DESC:FIELD OF THE INVENTION

(0001) The invention relates to a retrofit Rechargeable Energy Storage System (REESS) mounting structure and arrangement inside an automobile.

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.

(0003) At least one prior art (US 2009/0014221 A1) for OEM hybrid LPG-electric powertrain solution used the boot space behind the rear seat back for MPV, RV or SUV application to mount a LPG bomb or battery module. However, the said prior art fails to convincingly safeguard the battery module in case of a side collision while being unclear on the exact positioning of the module and advantages from such positioning.

(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 INVENTION

(0005) The present invention comprises of an arrangement of mounting additional REESS or battery pack as a retrofit inside an existing automobile. 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 a raised tray and related anchoring arrangement to hold the battery pack or REESS wherein the tray itself is fixed rigidly to the vehicle floor in the trunk immediately behind the rear seats and above the rear axle such that it fits between the rear wheel wells.

(0007) The invention also includes a recess created by raising of the said tray as mentioned above to allow for rigid fixing of the power and control electronics module in close proximity of the battery pack or REESS.

BRIEF DESCRIPTION OF THE DRAWINGS

(0008) Fig. 1 is a schematic view showing the complete assembly of the mounting device with battery pack and power/control unit along with additional heat sink as mounted inside a cutaway section of vehicle trunk.

(0009) Fig. 2 is an isometric view of the same set-up as Fig.1.

(0010) Fig. 3 is the front view of battery pack mounting assembly with battery pack and controller unit placed underneath.

(0011) Fig. 4 is an isometric view of the same set-up as in Fig. 3.

(0012) Fig. 5 is an isometric view of the battery pack mounting assembly exclusively.

Reference Numerals in Drawings
10 Battery pack
12 Parallel rails to hold battery pack
14 Transverse rails
16 Additional linking plates
18 Automobile trunk floor
20 Passenger seats
22 Power control module
24 Heat sink
26 Clamping plate and bolt arrangement
28 Wheel Well
30 Recess for spare wheel storage

DETAILED DESCRIPTION OF THE INVENTION

(0013) Figure 1 shows a perspective view of the present invention in its assembled state. The battery pack or REESS (10) is held between two parallel rails (12). The aforementioned rails may be rigidly fixed upon two transverse rails (14), supporting rails (12) at their ends while linking them together. The rails (12) may additionally be linked transversely with additional metal plates (16). The rails (14) are rigidly linked to the trunk floor (18) of the automobile immediately after the last row of passenger seats (20) and between the wheel wells (28). The rails (14) & the trunk floor (18) create a recessed space between them wherein the power and control module (22) may be rigidly fixed to trunk floor (18). A separate heat sink (24) may be fixed between the power control module (22) and trunk floor (18). A clamping plate and bolt arrangement (26) holds down the battery pack securely in place.

(0014) While a specific form of embodiment of the current invention has been described and illustrated for better clarity, the above description 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

(0015) Major advantages perceived with the described invention are as below:
1. The complete REESS assembly and mounting unit is assembled between the rear wheels & suspension assembly, immediately behind the final row of passenger seats, symmetric to the central longitudinal axis of the vehicle. This allows for near equal load distribution of the vehicle weight on to the front & rear axles which lead to improved stability & handling of the vehicle.

2. With aforementioned position as described in point 1, the REESS is also isolated or “firewalled” from fuel tank by the seats & the vehicle floor allowing uncompromised safety of vehicle occupants.

3. With aforementioned position as described in point 1, the REESS 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 last row of passenger seats, in the trunk with seat back acting like a “firewall”.
b) Safe from damage in the event of side-on collision due to presence of transversely mounted rear axle and a stronger frame in the vicinity for mounting of suspension components – which together prevent crushing of the vehicle, and hence of the REESS, from sides.
c) 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.

4. The aforementioned position of the REESS and mounting assembly as described in point 1 above allows usage of the inbuilt vents inside the trunk to evacuate and prevent buildup of any harmful gases (if any) released by the chemical reactions taking place inside the batteries (if used as REESS).

5. The aforementioned position of the REESS and mounting assembly as described in point 1 above, allows for retention of large usable trunk space even with the REESS and power/control unit and/or heatsink installed.
,CLAIMS:WE CLAIM:

1) A retrofit Rechargeable Energy Storage System (REESS) layout structure in a vehicle comprising:
a closed compartment, preferably the luggage compartment of the vehicle;
backrests of the last row of passenger seats;
wheel well structures protruding into the said closed compartment, supporting the suspension mounts; and
a sturdy frame supported by the floor of the aforementioned closed compartment, between the said wheel wells and behind the last row of passenger seats; said frame may be fastened to the said floor by suitable means wherein the said frame supports the said REESS;
wherein:
a recessed cavity under the said frame such that it is bound on the top by the width and length of the said frame, bound on the bottom by the said floor and bound on the back by the said backrest of last row of passenger seats; and
a provision for securing a heatsink and/or any electronic devices in the said recess.

2) The REESS layout structure according to claim 1, wherein:
a) the said frame is mounted transversely to the vehicle longitudinal axis when viewed in plan view, wherein the said frame is bound by the wheel wells on sides and the backrest of the last row of passenger seats in the front;
b) the said layout ensures safety of the REESS and high voltage electronics in the event of a head-on collision as the complete assembly is securely mounted behind the last row of passenger seats, in the trunk with seat back acting like a “firewall”;
c) the said layout and frame orientation add to resistance of the vehicle against getting crushed under lateral loading around wheel well region, thereby protecting the REESS and high voltage said electronics in case of a collision;
d) the said layout ensures safety of the REESS and high voltage electronics 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;
e) the said layout allows for dissipation of heat from said electronics to the said floor thereby allowing optimization of said heatsink;
f) the said layout allows for placement of said electronics in close proximity of the said REESS thereby reducing transmission losses;
g) the said layout allows for near equal load distribution of the weight on to the front & rear axles which lead to improved stability & handling of the vehicle;
h) the said layout allows for the REESS to be isolated or “firewalled” from fuel tank by the vehicle floor; and from passengers by the seats allowing uncompromised safety of vehicle occupants;
i) the said layout allows for retention of majority of space in the trunk even after the REESS and related electronics have been installed;
j) the said layout allows usage of the inbuilt vents inside the trunk to evacuate and prevent buildup of any harmful gases (if any) released by the chemical reactions taking place inside the batteries (if used as REESS).