Claims:1. A modular battery pack enclosure (100) for an eco-friendly vehicle, said enclosure (100) comprising:
a lower casing (102) removably coupled to an upper casing (104), said lower casing(102) having a base (102a),a pair of longitudinal walls (102b) and a pair of transverse walls (102c) extending transversely from said base (102a)which are joined at corners;
a plurality of longitudinal crush members(106), where each of said longitudinal crush member (106)is coupled onto corresponding longitudinal side of said lower casing (102);
a plurality of reinforcement members(108a, 108b, 108c, 108d) disposed within said lower casing (102) at predetermined positions;
a plurality of first mounting member (110) connected to said longitudinal crush members (106)at predetermined positions; and
a plurality of second mounting member (112) connected to one of said transverse walls (102c)at predetermined positions,
wherein,
said plurality of first mounting member (110) and said plurality of second mounting member (112) are adapted to connect said enclosure to a predetermined portion of said eco-friendly vehicle; and
said longitudinal crush member (106) is adapted to deform to absorb collision energy received by said battery enclosure (100) in an event of side collision.

2. The modular battery pack enclosure (100) as claimed in claim 1, wherein said enclosure (100) comprises,
a plurality of first mounting brackets (118) connected to underside of said lower casing (102) and said longitudinal crush members (106), said plurality of first mounting brackets (118) is located below said first mounting members (110); and
a plurality of second mounting bracket (120), where each of said second mounting bracket (120) is connected to underside of said lower casing (102) and said plurality of second mounting bracket (120) is located below corresponding said second mounting members (112),
wherein,
said plurality of first and second mounting members (110, 112) and said plurality of first and second mounting brackets (118, 120) are adapted to mount said battery pack enclosure (100) to a predetermined portion of said eco-friendly vehicle;
said second mounting members (112) and said second mounting brackets (120) are adapted to restrict a movement of said battery pack enclosure (100) in a forward or rearward direction of the vehicle;
each of said first and second mounting brackets (118, 120) are made-up of material selected from a group consisting of high strength steel and CR grade steel cross-section;
said first mounting brackets (118) is transverse to said longitudinal crush members (106); and
said second mounting brackets (120) is transverse to said first mounting brackets (118) and is parallel to said longitudinal crush members (106).

3. The modular battery pack enclosure (100) as claimed in claim 1, wherein said battery pack enclosure (100) includes:
a plurality of first insert members (114), where each of said first insert member (114) is adapted to be received by a first insert member receiving portion (134) defined in each of said first mounting member (110), said longitudinal crush member (106) and said first mounting bracket (118),
wherein,
said first insert members (114) is adapted to absorb collision energy received by said enclosure (100) in the event of side collision;
said first insert members (114) is adapted to facilitate deformation of said longitudinal crush member (106) in a proportioned manner;
each of said first insert member (114) is a hollow first insert member; and
each of said first insert member (114) is adapted to allow a fastener there through for securing said battery pack enclosure (100) to the vehicle.

4. The modular battery pack enclosure (100) as claimed in claim 1, wherein said battery pack enclosure (100) includes:
a plurality of second insert members (116), where each of said second insert member (116) is adapted to be received by a second insert member receiving portion (132) defined in each of said longitudinal crush member (106),
wherein,
said second insert members (116) is adapted to absorb collision energy received by said enclosure (100) in the event of side collision;
said second insert members (116) is adapted to facilitate deformation of said longitudinal crush member (106) in a proportioned manner; and
each of said second insert member (116) is a hollow second insert member.
5. The modular battery pack enclosure (100) as claimed in claim 1, wherein said plurality of reinforcement members (108a-108d) comprises,
a plurality of longitudinal reinforcement members (108a);
a plurality of first cross reinforcement members (108b);
a second cross reinforcement member (108c); and
a third cross reinforcement member (108d),
wherein,
said reinforcement members (108a-108d) are rigid members which are adapted to prevent transmission of impact energy in a direction towards said battery pack stored in said lower casing (102) thereby protecting the battery pack in the event of side collision;
each of said longitudinal reinforcement member (108a) is connected to inner walls of corresponding longitudinal wall (102b) of said lower casing (102);
each of said first transverse reinforcement member (108b) is connected to said longitudinal reinforcement members (108a);
said second cross reinforcement member (108c) is disposed in between corresponding said first cross reinforcement member (108b) and said third cross reinforcement member (108d);
said third cross reinforcement member (108d) is connected to inner walls of corresponding transverse wall (102c) of said lower casing (102) and is adjacent to said second mounting member (112); and
each of said reinforcement members (108a-108d) is fabricated from at least one of steel alloys, aluminium alloys, polymeric based composite materials.
6. The modular battery pack enclosure (100) as claimed in claim 1, wherein said lower casing (102) defines a battery receiving portion (102d) which is adapted to receive the at least one battery pack;
said lower casing (102) includes a plurality of corrugations (128) defined on upper surface of said base (102a) for reinforcing said lower casing (102);
said upper casing (104) includes a ceiling wall (104a), a pair of longitudinal descending walls (104b) and a pair of transverse descending walls (104c), where each of said longitudinal and cross descending walls (104b, 104c) extends transversely from said ceiling wall (104a), which are joined at corners;
each of said longitudinal crush member (106) extends along a lengthwise direction of the vehicle; and
each of said longitudinal crush member (106) is a hollow longitudinal crush member.

7. The modular battery enclosure (100) as claimed in claim 3, wherein said lower casing (102) includes a first peripheral flange (122) extending outwardly from edges of said longitudinal walls (102b) and said transverse walls (102c); and
said upper casing(104) includes a second peripheral flange (124) extending outwardly from edges of said longitudinal descending walls (104b) and said transverse descending walls (104c),
wherein,
a plurality of fastening means (126) are adapted to removably couple said first peripheral flange(122) with said second peripheral flange (124); and
each of said fastening means (126) is selected from a group consisting of a bolt, a nut and a removable fastener.
8. The modular battery pack enclosure (100) as claimed in claim 1, wherein said modular battery pack enclosure (100) comprises a plurality of handling means(130) adapted to facilitate lifting and handling of said battery enclosure (100) from one place to another place,
wherein,
said plurality of handling means (130) is connected on each of said longitudinal crush member (106); and
each of said handling means (130) is one of a hook, a bracket, a handle and an eyebolt.
9. A method (500) of providing a modular battery pack enclosure (100) for eco-friendly vehicles, said method (500) comprising:
providing a lower casing (102), where said lower casing (102) includes a base (102a), a pair of longitudinal walls (102b) and a pair of transverse walls (102c), where each of said longitudinal and transverse walls (102c)extends transversely from said base (102a),which are joined at corners;
connecting at least one longitudinal crush member (106) onto said corresponding each longitudinal wall (102b) of said lower casing (102);
disposing a plurality of reinforcement members (108a-108d) within said lower casing (102) at predetermined locations;
connecting a plurality of first mounting members (110) onto said longitudinal crush members (106)at predetermined positions; and
connecting a plurality of second mounting members (112) to one of said transverse walls (102c)at predetermined positions,
wherein,
said plurality of first and second mounting members (110, 112)are adapted to mount said battery pack enclosure (100) to a predetermined portion of said eco-friendly vehicle;
said reinforcement members (108a-108d) are rigid reinforcement members which are adapted to prevent transmission of impact energy in a direction towards battery pack and thereby protecting the battery pack in the event of side collision; and
at least one of said longitudinal crush member (106) is adapted to deform to absorb collision energy received by said battery enclosure (100) in an event of side collision.

10. The method (500) as claimed in claim 9, wherein said method (500) comprises:
connecting a plurality of first mounting brackets (118) to an underside of said lower casing (102) and said longitudinal crush members (106);
connecting a plurality of second mounting brackets (120) to an underside of said lower casing (102) and said second mounting members (112);
inserting first insert members (114) into a first insert member receiving portion (134) defined in each of said first mounting member (110), said longitudinal crush member (106) and said first mounting bracket (118); and
inserting second insert members (116) into a second insert member receiving portion (132) defined in each of said longitudinal crush member (106),
wherein,
said plurality of first and second mounting members (110, 112) and said plurality of first and second mounting brackets (118, 120) are adapted to mount said battery pack enclosure (100) to a predetermined portion of said eco-friendly vehicle; and
each of said first and second insert member (114, 116) are adapted to absorb collision energy received by said enclosure (100) in the event of side collision.
, Description:TECHNICAL FIELD

[001] The embodiments herein generally relate to automobile batteries and more particularly, to a modular battery pack enclosure for eco-friendly vehicles. Further, the embodiments herein relates to the modular battery pack enclosure which provides reduced weight, improved structural stiffness and collision protection characteristics.

BACKGROUND
[002] In response to the demands of consumers who are driven both by ever-escalating fuel prices and dire consequences of global warming, the automobile industry is slowly starting to embrace the need for ultra-low emission and high efficiency cars. While some within the industry are attempting to achieve these goals by engineering more efficient internal combustion engines, others are incorporating hybrid or all-electric drive trains into their vehicle drive. However, to be successful, the electric vehicle must meet consumer’s expectations relative to performance, range, reliability, lifetime and cost. These expectations, in turn, place considerable importance on the design, configuration and implementation of the electric vehicle's batteries. Conventionally, electric vehicles use batteries that are enclosed in an enclosure or housing that is assembled to the vehicle body.
[003] The batteries for electric vehicles come in numerous shapes and sizes and may use any of technologies for e.g., lithium ion, nickel metal hydride, and so forth. While lithium ion battery packs provide a larger energy density, lithium ion packs are known to be unstable when subject to large impact forces. As a result, much effort has been placed in developing enclosures that protect the batteries in the event of a collision. Also, packaging lithium ion batteries is particularly difficult due to the need for corrosion resistance, crashworthiness and vibration resistance.
[004] Further, many of the enclosures developed are bulky in nature and they add a considerable amount of weight to the electric vehicle, thereby negatively affecting the vehicle's operating range. Since the Distance to Empty (DTE) of electric vehicles is inversely proportional to the vehicle weight, a reduction of weight has become increasingly important in the development of electric vehicles. Thus, attempts to use lightweight materials for various parts of electric vehicles are being actively made. For example, the metallic materials commonly used are replaced with a plastic composite material/fiber reinforced resin material to form battery pack cases. In consequence of this, the vehicle becomes lighter in construction, however, resistance to shock or impact declines and the vehicles become more susceptible to damage in collision (or accidents) of all kinds.
[005] Therefore, there exists a need for a modular battery pack enclosure for eco-friendly vehicles, which obviates the aforementioned drawbacks. Further, there exists a need for the modular battery pack enclosure for eco-friendly vehicles, which provides reduced weight, improved structural stiffness and collision protection characteristics.

OBJECTS
[006] The principal object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles.
[007] Another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles which is made-up of lightweight materials to reduce overall weight of the vehicle and thereby improving an operating range (or distance to empty) of the vehicle.
[008] Yet another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles which provides improved structural stiffness and durability.
[009] Still another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles which include higher modal stiffness ensuring battery pack frequencies are higher than induced frequency from the vehicle structure.
[0010] Another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles which includes a plurality of longitudinal crush members to provide collision protection characteristics and thereby preventing transfer of collision energy to the battery pack.
[0011] Another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles which is adapted to transfer crush load from one side of the vehicle to another side, during side collision.
[0012] Yet another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles, which includes a plurality of external brackets and a plurality of reinforcement members coupled to the battery pack enclosure to improve the structural stiffness of the battery pack enclosure.
[0013] Still another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles, which is adjustable for different load paths to meet desired impact, torsional and modal load.
[0014] Still another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles which is inexpensive and easy to manufacture.
[0015] Another object of the embodiments disclosed herein is to provide a method of providing a modular battery pack enclosure for eco-friendly vehicles.
[0016] Also, another object of the embodiments disclosed herein is to provide a modular battery pack enclosure for eco-friendly vehicles, which facilitates passive and active cooling (liquid and air cooling).
[0017] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0018] The embodiments of the invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0019] FIG. 1a depicts a perspective view of a modular battery pack enclosure, according to embodiments as disclosed herein;
[0020] FIG. 1b depicts a perspective view of a lower casing of the modular battery pack enclosure, according to embodiments as disclosed herein;
[0021] FIG. 1c depicts a perspective view of an upper casing of the modular battery pack enclosure, according to embodiments as disclosed herein;
[0022] FIG. 2 depicts a top view of a lower casing of the modular battery pack enclosure, according to embodiments as disclosed herein;
[0023] FIG. 3 depicts a bottom view of the lower casing, showing a plurality of first mounting brackets and a plurality of second mounting brackets connected to an underside of the lower casing, according to embodiments as disclosed herein;
[0024] FIG. 4a depicts a cross-sectional view of the modular battery pack enclosure, according to embodiments as disclosed herein;
[0025] FIG. 4b depicts another cross-sectional view of the battery pack enclosure showing second insert members received by second insert member receiving portion of longitudinal crush members, according to embodiments as disclosed herein;
[0026] FIG. 4c depicts another cross-sectional view of the battery pack enclosure, showing first insert members received by first insert member receiving portion of each of first mounting member, longitudinal crush member, and first mounting bracket, according to embodiments as disclosed herein;
[0027] FIG. 4d depicts longitudinal cross-sectional view of the lower casing of the modular battery pack enclosure, according to embodiments as disclosed herein;
[0028] FIG. 4e depicts lateral cross-sectional view of the lower casing of the modular battery pack enclosure, according to embodiments as disclosed herein; and
[0029] FIG. 5 depicts a flowchart indicating a method of providing a modular battery pack enclosure for eco-friendly vehicles, according to an embodiment of the invention as disclosed herein.

DETAILED DESCRIPTION
[0030] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. 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.
[0031] The embodiments herein achieve a modular battery pack enclosure for eco-friendly vehicles. Further, the embodiments herein achieve the modular battery pack enclosure for eco-friendly vehicles, which is made-up of lightweight materials to reduce overall weight of the vehicle and thereby improving an operating range (or distance to empty) of the vehicle. Furthermore, the embodiments herein achieve the modular battery pack enclosure for eco-friendly vehicles which provides improved structural stiffness and durability. The embodiments herein achieve a method of providing a modular battery pack enclosure for eco-friendly vehicles. Referring now to the drawings, and more particularly to Figs. 1 through 5, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0032] FIG. 1a depicts a perspective view of a modular battery pack enclosure, according to embodiments as disclosed herein. In an embodiment, the modular battery pack enclosure (100) includes a lower casing (102) (as shown in FIG. 1 and FIG. 2), an upper casing (104), a plurality of longitudinal crush members (106), a plurality of reinforcement members (108a, 108b, 108c, 108d), (as shown in FIG. 2), a plurality of first mounting members (110), a plurality of second mounting members (112), a plurality of first insert members (114), a plurality of second insert members(116), plurality of first mounting brackets (118) (as shown in FIG. 3), a plurality of second mounting brackets (120) (as shown in FIG. 3),a first peripheral flange (122) (as shown in FIG. 2), a second peripheral flange (124) (not shown), a fastening means (126), a plurality of corrugations (128) (as shown in FIG. 2), and a lifting means (130).
[0033] FIG. 2 depicts a top view of a lower casing of the modular battery pack enclosure, according to embodiments as disclosed herein. The modular battery pack enclosure (100) is made by coupling the lower casing (102) and the upper casing (104). The lower casing (102) includes a base (102a) as shown in FIG. 1b. The base (102a) is substantially formed in a rectangular in shape. However, it is also within the scope of the invention to any shape for the base without otherwise deterring the intended function of supporting battery pack as can be deduced from the description and corresponding drawings. Further, the lower casing (102) includes a pair of longitudinal walls (102b) (as shown in FIG. 4d) and a pair of transverse walls (102c)(as shown in FIG. 4e)which extends transversely from the base (102a). The pair of longitudinal walls (102b) and the pair of transverse walls (102c) are joined at corners to define a battery receiving portion (102d) to receive the battery pack (not shown). In an embodiment, the lower casing (102) is made-up of material selected from a group consisting of steel such as cold rolled sheet, high strength low alloy steel sheets, Aluminium alloys (like 5000 or 6000 series alloys), and polymeric based composite materials (like carbon fiber based, glass fiber based). However, it is also within the scope of the invention to provide any suitable material for lower casing without otherwise deterring the intended function of battery pack enclosure as can be deduced from the description and corresponding drawings. The upper casing (104) includes a ceiling wall (104a), and a pair of longitudinal descending walls (104b) and a pair of transverse descending walls (104c) extending transversely from said ceiling wall (104a) as shown in FIG. 1c.In an embodiment, the upper casing (104) is made-up of material selected from a group consisting of steel such as cold rolled sheet, high strength low alloy steel sheets, Aluminium alloys (like 5000 or 6000 series alloys), and polymeric based composite materials (like carbon fiber based, glass fiber based). However, it is also within the scope of the invention to provide any suitable material for upper casing without otherwise deterring the intended function of battery pack enclosure as can be deduced from the description and corresponding drawings. The lower casing (102) defines a battery receiving portion (102d) which is adapted to receive the battery pack (not shown). Further, the lower casing (102) includes a first peripheral flange (122) extending outwardly from edges of the corresponding pair of longitudinal walls (102b) and the pair of transverse walls (102c). Furthermore, the upper casing (104) includes a second peripheral flange (124) extending outwardly from edges of the pair of longitudinal descending walls (104b) and the pair of lateral descending walls (104c). The first peripheral flange (122) and the second peripheral flange (124) are joined by a fastening means (126). In an embodiment, the fastening means (126) is selected from a group consisting of a bolt, a nut and a removable fastener. The lower casing (102) includes the plurality of corrugations (128) which are defined on an upper surface of the base (102a) to provide reinforcement to the lower casing (102).
[0034] The modular battery enclosure (100) includes at least one longitudinal crush member (106) which is coupled to corresponding longitudinal walls (102b) of the lower casing (102) as shown in FIG. 4a. In an embodiment, the longitudinal crush member (106) is configured to extend along entire length of the battery enclosure (100) along the longitudinal direction. In an embodiment, the longitudinal crush member (106) is coupled to the longitudinal walls (102b) of the lower casing (102) by welding. However, it is also within the scope of the invention to provide any coupling method to assemble the longitudinal crush member (106) to the longitudinal walls (102b) without otherwise deterring the intended function of battery pack enclosure as can be deduced from the description and corresponding drawings. The longitudinal crush member (106) is made-up of predetermined length (not shown) and breadth (not shown). Further, the longitudinal crush member (106) is adapted to deform during collision and thereby prevent transfer of collision energy to the battery pack (not shown) stored inside the lower casing (102). In an embodiment, the longitudinal crush member(106) is at least a hollow member. Further, the longitudinal crush member (106) is made-up of material selected from a group consisting of steel, aluminum, polymer and any other composite material.
[0035] The modular battery enclosure (100) includes the first insert member (114) which is adapted to be received by a first insert member receiving portion (134) defined in each of the first mounting member (110), the longitudinal crush member (106) and the first mounting bracket (118). The first insert members (114) are adapted to absorb impact energy received in the event of side collision. The first insert members (114) are adapted to facilitate deformation of the longitudinal crush member (106) in a proportioned manner. In an embodiment, each of the first insert member (114) is a hollow first insert member. However, it is also within the scope of the invention to provide any type of insert member without otherwise deterring the intended function of battery pack enclosure as can be deduced from the description and corresponding drawings. Further, each of the first insert member (114) is adapted to allow a fastener to secure the battery pack enclosure (100) to the vehicle.
[0036] Further, the battery pack enclosure (100) includes the plurality of second insert members (116) which are adapted to be received by a second insert member receiving portion (132) defined in each of the longitudinal crush member (106). The second insert member (116) is adapted to absorb impact energy received by the enclosure (100) in the event of side collision. The plurality of second insert members (116) are adapted to facilitate deformation of the longitudinal crush member (106) in a proportioned manner. In an embodiment, the second insert member (116) is a hollow second insert member. However, it is also within the scope of the invention to provide any type of insert member without otherwise deterring the intended function of battery pack enclosure as can be deduced from the description and corresponding drawings.
[0037] The modular battery enclosure (100) includes the plurality of reinforcement member (108) which is disposed within the lower casing (102). The plurality of reinforcement member (108) further includes a plurality of longitudinal reinforcement members (108a) and a plurality of first transverse reinforcement members (108b), a second transverse reinforcement members (108c), and a third transverse reinforcement members (108d). In an embodiment, the plurality of longitudinal reinforcement members (108a) and the plurality of transverse reinforcement members (108b-108d) are connected to inner walls of the lower casing (102) corresponding to the pair of longitudinal walls (102b) and the pair of transverse walls (102c). The first transverse-reinforcement member (108c) is connected between the longitudinal reinforcement members (108a). Furthermore, the second cross reinforcement member (108c) is disposed in between corresponding the first cross reinforcement member (108b) and the third cross reinforcement member (108d).Further, the third cross reinforcement member (108d) is connected to the inner walls of corresponding transverse wall (102c) of the lower casing (102) which is provided adjacent to the second mounting member (112).The plurality of reinforcement member (108) is provided in the modular battery enclosure to prevent transmission of impact energy to the battery pack during an accident or side collision. The plurality of reinforcement member (108) is made-up of material selected from steel (such as cold rolled IS513 grade, high strength low alloy steel grade, advanced high strength steels), aluminium alloys (like 5000 or 6000 series alloys), polymeric based composite materials (like carbon fiber based, glass fiber based).However, it is also within the scope of the invention to provide any suitable material for reinforcement member without otherwise deterring the intended function of battery pack enclosure as can be deduced from the description and corresponding drawings.
[0038] The modular battery enclosure (100) includes the plurality of first mounting member (110). The plurality of first mounting member (110) is connected to the longitudinal crush members (106)at predetermined positions. The plurality of first mounting member (110) is provided to connect the battery enclosure (100) to a chassis (not shown) of the eco-friendly vehicle. Further, each of the first mounting member (110) is adapted to define an opening (hereafter referred to as first insert receiving portion (134) in this description) which is configured to receive the first insert member (114) as shown in FIG. 4c.
[0039] Further, the modular battery enclosure (100) includes the plurality of second mounting member (112) which is connected to one of the transverse walls (102c). Further, the plurality of second mounting member (112) are coupled to the transverse walls (102c) at predetermined positions. The plurality of second mounting member (112) is provided to connect the battery enclosure (100) to the chassis (not shown) of the vehicle. Further, each of the second mounting member (112) is adapted to define an opening (hereafter referred to as first insert receiving portion (134) in this description) which is configured to receive the first insert member (114).
[0040] FIG. 3 depicts a bottom view of the lower casing, showing a plurality of first mounting brackets and a plurality of second mounting brackets connected to an underside of the lower casing, according to embodiments as disclosed herein. The modular battery enclosure (100) includes the plurality of first mounting bracket (118) which are connected to underside of the lower casing (102). The plurality of first mounting bracket (118) are located below the corresponding first mounting members (110). In an embodiment, the first mounting bracket (118) is fabricated such that it extends laterally between the first mounting members (110) defined in corresponding longitudinal walls (102b) of the lower casing (102) as shown in FIG. 3. In an embodiment, the first mounting brackets (118) are fabricated separately and assembled to the lower casing (102) by any known method such as welding. In an embodiment, the first mounting brackets (118) are coupled to the lower casing (102) by a joining method selected from a group comprising of resistance spot welding, resistance seam welding, CO2 welding, MIG welding, MAG welding, laser welding, metal to metal adhesive bonding. In another embodiment, the first mounting bracket (118) is manufactured integrally with the lower casing (102). Further, each of the first mounting bracket(118) define an opening (hereafter referred to as first insert receiving portion (134) in this description) which is configured to receive the first insert member (114).
[0041] The modular battery enclosure (100) includes plurality of second mounting bracket (120). The plurality of second mounting bracket (120) are connected to underside of the lower casing (102). The plurality of second mounting bracket (120) are located below the corresponding second mounting members (112).In an embodiment, the second mounting bracket (120) is fabricated such that it extends longitudinally between the second mounting member (112) and the corresponding transverse wall (102c) of the lower casing (102) as shown in FIG. 3. In an embodiment, the second mounting bracket (120) are fabricated separately and assembled to the lower casing (102) by any known method such as welding. In an embodiment, the second mounting brackets (120) are coupled to the lower casing (102) by a joining method selected from a group comprising of resistance spot welding, resistance seam welding, CO2 welding, MIG welding, MAG welding, laser welding, metal to metal adhesive bonding. In another embodiment, the second mounting bracket (120) is manufactured integrally with the lower casing (102). Further, each of the second mounting bracket(118) define an opening (hereafter referred to as first insert receiving portion (134) in this description) which is configured to receive the first insert member (114). The second mounting members (112) along with the second mounting brackets (120) are adapted to restrict a movement of the battery pack enclosure (100) in a forward or rearward direction of the vehicle. In an embodiment, the first mounting brackets (118)and the second mounting brackets (120) are made-up of material selected from a group consisting of high strength steel and CR grade steel cross-section. The first mounting brackets (118) are disposed transverse to the longitudinal crush members (106) and the second mounting brackets (120) are disposed transverse to the first mounting brackets (118), such that the second mounting brackets (120) are parallel to the longitudinal crush members (106).
[0042] Further, the modular battery enclosure (100) is designed to enclose high voltage cables (HV cables) and low voltage cables (LV cables) such that the cables are unaffected during collision i.e. the HV cables and the LV cables are positioned between the longitudinal walls (102b) and are unaffected during collision. Furthermore, the modular battery enclosure (100) is provided with a handling means (130) for moving the battery enclosure (100) from one place to another place. In an embodiment, the lifting means is a hook which is affixed to a predetermined position of the battery enclosure (100). However, it is also within the scope of the invention to provide any type of lifting means for handling the battery enclosure without otherwise deterring the intended function of modular battery pack enclosure as can be deduced from the description and corresponding drawings. In an embodiment, the handling means (130) is at least one of a hook, a bracket, a handle and an eyebolt. The handling means (130)may be connected on each of the longitudinal crush member (106) for moving the battery enclosure (100) from one place to another place.
[0043] In an embodiment, the modular battery enclosure (100) is designed to withstand vibration and mechanical shocks. The plurality of internal reinforcement members (108) which are disposed within the lower casing (102) are fabricated using rigid materials such that they are stiffer and stronger to control random vibration loads. Further, the plurality of reinforcement members (108a, 108b, 108c, 108d) are evenly positioned with respect to the longitudinal crush members (106), the second mounting members(112), the first mounting brackets (118), and the second mounting brackets(120) such that the random vibration loads are evenly divided on to chassis mounting members (i.e. the first mounting member (110), second mounting member(112), the first mounting brackets (118) and the second mounting brackets (120)). A centre of gravity position (CG position) of the modular battery enclosure (100) (having the batteries, electrical and electronic components) is arrived at middle of the battery pack (laterally). When a collision occurs, the impact energy of the collision is evenly distributes to all mounting locations (i.e. six mounting locations) to mitigate mechanical shock as well as random vibrations, thereby facilitating in control of random vibration loads and mechanical shocks.
[0044] FIG. 5 depicts a flowchart indicating a method of providing a modular battery pack enclosure for eco-friendly vehicles, according to an embodiment of the invention as disclosed herein. In an embodiment, a method (500) of providing a modular battery pack enclosure (100) for eco-friendly vehicles is described below. The method includes providing a lower casing (102), said lower casing (102) having a base (102a), and a pair of longitudinal walls (102b) and a pair of transverse walls (102c) extending transversely from said base (102a) and joined at corners (At step 502). Further, the method includes connecting at least one longitudinal crush member (106) onto said corresponding each longitudinal wall (102b) of said lower casing (102) (At step 504). Additionally, the method includes disposing a plurality of reinforcement member (108a-108d) within said lower casing (102) (At step 506). Moreover, the method includes connecting a plurality of first mounting members (110) onto said longitudinal crush members (106)at predetermined positions (At step 508). Also, the method includes connecting a plurality of second mounting members (112) connected to one of said transverse walls (102c)at predetermined positions (At step 510). The plurality of first and second mounting members (110, 112) are adapted to mount the battery pack enclosure (100) to a predetermined portion of said eco-friendly vehicle. Further, the reinforcement members (108a-108d) are rigid reinforcement members which are adapted to prevent transmission of impact energy in a direction towards battery pack and thereby protecting the battery pack in the event of side collision. The longitudinal crush member (106) is adapted to deform to absorb collision energy received by the battery enclosure (100) in an event of side collision.
[0045] The method (500) of providing a modular battery pack enclosure (100) for eco-friendly vehicles further includes, connecting a plurality of first mounting brackets (118) to an underside of said lower casing (102) and said longitudinal crush members (106). Furthermore, the method includes connecting a plurality of second mounting brackets (120) to an underside of said lower casing (102) and said second mounting members (112). Additionally, the method includes inserting first insert members (114) into a first insert member receiving portion (134) defined in each of said first mounting member (110), said longitudinal crush member (106) and said first mounting bracket (118). Also, the method includes inserting second insert members (116) into a second insert member receiving portion (132) defined in each of said longitudinal crush member (106). The plurality of first and second mounting members (110, 112) and said plurality of first and second mounting brackets (118, 120) are adapted to mount the battery pack enclosure (100) to a predetermined portion of said eco-friendly vehicle. The reinforcement members (108a-108d) are rigid reinforcement members which are adapted to prevent transmission of impact energy in a direction towards at least one battery pack stored in said lower casing (102) thereby protecting the battery pack in the event of side collision. The first and second insert members (114, 116) are adapted to absorb collision energy received by said enclosure (100) in the event of side collision.
[0046] The technical advantages of the modular battery enclosure (100) described in the embodiments herein includes higher capacity to withstand loads, High modal stiffness, Uniquely designed and positioned external brackets to meet structural requirements, inexpensive and easy to manufacture, made-up of lightweight materials to reduce overall weight of the vehicle and thereby improving an operating range (or distance to empty) of the vehicle, improved collision protection characteristics and thereby preventing transfer of collision energy into the battery enclosure, and facilitates passive and active cooling.
[0047] The foregoing description of the specific embodiments will 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 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.