Description:FIELD OF THE INVENTION

[0001] The present invention is focused towards a battery mounting assembly for electrically powered vehicles that provides a solution for mounting batteries within vehicle with enhanced stability, thereby minimizing any risk of movement or dislodgement of the batteries due to vibrations encountered while movement of the vehicles.

BACKGROUND OF THE INVENTION

[0002] Securing the battery properly in a vehicle is crucial for several reasons, encompassing safety, performance, and vehicle integrity. Proper mounting ensures that the battery remains in its designated position, helping to contain any potential leaks of corrosive or hazardous materials. When batteries are mounted securely, their electrical connections are less likely to become loose or damaged. This reduces the risk of electric shock or fire caused by exposed or faulty connections. Effective mounting often involves ensuring proper thermal management. In many early automobiles, lead-acid batteries were mounted in the engine compartment. Batteries were typically placed on a metal tray or bracket within the engine bay. Lead-acid batteries are heavy, and their placement in the engine bay affected vehicle's weight distribution, potentially impacting handling and performance.

[0003] Specific battery compartments or enclosures often made from reinforced plastic or metal were designed within the vehicle over which battery was housed. These compartments/ enclosures restricted flow of air, and thereby fails in dissipating the heat from the battery. As vehicles become more advanced, vibration dampening mounts were introduced that utilized advanced rubber, foam, or polymer-based materials to absorb vibrations and shock that could affect the battery. However, vibration dampening mounts degrade over time, requiring regular inspection and replacement, and incorporation of advanced dampening mounts increases initial vehicle production costs.

[0004] US11325453B2 discloses a mounting system is provided for positioning a battery in a vehicle, particularly between frame rails of a vehicle chassis. The system includes a battery housing that may include a base portion on which at least one battery is placed, a cover portion, and a side wall perimeter portion extending between the base portion and cover portion. A plurality of mounting brackets is coupled to the battery housing and configured for removably securing the battery housing to a structural component of the vehicle in a manner that allows for limited movement of the structural component, such as minor twisting of frame rails, without the displacement of the battery housing. Each mounting bracket may include at least one flexible portion that is elastically positioned to conform to a shape of at least a portion of the structural component. Methods for securing the battery housing in a vehicle chassis are also disclosed. Although, US’453 provides a mounting system for securing battery(s) with base portion of a vehicle. However, the above cited system is inefficient in dissipating heat from the battery(s), which leads to higher operating temperatures and accelerates the degradation of battery materials, and gradually reduces the battery’s overall performance and shortening its lifespan.

[0005] US7717207B2 discloses two side members are provided so as to be in side portions of a vehicle. Each side member is provided with a kick-up portion curved upward. A cross member is provided so as to interconnect side surfaces of forward portions of the kick-up portions of the two side members. A forward portion of a battery pack is fixed to an upper surface of the cross member via forward brackets welded to the forward portion of the battery pack. A rearward portion of the battery pack is fixed to upper surfaces of rearward portions of the kick-up portions of the two side members via a bridge provided so as to interconnect the two side members. Though, US’207 is capable of providing a robust support for the battery pack, enhancing vehicle stability and safety. However, the above cited disclosure is incapable of facilitating adequate thermal management features, and suffers from heat dissipation issues, affecting battery’s performance and safety. Additionally, over time, the connections between the battery pack and the cross member or bridge may experience wear, leading to potential issues with securing the battery pack properly.

[0006] Having reference to the above disclosed technologies, i.e., it shall be apparent to a person skilled in the art that the existing systems, devices and embodiments are only focused towards installation of the batteries within the vehicle chassis. The existing technologies possess some major drawbacks due to which the current requirements are not met as they are completely silent on ensuring stability of the batteries and also lack in providing means for proper management of heat dissipation from the batteries while they are in activated/charged conditions.

[0007] Thus, having regard to such limitations/drawbacks, there is a critical need for an assembly that not only provides a solution for mounting of batteries within electrically powered vehicles but also ensures stability along with minimizing the risk of movement or dislodgement of the batteries due to vibrations encountered while movement of the vehicles. In furtherance to above, the developed assembly also needs to focus towards focused towards managing and dissipating heat released from batteries installed within vehicles to maintain optimal battery performance.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop an assembly that provides a solution for mounting batteries within the vehicle with enhanced stability, thereby minimizing any risk of movement or dislodgement of the batteries due to vibrations encountered while movement of the vehicles.

[0010] Another embodiment of the present invention is providing a means for a rigid affixing of the battery within the vehicle in a removable manner for allowing convenient disassembly for maintenance activities.

[0011] Another object of the present invention is to develop an assembly that is focused towards enabling mounting of conventional batteries and as well as batteries provided with heat dissipation equipment without hampering the functioning of heat dissipation equipment.

[0012] Another object of the present invention is to propose a simpler design that can be conveniently installed within different vehicles without affecting the construction of the vehicle.

[0013] Another object of the present invention is to provide an assembly which is reliable in nature and requires minimal maintenance.

[0014] Yet another object of the present invention is to develop an assembly that minimizes the chances of crushing/pressing of delicate parts of batteries while installation within the vehicle chassis.

[0015] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0016] The present invention pertains to battery mounting assembly for electrically powered vehicles that provides a means for securely mounting batteries within a vehicle, ensuring stability and reducing the risk of undesired movement or dislodgement due to vibrations experienced during vehicle operation.

[0017] According to an embodiment of the present invention, a battery mounting assembly is designed to secure a liquid-cooled battery in a rear portion of an electrically powered vehicle, attaching to a pair of long arms on the vehicle's chassis. The assembly includes a mounting frame, which consists of two parallel longitudinal members rigidly connected by a pair of lateral members. Beneath the mounting frame, a series of bent plates are positioned to fit into corresponding slots in the chassis, preventing any displacement of the frame relative to the chassis.

[0018] A removable base is attached to the mounting frame, specifically designed to secure the battery within the frame. The base is equipped with multiple screw arrangements that allow screws to be fastened into holes in the frame, ensuring the base is securely fixed in place.

[0019] According to another embodiment of the instant invention, the mounting assembly adapted to be compatible with batteries having inlet and outlet conduits meant for flow of coolant fluid for heat dissipation of the battery.

[0020] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an exploded view of a battery mounting assembly for electrically powered vehicles;
Figure 2 illustrates an isometric view of a mounting frame associated with the proposed assembly; and
Figure 3 illustrates an isometric view of a base in connection with a battery associated with the assembly.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0023] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0024] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0025] The present invention is envisioned towards a battery mounting assembly for electrically powered vehicles that provides a solution for mounting batteries within a vehicle, ensuring both stability and security while simultaneously managing and dissipating heat to maintain optimal battery performance and safety.

[0026] Various implementations of the prior art for the mounting of batteries in electrically powered vehicles merely hold the battery at a specific location of the vehicle without arresting the movement of the battery along all directions. Typical clamping means that maybe applied for affixing the battery at a specific location hinder the installation and effective functioning of paraphernalia incorporated along with the battery relating to heat dissipation of the battery for maintaining an optimum health of the battery and prolonging the life of the battery.

[0027] The instant invention develops a means for rigidly affixing a battery of an electrically driven vehicle, within the vehicle, in a conveniently-removable manner, while allowing for the integration of equipment relating to heat dissipation of the battery. The heat dissipation equipment includes but is not restricted to a tank for containing a coolant fluid, plurality of conduits for a passage of the coolant and a pump for the circulation of the coolant via the conduits.

[0028] Referring to Figure 1 and 2, an exploded view of a battery mounting assembly for electrically powered vehicles and an isometric view of a mounting frame associated with the proposed assembly are illustrated, respectively, comprising a mounting frame 103 with longitudinal and lateral members (104, 105) rigidly joined with each other, multiple bent plates 106 disposed underneath the mounting frame 103, multiple brackets with slots 107 formed within chassis 102 of a vehicle, a base 108 removably attached onto the mounting frame 103, multiple screw arrangement with screws 109 configured with the base 108 and a set of symmetrically crafted holes 110 engraved on the frame 103.

[0029] The assembly as disclosed herein is focused towards installation of a liquid-cooled battery 101 in the rear portion of an electrically powered vehicle, securely mounting it onto the long arms of the vehicle's chassis 102. This assembly ensures optimal stability and proper alignment of the battery 101 on the long arms, behind the passenger’s cabin. The vehicle as mentioned herein is a three-wheeler electrically powered vehicle. The reason behind mounting of the battery 101 on the long arms is: it provides a robust structural foundation to the vehicle, helping to maintain the vehicle’s overall integrity, thereby making it ideal for bearing weight of the battery 101 when installed. The battery 101 as disclosed herein is an 8.8 Kwh liquid cooled battery 101.

[0030] The long arms of the chassis 102 refer to the elongated load-bearing parts of the chassis of the vehicle, which a specifically located along a length of the vehicle. Typically, the long arms of the chassis are substantially parallel with one another.

[0031] In an alternative implementation of the present invention, the assembly is installed on transversely located arms of the chassis of the vehicle which are the load bearing parts of the chassis disposed perpendicularly with respect to the longitudinally located long arms of the chassis 102.

[0032] The assembly includes a mounting frame 103 consisting of two longitudinal members 104 arranged parallel to each other, which are rigidly connected by a pair of lateral members 105. This configuration provides a sturdy and stable structure, ensuring the frame 103 maintains its shape and integrity under load. The parallel longitudinal members 104 are designed to distribute the weight evenly, while the lateral members 105 enhance the overall rigidity of the frame 103, preventing any flexing or distortion. In an embodiment of the present invention, the lateral members 105 arranged perpendicularly in between the longitudinally members 104 are 410 mm apart from each other. This robust design is essential for securely supporting and stabilizing battery 101 within the vehicle's chassis 102. The mounting frame 103 possesses an overall length of 795 mm and a width of 690 mm.

[0033] The grid arrangement of the longitudinal members 104 and the lateral members 105, in the preferred embodiment of the present invention, provides structural integrity and resistance against mechanical loads including compressive stresses, tensile stresses, torsional stresses and fatigue stresses while optimising the mass of the overall assembly. This ensures a minimal increment in the over mass of the vehicle, thus preventing a significant reduction in the efficiency of the vehicle.

[0034] In another embodiment of the instant invention, more than a pair of longitudinal members 104 and lateral members 105 are provided in a grid formation for enhancing the rigidity of the assembly against higher mechanical loads that may arise from the vehicle traversing over rough terrains.

[0035] The dimensions relating to the assembly mentioned herewith merely depict the dimensions of one of the various possible embodiments of the instant invention, specific to a particular vehicle. In other embodiments of the present invention the dimensions of the assembly are adapted to suit the dimensions of the vehicle. An embodiment of the assembly is configured for mounting of a plurality of batteries on said assembly, thus involves longitudinal members 104 and lateral members 105 having rectilinear and cross-sectional dimensions as per the required mounting area and the mass of the plurality of batteries.

[0036] The longitudinal and lateral members (104, 105) as described above, are constructed using box section tubes that are oriented to form the mounting frame 103. Box section tubes are employed due to their superior structural properties. Firstly, the closed cross-sectional design of the frame 103 provides excellent resistance to bending and torsion, ensuring that the mounting frame 103 remains rigid and stable under various loads and during mounting of the battery 101. Additionally, the box section tubes offer a high strength-to-weight ratio, more particularly, they provide significant structural support without adding excessive weight to the vehicle. The reduced weight improves handling and fuel economy while still providing the necessary durability. The box section tubes as disclosed herein bears a dimension of 20mm X 40mm, respectively.

[0037] The longitudinal members 104 and lateral members 105, of the preferred embodiment of the present invention, are selected to be constructed from box section tubes, i.e., hollow tubes having a square cross-section to achieve an optimized strength to weight ratio. An embodiment of the present invention employs tubes having rectangular cross-section to increase the surface area of the assembly facing the battery.

[0038] In another embodiment of the instant invention, instead of box section tubes, channels having L-shaped cross-section are implemented as required by a chassis 102 in cases where installation of box section tubes are not feasible. Furthermore, in yet another variation of the invention, the channels having C-shaped cross-section are used for forming the longitudinal members 104 and lateral members 105 of the assembly. Depending on the restrictions raised by the specific configuration of the chassis 102, a combination of the tube having box section and channels with L-shaped or/and C-shaped channels is used to construct the assembly.

[0039] Each of the longitudinal members 104 is equipped with a series of bent plates, positioned at equal distances along their length. These bent plates 106 are oriented perpendicularly and extend beneath the longitudinal members 104. The mounting frame 103 is securely attached to the vehicle chassis 102 by engaging these perpendicularly disposed bent plates 106 into corresponding brackets with slots 107 formed within the chassis 102. This precise engagement ensures that the frame 103 remains firmly in place, preventing any displacement relative to the chassis 102, even when the vehicle is in motion. This engagement not only provides a stable and secure attachment, but also ensures that the battery 101 mounted on the frame 103 is held securely, regardless of the forces and other vibrations experienced during vehicle operation. The bent plates 106 as mentioned herein possesses a thickness of 3 mm.

[0040] In one embodiment of the present invention, the bent plates 106 are provided with a flat elongated rectangular structure configured to insert into brackets with slots 107 the chassis, the brackets with slots 107 having a cross-sectional shape similar to the cross-sectional shape of the bent plates 106 to enable a substantially snug fit of the bent plates 106 in the brackets with slots 107 in order to prevent a dislocation of the assembly and the battery in the plane of the assembly.

[0041] In another variation of the instant invention, additional bent plates 106 are also provided attached with the lateral members 105 for engaging with available brackets with slots in the chassis 102, immediately below the lateral members 105. In one more embodiment of the present invention, the bent plates are provided with latches/locks to firmly lock the frame and prevent the undesired movement of the battery.

[0042] In another embodiment of the present invention cylindrical projections are attached with the assembly, instead of bent plates 106, for sliding into annular brackets with slots formed in the chassis for arrest a translation of the assembly during an operation of the vehicle.

[0043] In a preferred embodiment of the present invention, the bent plates 106 are an integral part of the assembly to ensure rigidity of the strength of the joints between the bent plates 106 and the assembly. In an embodiment of the present invention, the bent plates 106 are attached with the longitudinal members 104 by means of welding.

[0044] In another embodiment of the present invention, the bent plates 106 are disposed on the longitudinal members 104 in a removable manner by means of a fastening means such as screws and nuts integrated in the longitudinal members 104. Such an implementation allows for a convenient maintenance or replacement of damaged bent plates 106.

[0045] After successfully installing the mounting frame 103 onto the vehicle's chassis 102, the next step involves mounting of the battery 101 onto this frame 103. To facilitate this, a removable base 108 is utilized to securely attach to the mounting frame 103, providing a stable platform for the battery 101 to be mounted on the frame 103. The base 108 is configured with multiple screw arrangements that align with pre-drilled holes 110 on the mounting frame 103. These screws 109 are then fastened with the holes 110, ensuring the base 108 is firmly anchored to the frame 103. This secure attachment not only keeps the battery 101 in place but also enhances its safety and stability during vehicle operation, minimizing any risk of movement or dislodgement due to vibrations. The design allows for easy removal and reinstallation of the base 108 when necessary, ensuring both ease of maintenance and a strong, reliable connection between the battery 101 and the mounting frame 103. The screws 109 as disclosed herein are M16 type having a pitch of 1.25 mm to the battery 101 mount. (as illustrated in figure 3)

[0046] The screws 109 with a thread size of 16 millimetres and having a thread pitch of 2 millimetres, provides excellent load-bearing capacity, making it ideal for heavy-duty applications where strength and reliability are crucial. Its substantial size ensures that it securely fastens large and heavy components, minimizing the risk of loosening or failure under significant stress. This type of screw 109 is also compatible with various materials and is used with different types of nuts and washers, further enhancing its adaptability and effectiveness in securing components, so for these reasons, M16 type of screws 109 are used for firmly holding the base 108 equipped with the battery 101 to against the mounting frame 103.

[0047] The specification relating to the screws 109 mentioned herewith merely depict the specifications of one of the various possible means of fastening, specific to a particular chassis 102 of the vehicle. In other embodiments of the present invention the specifications of the screws are selected as dictated by the dimensions of the chassis 102, mass of the battery or batteries carried by the assembly and the mechanical load the chassis 102 and the assembly are designed to undergo.

[0048] Yet another embodiment of the present invention employs threaded bolts, wherein fastening is provided by a pair of nuts coupled on to each of the ends of the bolt.

[0049] In an embodiment of the present invention, the assembly is adapted to allow for the integration of paraphernalia relating to heat dissipation of the battery.

[0050] In the mentioned embodiment, the mounting frame 103 incorporates a fluid inlet and outlet hose (111, 112) that connects to the battery 101 once it is securely positioned on the frame 103. This arrangement of the hoses (111, 112) plays a critical role in the battery’s 101 operation by facilitating the flow of coolant. The fluid inlet hose 111 delivers coolant to the battery 101, ensuring that it remains at an optimal temperature during operation. Meanwhile, the outlet hose 112 allows the warmed coolant to exit the battery 101 and return to the cooling unit for re-circulation. This continuous flow of coolant helps to maintain efficient thermal management, thereby enhancing the performance and longevity of the battery 101.

[0051] In an embodiment of the present invention, the hoses (111, 112) as disclosed are strategically placed on the frame 103 in a manner that when the battery 101 along with base 108 is mounted on the frame 103, it does not restrict the flow of the coolant/fluid via the hoses (111, 112) by imparting any forces perpendicular to the cross-section of the hoses (111, 112) which may result in a reduction of the cross-sectional area of the hoses (111, 112). And reduction of the cross-sectional area of the hoses (111, 112) leads to improper flow of coolant to the battery 101 and vice-versa.

[0052] An embodiment of the assembly of the present invention is specifically adapted to enable the positioning of the components relating to the heat dissipation, installed with the battery, wherein clearances are provided along the longitudinal members 104 and lateral members 105 for positioning and passage of the hoses (111, 112) without any restriction to the passage of fluid within the hoses (111, 112) which may hamper the efficiency of the provided heat dissipation equipment.

[0053] The invention works best in the following manner, where the battery 101 mounting assembly as disclosed in the invention is developed to secure a liquid-cooled battery 101 in the rear section of an electrically powered vehicle, attaching to a pair of long arms on the vehicle's chassis 102. The assembly features a mounting frame 103 comprised of two parallel longitudinal members 104, which are rigidly connected by a pair of lateral members 105. Beneath the mounting frame 103, a series of bent plates 106 are positioned to align with and fit into corresponding brackets with slots 107 in the chassis 102, effectively preventing any displacement of the frame 103 relative to the chassis 102. Additionally, a removable base 108 is affixed to the mounting frame 103, designed specifically to hold the battery 101 securely. This base 108 includes multiple screw arrangements that enable screws 109 to be inserted into pre-drilled holes 110 in the frame 103, ensuring that the base 108 remains firmly attached and stable.

ADVANTAGES OF THE PRESENT INVENTION

[0054] A primary advantage of the battery mounting assembly for electrically powered vehicles, includes a rigid yet removable mounting of the battery within the vehicle thus preventing a translation of the battery during an operation of the vehicle.

[0055] The assembly of the present invention enables the affixing of the battery rigidly onto the chassis 102 of the vehicle which causes the battery to be fastened to a lower region of the vehicle thus effectively lowering the centre of gravity of the vehicle which further enhances the stability of the vehicle since the battery is one of the heavier components of the vehicle.

[0056] Such a mounting of the battery directly with the chassis 102 of the electrically powered vehicle, affixes the location of the center of gravity of the battery with respect to the center of gravity of the vehicle that prevents a shifting of the overall center of gravity of the vehicle during a driving of the vehicle over an uneven terrain.

[0057] The present mounting assembly rigidly holds the battery onto the chassis while allowing for an easy disassembly of the battery as and when required for maintenance purposes or for the replacement of the battery.

[0058] The versatile assembly of the instant invention is adapted for securing of both the conventional batteries and as well as batteries incorporated with heat dissipation equipment for the cooling of the battery.

[0059] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A battery mounting assembly, for securing a liquid cooled battery 101 in a rear portion of an electrically powered vehicle, the assembly comprising:

i) a mounting frame 103 composed of a pair of longitudinal members 104 arranged parallelly with one another, wherein said longitudinal members are rigidly joined via a pair of lateral members 105 and are structurally placed over a chassis 102 of said vehicle;
ii) a plurality of bent plates 106 disposed underneath said mounting frame 103, wherein said bent plates are inserted within a plurality of bracket with slots 107 formed within said chassis 102 for preventing displacement of said mounting frame 103 with respect to said chassis 102; and
iii) a base 108 removably attached onto said mounting frame 103, wherein said base 108 is configured to enable securing of said battery 101 with said frame 103, wherein said base 108 is configured with multiple screw arrangements that are utilized to fasten screws 109 of said arrangement within symmetrically crafted holes 110 engraved on said frame 103 for securely fixing said base 108 on said frame 103.

2) The assembly as claimed in claim 1, wherein said lateral members 105 are arranged perpendicularly in between said longitudinal members 104 for providing stability to said base 108 when placed on said frame 103.

3) The assembly as claimed in claim 1, wherein said bent plates 106 are disposed over the longitudinal members.

4) The assembly as claimed in claim 1, wherein said frame 103 includes a fluid inlet and outlet hose (111, 112) that are connected with said battery 101 once said battery 101 is properly positioned on said frame 103.

5) The assembly as claimed in claim 1, wherein said longitudinal and lateral members (104, 105) as described above, are constructed using box section tubes.

6) The assembly as claimed in claim 1, said lateral members 105 are apart from each other by a dimension of 410 mm.

7) The assembly as claimed in claim 1, wherein overall length and width of said frame 103 are 795 mm and 690 mm, respectively.

8) The assembly as claimed in claim 1 and 5, wherein dimension of said mentioned box section tubes is 20mm X 40mm.

9) The assembly as claimed in claim 1, wherein said bent plates 106 as mentioned possesses a thickness of 3 mm.

10) The assembly as claimed in claim 1, wherein said screws 109 as mentioned herein are of M16 type and possesses a thread pitch of 2 millimeters.