DESC:FIELD OF INVENTION
[01] The present invention relates to a connector assembly for a battery and more particularly relates to the connector assembly for a swappable battery used in vehicle, preferably in electric vehicles.

BACKGROUND OF THE INVENTION
[02] With the recent rapidly growing popularity of electric vehicles, the need for battery charging stations is increasing day by day. However, installation of battery charging stations at close distances is not an easy task and requires a lot of infrastructure, safety protocols and investment. Further, charging of battery takes time and it is not practical for the vehicle user to wait for long time in between his journey for charging the batteries. Alternatively, battery swapping kiosk or facility is a good option for substituting battery charging requirement. At such facility, the discharged battery or battery with low power is replaced with a fully charged battery and user can continue his journey without waiting long.
[03] Currently, the electric vehicles employing swappable batteries are fitted with a battery enclosure on the vehicle for receiving and removing the batteries (or single battery). The battery delivers power to the various components of vehicle through a male and female connectors (plug and socket). In a particular scenario, the battery has the male connector to be coupled with the female connector fixed on the battery enclosure of the vehicle or vice versa. The coupling between the female connector and the male connector happens in a single fixed orientation. Hence, achieving the single fixed connection every time during battery swapping is major challenge for EV manufactures.
[04] The swapping of batteries requires frequent coupling and de-coupling of male and female connectors pose multiple challenges. For e.g. the connectors may get damaged and reduced life citing reason of wrong orientation of the battery during insertion and power pins prone to dust or dirt when exposed to external environment during battery swapping. Any damage to the connector, results failure of making proper electrical connections thereby making vehicle immovable. The replacement of connector is time consuming and costly. Further, the threat of water entry in the gap provided between the battery and the battery enclosure, this can degrade to life of battery, components, can damage the various electrical components and may cause safety hazards such as fire.
[05] Mostly, ease of replacement is provided for swappable battery pack, often leads to battery theft concern due to improper locking of battery with the vehicle. Further, undesirable noise and jolting sound are observed when vehicle is driven over a bumpy and rough terrain, this is due to improper mounting of the battery pack in the battery enclosure.
[06] To avoid the above cited challenges, the connector mounted on battery enclosure is provided with a flexible movement in order to accommodate different orientations of the battery without imparting any imbalance force on the connector. In particular methodology, a specialized fasteners in form of bolt, screw, etc. are provided that facilitate in providing gap in the connector in order to smoothly connect the battery with the connector without imparting any imbalance force between the male connector and female connector while battery swapping. However, such fasteners need high precision designing and manufacturing tools, incurring high cost and complexity. Further, in certain arrangements in order to smoothly connect the battery with the connector without imparting any imbalance force, additional components are used to serve the requirement, for e.g. multiple resilient members, steel balls, etc. are added around the connectors.
[07] Another common challenge faced in the subject field is complex design of connectors and high cost involved in manufacturing.
[08] Therefore, there is a need of an improved connector assembly for smoothly connecting the battery without any imbalance force. Further, the connector assembly should address the above cited problems of improper locking, battery theft, water intrusion, misaligned connection in the power pins, undesirable noise, complex design and high manufacturing cost.
[09] Furthermore, there exists a need for battery connector system in the swappable battery arrangement, which obviates the abovementioned drawbacks and provides an easy maintenance, simple and cost effective arrangement. Supplementing to solution offered, the improved arrangement will provide a smooth and hassle-free replacement of battery in the battery enclosure.

OBJECT OF THE INVENTION
[010] An object of the invention is to provide an improved connector assembly for connecting a battery in vehicle ensuring damage-less, hassle-free and easy swapping of battery in the vehicle.
[011] Another object of the invention is to provide a simple and cost-effective arrangement for battery connection.
[012] Still another object of the invention is to eliminate undesirable noise, water intrusion, improper locking and battery theft issue associated with battery swapping.
[013] A further object of the invention is to prevent misaligned connection of the connector assembly with the battery.
[014] Still another object of the invention is to overcome shortcomings of the existing systems explained in background section.

SUMMARY OF THE INVENTION
[015] With these objectives in view, the present invention provides a connector assembly for a battery in a vehicle comprising:
a battery enclosure for receiving at least a battery;
a connector mounted on the battery enclosure for electrically connecting the battery with at least one electrical component of the vehicle; wherein;
the connector is secured on the battery enclosure using at least a plate having a first clearance of predefined distance with respect to the plate for enabling movement of the connector in at least transverse, longitudinal and vertical direction.
[016] According to a preferred embodiment of present invention, the connector is mounted on the battery enclosure using an adaptor wherein; the adaptor is fixed on the battery enclosure using at least a fastener.
[017] The battery enclosure is preferably fixed on the vehicle frame.
[018] The battery enclosure is provided with an opening preferably at it bottom part having a recess configured to mount the adapter. The recess is preferably provided with a flange surface. The adapter is completely accommodated within the recess such that no part of adapter extends beyond the recess. Preferably, a suitable clearance may be provided between the adapter and the recess of battery enclosure for fitment.
[019] The adapter is designed to have second clearance of predefined distance w.r.t. the connector for enabling movement of the connector there between. The movement is preferably enabled in transverse, longitudinal and vertical directions.
[020] According to another embodiment, the adapter may be provided as an integral part of the recess of battery enclosure. The recess of battery enclosure is then provided to have a predefined clearance w.r.t. the connector.
[021] According to a preferred embodiment of present invention, the plate is fixed on the battery enclosure preferably using fasteners such that at least a clearance is provided between the plate and the connector in transverse, longitudinal and vertical direction. Preferably, the plate is abutted on the flange surface of the recess of the battery enclosure. A suitable gap is provided between the flange surface of the plate and the flange surface of the recess for better fitment.
[022] The plate is provided with a metal strip used for resting at least the battery surface.
[023] The battery is mounted in the battery enclosure and engaged with the connector using plurality of connecting means provided on the battery for making electrical connection of the battery with at least one of the electrical component. For example: motor, inverter, MCU, Auxiliary battery etc. The connecting means may be in the form of electrical pins known in the art.
[024] The bottom surface of the battery is designed to have a third clearance w.r.t. the plate in engaged position of the battery with the connector.
[025] According to one of the embodiment, the clearances between at least one of the connector, adaptor, plate, battery are equivalent.
[026] Preferably, the clearances in longitudinal, transverse and vertical directions is in the range of 0.5 to 3 mm.
[027] The battery or the battery enclosure is provided with a locking means preferably a solenoid lock for locking the battery with battery enclosure to prevent any theft of batteries.
[028] According to one of the embodiment, the connector assembly may be suitably provided with a sealing means at the engaging portion to prevent any entry of water, dust etc. in the battery or the electrical component or in the electric connections thereof.
[029] According to another embodiment, the connector is designed to engage the battery in plurality of different orientations. According to one of the embodiment, the battery enclosure is provided with a provision for mounting plurality of batteries simultaneously; wherein the batteries are removable batteries. The battery enclosure, adapter and the plate are made of plastic material.
[030] The plate is provided with battery resting surfaces for resting the batteries and may also be provided with a damping means in the form of rubber pads to prevent any vibrations.
[031] According to another embodiment, the battery enclosure means is provided with guiding means for guiding the batteries in desired orientation while inserting into the battery enclosure.

BRIEF DESCRIPTION OF DRAWINGS
[032] The above and other objects, features, and advantages of the present disclosure will be more apparent from the detailed description taken in conjunction with the accompanying drawings. One or more embodiments of the present invention are now described, by way of example only with reference to the accompanied drawings wherein like reference numerals represent like elements.
[033] Figure 1 illustrates an exploded view of a battery mounting arrangement according to prior art system;
[034] Figure 2 illustrates an exploded view connector assembly, according to an embodiment of the present disclosure;
[035] Figures 3(a) to 3(c) illustrate an adapter and its mounting arrangement, according to an embodiment of the present disclosure;
[036] Figures 4(a) to 4(c) illustrate assembly of the connector with the adapter, according to an embodiment of the present disclosure;
[037] Figures 5(a) to 5(c) illustrate assembly of the connector in the battery enclosure, according to an embodiment of the present disclosure;
[038] Figures 6(a) to 6(b) illustrate plate, according to an embodiment of the present disclosure;
[039] Figures 7(a) to 7(c) illustrate assembly of the battery in the battery enclosure, according to an embodiment of the present disclosure;
[040] Figure 8 illustrate a battery provided with locking means, according to an embodiment of the present disclosure; and
[041] Figure 9 illustrate a plate provided with battery resting surface, according to an embodiment of the present disclosure.

DETAIL DESCRIPTION OF THE INVENTION
[042] The invention along with preferred embodiments will now be described in detail with reference to the accompanying drawings. The preferred embodiment does not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
[043] It will be readily understood that components of the present invention, as generally described and illustrated in figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the invention as represented in the figures is not intended to limit the scope of the invention but is merely representative of certain examples of presently contemplated embodiments in accordance with the invention. The presently described embodiments will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
[044] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in respect as illustrative and not restrictive.
[045] Figure 1 illustrates the battery mounting arrangement according to prior art system, a battery (100) is mounted within a battery enclosure (102). The battery (100) is electrically connected to at least one of the electrical components of a vehicle (not shown) using a connector (105), wherein the connector (105) is mounted fixedly on the battery enclosure (102) using plurality of fasteners. Due to the problems cited in the background section above, the electrical connections means of the connector (105) gets damaged in case the battery (100) is not properly aligned with the connector (105) while insertion. Hence, there is a need to dynamically adjust the position of the connector (105) basis the orientation of the battery (100) while insertion to avoid any damages to the electrical connection means.
[046] In order to achieve the objects of the present invention and to solve the above cited problem; a connector assembly is proposed by the present invention as illustrated in Fig. 2. The connector assembly comprising a battery enclosure (202) for receiving at least a battery (200); a connector (205) mounted on the battery enclosure (202) for electrically connecting the battery (200) with at least one electrical component of the vehicle; wherein; the connector (205) is secured on the battery enclosure (202) using at least a plate (210).

[047] According to a preferred embodiment of present invention, the connector (205) is mounted on the battery enclosure (202) using an adaptor (215) wherein; the adaptor (215) is fixed on the battery enclosure (202) using at least a fastener (208). The battery enclosure (202) is provided with an opening preferably at its bottom part having a recess (220) configured to mount the adapter (215).
[048] Referring to the Figs. 3(a) to 3(c) illustrating, the adapter (215) and its mounting arrangement. The adapter (215) is completely accommodated within the recess (220) such that no part of adapter (215) extends beyond the recess (220). Preferably, a suitable clearances (C) may be provided between the adapter (215) and the recess (220) of battery enclosure for fitment. The recess (220) is preferably provided with the flange surface (220a) used for resting or locating a flange surface (215a) of the adapter (215) within the recess (220) of the battery enclosure (202).
[049] Figs. 4(a) to 4(c) illustrating assembly of the connector (205) with the adapter (215) according to one of the embodiment of present invention. A second clearance (X1, Y1, Z1) is provided between the adapter (215) and the connector (205) for easy movement of the connector (205) within the adapter (215). Fig. 4(a) illustrates the connector (205) mounted on the adapter (215). The Fig. 4(b) illustrates the sectional view of the assembly of Fig. 4(a) along longitudinal axis A-A demonstrating a clearance (X1) of predefined distance between the adapter (215) w.r.t. the connector (205) for enabling movement of the connector (205) there between along longitudinal direction. Further, at least a part of the connector (205) is having a clearance (Z1) of predefined distance with the part of the adapter (215) in vertical direction. The Fig. 4(c) illustrates the sectional view of the assembly of Fig. 4(a) along transverse axis B-B demonstrating a clearance (Y1) of predefined distance between the adapter (215) w.r.t. the connector (205) for enabling movement of the connector (205) along transverse direction. Therefore, the battery recess (220), the adapter (215) and the connector (205) are designed to enable movement of the connector (205) in transverse and longitudinal directions.
[050] According to another embodiment, the adapter (215) may be provided as an integral part of the recess (220) of battery enclosure (202). The recess (220) of battery enclosure (202) is then provided to have a predefined clearance w.r.t. the connector (205) equivalent to the clearance provided by the adapter (215).
[051] The connector (205) is further secured on the battery enclosure (202) using a plate (210) wherein the plate (210) is fixed on the battery enclosure (202) preferably using fasteners as illustrate in Fig. 5(a). The connector (205) and the plate (210) is provided with a first clearance (X2, Y2, Z2) for enabling smooth movement of the connector (205) in the plate (210). Referring to the Figs. 5(b) to 5(c) illustrating the sectional view of assembly of Fig. 5(a) along longitudinal axis A-A and the traverse axis B-B respectively. The plate (210) is having a clearance (X2) of predefined distance with respect to the connector (205) for enabling movement of the connector (205) at least in longitudinal direction. Further, at least a part of the connector (205) is having a clearance (Z2) of predefined distance with the plate (210) in vertical direction. Preferably, the plate (210) is provided with the flange surface (210a) abutted against the flange surface (220a) of the recess (220) of the battery enclosure (202). A suitable gap is provided between the plate (210) and the flange surface (220a) of the recess (220) for better fitment of the plate (210) on the recess (220). Fig. 5(c) illustrating a clearance (Y2) between the connector (205) and the plate (210) along transverse axis B-B. Therefore, the connector (205) and the plate (210) are designed to enable movement of the connector (205) in transverse, longitudinal directions and vertical direction, while securing the connector (205) w.r.t. the battery enclosure (202).
[052] The plate (210) is provided with a metal strip (610) used for resting at least the battery surface as illustrated in Figs. 6(a) to 6(b).
As illustrated in the Figs. 7(a) to 7(c), the battery (200) is mounted in the battery enclosure (202) and engaged with the connector (205) using plurality of connecting means provided on the bottom surface (200a) of the battery (200) for making electrical connection of the battery (200) with at least one of the electrical component. For example: motor, inverter, MCU, Auxiliary battery etc. The connecting means may be in the form of electrical pins known in the art. The Fig. 7(b) and Fig. 7(c) illustrate the sectional view of the battery mounted in the battery enclosure of Fig. 7(a) along longitudinal axis A-A and transverse axis B-B. The bottom surface (200a) of the battery (200) is designed to have third clearances X3 & Y3 in longitudinal and traverse directions respectively w.r.t. the plate (210) in engaged position of battery (200) with the connector (205) as illustrated in the Figures 7(b) and 7(c). Due to these clearances the connector (205) movement is not obstructed by the battery surfaces in engaged position.
[053] According to one of the embodiment, the connector assembly may be suitably provided with a sealing means at the engaging portion to prevent any entry of water, dust, etc. in the battery or the electrical component or in the electric connections.
[054] According to one of the embodiment, the clearances between at least one of the connector (205), adaptor (215), plate (210), and battery (200) are equivalent. Preferably, the clearances in longitudinal, transverse and vertical directions are in the range of 0.5 to 3 mm.
[055] As illustrated in Fig. 8, at least the battery (200) or the battery enclosure (202) is provided with a locking means preferably a solenoid lock for locking the battery (200) with battery enclosure (202) to prevent any theft of batteries. The solenoid lock is engaged against a provision (800) on the battery (200) for locking purpose.
[056] According to one of the embodiment, the battery enclosure (202) is preferably fixed on the vehicle frame. The battery enclosure (202) is provided with a provision for mounting plurality of batteries simultaneously. The batteries are removable batteries wherein; the batteries may be pulled out using a handle (802) and replaced with any new batteries. The battery enclosure (202), adapter (215) and the plate (210) are preferably made of plastic material. The fasting means described herein above may be provided in the form of bolts, screws etc. or through any other suitable joining means.
[057] The plate (210) is provided with battery resting surfaces (910) as illustrated in Fig. 9 for resting the battery and may also be provided with a damping means in the form of rubber pads (not shown) to prevent any vibrations.
[058] According to another embodiment, the battery enclosure means is provided with guiding means for guiding the batteries in desired orientation while inserting into the battery enclosure (202).
[059] According to another embodiment, the connector (205) is designed to engage the battery (200) in plurality of different orientations.
[060] Although the exemplary forms of the present disclosure have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the present disclosure.
,CLAIMS:1. A connector assembly for a battery (200) in a vehicle comprising:
a battery enclosure (202) for receiving at least a battery (200);
a connector (205) mounted on the battery enclosure (202) for electrically connecting the battery (200) with at least one electrical component of the vehicle;
characterized in that the connector (205) is secured on the battery enclosure (202) using at least a plate (210), wherein the connector (205) and the plate (210) is provided with a first clearance (X2, Y2, Z2) for enabling movement of the connector (205) in at least longitudinal, transverse and vertical direction.

2. The connector assembly for the battery (200) as claimed in claim 1, wherein the connector (205) is mounted on the battery enclosure (202) using an adaptor (215).

3. The connector assembly for the battery (200) as claimed in claim 2, wherein the battery enclosure (202) includes a bottom part provided with a recess (220) configured to mount the adapter (215).

4. The connector assembly for the battery (200) as claimed in claim 2, wherein the adaptor (215) is fixed on the battery enclosure (202) using at least a fastener (208).

5. The connector assembly for the battery (200) as claimed in claim 3, wherein the recess (220) is provided with a flange surface (220a).

6. The connector assembly for the battery (200) as claimed in claim 3, wherein the adapter (215) is completely accommodated within dimensions of the recess (220).

7. The connector assembly for the battery (200) as claimed in claim 3, wherein the adapter (215) and the recess (220) of battery enclosure (202) is provided with clearance (C).

8. The connector assembly for the battery (200) as claimed in claim 5, wherein the adapter (215) and the connector (205) is provided with a second clearance for easy movement of the connector (205) within the adapter (215).

9. The connector assembly for the battery (200) as claimed in claim 8, wherein the second clearance (X1, Y1, Z1) is provided for enabling movement in longitudinal, transverse and vertical directions.

10. The connector assembly for the battery (200) as claimed in claim 3, wherein the adapter (215) is provided as an integral part of the recess (220) of battery enclosure (202).

11. The connector assembly for the battery (200) as claimed in claim 10, wherein the recess (220) of battery enclosure (202) and the connector (205) is provided with a clearance.

12. The connector assembly for the battery (200) as claimed in claim 1, wherein the plate (210) is fixed on the battery enclosure (202) using fasteners.

13. The connector assembly for the battery (200) as claimed in claim 5, wherein the plate (210) having a flange surface (210a) is abutted against the flange surface (220a) of the recess (220) of the battery enclosure (202).

14. The connector assembly for the battery (200) as claimed in claim 5, wherein the flange surface (210a) of the plate (210) and the flange surface (220a) of the recess (220) is provided with a gap for better fitment of the plate (210) on the recess (220).

15. The connector assembly for the battery (200) as claimed in claim 1, wherein the plate (210) is provided with a metal strip (610) used for resting at least battery surface (200a).

16. The connector assembly for the battery (200) as claimed in claim 1, wherein the electrical component includes at least a motor, an inverter, an MCU, or an auxiliary battery.

17. The connector assembly for the battery (200) as claimed in claim 15, the bottom surface (200a) of the battery (200) and the plate (210) is provided with a third clearance (X3, Y3) in an engaged position of the battery (200) with the connector (205).

18. The connector assembly for the battery (200) as claimed in any one of the preceding claims, wherein the clearances between at least one of the connector (205), the adaptor (215), the plate (210), the battery (200) are equivalent.

19. The connector assembly for the battery (200) as claimed in claim 18, wherein the clearances in longitudinal, transverse and vertical directions is in the range of 0.5 to 3 mm.

20. The connector assembly for the battery (200) as claimed in claim 1, wherein at least the battery (200) or battery enclosure (202) is provided with a locking means for locking the battery (200) with the battery enclosure (202) to prevent any theft of batteries.

21. The connector assembly for the battery (200) as claimed in claim 20, wherein the locking means is a solenoid lock.

22. The connector assembly for the battery (200) as claimed in claim 1, wherein the connector assembly is provided with a sealing means at the engaging portion to prevent any entry of water, dust in the battery or the electrical component or in the electric connections thereof.

23. The connector assembly for the battery (200) as claimed in claim 1, wherein the connector (205) is designed to engage the battery (200) in plurality of different orientations.

24. The connector assembly for the battery (200) as claimed in claim 23, wherein the battery enclosure (202) is provided with a provision for mounting plurality of batteries.

25. The connector assembly for the battery (200) as claimed in claim 23, wherein the batteries are removable batteries.

26. The connector assembly for the battery (200) as claimed in claim 2, wherein the battery enclosure (202), the adapter (215) and the plate (210) are made of plastic material.

27. The connector assembly for the battery (200) as claimed in claim 1, wherein the plate (210) is provided with battery resting surfaces (910) for resting of the battery (200).

28. The connector assembly for the battery (200) as claimed in claim 27, wherein the battery resting surfaces (910) are provided with damping means in the form of rubber pads to prevent vibrations.

29. The connector assembly for the battery (200) as claimed in claim 1, wherein the battery enclosure (202) is provided with guiding means for guiding the battery in desired orientation while inserting into the battery enclosure (202).

30. The connector assembly for the battery (200) as claimed in claim 1, wherein the battery enclosure (202) is fixed on a vehicle frame.