# US 12,603,357 B2 · Epp foam based UAV battery enclosure > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,603,357 B2 - Document ID: US12603357B2 - Status: Granted - Kind: B2 - Application number: 17/858,653 - Filed: 2022-07-06 - Published: 2023-01-12 - Granted: 2026-04-14 - Earliest claimed: 2022-07-06 - Assignees: Ideaforge Technology Pvt. Ltd. - Applicants: ideaForge Technology Pvt. Ltd. - Inventors: Rahul Singh; Ankit Mehta; Ashish Bhat; Vishal Khetmali; Gulab Mali - Web page: https://patentgrep.com/patent/US12603357B2 ## CPC - H01M 10/658: by thermal insulation or shielding - B60L 50/64: Constructional details of batteries specially adapted for electric vehicles - B60L 58/10: for monitoring or controlling batteries - B60L 58/27: by heating - H01M 10/615: Heating or keeping warm - H01M 10/625: Vehicles - H01M 10/633: characterised by algorithms, flow charts, software details or the like - H01M 10/6571: Resistive heaters (arrangements for heating the battery by its resistance to the internal current H01M10/637) - H01M 50/227: Organic material - H01M 50/249: specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64) - H01M 50/293: characterised by the material - B60L 2240/545: Temperature - B60L 2260/32: Auto pilot mode - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract A thermal management device 100 for a battery pack 104 of an UAV comprises an insulating enclosure 102 that is made of a material comprising at least an EPP foam for enclosing the battery pack 104, and one or more heating coils 110. The heating coils 110 are electrically powered from an external power source 112 for pre-heating the insulating enclosure 102 to a predefined temperature before flight of the UAV. The EPP foam of the insulating enclosure 102 provides high thermal insulation for retaining the heat of the insulating enclosure 102 for heating the battery pack 104 and maintaining the temperature of the battery pack 104 above a threshold temperature when the UAV flies in a sub-zero ambient temperature. A case of the enclosure incorporates structural carbon tubes that engage with holes in a cap of the enclosure to strengthen the insulating enclosure. ## Claims ### Claim 1 A thermal management device for a battery pack, the thermal management device comprising: an insulating enclosure for enclosing the battery pack, wherein the insulating enclosure is made of a material comprising at least an expanded polypropylene (EPP) foam; and wherein the insulating enclosure is adapted for retaining heat of the insulating enclosure for heating the battery pack in a sub-zero ambience temperature; wherein the insulating enclosure comprises a case that is open at one side for accommodating the battery pack, and a cap to sit on the open side of the case for closing the case and for covering the battery entirely; and wherein the case of the insulating enclosure incorporates a plurality of structural carbon tubes at the open side extending outwards, and the cap incorporates a plurality of holes at the corresponding positions to take in the plurality of structural carbon tubes when the cap is fitted on the open side of the case. ### Claim 2 (depends on 1) The thermal management device as claimed in claim 1, wherein the thermal management device comprises one or more heating coils configured between the battery pack and the insulating enclosure, the one or more heating coils being electrically powered from a power source for heating the insulating enclosure to a predefined temperature. ### Claim 3 (depends on 2) The thermal management device as claimed in claim 2, wherein the one or more heating coils comprise a thermostat to cut-off the power supply to the one or more heating coils from the power source when the insulating enclosure is heated to the predefined temperature. ### Claim 4 (depends on 2) The thermal management device as claimed in claim 2, wherein the insulating enclosure and the one or more heating coils are configured to provide uniform heat distribution across the battery pack. ### Claim 5 (depends on 1) The thermal management device as claimed in claim 1, wherein the plurality of structural carbon tubes are configured to strengthen the insulating enclosure. ### Claim 6 (depends on 1) The thermal management device as claimed in claim 1, wherein a density of the EPP foam of the insulating enclosure is in a range of 25-30 grams per liter. ### Claim 7 (depends on 1) The thermal management device as claimed in claim 1, wherein the EPP foam comprises one or more blends. ### Claim 8 (depends on 1) The thermal management device as claimed in claim 1, wherein the material of the insulating enclosure comprises one or more plastics. ### Claim 9 An unmanned aerial vehicle, comprising: a thermal management device for a battery pack of the unmanned aerial vehicle, the thermal management device comprising: an insulating enclosure for enclosing the battery pack of the unmanned aerial vehicle, wherein the insulating enclosure is made of a material comprising at least an EPP foam; and wherein the insulating enclosure is adapted for retaining heat of the insulating enclosure for heating the battery pack when the unmanned aerial vehicle flies in a sub-zero ambience temperature; wherein the insulating enclosure comprises a case that is open at one side for accommodating the battery pack, and a cap to sit on the open side of the case for closing the case and for covering the battery entirely; and wherein the case of the insulating enclosure incorporates a plurality of structural carbon tubes at the open side extending outwards, and the cap incorporates a plurality of holes at the corresponding positions to take in the plurality of structural carbon tubes when the cap is fitted on the open side of the case. ### Claim 10 (depends on 9) The unmanned aerial vehicle as claimed in claim 9, wherein the unmanned aerial vehicle comprises one or more heating coils configured between the battery pack and the insulating enclosure, the one or more heating coils being electrically powered from an external power source for pre-heating the insulating enclosure to a predefined temperature before flight of the UAV to heat the battery pack. ### Claim 11 (depends on 10) The unmanned aerial vehicle as claimed in claim 10, wherein the one or more heating coils comprise a thermostat to cut-off the power supply to the one or more heating coils from the external power source when the insulating enclosure is heated to the predefined temperature. ### Claim 12 (depends on 10) The unmanned aerial vehicle as claimed in claim 10, wherein the insulating enclosure and the one or more heating coils are configured to provide uniform heat distribution across the battery pack. ### Claim 13 (depends on 9) The unmanned aerial vehicle as claimed in claim 9, wherein the plurality of structural carbon tubes are configured to strengthen the insulating enclosure. ### Claim 14 (depends on 9) The unmanned aerial vehicle as claimed in claim 9, wherein a density of the EPP foam of the insulating enclosure is in a range of 25-30 grams per liter. ### Claim 15 (depends on 9) The unmanned aerial vehicle as claimed in claim 9, wherein the EPP foam comprises one or more blends. ### Claim 16 (depends on 9) The unmanned aerial vehicle as claimed in claim 9, wherein the material of the insulating enclosure comprises one or more plastics.