Description:A BATTERY ASSEMBLY IN A VEHICLE
FIELD OF THE INVENTION
[0001]
The present subject matter is related, in general to a wire routing mechanism from a battery of a vehicle, and more particularly, but not exclusively to an efficient high voltage wire routing mechanism from a battery to a motor of a vehicle. 5
BACKGROUND OF THE INVENTION
[0002]
In recent times, there has been a growing dependence on electrical energy to power a wide range of electronic devices and the emerging electric vehicle (EV) industry. This increasing reliance on electrical energy has highlighted the need for robust high-power electrical energy storage systems, such as batteries, to support 10 these applications. These energy storage systems not only have to deliver high power but also incorporate safety features to manage any potential malfunctions effectively. High-power vehicles demand correspondingly high-power batteries and higher dimension cables to operate at their peak performance. These vehicles are equipped with a motor that draw power from these batteries through a plurality of 15 cables. The batteries themselves consist of a positive terminal and a negative terminals, and the plurality cables connect the positive terminal to the motor's positive terminal and the negative terminals to the motor's negative terminals. The proper routing of this cable network is of paramount importance to ensure safety, prevent damage, and minimize energy loss due to the transfer of charges from the 20 battery to the motor.
[0003]
Various approaches have been proposed in prior art to address the challenge of routing these cables effectively from the battery to the motor. In one common approach found in prior art, the cables are routed alongside the entire length of the battery, covering a considerable distance between the battery and the 25 motor. However, this method presents several issues, including the use of lengthy cables that can lead to transmission losses, increased risk of short circuits, and potential cable damage due to proximity to other vehicle components. Additionally,
3
this routing approach necessitates multiple bends in the cables, which can
compromise their durability and performance. Furthermore, in this configuration, both the positive and negative terminals of the battery are connected to a single internal connector, which poses the risk of a short circuit. This problem becomes even more pronounced in vehicles equipped with more than one high-power 5 battery, as these vehicles require larger-diameter high-power cables that are more susceptible to bending. Furthermore, joining the larger diameter cables at a single internal connector is not feasible as these would need more space in a compact vehicle layout.
[0004]
Further, high-power batteries store a significant amount of energy, and 10 proper grounding is vital to prevent electrical hazards. In high-power electrical systems like those found in electric vehicles, grounding provides a safe path for fault currents to dissipate into the Earth, reducing the risk of electric shock and fire in case of electrical faults or malfunctions. Further grounding helps reduce electromagnetic interference (EMI) and radio frequency interference (RFI). This 15 ensures that sensitive electronic components within the vehicle can operate reliably without interference. Conventionally, the negative terminals of the battery is connected to an auxiliary wire, which is further mounted on the frame for grounding of the vehicle. However, such a mechanism of grounding, requires an additional wire which is again prone to bending and requires additional space. Further, this 20 mechanism of grounding can be feasible in vehicles having single battery, however said mechanism of grounding is not feasible for one or more battery system in the vehicle due to more compact layout of the vehicle.
[0005]
Therefore, there is a need for an improved cable routing mechanism for vehicles with one or more high-power batteries and plurality of high-power cables 25 connecting these batteries to the electric motor to provide an enhanced efficiency, safety, and reliability in managing the power transfer within the vehicle's electrical system.
[0006]
Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of 30
4
described systems with some aspects of the present disclosure, as set forth in the
remainder of the present application and with reference to the drawings.
SUMMARY
[0007]
As per an aspect of the present invention, a vehicle comprises a frame 5 assembly which is extending from front to a rear portion of the vehicle; a battery assembly which is configured to power the vehicle. The battery assembly comprises a first junction assembly, and a second junction assembly. The first junction assembly, and the second junction assembly is mounted to at least a portion of the frame assembly. The vehicle also comprises a first energy storage device and a 10 second energy storage device. A first predefined terminal of the first energy storage device and a second energy storage device is electrically connected to the first junction assembly, and a second predefined terminal of the first energy storage device, and the second energy storage device being electrically connected to the second junction assembly. 15
[0008]
As per an embodiment of the present invention, the frame assembly comprises a left sub frame, and a right sub frame, wherein the left sub frame, and a right sub frame being rearwardly downwardly extending from a head tube of the vehicle, wherein the first junction assembly being mounted to a portion of the left sub frame, and the second junction assembly being mounted to a portion of the right 20 sub frame when viewed from a front view of the vehicle.
[0009]
As per an embodiment of the present invention, the first predefined terminal being positive terminal of the first energy storage device and the second energy storage device, and the second predefined terminal being the negative of the first energy storage device and the second energy storage device. 25
[00010]
As per an embodiment of the present invention, the first junction assembly comprises a first conductive member, a second conductive member, and a first junction cover member, the first conductive member and the second conductive
5
member being an electrically conductive members, and the first junction cover
member being an electrically insulating member.
[00011]
As per an embodiment of the present invention, the first junction cover member comprises a top portion, a bottom portion, a wall portion, and an extending arm, the extending arm extends from the bottom portion, wherein the wall portions 5 join the top portion, and the bottom portion.
[00012]
As per an embodiment of the present invention, the first conductive member comprises a base portion, and an extending portion, the extending portion extends from the base portion, wherein the base portion comprises a plurality of pair of openings for enabling two-point mounting of said first predefined terminal 10 of the first energy storage device and the second energy storage device.
[00013]
As per an embodiment of the present invention, a charging cable being connected to one of the plurality of pair of openings
[00014]
As per an embodiment of the present invention, the bottom portion of the first junction cover member comprises plurality of positive cavities, the plurality of 15 positive cavities being configured to map with the plurality of pair of openings to detachably mount the base portion of the first conductive member to the first junction cover member.
[00015]
As per an embodiment of the present invention, the extending arm of the first junction cover member comprises first portion and a second portion, wherein 20 the profile of the first portion and the profile of the second portion being similar to the profile of the extending portion of the first conductive member and the second conductive member respectively, such that at least a portion of the extending portion and the second conductive member being insulated by the extending arm of the second structure. 25
[00016]
As per an embodiment of the present invention, the top portion of the first junction cover member comprises at least one opening to mount the first junction assembly to the left subframe by one or more mounting means.
6
[00017]
As per an embodiment of the present invention, the edge of the extending portion being downwardly extending to detachably attach the first junction assembly to a relay assembly of the battery assembly.
[00018]
As per an embodiment of the present invention, the second conductive member comprises a top mounting opening, and a bottom mounting opening, 5 wherein the top mounting opening being electrically connected to an ECU of the battery assembly, and the bottom mounting opening being electrically connected to the relay assembly.
[00019]
As per an embodiment of the present invention, the second junction assembly comprises a second junction base member, and a second junction cover 10 member, wherein the second junction base member being electrically connected the second predefined terminal of the first energy storage device, and the second energy storage device.
[00020]
As per an embodiment of the present invention, the second junction base member being an electrically conducting material and the second junction cover 15 member being an electrically insulating member.
[00021]
As per an embodiment of the present invention, the second base member comprises a first step portion, and a second step portion, the first step portion, and the second step portion are connected by a second junction wall portion.
[00022]
As per an embodiment of the present invention, the first step portion is 20 electrically connected to the negative terminals of the first energy storage device, and the second energy storage device through a plurality of pair of openings on the first step portion.
[00023]
As per an embodiment of the present invention, the charging cable being connected to one of the plurality of pair of openings and an ECU cable being 25 connected to the another set of plurality of pair of openings.
[00024]
As per an embodiment of the present invention, the second step portion also comprises a cutout section.
7
[00025]
As per an embodiment of the present invention, the vehicle as claimed in claim 1 wherein, the second step portion comprise one or more mounting opening for mounting the second junction assembly to the RH subframe assembly.
[00026]
As per an embodiment of the present invention, the vehicle as claimed in claim 1 wherein, the second junction base member being detachably connected to 5 the second junction cover member through a plurality of pair of openings in the second junction base members and a plurality of negative cavities in the second junction cover member.
[00027]
As per an embodiment of the present invention, the second junction base member comprises a mounting portion, wherein the mounting portion being 10 mounted to at least a portion of the right subframe by one or mor mounting means.
[00028]
As per an embodiment of the present invention, the at least a portion of the surface of the first conductive member and the second conductive member comprises a plurality of surface cavities.
[00029]
As per an embodiment of the present invention, the at least a portion of the 15 surface of the first conductive member and the second conductive member comprises plurality of surface cutouts.
[00030]
As per an embodiment of the present invention, the first junction cover member and the second junction cover member comprise plurality of ribs on an outer surface. 20
[00031]
As per an embodiment of the present invention, the plurality of cables being routed along at least a portion first energy storage device and the second energy storage device towards a motor being disposed at the at rear portion of the vehicle via the first junction assembly, and the second junction assembly.
BRIEF DESCRIPTION OF THE DRAWINGS 25
[00032]
The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
8
[00033]
Figure 1 and Figure 2 exemplarily illustrate a front view and a side perspective view of a vehicle layout by omitting a few components for clarity.
[00034]
Figure 3 exemplarily illustrates a side view of a vehicle layout by omitting a few components for clarity.
[00035]
Figure 4 exemplarily illustrates a bottom perspective view of a portion of 5 the vehicle layout by omitting a few components for clarity.
[00036]
Figure 5 exemplarily illustrates a side perspective view of a portion of the vehicle layout by omitting a few components for clarity.
[00037]
Figure 6, Figure 7, and Figure 8 exemplarily illustrate a left side perspective view of a portion of the vehicle layout by omitting a few components 10 for clarity.
[00038]
Figure 9 exemplarily illustrates a right-side perspective view of a portion of the vehicle layout by omitting a few components for clarity
[00039]
Figure 10 exemplarily a left-side perspective view of the first junction assembly. 15
[00040]
Figure 11 exemplarily illustrates a right-side perspective view of the first junction assembly.
[00041]
Figure 12 exemplarily illustrates a bottom perspective view of the first junction assembly.
[00042]
Figure 13 exemplarily illustrates a exploded view of the first junction 20 assembly.
[00043]
Figure 14 exemplarily a left-side perspective view of the second junction assembly.
[00044]
Figure 15 exemplarily illustrates a bottom right-side perspective view of the second junction assembly. 25
[00045]
Figure 16 exemplarily illustrates an exploded view of the second junction assembly.
9
DETAILED DESCRIPTION
[00046]
The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are 5 discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable 10 approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[00047]
References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that 15 the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment. 20
[00048]
The present invention now will be described more fully hereinafter with different embodiments. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather those embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the invention to those skilled 25 in the art.
[00049]
The object of the present invention is to provide a battery assembly for a vehicle comprising a first energy storage device and a second energy storage device to power the vehicle. As per an embodiment, the first energy storage device and the
10
second energy storage device are high power batteries supplying electrical power
for functioning of the vehicle. Typically, high power vehicles require high power batteries such as ranging from 30kwh-200kwh, therefore it is crucial to efficiently route these cables to prevent bending, damage while ensuring a compact layout. Therefore, the present invention provides a vehicle comprising the battery assembly 5 comprising: a first junction assembly, and a second junction assembly. As per an embodiment, the first junction assembly, and the second junction assembly are bus bars which are electrically connected to a positive terminal and a negative terminal of each of the energy storage devices respectively.
[00050]
Furthermore, it is also an objective of the present invention to provide 10 optimum grounding of the electrical connection in the vehicle to ensure safety of the vehicle, proper electrical operation, and protection against electrical hazards such as prevention from electrical shock, reduction in electromagnetic interference etc. Therefore, the present invention provides the first junction assembly, and the second junction assembly are mounted to at least a portion of the frame assembly. 15 More specifically, one of the first junction assembly and the second junction assembly which is connected to the negative terminals is conductively connected to the frame assembly, which is further connected to the ground or earth through plurality of wheels of the vehicle. Thus, the present invention ensures proper grounding of the electrical connection while eliminating the need of an auxiliary 20 cable, thereby eliminating the complexity of bending and damage to said cable or hose, while ensuring minimal space.
[00051]
It is yet another objective of the present invention to provide optimum insulation of the first junction assembly and the second junction assembly to prevent interference between other components of the vehicle thereby ensuring 25 electrical safety, reliability for proper functioning of critical components of the vehicle such as sensors, lighting etc, efficient power distribution etc. Thereby the present invention provides that the first junction assembly which is the positive junction assembly comprises a first conductive member, a second conductive members and a first junction cover member. The first conductive member and the 30
11
second conductive member are electrically conductive members such as metals
, while the first junction cover member is an electrically insulating material such as plastic. The first conductive member is connected to the first energy storage device and the second energy storage device while the second conductive member is connected to a electronic control unit (ECU, sometimes referred as controller) and 5 a relay assembly for driving a motor of the vehicle. To prevent contact of said first conductive member and the second conductive member with other electrical components, the first junction cover member covers at least a portion each of the first conductive member and the second conductive member. Thus, the profile of the first junction cover member is mapped with the profile of the first conductive 10 member and the second conductive member. Further, since the positive terminals of the battery are more susceptible to failures due to higher voltage potential as compared to negative terminals, therefore it is extremely important to insulate the first junction assembly i.e., the positive junction assembly from the frame assembly to prevent electrical hazard. Thus, the first junction assembly is mounted to the 15 frame assembly through the first junction cover member.
[00052]
Further, it is an objective of the present invention to provide a stiff contact between the first conductive member and the second conductive member with their respective cover members. Therefore, at least a surface of the first conductive member and the second conductive member comprises a plurality of surface 20 cavities, thus when a first junction cover member made of plastic is poured on said surface the plurality of surface cavities helps in creating mechanical interlocking as the melted plastic flow into said cavities and solidifies. Further, the plurality of surface cavities increases surface area which promotes stronger bond between two materials, and increased stiffness. 25
[00053]
Further, it is an objective of the present invention to provide the safe routing of wires without compromising on overall weight of the assembly, to ensure ease of handleability and manoeuvrability. Therefore, the present invention provides plurality of surface cutouts to reduces weight while also ensuring minimal dimension requirements for effective flow of electrical energy. 30
12
[00054]
The aforesaid and other advantages of the present subject matter would be described in greater detail in conjunction with the figures & embodiment in the following description.
[00055]
Figure 1 and Figure 2 exemplarily illustrate a front view and a side perspective view of a vehicle layout by omitting a few components for clarity. 5 Figure 3 exemplarily illustrates a side view of a vehicle layout by omitting a few components for clarity. Figure 1, Figure 2, and Figure 3 are explained together for sake of brevity. A frame assembly (100) comprises a head tube (102) which is disposed at a front portion of the vehicle, a right upper sub frame (102a), and a left upper sub frame (102b) extending towards a rear portion of the vehicle from the 10 head tube (102). The right upper sub frame (102a), and a left upper sub frame (102b) are substantially rearwardly parallel to each other. The frame assembly (100) also comprises a right subframe (202a) and a left subframe (202b) which extends rearwardly downwards from the head tube (102). As per an embodiment of the present invention, the vehicle is an electric vehicle or a hybrid vehicle comprising 15 high power battery assembly (110). The battery assembly (110) comprises a first energy storage device (104) and a second energy storage device (106) which are supported on a portion of the right subframe (202a) and the left subframe (202b) . The first energy storage device (104) and the second energy storage device (106) are configured to power the electrical requirements of the vehicle. For example, to 20 drive the vehicle the battery assembly (110) is configured to power a motor (not shown) of the vehicle by drawings an electrical energy stored in the first energy storage device (104) and the second energy storage device (106) through plurality of cables (108). The plurality of cables (108) carries high power voltage, that plays a critical role in safely transmitting electrical energy within the vehicle’s electrical 25 system. The plurality of cables (108) extends from the first energy storage device (104) and the second energy storage device (106) through a battery connector (112a, 112b) of each energy storage device (102a, 102b) respectively. The battery connector (112a, 112b) serves as an interface between the energy storage devices (102a, 102b) and the rest of the vehicle’s electrical system. Typically, the motor 30 receives the power from the first energy storage device (104) and the second energy
13
storage device (106
) after conversion of the DC to AC voltage. The electric motor is controlled by an electronic control unit (ECU) (114), that manages the speed and torque generated by the motor. Once the ECU (114) receives an input from a user through an accelerator or other vehicle sensors, the motor receives an input from the ECU, whereby the motor generates torque for movement of the vehicle. 5
[00056]
Figure 4 exemplarily illustrates a bottom perspective view of a portion of the vehicle layout by omitting a few components for clarity. Figure 5 exemplarily illustrates a side perspective view of a portion of the vehicle layout by omitting a few components for clarity. The battery assembly (110) also comprises a first junction assembly (402), and a second junction assembly (404). The first 10 junction assembly (402), and the second junction assembly (404) are mounted to a portion of the frame assembly (100). For example, as per an embodiment, the first junction assembly (402) is mounted to a portion of the left subframe (202b) and the second junction assembly (404) is mounted to a portion of right subframe (202a). The primary function of the first junction assembly (402), and the second junction 15 assembly (404) is to enable proper routing of the plurality of cables (108) and ensure optimum grounding of the battery assembly (110). Each of the first energy storage device (104) and the second energy storage device (106) comprises a negative terminal (not shown) and a positive terminal (not shown). For ease of comprehension, the plurality of cables (108) that originate from respective positive 20 terminal and negative terminal will be referred as positive and negative terminals of the energy storage devices. The first energy storage device (104) comprises a first positive terminal (108ap) and a first negative terminal (108an), similarly, the second energy storage device (106) comprises a second positive terminal (108bp) and a second negative terminal (108bn). The positive terminals (108ap, 108bp) are 25 connected to the first junction assembly (402), while the negative terminal (108an, 108bn) is connected to the second junction assembly (404). Therefore, the first junction assembly (402) can also be referred to as a positive junction assembly, while the second junction assembly (404) can be referred to as negative junction assembly. The substantial distance between the first junction assembly (402) and 30 the second junction assembly (404) restricts the chances of short circuiting.
14
[00057]
Figure 6, Figure 7, and Figure 8 exemplarily illustrate a left side perspective view of a portion of the vehicle layout by omitting a few components for clarity. Figures 6, 7, and 8 are explained together for sake of brevity. The first junction assembly (402) is mounted to a portion of the left subframe (202b) and the second junction assembly (404) is mounted to a portion of right subframe (202a) 5 by a plurality of mounting means (602). The first junction assembly (402) is mounted to the left subframe (202b) in an insulated way by a first junction cover member (702) of the first junction assembly (402). While on the other hand, the second junction assembly (404) is conductively mounted to the right subframe (202a). The first junction assembly (402) comprises a first conductive member 10 (802), a second conductive member (704), and a first junction cover member (702). The first conductive member (802) has an extending portion (706) which is connected to a portion of a relay assembly (804). Further, the second conductive member (704) is connected to the relay assembly (804) and the ECU (114) for establishing a connection between the first junction assembly (402) and the ECU 15 (114) for controlling the motor of the vehicle. The relay assembly (804) acts on an electromagnetic switch which controls the flow of the electricity to the ECU (114). The relay assembly is connected to the first junction assembly (402), because the first junction assembly (402) comprises a positive terminal which requires a controlled flow of electricity to prevent live wires from the positive terminal which 20 can cause electrical hazards. In more detail, a connection between the relay assembly (804) and the second junction assembly (404) is not warranted because electrical charges naturally flow from positive to negative, and since the second junction assembly (404) is already conductively connected to the frame assembly (100) for grounding. If the relay assembly (804) would be connected to the negative 25 junction assembly or the second junction assembly (404), it would fail to serve its purpose of controlling the current in the circuit, because there is already a direct electrical path for the electrical charges to flow between the frame assembly (100) and the second junction assembly (404).
[00058]
Moreover, it is crucial to note that the second junction assembly (404) is 30 connected to the ECU (114) by an ECU cable (806) The ECU cable (806) primarily
15
eliminates the
overhang requirement in the second junction assembly (404) for connecting with the ECU (114) to the second junction assembly (404). On the other hand, due to restricted space between the first junction assembly (402) and the ECU (114), routing of cables could potentially damage and or require more space due to bending requirement of plurality of cables. Thus the first junction assembly (402) 5 comprises the extending portion (706) for compact connection between the ECU (114) and the first junction assembly (402) via the relay assembly (804). The detailed layout description of the first junction assembly (402) and the second junction assembly (404) is described in the following figures and description.
[00059]
Figure 9 exemplarily illustrates a right-side perspective view of a portion 10 of the vehicle layout by omitting a few components for clarity. The first junction assembly (402) is connected to the first positive terminal (108ap), the second positive terminal (108bp), and a charging cable. While the second junction assembly (404) is connected to the first negative terminal (108ap), the second negative terminal (108bp), a charging cable, and the ECU cable (806). 15
[00060]
Figure 10 exemplarily a left-side perspective view of the first junction assembly. Figure 11 exemplarily illustrates a right-side perspective view of the first junction assembly. Figure 12 exemplarily illustrates a bottom perspective view of the first junction assembly. Figure 13 exemplarily illustrates an exploded view of the first junction assembly (402). The first junction assembly (402) primarily 20 comprises the first junction cover member (702), the first conductive member (802), and the second conductive member (704). The first junction cover member (702) is made of an electrically insulated material, for example plastic, while the first conductive member, and the second conductive member (704) are made of electrically conductive material such as metal. The first junction cover member 25 (702) comprises a top portion (702a), a bottom portion (702b), a wall portion (702c), and an extending arm (702d). The extending arm (702d) extends from the bottom portion (702b), and wherein the wall portion (702c) joins the top portion (702a), and the bottom portion (702b). The top portion (702a) of the first junction
16
cover member (702)
enables to join the first junction assembly (402) to the left subframe (202b) through at least one opening (702aa).
[00061]
The first conductive member (802) comprises a base portion (802b), and an extending portion (706), wherein the extending portion (706) extends from the base portion (802b). The positive terminals (108ap, 108bp) from the first energy 5 storage device (104), and the second energy storage device (106) are connected to the base portion (802b) of the first conductive member (802). Thus, the first conductive member (802) acts as a positive bus bar for the battery assembly (110). Moreover, the charging cable of the battery assembly (110) is connected to the base portion (802b). The base portion (802b) enables two-point mounting of each of the 10 positive terminals (108ap, 108bp), and the charging cable through a plurality of pair of openings (802bb) on the base portion (802b). As per an embodiment, the plurality of pair of openings (802bb) comprises three pairs of openings each for the charging cable and two positive terminals (108ap, 108bp) of the first energy storage device (104) and the second energy storage device (106). The bottom portion (702b) of the 15 first junction cover member (702) comprises plurality of positive cavities (702bb) mapping with the plurality of pair of openings (802bb) to detachably mount the base portion (802b) of the first conductive member (802) to the first junction cover member (702). The plurality of positive cavities (702bb) is configured to accommodate the dimension of the one or more mounting means (not labeled) used 20 for mounting the first conductive member (802) to the first junction cover member (702). The two-point mounting of the positive terminals (108ap, 108bp) and the charging cable provide stiff mounting and anti-rotation advantages. An edge (706a) of the extending portion (706) extends downwards to connect the first conductive member (802) with the relay assembly (804). The surface of the first conductive 25 member (802) and the second conductive member (704) comprises a plurality of surface cavities to provide stiff contact with the first junction cover member (702). Therefore, at least a surface of the first conductive member (802) and the second conductive member (704) comprises a plurality of surface cavities (1302), thus when a first junction cover member (702) made of plastic is poured on said surface 30 the plurality of surface cavities (1302) helps in creating mechanical interlocking as
17
the melted plastic flow into said cavities and solidifies. Further, the
plurality of surface cavities (1302) increases surface area which promotes stronger bond between two materials, and increased stiffness.
[00062]
The second conductive member (704) comprises a top mounting opening, and a bottom mounting opening. The top mounting opening (704a) is electrically 5 connected to the ECU (114), and the bottom mounting opening (704b) is electrically connected to the relay assembly. Thus, the electrical charge flows from the base portion (802b) to the ECU (114) via the relay assembly (804) and the bottom mounting opening (704b) for powering the motor. Moreover, the first conductive member (802) and the second conductive member (704) comprise plurality of 10 surface cutouts (1304) which reduce overall weight while also ensuring minimal dimensional requirements is ensured for effective flow of electrical energy. This ensures to provide the safe routing of wires without compromising on overall weight of the assembly and thereby the vehicle, to ensure ease of handleability and manoeuvrability. 15
[00063]
The extending arm (702d) of the first junction cover member (702) comprises first portion (702da) and a second portion (702db), wherein the profile of the first portion (702da) and the profile of the second portion (702db) maps with the profile of the extending portion (706) of the first conductive member (802) and the second conductive member (704) respectively. This ensures that at least a 20 portion of the extending portion (706) and the second conductive member (704) is insulated by the extending arm (702d) of the first junction cover member (702). The insulation of the substantial portion of the first conductive member (802) and the second conductive member (704) is crucial to prevent contact with the other components of the vehicle to prevent short circuiting, electrical shocks, and fires. 25 This is also important to maintain integrity of the electrical system, by preventing disruption in functioning of other electrical components.
[00064]
The first junction cover member (702) comprises plurality of ribs on its outer surface. The plurality of ribs (1202) aims to increase the strength by providing additional support and reinforcement. More elaborately, the first conductive 30
18
member (802)
and the second conductive member (704) are made of metals which are heavy and will apply load on the first junction cover member (702), thus it requires a strong first junction cover member (702) to support them. Thus, the plurality of ribs (1202) on the first junction cover member (702) helps distribute applied loads of the first conductive member (802) and the second conductive 5 member (704) more evenly across the surface of the cover. The plurality of ribs (1202) act as load-bearing members, spreading the load over a larger area. This prevents localized stress concentrations that could lead to deformation or failure. The plurality of ribs (1202) resist bending or flexing, making the first junction cover member (702) more stable under load. This increased stiffness helps maintain the 10 shape and structural integrity of the first junction cover member (702).
[00065]
Figure 14 exemplarily a left-side perspective view of the second junction assembly (404). Figure 15 exemplarily illustrates a bottom right-side perspective view of the second junction assembly (404). Figure 16 exemplarily illustrates an exploded view of the second junction assembly (404). The second junction 15 assembly (404) comprises a second junction base member (404a), and a second junction cover member. The second junction base member (404a) is an electrically conductive member like a metal. The second junction cover member (404b) is an electrically insulating member like plastic. The second junction assembly (404) acts as a negative bus bar which is electrically connected to the negative terminal of 20 each of the energy storage devices respectively (104, 106). It is important to provide optimum grounding of the electrical connection in the vehicle to ensure safety of the vehicle, proper electrical operation, and protection against electrical hazards such as prevention from electrical shock, reduction in electromagnetic interference etc. The second junction base member (404a) comprises a first step portion (404aa), 25 and a second step portion (404ab), the first step portion (404aa), and the second step portion (404ab) are connected by a second junction wall portion (404ac). The first step portion (404aa) is electrically connected with the negative terminals (108an, 108bn) of the first energy storage device (104), and the second energy storage device (106). The second step portion (404ab) comprise one or more mounting 30 opening (404abo) for mounting the second junction assembly (404) to the right
19
subframe.
The right subframe is further connected to the ground or earth through plurality of wheels of the vehicle. Thus, the present invention ensures proper grounding of the electrical connection while eliminating the need of an auxiliary cable, thereby eliminating the complexity of bending and damage to said cable or hose, while ensuring minimal space. The second junction wall portion (404ac) 5 comprises a wall cavity (1602), which aims to reduce the overall weight of the second junction assembly (404). The first step portion (404aa) comprises a plurality of pair of openings (1602) to mount the negative terminals (108an, 108bn) of the first energy storage device (104), and the second energy storage device (106). Moreover, the charging cable is also connected to one of the plurality of pair of 10 openings. Also, the ECU cable (806)is connected to the another set of plurality of pair of openings (1602). The second step portion (404ab) also comprises a cutout section (404abc), which aims to reduce the material cost and weight of the assembly.
[00066]
The second junction cover member (404b) comprises a cover member first 15 step (1606), a cover member second step (1610), a cover member wall portion (1608). The cover member wall portion (1608) connects the cover member first step (1606), a cover member second step (1610). The first step portion (404aa) is mounted to the cover member first step (1606) through the plurality of pair of openings and a plurality of negative cavities (1606a) being on the cover member 20 first step (1606). The cover member second step (1610) comprises a pair of protrusions, wherein plurality of protrusions (1610a) assists in routing of a vehicle cables such as a stand cable.
[00067]
The second junction cover member (404b) comprises plurality of ribs (1202) on its outer surface. The plurality of ribs (1202) aims to increase the strength 25 by providing additional support and reinforcement. More elaborately, the second junction base member (404a) is made of metals which is heavy and will apply load on the second junction cover member (404b) , thus it requires a strong second junction cover member (404b) to support them. Thus, the plurality of ribs (1202) on the second junction cover member (404b) helps distribute applied loads of the 30
20
first conductive member (802)
and the second conductive member (704) more evenly across the surface of the cover. The plurality of ribs (1202) act as load-bearing members, spreading the load over a larger area. This prevents localized stress concentrations that could lead to deformation or failure. The plurality of ribs (1202) resist bending or flexing, making the first junction cover member (702) more 5 stable under load. This increased stiffness helps maintain the shape and structural integrity of the first junction cover member (702).
[00068]
Advantageously, the present invention provides a vehicle comprising the battery assembly (110) comprising: a first junction assembly (402), and a second junction assembly (404). As per an embodiment, the first junction assembly (402), 10 and the second junction assembly (404) are bus bars which are electrically connected to a positive terminal and a negative terminals of each of the energy storage devices respectively. Thus, routing and bending of long wires connected to the terminals of the first energy storage device (104) and the second energy storage device (106) and other vehicle components can be eliminated. 15
[00069]
More specifically, one of the first junction assembly (402) and the second junction assembly (404) which is connected to the negative terminals is conductively connected to the frame assembly (100), which is further connected to the ground or earth through plurality of wheels of the vehicle. Thus, the present invention ensures proper grounding of the electrical connection while eliminating 20 the need of an auxiliary cable, thereby eliminating the complexity of bending and damage to said cable or hose, while ensuring minimal space.
[00070]
The present invention provides that the first junction assembly (402) which is the positive junction assembly comprises a first conductive member, a second conductive member (704) and a first junction cover member (702). The first 25 conductive member (802) and the second conductive member (704) are electrically conductive members such as metals, while the first junction cover member (702) is an electrically insulating material such as plastic. The first conductive member (802) is connected to the first energy storage device, the second energy storage device (106) and the relay assembly (804) while the second conductive member 30
21
(704)
is connected to an electronic control unit (114) and the relay assembly (804) for driving a motor of the vehicle. The relay assembly (804) enable controlled flow of current to the motor. To prevent contact of said first conductive member (802) and the second conductive member (704) with other electrical components, the first junction cover member (702) covers at least a portion each of the first conductive 5 member (802) and the second conductive member. Further, since the positive terminals (108ap, 108bp) of the battery are more susceptible to failures due to higher voltage potential as compared to negative terminals, therefore it is extremely important to insulate the first junction assembly (402) i.e., the positive junction assembly from the frame assembly (100) to prevent electrical hazard. Thus, the first 10 junction assembly (402) is mounted to the frame assembly (100) through the first junction cover member (702).
[00071]
Further, advantageously the present invention provide a stiff contact between the first conductive member (802) and the second conductive member (704), and the second junction base member (404a) with the first junction cover 15 member (702) and the second junction cover member (404b). Therefore, at least a surface of the first conductive member (802) and the second conductive member (704) comprises a plurality of surface cavities, thus when a first junction cover member (702) made of plastic is poured on said surface the plurality of surface cavities (1302) helps in creating mechanical interlocking as the melted plastic flow 20 into said cavities and solidifies. Further, the plurality of surface cavities (1302) increases surface area which promotes stronger bond between two materials, and increased stiffness.
[00072]
Further, advantageously the present invention to provide the safe routing of wires without compromising on overall weight of the assembly, to ensure ease 25 of handleability and manoeuvrability. Therefore, the present invention provides plurality of surface cutouts (1304) to reduces weight while also ensuring minimal dimension requirements for effective flow of electrical energy. Further advantageously, the first junction cover member (702) and the second junction cover member (404b) comprise plurality of ribs (1202) on its outer surface. The 30
22
plurality of ribs (1202
) aims to increase the strength by providing additional support and reinforcement. Further advantageously, the cover member second step (1610) comprises a pair of protrusions, wherein pair of protrusions assists in routing of a cables such as a vehicle stand cable.
[00073]
The use of separate bus bars for positive and negative terminals of two 5 battery packs helps minimize bends in the vehicle's bottom portion. This configuration optimizes the length of the high-voltage wiring harness, reducing overall complexity and potential power losses. The junction point with a busbar assembly allows for individual connections of negative and positive terminals of the two battery packs. By merging these connections into a single output to the 10 motor unit, the invention facilitates efficient and balanced power distribution from dual batteries to the motor. The bus bars, especially the negative bus bar, are securely mounted onto the frame member. The negative bus bar is mounted to the frame through a metal plate, ensuring a secure and grounded connection, contributing to the safety and stability of the EV. The junction assembly design 15 includes specific components such as conductive members, cover members, and insulating features. This design enhances the reliability and durability of the electrical connections, ensuring proper insulation and preventing unintended electrical contacts. The first junction assembly includes openings for enabling two-point mounting of the predefined terminals of the energy storage devices. This 20 flexibility in charging configurations allows for easy adaptation to different charging setups or requirements. The detachable connections between components such as the junction base members and cover members. Detachable connections simplify maintenance, repairs, or component replacements, enhancing the overall serviceability of the EV. The junction cover members include features such as 25 extending arms that insulate conductive members. This ensures that at least a portion of the conductive members is insulated, preventing unintended electrical contact and potential safety hazards. The extending edge of the extending portion of the first junction assembly attaches to a relay assembly of the battery assembly. This secure attachment ensures a reliable electrical connection between the junction 30 assembly and the relay assembly. Thus, the claimed invention's technical
23
advantages lie in its innovative design and configuration, aiming to enhance the
efficiency, safety, and serviceability of electric vehicles with dual battery packs.
[00074]
In light of the above-mentioned advantages and the technical advancements provided by the disclosed method and system, the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the 5 claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the routing of wire assembly from itself as the constructional features provide a technical solution to a technical problem.
[00075]
The technical problem being solved by the described invention is 10 optimization of the high-voltage (HV) wiring harness in electric vehicles (EVs) with dual battery packs. The invention addresses several challenges and aims to provide solutions to the technical challenges. The vehicle, due to its high power requirements, utilizes two batteries. The invention seeks to efficiently manage power distribution from these two batteries to the motor unit. The invention 15 introduces a configuration using separate bus bars for positive and negative terminals of two battery packs. This configuration is intended to minimize bends in the vehicle's bottom portion and optimize the length of the high-voltage wiring harness.
[00076]
The invention discloses a junction point with a busbar assembly, 20 comprising a left busbar (negative) and a right busbar (positive). This assembly individually connects the negative terminals and positive terminals of the two battery packs before merging them into a single output to the motor unit. The aim is to reduce wiring complexity and improve overall efficiency in power distribution. The bus bars, both positive and negative are being securely mounted onto the frame 25 member. The negative bus bar is mounted to the frame through a metal plate, ensuring the entire frame is at a negative charge for secure earthing. The disclosure provides specific details of the junction assembly, including conductive members, cover members, and insulating components. The design of the junction assembly
24
addresses the need for secure and insulated connections between the batteries,
charging point, and motor unit.
[00077]
By addressing these technical challenges, the claimed invention aims to provide an improved and efficient solution for managing power flow in electric vehicles with dual battery packs, optimizing the wiring harness, and ensuring secure 5 and effective connections.
[00078]
Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by 10 any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
[00079]
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various 15 aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
[00080]
A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples 20 and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[00081]
Those skilled in the art will appreciate that any of the aforementioned steps 25 and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application. In addition, the systems of the aforementioned embodiments may be implemented using a wide variety of suitable processes and
25
system modules, and are not limited to any particular computer hardware, software,
middleware, firmware, microcode, and the like. The claims can encompass embodiments for hardware and software, or a combination thereof.
[00082]
While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes 5 may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure is not limited to the particular embodiment disclosed, but that the present disclosure will 10 include all embodiments falling within the scope of the appended claims. , Claims:CLAIMS
I/We claim:
1.
A vehicle comprising:
a frame assembly (100), extending from front to a rear portion of the vehicle; 5
a battery assembly (110), the battery assembly (110) being configured to power the vehicle;
the battery assembly (110) comprises:
a first junction assembly (402), and a second junction assembly (404); 10
the first junction assembly (402), and the second junction assembly (404) being mounted to at least a portion of the frame assembly (100);
a first energy storage device (104) and a second energy storage device (106); 15
wherein a first predefined terminal of the first energy storage device (104) and the second energy storage device (106) being electrically connected to the first junction assembly (402), and
a second predefined terminal of the first energy 20 storage device (104), and the second energy storage device (106) being electrically connected to the second junction assembly (404).
2.
The vehicle as claimed in claim 1 wherein, the battery assembly (110) being configured to power a motor of the vehicle by drawing an electrical energy 25 stored in the first energy storage device (104) and the second energy storage device (106) through plurality of cables (108), wherein the plurality of cables (108) originates from respective first predefined terminal and the second predefined terminal of the the first energy storage device (104) and the second energy storage device (106). 30
27
3.
The vehicle as claimed in claim 1 wherein, the plurality of cables (108) being routed along at least a portion first energy storage device (104) and the second energy storage device (106) towards a motor being disposed at the at rear portion of the vehicle via the first junction assembly (402), and the second junction assembly (404). 5
4.
The vehicle as claimed in claim 1 wherein, the frame assembly (100) comprises a left subframe (202b), and a right subframe (202a), wherein the left subframe (202b), and a right subframe (202a) being rearwardly downwardly extending from a head tube (102) of the vehicle, wherein the first junction assembly (402) being mounted to a portion of the left subframe 10 (202a), and the second junction assembly (404) being mounted to a portion of the right subframe (202b) when viewed from a front view of the vehicle.
5.
The vehicle as claimed in claim 1 wherein, the first predefined terminal being positive terminals (108ap, 108bp) of the first energy storage device 15 (104) and the second energy storage device (106), and the second predefined terminal being the negative terminals (108an, 108bn) of the first energy storage device (104) and the second energy storage device (106) .
6.
The vehicle as claimed in claim 1 wherein, the first junction assembly (402) 20 comprises a first conductive member (802), a second conductive member (704), and a first junction cover member (702), the first conductive member (802) and the second conductive member (704) being an electrically conductive members, and the first junction cover member (702) being an electrically insulating member. 25
7.
The vehicle as claimed in claim 1 wherein, the first junction cover member (702) comprises a top portion (702a), a bottom portion (702b), a wall portion (702c), and an extending arm (702d), the extending arm (702d) extends from the bottom portion (702b), wherein the wall portion (702c) 30 joins the top portion (702a), and the bottom portion (702b).
28
8.
The vehicle as claimed in claim 1 wherein, the first conductive member (802) comprises a base portion (802b), and an extending portion (706) , the extending portion (706) extends from the base portion (802b), wherein the base portion (802b) comprises a plurality of pair of openings (802bb) for 5 enabling two-point mounting of said first predefined terminal of the first energy storage device (104) and the second energy storage device (106) .
9.
The vehicle as claimed in claim 1 wherein, a charging cable being connected to one of the plurality of pair of openings (802bb) 10
10.
The vehicle as claimed in claim 1 wherein, the bottom portion (702b) of the first junction cover member (702) comprises plurality of positive cavities (702bb), the plurality of positive cavities (702bb) being configured to map with the plurality of pair of openings (802bb) to detachably mount the base 15 portion (802b) of the first conductive member (802) to the first junction cover member (702).
11.
The vehicle as claimed in claim 1 wherein, the extending arm (702d) of the first junction cover member (702) comprises first portion (702da) and a 20 second portion (702db), wherein the profile of the first portion (702da) and the profile of the second portion (702db) being similar to the profile of the extending portion (706) of the first conductive member (802) and the second conductive member (704) respectively, such that at least a portion of the extending portion (706) and the second conductive member (704) 25 being insulated by the extending arm (702d).
12.
The vehicle as claimed in claim 1 wherein, the top portion (702a) of the first junction cover member (702) comprises at least one opening (702aa) to mount the first junction assembly (402) to the left subframe (202b) by one 30 or more mounting means (602).
29
13.
The vehicle as claimed in claim 1 wherein, the edge (706a) of the extending portion (706) being downwardly extending to detachably attach the first junction assembly (402) to a relay assembly (804) of the battery assembly (110).
5
14.
The vehicle as claimed in claim 1 wherein, the second conductive member (704) comprises a top mounting opening (704a), and a bottom mounting opening (704b), wherein the top mounting opening (704a) being electrically connected to an ECU (114) of the battery assembly (110), and the bottom mounting opening (704b) being electrically connected to the relay assembly 10 (804).
15.
The vehicle as claimed in claim 1 wherein, the second junction assembly (404) comprises a second junction base member (404a), and a second junction cover member (404b), wherein the second junction base member 15 (404a) being electrically connected the second predefined terminal of the first energy storage device, and the second energy storage device (106) .
16.
The vehicle as claimed in claim 1 wherein, the second junction base member (404a) being an electrically conducting material and the second junction 20 cover member (404b) being an electrically insulating member.
17.
The vehicle as claimed in claim 1 wherein, the second junction base member (404a) comprises a first step portion (404aa), and a second step portion (404ab), the first step portion (404aa), and the second step portion (404ab) 25 are connected by a second junction wall portion (404ac).
18.
The vehicle as claimed in claim 1 wherein, the first step portion (404aa) is electrically connected to the negative terminals (108an, 108bn) of the first energy storage device (104), and the second energy storage device (106) 30 through a plurality of pair of openings (1604) on the first step portion (404aa).
30
19.
The vehicle as claimed in claim 1 wherein, the charging cable being connected to one of the plurality of pair of openings (1604) and an ECU cable (806) being connected to the another set of plurality of pair of openings (1604). 5
20.
The vehicle as claimed in claim 1 wherein, the second step portion (404ab) also comprises a cutout section (404abc).
21.
The vehicle as claimed in claim 1 wherein, the vehicle as claimed in claim 10 1 wherein, the second step portion (404ab) comprise one or more mounting opening (404abo) for mounting the second junction assembly (404) to the right subframe (202a).
22.
The vehicle as claimed in claim 1 wherein, the vehicle as claimed in claim 15 1 wherein, the second junction base member (404a) being detachably connected to the second junction cover member (404b) through a plurality of pair of openings (1604) in the second junction base members and a plurality of negative cavities (1606a) in the second junction cover member (404b) . 20
23.
The vehicle as claimed in claim 1 wherein, the at least a portion of the surface of the first conductive member (802) and the second conductive member (704) comprises a plurality of surface cavities (1302).
25
24.
The vehicle as claimed in claim 1 wherein, the at least a portion of the surface of the first conductive member (802) and the second conductive member (704) comprises plurality of surface cutouts (1304).
25.
The vehicle as claimed in claim 1 wherein, the first junction cover member 30 (702) and the second junction cover member (404b) comprise plurality of ribs (1202) on an outer surface.
31
26.
A battery assembly (110) comprises:
a first junction assembly (402), and a second junction assembly (404);
a first energy storage device (104) and a second energy storage 5 device (106) ;
wherein a first predefined terminal of the first energy storage device (104) and the second energy storage device (106) being electrically connected to the first junction assembly (402), and
a second predefined terminal of the first energy storage 10 device, and the second energy storage device (106) being electrically connected to the second junction assembly (404).
Dated this 6th day of December 2023