to be managed for the chemical reactions to occur normally, ensuring the battery's safety and effectiveness. To control the battery's temperature, cooling plates can be placed on the bottom and top of the battery. However, because the battery's temperature management system can only control the temperature of a small portion of the battery, the battery may act irregularly. Moreover, a liquid coolant may be utilized to cool the battery, such as, for example, water, or a refrigerant, which may be carried via tubes surrounding the battery to transmit heat away from the batteries. However, this can make the battery bulky and add to the cost of the battery and thereby making the battery difficult to maintain.

Furthermore, in some instances, it may be necessary to heat the battery to raise its present temperature to one that is adequate for operation. However, such functionality is unable to be provided by the current technologies, which may result in inefficient power use and shorter battery life.

Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks of temperature regulation of the battery.

SUMMARY

The present disclosure seeks to provide a cover element for a lid of a battery. The present disclosure also seeks to provide a cover unit for a plurality of lids of a battery array. The present disclosure seeks to provide a solution to the existing problem of the conventional battery pack. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in prior art, and provides an effective, cost-efficient, and fast method to cool the battery.

In first aspect, an embodiment of the present disclosure provides a cover element for a lid of a battery, the cover element comprising a body having a central part that includes a first hollow region, a second hollow region and a third region arranged between the first hollow region and the second hollow region, wherein the third region includes at least one opening therein; and a first channel formed in the third region; and a peripheral part surrounding the central part, wherein the peripheral part includes an inlet; an outlet; and a second channel formed in the peripheral part, wherein the first channel and the second channel fluidically couple the inlet and the outlet, wherein the cover element, in use, is arranged on top of the lid of the battery such that a first terminal and a second terminal of the battery extend outwards through the first hollow region and the second hollow region, respectively, and the at least one opening is aligned with respect to a pressure vent of the lid, and when a fluid is circulated from the inlet to the outlet via the first channel and the second channel, the fluid regulates a temperature of the battery.

In second aspect, an embodiment of the present disclosure provides a cover unit for a plurality of lids of a battery array, the cover unit comprising: a plurality of lids; and a plurality of cover elements according to any of the claims 1-9, wherein the plurality of cover elements are arranged on top of the plurality of lids.

Embodiments of the present disclosure substantially eliminate or at least partially address the aforementioned problems in the prior art and enable an effective, cost-efficient, and reliable cover element for a lid of a battery. The cover element is easy to manufacture. Moreover, the cover element has a compact design and having the first channel and the second channel to provide cooling by circulating fluid to regulate the temperature of the battery.

Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow.

It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those skilled in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

FIG. 1 is a cover element for a lid of a battery, in accordance with an embodiment of the present disclosure;

FIG. 2A and 2B are a perspective view and a bottom view of a cover element, respectively, in accordance with an embodiment of the present disclosure; and

FIG. 3A and 3B are a top view and a cross-sectional view of a cover unit, respectively, in accordance with an embodiment of the present disclosure.

In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.

DETAILED DESCRIPTION OF EMBODIMENTS

The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practising the present disclosure are also possible.

In first aspect, an embodiment of the present disclosure provides a cover element for a lid of a battery, the cover element comprising a body having a central part that includes a first hollow region, a second hollow region and a third region arranged between the first hollow region and the second hollow region, wherein the third region includes at least one opening therein; and a first channel formed in the third region; and a peripheral part surrounding the central part, wherein the peripheral part includes an inlet; an outlet; and a second channel formed in the peripheral part, wherein the first channel and the second channel fluidically couple the inlet and the outlet, wherein the cover element, in use, is arranged on top of the lid of the battery such that a first terminal and a second terminal of the battery extend outwards through the first hollow region and the second hollow region, respectively, and the at least one opening is aligned with respect to a pressure vent of the lid, and when a fluid is circulated from the inlet to the outlet via the first channel and the second channel, the fluid regulates a temperature of the battery.

In second aspect, an embodiment of the present disclosure provides a cover unit for a plurality of lids of a battery array, the cover unit comprising: a plurality of lids; and a plurality of cover elements according to any of the first aspect, wherein the plurality of cover elements are arranged on top of the plurality of lids.

The present disclosure provides the aforementioned cover element for a lid of a battery and the aforementioned cover unit for a plurality of lids of a battery array. The cover element is configured to provide effective heat regulation within the battery. In this regard, the cover element comprises the central part and the peripheral part forming the cover plate. Moreover, the central part has the first hollow region, the second hollow region and the third region. The third region has a hollow-core structure having a first channel arranged therein to evenly distribute thermal energy (i.e., heat) throughout the battery. In addition, the fluid flow enables the battery to be cooled or heated efficiently. Furthermore, the fluid flows in the cover element around the first terminal, the second terminal and in the central part of the battery to enable better cooling thereof.

Throughout the present disclosure, the term "lid" as used herein refers to an element that serves as a cap designed and adapted to be mounted over the battery to cover the opening therein. The term "cover element" as used herein refers to a modular element mounted over the lid of the battery. The cover element is configured to provide additional cooling to the battery by allowing the fluid to flow therein. Optionally, the thickness of the cover element may be in a range from 3 to 30 mm. Optionally, the cover element is adapted to be detachably attached to the lid of the battery, using an attachment means. Typically, the attachment means may be an extra part or extension that may be attached to the cover element to detachably attach the lid of the battery. It will be appreciated that the attachment means may be a snap-fit joint, latch joint, ratchet joint and so forth.

Suitably, a thermal paste is applied between the cover element and the lid of the battery to regulate the heat either by cooling or heating the battery. It will be appreciated that the lid protects the battery from the outside temperature and environmental conditions. Optionally, the lid of the battery may be implemented to have a shape that is substantially a cube, a cuboid, a cylinder, or similar, corresponding to the shape of the battery. Moreover, the lid is dimensioned according to the dimensions of the battery so that the lid abuts its side edges tightly against the side edges of the battery. Optionally, the cover element is manufactured using any one of: a three-dimensional (3D) printing technique, a casting technique, an injection molding technique, forming of sheet metal. In this regard, the cover plate may be manufactured using 3D printer. Depending on the selection of the manufacturing method, the manufacturing of the cover element may require joining of two separate parts together. Optionally, the cover plate may be manufactured using precision casting, forming and a combination thereof.

Optionally, a material used for manufacturing the cover element is any of: a non-ferrous metal, a non-ferrous alloy, a plastic material, a non- metal material, a ferrous metal. In this regard, the cover element may be fabricated using any of the materials but not limited to aluminium, copper, stainless steel, alloys, plastics, rubbers, ceramics, 3D printing materials and the combination thereof.

The term "central part" as used herein refers to a region comprising the first hollow region, the second hollow region and a third region. The term "first hollow region and second hollow region" as used herein refers to the through-recesses that are adapted to allow the terminals of the battery to pass therethrough. In this regard, the cover element designed to be arranged on the lid of the battery. The cover element has hollow openings for the first and second hollow regions that allow, when arranged on the lid, the first and the second terminals of the battery to extend therefrom. Optionally the length and the width of the area of the first and second hollow regions may be in the range of 8-20 mm or 8-30 mm. The term "first terminal and second terminal" as used herein refers to electrical contact or an electrode of a given battery. Notably, at least one of the first and second terminal have one positive terminal and one negative terminal. Optionally, the first terminal may be the positive terminal and the second terminal may be the negative terminal. Optionally, the second terminal may be the positive terminal and the first terminal may be the negative terminal. Suitably, the first and second hollow regions are placed on both ends of the central part arranged on the cover element, respectively, opposite to each other. Moreover, the position of the through-recesses on the cover element corresponds to the position of the first and the second terminal of the battery. Optionally, the first and second hollow regions may be implemented as slits. More optionally, the first and second hollow regions may have a rectangular cross-section, a circular cross-section, or any polygonal shape. Optionally, the first and the second terminals of the battery are complimentary to the first and second hollow regions.

Optionally, a first insulator surrounds at least sides of the first terminal and a second insulator surrounds at least sides of the second terminal. When surrounding, it allows reveal the top of the insulators to make the electrical connections between the terminals, e.g., via busbars. The dimensions of the first hollow region and the second hollow region corresponds to dimensions of an arrangement of the first insulator surrounding the first terminal and dimensions of an arrangement of the second insulator surrounding the second terminal, respectively. The "first insulator and second insulator" as used herein refers to a non-conducting layer that is configured to surround the first terminal and the second terminal of the battery. Notably, the first insulator and the second insulator completely surround the first terminal and the second terminal. Optionally, the first hollow region is adapted to correspond to dimensions of the first terminal of the battery, and the second hollow region is adapted to correspond to dimensions of the second terminal of the battery. In this regard, the first insulator and the second insulator are designed in such a way that when arranged over the first terminal and the second terminal enables it to pass through the recess of the first hollow region and the second hollow region. Suitably, the use of the first insulator and the second insulator prevents electrical shocks and short circuits in the battery. The first insulator and the second insulator may be fabricated from at least one of: plastic, rubber, and the like.

The term "third region" as used herein refers to the space between the first and second hollow regions. Said space has a hollow-core structure, having a first channel extending in lengthwise direction between the side edge of the first hollow region and the side edge of the second hollow region, and in height wise direction between the top surface and the bottom surface, and further in the width wise direction between the surrounding peripheral part. The first channel is in fluid communication with the peripheral part all the way between the side edges of the first hollow region and the second hollow region. The third region may be straight or curved. The top surface of the third region is exposed to the environment and the bottom surface of the third region is in contact with the lid of the battery. Optionally, the contact of the third region with the lid of the battery may have a layer of a thermal paste.

The term "at least one opening" as used herein refers to a cavity on the third region between the first and the second hollow region. Optionally, the at least one opening may be circular, rectangular, and so forth. The at least one opening is fabricated corresponding to the pressure vent of the battery.

The term "pressure vent" as used herein refers to a pressure release valve that allows the gases produced during the operation of the battery to escape into the atmosphere to avoid the breakdown of the battery. The pressure vent is provided on the upper side of the battery. Optionally, the pressure vent is fabricated of the same material as the battery. Optionally, the pressure vent may be circular, rectangular, and so forth. The pressure vent has a predetermined breaking region of a reduced material thickness. The material thickness in the breaking region is preferably less than in the surrounding region, thereby allowing the breaking region to rupture at a predetermined pressure threshold with the increase of internal pressure of the battery. Notably, the at least one opening is aligned with respect to a pressure vent of the lid to allow the gases produced within the battery to escape the cover element. In one embodiment, the diameter of the at least opening may be larger than the pressure vent. Optionally the diameter of the at least one opening is dimensioned to allow the pressure vent to bulge upwards, for example, at least 5 mm, and have a diameter of at least 2 mm or more larger than the diameter of the pressure vent. The shape of the at least one opening may match the shape of the pressure vent. For example, it can be round, oval, or square in shape.

The term "peripheral part" as used herein refers to an enclosed portion configured to surround the first hollow region, second hollow region and the third region. The peripheral part is configured to form a wall around the first hollow region, second hollow region and the third region. It will be appreciated that the peripheral part may be fabricated as integrally with the central part or fabricated separately from the central part but rigidly fixed to the central part. Notably, the peripheral part is provided with the second channel. The term "second channel" as used herein refers to a passage configured to allow fluid to flow therein. The second channel is arranged within the peripheral part of the cover element to cool or heat the battery. Notably, both the first channel and the second channel provide a pathway in the cover element that allows the fluid to flow in the central part and the peripheral part, and hence circulate the fluid around the terminals of the battery. Optionally, the fluid may flow due to a pressure gradient. More optionally, the fluid may flow due to pneumatic force exerted using an external source. Optionally, the fluid is any one of: a cooling fluid or a heating fluid. In this regard, the fluid may be a coolant. Alternatively, the fluid also enables the heating of the battery (for example, during cold weather) to maintain the required operating temperature. As an example, the fluid carries the heat produced during the operation of the battery from one reservoir to another to provide cooling thereof.

The term "inlet" as used herein refers to port(s) configured to provide the fluid into the first channel, or the second channel and the term "outlet" as used herein refers to port(s) configured to extract out the fluid from the second channel or the first channel. The fluid flows from the inlet to the outlet via the first channel and/or the second channel in the cover element. It will be appreciated that the inlet and the outlet have an opening arranged outside the cover element to deliver and extract the fluid, respectively. Optionally the diameter of the inlet and outlet may be in the range of 3 to 10 mm. Optionally, the diameter of the inlet and the outlet may be the same. Optionally, the diameter of the inlet and the outlet may be different. Optionally, the length of the inlet and outlet may be in the range of 5 to 10 mm. Optionally, the length of the inlet and the outlet may be the same. Optionally, the length of the inlet and the outlet may be different. Optionally, the fluid is fed from a fluid source into a given channel, via the inlet, and the fluid is drained from the given channel towards a fluid drain, via the outlet. The term "fluid source" as used herein refers to a reservoir that supplies fluid to the first channel and the second channel. The fluid may be supplied for the thermal regulation of the battery. Optionally, the fluid source may lie outside the battery lid module. Herein, the first channel and the second channel are fluidically coupled to the fluid source that allows the fluid from the fluid source to flow into the first channel and the second channel. The term "fluid drain" as used herein refers to the reservoir that receives fluid from the first channel and second channel. Optionally, the fluid drain may lie outside the battery.

Optionally, the cover element comprises a first fluidic connection means and a second fluidic connection means, wherein the first fluidic connection means is configured to fluidically couple the inlet with the fluid source, and the second fluidic connection means is configured to fluidically couple the outlet with the fluid drain. The term "first fluidic means and second fluidic means" as used herein refers to means of connection configured to fluidically couple the inlet and the outlet with the fluid source and the fluid drain, respectively. It will be appreciated that the first fluidic means and second fluidic means provide a leak-proof connection between the inlet and the outlet with the fluid source and the fluid drain, respectively.

The present disclosure also relates to the cover unit as described above. Various embodiments and variants disclosed above apply mutatis mutandis to the cover unit.

The term "cover unit" as used herein refers to a casing configured to enclose battery array. Notably, the cover unit comprises the plurality of lids corresponding to each battery of the battery array and the plurality of cover elements corresponding to each of the plurality of lids connected together to form the cover unit. The term "battery array" as used herein refers to an arrangement of a group of battery cells arranged in series or parallel connections. Notably, the battery cell arrangement has a higher voltage when the group of battery cells are connected in a series connection than when the group of battery cells are connected in a parallel connection Herein, the plurality of cover elements is arranged on top of the plurality of lids. Optionally, the cover unit dimensioned to accommodate the battery array

Herein, the plurality of cover elements are arranged side by side. Optionally, the cover unit is made of insulating material. The insulating material may, for example, be a material such as plastic, rubber, and the like.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIG. 1, is a cover element 100 for a lid 102 of a battery 104, in accordance with an embodiment of the present disclosure. As shown in FIG. 1, the cover element 100 comprising a central part 106 and a peripheral part 108. The central part 106 comprises a first hollow region 110, a second hollow region 112 and a third region 114 arranged between the first hollow region 110 and the second hollow region 112. The battery 104 having a first terminal 116 and a second terminal 118 extends outwards through the first hollow region 110 and the second hollow region 112, respectively. The central part has a first channel 120, which is configured to flow the fluid therein. The peripheral part 108 includes an inlet 122, an outlet 124 and a second channel 126 (as shown with a dashed line) formed in the peripheral part 108. The cover element 100, in use, is arranged on top of the lid 102 of the battery 104. The third region 114 includes at least one opening 128 aligned with respect to a pressure vent 130 of the lid. When the fluid is circulated from the inlet 122 to the outlet 124 via the first channel 120 and the second channel 126, the fluid transfers the heat dissipated by the battery and hence regulates a temperature of the battery 104.

Moreover, the cover element 100 comprises a first fluidic connection means 132 and a second fluidic connection means 134, wherein the first fluidic connection means 132 is configured to fluidically couple the inlet 122 with the fluid source, and the second fluidic connection 134 means is configured to fluidically couple the outlet 124 with the fluid drain. Furthermore, a first insulator 136 surrounds at least sides of the first terminal 116 and a second insulator 138 surrounds at least sides of the second terminal 118, and wherein the dimensions of the first hollow region 110 and the second hollow region 112 corresponds to dimensions of an arrangement of the first insulator 136 surrounding the first terminal 116 and dimensions of an arrangement of the second insulator 138 surrounding the second terminal 118, respectively. In Fig. 1, the first insulator and the second insulator are provided with a removable cover on top of the insulators. The removable covers are shown with a dashed line on top of the insulators 136, 138. When the covers are removed from the insulators, the terminals are revealed through the insulators, so that the terminals can be connected with e.g., busbars.

Referring to FIG. 2A and 2B are a perspective view and a bottom view of a cover element 200, respectively, in accordance with an embodiment of the present disclosure. As shown in FIG. 2A, the cover element 200 comprising a central part 202 and a peripheral part 204. The central part 202 comprising a first hollow region 206, a second hollow region 208 and a third region 210 arranged between the first hollow region 206 and the second hollow region 208. As shown, in this example, the thickness of the central part 202 is less than the thickness of the peripheral part 204. The third region 210 includes at least one opening 212 to enable the gases to escape therefrom. The central part 202 has a first channel (as shown with a dashed line in FIG. 1) formed in the third region 210. The first channel extends in lengthwise direction between the side edges of the first hollow region and the second hollow region, and in width wise direction between the peripheral part (in FIG. 2A, the lengthwise direction is shown by two-way horizontal arrow, and the height wise direction is shown with two-way vertical arrow, and the width wise direction with two-way inclined arrow). The peripheral part 204 includes an inlet 216, an outlet 218 and the second channel (as shown with a dashed line in FIG. 1) formed in the peripheral part 204. The cover element 200 comprises a first fluidic connection means 220 and a second fluidic connection means 222, wherein the first fluidic connection means 220 is configured to fluidically couple the inlet 216 with the fluid source, and the second fluidic connection means 222 are configured to fluidically couple the outlet 218 with the fluid drain. As shown in FIG. 2B the cover element 200 comprising a central part 202 and a peripheral part 204. The central part 202 comprising a first hollow region 206, a second hollow region 208 and a third region 210 arranged between the first hollow region 206 and the second hollow region 208. The at least one opening 212 is completely through the third region 210. The peripheral part 204 and the third region 210 same surface.

Referring to FIG. 3A and 3B are a top view and a cross-sectional view of a cover unit 300, respectively, in accordance with an embodiment of the present disclosure. As shown in FIG. 3A, the cover unit 300 for a plurality of lids of a battery array, the cover unit comprising a plurality of lids (not shown) and a plurality of cover elements 302 wherein the plurality of cover elements 302 are arranged on top of the plurality of lids. As shown, a fluid is fed from a fluid source into a given channel, via an inlet 304, and the fluid is drained from the given channel towards a fluid drain, via an outlet 306. Each of the plurality of cover elements 302 includes a first hollow region 308, the second hollow region 310, and the third region 312. Moreover, the third region 312 includes at least one opening 314. As shown in FIG. 3B, a cross-sectional view of the cover unit 300 for a plurality of lids of a battery array. As shown, the plurality of cover elements 302 each having a first channel 316 fluidically couple with the inlet and the outlet. Notably, a fluid is circulated from the inlet 304 to the outlet 306 via the first channel 316. Suitably, the first channel is fluidically coupled with each of the plurality of cover elements 302. Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a nonexclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.