Description:FIELD
The present disclosure generally relates to a modular battery pack frame assembly for an electric vehicle. In particular, the present disclosure relates to battery pack frame structures and their interconnection in the electric vehicles.
BACKGROUND
Electric Vehicles (EVs) have gained significant traction in recent years due to their environmental benefits and the growing need for sustainable transportation solutions. A crucial component of an electric vehicle is the battery pack, which stores and provides electrical energy to power the electric vehicle. However, conventional battery pack designs often lack versatility, modularity, and efficient assembly and maintenance processes.
Conventional battery pack designs often lack flexibility and modularity, making it challenging to accommodate different battery sizes, configurations, and future upgrades. Additionally, assembly and maintenance of the battery packs can be time-consuming and complex.
To resolve the aforementioned issues, the present invention proposes a modular battery pack frame assembly for an electric vehicle, and which overcomes the limitations of existing designs by providing modularity, structural integrity, ease of assembly and maintenance, optimal space utilization, and adaptability to different battery configurations.

OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a modular battery pack frame assembly for an electric vehicle.
Another object of the present disclosure is to provide the modular battery pack frame assembly that allows for easy customization and adaptability to different battery sizes, configurations, and future upgrades.
Another object of the present disclosure is to provide internal and external solid extrusions, such as aluminium base solid extrusions, which enhance the structural integrity and durability of the battery pack frame assembly.
Another object of the present disclosure is to provide the modular battery pack frame that includes fastening elements and mounting brackets for simplifying the assembling and disassembling process of the battery pack to reduce installation and maintenance time, allowing for efficient production processes.
Another object of the present disclosure is to provide the modular battery pack frame that maximizes the storage capacity of the battery pack without compromising safety or performance.
Another object of the present disclosure is to provide the modular battery pack frame that provides modularity and ease of assembly of the battery pack frame assembly resulting in cost savings during manufacturing, assembly, and maintenance processes, the simplified installation and maintenance procedures reduce labour and time requirements, improving operational efficiency and lowering overall production costs.
Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.

SUMMARY
The present disclosure envisages a modular battery pack frame assembly for an electric vehicle. The assembly comprises a base modular frame, a plurality of vertical side frame members secured along operative edges of the base modular frame, a plurality of extrusions configured to extend from side frame members in an operative inward direction, at least one auxiliary modular frame, and a plurality of fastening elements. The fastening elements are configured to be received in the extrusions to facilitate locking of the auxiliary modular frame on top of the base modular frame to facilitate formation of the modular battery pack frame assembly.
In an aspect, the auxiliary modular frame has vertical auxiliary side frame members secured along its corresponding edges. The auxiliary side frame members include auxiliary extrusions that allow passage of the fastening elements therethrough to facilitate locking of the auxiliary modular frame on top of the base modular frame.
In an aspect, the fastening elements are fastened at a uniform distance from each other for securing the auxiliary side frame members that are overlapping with the side frame members.
In an aspect, auxiliary extrusions of the auxiliary modular frame and the internal solid extrusions of the base modular frame are aluminum base solid extrusions.
In an aspect, two oppositely positioned side frame members of the base modular frame include a top internal extension to mount a top cover for the base modular frame. The base modular frame further includes a bottom internal extension to mount a bottom cover for the base modular frame.
In an aspect, in the base modular frame, the bottom internal extension mounts a cooling plate disposed above the bottom cover.
In an aspect, two oppositely positioned auxiliary side frame members of the auxiliary modular frame include a top internal extension to mount a top cover for the auxiliary modular frame. The auxiliary modular frame further includes a bottom internal extension to mount a cooling plate for the auxiliary modular frame.
In an aspect, the cooling plate of the auxiliary modular frame and the top cover of the base modular frame include auxiliary windows to transfer coolant hoses and electrical connections from the base modular frame to the auxiliary modular frame.
In an aspect, one of the side frame members of the base modular frame includes electrical connectors and coolant spouts.
In an aspect, the electrical connectors include a low voltage connector and a high voltage connector.
In an aspect, two oppositely positioned side frame members of the base modular frame include mounting brackets formed at equal distances on external side of the base modular frame.
In an aspect, two oppositely positioned side frame members of the assembly of the base modular frame and the auxiliary modular frame include mounting brackets formed at equal distances on the external side of the base modular frame.
In an aspect, the mounting brackets are external solid extrusions.
In an aspect, the external solid extrusions are one of T-shaped extrusions, L-shaped extrusions, and inverted L-shaped extrusions.
In an aspect, the auxiliary modular frame partially overlaps a top cover of the base modular frame.
In an aspect, the auxiliary modular frame completely overlaps a top cover of the base modular frame.
In an aspect, the base modular frame is a bottom layer of the assembly and the auxiliary modular frame is a top layer of the assembly.
In an aspect, the base modular frame and the auxiliary modular frame include compartments to accommodate cell modules.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A modular battery pack frame assembly for an electric vehicle of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figures 1A and 2 illustrate a base module of a modular battery pack frame assembly for an electric vehicle, in accordance with an embodiment of the present disclosure;
Figures 1B, 1C, 3A, and 3B, illustrate a base module and top module of a modular battery pack frame assembly for an electric vehicle, in accordance with an embodiment of the present disclosure;
Figure 4 illustrates the locking of an auxiliary modular frame on top of the base modular frame of a modular battery pack frame assembly, in accordance with an embodiment of the present disclosure;
Figures 5A, 5B and 6 illustrate auxiliary windows of a modular battery pack frame assembly, in accordance with an embodiment of the present disclosure;
Figure 7 illustrates the placement of electrical connectors and coolant spouts in a modular battery pack frame assembly, in accordance with an embodiment of the present disclosure;
Figure 8A illustrates the placement of mounting brackets in the base modular frame of the modular battery pack frame assembly, in accordance with an embodiment of the present disclosure;
Figure 8B illustrates the placement of mounting brackets in the base modular frame and the auxiliary modular frame of the modular battery pack frame assembly, in accordance with an embodiment of the present disclosure; and
Figures 9, 10 and 11 illustrate various designs of external solid extrusion mounting brackets in a modular battery pack frame assembly, in accordance with an embodiment of the present disclosure.

REFERENCE NUMERALS
100 – Assembly
101 – Base Modular Frame
102 – Side Frame Members
102T - Top Internal Extension of Base Modular Frame
102B - Bottom Internal Extension of Base Modular Frame
103a – Internal Solid Extrusion
103b – Auxiliary Extrusions
104 – Fastening Elements
105 – Auxiliary Modular Frame
106 – Auxiliary Side Frame Members
106T - Top Internal Extension of Auxiliary Modular Frame
106B - Bottom Internal Extension of Auxiliary Modular Frame
107 – Top Cover of Base Modular Frame
108a- Bottom Cover Of Base Modular Frame
108b- Bottom Layer Of Base Modular Frame
109 - Cooling Plate Of Base Modular Frame
110a - Top Cover Of Auxiliary Modular Frame
110b - Top Layer Of Auxiliary Modular Frame
112 - Cooling Plate Of Auxiliary Modular Frame
113 - Auxiliary Windows
114a - Coolant Hoses
114b- Electrical Connections
115a - Mounting Brackets Of Base Modular Frame
115b- Mounting Brackets Of Base Modular Frame And Auxiliary Modular Frame
119 - Cell Modules
120- Coolant Spouts
121- Low Voltage Connector
122- High Voltage Connector
123- Compartments
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Electric vehicles (EVs) have gained significant traction in recent years due to their environmental benefits and the growing need for sustainable transportation solutions. A crucial component of an electric vehicle is the battery pack, which stores and provides electrical energy to power the vehicle. However, conventional battery pack designs often lack versatility, modularity, and efficient assembly and maintenance processes.
Conventional battery pack designs often lack flexibility and modularity, making it challenging to accommodate different battery sizes, configurations, and future upgrades. Additionally, assembly and maintenance of the battery packs can be time-consuming and complex.
To resolve the above mentioned issues, the present invention proposes a modular battery pack frame assembly for an electric vehicle that overcomes the limitations of existing designs by providing modularity, structural integrity, ease of assembly and maintenance, optimal space utilization, and adaptability to different battery configurations.
To overcome the above-mentioned drawbacks, the present disclosure envisages a modular battery pack frame assembly for an electric vehicle (hereinafter referred to as “assembly 100”).
Figures 1A and 2 illustrate a base modular frame 101 of a modular battery pack frame assembly 100 (assembly 100, hereinafter for the sake of brevity) for an electric vehicle, in accordance with an embodiment of the present disclosure. The assembly 100 comprises a base modular frame 101 and at least one auxiliary modular frame 105. As can be seen from Figure 2, a plurality of vertical side frame members 102 are secured along the operative edges of the base modular frame 101. A plurality of extrusions 103a is configured to extend from the side frame members in an operative inward direction . A plurality of fastening elements (104) is configured to be received in the extrusions (103a) to facilitate locking of the auxiliary modular frame (105) on top of the base modular frame (101) to facilitate formation of the modular battery pack frame assembly 100.
Two oppositely positioned side frame members 102 of the base modular frame 101 include a top internal extension 102T and a bottom internal extension 102B. The top internal extension 102T of two oppositely positioned side frame members 102 of the base modular frame 101 is configured to mount a top cover 107 for the base modular frame 101. The bottom internal extension 102B of two oppositely positioned side frame members 102 of the base modular frame 101 is configured to mount a bottom cover 108a for the base modular frame 101. In addition to the base modular frame 101, the bottom internal extension 102B mounts a cooling plate 109 that is disposed above the bottom cover 108a.
Referring now to Figures 1B, 1C, 3A, and 3B illustrating the base modular frame 101 and the auxiliary modular frame 105 of the modular battery pack frame assembly 100 for an electric vehicle in accordance with an embodiment of the present disclosure.
The auxiliary modular frame 105 has vertical auxiliary side frame members 106 secured along its corresponding edges. The auxiliary modular frame 105 includes auxiliary extrusions (103b) configured to allow passage of the fastening elements (104) therethrough to facilitate locking of the auxiliary modular frame (105) on top of the base modular frame (101). Two oppositely positioned auxiliary side frame members 106 of the auxiliary modular frame 105 include a top internal extension 106T and a bottom internal extension 106B. The top internal extension 106T of two oppositely positioned auxiliary side frame members 106 is configured to mount a top cover 110a for the auxiliary modular frame 105. The bottom internal extension 106B of two oppositely positioned auxiliary side frame members 106 is configured to mount a cooling plate 112 for the auxiliary modular frame 105. The auxiliary modular frame 105 partially overlaps a top cover 107 of the base modular frame 101.
As can be seen from Figures 3A and 3B, in the assembly 100, the auxiliary modular frame 105 completely overlaps a top cover 107 of the base modular frame 101. The base modular frame 101 is a bottom layer 108b of the assembly 100 and the auxiliary modular frame 105 is a top layer 110b of the assembly. Also, as can be seen from Figure 3B, both base modular frame 101 and auxiliary modular frame 105 include compartments 123 to accommodate a plurality of cell modules 119.
Figure 4 illustrates a cross-sectional view of a locking of the auxiliary modular frame 105 on top of the base modular frame 101 of a modular battery pack frame assembly 100 in accordance with an embodiment of the present disclosure. In an aspect, each of the side frame members 102 has internal solid extrusion 103a. The fastening elements 104 are fastened at uniform distances from each other for securing the auxiliary side frame members 106 that are overlapping the side frame members 102. In an aspect, the auxiliary extrusions 103b of the auxiliary modular frame 105 and the internal solid extrusion 103a of the base modular frame 101 are metallic extrusions, particularly aluminum based solid extrusions. With the embodiment disclosed herein, the internal solid extrusion 103a of the auxiliary modular frame 105 is formed to receive the fastening elements 104 to lock the auxiliary modular frame 105 on top of the base modular frame 101.
Figures 5A, 5B and 6 illustrate auxiliary windows of the modular battery pack frame assembly 100 in accordance with an embodiment of the present disclosure. As can be seen, the cooling plate 112 of the auxiliary modular frame 105 and the top cover 107 of the base modular frame 101 include one or more auxiliary windows 113 to transfer coolant hoses 114a and electrical connections 114b from the base modular frame 101 to the auxiliary modular frame 105.
Figure 7 illustrates electrical connectors and coolant spouts of the modular battery pack frame assembly 100 in accordance with an embodiment of the present disclosure. One of the side frame members 102 of the base modular frame 101 includes coolant spouts 120 and electrical connectors. The electrical connectors include a low-voltage connector 121 and a high-voltage connector 122.
Figure 8A illustrates mounting brackets in the base modular frame 101 of the modular battery pack frame assembly 100 in accordance with an embodiment of the present disclosure. As can be seen, two oppositely positioned side frame members 102 of the base modular frame 101 include a plurality of mounting brackets 115a formed at equal distances on external side of the base modular frame 101. Such mounting brackets 102 facilitate the mounting of the base modular frame 101 or the modular battery pack frame assembly 100 in a casing of the electric vehicle.
Figure 8B illustrates mounting brackets in side frame members of the base modular frame 101 and the auxiliary modular frame 105 of the modular battery pack frame assembly 100 in accordance with an embodiment of the present disclosure. As can be seen, two oppositely positioned side frame members of the assembly 100 of the base modular frame 101 and the auxiliary modular frame 105 include a plurality of mounting brackets 115b formed at equal distances on external side of the base modular frame 101. The mounting brackets 115a, 115b are external solid extrusions and facilitate the mounting of the modular battery pack frame assembly 100 in a casing of the electric vehicle.
Figures 9, 10 and 11 illustrate various designs of the external solid extrusions mounting brackets in the modular battery pack frame assembly 100 in accordance with an embodiment of the present disclosure. The external solid extrusions can be of T-shaped extrusions, L-shaped extrusions, and inverted L-shaped extrusions. The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a battery pack frame assembly for the electric vehicle that:
• provides a modular battery pack frame assembly for an electric vehicle,
• provides the modular battery pack frame assembly that allows for easy customization and adaptability to different battery sizes, configurations, and future upgrades,
• provides internal and external solid extrusions, such as aluminium base solid extrusions, to enhance the structural integrity and durability of the battery pack frame assembly,
• provides the modular battery pack frame that includes fastening elements and mounting brackets to simplify the assembling and disassembling process of the battery pack to result in reduced installation and maintenance time, allowing for efficient production processes,
• provides a modular battery pack frame that maximizes the storage capacity of the battery pack without compromising safety or performance, and
• provides the modular battery pack frame that provides modularity and ease of assembly of the battery pack frame assembly resulting in cost savings during manufacturing, assembly, and maintenance processes, the simplified installation and maintenance procedures reduce labour and time requirements, improving operational efficiency and lowering overall production costs.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the description of invention. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A modular battery pack frame assembly (100) for an electric vehicle, said assembly (100) comprising:
• a base modular frame (101);
• a plurality of vertical side frame members (102) secured along operative edges of said base modular frame (101);
• a plurality of extrusions (103a) configured to extend from said side frame members (102) in an operative inward direction;
• at least one auxiliary modular frame (105);
• a plurality of fastening elements (104) configured to be received in said extrusions (103a) to facilitate locking of said auxiliary modular frame (105) on top of the base modular frame (101) to facilitate formation of said modular battery pack frame assembly.
2. The assembly (100) as claimed in claim 1, wherein said auxiliary modular frame (105) has vertical auxiliary side frame members (106) secured along its corresponding edges, wherein said auxiliary side frame members (106) include auxiliary extrusions (103b) configured to allow passage of said fastening elements (104) therethrough to facilitate locking of said auxiliary modular frame (105) on top of the base modular frame (101).
3. The assembly (100) as claimed in claim 2, wherein said fastening elements (104) are fastened at a uniform distance from each other for securing said auxiliary side frame members (106) overlapping with said side frame members (102).
4. The assembly (100) as claimed in claim 2, wherein said auxiliary extrusions (103b) of said auxiliary modular frame (105) and said internal solid extrusions (103a) of said base modular frame (101) are aluminum base solid extrusions.
5. The assembly (100) as claimed in claim 1, wherein at least two oppositely positioned side frame members (102) of said base modular frame (101) include:
a top internal extension to mount a top cover (107) of the base modular frame (101); and
a bottom internal extension to mount a bottom cover (108a) of the base modular frame (101).
6. The assembly (100) as claimed in claim 4, wherein said bottom internal extension is configured to mount a cooling plate (109) disposed above said bottom cover (108a) thereupon.
7. The assembly (100) as claimed in claim 6, wherein at least two oppositely positioned auxiliary side frame members (106) of said auxiliary modular frame (105) include:
a top internal extension to mount a top cover (110a) for said auxiliary modular frame (105); and
a bottom internal extension to mount a cooling plate (112) for said auxiliary modular frame (105).
8. The assembly (100) as claimed in claim 7, wherein said cooling plate (112) of said auxiliary modular frame (105) and said top cover (107) of said base modular frame (101) include one or more auxiliary windows (113) to transfer coolant hoses (114a) and electrical connections (114b) from said base modular frame (101) to said auxiliary modular frame (105).
9. The assembly (100) as claimed in claim 8, wherein one of the side frame members (102) of said base modular frame (101) includes electrical connectors and coolant spouts (120), and wherein the electrical connectors include a low voltage connector (121) and a high voltage connector (122).
10. The assembly (100) as claimed in claim 1, wherein at least two oppositely positioned side frame members (102) of said base modular frame (101) include a plurality of mounting brackets (115a) formed at equal distance on external side of said base modular frame.
11. The assembly (100) as claimed in claim 1, wherein at least two oppositely positioned side frame members (102) of said assembly of said base modular frame (101) and said auxiliary modular frame (105) include a plurality of mounting brackets (115b) formed at equal distance on external side of said base modular frame
12. The assembly (100) as claimed in claim 11, wherein said mounting brackets (115a, 115b) are external solid extrusions, and wherein said external solid extrusions are one of T-shaped extrusions, L-shaped extrusions, and inverted L-shaped extrusions.
13. The assembly (100) as claimed in claim 1, wherein said auxiliary modular frame (105) either partially overlaps a top cover (107) of said base modular frame (101) or completely overlaps a top cover (107) of said base modular frame (101).
14. The assembly (100) as claimed in claim 1, wherein said base modular frame (101) is a bottom layer (108b) of said assembly and said auxiliary modular frame (105) is a top layer (110b) of said assembly.
15. The assembly (100) as claimed in claim 1, wherein said base modular frame (101) and said auxiliary modular frame (105) include compartments (123) to accommodate cell modules (119).

Dated this 07th day of July, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI