Description:FIELD OF THE INVENTION
[001] Present invention generally relates to a mounting assembly, and more particularly relates to a damper member in the mounting assembly for an energy storage unit.

BACKGROUND OF THE INVENTION
[002] The automotive industry, particularly the sector related to two-wheeled vehicles such as motorcycles, has witnessed continuous advancements in technology to improve safety, performance, and overall user experience. One critical component of these vehicles is the battery pack, which powers the electrical systems and ensures the smooth functioning of various electronic components. However, traditional methods of mounting batteries onto vehicle frames have presented a range of technical challenges, necessitating innovative solutions.
[003] Existing battery mounting assembly for vehicles, for example a motorcycle, often involve loose constraints and inadequate dampening of vibrations. In the existing designs, the mounting assembly is placed under a battery tray and fastened. This leads to issues such as, but not limited to, battery instability, higher failure rates due to vibration-induced damage, and reduced overall safety.
[004] In one kind of existing design of the mounting assembly in a battery pack, as there are many critical components inside the battery pack like cells, an interconnect is welded through spot welding process. However, the spot-welded interconnector is not strong enough to withstand vibrations. The vibrations from a road will be directly transferred to a frame of the vehicle and from the frame the vibrations will be transferred to the battery pack. Thus, the vibrations can render the battery pack useless. The mounting assembly of the battery pack must withstand high end frequency vibrations.
[005] As illustrated above, one prevalent technical problem associated with existing battery mounting methods is the inadequate dampening of vibrations. Motorcycles, by their nature, are exposed to a variety of road conditions, leading to vibrations that can adversely affect the stability and integrity of the battery pack. The conventional approach of securing the battery under the tray and fastening it through simple belts or loose constraints often results in vibrations being directly transferred to the battery components. This can lead to increased failure rates and potential damage to internal components, affecting the overall reliability and safety of the battery.
[006] The mechanical stress on battery components due to road-induced vibrations poses a significant safety concern. The potential for short circuits caused by excessive vibrations can lead to critical failures, compromising the safety of the vehicle and its occupants. Existing designs, which may rely on spot welding for interconnections within the battery pack, are vulnerable to the strong vibrations experienced during typical vehicle operation. This increases the risk of short circuits and underscores the need for a more robust and secure mounting solution.
[007] Traditional battery mounting methods may lack serviceability and ease of maintenance. Replacing or servicing the battery pack becomes a cumbersome task, especially if the mounting system is not designed with user-friendly features. Improved serviceability is crucial for minimizing downtime and ensuring that users can easily address issues related to the battery, enhancing the overall ownership experience. The performance of the battery pack is closely tied to its mounting system. Inadequate attachment methods can result in a compromised electrical connection, affecting the overall performance of the vehicle. Moreover, the longevity of the battery is a key consideration. Vibration-induced stress and damage can significantly reduce the operational lifespan of the battery, necessitating frequent replacements and increasing the cost of ownership.
[008] Thus, there is a need to overcome the problems causing from the vibration and a need for a battery mounting assembly that addresses these problems.

SUMMARY OF THE INVENTION
[009] In one aspect, the present invention is directed to a mounting assembly. The mounting assembly comprises a casing configured to accommodate one or more energy storage units. The casing comprises one or more mounting provisions disposed at a periphery of the casing. The mounting assembly comprises one or more damper members disposed at the one or more mounting provisions. The one or more damper members being configured to absorb vibrations during movement of a vehicle and restrain the movement of the one or more energy storage units inside the casing.
[010] In an embodiment, the one or more mounting provisions comprises an eye mount connected to the periphery of the casing.
[011] In a further embodiment, the one or more damper members comprises a sleeve assembly and an elastic member. The elastic member being disposed inside the sleeve assembly.
[012] In a further embodiment, the sleeve assembly being a cylindrical member made of a metallic material. The sleeve assembly comprises a first sleeve member and a second sleeve member concentrically disposed inside the first sleeve member forming a space between the first sleeve member and the second sleeve member.
[013] In a further embodiment, the space in the sleeve assembly being configured to accommodate the elastic member.
[014] In a further embodiment, the sleeve assembly is press fitted into the one or more mounting provisions of the casing. The casing is connected to a frame of the vehicle through the one or more damper members.
[015] In a further embodiment, the casing is constrained from a top portion of the casing.
[016] In a further embodiment, the mounting assembly comprises a third mounting provision at a bottom portion of the casing. The third mounting provision is configured to fasten the bottom portion of the casing to constrain movement of the one or more energy storage units inside the casing.
[017] In a further embodiment, the one or more damper members are disposed at the third mounting provision.
[018] In a further embodiment, the elastic member is made of a rubber material and the sleeve assembly is made of a steel material.
[019] In a further embodiment, the casing comprises two mounting provisions for accommodating two damper members.
[020] In a further embodiment, the casing is directly mounted on the frame of the vehicle.
[021] In a further embodiment, the one or more damper members are made of vibration-dampening materials, comprising elastomeric materials and pneumatic shock absorbers.

BRIEF DESCRIPTION OF THE DRAWINGS
[022] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a perspective view of a mounting assembly for one or more energy storage units, in accordance with an embodiment of the present invention.
Figures 2 – 3 illustrate front and top perspective views of the mounting assembly shown in Figure 1, in accordance with an embodiment of the present invention.
Figure 4 illustrates a perspective view of a damper member of the mounting assembly shown in Figures 1 – 3, in accordance with an embodiment of the present 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] An object of the claimed invention is to develop a battery mounting system that effectively dampens vibrations originating from the road, ensuring that the battery pack remains stable and secure during various operating conditions. The rubber inserts (damping element) sandwiched between steel cylindrical sleeves, to absorb and dissipate vibrations, thus significantly reducing the risk of failure and damage to internal components. Another object of the claimed invention is to enhance the overall safety of the battery pack by isolating it from harmful vibrations, reducing the potential for mechanical stress on components, and mitigating the risk of short circuits caused by excessive vibrations. Another object of the claimed invention is to Increase the operational lifespan of the battery by minimizing vibration-induced damage, contributing to long-term reliability and performance.
[025] Another object of the claimed invention is to provide a comprehensive and reliable solution for attaching the battery pack to the vehicle frame, going beyond traditional methods that may involve simple belts or loose constraints. Another object of the claimed invention is to design the battery mounting system with user-friendly features to facilitate ease of assembly, maintenance, and replacement. Another object of the claimed invention is to develop a battery mounting solution that balances effectiveness with cost considerations, aiming for an efficient and economical design that can be widely adopted in the automotive industry. Thus, the claimed invention aims to revolutionize battery mounting methods in the automotive industry, providing a solution that improves safety, longevity, and overall performance while offering user-friendly features and cost-effective design considerations.
[026] The present invention generally relates to a mounting assembly, and more particularly relates to a damper member in the mounting assembly for an energy storage unit.
[027] Figure 1 illustrates a perspective view of a mounting assembly 100 for one or more energy storage units (not shown), in accordance with an embodiment of the present invention. The term “energy storage unit” as referred in the present disclosure is a “battery pack”, and the term “battery pack” is used interchangeably in place of the term “energy storage unit” and more often with the “battery pack” for brevity. The battery pack typically contains a plurality of battery modules which are being charged by an external electrical source and/or by a regenerative braking system in a vehicle (not shown), and stored energy from the battery modules may be utilized for supplying electrical energy to one or more electric and/or electrical components of the vehicle and/or for suppling electrical energy to a motor (not shown) for driving the vehicle. Thus, the application of the mounting assembly 100 may be found in vehicles, such as, but not limited to, internal combustion engine vehicles, electric vehicles and hybrid vehicles. In some embodiments, the mounting assembly 100 may also find its applications apart from vehicles like any machine driven or operated by the energy of the battery pack. It may be understood that the term “vehicle” as used herein may include, but not limited to, a two-wheeled vehicle (like scooter or bike) or a three-wheeled vehicle or a four or multi wheeled vehicle. In some embodiments, the battery module of the battery pack may include, cells made of, but not limited to, Lithium-ion material. It may be contemplated that the battery cells are not limited to only Lithium-ion, and the cells may be made of any other material and thus, the scope of application of the present invention may not be limited to only battery pack having Lithium-ions.
[028] As shown in Figure 1, the mounting assembly 100 for the energy storage unit comprises a casing 102. The casing 102 is an external structure which is in the form of a housing or an enclosure. In some embodiments, the casing 102 may be made of materials like a metal or a polymer or its combination thereof. In the illustrated embodiments, the casing 102 comprises a plurality of vertical walls (not shown) extending from a base member (not shown) forming the housing or the enclosure. Typically, the casing 102 is in the form of a substantially cuboidal shape and has an open end (not shown) at a top portion “T” (shown in Figure 2). The cuboidal shape of casing 102 as disclosed in the present invention should not be meant to be limiting the scope of the present invention. In an embodiment, the casing 102 is constrained from the top portion “T” of the casing 102. The open end at the top portion “T” of the casing 102 is configured to receive the one or more energy storage units and the plurality of walls along with the base member accommodates the one or more energy storage units.
[029] As shown in Figures 1 – 3, the casing 102 of the mounting assembly 100 comprises one or more mounting provisions 104. In the illustrated embodiments, the one or more mounting provisions 104 are disposed at a periphery “P” (shown in Figures 1 and 2) of the casing 102. That is to say, the one or more mounting provisions 104 are provided at an external side surface of the casing 102. It should be contemplated that the illustrated embodiment of peripheral mounting of the one or more mounting provisions 104 should not be meant to be limiting the scope of the present invention. The one or more mounting provisions 104 may also be provided at any other place on an outer surface (not shown) of the casing 102 which may facilitate mounting of the casing 102 with a frame 12 of the vehicle. In an embodiment, the one or more mounting provisions 104 comprises an eye mount 104A (clearly shown in Figure 2) connected to the periphery “P” of the casing 102. In some embodiments, the one or more mounting provisions 104 or the eye mount 104A may be welded to the periphery “P” of the casing 102. In some other embodiments, the one or more mounting provisions 104 or the eye mount 104A may be connected to the periphery “P” through a fastening member (not shown). Thus, the method of fabrication or joining of the one or more mounting provisions 104 or the eye mount 104A with the casing 102 should not be meant to be limiting the scope of the present invention. In the illustrated Figures 1 – 3, the one or more mounting provisions 104 or the eye mount 104A are provided at corners of the casing 102. However, the location of the one or more mounting provisions 104 or the eye mount 104A may also be other than the corners of the casing 102. The location of the one or more mounting provisions 104 or the eye mount 104A at the corners of the casing 102 may provide a stable or a firm mounting of the casing 102 with the frame 12 of the vehicle. In an embodiment, the casing 102 is connected to the frame 12 (shown in Figure 1) of the vehicle through one or more damper members 106.
[030] In some exemplary embodiment, the frame 12 may include an additional structural member (not shown) extending vertically from a top to a bottom of the vehicle, and the casing 102 may be fastened to the structural member of the frame 12.
[031] In an embodiment as shown in Figure 3, the mounting assembly 100 comprises a third mounting provision 104B at a bottom portion 102A of the casing 102. The third mounting provision 104B is configured to fasten the bottom portion 102A of the casing 102 to constrain movement of the one or more energy storage units inside the casing 102. That is to say, the third mounting provision 104B is fastened to the bottom portion 102A of the casing 102 to constrain the movement of the battery pack in a left-right direction. In an embodiment, the one or more damper members 106 are disposed at the third mounting provision 104B.
[032] Referring again to Figures 1 – 3 in conjunction with Figure 4, the mounting assembly 100 comprises the one or more damper members 106. In the illustrated embodiment, the one or more damper members 106 are disposed at the one or more mounting provisions 104. That is to say, the one or more damper members 106 are disposed inside the one or more mounting provisions 104 of the casing 102. In an embodiment, the one or more damper members 106 are configured to absorb vibrations during movement of the vehicle and restrain the movement of the one or more energy storage units inside the casing 102.
[033] In the illustrated embodiment, the casing 102 comprises two mounting provisions 104 for accommodating two damper members 106. In some other embodiments, the casing 102 may include four mounting provisions, where two mounting provisions can be provided at the top portion “T” of the casing 102 and two mounting provisions can be provided at the bottom portion 102A of the casing 102. Thus, each of the top portion “T” and bottom portion 102A of the casing 102 may include two damper members 106. In an embodiment, the casing 102 is directly mounted on the frame 12 of the vehicle.
[034] As shown in Figure 4, the one or more damper members 106 comprises a sleeve assembly 108 and an elastic member 110. The term “damper member” in the present disclosure is interchangeably used with a term “silent block”. It should be understood that both the terms “damper member” and “silent block” are relating to the same component, and they are one and the same. In an embodiment, the elastic member 110 is disposed inside the sleeve assembly 108. The sleeve assembly 108 is press fitted into the one or more mounting provisions 104 of the casing 102 such that the sleeve assembly 108 is firmly fixed inside the one or more mounting provisions 104. In the illustrated embodiment, the sleeve assembly 108 is a cylindrical member made of a metallic material. It is contemplated that the sleeve assembly 108 may also be made of any other rigid or stiff material apart from the metallic material. Therefore, the metallic material used for the sleeve assembly 108 should not be constructed to be limiting the scope of the present invention.
[035] Referring again to the Figure 4, in an embodiment, the sleeve assembly 108 comprises a first sleeve member 108A and a second sleeve member 108B. The second sleeve member 108B is concentrically disposed inside the first sleeve member 108A and forms a space “G” between the first sleeve member 108A and the second sleeve member 108B. In an embodiment, the space “G” in the sleeve assembly 108 is configured to accommodate the elastic member 110. In an embodiment, the elastic member 110 is made of a rubber material and the sleeve assembly 108 is made of a steel material.
[036] In some embodiments, the sleeve assembly 108 may comprise more than two sleeve members (first and second sleeve members 108A, 108B). In an exemplary embodiment, the sleeve assembly 108 may comprise a third sleeve member (not shown) which is disposed over the first sleeve member 108A. Thus, a gap or space formed between the first sleeve member 108A and the third sleeve member may be inserted with another elastic member similar to the elastic member 110. Thus, the illustrated embodiment of the sleeve assembly 108 having only two sleeve members 108A, 108B and the elastic member 110 between the sleeve members 108A, 108B should not be meant to be limiting the scope of the present invention. The increasing number of concentric sleeve members and the elastic member may be dependent on the overall design, load and vibration dampening requirements of the mounting assembly 100. In some embodiments where there are three sleeve members and two elastic members, size (for example: thickness) of the elastic members may be varied or kept substantially equal. For example, the inner most elastic member may have a thickness more than the outer most elastic member or vice versa. Thus, it is contemplated that the thicknesses of the elastic members may be varied based on the vibration dampening requirements. Similarly, if the sleeve assembly 108 comprises three sleeve members disposed concentrically, the gap between the first sleeve member 108A, the second sleeve member 108 and the third sleeve member may be varied based on the thickness of the elastic members.
[037] In some embodiments, the inner most elastic member may have an elasticity less than the outer most elastic member or vice versa. Thus, it is contemplated that the elasticity of the elastic members may be varied based on the vibration dampening requirements.
[038] In some other embodiment, different kinds of rubber material can be used for the elastic member based on intensity of vibrations. Based on the type of rubber material, calculation of the hardness of rubber and elasticity of rubber can be done for obtaining elastic member for the damper member 106.
[039] In some embodiments where there are three sleeve members and two elastic members, the size (for example: thickness) of the sleeve members may be varied or kept substantially equal. For example, the first sleeve member 108A may have a thickness more than the second sleeve member 108B. Similarly, the third sleeve member may have a thickness other than the thicknesses of the first and second sleeve members 108A, 108B. Thus, it is contemplated that the thicknesses of the sleeve members may be varied based on the vibration dampening requirements. Similarly, all the sleeve members of the sleeve assembly 108 may be made of metallic material or a non-metallic material like a polymer or plastic member. Thus, the thickness of the three sleeve members disposed concentrically and the material may be varied based on the parameters associated with the elastic members and dampening requirements.
[040] In some embodiments, length of the damper members 106 may be designed such that the length of the damper members 106 may substantially match with a length of the mounting provision.
[041] In an embodiment, the silent block 106 is made of other vibration-dampening materials or systems, such as, but not limited to, elastomeric materials and pneumatic shock absorbers. The mounting assembly 100 having the silent block 106 dampens vibrations and provides a secure yet flexible attachment between the battery pack and the frame 12 of the vehicle.
[042] The technical problem being solved by the claimed invention is the inadequacies and drawbacks associated with existing battery mounting methods for vehicles, particularly motorcycles. The conventional methods, such as placing the battery under the tray and fastening it through, often result in loose constraints and insufficient dampening of vibrations. This can lead to various issues, including battery instability, higher failure rates due to vibration-induced damage, and compromised overall safety.
[043] The invention addresses these problems by introducing a "silent block" battery mounting system. This system includes rubber inserts sandwiched between two steel cylindrical sleeves, creating a unique mechanism that dampens vibrations and provides a secure yet flexible attachment between the battery pack and the motorcycle frame. The use of rubber inserts effectively absorbs and dissipates vibrations originating from the road, enhancing battery safety, longevity, and overall performance.
[044] The invention goes beyond traditional attachment methods by incorporating the silent block mechanism, offering a comprehensive solution that combines secure attachment with advanced vibration dampening. This innovation significantly reduces failure rates, enhances battery pack safety, and extends the overall life of the battery. The technical problem of ensuring better battery-pack-to-frame attachment while minimizing the transmission of road-induced vibrations is effectively addressed by the proposed solution. Additionally, the invention aims to reduce mechanical stress on battery components, mitigate potential short circuits caused by excessive vibrations, and improve overall serviceability and ease of assembly.
[045] Advantageously, present invention addresses a challenge of ensuring better battery-pack-to-frame attachment while minimizing transmission of road-induced vibrations. The present invention reduces mechanical stress on battery components. The present invention reduces potential short circuits caused by excessive vibrations. The present invention enhances battery longevity and reduces maintenance requirements. The present invention solves the problem of directly transferring the vibrations from the frame to the battery back since the damper members are provided in the mounting assembly.
[046] The mounting assembly disclosed in the present invention provides technical advantages of serviceability, prevents failure due to short circuit of internal components (cells/busbars with the casing), prevents failure of battery pack, the potential fire accident due to the internal parts for circuiting and sell for circuiting, increases performance, increases handling, increases ease of assembly.
[047] The silent block in the mounting assembly utilizes the elastic member (rubber insert) to absorb and dissipate vibrations originating from the road. The steel cylindrical sleeve members provide a structural integrity and prevent excessive movement. Combined mechanism of the sleeve assembly and the elastic member effectively isolates the battery pack from harmful vibrations, thus enhancing battery safety and longevity. Whenever any shocks or vibrations are observed by the silent block, the shocks or vibrations travel to through the first sleeve member towards the second sleeve member, and then go to the elastic member, which will dampen it before it reaches the components of the battery pack.
[048] The mounting assembly having the silent block offers a balanced combination of simplicity, reliability, and effectiveness in dampening vibrations while securely mounting the battery pack.
[049] The claimed invention introduces a specific and tangible technical solution to a well-defined problem in the field of battery mounting for vehicles. The use of a "silent block" mechanism, consisting of rubber inserts sandwiched between steel cylindrical sleeves, is a concrete and practical approach to address the inadequacies of existing methods. The invention provides a detailed and concrete implementation of the silent block system, including the arrangement of components (rubber inserts and steel sleeves), their specific placement in the battery mounting process, and the functional aspects of vibration dampening. This concrete implementation distinguishes the invention from abstract or theoretical concepts.
[050] The silent block mechanism, as described in the above disclosure, represents a design for battery mounting. The use of rubber inserts for vibration isolation, press-fitted onto the battery casing mount, is a specific and inventive arrangement that departs from conventional methods. The invention is presented within a clear problem-solution framework, addressing specific technical challenges in the prior art. The identified problems, such as vibration-induced failures and safety concerns, are clearly articulated, and the silent block solution is tailored to provide a practical resolution to these challenges.
[051] The invention involves the integration of expertise from material science and mechanical engineering to conceptualize and implement the silent block mechanism. This multidisciplinary approach adds complexity to the invention, making it less likely to be an obvious solution to a person skilled in the art without the specific insights provided. Further, the invention involves non-trivial design choices, such as the use of different types of rubber based on vibration intensity, calculations of rubber hardness and elasticity, and the press-fitting of silent blocks onto the battery casing mount. These design choices contribute to the non-obvious nature of the invention. Thus, the claimed invention is characterized by its specific and practical solution to technical problems, concrete implementation, non-obvious design choices, and the integration of multiple disciplines. These factors collectively contribute to its non-abstract nature and render it non-obvious to a person skilled in the art.
[052] 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 and Characters:
12: Frame of a vehicle
100: Mounting assembly
102: Casing
102A: Bottom portion of casing
104: One or more mounting provisions
104A: Eye mount
104B: Third mounting provision
106: One or more damper members
108: Sleeve assembly
108A: First sleeve member
108B: Second sleeve member
110: Elastic member
P: Periphery the casing
G: Space
T: Top portion of casing
, Claims:WE CLAIM:
1. A mounting assembly (100), the mounting assembly (100) comprising:
a casing (102) configured to accommodate one or more energy storage units, the casing (102) comprising one or more mounting provisions (104) disposed at a periphery (P) of the casing (102); and
one or more damper members (106) disposed at the one or more mounting provisions (104), the one or more damper members (106) being configured to absorb vibrations during movement of a vehicle and restrain the movement of the one or more energy storage units inside the casing (102).

2. The mounting assembly (100) as claimed in claim 1, wherein the one or more mounting provisions (104) comprises an eye mount (104A) connected to the periphery (P) of the casing (102).

3. The mounting assembly (100) as claimed in claim 1, wherein the one or more damper members (106) comprises a sleeve assembly (108) and an elastic member (110), the elastic member (110) being disposed inside the sleeve assembly (108).

4. The mounting assembly (100) as claimed in claim 3, wherein the sleeve assembly (108) being a cylindrical member made of a metallic material, the sleeve assembly (108) comprises a first sleeve member (108A) and a second sleeve member (108B) concentrically disposed inside the first sleeve member (108A) forming a space (G) between the first sleeve member (108A) and the second sleeve member (108B).

5. The mounting assembly (100) as claimed in claim 4, wherein the space (G) in the sleeve assembly (108) being configured to accommodate the elastic member (110).

6. The mounting assembly (100) as claimed in claim 1, the sleeve assembly (108) is press fitted into the one or more mounting provisions (104) of the casing (102), and wherein the casing (102) being connected to a frame (12) of the vehicle through the one or more damper members (106).

7. The mounting assembly (100) as claimed in claim 1, wherein the casing (102) is constrained from a top portion (T) of the casing (102).

8. The mounting assembly (100) as claimed in claim 1 comprising a third mounting provision (104B) at a bottom portion (102A) of the casing (102), the third mounting provision (104B) being configured to fasten the bottom portion (102A) of the casing (102) to constrain movement of the one or more energy storage units inside the casing (102).

9. The mounting assembly (100) as claimed in claim 8, wherein the one or more damper members (106) being disposed at the third mounting provision (104B).

10. The mounting assembly (100) as claimed in claim 3, wherein the elastic member (110) being made of a rubber material and the sleeve assembly (108) being made of a steel material.

11. The mounting assembly (100) as claimed in claim 1, wherein the casing (102) comprises two mounting provisions (104) for accommodating two damper members (106).

12. The mounting assembly (100) as claimed in claim 1, wherein the casing (102) is directly mounted on the frame (12) of the vehicle.

13. The mounting assembly (100) as claimed in claim 1, wherein the one or more damper members (106) are made of vibration-dampening materials, comprising elastomeric materials and pneumatic shock absorbers.

Dated this 22nd day of November 2023
TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

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