Description:FIELD OF THE INVENTION

[0001] The present invention relates to electro-mobility sector and in particular to a robust battery mounting apparatus, structurally designed to provide a vibration resistant platform for battery installation in electrical vehicles, with sufficient space/provisions for incorporating thermal cooling assembly.

BACKGROUND OF THE INVENTION

[0002] The e-mobility sector is rapidly evolving, driven by growing economic and environmental concerns. Electric vehicles (EVs) utilize various mechanisms to efficiently transfer power to the wheels while minimizing energy losses. One of the key challenges currently faced in this industry is the development of suitable battery accommodation systems. These systems must be designed with careful consideration of multiple factors, including the type of battery to be housed, the integration of effective cooling mechanisms to prevent overheating, and the implementation of a reliable battery management and control system. As the demand for electric vehicles continues to increase, innovative solutions for battery mounting and accommodation are essential to ensure optimal performance, safety, and longevity of the vehicle's power system.

[0003] The existing battery accommodation structures in vehicles involve significant technical hurdles, hindering effectiveness and performance of the batteries disposed within such structures. Many current support structures struggle with inadequate vibration resistance, leading to potential damage to the battery and associated components during operation. Furthermore, the complexity and rigidity of some mounting systems can limit adaptability and ease of integration with different battery types or cooling solutions, leading to increased costs and installation challenges. Addressing these limitations is crucial for advancing battery technology and enhancing the reliability and safety of electric vehicles.

[0004] The rigidity of some designs also prevents easy integration with evolving battery technologies and cooling solutions, making them less adaptable to future advancements. Despite advancements in device development and prior art, effective mechanisms for fulfilling all requirements remain elusive. Existing solutions often fall short in adequately mitigating the identified limitations, underscoring the ongoing need for innovation in this domain. Some of the existing devices/apparatus/methods are as highlighted in the succeeding paragraphs.

[0005] In one of the prior art, EP1598230A1, the invention aims to provide the battery mounting structure of an electric vehicle in which running wind is effectively utilized and the cooling efficiency of a battery is enhanced. The invention provides a battery mounting structure of an electric vehicle based upon an electric vehicle which can be run using a motor as a driving source and which is provided with a body frame (2) where a front frame (4) is extended from a head pipe (3) toward the rear of the body diagonally downward and characterized in that a battery (70) for supplying power to the motor is attached to the front frame (4) of the body frame in such configuration that the cooling face of the battery (70) is directly exposed to running wind. The vehicle can be a hybrid scooter.

[0006] In one more prior art, US8286743B2, An improved protection system for a battery pack mounted between the passenger cabin floor panel of an electric vehicle and the driving surface is provided, the system utilizing a ballistic shield mounted under the electric vehicle and interposed between the battery pack enclosure and the driving surface, where the ballistic shield is spaced apart from the enclosure bottom panel. A layer of a compressible material may be interposed between the ballistic shield and the battery pack enclosure.

[0007] Therefore, the existing technology possess some major drawbacks due to which the current requirements are not met. Hence, it is pertinent to note that the existing technology is not focused to address the issues related to battery mounting structures that can provide a robust and stable mounting of batteries, eliminating the dislodging or displacement of batteries from the mounting position.

[0008] Thus, having regard to such limitations/drawbacks, there is a critical need for providing a robust battery mounting structure that can withstand vibrations and provides sufficient space and provisions for connection of the battery thermal cooling mechanisms, i.e. pipes, valves, regulators etc.

OBJECTS OF THE INVENTION

[0009] The principal object of the present invention is to provide a battery mounting apparatus that can stably hold the battery in electrical vehicles.

[0010] Another object of the present invention is to provide an apparatus that is structurally robust and easy to install over the vehicle chassis.

[0011] Another object of the present invention is to provide an apparatus that prevents any kind of dislodgement of the batteries due to extensive vibration and impact during movement of the electrical vehicles.

[0012] Another object of the present invention is to increase the number of clamping points to prevent any displacement of the battery from initial position.

[0013] Another object of the present invention is to provide a battery mounting apparatus that provides sufficient space and provisions for installation of thermal cooling mechanism/unit.

[0014] Yet another object of the present invention is to reduce the servicing cost/time by reducing the number of parts in the structure.

[0015] Yet another object of the present invention is to provide a mechanism that can be easily retrofitted in existing vehicles with minor alterations as the proposed mechanism do not require any alteration in the design of the vehicle chassis.

[0016] 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

[0017] The present invention relates to a robust battery mounting apparatus that provides a rigid and stable platform for vibration resistant and stable placement of the battery within electrical vehicles. The apparatus is designed with provisions and space for proper installation of thermal systems, thus providing a stable battery mounting apparatus without affecting the existing design of the thermal cooling systems.

[0018] According to the principal embodiment of the present invention, the robust battery mounting apparatus includes multiple longitudinal bars that are mounted over a long arm of a vehicle’s chassis in a parallel orientation, multiple lateral bars installed below the longitudinal bars to form a support platform for placing a battery unit, one or more brackets to fuse the longitudinal members together, two sets of orthogonal members, each set including two orthogonal member, wherein the orthogonal members are fastened over the bracket/support platform in a vertically upright position by means of one or more fasteners, a bent plate installed over each of the orthogonal member, multiple protruded elements integrated with the battery unit which are positioned and clamped with the bent plates to firmly mount the battery.

[0019] According to an embodiment of the present invention, the longitudinal bars are three in number, lateral bars are two in number, orthogonal members, bent plates and protruded elements are four in number. In this embodiment, the longitudinal and lateral bars act as a support platform for placing battery unit and the orthogonal members, bent plates and protruded elements act as a clamping mechanism to firmly clamp the battery unit.

[0020] In one embodiment, the bent plates are in surface to surface contact with each other. The bent plates are crafted with holes and the protruded elements are carved with cavities, both of which align together for insertion of one or more fasteners for attachment of the bent plates with the protruded elements. The attachment of the bent plate and protruded elements, ensure clamping of the battery unit with the present apparatus.

[0021] 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

[0022] 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 a side elevation view, highlighting installation of the proposed apparatus over chassis of the vehicle;
Figure 2 illustrates an isometric view of the proposed apparatus; and
Figure 3 illustrates a top view of the proposed apparatus.

DETAILED DESCRIPTION OF THE INVENTION

[0023] 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.

[0024] 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.

[0025] 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.

[0026] In the existing state of the art, the battery mounting structures are not reliable enough as they involve a complex arrangement of components which not only increases the number of components but also make the installation process more difficult. Adding to this, the existing structures are not completely vibration proof and the displacement of batteries from its original position is generally noticed. Due to such displacements, the electric connecting wires with the batteries or hoses connected with the battery cooling systems are damaged, which increases the frequency of maintenance and chances of fire hazards.

[0027] The present invention addresses these issues by proposing a novel technical solution that mitigates the aforementioned drawbacks and limitations. This innovation aims to provide a robust battery mounting apparatus that can withstand various level of impacts and prevents the displacement of batteries from original position during movement of the electrical vehicles. The apparatus is integrated with a well-supported structure that is rigid in nature, preventing the battery from getting damaged due to minor level of impacts.

[0028] The vehicle introduced in the present invention, can be a three/four wheeler vehicle that in general comprises of a frame/chassis that further comprises a long arm, three/four wheels integrated at posterior and anterior side of the vehicle, respectively, electric motors supported by the frame and wheels, a seat for the driver, and a set of handlebars/steering wheel adapted to be gripped by the hands of the rider for steering the vehicle in different directions, a battery cooling system, multiple electric connections etc.

[0029] The present invention pertains to a durable and adaptable battery mounting apparatus specifically designed for easy integration into existing three-wheeler electric vehicles without requiring any modifications to the vehicle's original design or structure. The apparatus is specifically integrated at behind the back seat of the vehicle. This innovative mounting apparatus is engineered to accommodate the installation of a battery cooling system by providing ample space and necessary provisions for the inclusion of components such as chambers and hoses. The mounting system ensures that the cooling mechanism can be efficiently implemented, enhancing the overall performance and longevity of the battery while maintaining the structural integrity and aesthetic profile of the vehicle. Its versatility allows for seamless retrofitting into a wide range of three-wheeler models, offering a practical solution for manufacturers and users seeking to upgrade their vehicles with advanced cooling capabilities.

[0030] Referring to figure 1 of the present invention, the robust battery mounting apparatus includes several mechanical elements that are integrated together to construct a rigid structure for stably holding a battery unit 111. The apparatus is installed over the chassis 101 of a three wheeler electric vehicle. More specifically, the chassis 101 of the vehicle includes a long arm integrated at the bottom side of the vehicle. Figure 1 illustrates the long arm/chassis 101 that is structurally constructed to bear heavy loads and hence is used as a supporting structure for the present apparatus. The long arm includes two longitudinal members that intersect at a particular point to form a rigid structural support. In an embodiment, the long arm may be constructed using various elements including but not limited to forged steel, or other lightweight material with structural strength.

[0031] The long arm may include one or more latches or slots for installation of multiple longitudinal bars 102. The longitudinal bars 102 are installed over the long arm of the chassis 101, specifically in a parallel orientation to create a support platform 105. In an embodiment, the apparatus comprises of three longitudinal bars 102, i.e. a first 201, second 202 and third 203 longitudinal bars (Figure 2). The first 201 and third 203 longitudinal bars form the outer periphery of the support platform 105 while the second 202 longitudinal bar is installed in between the first 201 and third 203 longitudinal bar.

[0032] In another embodiment, the longitudinal bars 102 are equidistantly arranged with respect to each other, wherein the total distance in between the outer i.e. first 201 and third 203 longitudinal bars is preferably 350 mm with a tolerance in of + 2 mm. In an embodiment, the first 201 and the third 203 longitudinal bars are having equal distance with respect to the second 202 longitudinal bar. In an embodiment, the length of the longitudinal bars 102 fall in the range of 586-985 mm.

[0033] The support platform 105 constructed through the longitudinal bars 102, include a first end 204 and second end 205, wherein the length of each longitudinal bar 102 is equal and hence the end portions of all the longitudinal bars are collinear with respect to each other. Both, first end 204 and second end 205 are fused with two or more brackets 104 to structurally integrate/hold all the longitudinal bars 102 together for forming the support platform 105. In an embodiment, the brackets 104 form the corner portions of the support platform 105, wherein each of the brackets 104 are designed with thickness preferably 60 mm with tolerance of + 1 mm.

[0034] In another embodiment of the present invention, one or more fasteners are used to integrate the brackets 104 with the longitudinal bars 102. In one more embodiment, the number of longitudinal bars 102 may be increased to provide additional support to battery unit 111. In an embodiment, the support platform 105 is designed in a rectangle shape, not being limited to such shape and may be altered in different cross sections to support batteries of different shape and sizes.

[0035] The three longitudinal bars 102 are mechanically supported by two lateral bars 103 that are fabricated at the bottom surface of the longitudinal bars 102. In an embodiment, the lateral bars 103 are installed in between the first end 204 and second 205 end of the longitudinal bars 102. In another embodiment, the lateral bars include a first and a second lateral bars, wherein the first lateral bar is at a distance “d” with respect to a first end 204 of the support platform 105 and similarly the second lateral bar is also at a distance “d” from the second end 205 of the support platform 105, thus forming a symmetric arrangement. In one more embodiment, the end points of the lateral bars 103 are fused with the first 201 and third 203 longitudinal bars while the center region of the lateral bars 103 is fused with the second 202 longitudinal bar. In another embodiment, the number of lateral bars 103 may be increased to increase the structural rigidity of the support platform 105.

[0036] The longitudinal 102 and lateral 103 bars are specifically chosen to be made from hollow tubes with a square cross-section, known as box section tubes, in order to maximize the balance between strength and weight efficiency. By utilizing this structural configuration, the design achieves enhanced load-bearing capacity without unnecessary material bulk, ensuring a lightweight yet robust framework. In an alternative embodiment of the invention, the use of tubes with a rectangular cross-section is implemented. This modification is intended to further improve the overall functionality by expanding the surface area of the assembly that directly interfaces with the battery. The increased surface area provides better support, potentially enhancing thermal management and structural integrity in applications requiring close contact with battery components. This design consideration ensures that the assembly optimally supports the battery while maintaining an efficient material profile.

[0037] The brackets 104 being associated with the first end 204 and second end 205 of the support platform 105 are further installed with multiple orthogonal members 106. The orthogonal members 106 are crafted with grooves that align with the grooves carved in the brackets 104/longitudinal bars 102. The grooves are fastened with one or more fasteners to mechanically assemble the orthogonal members 106 with the brackets 104/longitudinal bars 102 in an upright position. In an embodiment, the fasteners include but not limited to a bolt, a torque nut, a washer. In an embodiment, the fasteners are made up of material including but not limited to steel.

[0038] In a preferred embodiment, the present apparatus includes two sets of orthogonal members 106, each set including two orthogonal members. One set of the orthogonal members 106 is fabricated over the first end 204 and the other set of the orthogonal members 106 is fabricated at the second end 205 of the support platform 105, again creating a symmetrical arrangement. In an embodiment, the distance in between two orthogonal members 106 of one set is equal. In an embodiment, the thickness of the orthogonal members 106 is preferably 4 mm + 1 mm tolerance.

[0039] The orthogonal members 106, include a proximal 206 and distal 207 portion, wherein the proximal portion 206 being affixed with the bracket 104/longitudinal bar 102 and the distal portion 207 being the free end. The distal portion 207 of the orthogonal members 106 are fused with one or more bent plates 107. The design of the bent plates 107 being affixed over the orthogonal member 106 is illustrated in figure 2. As the bent plates 107 are installed over the orthogonal members 106, the bent plates 107 follow the same symmetry with respect to orthogonal members 106, i.e., two bent plates 107 are positioned towards the first end 204 side of the support platform 105 while the other two bent plates 107 are positioned towards the second end 205 side the support platform 105. Each of the bent plates 107 include one flat portion crafted with a hole 108 for fastening purpose. In an embodiment, the thickness of the bent plates 107 is preferably 4 mm + 1 mm tolerance. In another embodiment, the height of the apparatus after mounting the bent plates 107 is preferably 400 mm with minor tolerance.

[0040] The battery unit 111, is installed with multiple projected elements 109 integrated at side portions, specifically at top side portion of the battery unit 111. In an embodiment, four projected elements 109 are installed over the battery unit 111. The projected elements 109 are mechanically fused with the battery unit 111 by means of one or more fasteners. In an embodiment, two projected elements 109 are installed over a first side 111a of the battery unit 111 while the other two projected elements 109 are installed at a second side 111b of the battery unit 111. The fasteners ensure firm and rigid adherence in between projected elements 109 and battery unit 111, providing a unified assembly. The firm attachment enable handling/clamping of the battery unit 111 through the projected elements 109.

[0041] The installation of the projected elements 109 is a mirror image with respect to the placement of bent plates 107. Due to such placement, the projected elements 109 are symmetrically placed over the bent plates 107, with surface to surface contact i.e., the projected elements 109 rests over the bent plates 107, i.e. the projected elements 109 installed at the first side 111a of the battery unit 111 are positioned over the bent plates 107 installed at the first end 204 of the support platform 105 while the projected elements 109 installed at the second side 111b of the battery unit 111 are positioned over the bent plates 107 installed at the second end 205 of the support platform 105. The battery unit 111 is integrated with the projected elements 109 in a way that while the projected elements 109 rests over the bent plates 107, the bottom surface of the battery unit 111 is in contact with the support platform 105. As explained earlier, the support platform 105 is created through the integration of longitudinal 102 and lateral 103 bars.

[0042] Each of the projected element 109 is crafted with a cavity 110 that align with the holes 108 of the bent plates 107 respectively. In an embodiment, the cavities 110 and holes 108 are of similar shape and size. One or more fasteners are inserted through the cavity 110 and hole 108 for firmly fastening the projected elements 109 with the bent plates 107. As the projected elements 109 are connected with the battery unit 111, assembling the projected elements 109 with the bent plates 107 ensures firm mounting of the battery unit 111 with the orthogonal members 106. Through the proposed apparatus, the battery unit 111 is secured at two portions, i.e. one through the clamping of the projected elements 109 and bent plates 107, and the other support platform 105 over which the battery unit 111 rests. Through this arrangement, the battery unit 111, is firmly installed at the back side of the vehicle.

[0043] In an embodiment, various types of fasteners can be utilized in assembly processes, each offering specific advantages depending on the application. Common fasteners include bolts, screws, and nuts, with specifications like the M16 bolt (16mm diameter), which is widely used for its high tensile strength and load-bearing capacity. Hex-head bolts and machine screws are often preferred for their ease of installation and removal, while socket head screws are used in situations where space is limited. Fasteners like self-tapping screws provide the added benefit of creating their own threads in softer materials, eliminating the need for pre-tapped holes. Washers are commonly used alongside these fasteners to distribute the load evenly and prevent damage to the material. The use of high-quality fasteners, such as those made from stainless steel or alloy steel, offers enhanced corrosion resistance, durability, and long-term reliability, making them ideal for demanding environments where strength and longevity are critical factors.

[0044] The specifications related to the screws mentioned here serve as an example of one possible fastening method specifically designed for a particular vehicle chassis 101. However, in other embodiments of the invention, the choice of screws and fastening mechanisms can vary based on several factors, including the dimensions of the chassis 101, the weight of the battery or batteries supported by the assembly, and the mechanical stresses the chassis 101 and assembly are intended to withstand. The fastener selection process is thus highly flexible and influenced by the system's structural requirements, ensuring that the components are optimized for strength, durability, and compatibility with the mechanical loads. This allows for adjustments in the specifications of the screws and other fasteners, depending on the design parameters and performance demands in different applications.

ADVANTAGES OF THE INVENTION

[0045] The proposed invention relates to a robust battery mounting apparatus that is specially designed to support Amaron batteries/A85 Amara Raja within compact size. The present invention is developed with consideration of the space and provisions required for installation of battery cooling or thermal systems. The apparatus is designed to support the battery with increased stability to avoid displacement due to minor vibrations or impacts.

[0046] Further, the installation position of the apparatus provisions the battery to be easily removed or installed while performing one or more maintenance operations over the battery pack or connecting components. The One of the primary benefits is improved structural integrity, ensuring that the battery remains securely in place even under harsh operating conditions such as high vibrations, extreme temperatures, or impact forces, which is crucial for applications like electric vehicles and aerospace. This not only boosts safety but also extends the overall lifespan of the battery by reducing mechanical stresses.

[0047] The present invention include lighter structure, a compact and streamlined design that reduces overall weight without compromising strength, contributing to better energy efficiency in vehicles.

[0048] 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.

List of Referral Numerals

101- Chassis
102- Longitudinal Bars
103- Lateral Bars
104- Brackets
105- Support platform
106- Orthogonal members
107- Bent plates
108- Holes in Bent plates
109- Projected elements
110- Cavities in projected elements
111- Battery unit/Battery
111a- First side of the battery unit
111b- Second side of the battery unit
201- First longitudinal Bar
202- Second longitudinal Bar
203- Third longitudinal Bar
204- First end of the support platform
205- Second end of the support platform
206- Proximal portion of the orthogonal members
207- Distal portion of the orthogonal members , Claims:1) A robust battery mounting apparatus, comprising:

i) at least three longitudinal bars 102, aligned parallel to each other and positioned over a chassis 101, with end portion of the bars 102 fused together using two or more brackets 104, creating a support platform 105 for placement of a battery unit 111;
ii) at least two lateral bars 103, equidistantly disposed in between end portions of the longitudinal bars 102, to structurally support the longitudinal bars 102;
iii) at least four orthogonal members 106, affixed with the brackets 104 in an upright position, wherein distal portions 207 of each orthogonal member 106 is fused with a horizontally oriented bent plate 107 crafted with a hole 108; and
iv) at least four projected elements 109 integrated with the battery unit 111, positioned over the bent plates 107 in an overlapping orientation, wherein said projected elements 109 are crafted with cavities 110 that collinearly align with the holes 108 of bent plates 107 for fastening via one or more fasteners to stably hold the battery unit 111.

2) The apparatus as claimed in claim 1, wherein the chassis 101 includes a long arm that provides structural support to the longitudinal bars 102.

3) The apparatus as claimed in claim 1, wherein the base portion of battery unit 111 rests over the support platform 105, created through the integration of longitudinal 102 and lateral 103 bars using brackets 104.

4) The apparatus as claimed in claim 1, wherein the orthogonal members 106 comprises of a proximal 206 and distal 207 portions.

5) The apparatus as claimed in claim 4, wherein the proximal portion 206 is fastened with the brackets 104 using one or more screws, while the distal portion 207 are assembled with the projected elements 109.

6) The apparatus as claimed in claim 1, wherein the bent plates 107 are in surface to surface contact with the projected elements 109.

7) The apparatus as claimed in claim 1, wherein the support platform 105 includes a first end 204 and a second end 205 framed in a manner that two orthogonal members 106 with bent plates 107 are installed at a first end 204 of the support platform 105 while the other two orthogonal members 106 with bent plates 107 are installed at a second end 205 of the support platform 105.

8) The device as claimed in claim 1, wherein two protruded elements 109 are installed over a first side 111a of the battery unit 111 while the other two protruded elements 109 are installed over a second side 111b of the battery unit 111.

9) The device as claimed in claim 7 and 8, wherein the two protruded elements 109 installed over the first side 111a of the battery unit 111 couple with the orthogonal members 106 installed at the first end 204 and similarly, the two protruded elements 109 installed over the second side 111b couple with the orthogonal members 106 installed at the second end 205 of the support platform 105.

10) The apparatus as claimed in claim 1, wherein the width of the support platform 105 is preferably 350 mm.

11) The apparatus as claimed in claim 1, wherein the height of the support platform 105 integrated with the orthogonal members 106 is preferably 400 mm.

12) The apparatus as claimed in claim 1, wherein the brackets 104 that adjoin the longitudinal bars 102 are preferably of 4 mm thickness.

13) The apparatus as claimed in claim 1, wherein the bent plates 107 and orthogonal members 106 are preferably of 4 mm thickness.