Description:FIELD OF THE INVENTION
[001] Present invention generally relates to an energy storage assembly for a vehicle, and more particularly relates to a split energy storage units in the vehicle.

BACKGROUND OF THE INVENTION
[002] In the existing design of Electric Vehicles (EV) motorcycles, there are several challenges related to a battery pack assembly, handling, and servicing. Traditional designs and the prior arts feature a single High-Voltage (HV) battery pack, which encompasses the serviceable components within the battery packs. This poses risks during assembling and maintenance due to its high voltage. Additionally, the arrangement of serviceable components within the battery pack complicates the maintenance procedures and accessibility.
[003] Traditional designs feature a single, high-voltage battery pack, posing safety risks during assembly and maintenance, as the entire system operates at a high voltage (e.g., 400V). Assembling and handling a high-voltage battery pack involve inherent safety concerns, with the risk of electric shock and related injuries. Further, single battery pack configurations face challenges in thermal management, especially with cylindrical cells, as cooling both cell tabs within a single casing becomes problematic. Efficient cooling is crucial for maintaining optimal battery performance and longevity.
[004] Servicing a single HV battery pack is challenging, as accessing serviceable components such as fuses, connectors, and contactors requires opening the entire battery pack. Opening the entire battery pack for maintenance compromises the waterproofing and dustproofing of the system, exposing internal components to environmental contaminants. Further, assembling a high-voltage battery pack is inherently difficult due to safety concerns associated with the elevated voltage (e.g., 400V). The complexity of the assembly process contributes to increased downtime during maintenance.
[005] Thus, a single battery pack design poses challenges related to the center of gravity, making it difficult to maintain balance and stability within the motorcycle frame. This can impact the overall handling and performance of the electric motorcycle.
[006] Thus, there is a need in the art to overcome the aforesaid problems by providing a vehicle having a split energy storage units that addresses these problems.

SUMMARY OF THE INVENTION
[007] In one aspect, the present invention is directed to a vehicle. The vehicle comprises a frame member. The frame member extends in a vehicle front-rear direction. The vehicle further comprises an energy storage assembly connected to the frame member. The energy storage assembly comprises at least a pair of energy storage units. Each energy storage unit of the pair of energy storage units being connected to each other in a series connection. The vehicle further comprises a Power Distribution Unit (PDU). The PDU being connected between the pair of energy storage units and configured to combine voltages of the pair of energy storage units.
[008] In an embodiment, the pair of energy storage units comprise a high voltage energy storage unit.
[009] In a further embodiment, the PDU is connected to the pair of energy storage units through high voltage cables and high voltage connectors.
[010] In a further embodiment, the PDU is disposed below a rider seat of the vehicle.
[011] In a further embodiment, each energy storage unit of the pair of energy storage units is having a high voltage capacity of 200 V.
[012] In a further embodiment, the PDU is configured to distribute power to one or more electrical and/or electronic components of the vehicle. The one or more electrical and/or electronic components comprise a motor controller, a DC-DC converter and a charger.
[013] In a further embodiment, each of the energy storage unit is disposed on either side of the frame member of the vehicle.
[014] In a further embodiment, the vehicle comprises a casing accommodating each of the energy storage unit.
[015] In a further embodiment, each of the energy storage unit comprises a cell tab. The cell tab being configured to contact with the casing through a gap filler allowing an air flow over the casing for transferring heat from the cell tab to the gap filler, thereafter from the gap filler to the casing and from the casing to atmosphere.
[016] In a further embodiment, the PDU is configured to accommodate one or more fuses and one or more contactors.

BRIEF DESCRIPTION OF THE DRAWINGS
[017] 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 schematic block diagram of an energy storage assembly of a vehicle, in accordance with an embodiment of the present invention.
Figure 2 illustrates a schematic block diagram of a Power Distribution Unit (PDU) connected to one or more electrical / electronic components of the vehicle, in accordance with an embodiment of the present invention.
Figure 3 illustrates a perspective view of the energy storage assembly having one or more energy storage units connected to the PDU of the vehicle, in accordance with an embodiment of the present invention.
Figure 4 illustrates a perspective view of the energy storage unit connected to a frame member of the vehicle, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[018] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[019] The claimed invention addresses the technical challenges by splitting the HV battery pack into two halves, each with reduced voltage. This significantly mitigates safety risks during assembly and handling. The introduction of a Power Distribution Unit (PDU) further enhances safety and serviceability by connecting the split battery packs in series, effectively combining their voltages. The PDU, located below the rider seat, not only ensures efficient power distribution but also improves maintenance accessibility, simplifying servicing procedures. This inventive solution addresses key technical issues, offering a safer, more modular, and serviceable design for EV motorcycle battery packs.
[020] An object of the invention is to significantly reduce safety risks associated with high-voltage operations during battery pack assembly and handling by splitting the high-voltage (HV) battery pack into two halves, each with reduced voltage. The invention aims to make the assembly process safer and more manageable, minimizing the risk of electric shock and related injuries. Another object of the claimed invention is to address thermal management challenges by efficiently cooling both cell tabs within the battery pack. The split battery pack design allows for effective cooling of both cell tabs by maintaining a battery casing and utilizing a gap filler, ensuring optimal thermal management and preventing overheating.
[021] Another object of the claimed invention is to improve the accessibility of serviceable components within the battery pack, reducing downtime during maintenance. All serviceable components, including fuses and contactors, are placed inside a dedicated Power Distribution Unit (PDU) box. This PDU box, located below the rider seat, facilitates easy access for maintenance, streamlining servicing procedures. Another object of the claimed invention is to simplify the assembly of the EV motorcycle's battery pack, making it easier and more efficient. The split battery pack design not only reduces the overall weight but also lowers the voltage, making the assembly process safer and more accessible. This contributes to a more streamlined assembly procedure.
[022] Another object of the claimed invention is to address challenges related to the center of gravity, enhancing the overall balance and stability of the EV motorcycle. By splitting the battery pack into two separate units and strategically locating them on either side of the frame, the invention aims to optimize the center of gravity, positively impacting the motorcycle's handling and performance. Another object of the claimed invention is to introduce an innovative approach to power distribution that enhances safety and efficiency. The PDU connects the split battery packs in series, effectively combining their voltages. This not only maintains the original voltage but also ensures efficient power distribution to key components, such as the motor controller, charger, and DC-DC converter. Another object of the claimed invention is to safeguard internal components from environmental contaminants and enhance the overall durability of the battery pack. The invention's design minimizes the need to open the entire battery pack during maintenance, preserving the waterproofing and dustproofing of the system and protecting internal components from external elements.
[023] In view of the above, the claimed invention seeks to address multiple technical challenges in the current design of EV motorcycle battery packs, offering a comprehensive solution that prioritizes safety, serviceability, and performance.
[024] Present invention generally relates to an energy storage assembly 100 for a vehicle 10, and more particularly relates to a split energy storage units 102A, 102B in the vehicle 10.
[025] Figure 1 illustrates a schematic block diagram of an energy storage assembly 100 of the vehicle 10, in accordance with an embodiment of the present invention. In an embodiment, the energy storage assembly 100 comprises at least a pair of energy storage units 102A, 102B and a Power Distribution Unit (PDU) 104. The term “energy storage unit” as referred in the present disclosure is a “battery pack”, and the term “battery pack” is interchangeably used 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 (not shown) which are being charged by an external electrical source and/or by a regenerative braking system in the vehicle 10, and the 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 10 and/or for suppling electrical energy to a motor (not shown) for driving the vehicle 10. Thus, the application of the present invention may be found in vehicles, such as, but not limited to, internal combustion engine vehicles, electric vehicles and hybrid vehicles. In some embodiments, the present invention 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.
[026] Referring again to the Figure 1 in conjunction with Figures 2 and 3, the PDU 104 is connected to the pair of energy storage units 102A, 102B through high voltage cables 106 (shown in Figure 3) and high voltage connectors 108 (shown in Figure 3). In an embodiment, the PDU 104 is connected between the pair of energy storage units 102A, 102B and configured to combine voltages of the pair of energy storage units 102A, 102B. In an exemplary embodiment, the PDU 104 is disposed below a rider seat (not shown) of the vehicle 10. The PDU 104 is configured to distribute power to one or more electrical and/or electronic components of the vehicle 10. In an exemplary embodiment, the one or more electrical and/or electronic components comprise, but not limited to, a motor controller 16, a DC-DC converter 18 and a charger 20 (shown in Figure 2). In some other embodiments, the PDU 104 is configured to accommodate one or more fuses (not shown) and one or more contactors (not shown).
[027] Referring to Figure 3, it illustrates a perspective view of the energy storage assembly 100 having the pair of energy storage units 102A, 102B connected to the PDU 104 of the vehicle 10, in accordance with an embodiment of the present invention. As illustrated, the energy storage assembly 100 comprises two energy storage units 102A, 102B. However, for explanation purpose and brevity, one energy storage unit is being considered. In an embodiment, the energy storage unit 102A is housed in a casing 110. The casing 110 is an external structure which is in the form of a housing or an enclosure. In some embodiments, the casing 110 may be made of materials like a metal or a polymer or its combination thereof. In the illustrated embodiments, the casing 110 comprises a plurality of vertical walls (not shown) extending from a base member (not shown) forming the housing or the enclosure. Typically, the casing 110 is in the form of a substantially cuboidal shape. The cuboidal shape of casing 110 as disclosed in the present invention should not be meant to be limiting the scope of the present invention. In an embodiment, the casing 110 is constrained from a top portion “T” (shown in Figure 4) of the casing 110. In an embodiment, the casing 110 is adapted to accommodate each of the energy storage unit 102A, 102B.
[028] The energy storage assembly 100 comprises the at least a pair of energy storage units 102A, 102B (shown in Figure 1). In an embodiment, the pair of energy storage units 102A, 102B comprise a high voltage energy storage unit. In an exemplary embodiment, each energy storage unit of the pair of energy storage units 102A, 102B is having a high voltage capacity of 200 V. Each energy storage unit 102A, 102B of the pair of energy storage units 102A, 102B is connected to each other in a series connection. In other words, the casings 110 having the energy storage units 102A, 102B are placed side by side and behind the casings 110 there is the PDU 104 and connected through the High Voltage (HV) connectors 108 and the HV cables 106. The series connection of the energy storage units 102A, 102B (two halves of the battery pack) reduces risk of handling HV battery pack while assembling and servicing them.
[029] By splitting the battery pack 102A, 102B and using the PDU 104 to manage voltages, effectively reduces safety risks during the battery pack assembly and handling. Furthermore, positioning of the PDU 104 beneath a rider seat (not shown) of the vehicle 10 enhances maintenance accessibility (easy maintenance access to contactors and fuses), simplifying servicing procedures and reducing downtime.
[030] Further, each of the energy storage unit 102A, 102B comprises a cell tab (not shown). The cell tab is configured to contact with the casing 110 through a gap filler allowing an air flow over the casing 110 for transferring heat from the cell tab to the gap filler, thereafter from the gap filler to the casing 110 and from the casing to atmosphere.
[031] Referring to Figure 4, the vehicle 10 comprises one or more structural component, including, but not limited to, a frame member 12. The frame member 12 may also be referred as a chassis of the vehicle 10 which extends in a vehicle front-rear direction “D1”. The energy storage assembly 100 having the pair of energy storage units 102A, 102B and the PDU 104 are connected to the frame member 12. In the illustrated embodiment, connectivity of one casing 110 of the one energy storage unit 102A is shown. It should be understood that another casing 110 comprising another energy storage unit 102B can be provided at a side opposite to the casing 110 having the energy storage unit 102A. That is to say, each of the energy storage units 102A, 102B is disposed on either side of the frame member 12 of the vehicle 10.
[032] In the present invention, location of the PDU 104 below the rider’s seat and splitting of the battery packs 102A, 102B into two provides a technical advantage of easy to service, since only the rider’s seat will have to be lifted.
[033] In the existing designs, usually, a single battery pack is made for a single vehicle. In the single battery effect, there are challenges related to the battery thermal management because with cylindrical cells it would not be able to cool both the cell tabs within a single container or single battery casing. However, by splitting the battery packs into two, cooling both the cell tabs by keeping a battery casing and filling the gap between the cell tab and battery casing can be achieved. In other words, thermal management is done by keeping both the cell tabs in contact with the battery casing through the gap filler and there is an air flow over this casing. So, whenever cells of the battery modules heat up, heat will be transferred to the gap filler and from the gap filler to the casing and from the casing to air / atmosphere. Airflow exists in an inner side as well as an outer side of the battery pack.
[034] The present invention solves the problems related to serviceability. Whenever something goes wrong inside a single battery pack like fuse or connector or any contactor, there is a need to open the whole battery pack, which affects the waterproof and dust proofing of the battery pack. The battery pack will be exposed to the outside environment and all the cells, and the components inside will also be contaminated.
[035] The present invention further solves the problems related to assembling. Assembling the battery pack is difficult because this is a high voltage system (400 volts), and which is lethal to a human body. By splitting the battery pack, the voltage is also split and therefore, handling and assembling from a safety perspective is improved.
[036] Further, all the serviceable components are placed inside a separate unit which is the PDU. All the fuses and contactors which are serviceable are kept inside this PDU. The PDU is located below the rider seat, so it is easy to service whenever there is a need to service it. That is to say, the rider seat is removed and through a screwdriver a top cover (not shown) of the PDU is removed and all the components are accessible. The PDU is safe because it will be covered with the frame member 12 on both sides of the PDU. So, even in case of any vehicle fall, the PDU 104 will be safe because the impact will be on the frame member 12.
[037] The PDU is configured to distribute power to high voltage systems. All the electrical connections are done via the PDU. The flow from these two battery packs will go to the PDU, then it will be distributed to the motor controller 16, the DC-DC converter 18 and the charger 20.
[038] The battery pack location is at left and right of the frame. If a single battery pack is used, then all the internal components will be challenging to keep it as at centre of gravity in a centre of the battery pack. By splitting, comparatively the centre of gravity is manageable and while handling and assembling the battery pack onto the frame member 12 will also be easy.
[039] Further, the single battery pack would weight about 60 kg. However, by splitting, weight of each battery pack would be about 30 kg, which is easy to handle / lift during any replacement of maintenance.
[040] Advantageously, present invention addresses the problems faced by the prior arts. The present invention ensures that the overall battery pack retains its original voltage while reducing the risk associated with high-voltage handling. The present invention offers significant advantages over the traditional single, high-voltage battery pack design. By splitting the battery pack and connecting it in series using the PDU, the risks associated with high-voltage handling during assembling and maintenance are greatly minimized. Additionally, as the PDU is positioned below the rider seat, such arrangement enhances maintenance accessibility and handling.
[041] Traditional designs have primarily focused on single battery packs with integrated components. However, the present invention provides a novel solution by introducing a novel approach of splitting the battery pack into two separate units and connecting them in series using the dedicated PDU.
[042] In addition to addressing the safety risks during battery pack assembling and maintenance, the present invention also aims to improve the modularity and serviceability of key components within the EV motorcycle.
[043] The split battery pack consists of two separate battery units, each with reduced voltage. These units are connected in series using the PDU, which ensures that the overall voltage matches the original battery pack's voltage. The combination of split battery packs and the dedicated PDU offers a more comprehensive and safer solution for addressing both the assembling and servicing challenges.
[044] Present invention solves the challenges faced for thermal management when a single battery pack is used. Further, by providing a split battery pack, cooling of both cell tabs is easier. Serviceability issues like waterproofing and other challenges faced due to opening of the entire battery pack is reduced due to splitting of the battery pack. Further, by splitting the battery pack, voltage of each battery pack is reduced, and thus it is easy to handle and easy to assemble since the battery pack having 200V is less lethal than the battery pack having 400V. The present invention uses different battery casings for each battery pack and thus increases safety concerns. In addition, as the PDU houses all the components like all fuses and contactors inside the PDU, the safety is further enhanced. Since the PDU is disposed below the riders’ seat, the PDU is easy to service and safe from any external impact in case of accidents.
[045] In prior arts, a single battery pack poses challenges related to centre of gravity. However, since the splitting of battery pack and series connection are provided in the present invention, it overcomes the challenges and associated limitations related to the centre of gravity. Easy to assemble the casings because of reduced weight of each battery pack.
[046] The present invention solves the problems related to serviceability. Whenever something goes wrong inside a single battery pack like fuse or connector or any contactor, there is a need to open the whole battery pack, which affects the waterproof and dust proofing of the battery pack. The battery pack will be exposed to the outside environment and all the cells, and the components inside will also be contaminated. The claimed invention is not abstract because it addresses specific and tangible technical challenges associated with the design and operation of electric vehicle (EV) motorcycle battery packs. It introduces concrete and practical solutions to enhance safety, serviceability, and overall performance, addressing issues such as high-voltage risks, thermal management, assembly complexity, and center of gravity optimization.
[047] The invention introduces specific and tangible elements, including the split battery pack design, the Power Distribution Unit (PDU), and the arrangement of components below the rider seat. These elements have practical applications and contribute to the functionality and safety of the EV motorcycle. The invention directly addresses practical challenges in the existing state of the art, such as the risks associated with high-voltage operations during assembly and maintenance, thermal management issues, and difficulties in servicing and assembling single high-voltage battery packs.
[048] The split battery pack configuration and the use of a dedicated PDU to connect the split packs in series represent an innovative approach not obvious within the current art. This unique configuration enhances safety, serviceability, and overall efficiency. The invention provides specific technical advantages, including reduced high-voltage safety risks, improved thermal management, enhanced serviceability, simplified assembly processes, optimized center of gravity, innovative power distribution, and environmental protection. These advantages are grounded in practical engineering solutions.
[049] The claimed invention involves a departure from traditional single high-voltage battery pack designs. The idea of splitting the battery pack into two halves, reducing voltage, and connecting them in series using a PDU is not an obvious solution within the current art. The combination of these elements to address multiple challenges simultaneously leads to a technological development within the HV battery packs for EV’s. Further, the invention is not a theoretical or conceptual idea but is directly applicable to the field of electric vehicles. It provides a real-world solution to technical challenges faced by EV motorcycles, making it more than an abstract concept. Also, the claimed invention has a tangible impact on the design and functionality of EV motorcycles, offering practical benefits in terms of safety, performance, and ease of maintenance. It goes beyond theoretical concepts and has clear implications for the improvement of real-world electric vehicle systems.
[050] In view of the above, the claimed invention is not abstract because it introduces specific, practical, and non-obvious solutions to technical challenges in the field of EV motorcycle battery pack design, addressing real-world issues and providing concrete advantages.
[051] 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:
10: Vehicle
12: Frame member
16: Motor controller
18: DC-DC converter
20: Charger
100: Energy storage assembly
102A, 102B: Pair of energy storage units
104: Power Distribution Unit (PDU)
106: High voltage cables
108: High voltage connectors
D1: Vehicle front-rear direction
, Claims:1. A vehicle (10) comprising:
a frame member (12), the frame member (12) extending in a vehicle front-rear direction (D1);
an energy storage assembly (100) connected to the frame member (12), the energy storage assembly (100) comprising:
at least a pair of energy storage units (102A, 102B), each energy storage unit (102A, 102B) of the pair of energy storage units (102A, 102B) being connected to each other in a series connection; and
a Power Distribution Unit (PDU) (104), the PDU (104) being connected between the pair of energy storage units (102A, 102B) and configured to combine voltages of the pair of energy storage units (102A, 102B).

2. The vehicle (10) as claimed in claim 1, wherein the pair of energy storage units (102A, 102B) comprise a high voltage energy storage unit.

3. The vehicle (10) as claimed in claim 1, wherein the PDU (104) is connected to the pair of energy storage units (102A, 102B) through high voltage cables (106) and high voltage connectors (108).

4. The vehicle (10) as claimed in claim 1, wherein the PDU (104) is disposed below a rider seat of the vehicle (10).
5. The vehicle (10) as claimed in claim 1, wherein each energy storage unit of the pair of energy storage units (102A, 102B) is having a high voltage capacity of 200 V.

6. The vehicle (10) as claimed in claim 1, wherein the PDU (104) is configured to distribute power to one or more electrical and/or electronic components of the vehicle (10), the one or more electrical and/or electronic components comprise a motor controller (16), a DC-DC converter (18) and a charger (20).

7. The vehicle (10) as claimed in claim 1, wherein each of the energy storage unit (102A, 102B) is disposed on either side of the frame member (12) of the vehicle (10).

8. The vehicle (10) as claimed in claim 1 comprising a casing (110) accommodating each of the energy storage unit (102A, 102B).

9. The vehicle (10) as claimed in claim 8, wherein each of the energy storage unit (102A, 102B) comprises a cell tab, the cell tab being configured to contact with the casing (110) through a gap filler allowing an air flow over the casing (110) for transferring heat from the cell tab to the gap filler, thereafter from the gap filler to the casing (110) and from the casing to atmosphere.

10. The vehicle (10) as claimed in claim 1, wherein the PDU (104) is configured to accommodate one or more fuses and one or more contactors.