Field of the invention:

[0001] The present invention relates to a housing module for a battery pack and an electric vehicle comprising the same.

Background of the invention:

[0002] A patent literature WOl 5137869 discloses an installation of hybrid components in a vehicle. The present invention relates to an installation of hybrid components in a vehicle comprising a frame rail with an extension the longitudinal direction of the vehicle. The installation comprises a first unit, comprising an electric energy storage device, a second unit comprising at least one component in a cooling system, and fastening elements with which the first unit and the second unit may be attached on the frame rail. The first unit is attached in a position adjoining a side surface of the frame rail, and the second hybrid component is attached at a greater distance from the frame rail and in a position at least partly outside of the first unit.

Brief description of the accompanying drawings:

[0003] An embodiment of the disclosure is described with reference to the following accompanying drawing,

[0004] Fig. 1 illustrates a housing module for a battery pack, according to an embodiment of the present invention;

[0005] Fig. 2 illustrates an exploded view of the housing module, according to an embodiment of the present invention;

[0006] Fig. 3 illustrates locking mechanism in the housing module, according to an embodiment of the present invention;

[0007] Fig. 4 illustrates front view of the locked and unlocked position of a battery pack, according to an embodiment of the present invention, and

[0008] Fig. 5 illustrates an electric vehicle with the housing module, according to an embodiment of the present invention. Detailed description of the embodiments:

[0009] Fig. 1 illustrates a housing module for a battery pack, according to an embodiment of the present invention. The housing module 100 comprises an enclosure 102 comprising at least one storage space accessible from one side, characterized by, at least one snap tensioner 110 mounted to at least two inner surfaces 120 of the enclosure 102 in an operative configuration. Further, at least one stopper 114 mounted in the enclosure 102. The snap tensioners 110 defines a space inside the enclosure 102 for easy and convenient insertion and removal of battery packs 202. In an embodiment, the housing module 100 is usable for a battery charging station (makeshift/temporary or permanent), a vehicle 500 (shown in Fig. 5), or independent housing by a consumer in house or office as per the requirement.

[0010] In an embodiment, the at least one snap tensioner 110 and the at least one stopper 114 are mounted directly on the inner surfaces 120 of the enclosure 102. The inner surfaces 120 are then provided with holes on which the snap tensioners 110 are to be mounted. Alternatively, the at least one snap tensioner 110 and the at least one stopper 114 are mounted through brackets 112. The brackets 112 are in turn mounted/affixed to the inner surfaces 120. The brackets 112 are either riveted/bolted/screwed on the inner surface 120 of the enclosure 102 or is mounted by sliding into guides (not shown) provided on the inner surfaces 120.

[0011] In an embodiment, the at least one snap tensioner 110 comprises two snap tensioners 110 (shown in top detailed view) on each of two side surfaces 104, two snap tensioners 110 (shown in bottom detailed view) on a base surface 106, and the at least one stopper 114 comprising one stopper 114 on the base surface 106. In the base surface 106, the stopper 114 is mounted to same bracket 112 on which the snap tensioner 110 is mounted. However, the same must not me understood in limiting sense, as the stopper 114 is mountable at separate location as well. Further, it must be understood that a different combination of number of snap tensioners 110 are possible based on requirement, such as one on each side surface 104 and the base surface 106, two on each side surfaces 104 and one on the base surface 106, one on a first side surface 104, two on a second side surface 104 and two on the base surface 106, etc.

[0012] The housing module 100 further comprises at least one thermal insulation pad 118 positioned inside the enclosure 102 in contact with the at least one inner surface 120, namely the side surfaces 104, rear surface, top surface and base surface 106. The top surface is opposite to the base surface 106 within the enclosure 102. The rear surface is opposite to the opening of the enclosure 102.

[0013] In accordance to an embodiment, the housing module 100 comprises at least two temperature sensor placed at diagonally opposite corners of the enclosure 102. The at least two temperature sensors are for a single battery pack 202 (shown in Fig. 2). In case of the housing module 100 with multiple enclosures 102, the set of temperature sensors are provided for each enclosure 102. In accordance to another embodiment, an environmental sensor is integrated to evaluate pressure, temperature and humidity inside the enclosure 102 to monitor derating zones. The housing module 100 has a provision to modularly integrate power lines of different sizes of battery packs 202. In yet another embodiment, the design of the housing module 100 enables direct interface with crash or inertial sensor input to this design interface for active power management to and from the battery packs 202 for safety concerns. The housing module 100 is scalable to any shape and size of battery packs 202.

[0014] Fig. 2 illustrates an exploded view of the housing module, according to an embodiment of the present invention. The exploded view shows two thermal insulation pads 118, two brackets 112 for mounting on the side surface 104 and two more brackets 112 mounted on the base surface 106. The battery pack 202 is also shown for clarity in understanding. The insulation pads 118 provides thermal insulation for efficient heat transfer/management. The housing module 100 also comprises a dampener (not shown) to dampen insertion of the battery pack 202. [0015] In one embodiment, the housing module 100 is provided with temperature regulating means to maintain the temperature of the battery pack 202 within an operating range. The temperature regulating means comprises circulation ducts carrying coolant or refrigerant from a dedicated source or from the air conditioning unit. Alternatively, the thermal insulation pads 118 are provided within the enclosure 102. In yet alternative embodiment, a combination of the temperature regulating means and the thermal insulation pads 118 are provided. The housing module 100 is thus made suitable for both, i.e. for on-board charging mechanism and swapping mechanism with selective use of the temperature regulating means or the thermal insulation pads 118 or both based on the requirements. The on-board charging mechanism comprises charging of single battery pack 202 or combination of multiple battery packs 202 connected in series/parallel or both.

[0016] In accordance to an embodiment of the present invention, the housing module 100 comprises a controller (not shown) connected to a display screen 116 and at least one temperature sensor (not shown). The controller is adapted to alert a user when the temperature inside the enclosure 102 exceeds a threshold value. The display screen 116 is mounted on any one of an outer surface of the enclosure 102 and a door 108 of the enclosure 102. The controller is compatible Controller Area Network (CAN) protocol or other similar protocols, and enabled to inform services and predictive maintenance schedule through color coded indications, communicate and diagnose error flags, etc.

[0017] The housing module 100 also comprises a connector interface 204 at an end opposite to the opening for insertion of the battery pack 202. The connector interface 204 is externally connectable to a load or source and internally connectable to the battery pack 202. The connector interface 204 enables power supply to and from the battery pack 202 during charging and discharging to a load. The housing module 100 is fixable to a chassis 506 (shown in Fig. 5) of the vehicle 500. The fixture or integration is any one a removable and permanent by mechanical interface. [0018] In an embodiment, the housing module 100 is provided for the electric vehicle 500 having the chassis 506 with an intermediate section for holding battery packs 202. The intermediate section is a subassembly for load carrying member of front and rear chassis module with body of the vehicle 500. The intermediate section comprises housing modules 100 designed and developed for both low and high voltage battery packs 202. The door mechanisms for battery pack 202, wiring circuits, connectors and sensors are part of the housing module 100. Also, a temperature regulation means or the thermal insulation for the battery pack 202 are within the housing module 100. The housing module 100 is designed and analyzed (for static and dynamic conditions) to withstand the worst case loading/vibration scenarios.

[0019] A working of inserting the battery pack 202 in the housing module 100 is explained. During insertion, the battery pack 202 slides inside the enclosure 102 against the snap tensioner 110 at inner surfaces 120 of the enclosure 102. The snap tensioner 110 exerts force onto the battery pack 202 for alignment and tight positioning inside the housing module 100. A slide stopper mechanism assists in locking rear position of the battery pack 202 with the connector interface 204. A rubber limiter/stopper (not shown) for further guiding into housing module 100 is also provided. Once inserted, the stopper 114 is positioned to lock the battery pack 202 in the enclosure 102.

[0020] Fig. 3 illustrates locking mechanism in the housing module, according to an embodiment of the present invention. The locking mechanism comprises the stopper 114 in a locked position 310 and unlocked position 320. The stopper 114 is similar to a retractable/flexible clip which is inserted in a slot 312 provided on the bracket 112. The slot 312 comprises a first shoulder 306 and a second shoulder 308 to transition between locked positon 310 and unlocked position 320. There are other shoulders at extreme ends to retain the stopper 114 within the slot 312. In the locked position 310, the stopper 114 is shown at the half-way mark or at the second shoulder 308. If moved further in the direction 304, another position is available, which is also a locked position providing a firm locking. The stopper 114 locks the battery pack 202 when moved towards the first direction 304. Similarly, the stopper 114 is in unlocked position 320 when moves in the second direction 302, which is opposite to the direction 304.

[0021] Fig. 4 illustrates front view of the locked and unlocked position of a battery pack, according to an embodiment of the present invention. In continuation to the locking mechanism shown in Fig. 3, a first view 410 and a second view 420 shows the battery pack 202 in locked position 310 and unlocked position 320. In the first view 410, the stopper 114 is in the extreme left position, thereby allowing the movability (insertion or removal) of the battery pack 202. However, in the second view 420, the stopper 114 is just moved in the opposite direction shown in the first view 410, which locks the battery pack 202. In the present invention, the stopper 114 is designed to work with the profile of the battery pack 202.

[0022] In another embodiment, a different stopper 114 is used to lock and unlock the battery pack 202. For example, the top or bottom surface at the opening of the enclosure 102 is fit with a simple swivel member which locks and unlocks the battery pack 202. Otherwise a simple latch mechanism is employed. The stopper 114 must not understood to be restricted to the present disclosure.

[0023] Fig. 5 illustrates a vehicle with the housing module, according to an embodiment of the present invention. The vehicle 500 comprises a cabin 502 and a carrier (not shown). The carrier is arranged rear of the cabin 502. The vehicle 500 is characterized by, the housing module 100 to hold at least one battery pack 202. The housing module 100 is located in a space selected from a group comprising a first space between the cabin 502 and the carrier, and a second space between the carrier and a chassis 506 of the vehicle 500. The chassis 506 is shown covered with a flat surface for simplicity in understanding and the same must not be understood in limiting manner. The housing module 100 is installable irrespective of type of chassis 506. The vehicle 500 is either an electric vehicle 500 or fuel based vehicle 500. [0024] A first perspective view 510 shows the first space, and a second perspective view 520 shows the second space. The housing module 100 is adaptable for high or low voltage battery packs 202. Further, the housing module 100 is an independent module as retrofit to vehicle 500 or inbuilt in new vehicles 500. The housing module 100 is provided with features to indicate the condition of the battery pack 202.

[0025] In the first perspective view 510, the housing module 100 is provided behind the cabin 502. The door 108 of the housing module 100 is accessible from both the sides of the vehicle 500. The housing module 100 is shown with the three enclosures 102, which are accessible through the single door 108. Alternatively, a single door 108 is provided for each enclosure 102. A lid 504 is provided to manage the electrical connections of the battery packs 202 with a drive system of the vehicle 500, such as a drive motor or generator and other associated circuits known in the art. The carrier is either displaced according to the size of the housing module 100 or the housing module 100 is provided as per the gap between the cabin 502 and the carrier. Alternatively, the carrier of reduced length is fit to the vehicle 500.

[0026] In the second perspective view 520, the housing module 100 is provided on the chassis 506 or underneath the carrier. The enclosures 102 of the housing module 100 are again accessible from the sides. The lid 504 is now faces the side opposite to the ground.

[0027] According to an embodiment of the present invention, the housing module 100 is compatible as retrofit version for conversion of vehicle 500 with combustion engines to electric vehicle 500 and as-is fit to new development of electric vehicles 500. Additionally, the housing module 100 is retrofit arrangement for present transport vehicles 500 (not restricted thereto) with feasibility of integration at different position and orientations. The housing module 100 is designable to accommodate multiple batteries and is scalable to an individual integrated battery packs 202. Based on type of vehicle 500, the housing module 100 is adaptable to be made functional with at least once integrated enclosure 102 with respective provision for vibration, assembly, serviceability and thermal management. [0028] In accordance to an embodiment, the housing module 100 is designed as part of frame structure of the chassis 506. Accordingly, the weight distribution of the housing module 100 is designed considering the front axle weight and rear axle weight of the vehicle specifications. The center of gravity is then achieved based on the packaging or assembly of the housing module 100 at defined orientation and position on the vehicle 500. The housing module 100 is applicable for on-board charging and swap-ability concepts.

[0029] According to the embodiments of the present invention, the housing module 100 for defined swappable and on-board battery compartment for passenger and Light Commercial Vehicles (LCV) is provided. The housing module 100 is also referred to as modular battery holder module, because of the replaceable internal components such as the brackets 112, snap tensioners 110, stopper 114, thermal insulation pads 118 and the like. The housing module 100 acts as housing for high or low voltage battery packs 202. The housing module 100 is further possible to retrofit to the vehicles 500 or is inbuilt to the vehicle 500. The housing module 100 further provided with features to indicate the conditions of the battery pack 202. The housing module 100 minimizes the vibration and thermal effects on the battery pack 202 during the course of functionality of the vehicle 500. The housing module 100 is designed for vehicle dynamic loading conditions. The snap tensioners 110 avoids the vibration transfer from the chassis 506 of the vehicle 500 to the battery pack 202. The proposed design of the housing module 100 is suitable for ease of battery swap-ability and on-board charging concept. The present invention discloses a retrofit arrangement of housing modules 100 as an extended assembly for the chassis 506 of the vehicle 500 or integrated into new vehicle 500.

[0030] It should be understood that embodiments explained in the description above are only illustrative and do not limit the scope of this invention. Many such embodiments and other modifications and changes in the embodiment explained in the description are envisaged. The scope of the invention is only limited by the scope of the claims.

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