Intellectual Property India Publishes Patent Application for An Integrated Conditioning Structure For An Energy Storage System (ess)

MUMBAI, India, Sept. 7 -- Intellectual Property India has published a patent application (202541082135 A) filed by Exponent Energy Private Limited on August 29, 2025, for An Integrated Conditioning Structure For An Energy Storage System (ess).

Inventors include Krishna Prasath Ramabadhran; and Aswin Krishna K.

The application for the patent was published on September 04, 2026, under issue no. 36/2026.

Abstract: DETAILED DESCRIPTION [0032] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented, and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown. [0033] References to “one embodiment,” “various embodiments,” “some embodiments,” or “an embodiment” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment. The terms “comprise”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system or method. In other words, one or more elements in a system or apparatus preceded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus. [0034] The terminology “Energy storage system (ESS)”, “ESS”, “battery”, “battery pack”, “battery system”, “battery pack system” has the same meaning and used alternatively throughout the specification. The terminology “ribs”, “internal ribs”, “one or more ribs”, “one or more internal ribs”, “plurality of internal ribs”, “ribs”, “one or more ribs”, “dividers”, “fins”, “walls”, “spacer” has the same meaning and used alternatively throughout the specification. The terminology “integrated conditioning structure”, “conditioning structure”, “structure”, “integrated structure” has the same meaning and used alternatively throughout the specification. The terminology “plurality of elongated extruded conditioning channels”, “plurality of extruded conditioning channels”, “conditioning channels”, “extruded conditioning channel”, “elongated extruded conditioning channels”, “channels”, “extruded channels”, “plurality of conditioning channels”, “plurality of channels”, “extruded conditioning channels” has the same meaning and used alternatively throughout the specification. [0035] An object of the invention is to provide an integrated conditioning structure for an Energy Storage System (ESS) having a plurality of elongated extruded conditioning channels with a uniform cross-sectional profile configured to facilitate controlled distribution of conditioning fluid. [0036] Another objective of the present invention is to provide an integrated conditioning structure having internally formed ribs that divide each elongated extruded conditioning channel into a plurality of parallel conditioning-fluid flow paths, thereby facilitating substantially uniform distribution of conditioning fluid and improved thermal conditioning of the ESS. [0037] Yet another objective of the present invention is to provide an integrated internal flow-reversal arrangement within the elongated extruded conditioning channels, thereby enabling conditioning fluid to flow in a first direction through at least one inlet flow path and return in an opposite direction through at least one outlet flow path without requiring external flow-reversal plumbing. [0038] Yet another objective of the present invention is to provide a compact and integrated conditioning-fluid circuit having fluid inlets and fluid outlets disposed on a common side of the elongated extruded conditioning channels, thereby reducing external tubing, bends, fittings, interfaces, and associated leakage opportunities. [0039] Yet another objective of the present invention is to provide an integrated conditioning structure in which the internal flow-reversal arrangement is formed by selective machining of the internal ribs of an extruded conditioning channel. [0040] Yet another objective of the present invention is to provide an integrated conditioning structure that combines thermal conditioning and structural functionality by utilizing side and central extrusion conditioning channels. [0041] Yet another objective of the present invention is to provide an integrated conditioning structure having front and rear extruded plates and closure plates configured to provide lateral structural stiffness and form a substantially leak-resistant conditioning-fluid circuit, thereby reducing component count and facilitating a robust, scalable, and readily manufacturable ESS architecture. [0042] Figure 1 is a diagram that illustrates an integrated conditioning structure (100) for an energy storage system (ESS), in accordance with an embodiment of present subject matter. The integrated conditioning structure (100) typically includes a base plate (102), a plurality of elongated extruded conditioning channels (104), a front extruded plate, and a rear extruded plate (110). Further, each of the plurality of elongated extruded conditioning channels (104) may comprise a uniform cross-sectional profile (106) along at least a portion of its length. [0043] In an embodiment, the front extruded plate (108) and the rear extruded plate (110) may be secured to opposing ends of the plurality of elongated extruded conditioning channels (104) and to the base plate (102). In an exemplary embodiment, the front extruded plate (108) and the rear extruded plate (110) may be configured to provide lateral stiffness to the integrated conditioning structure (100). In another exemplary embodiment, the front extruded plate (108) and the rear extruded plate (110) may be variable in lengths. The length of these plates may be varied based on design requirements. [0044] In one embodiment, the base plate (102) may be configured to serve as a structural foundation for the integrated conditioning structure (100). In an exemplary embodiment, the base plate (102) may be constructed from a thermally conductive metal including but not limited to an aluminum or a copper for providing a flat, and weldable surface for the integrated conditioning structure (102). [0045] In an embodiment, the plurality of elongated extruded conditioning channels (104) may be secured to the base plate (102). In an exemplary embodiment, the plurality of elongated extruded conditioning channels (104) may be secured by either direct weld or by other attachment mechanism. Further, the plurality of elongated extruded conditioning channels (104) may create a scalable frame that integrates both conditioning and mechanical support. Further, each of the plurality of elongated extruded conditioning channels (104) may comprise the uniform cross-sectional profile (106) along at least the portion of its length. In an embodiment, the plurality of elongated extruded conditioning channels (104) may be produced via an extrusion process that forms one or more internal ribs (302). In one embodiment, the plurality of elongated extruded conditioning channels may be scalable by increasing the length and the number of extruded conditioning channels (104). Further, the plurality of extruded conditioning channels (104) may have different lengths within the same energy storage system (ESS). In an exemplary embodiment, the number of the plurality of elongated extruded conditioning channels (104) may be selectable according to a size, energy capacity, or thermal load of the energy storage system (ESS). In an embodiment, the plurality of elongated extruded conditioning channels (104) may provide both a coolant-flow enclosure and a structural reinforcement without requiring a separate structural member corresponding to each conditioning channel. [0046] In one embodiment, the length of the plurality of elongated extruded conditioning channels may be varied based on thermal requirement of the energy storage system (ESS). For example, longer extruded conditioning channels may be used for large-format energy storage systems, while shorter extruded conditioning channels may be used for compact energy storage systems. In another embodiment, the count of the plurality of extruded conditioning channels may be varied based on size requirement of the energy storage system (ESS). For example, longer channels may be used for large-format ESS, while shorter ones may be suited for compact systems. In an exemplary embodiment, the number of extruded conditioning channels may be configured in accordance with the energy capacity of the energy storage system (ESS). For example, the energy storage system rated at 35 kWh may incorporate three columns of extruded conditioning channels to facilitate optimal thermal management. Furthermore, the energy storage system with a lower energy rating of 24 kWh, may employ a reduced number of columns or shorter extruded conditioning channels lengths to achieve an efficient thermal balance. [0047] In an embodiment, the integrated conditioning structure (100) may comprise one or more closure plates (402) secured to ends of the plurality of elongated extruded conditioning channels (104), to seal a plurality of parallel conditioning-fluid flow paths (304, 312). In an exemplary embodiment, the one or more closure plates (402) may be secured to form a substantially leak-resistant conditioning-fluid circuit. In an exemplary embodiment, the one or more closure plates (402) may be configured for sealing the integrated conditioning structure (100) for the energy storage system (ESS) and creating a leak-proof, mechanically robust assembly. In another exemplary embodiment, the integrated conditioning structure (100) may enable rapid configuration of the energy storage systems (ESS) with different energy capacities and conditioning needs without requiring redesign of structural or thermal components. [0048] Now, referring to Figure. 2, that illustrates the plurality of elongated extruded conditioning channels (104), in accordance with an embodiment of present subject matter. Further, plurality of elongated extruded conditioning channels (104) may comprise one or more side extrusion conditioning channels (202) and one or more central extrusion conditioning channels (204). [0049] In an embodiment, at least one of the one or more side extrusion conditioning channels (202) may comprise an integrated mounting feature for attachment of the integrated conditioning structure (100) to a vehicle chassis. In an exemplary embodiment, the one or more side extrusion conditioning channels (202) may be placed vertically and horizontally. In another exemplary embodiment, the integrated conditioning structure (100) may be configured for both mounting the conditioning structure on an object (such as the vehicle chassis) using the integrated mounting feature as well as conditioning the energy storage system (EES). [0050] In an embodiment, the one or more central extrusion channels (204) are positioned in a predefined manner to provide thermal conditioning to a plurality of storage cells supported by the integrated conditioning structure (100). In an exemplary embodiment, the one or more central extrusion conditioning channels (204) may provide structural reinforcement for the integrated conditioning structure (100). In an exemplary embodiment, the one or more central extrusion conditioning channels (204) may be placed vertically. [0051] Now, referring to Figure. 3, that illustrates the uniform cross-sectional profile (106) of each of the plurality of elongated extruded conditioning channels (104), in accordance with an embodiment of present subject matter. Further, the uniform cross-sectional profile (106) may comprise one or more internal ribs (302), and an internal flow-reversal arrangement (306). Further, the uniform cross-sectional profile (106) may comprise at least one of one or more fluid inlets (308) and one or more fluid outlets (310). [0052] In an embodiment, the one or more internal ribs (302) may be integrally formed within each of the plurality of elongated extruded conditioning channel (104). Further, the one or more internal ribs (302) may be formed integrally during the extrusion process. In an embodiment, the one or more internal ribs (302) may be of variable size. Further, the one or more internal ribs (302) configured to divide an interior of the elongated extruded conditioning channel into a plurality of parallel conditioning-fluid flow paths (304, 312). Further, the one or more ribs (302) may be configured to guide flow of a fluid through the plurality of parallel conditioning-fluid flow paths (304, 312), enabling better distribution and higher surface area contact with the energy storage system (ESS). [0053] In an embodiment, the plurality of parallel conditioning-fluid flow paths (304, 312) comprises at least one inlet flow path (304) and at least one outlet flow path (312). In an exemplary embodiment, the plurality of parallel conditioning-fluid flow paths (304, 312) may be adjusted in number based on conditioning demands and size constraints of the energy storage system (ESS). Further, the plurality of parallel conditioning-fluid flow paths (304, 312) may be configured to enhance heat dissipation of the ESS. [0054] In an embodiment, the internal flow-reversal arrangement (306) may be configured to reverse the direction of fluid flow with the plurality of parallel conditioning-fluid flow paths (304, 312). Further, the internal flow-reversal arrangement (306) is configured to reverse the direction of fluid flow between the at least one inlet flow path (304) and the at least one outlet flow path (312). In one embodiment, the fluid may flow from the inlet flow path (304) to the outlet flow path (312). In another embodiment, the fluid may flow from the outlet flow path (312) to the inlet flow path (304). [0055] In an embodiment, the internal flow-reversal arrangement (306) may be formed by selective machining of the one or more internal ribs (302). Further, at least one internal rib may be configured to separate the at least one inlet flow path (304) and the at least one outlet flow path (312) through extending along the length of the corresponding elongated extruded conditioning channel. Further, the at least one internal rib may be unmachined at an entry end of the corresponding elongated extruded conditioning channel to prevent direct fluid communication between the inlet flow paths (304) and the outlet flow paths (312). [0056] In an embodiment, the one or more fluid inlets (308) and the one or more fluid outlets (310) may be disposed on a common side at a distal end of the corresponding elongated extruded conditioning channel (104). Further, the at least one inlet flow path (304) may be fluidly coupled with the one or more fluid inlets (308) and the at least one outlet flow path (312) may be fluidly coupled with the one or more fluid outlets (310). In an exemplary embodiment, the one or more fluid inlets (308) and the one or more fluid outlets (310) may be connected to a plurality of flow paths through machined manifold regions formed in the corresponding extruded conditioning channel. [0057] In an embodiment, the internal flow-reversal arrangement (306) may be configured to flow of conditioning fluid from the one or more fluid inlets (308) along the at least one inlet flow path (304) in a first direction, reverse the direction within the corresponding elongated extruded conditioning channel and return the flow of conditioning fluid along the at least one outlet flow path (312) towards the one or more fluid outlets (310) in an opposite direction. In an exemplary embodiment, the internal flow-reversal arrangement (306) may be formed without a separate internal tube extending between the inlet (308) and the outlet (310). [0058] In an exemplary embodiment, each of the one or more internal ribs (302) may comprise a plurality of precision-machined openings having different flow-control dimensions or positions along the corresponding elongated extruded conditioning channel. Further, each of the plurality of precision-machined openings may comprise different cross-sectional areas. Further, the cross-sectional areas may vary along the length of the corresponding elongated extruded conditioning channel. In an exemplary embodiment, the plurality of elongated extruded conditioning channels (104) may be oriented substantially vertically, and the asymmetric distribution of the machined openings may compensate for a pressure variation associated with the vertical orientation. In another exemplary embodiment, the plurality of machined openings may be formed in the one or more internal ribs after formation of the conditioning channels by extrusion. Further, the plurality of precision-machined openings may be distributed asymmetrically along the corresponding elongated extruded conditioning channel, to compensate for differences in hydraulic pressure drop among the plurality of parallel conditioning-fluid flow paths (304, 312). [0059] In an exemplary embodiment, the interior of the plurality of elongated extruded conditioning channels (104) may be coated with corrosion-resistant material to improve heat transfer. Further, the conditioning fluid may comprise at least one of but not be limited to water, a glycol-based mixtures, a dielectric fluid or a combination thereof. Further, the integrated conditioning structure (100) may ensure uniform conditioning, structural support, modular scalability, and manufacturing simplicity, making it ideal for next-generation electric vehicles and stationary energy storage system (ESS) deployments. In another embodiment, the energy storage system (ESS) may comprise a plurality of storage cells. [0060] In another exemplary embodiment, the plurality of conditioning-fluid flow paths (304, 312) may comprise six inlet flow paths and six outlet flow paths. Further, the number of the plurality of the conditioning-fluid flow paths (304, 312) may be selected according to a thermal load of the plurality of storage cells. Further, the number and length of the plurality of elongated extruded conditioning channels (104) may be independently variable to provide different energy storage system configurations using a common conditioning-channel architecture. In another exemplary embodiment, a selective adjustment of hydraulic resistance may produce a more uniform conditioning-fluid distribution among the plurality of flow paths and reduces a difference in conditioning-fluid flow among at least two of the plurality of parallel conditioning-fluid flow paths (304, 312). [0061] Now, referring to Figure. 4, that illustrates each of the plurality of elongated extruded conditioning channels (104), in accordance with an embodiment of present subject matter. Further, each of the plurality of elongated extruded conditioning channels (104) may comprise the one or more fluid inlets (308), and the one or more fluid outlets (310) disposed on the common side at the distal end. Further, each of the plurality of elongated extruded conditioning channels (104) may comprise the one or more closure plates (402) secured to ends of the plurality of elongated extruded conditioning channels (104). [0062] Now, referring to Figure. 5, that illustrates an open view (500) of the various component of the integrated conditioning structure (100), in accordance with an embodiment of present subject matter. Further, the integrated conditioning structure (100) may comprise the base plate (102), the front extruded plate (108), and the rear extruded plate (110). [0063] Let us delve into detailed working examples of the present disclosure. The following examples illustrate the integrated conditioning structure for an energy storage system (ESS). [0064] Working Example 1: [0065] A conditioning fluid enters each of the plurality of elongated extruded conditioning channels through a single inlet located at the bottom of each of plurality of elongated extruded conditioning channels. Further, the conditioning fluid is distributed evenly across the plurality of parallel conditioning-fluid flow paths formed by one or more internal ribs. Further, at the rear end, precision machining selectively connects the one or more inlet flow paths (304) and the one or more outlet flow paths (312), creating an internal flow reversal arrangement. Further, in the internal flow reversal arrangement, the conditioning fluid enters through the single inlet and flows downward in one section. Further, the conditioning fluid reverses direction inside the plurality of extruded conditioning channels, flows upward through adjacent paths and exits via a single outlet on the same side. Further, the plurality of precision-machined openings in the ribs balances the pressure drop across the plurality of parallel conditioning-fluid flow paths, for equalizing conditioning fluid distribution and preventing hotspots. Further, the unmachined ribs near the inlet prevent mixing of conditioning fluid streams, maintaining efficient thermal management. [0066] A person skilled in the art will understand that the scope of the disclosure is not limited to scenarios based on the aforementioned factors and using the aforementioned techniques and that the examples provided do not limit the scope of the disclosure. [0067] Various embodiments of the disclosure encompass numerous advantages including the integrated conditioning structure for the energy storage system (ESS). The disclosed integrated conditioning structure have several technical advantages, but not limited to the following: ? Improved Thermal Uniformity: The integrated structure provides more uniform distribution of conditioning fluid through a plurality of parallel conditioning-fluid flow paths using integrally formed internal ribs and an internal flow-reversal arrangement. This promotes consistent temperature distribution across the energy storage system, reduces thermal gradients and localized hotspots, and improves the thermal performance and operating reliability of the storage cells. ? Reduced External Plumbing Complexity: By providing the fluid inlet and fluid outlet on a common side of the elongated extruded conditioning channel and reversing the fluid flow internally, the structure reduces or eliminates the need for externally routed flow-reversal conduits, U-bends, and associated plumbing. This simplifies ESS packaging and reduces potential leakage interfaces. ? Improved Flow Balancing: The precision-machined openings provided in the internal ribs can have selectively varied cross- sectional dimensions and positions along the length of the conditioning channel. Such variation compensates for differences in hydraulic pressure drop between parallel flow paths and promotes balanced conditioning-fluid distribution, thereby improving thermal uniformity throughout the energy storage system. ? Modular and Scalable Architecture: The integrated conditioning structure can be scaled by changing the length, number, and arrangement of the elongated extruded conditioning channels according to the required energy storage systems capacity, thermal load, cell configuration, and available packaging space. This enables a common architectural design to be adapted for different energy storage system sizes and form factors. ? Structural and Thermal Integration: The elongated extruded conditioning channels perform both conditioning-fluid containment and structural reinforcement functions. Further, integrated mounting features provided in one or more side extrusion conditioning channels facilitate attachment to a vehicle chassis. This reduces the requirement for separate structural support members and contributes to improved packaging efficiency and structural integration. ? Improved Packaging Efficiency: The integration of thermal-conditioning and structural functions within the same extruded components, together with the internal flow-reversal arrangement and same-side fluid connections, enables a more compact conditioning architecture. Accordingly, the structure can reduce packaging volume and potentially reduce overall system weight. ? Enhanced Manufacturing Efficiency: The use of elongated extruded channels having a substantially uniform cross-sectional profile enables efficient manufacturing of the conditioning structure. Precision machining can subsequently be employed to selectively form flow-reversal features and flow-control openings, while welding or other joining techniques can be used for assembly, thereby supporting repeatable and scalable production. ? Reduced Component Count and Assembly Complexity: By integrating fluid-flow passages, flow-reversal functionality, structural reinforcement, and mounting features into the extruded conditioning channels, the invention reduces the number of separate components required for thermal and structural functions. This can simplify assembly operations, reduce assembly time, and improve manufacturing consistency. ? Flexible Installation and Packaging: The conditioning channels can be arranged in predefined positions, including central and side channel configurations, to provide thermal conditioning to a plurality of storage cells. The architecture can also accommodate vertically oriented conditioning channels and different cell arrangements, thereby providing flexibility in designing energy storage systems for automotive and industrial applications. ? Improved Energy Storage System Performance: By providing balanced fluid distribution, reduced thermal gradients, effective thermal coupling with storage cells, and integrated structural support, the integrated structure contributes to improved temperature management, operating reliability, and potentially improved service life of the energy storage system. [0068] In summary, these technical advantages overcome the limitations of existing conditioning architectures for Energy Storage Systems (ESS) by providing improved thermal uniformity and flow balancing through parallel conditioning-fluid flow paths, internal ribs, and an internal flow-reversal arrangement. The integrated conditioning structure reduces external plumbing complexity and leakage opportunities, while providing structural and thermal integration, improved packaging efficiency, reduced component count and assembly complexity, and enhanced manufacturing efficiency. Further, the modular and scalable architecture enables adaptation of the elongated extruded conditioning channels for different ESS capacities, thermal loads, cell configurations, and packaging requirements, thereby providing improved ESS performance and flexible installation and packaging. [0069] The claimed invention of the integrated conditioning structure for the energy storage system (ESS) involves tangible components, base plate (102), plurality of elongated extruded conditioning channels (104), front extruded plate (108), rear extruded plate (118) and uniform cross-sectional profile (106) to achieve specific technical outcomes. [0070] In light of the above-mentioned advantages and the technical advancements provided by the disclosed integrated conditioning structure, the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the functioning of the device itself as the claimed steps provide a technical solution to a technical problem. [0071] The present disclosure may be realized in hardware, or a combination of hardware and software. The present disclosure may be realized in a centralized fashion, in at least one computer system, or in a distributed fashion, where different elements may be spread across several interconnected computer systems. A computer system or other apparatus adapted for carrying out the methods described herein may be suited. A combination of hardware and software may be a general-purpose computer system with a computer program that, when loaded and executed, may control the computer system such that it carries out the methods described herein. The present disclosure may be realized in hardware that comprises a portion of an integrated circuit that also performs other functions. [0072] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications. [0073] Those skilled in the art will appreciate that any of the aforementioned steps and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application. In addition, the systems of the aforementioned embodiments may be implemented using a wide variety of suitable processes and system modules, and are not limited to any particular computer hardware, software, middleware, firmware, microcode, and the like. The claims can encompass embodiments for hardware and software, or a combination thereof. [0074] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure is not limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.

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