DESC:FIELD OF THE INVENTION

(0001) The invention relates to a retrofit Rechargeable Energy Storage System (REESS) mounting structure and arrangement along with related electronics on an automobile, especially with a ladder frame chassis or a body-on-frame construction.

PRIOR ART AND PROBLEM TO BE SOLVED

(0002) There are multiple examples of battery, battery pack or as a broader all-encompassing term - Rechargeable Energy Storage Systems (REESS) mounting and arrangement for automobiles. Most of these describe such solutions for Original Equipment Manufacturer (OEM) placement of the REESS which allows the OEM more freedom to package other related components around the REESS. These solutions describe mounting of REESS under one or multiple seats inside the automobile, embedded inside the floor panel or mounted with special structures below the floor panel. Normally these solutions require extensive modifications to the frame or chassis of the vehicle itself which leads to higher development costs.

(0003) US Patent 3838745 discloses such an arrangement of battery pack mounting arrangement underneath the carriage of an automobile. However, the arrangement is disclosed for a fully electric vehicle with a strong focus on ease of battery box replacement by use of rails and rollers. US Patent 4058182 again discloses a battery pack design for a pure electric vehicle as an OEM solution wherein the battery pack occupies space where a fuel tank is conventionally placed in an automobile. Again, the focus of invention in this case is on a design feature that allows the electric power source to be detached and dropped from the vehicle upon impact of pre-determined strength. US Patent 1209960 discloses a battery cradle design for electric vehicle focusing on easy removal and replacement of batteries from the cradle, possibly at battery replacement stations. The cradle specifically provides for a cradle door arrangement that allows it to be opened flat and act as an extension of cradle floor to allow individual cells or batteries to be placed initially before taking them out or pushing them inside the cradle. US Patent 778560 discloses a method for supporting and shifting batteries in automobiles. Here again, the focus of design is on easy removal and refitment of batteries at swapping stations.

(0004) The REESS mounting structure must have enough strength to support the weight of the REESS itself which could be as heavy as 100 kilogram depending on application. Apart from this static load, it should be able to endure the dynamic stresses experienced during movement of the automobile while safely and securely holding the REESS together. As the weight of the REESS becomes a significant part of the vehicle, its positioning inside the vehicle becomes an important aspect since it affects its ride, performance and handling apart from passenger safety.

SUMMARY OF THE INVENTION

(0005) The present invention comprises of an arrangement of mounting additional REESS or battery pack as a retrofit inside an existing automobile especially with a ladder frame chassis or a body-on-frame construction. Such activity may be undertaken to add hybrid powertrain functionality or conversion to a pure electric powertrain, of an existing, conventional internal combustion engine powered automobile.

(0006) The invention includes multiple embodiments of a framework of racks hung from the underbody frame holding equal number of batteries on either side of the vehicle longitudinal axis and related anchoring arrangement to hold the battery pack wherein the racks are mounted on the frame, close to the center of wheelbase, between the front and rear axles.

(0007) In the first embodiment, the invention includes a tray holding frame created by the connecting framework between battery holding racks as mentioned above to allow for rigid fixing of the power and control electronics module in close proximity of the battery pack, under the vehicle load bay floor.

(0008) In the second & third embodiment, the power and control unit is independently mounted on the transverse beams of ladder frame in close proximity of the battery pack under the vehicle load bay floor.

BRIEF DESCRIPTION OF THE DRAWINGS

(0009) The present invention may be better understood and its numerous objects, features, components and advantages are made apparent to those skilled in the art, by referring to the accompanying drawings, in which:

(0010) Fig.1 is an isometric view of first embodiment of the disclosed invention showing the complete assembly of the mounting device with battery pack and power/control unit as mounted over the connecting rails.

(0011) Fig.2 is a top view of the same set-up as in Fig.1.

(0012) Fig.3 shows the top view of the first embodiment of the disclosed invention showing the system as located in an intra-city load carrier vehicle.

(0013) Fig.4 shows top view of the second embodiment of the proposed invention where the control unit is independently mounted on the transverse beams of ladder frame.

(0014) Fig.5 shows the front of layout proposed in Fig.4.

(0015) Fig.6 is an isometric view of layout proposed in Fig.4.

(0016) Fig.7 is a plan view of embodiment 2 as described further in this document.

(0017) Fig.8 is a left hand side view of embodiment 2 as shown in Fig.7.

(0018) Fig.9 is a top view of the REESS cradle as per embodiment 2 without batteries.

(0019) Fig.10 is a left hand side view of REESS cradle as shown in Fig. 9.

(0020) Fig.11 is a front view of REESS cradle as shown in Fig. 9.

(0021) Fig.12 is a front view of the power and control module mounting arrangement as per embodiment 2.

(0022) Fig.13 is a left hand side view of the power and control module mounting arrangement as per embodiment 2.

(0023) Fig.14 is a top view of the power and control module mounting arrangement as per embodiment 2.

(0024) Fig.15 is an isometric view of the power and control module mounting arrangement as per embodiment 2.

(0025) Fig.16 is a front view of REESS cradle with batteries installed.

(0026) Fig. 17 is a top view of REESS cradle with batteries installed as shown in Fig.16.

(0027) Fig. 18 is a left hand side view of REESS cradle with batteries installed as shown in Fig.16.

Reference Numerals in Drawings
10 Power control module
12 Support rails for control module
14 Battery Pack
16 Cradle frame
18 Battery clamping arrangement
20 Longitudinal member, ladder Frame
22 Transverse member, ladder frame / load bay structure
24 Load bay

DETAILED DESCRIPTION OF THE INVENTION

(0028) The particular embodiments of the present invention will now be described with reference to the accompanying drawings. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention. The detailed description is construed as a description of the currently preferred embodiment of the present invention and does not represent the only form in which the present invention may be practiced. This is to be understood that the same or equivalent functions may be accomplished, in any order unless expressly and necessarily limited to a particular order, by different embodiments that are intended to be encompassed within the scope of the present invention.

(0029) The embodiments are chosen and described to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.

Embodiment 1
(0030) Figure 3 shows a top view of the present invention’s first embodiment in its assembled state. The battery pack #14 is divided into two units of with equal number of battery units and held in 2 separate “cradle” frames #16 on either side of the ladder frame structure #20. The batteries may be held down in their cradles using clamping arrangement #18. These aforementioned cradle frames may be rigidly hung and fixed upon 2 longitudinal members of the ladder frame #20. Also they may be linked by 2 transversely mounted rails #12 for added strength of the complete structure. The rails #12 are rigidly linked to the top of the closest transverse member #22 of the ladder frame immediately below the load bed #. The rails #12 & the load bed #24 create a recessed space between them wherein the power and control module #10 is rigidly fixed to rails #12.

Embodiment 2
(0031) Second embodiment of the invention is presented in Fig.4, Fig.5 & Fig.6. In this configuration, the REESS or battery pack #14 arrangement on the vehicle is retained as disclosed in embodiment 1. However the REESS cradles #16 are redesigned to be hung independent of each other and are not linked to each other. Two support rails #12 for power & control module #10 are mounted across the transverse frame members #22, independent from the REESS cradles #16. These aforementioned support rails #12 help secure the power & control module #10 with the vehicle.

Embodiment 3
(0032) Figure 7 shows the top view of present invention’s second embodiment in its assembled state on a representative vehicle frame. The battery pack #14 consists of four batteries secured in a single cradle structure #16 hung across two of the transverse frame structures #22 of load bed while being confined within the boundary of longitudinal frame members #20. The aforementioned cradle #16 is designed to accommodate the driveshaft in between in case the vehicle is a rear wheel drive. One of the cradle mounts may be hinged to allow easy loading or unloading of individual batteries during installation or service. The cradle mounting also ensures restriction of all degrees of motion to ensure the battery pack #14 is rigidly held when in motion. Another advantage gained from such an arrangement is deterrence to theft of batteries while retaining the visual appearance of a conventional vehicle since the battery pack #14 and controller #10, both are hidden from plain view.
The power and control module #10 is mounted ahead of the battery pack #14 using two support brackets #12 that are clamped via bolts to two of the transverse frame structures #22 of load bed #24.

(0033) While few specific forms of embodiment of the current invention has been described and illustrated for better clarity, the above descriptions must be understood as an example and not as a limitation to the scope of the current invention. It is clear that multiple modifications to the current invention could be made by anyone with ordinary skill in the art, while still being within the scope of the invention which is to be determined by the following claims.

Advantages of the Invention Compared to Prior Art
(0034) Major advantages perceived with the described invention are as below:
1. In all embodiments, the complete battery pack assembly and mounting unit is assembled midway between the front and rear axles symmetric to the central longitudinal axis of the vehicle. This allows for maintaining load distribution ratio of the vehicle weight on to the front & rear axles similar to original vehicle which allow retention of original stability & handling of the vehicle.
2. With aforementioned position as described in point 1, the battery pack is – in most scenarios –
a) Safe from damage in the event of a head-on collision as the complete assembly is securely mounted behind the driver cabin, under the load bay.
b) Safe from damage in the event of a rear end collision as the spare tyre and inbuilt crumple zones of the vehicle rear end structure absorb the energy from impact.
c) Safe from damage in the event of a side-on collision (specifically under second embodiment of the REESS mounting structure and layout) as the complete assembly and electronics are secured within the longitudinal rails of the ladder frame structure.
3. The aforementioned position of the battery pack and mounting assembly as described in point 1 above allows any gases released by the chemical reactions taking place inside the batteries to be released away from driver/passengers.
4. The aforementioned position of the battery pack and mounting assembly as described in point 1 above, allows for retention of the complete load bay even with the battery pack and power/control unit installed.
5. Embodiment 2 especially provides for deterrence to theft of batteries or control unit while retaining the visual appearance of a conventional vehicle since the battery pack and controller, both are hidden from plain view.
,CLAIMS:WE CLAIM:

1) A Retrofit Rechargeable Energy Storage System (REESS) layout structure in a vehicle, comprising:
a single or plurality of REESS units;

a REESS case or cage or cradle that may include: a REESS tray which may be perforated for reduced weight; a cover to protect the REESS from environment; and

a ladder frame structure of the automobile or its load bay / carriage with at least two longitudinal members and plurality of transverse members, as part of their structure;

wherein:

a) As per embodiment 1 of the invention the aforementioned REESS cradles are hung on either side of the vehicle, by the longitudinal ladder frame members such that they lie on the outer side of the said longitudinal members, interconnected by a couple of transverse cage members that may provide a mounting location for securing the related power and control electronics. The cages are hung such that when viewed from top, the complete arrangement is symmetric to the vehicle longitudinal axis and lies within the envelope formed by the front and rear axles, and the track width of the vehicle. The cradles provide for strapping or securing of the REESS contained inside them to prevent them from dislodging when the vehicle is in operation,

b) As per embodiment 2, the REESS cradles are mounted similar to embodiment 1 wherein they are independent of each other, i.e. there is no transverse interconnection between the two REESS cradles. The power and control module is mounted separately, before the front axle but ahead of the battery pack and cradle arrangement via a separate set of transverse rails mounted across the aforementioned longitudinal frame members. However, the said power and control module may be mounted behind the said battery pack and cradle arrangement within the vehicle boundary if availability of space is not a constraint. The said control module may be mounted in multiple ways through suitable clamping brackets, a single embodiment of which is presented in embodiment 2,

c) As per embodiment 3 of the invention, a single, hinged at one end or rigidly mounted, cradle structure retains the battery pack while itself being mounted or hung from the aforementioned transverse structural members of the vehicle or carriage frame, under the load bay/carriage floor, within the boundaries of the longitudinal members of the vehicle frame structure, between the front and rear axles. The said cradle structure mounting ensures that motion in all degrees of freedom is restricted when in operation. The said cradle structures also allows for accommodation of the driveshaft, including consideration for the said driveshaft’s vertical displacement during vehicle operation over irregular terrain. Incorporation of hinge at one end as mentioned before also allows for easier mounting and dismounting of individual batteries during installation or removal. Especially in this embodiment, the layout allows the complete system to be concealed within the vehicle boundaries, thereby retaining the exterior design or looks of the vehicle being retrofitted. This concealment helps in theft prevention of battery pack.

2) The REESS layout structure as claimed in Claim 1, wherein:

a) said layout allows for direct and better dissipation of heat from electronics of power and control unit to the atmosphere by convection;
b) said layout allows for the REESS and power & control unit to be placed in close proximity to reduce losses in power transmission; and
c) said layout allows for improved protection of the REESS and power & control unit in the event of a frontal, side or rear collision as explained in advantages (refer section 0034).

Dated this 28th day of July, 2016
RANA, Vikrant (PA-248)
S.S. Rana & Co.
Attorneys for the Applicant
Altigreen Propulsion Labs Private Limited