, Description:FIELD OF INVENTION:

The present invention relates to a battery mounting structure for vehicle provided in the front end of the vehicle to carry safely the battery assembly.

BACKGROUND OF INVENTION:

The battery mounting structure is generally provided in the vehicle for the placement of the battery assembly in the front end of the vehicle. It consists of a battery mounting bracket and other adjacent attached members to provide adequate stiffness to bear the dynamic loads generated due to heavy weight of the battery assembly. Hence generally such structures are designed using advanced lightweight materials (composites or High strength steels). However the usage of such kind of materials increases the cost of the battery mounting structure significantly.

In the current design (figure-1), as per the vehicle layout and packaging constraints, the battery assembly (1), consisting of battery (2) placed in a tray (3), is partially mounted on engine mount (4) and the remaining portion of the battery assembly (1) is supported by battery mounting bracket (5). This enables to transfer the battery loads partially to the engine mount resulting into lighter battery mounting structure requirement.

The main disadvantages associated with current design are:

• As the battery system is directly mounted on Engine mount, there is a chance of transferring engine vibrations directly to battery assembly and this may reduce the durability of battery mounting tray.

• Design of engine mounting structure is affected by the battery system. This may result into heavier engine mount.

• The current battery mounting structure design uses multiple components; handling of these components on assembly line requires additional time and floor space.

• The limitation of the current design is that the battery assembly has to be packaged adjacent to the engine mount only. Alternative solution is needed to package the battery assembly away from engine mount

Therefore, continuous efforts had been undertaken by the manufacturers, researchers to find a suitable solution to these problems and different products had been patented.

JP Patent No. 4601837B2 on “THE BATTERY BRACKET STRUCTURE” tried to solve the problem of providing a battery bracket structure capable of mounting a large battery, high in impact absorption efficiency in a head-on collision, and capable of fitting a front fender even when a wheel apron is omitted. It discloses a battery bracket 8 structure having a perpendicular surface 11 joined with the inner side surface 2 of a front frame 1 of a closed section extended in the longitudinal direction of a vehicle body and a horizontal surface 12 extending horizontally toward an outer side surface from the upper end part of the perpendicular surface 11 with the battery held thereby, a fragile part 14 is formed in a corner between the perpendicular surface 11 and the horizontal surface 12. While the large battery can be mounted due to high strength by shear joining with the front frame 1 on the perpendicular surface 11, the battery bracket 8 is easily deformed by the presence of the fragile part 14 provided on the corner. Thus, the deformation of the front frame 1 is not impaired, and an impact load can be stably and reliably absorbed. (see: Fig. # 5 and 6 of this citation). This design is compatible only to position the battery assembly on the apron side member with wide top face.

JP Patent Application No. 2003276530A on “MOUNTING STRUCTURE OF BATTERY BRACKET”, according to claim 3 of the invention, described in the claim 2 in battery bracket mounting structure, frame member and the convex side of the bead is formed, and this projecting from the side of the bottom battery bracket is fixed over the L-shaped gusset is provided, this gusset extending over the upper surfaces of the convex bead projecting groove and fitted to and recessed part is formed. Claim 3 according to the invention, the invention of claim 2, in addition to the effect of the, frame member and the convex side of the bead is formed, and a bracket projecting from the side of the bottom of the battery over by gusset is fixed, the mounting strength of the skeleton member battery bracket can increase the suppression of resonance effect can be enhanced.(see: Fig.1 of this citation).The design is compatible only to position the battery assembly on the apron side member near crash crumble zone.

JP Patent Application No. 2012171379A on “BATTERY SUPPORTING STRUCTURE” tried to provide a battery supporting structure capable of surely supporting a battery even after a front-side frame is deformed by vehicle collision, without disturbing the deformation of the front-side frame. In this citation, in a battery supporting structure 1 having a front-side frame 3 and a battery bracket 4 mounted on the front-side frame so as to support a battery 5 in a car body, the front-side frame includes: a boundary line 13 which is formed by a load in collision more easily than other portions; a front part 11 which is positioned in front of the boundary line 13; and a rear part 12 which is positioned behind the boundary line. The battery bracket includes a front bracket 25 mounted in the front part and a rear bracket 26 mounted in the rear part and having higher rigidity than that of the front bracket, and the front bracket and the rear bracket are joined and arranged across the boundary line in a longitudinal direction.(see: Fig. 3 as given in this citation) The design is compatible to position the battery assembly anywhere on apron side member but the battery mounting level is raised above the apron side member.

JP Patent Application No. 2008114735A on “BATTERY SUPPORT STRUCTURE F OR AUTOMOBILE” provideda battery support structure for an automobile capable of supporting a battery with only power train mount bracket, reduced in the number of part items, improved in assembling accuracy, and secured in stability when supporting the battery at several support points. In the instant citation, this battery support structure comprises a battery supported by a car body side bracket 23 of the power train mount 21, the top surface 28a restricting the top of amount rubber, a fastening part 28b fastened to a car body frame in front and rear of the top surface 28a, a first battery support part 28c formed in the top surface 28a and secondbattery support parts 30 and 31 integrally formed with the fastening part 28b and extended upward from the fastening part 28b. (see: Fig. 6 given in this citation)The design is compatible only to position the battery assembly on the apron side member near powertrain because the structure is required to mount on the powertrain and apron side member.

JP Patent Application No. 2015209117A on “The battery mounting structure of an automobile” tried to solve the problem that if side impact collision energy from a side surface of the vehicle or the like is applied, the collision energy is absorbed by a battery for driving an automobile battery can be surely protected. In this case, the battery frame 28, front wall 30 and a pair of rear wall 31 and, and a pair of left wall 41 and the right wall 42, corner R at right angles in a wall member and a connection member 50, is provided. The coupling member 50, which has an Lshaped cross section, and the left wall 41 above the right wall 42 is curved to the outside in the width direction and curved portion 56, through the curved portion 56, and a front wall 30 and rear wall 31 is connected to the upper end of the lower floor frame 14 and a fixed part 57, is provided. (see: Fig. 5 as given in this citation)

In view of continuous effort, there is still a need of a mounting structure which can hold the battery assembly independently and transfers loads to vehicle member. This has been provided by the instant invention based on cantilever beam. The subject invention is not only a least cost design as it is entirely made by using conventional materials (low carbon steel sheet metal) but also uses conventional manufacturing process (spot welding) to assemble with the vehicle.

OBJECTS OF THE INVENTION:

The main object of the invention is to provide a two component battery mounting structure having a battery mounting bracket with a gusset bracket which is easy to manufacture and assemble in the vehicle.

Another object of this invention is to develop a battery mounting structure which is compatible to mount on any member of the vehicle which has angular surface (horizontal top and vertical side face) thereby enabling to package it anywhere in the front end of the vehicle.

An additional object of this invention is to place the main battery mounting bracket in such a way that the top face where the battery assembly is placed is kept as low as possible to increase the structure stability and to minimize toppling tendency of the battery.

Yet another object of this invention is to ensure that the new battery mounting structure should be a light weight design which can compete with other designs using composite materials.

A further object of this invention is to provide a straight bead (rectangular channel) at the center of main battery mounting bracket to maximize the bending stiffness of the main battery mounting bracket and also to maximize the mounting stiffness at the bolt mounting locations in the main bracket thereby eliminating the usage of additional reinforcements at bolt mounting locations.

Yet another objective of this invention is that the battery mounting structure should not affect the design of other structure of the vehicle such as engine mount design.

Another objective is to provide a cost effective battery mounting structure by using conventional materials (low carbon steel sheet metal) and using conventional manufacturing process (spot welding) to assemble with the vehicle.

The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of disclosure. Accordingly, other objects and a full understanding of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention are to be defined by the claims taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

Further objects and advantages of this invention will be more apparent from the ensuing description when read in conjunction with the accompanying drawings wherein:

Figure 1 : Existing battery mounting structure design.

Figure 2 : Detailed view of invented battery mounting
Structure.

Figure 3(a) : Exploded view of instant battery mounting
structure and battery assembly.

Figure 3(b) : Exploded view of instant battery mounting
structure.

Figure 4(a): Feature details of the battery mounting structure: Battery Mounting Bracket & Gusset Bracket - Front View.

Figure 4(b) : Feature details of the battery mounting structure: Battery Mounting Bracket & Gusset Bracket - Top View.

Figure 4(c) : Feature details of the battery mounting structure: Battery Mounting Bracket & Gusset Bracket - Side View.

Figure 4(d) : Feature details of the battery mounting structure: Gusset Bracket (Front View, Side view, Top view and Oblique view).

Figure 5(a) : Design Validation – CAE results.

Figure 5(b) : Design Validation – Physical testing results.
While the invention is described in conjunction with the illustrated embodiments, it is understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents which may be included within the spirit and scope of the invention disclosure as defined by the claims.

STATEMENT OF THE INVENTION:

According to the invention, there is provided a battery mounting structure comprising (a) battery mounting bracket member(18), having U-shaped upper platform (18a) with two inverted L-shaped legs (18b), the rear end (16) of said battery mounting bracket (18) is attached to a horizontal flange F3 and two vertical flanges F1 & F2, each provided with plurality of spot welds, for securing said bracket with any front end member of the vehicle which has angular surfaces (horizontal top and vertical side face) such as apron side member; and (b) a C-shaped gusset bracket (19), placed between two L-shaped legs of said mounting bracket (18) at lower portion, the side faces of which is welded to said mounting bracket (18) with spot weld (20) provided on each face and the middle face between two side faces of said gusset bracket (19) is further secured with the vehicle number by plurality of spot welds provided on it.
DETAILED DESCRIPTION OF THE INVENTION:

At the outset of the description, which follows, it is to be understood that the ensuing description only illustrate aparticular form of theinvention. However, such a particular form is only an exemplary embodiment and the teachings of the invention are not intended to be taken restrictively.

For the purpose of promoting an understanding of the principles of the invention, reference is now to be made to the embodiments illustrated and the specific language would be used to describe the same. It is nevertheless to be understood that no limitations of the scope of the invention is hereby intended, such alterations and further modifications in the illustrated bag and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

The embodiments are described with reference to the drawings in which like parts are referred to by like numerals. These embodiments are for illustrative purpose only and it should be noted that invention is not limited to the embodiments illustrated in the drawings. Certain details, e.g. manufacturing / assembly details, have been omitted since they are not necessary to understand product functioning.

As used herein and subsequently in the claims, the singular form ‘a’, ‘an’, and ‘the’ includes plural reference unless the context clearly indicates otherwise.

The present invention describes a battery mounting structure made to support the entire battery assembly weight on a single structure and suitable to position it anywhere on any member of the vehicle which has angular surface (horizontal top and vertical side face).In this invention, the battery assembly (1) is independently mounted on a single structure (Figure 2 and Figure 3). To improve the load bearing capacity of battery mounting structure and keeping the cost and weight within the limit, this structure is devised using two major components; first component is battery mounting bracket which is main load bearing bracket and the second component is gusset bracket which supplementary bracket which maximizes the load bearing capacity of the whole structure.

Referring to Figure 2, the present invention relates to the battery mounting structure which comprises of a battery mounting bracket (9) having an upper platform with two inverted L shaped legs, on which the battery assembly (6) consisting of battery (7) in a tray (8), is placed, and a C-shaped gusset bracket (10) which is placed between two inverted L-shaped legs of the battery mounting bracket (9) at lower portion and its side faces are welded to the battery mounting bracket (9) with 2 spot welds and rear face is welded to the vehicle front end member (11) with 2 more spot welds. The battery mounting structure could be secured anywhere with the vehicle front end member having an angular surface (horizontal top and vertical side face) by means of vertical flanges F1 & F2 and horizontal flange F3 provided with the battery mounting bracket(9).

Figure 3 shows the exploded view of battery mounting structure showing different parts namely battery assembly & battery mounting structure (10)[Fig3(a)]as well as battery mounting structure (16) alone[Fig.3(b)]. Figure 3(a) relates to the battery mounting structure and battery assembly (10) which shows battery assembly consisting of battery (11) placed in an appropriate battery tray (12) to be placed on the upper platform of battery mounting bracket (15, 18), said upper platform is of inverted U shaped having plurality of holes indicating the battery mounting locations (17) for fixing the battery assembly properly. A depressed rectangular channel (straight bead) is further provided in the middle of upper platform which splits battery mounting locations (17) namely M1 & M2 from M3 & M4 to enhance the load bearing capacity bracket. (see:fig. 3(b) and fig.4(b)). The gusset bracket (19) is spot welded between two inverted L-shaped legs of the battery mounting bracket (18) at spot weld positions (20) provided on the side face of the gusset bracket and on the lower end of the inverted L-shaped legs of battery mounting bracket.

Figure 4 gives the feature details of battery mounting structure namely battery mounting bracket giving its front view [Fig 4(a)], top view [Fig.4(b)] and side view [4 (c )] as well as various views of Gusset bracket [Fig4 (d)].

Fig 4(a) gives the front view of the battery mounting bracket showing Gusset side face spot weld (21) on the lower portion of the inverted L-shaped leg of the battery mounting bracket. Similar spot weld is also provided on the other leg-shaped leg of the mounting bracket. These two spot welds (2 No.) enable to join the battery mounting bracket and gusset bracket to maximize the load bearing capacity.

The upper platform of battery mounting bracket is shown in its top view Fig.4(b) wherein a rectangular depressed channel (22a) is provided in the center of the this upper platform and plurality of holes M1, M2, M3 and M4 (22) as mounting locations for the battery assembly are provided on either side of this channel. The rear side of the mounting channel is provided with horizontal face flange (F3)having plurality of spot welds and two vertical flanges (F1 and F2 :see Figure 4c ) to secure the battery mounting structure with the vehicle member over the apron side member in such a way that battery mounting level is kept very close to the apron side member top face to increase the structure rigidity as well as to minimize the supporting members.

Fig. 4( c) depicts the side view of mounting bracket clearly indicating two vertical face flanges F1 and F2 (26), attached to two legs of the mounting bracket, having plurality of spot welds (25) on each vertical flange for securing the mounting structure with the vehicle member on the front end. Plurality of spot welds (29) are also provided in the middle portion on the gusset bracket (28) for the same purpose. There are also plurality of location holes provided on the middle portion of the Gusset bracket for the placement of battery mounting structure appropriately on the vehicle member. The upper platform of the battery mounting bracket has also a depressed rectangular channel (straight central bead) (27) in its middle to enhance the stiffness of battery mounting region and to avoid additional reinforcement at the mounting locations for battery assembly.

Figure 4(d) shows the front view (30), side view (31), top view (32) and oblique view (33) of C-shaped Gusset bracket which has two side faces and a middle face connecting two side faces. There is slight depressed portion in the middle of the middle face having location holes (34) and plurality of spot welds (35) adjacent to the depressed portion for appropriately placing the Gusset bracket between inverted L-shaped legs of battery mounting bracket and further securing with vehicle Apron side member to increase the structural rigidity ,

The legends used in Figure 4 is given in a nut shell as follows:

Fig. 4(a) : Front View

21 : Gusset side face spot welds:
To join the battery mounting
Bracket with Gusset bracket (2 No.)

Fig. 4(b) : Top View

22 : M1, M2, M3 & M4:
Mounting locations for battery assembly

22a : Rectangular channel (Straight central bead)

Fig 4(c ) : Side View

25 : Vertical face spot welds (6 No.)

26 : F1 and F2: Vertical face flanges

27 : Rectangular Chanel (Straight bead)

28 : Gusset bracket

29 : Gusset rear face spot welds (2 No.)

Figure 4(d) : Gusset bracket

30 : Front view

31 : Side View

32 : Top view

33 : Oblique View

It is pertinent to mention here that the battery mounting structure is cantilever support design and fixed end is attached to the vehicle member. Basic shape of the structure is combination of double L and inverted U type. Lower portion of inverted U is connected with C-shaped Gusset bracket. This C-shaped Gusset bracket is used as an auxiliary bracket at the lower end of the main mounting bracket to maximize the load bearing capacity. Spot welds are used to join the mounting structure with the apron side member of the vehicle on the front end. To enhance the stiffness of the battery mounting region, single straight central bead (rectangular channel) is provided in the main battery mounting bracket and battery mounting level is kept very close to the apron side member top face to increase the structural rigidity as well as to minimize the supporting members.

In the instant invention, battery mounting level, close to apron side member, removes many disadvantages which are associated with raised battery mounting level above the apron side member such as

• Increase in moments in the battery mounting structure and it will deteriorate the strength and durability performance. To counter the same, structure needs to be strengthened accordingly by addition of more reinforcement which leads to heavy structure;

• Increase in the battery system acceleration levels during running condition band this increases the toppling tendency of the battery. To counter the same, the battery needs to be held rigidly with high strength brackets.

• Increase in battery mounting system deflection causes decrease in the structural rigidity. To counter the same, additional mounting points need to be added to decrease the deflection thereby improving structure rigidity and by adding mounting support from front end will have adverse effect in frontal crash and it will increase the chances of battery dislocation from mounting structure during frontal crash.

In the present invention, above issues have been eliminated by designing the battery structure in such a way that the battery mounting level is kept very close to the apron side member top face. This ensures high rigidity, reduced moments, decreased battery acceleration levels band eliminates the usage of additional reinforcements as well as additional mounting support from the front end. Thus the mounting structure becomes lighter which allows to meet the vehicle weight and cost targets. As the present invention eliminates front end mounting support, it minimizes the chances of battery dislocation during full frontal crash.

According to the present invention, the important features of the battery mounting structure are summarized in a nut-shell as follows:

• The battery mounting structure has 2 major parts :- Battery mounting bracket & Gusset bracket (Figure-3a and Fig. 3b)

• Battery mounting bracket (as explained in Figure-3b) is main structural load bearing member on which the battery assembly is mounted.

• The top of the battery mounting bracket, 4 holes (M1, M2, M3, & M4) (Figure 4b) are provided to mount the battery assembly using bolt joints and the rectangular Channel which splits M1 and M2 from M3 and M4 is provided to enhance the load bearing capacity bracket (Figure-4b: Top view &Figure -4c:Side view).

• In Battery mounting bracket, flanges F1, F2, & F3 are provided to spot weld the bracket to the vehicle front end side member. There are 6 spot welds used on the flanges F1 & F2 while there are 7 spot welds used on the flange F3 to join the bracket with vehicle member. (Figure-4b and Figure-4c: Top view &side view)

• The Gusset bracket (Figure-4d) is designed to support the battery mounting bracket by sharing and transferring the load to the vehicle member. This bracket maximizes the load bearing capacity of the whole structure

• The Gusset bracket is made in C-shape such that it can be placed between two legs of the battery mounting bracket at lower portion and its side faces are welded to the battery mounting bracket with 2 spot welds and rear face is welded to the vehicle member with 2 more spot welds [Figure 4(d)]

This new battery mounting structure has following advantages:

• In the instant battery mounting structure, no additional support is required other than battery mounting structure. New design can hold the battery independently and this enables to package the structure anywhere in the vehicle front end.

• The new battery mounting structure is a light weight design and can compete with the other designs which use composite materials.

• The instant battery mounting structure is a cost efficient structure as it is entirely made by using conventional materials (low carbon steel sheet metal) and uses conventional manufacturing process (spot welding) to assemble with the vehicle

• This battery mounting structure does not affect the design of other structure whereas in current design battery assembly mounting affects engine mount design.

• The battery mounting structure is 2 component structures simple to manufacture and assemble in the vehicle. The handling of the parts is easy on the assembly line.

Design Validation:

New design of the battery mounting structure was first validated in different conditions using CAE tools on virtual prototype and the final validation is done on the physical prototype to confirm the CAE result. Figure 5(a) and Figure 5 (b) indicate CAE and physical testing results wherein CAE evaluation indicated that stress levels are well within the target criteria and during physical testing, no panel or spot cracks are observed during and after the test. All the results ( CAE evaluation and Physical testing) have proven that the invented battery mounting structure can withstand the dynamic loads and safely carry the battery assembly.

All documents cited in the description are incorporated herein by reference. The present invention is not to be limited in scope by the specific embodiments and examples which are intended as illustration of a number of aspects of the scope of this invention. Those skilled in the art will know or to be able to ascertain using no more than routine experimentation many equivalents to the specific embodiments of the invention described herein.

It is to be noted that the present invention is susceptible to modifications, adaptations and changes by those skilled in the art. Such variant embodiments employing the concepts and features of this invention are intended to be within the scope of the present invention, which will be further set forth under the claims.

Claims:WE CLAIM

1. Battery mounting structure for vehicle comprising:

a) a battery mounting bracket member(18), having U-shaped upper platform (18a) with two inverted L-shaped legs (18b), the rear end (16) of said battery mounting bracket (18) attached to a horizontal flange F3 and two vertical flanges F1 & F2 , each provided with plurality of spot welds, for securing said bracket (18) with any front end member of the vehicle which has angular surfaces (horizontal top & vertical side face) such as apron side member; and

b) a C-shaped gusset bracket (19), placed between two L-shaped legs of said mounting bracket (18) at lower portion, the side faces of which is welded to said mounting bracket (18) with spot weld (20) provided on each face and middle face between two side faces of said gusset bracket (19) is further secured with the vehicle number by plurality of spot welds provided on it.

2. The battery mounting structure as claimed in claim 1, wherein the upper platform (18a) has plurality of mounting holes (M1, M2, M3, M4..) as battery assembly mounting locations (22) for mounting the battery assembly using bolt joints and a depressed rectangular channel (27), in the middle of the upper platform (18a) which splits member mounting locations (22) on the either side of the said channel (27), to enhance the stiffness of the battery mounting region.

3. The battery mounting structure as claimed in claim 1, wherein the upper platform (18a) level is kept very close to the apron side member top face of the vehicle to minimize the mounting structure deflections and to increase the structural stability.

4. The battery mounting structure as claimed in claim 1, wherein the middle part of middle face between the two side faces of said gusset bracket (19) is depressed and has plurality of location holes (34) for appropriately placing between inverted L-shaped legs of said mounting bracket (18), to enhance the rigidity of the structure.

5. The battery mounting structure as claimed in preceding claims as substantially described herein with reference to the accompanying drawings.