Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 1003
COMPLETE SPECIFICATION
[See section 10, Rule 13]

TITLE OF INVENTION
A FRAME ASSEMBLY FOR SUPPORTING A BATTERY MODULE OF A VEHICLE

APPLICANT
MAHINDRA ELECTRIC AUTOMOBILE LIMITED, an Indian company, having its address at Mahindra Tower, Pandurang Budhkar Marg, Nr. Doordarshan Kendra, Worli, Mumbai, Mumbai City, Maharashtra 400018, India

PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed:
FIELD OF THE INVENTION
[001] The present invention generally relates to a frame assembly. More particularly, the present invention relates to a frame assembly for supporting a battery module of a vehicle.

BACKGROUND OF THE INVENTION
[002] Generally, in conventional electric or hybrid vehicles, a frame assembly is required to support/ mount a battery pack on the vehicle underfloor. The frame assembly houses the battery pack and safeguards it from external forces or impacts produced during the crash or collision of vehicle. To increase the impact absorption capacity, the conventional frame assemblies are constructed in such a manner that the frame section receiving the impact crumbles in the event of the crash or collision.
[003] It has been observed that the existing frame assemblies securing the battery pack exhibit uncontrolled crumbling during crashes, primarily due to existing design or configuration. This uncontrolled crumbling occurs in a single stage, causing the impacted frame section to collapse rapidly, transmitting the impact to the battery packs with minimal resistance which is unexpected.
[004] Due to such uncontrolled crumbling, the entire frame assembly of the vehicle crumbles or deforms in a single stage and as a result the impact directly reaches the battery packs which poses serious safety risks to occupants of the vehicle.
[005] Moreover, these existing assemblies fail to effectively mitigate the impact of the vehicle crash on the battery modules. It has been further observed that owing to space constraints, creating a crumble zone in the frame assembly poses a significant challenge in terms of both design and manufacturing.
[006] Thus, there is a need in the art for an improved frame assembly for supporting a battery pack, which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[007] In one aspect, the present invention is directed towards a frame assembly for supporting a battery module of a vehicle. The frame assembly has an outer frame. The outer frame has an outer wall and an inner wall. The inner wall is configured to surround the battery module. The frame assembly has a peripheral member. The peripheral member extends from at least one of the outer walls. The peripheral member has a plurality of horizontal members extending outwardly from the outer wall. Each horizontal member is spaced apart from each other and extending along the length of the outer wall, and at least two vertical members extends between the plurality of horizontal members. The configuration of the vertical members and the horizontal members is configured to form a plurality of crumble zones.
[008] In a further embodiment of the invention, the peripheral member extends from a lower side of the outer wall.
[009] In a further embodiment of the invention, an outer most vertical member has a thickness smaller than a thickness of other vertical members.
[010] In a further embodiment of the invention, one of the plurality of vertical members is configured to be positioned between 35% - 65% of the plurality of crumble zones.
[011] In a further embodiment of the invention, the peripheral member has an impact wall spaced apart from the outer most vertical member and interconnected with a plurality of horizontal members extending outwardly from the outer most vertical member.

BRIEF DESCRIPTION OF THE DRAWINGS
[012] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a frame assembly for supporting a battery module of a vehicle in a dismantled state of a battery module, in accordance with an embodiment of the present invention.
Figure 2 illustrates a perspective view of the frame assembly with an assembled state of the battery module, in accordance with an embodiment of the present invention.
Figure 3 is a perspective view of the frame assembly illustrating the configuration of the frame assembly, in accordance with an embodiment of the present invention.
Figure 4 illustrates a front cross sectional view of a portion of the frame assembly, in accordance with an embodiment of the present invention.
Figure 5 illustrates a configuration of the peripheral member of the frame assembly, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[013] The present invention relates to a frame assembly for supporting/mounting a battery module of a vehicle. The frame assembly is configured to effectively absorb the load during a crash event or collision of the vehicle.
[014] Figure 1 illustrates a frame assembly 100 for supporting a battery module 200 of a vehicle in a dismantled state of a battery module 200 with respect to the frame assembly 100, in accordance with an embodiment of the present invention. Figure 2 illustrates a perspective view of the frame assembly 100 in an assembled state of the battery module 200, in accordance with an embodiment of the present invention.
[015] As shown in Figures 1-2, the battery module 200 is constituted by a plurality of battery cells 210. The frame assembly 100 includes a base 102 and an outer frame 110 extending upwardly from the base 102. The base 102 is configured to receive the plurality of battery cells 210.
The outer frame 110 includes an outer wall 110a and an inner wall 110b opposite the outer wall 110a. The outer wall 110a is facing an exterior side of the vehicle. The inner wall 110b is configured to surround the battery cells 210 of the battery module 200.
[016] In an embodiment, the battery module 200 further incudes Printed Circuit Boards (PCBs) (not shown) and one or more busbars (not shown). The busbar is operably connected with terminals of the battery cells 210 and the Printed Circuit Boards (PCBs). The battery module 200 is configured to power an electric motor and other electrical/electronic systems of the vehicle. Furthermore, the battery module 200 includes a battery management system for monitoring the battery cells 210 of the battery module 200 and protect the battery module 200 in conditions of overcharging, short-circuiting, and overheating etc. The battery module 200 includes a controller (not shown), a Battery Disconnect Unit (BDU) (not shown) and a High Voltage Connection Header Unit (not shown). The controller includes a control circuit and is in communication with the each of the plurality of battery cells 210 of the battery module 200 and is configured to monitor the voltage/ temperature of each of the battery cells 210. The High Voltage Connection Header Unit acts as a connector for connecting the battery module 200 to an external source for charging the plurality of battery cells 210. In a non-limiting example, the Battery Disconnect Unit (BDU) is configured to disconnect the power supply from the battery module 200 to the vehicle based on the signal received from the controller unit.
[017] Referring to Figure 1, the outer frame 110 includes a peripheral member 120 extending from at least one of outer walls 110a of the outer frame 110. The peripheral member 120 extends outwardly from a lower side of the outer wall 110.
[018] In a further non-limiting example, an upper side of the outer wall 110 is adapted to be attached to the underfloor of the vehicle. The outer frame 110 of the frame assembly 100 includes a plurality of mounting holes (not shown) configured to receive attachment means for mounting the battery module 200 on the underfloor of the vehicle. The attachment means, include but are not limited to a fastener, nut/bolt, etc.
[019] Figure 3 is a perspective view of the frame assembly 100 illustrating the configuration of the frame assembly 100, in accordance with an embodiment of the present invention. As shown, the outer frame 110 is an integrated structure formed by four side frame portions 111. The frame assembly 100 includes a plurality of longitudinal support members 112a, 112b, 112c and a plurality of lateral support members 114a, 114b, 114c extending between the plurality of longitudinal support members 112a, 112b, 112c. Each of the plurality of longitudinal support members 12a, 112b, 112c and the plurality of lateral support members 114a, 114b, 114c extend between inner walls 110b of any two opposite side frame portions 111 of the outer frame 110. Such configuration imparts a structural integrity and stiffness to the frame assembly 100. As shown in a magnified view of Figure 3, the peripheral member 120 extends outwardly from the lower portions of the outer walls 110a of the outer frame 110.
[020] Figure 4 illustrates a front cross sectional view of a portion of the frame assembly 100, in accordance with an embodiment of the present invention. As shown, the peripheral member 120 includes a plurality of horizontal members 122 being spaced apart from each other. Each of the plurality of horizontal members 122 extends outwardly from the outer wall 110a along the length of the outer wall 110a and in a direction away from the battery module 200. The peripheral member 120 includes a plurality of vertical members 124 extending between the plurality of horizontal members 122. As shown, a space (S) is created between two of plurality of horizonal members 122 adjoined by two of plurality of vertical members 124.
[021] In an embodiment, the configuration of the plurality of vertical members 124 and the horizontal members 122 forms the crumble zones (CZ1), (CZ2). The peripheral member 120 includes an impact wall 125 spaced apart from the outer most vertical member (124) and interconnected with a plurality of horizontal members 122 extending outwardly from the outer most vertical member 124. The impact wall 125 is configured to receive the impact load in the event of crash/ collision of the vehicle.
[022] In an embodiment, the peripheral member 120 defines the plurality of crumble zones (CZ1, CZ2) (shown in Figure 4). The plurality of crumble zones (CZ1, CZ2) includes a first crumble zone (CZ1) and a second crumble zone (CZ2). The plurality of crumble zones (CZ1, CZ2) being configured to collapse sequentially in the event of the crash/ collision of the vehicle whereby the peripheral member 120 is subject to the impact produced due to such crash/collision. Sequential collapsing allows the crumbling or deformation of one crumble zone (CZ2) firstly followed by a subsequent deformation of another crumble zone (CZ1). As a result, the crumbling takes place in a non-singular stage and impact absorption capacity of the frame assembly 100 is increased which further prolongs the time period of impact in hitting the battery module 200. Such configuration of the peripheral member 120 with the plurality of crumble zones (CZ1, CZ2) of the frame assembly 100 increases the safety of the battery pack 200 in the event of crash/collision of the vehicle. In a non-limiting example, each side of the outer frame 110 includes the peripheral member 120 based on the requirements of the vehicle.
[023] In an embodiment, the plurality of the vertical members 124 are placed between the plurality of horizontal members 122 such that the plurality of vertical members 124 absorbs more impact load during collapsing and the duration of collapsing event is increased with a gradual reduction in the magnitude of the impact being transferred towards the battery module 200.
[024] Figure 5 illustrates a configuration of the peripheral member 120 of the frame assembly 100, in accordance with an embodiment of the present invention. The plurality of vertical members 124 (shown in Figure 4) include a first vertical member 124a (being the closest to the outer wall 110a), a second vertical member 124b, and a third vertical member 124c (being the farthest to the outer wall 110a). Similarly, the plurality of horizontal members 122 include a first horizontal member 122a, a second horizontal member 122b and a third horizontal member 122c.
[025] In a non-limiting example, the first vertical member 124a and the second vertical member 124b extend between the first horizontal member 122a, the second horizontal member 122b and the third horizontal members 122c to define the first crumble zone (CZ1) (shown in Figure 4). Likewise, the second vertical member 124b and the third vertical member 124c extend between the first horizontal member 122a, the second horizontal member 122b and the third horizontal members 122c to define the second crumble zone (CZ2).
[026] In an embodiment, the first vertical member 124a and the second vertical member 124b act as stopper walls. Each of the stopper walls are configured to resist the impact load being transferred during the event of the crash/ collision of the vehicle. The third vertical member 124c (i.e., the outer most vertical member) acts as a crumble wall.
[027] In an embodiment of the present invention, the thickness (t) of the third vertical member 124c is less than the thickness (T) of the first vertical member 124a or the second vertical member 124b.
[028] Such configuration increases the impact absorption capacity of the peripheral member 120 and safeguards the battery module 200 from getting damaged during the crash/collision of the vehicle.
[029] In an embodiment, the thickness of the impact wall 125 is greater than the thickness of the third vertical member 124c. Such configuration increases the stiffness of the peripheral member 120 of the outer frame 110.
[030] In an embodiment, the length of the first crumble zone (CZ1) and the second crumble zone (CZ2) collectively define an overall length (L). The second vertical member 124b is configured to be placed at a distance (x) (shown in Figure 5) measured from the impact wall 125 of the peripheral member 120 between 35% - 60% of the overall length (L) (shown in Figure 5). Such placement of the second vertical member 124b at 35% - 60% of the overall length (L) provides a greater impact absorption capacity by allowing the crumble zones (CZ1, CZ2) of the frame assembly 100 to crumble in two sequential stages during the collision or crash of the vehicle. The percentage of placement of the second vertical member 124b (stopper wall) with respect to overall length of the crumble zones (CZ1 and CZ2) can be calculated as:
Position of stopper wall in percentage (%) = (L-x)/ L X 100
[031] Advantageously, the present invention provides a frame assembly for supporting the battery module of the vehicle. The frame assembly includes a peripheral member defining a plurality of crumble zones configured to crumble in multiple stages to efficiently absorb the impact load during the crash or collision of the vehicle. The present invention improves the load absorbing capacity of the frame assembly during the crash of the vehicle and effectively protects the battery module from the impact of the crash or collision. The present invention further provides a controlled crumbling of the frame assembly by providing plurality of crumble zones. Further, the configuration of the peripheral member provides stiffening features that allows more time to collapse the frame assembly completely.
[032] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
, Claims:WE CLAIM:
1. A frame assembly (100) for supporting a battery module (200) of a vehicle, the frame assembly (100) comprising:
an outer frame (110), the outer frame (110) comprising:
an outer wall (110a) and an inner wall (110b), the inner wall (110b) surrounding the battery module (200);
a peripheral member (120) extending from at least one of the outer walls (110a), the peripheral member (120) having a plurality of horizontal members (122) extending outwardly from the outer wall (110a), each horizontal member (122) spaced apart from each other and extending along the length of the outer wall (110a), and at least two vertical members (124) extending between the plurality of horizontal members (122), configuration of the vertical members (124) and the horizontal members (122) forming a plurality of crumble zones (CZ1, CZ2).

2. The frame assembly (100) as claimed in claim 1, wherein the peripheral member (120) extends from a lower side of the outer wall (110a).

3. The frame assembly (100) as claimed in claim 1, wherein an outer most vertical member (124) has a thickness smaller than a thickness of other vertical members (124).

4. The frame assembly (100) as claimed in claim 1, wherein at least one of the plurality of vertical members (124) is configured to be positioned between 35% - 65% of the overall length of the plurality of crumble zones (CZ1, CZ2).

5. The frame assembly (100) as claimed in claim 1, wherein the peripheral member (120) comprises an impact wall (125) spaced apart from the outer most vertical member (124) and interconnected with a plurality of horizontal members (122) extending outwardly from the outer most vertical member (124).

Dated this 07th day of February 2024

MAHINDRA ELECTRIC AUTOMOBILE LIMITED
By their Agent & Attorney

(Janaksinh Jhala)
of Khaitan & Co
Reg No IN/PA-2193