Description:FIELD OF THE INVENTION
[001] The present invention relates to a battery box.

BACKGROUND OF THE INVENTION
[002] Conventionally, battery modules are encased inside an aluminium or plastic casing to protect the battery modules from external damage. The conventional battery casing has a plurality of walls. The plurality of walls is attached to each other through one or more fasteners and a sealant disposed between each wall.
[003] However, in the conventional battery casing for battery modules, the plurality of walls increases the overall part count of the battery casing. Further, the sealing surfaces of the battery casing increases due to increase in the number of sealants used to prevent leakage of fluids from the battery modules. Hence, the risk of leakage from one or more surfaces of the battery casing increases.
[004] Further, in some existing systems, a gap is provided between the top cover and the plurality of walls of the battery casing. The gap is provided for assembling a connector housing. The connector housing accommodates a connector which connects the battery modules with the vehicle control unit through wire routing. The connector housing is assembled as a separate part and inadvertently increases the part count and weight of the battery casing. Apart from this, the wire of the connector is routed inside the battery box which should be sealed properly to avoid any fluid leakage. This in turn will also increase the sealing surfaces. Further, the gap in which the connector housing is disposed can be exposed to external environmental conditions such as rain or dirt or dust, which if percolates inside the battery casing can increase the leakage of the fluids from the battery modules. Thus, the battery modules are prone to damage under above conditions.
[005] In some existing systems, the connector can be disposed in the bottom cover of the battery casing. However, such configurations require additional wire routing to route and connect the connector with the battery management system (BMS) of the battery modules. Further, additional wire routings are also required to connect the connector to a vehicle control unit.
[006] Thus, there is a need in the art for a battery box which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[007] In one aspect, the present invention is directed towards a battery box. The battery box comprises a casing. The casing is adapted to receive one or more battery modules. The casing is having an opening and a peripheral edge around the opening which forms a casing rim. The casing rim comprises a first extended portion extending outwardly from the peripheral edge of the casing. The battery box comprises a cover. The cover is adapted to cover the opening of the casing. The cover is having a skirting around a peripheral edge of the cover which forms a cover rim. The cover rim comprises a second extended portion extending outwardly from the peripheral edge of the cover wherein when the cover rim is disposed onto the casing rim. The first extended portion and the second extended portion form a housing for accommodating an electrical component.
[008] In an embodiment of the invention, the second extended portion of the cover is configured with a blind opening for accommodating a top part of the electrical component. The blind opening is facing towards the first extended portion of the casing.
[009] In another embodiment of the invention, the first extended portion of the casing is configured with a through opening for accommodating a portion of a bottom part of the electrical component. The through opening is coinciding with the blind opening of the second extended portion.
[010] In a further embodiment of the invention, the housing is formed by the first extended portion and the second extended portion is oriented horizontally and outwardly with reference to any one of a plurality of walls of the casing.
[011] In a further embodiment of the invention, the electrical component comprises a wiring harness which is configured to provide electrical connection between the one or more battery modules and electrical components of a vehicle.
[012] In an embodiment of the invention, the through opening of the first extended portion is configured to receive the bottom part of the electrical component whereby the bottom part of the electrical component is positioned in an overhang condition from the through opening and the top part of the electrical component is attached to the one or more battery modules.
[013] In another embodiment of the invention, the bottom part of the electrical component is connected to the vehicle via a mounting plate member of the battery box.
[014] In a further embodiment of the invention, the mounting plate member of the battery box is configured to allow passage of the wiring harness from the bottom part of the electrical component towards the base member 110A, thereby enabling electrical connection between the one or more battery modules and the vehicle.
[015] In a further embodiment of the invention, the battery box comprises a gasket. The gasket is disposed between the cover rim and the casing rim for preventing ingress of foreign particles into the battery box.
[016] In a further embodiment of the invention, the cover comprises an outer surface. The outer surface is having a depression projecting towards the opening of the casing of the battery box.
[017] In a further embodiment of the invention, the outer surface of the cover comprises a mounting portion for connecting a handle of the battery box with the cover.
[018] In a further embodiment of the invention, the cover comprises a plurality of slots at the peripheral edge of the cover to receive one or more fasteners.
[019] In a further embodiment of the invention, the casing comprises a plurality of slots at an inside surface of the peripheral edge of the opening of the casing to receive the one or more fasteners disposed through the corresponding plurality of slots of the cover for attaching the cover with the casing.
[020] In a further embodiment of the invention, the casing comprises a base member and the plurality of walls extending from the base member forming a unison casing.
[021] In a further embodiment of the invention, the peripheral edge of the casing rim has a profile which is configured to conform with a profile of peripheral edge of the cover rim.

BRIEF DESCRIPTION OF THE DRAWINGS
[022] Reference will be made to embodiments of the invention, examples of which may be illustrated in the accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a side view of a battery box in accordance with an embodiment of the present invention.
Figure 2 illustrates a perspective view of the battery box, in accordance with an embodiment of the present invention.
Figure 3 illustrates a perspective view of a casing of the battery box, in accordance with an embodiment of the invention.
Figure 4 illustrates a perspective view of a cover of the battery box, in accordance with an embodiment of the invention.
Figure 5 illustrates a top view of the casing of the battery box, in accordance with an embodiment of the invention.
Figure 6 illustrates a top view of the casing of the battery box showing through opening in the casing, in accordance with an embodiment of the invention.
Figure 7 illustrates an exploded view of the battery box, in accordance with an embodiment of the invention.
Figure 8 illustrates another exploded view of the battery box, in accordance with an embodiment of the invention.
Figure 9 illustrates the battery box having an electrical component with a wiring harness, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[023] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[024] Present invention relates to a battery box, more particularly relates to battery box for a vehicle.
[025] Referring to figure 1 and figure 2, the battery box 100 in various views is illustrated, in accordance with an embodiment of the present invention. In one aspect of the present invention, the battery box 100 for a vehicle (not shown), has a casing 104 and a cover 120. The battery box 100 functions as a protective casing for one or more battery modules 140 (shown in figure 8) disposed in the battery box 100. In an embodiment, the cover 120 and casing 104 may be manufactured by a material including, but not limited to, a polymer material or a metallic material or any other material known in the art. In an embodiment, as illustrated in figures 2 and 5, the casing 104 comprises a base member 110A and the plurality of walls 110B, 110C, 110D, 110E extending from the base member 110A forming a unison casing.
[026] As illustrated in figure 3, the casing 104 has an opening 104A. The one or more battery modules 140 is placed into the casing through the opening 104A. The casing 104 also has a peripheral edge 106A around the opening 104A forming a casing rim 106. As illustrated in figure 4, the battery box has the cover 120. The cover 120 is adapted to cover the opening 104A of the casing 104. The cover 120 has a skirting around a peripheral edge 122A of the cover 120 forming a cover rim 122. The cover 120 is disposed onto the casing 104.
[027] As shown in figures 7 and 8, the peripheral edge 106A of the casing rim 106 has a profile which is configured to conform with a profile of peripheral edge 122A of the cover rim 122. In an embodiment, the cover 120 comprises a plurality of slots 156 (shown in figure 4) at the peripheral edge 122A of the cover 120 to receive one or more fasteners. In another embodiment, the casing 104 comprises a plurality of slots 152 (shown in figure 3) at an inside surface 106B of the peripheral edge 106A of the opening 104A of the casing 104 to receive the one or more fasteners disposed through the corresponding plurality of slots 156 of the cover 120 for attaching the cover 120 with the casing 104. In some other embodiments, the cover 120 is mounted onto the casing 104 through a hinge mechanism (not shown). Thus, the mechanism used for attaching the cover 120 with the casing 104 should not be meant to be limiting the scope of the present invention. In another embodiment, as illustrated in figures 7 and 8, the battery box 100 further comprises a gasket 150. The gasket 150 is disposed between the cover rim 122 and the casing rim 106 for preventing ingress of foreign particles into the battery box 100.
[028] Further, the casing rim 106 has a first extended portion 108 extending outwardly from the peripheral edge 106A of the casing 104. The cover rim 122 comprises a second extended portion 124 extending outwardly from the peripheral edge 122A of the cover 120. The cover rim 122 is disposed onto the casing rim 106. The first extended portion 108 and the second extended portion 124 form a housing 132 (shown in figure 2) for accommodating an electrical component 130. In an embodiment, the housing 132 formed by the first extended portion 108 and the second extended portion 124 is oriented horizontally and outwardly with reference to any one of a plurality of walls 110B, 110C, 110D and 110E of the casing 104. However, it should be understood that the shape of the housing 132 would facilitate easy or smooth passage for accommodating the electrical component 130. In some embodiment, the electrical component 130 may include, but not limited to, a printed board circuit (not shown), a Battery Management System (BMS) (not shown) and one or more sensors (not shown). The electrical component 130 has a top part 130A and a bottom part 130B (shown in figure 8).
[029] In an embodiment, the second extended portion 124 of the cover 120 is configured with a blind opening for accommodating the top part 130A of the electrical component 130. In an embodiment, the blind opening faces downwards towards the first extended portion 108 of the casing 104. In another embodiment, the first extended portion 108 of the casing 104 is configured with a through opening 108A (shown in figure 6) for accommodating a portion of the bottom part 130B of the electrical component 130. The through opening 108A is located corresponding to the location of the blind opening of the second extended portion 124. In the illustrated embodiment, the through opening 108A and the blind opening are coinciding.
[030] In an embodiment, the top part 130A of the electrical component 130 is attached to the one or more battery modules 140 placed inside the casing 104 and the bottom part 130B of the electrical component 130 is positioned in an overhang condition from the through opening 108A of the casing 104.
[031] In an embodiment, as shown in figure 9, the battery box 100 includes a mounting plate member 170. The mounting plate member 170 is connected to the vehicle and provides structural support to the battery box 100. In an embodiment, the mounting plate member 170 is connected to a frame structure of the vehicle. In the illustrated embodiment, the bottom part 130B of the electrical component 130 is detachably attached to the mounting plate member 170. In another embodiment, the bottom part 130B of the electrical component 130 is connected to the vehicle through the mounting plate member 170 of the battery box 100. In an embodiment, the electrical component 130 comprises a wiring harness 180 configured to provide electrical connection between the one or more battery modules 140 and other electrical components of the vehicle. The mounting plate member 170 of the battery box 100 is configured to allow passage of the wiring harness 180 from the bottom part 130B of the electrical component 130 towards the base member 110A, thereby enabling electrical connection between the one or more battery modules 140 and the vehicle. In the illustrated embodiment, the mounting plate member 170 includes a through hole (not shown) to allow passage of the wiring harness 180 away from the bottom part 130B of the electrical component 130 towards the base member 110A.
[032] In an embodiment, as shown in figures 7, 8 and 9, the cover 120 comprises an outer surface 126. The outer surface 126 has a depression 128 projecting towards the opening 104A of the casing 104 of the battery box 100. In an embodiment, the outer surface 126 of the cover 120 comprises a mounting portion 154 for connecting a handle 160 of the battery box 100 with the cover 120. In an embodiment, the handle 160 is mounted in the depression 128 of the outer surface 126 to ensure better usage of space and enhance handling and aesthetics.
[033] Advantageously, the battery box as disclosed in the present invention increases performance, durability, aesthetics, manufacturability, ease of assembly, handling, comfort, market attractiveness and safety. The design as disclosed in the present invention can be applied in two-wheeled vehicles, three-wheeled vehicles or any other automotives in the industry.
[034] The battery box as disclosed in the present invention further provides an advantage by providing a single casing in place of multiple walled casing which reduces the overall part count of the battery casing. Further, as the number of part counts are reduced, it ultimately reduces the number of joints requiring use of sealants and prevents leakage of fluids from the battery module. Hence, the risk of leakage from one or more surfaces of the battery casing is reduced significantly. In the present invention, the gasket fits between cover rim and casing rim, ensuring that there is no exposure to external environmental conditions such as rain or dirt or dust. This further reduces the risk of leakage of the fluids of the battery module and protects the battery module from damage. Further, the housing for the electrical component formed integrally on the periphery of the joining area of the casing and the cover of the battery box reduces the part count and weight of the battery box. The present invention also reduces the requirement of additional wire routing to route and connect the connector with the battery management system (BMS) of the battery module.
[035] Furthermore, the present invention ensures a long-term durability of the battery module due to less sealing surfaces and less leakage from the battery. The present invention also improves serviceability of the battery due to lesser number of parts in the battery box. Also, reduction in the number of parts ensures the ease of manufacturability and ease of assembly of the battery box. In the present invention, due to non-interference of connector wirings, it is easy to disconnect the battery box from the vehicle.
[036] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

List of Reference Numerals
100 – Battery Box
104 – Casing
104A – Opening of the casing
106 – Casing rim
106A – Peripheral edge of the casing
106B – Inside surface
108 – First extended portion
108A – Through opening
110A – Base member
110B – Wall
110C – Wall
110D – Wall
110E – Wall
120 – Cover
122 – Cover rim
122A – Peripheral edge of the cover
124 – Second extended portion
126 – Outer surface of cover
128 – Depression
130 – Electrical component
130A – Top part
130B – Bottom part
132 – Housing
140 – Battery modules
150 – Gasket
152 – Slots (at the peripheral edge of the casing)
154 – Mounting portion
156 – Slot (at the peripheral edge of the cover)
160 – Handle
170 – Mounting plate
180 – Wiring harness
, Claims:WE CLAIM:
1. A battery box (100), comprising:
a casing (104), the casing (104) being adapted to receive one or more battery modules (140), the casing (104) having an opening (104A) and a peripheral edge (106A) around the opening (104A) forming a casing rim (106), the casing rim (106) comprising a first extended portion (108) extending outwardly from the peripheral edge (106A) of the casing (104); and
a cover (120), the cover (120) being adapted to cover the opening (104A) of the casing (104), the cover (120) having a skirting around a peripheral edge (122A) of the cover (120) forming a cover rim (122), the cover rim (122) comprising a second extended portion (124) extending outwardly from the peripheral edge (122A) of the cover (120);
wherein when the cover rim (122) being disposed onto the casing rim (106), the first extended portion (108) and the second extended portion (124) form a housing (132) for accommodating an electrical component (130).

2. The battery box (100) as claimed in claim 1, wherein the second extended portion (124) of the cover (120) is configured with a blind opening for accommodating a top part (130A) of the electrical component (130), the blind opening facing towards the first extended portion (108) of the casing (104).

3. The battery box (100) as claimed in claim 1, wherein the first extended portion (108) of the casing (104) being configured with a through opening (108A) for accommodating a portion of a bottom part (130B) of the electrical component (130), the through opening (108A) coinciding with the blind opening of the second extended portion (124).

4. The battery box (100) as claimed in claim 1, wherein the housing (132) formed by the first extended portion (108) and the second extended portion (124) is oriented horizontally and outwardly with reference to any one of a plurality of walls (110B, 110C, 110D and 110E) of the casing (104).

5. The battery box (100) as claimed in claim 1, wherein the electrical component (130) comprises a wiring harness (180) configured to provide electrical connection between the one or more battery modules (140) and electrical components of a vehicle.

6. The battery box (100) as claimed in claim 2 and claim 3, wherein the through opening (108A) of the first extended portion (108) being configured to receive the bottom part (130B) of the electrical component (130), whereby the bottom part (130B) of the electrical component (130) being positioned in an overhang condition from the through opening (108A) and the top part (130A) of the electrical component (130) being attached to the one or more battery modules (140).

7. The battery box (100) as claimed in claim 6, wherein the bottom part (130B) of the electrical component (130) being connected to the vehicle via a mounting plate member (170) of the battery box (100).

8. The battery box (100) as claimed in claim 7, wherein the mounting plate member (170) of the battery box (100) being configured to allow passage for the wiring harness (180) from the bottom part (130B) of the electrical component (130) towards the base member 110A, thereby enabling electrical connection between the one or more battery modules (140) and the vehicle.

9. The battery box (100) as claimed in claim 1 comprising a gasket (150), the gasket (150) being disposed between the cover rim (122) and the casing rim (106) for preventing ingress of foreign particles into the battery box (100).

10. The battery box (100) as claimed in claim 1, wherein the cover (120) comprises an outer surface (126), the outer surface (126) having a depression (128) projecting towards the opening (104A) of the casing (104) of the battery box (100).

11. The battery box (100) as claimed in claim 10, wherein the outer surface (126) of the cover (120) comprises a mounting portion (154) for connecting a handle (160) of the battery box (100) with the cover (120).

12. The battery box (100) as claimed in claim 1, wherein the cover (120) comprises a plurality of slots (156) at the peripheral edge (122A) of the cover (120) to receive one or more fasteners.

13. The battery box (100) as claimed in claim 12, wherein the casing (104) comprises a plurality of slots (152) at an inside surface (106B) of the peripheral edge (106A) of the opening (104A) of the casing (104) to receive the one or more fasteners disposed through the corresponding plurality of slots (156) of the cover (120) for attaching the cover (120) with the casing (104).

14. The battery box (100) as claimed in claim 1, wherein the casing (104) comprises a base member (110A) and the plurality of walls (110B, 110C, 110D, 110E) extending from the base member (110A) forming a unison casing.

15. The battery box (100) as claimed in claim 1, wherein the peripheral edge (106A) of the casing rim (106) has a profile which is configured to conform with a profile of peripheral edge (122A) of the cover rim (122).

Dated this 10 day of July 2023

TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471