Description:FIELD
The present disclosure relates to a battery pack, and more particularly, to a battery pack with an improved assembling structure for mounting different electrical components thereon.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Generally, battery pack includes critical electrical high voltage (HV) and low voltage (LV) components like Battery Management System (BMS), Cell Monitoring System (CMS), Battery Disconnect Unit (BDU), Busbars, harness etc. Conventionally, these electrical components are being mounted directly to the battery pack. Thus, it is difficult to isolate the electrical components from external bollard impacts.
Further, these electrical components are required to be protected from condensation or dew to avoid short circuit. However, the conventional method of mounting of these electrical components exposes the components to dew (water) which increases the possibility of short circuiting of the electrical components.
Furthermore, the conventional method requires an additional cover plate to safeguard the electrical components.
Therefore, there is a requirement for a housing for mounting electrical components, that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a housing for mounting electrical components.
Another object of the present disclosure is to provide a housing which protects the electrical components from external impact or shock load.
Still another object of the present disclosure is to provide a housing which isolates the electrical components from dew or condensed liquid.
Yet another object of the present disclosure is to provide a housing for electrical components which avoids short circuiting of the electrical components.
Still another object of the present disclosure is to provide a housing for electrical components which provides rigidity and ensures no damage of the electrical components.
Yet another object of the present disclosure is to provide a housing for electrical components which provides ease of assembly.
Still another object of the present disclosure is to provide a housing for electrical components which offers ease of serviceability.
SUMMARY
The present disclosure envisages a housing for mounting electrical components. The housing comprises a top cover, an upper base cover, a lower base cover, and at least a pair of stiffeners. The upper base cover has an operative upper mounting surface and a lower operative surface, the lower base cover has an upper operative surface.
The upper operative surface and the lower operative surface is defining an intermediate space therebetween to receive the pair of stiffeners. The pair of stiffeners are compressively abutting within the intermediate space between the upper operative surface and the lower operative surface. The housing is defined by operatively joining the top cover and the upper base cover so as to mount the electrical components therein.
In an embodiment, the lower base cover is configured with a pair of first flanges. Each of the first flange extends from an operative edge of the lower base cover.
In an embodiment, the upper base cover is configured with a pair of second flanges. Each of the second flange extends from an operative edge of the upper base cover.
In an embodiment, the intermediate space is defined by joining each of the second flange of the upper base cover with each of the first flange of the lower base cover by means of welding, brazing and fastening means.
In an embodiment, the top cover is configured with a pair of third flanges. Each of the third flange extends from an operative edge of the top cover.
In an embodiment, each of the third flange is configured to abut on each of the second flange and is further configured to be attached together.
In an embodiment, the housing includes at least a pair of first brackets, and at least a pair of second brackets. Each of the first bracket and the second bracket is mounted on the upper mounting surface of the upper base cover.
In an embodiment, the electrical components are selected from a group consisting of a high voltage and low voltage components which includes a battery management system (BMS), a cell monitoring system (CMS), a battery disconnect unit (BDU) or a combination thereof.
In an embodiment, the housing is sandwiched between a top cooling plate and a frame cover.
In an embodiment, the stiffeners are extending longitudinally along said intermediate space.
In an embodiment, the stiffeners are selected from a group consisting of composites or high-grade aluminum alloy.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A housing for mounting electrical components, of the present disclosure will now be described with the help of accompanying drawing, in which:
Figure 1 illustrates a perspective isometric front view of a housing to mount electrical components in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a perspective exploded isometric front view of a housing to mount electrical components in accordance with an embodiment of the present disclosure;
Figure 3 illustrates a perspective isometric front view of mounting of electrical components on different brackets provided on an operative surface of an upper base cover in accordance with an embodiment of the present disclosure;
Figure 4 illustrates a perspective front view of a housing with electrical components attached thereon in accordance with an embodiment of the present disclosure;
Figure 5 illustrates a perspective bottom view with transparent bottom plate and a perspective bottom view of the battery pack in accordance with an embodiment of the present disclosure;
Figure 6 illustrates an exemplary embodiment typical load transfer path in the cage on an event of bottom intrusion in accordance with an embodiment of the present disclosure; and
Figure 7 illustrates a graphical variation for simulation input on an event of bottom intrusion in pack in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING
100 Housing for mounting electrical components
10 top cover
12 lower base cover
12a first flange
12b upper operative surface
14 upper base cover
14a second flange
14b upper mounting surface
14c lower operative surface
16 intermediate space
18 stiffeners
20 electrical components
22 third flange
26 fastening means
28 first bracket
30 second bracket
36 cooling plate
38 base plate
40 slot
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 grader 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 “comprises”, “comprising”, “including”, and “having”, are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units 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.
When an element is referred to as being “mounted on”, “engaged to”, “connected to”, or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region or section from another component, region, or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper”, and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Typically, battery pack includes critical electrical high voltage (HV) and low voltage (LV) components like Battery Management System (BMS), Cell Monitoring System (CMS), Battery Disconnect Unit (BDU), Busbars, harness etc. Conventionally, these electrical components are being mounted directly to the battery pack. Thus, it is difficult to isolate the electrical components from external bollard impacts. Further, these electrical components are required to keep protected from condensation or dew to avoid short circuit. However, the conventional method of mounting of these electrical components exposes the components to dew (water) which increases the possibility of short circuiting of the electrical components. Furthermore, the conventional method requires an additional cover plate to safeguard the electrical components.
In order to address the aforementioned problems, the present disclosure envisages a housing for mounting electrical components (herein after referred as “housing 100”). The housing (100) is configured to be received within a slot (40) provided on a battery pack. The slot (40) is defined by arranging a plurality of longitudinal members and a plurality of cross members. Also, a plurality of battery modules is configured to be received within the slot provided within the battery pack. Figure 1 illustrates a perspective isometric front view of a housing to mount electrical components and Figure 2 illustrates a perspective exploded isometric front view of a housing to mount electrical components in accordance with an embodiment of the present disclosure.
The housing (100) is defined as a box-shaped compartment, have a defined length, a defined width and a defined height and enclosed operatively between a cooling plate and a base plate. The housing (100) comprises a top cover (10), an upper base cover (14), a lower base cover (12), and at least a pair of stiffeners (18). The lower base cover (12) is defined by an upright U-shaped cover plate and provided with an upper operative surface (12b) and a pair of first flanges (12a) thereon. Each of the first flange (12a) extends from an operative edge of the lower base cover (12). The upper base cover (14) is defined by an upright U-shaped cover plate and provided with an operative upper mounting surface (14b) and a lower operative surface (14c). The upper base cover (14) is configured with a pair of second flanges (14a). Each of the second flange (14a) extends from an operative edge of the upper base cover (14). The top cover (10) is defined by an inverted U-shaped cover plate and provided with a pair of third flanges (22). Each of the third flange (22) extends from an operative edge of the top cover (10). Each of the first flange (12a), the second flange (14a) and the third flange (22) is configured with a first hole thereon.
In an embodiment, the top cover (10), the lower base cover (12), and the upper base cover (14) are selected from a group selected from a mild steel, aluminum, alloy, composite and combination thereof.
In an embodiment, the housing (100) is configured to be mounted in the slot (40) provided in the battery frame or the battery pack by means of snap-fittings or fastening means.
Further, the first flange (12a), and the second flange (14a) are configured to operatively abut on one another in such a way that the upper operative surface (12b) of the lower base cover (12) and the lower operative surface (14c) of the upper base cover (14) are operatively opposite to each other and joined together to define an intermediate space (16) between the upper base cover (14) and the lower base cover (12). The intermediate space (16) is configured to receive the at least a pair of stiffeners (18) therein. The stiffeners (18) are compressively abutting within the intermediate space (16) of the upper operative surface (12b) and the lower operative surface (14c). The stiffener (18) extends longitudinally along the intermediate space (16). Advantageously, the stiffeners (18) provide the damping effect and absorb impact load and vibrations transmitted to the housing.
In an embodiment, the first flange (12a), and the second flange (14a) are joined together by means of welding, brazing or fastening means.
In an embodiment, the stiffeners (18) are selected from a group consisting of composites or high-grade aluminum alloy such as EN AW 5182 H111.
Further, the third flange (22) is configured to be aligned and operatively abutting the first flange (12a) and joined together to form the box-shaped housing. The box-shaped housing (100) facilitates the mounting of the different electrical components (20) therein. Advantageously, the cage configuration of the housing (100) protects the electrical components mounted thereon from the dew or the condensed liquid of the cooling plate and thus protects the electrical components from any short circuiting.
In an embodiment, the third flange (22) is joined together with the first flange (12a) and the second flange (14a) by means of welding, brazing or the fastening means.
In a preferred embodiment, the lower base cover (12) and the upper base cover (14) are operatively welded together and then the top cover (10) is configured to be operatively fastened to the upper base cover (14) by means of the fastening means.
Further, the housing (100) is provided with at least a pair of first brackets (28) and at least a pair of second brackets (30). Each of the first bracket (28) is defined by an inverted U-shaped strip with a plurality of second holes provided on a web portion of the first brackets (28); whereas each of the second bracket (30) is defined by an inverted U-shaped plate with a plurality of third holes provided on a web portion of each of the second brackets (30). The first bracket (28) and the second bracket (30) are configured to be mounted on the upper mounting surface of the upper base cover (14). The first bracket (28) and the second bracket (30) provide a mounting platform and a sufficient height for mounting the different electrical components thereon. Figure 3 illustrates a perspective isometric front view of mounting of electrical components on different brackets provided on an operative surface of an upper base cover and Figure 4 illustrates a perspective front view of a housing with electrical components attached thereon in accordance with an embodiment of the present disclosure.
In an embodiment, the first brackets (28) and the second brackets (30) are mounted to the operative surface of the housing by means of welding, and fastening means.
In an embodiment, the electrical components (20) are selected from a group consisting of a high voltage and low voltage components which include a battery management system (BMS), a cell monitoring system (CMS), a battery disconnect unit (BDU) or a combination thereof.
Since the housing (100) is provided with different number of flanges and the stiffeners, the housing is rigid enough to withstand the impact or shock load and thus, the housing protects the electrical components from the external impact.
EXAMPLE
In an exemplary embodiment, an operative base surface of the housing (bottom intrusion) to bottom intrusion, a load of 50J is applied. Figure 5 illustrates a perspective bottom view with a bottom plate and a perspective bottom view of the battery pack. The load is transferred from the base surface to a side surface of the housing.
Figure 6 illustrates an exemplary embodiment typical load transfer path in the cage on an event of bottom intrusion. As shown with the arrows, on an event of intrusion, the lower base cover is subjected to a load which deforms the lower base cover w.r.t the upper base cover. Further, the stiffeners provided on either side of the intermediate space facilitate the transfer of load towards the edges instead of impacting middle portion of the upper base cover on which the different electrical components are mounted. Since, the upper base cover and the lower base cover are configured to be connected to the operative edges of the top cover, therefore the load gets transfer from the base cover towards the top cover. Thus, it ensures that no load should transfer to the internal electronic components. The arrow head shows the direction of load transfer within the housing and energy absorption by the different members of the housing.
Figure 7 shows the simulation input on an event of bottom intrusion in the battery pack. Location below the cage design in the base plate is considered for the intrusion where a steel sphere is used for load application. The graph shows the force applied w.r.t time and corresponding displacement and velocity plots. Thus, the simulated graph shows that the peak force induced is around 11KN and the displacement is almost 16mm. Further the induced load transferred towards the cage design of the housing where in the cage design is protecting the electronic components inside. The maximum amount of force withstood by the base plate due to the deflection is around 79.18%, and remaining force is absorbed by the cage design of the housing .i.e. force absorbed due to deflection by base surface of cage configuration is around 16.80%, Force transmitted to the cage (side surface) is around 4.02%. The load on the housing can be varied based on the type of the material of the housing and the number of components used.
The foregoing description of the embodiments has been provided for purposes of illustration and 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 AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of the housing for mounting electrical components, that:
• protect the electrical components from external impact or shock load;
• isolate the electrical components from dew or condensed liquid;
• avoid short circuiting of the electrical components;
• provides rigidity and ensures no damage of the electrical components;
• ease of assembly; and
• ease of serviceability.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein.
The foregoing description of the specific embodiments so fully reveal 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.
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 housing (100) for mounting electrical components (20), said housing (100) comprising:
• a top cover (10);
• an upper base cover (14) having an operative upper mounting surface (14b) and a lower operative surface (14c);
• a lower base cover (12) having an upper operative surface (12b);
• an intermediate space (16), defined between said upper operative surface (12b) and said lower operative surface (14c); and
• at least a pair of stiffeners (18) compressively abutting within said intermediate space (16) between said upper operative surface (12b) and said lower operative surface (14c),
said housing (100) defined by operatively joining said top cover (10) and said upper base cover (14) to mount the electrical components (20) therein.
2. The housing (100) as claimed in claim 1, wherein said lower base cover (12) is configured with a pair of first flanges (12a), each of said first flange (12a) extends from an operative edge of said lower base cover (12).
3. The housing (100) as claimed in claim 2, wherein said upper base cover (14) is configured with a pair of second flanges (14a), each of said second flange (14a) extends from an operative edge of said upper base cover (14).
4. The housing (100) as claimed in claim 3, wherein said intermediate space (16) is defined by joining each of said second flanges (14a) of said upper base cover with each of said first flanges (12a) of said lower base cover by means of welding, brazing and fastening means.
5. The housing (100) as claimed in claim 4, wherein said top cover (10) is configured with a pair of third flanges (22), each of said third flange (22) extends from an operative edge of said top cover (10).
6. The housing (100) as claimed in claim 5, wherein each of said third flange (22) is configured to abut on each of said second flanges (14a) and are further configured to be attached together.
7. The housing (100) as claimed in claim 5, wherein each of said first flanges (12a), said second flanges (14a) and said third flanges (22) are configured with a plurality of first holes to receive a plurality of fastening means (26) therein.
8. The housing (100) as claimed in claim 1, wherein said lower base cover (12) and said upper base cover (14) are operatively welded together and said top cover (10) is configured to be operatively fastened with said upper base cover (14) by means of the fastening means.
9. The housing (100) as claimed in claim 1, wherein said top cover (10) is defined by an inverted U-shaped plate, said upper base cover (14), and said lower base cover (12) are defined by a U-shaped plate.
10. The housing (100) as claimed in claim 1, which includes at least a pair of first brackets (28), and at least a pair of second brackets (30), each of said first bracket (28) and said second bracket (30) are mounted on said upper mounting surface of said upper base cover (14).
11. The housing (100) as claimed in claim 10, wherein said first brackets (28) and said second brackets (30) are mounted by means of welding, and fastening means.
12. The housing (100) as claimed in claim 10, wherein each of said first brackets (28) is defined by an inverted U-shaped strip with a plurality of second holes provided on a web portion of each of said first brackets.
13. The housing (100) as claimed in claim 10, wherein each of said second brackets (30) is defined by an inverted U-shaped plate with a plurality of third holes provided on a web portion of each of said second brackets.
14. The housing (100) as claimed in claim 1, wherein said electrical components are selected from a group consisting of a high voltage and low voltage components which include a battery management system (BMS), a cell monitoring system (CMS), a battery disconnect unit (BDU) or a combination thereof.
15. The housing (100) as claimed in claim 1, wherein said housing (100) is configured to be mounted in a slot (40) provided in a battery frame by means of snap-fittings or fasteners.
16. The housing (100) as claimed in claim 1, wherein said housing is sandwiched between a top cooling plate (36) and a base plate (38).
17. The housing as claimed in claim 1, wherein said stiffeners (18) are extending longitudinally along said intermediate space.
18. The housing as claimed in claim 1, wherein said stiffeners (18) are selected from a group consisting of composites or high-grade aluminum alloy.
Dated this 27th day of March, 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