DESC:FIELD OF THE INVENTION
The present invention relates to a removable and swappable vehicle battery docking system and battery pack assembly with ergonomic, safety and battery pack performance considerations. The docking system in the electric vehicle includes a novel chassis, battery holder and tilting mechanism for the removal of the battery pack.

BACKGROUND OF THE INVENTION

Most of the two wheelers are installed with an engine (ICE) that generates power by burning fuels such as gasoline or diesel and is driven by the power generated by the engine. However, the exhaust gas generated by the combustion of the fuel includes pollutants such as nitrogen oxides (NOx), sulfide oxides (SOx), and greenhouse gases such as carbon dioxide (CO2), and is the main culprit of environmental pollution and global warming.

Therefore, in recent years, to minimize the emission of gases from the engine, such internal combustion engine-driven vehicles have been replaced with electric drive systems. In electric driven vehicle using electricity, a battery for storing the energy is mounted on the vehicle and it is utilised in the driving process. Such battery is required to be charged from time to time based on usage.

Currently, one of the major factors that limit the adoption of electronic vehicles (EVs) is the lack of charging infrastructure and the limitation of the ergonomic battery pack system and its docking.

Therefore, in recent years, to minimize the emission of gases from the engine, such internal combustion engine-driven vehicles have been replaced with electric drive systems. In electric driven vehicle using electricity, a battery for storing the energy is mounted on the vehicle and it is utilised in the driving process. Such battery is required to be charged from time to time based on usage.

In existing electronic two-wheelers (EV two-wheelers), removable or swappable battery packs are docked either under the seat as shown in Figures 1 and 2 or inside the floor as shown in Figure 3 or below the chassis as shown in Figure 4. However, there are two main problems with these systems. Firstly, the docking and undocking actions cause undue muscle stress and strain on the user. Second, the battery pack is enclosed and there is no provision for passive air cooling the battery pack. This increases the chance of battery pack overheating which may lead to dangerous fire hazards.

SUMMARY OF INVENTION

In an embodiment, the present invention provides a battery pack assembly (101) comprising a casing (101a), a battery enclosed in the battery cell inside the casing; a retractable telescopic handle (102) provided on the rear surface of the casing, a fixed handle (103) provided on the top of the casing, at least two moving wheels (104) rotatably installed under casing; a connection port on one side to electrically connect with the vehicle.

In an embodiment according to the present invention, the wheels support the battery pack assembly during the movement and transfer of the battery pack assembly.

In another embodiment the present invention provides a docking and undocking system in a vehicle for holding and storing the battery pack assembly comprising the docking space (400) positioned within and parallel to the downtubes (front) of the vehicle chassis extending till the bottom part, a door for closing and opening the docking space, and a coil/torsion spring loaded tilting mechanism (300) or motorized ejection system for supporting and assisting the docking and undocking of the battery pack assembly.

In an embodiment according to the present invention, the door at one end is provided with a hinge part rotatably connecting the lower side of the door with the bottom end of docking space, a locking system on the upper side of the door for fixing it with the upper end of the docking space.

In an embodiment according to the present invention, the coil/torsion spring mechanism (300) is placed at the bottom of the docking slot extended till the lower portion of the chassis.

In an embodiment according to the present invention, the coil/torsion spring mechanism comprises an L-shaped brace (301) having one end free to move and connected with the spring (302) on the other end.

In an embodiment according to the present invention, the free end of the brace (301) is pushed downwards with the weight of the battery fully stretching the spring/coil (302), removal of the weight releases the spring/coil (302) and the brace (301) is retracted upwards with a force assisting in the removal of the battery pack.

In an embodiment according to the present invention, the coil/torsion spring mechanism (300) automatically ejects the battery pack assembly from its docking station.

In an embodiment according to the present invention, the present invention provides an electric vehicle comprising a battery docking system wherein the dock for battery pack assembly is positioned within and parallel to the downtubes (front) of the vehicle chassis below the handlebar. A spring-loaded base/floor or a motorized ejection system is provided which assists the battery pack ejection according to an embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS
The exemplary embodiments herein may be better understood by referring to the following description in conjunction with the accompanying drawings in which like reference numerals indicate identically or functionally similar elements, of which:

Figure 1 illustrates the battery pack stored in the existing electronic two-wheelers;
Figure 2 illustrates the removable battery pack design known in the art;
Figure 3 illustrates removable battery pack docking on the floor of the electronic vehicle in a known way;
Figure 4 illustrates removable battery pack docking on the chassis according to the existing technology;
Figure 5 illustrates the battery pack with the retracted telescopic handle according to an embodiment of the present invention;
Figure 6 illustrates the battery pack with the open telescopic handle according to an embodiment of the present invention;
Figure 7 illustrates the position of the battery pack assembly dock according to an embodiment of the present invention;
Figure 8 illustrates the unlocking and ejection of the battery pack assembly from the dock according to an embodiment of the present invention;
Figure 9 illustrates the removal of the battery pack assembly from the dock according to an embodiment of the present invention;
Figure 10 illustrates the detachable and transportable battery pack assembly according to an embodiment of the present invention;
Figure 11 illustrates the spring ejection mechanism according to an embodiment of the present invention;
Figure 12 illustrates the spring ejection of assembly from the dock according to an embodiment of the present invention;
Figure 13 is a flow chart indicating the docking steps of the battery pack assembly into the docking system according to an embodiment of the present invention.
Figure 14 is a flow chart indicating the undocking steps of the battery pack assembly according to an embodiment of the present invention.

It should be understood that the above-referenced drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the disclosure. The specific design features of the present disclosure, including, for example, specific dimensions, orientations, locations, and shapes, will be determined in part by the particular intended application and use environment.

DETAILED DESCRIPTION OF THE INVENTION
The terminology used herein is to describe particular embodiments only and is not intended to be limiting to the present disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any or all combinations of one or more of the associated listed items.

It is understood that the term “vehicle”, “two-wheeler”, “bike” or other similar terms as used herein is inclusive of vehicles, in general, such as automobiles including sports bikes, electronic bikes, and the like.

An object of the present invention is to provide a battery docking and undocking system for a vehicle more particularly an electric two-wheeler and an electric two-wheeler equipped with the same.

A battery pack assembly as shown in Figure 5 for achieving the above object is detachably mountable in the receiving space provided in the electric two-wheeler. The battery pack assembly includes a casing (101), a battery enclosed in the battery cell inside the casing; a retractable telescopic handle (102) provided on the rear surface of the casing, a fixed handle (103) provided on the top of the casing, at least two moving wheels (104) rotatably installed under casing to support the battery pack assembly during the movement of the battery pack assembly body; a connection port on one side to electrically connect with the vehicle (Figure 6)

As shown in figure 7, the battery pack assembly docking system for a vehicle according to the present invention is positioned within and parallel to the downtubes (front) of the vehicle chassis.

The docking and undocking system of a vehicle battery assembly comprises- a docking space (400) positioned within and parallel to the downtubes (front) of the vehicle chassis extending to the bottom part, a door for closing and opening the battery pack assembly docking space while the battery pack assembly is completely mounted or removed from the docking space, respectively, a hinge part rotatably connecting lower side of the door with the bottom end of docking space and a locking system on the upper side of the door for fixing it with the upper end of the docking space, a coil/torsion spring loaded tilting mechanism (300) or motorized ejection system for supporting and assisting the docking and undocking of the battery pack assembly.

As shown in Figure 8, when the battery pack assembly is separated and moved from the electric two-wheeler, there is an advantage that the movement of the battery pack assembly can be easily performed with the help of the spring-loaded tilting mechanism provided on the floorboard of the vehicle.

As shown in Figure 9, the positioning of the battery pack is such that it makes docking and undocking of the battery pack easier as there is less vertical height required to lift the battery from the vehicle. It also provides passive air cooling of the battery pack. For undocking, the battery pack from the docking space, spring-loaded locking and pack ejection system are provided to assist the user.

Docking the battery pack is easier as provisions are provided to guide and slot it perfectly into the docking station. Undocking of the battery pack is aided by either spring or a motorized ejection system that positions the battery pack for optimal grab and lift to undock. Due to the positioning of the docking space, the vertical lift of the battery pack assembly is minimized. It also provides optimal passive air cooling. The battery pack assembly according to the present invention provides more space, locking and provision for the power connector (Figure 10).

As shown in Figure 11, the coil/torsion spring-loaded tilting mechanism is provided for supporting the battery pack and for assisting in the docking and undocking of the battery pack assembly. The coil/torsion spring mechanism is provided at the bottom of the slot.

The coil/torsion spring mechanism (300) is placed at the bottom of the docking slot and extended to the lower portion of the chassis. The coil/torsion spring mechanism comprises an L-shaped brace (301) having one end free to move and connected with the spring (302) on the other end, wherein the free end of the brace (301) is pushed downwards with the weight of the battery pack fully stretching the spring/coil (302), removal of the weight releases the spring/coil (302) and the brace (301) is retracted upwards with a force assisting in the removal of the battery pack as shown in Figure 12.

The docking system according to the present invention can be implemented in other scenarios where a relatively heavy pack of battery or cargo needs to be secured safely and easily in a vehicle.

The docking system is a closely integrated system that involves the vehicle chassis and the battery pack itself. It is the optimum solution for the defined problem statement, i.e. ease of docking and undocking of the battery pack. It would be difficult to come up with an alternative solution that can rival the efficiency and practicality of our invention.

An electric vehicle according to the present invention comprises a battery docking system wherein the dock for battery pack assembly is positioned within and parallel to the downtubes (front) of the vehicle’s (two-wheeler) chassis below the handlebar. A spring-loaded base/floor is provided which assists with the battery pack ejection. The positioning of the battery dock is such that it makes docking and undocking the battery pack easier due to less vertical height to lift the battery from the vehicle. It also provides passive air cooling of the battery pack.

In the electric two-wheeler, the battery pack assembly accommodating space is recessed parallel to the downtubes (front) of its chassis providing space for power connection. On the floorboard, a spring-loaded tilting mechanism is provided for supporting the battery pack and for assisting in the docking and undocking of the battery pack assembly.

A guide and slot are provided to assist in the docking of the battery pack assembly perfectly into the docking station. Undocking of the battery pack is aided by either spring or a motorized eject system that ejects and positions the battery pack for optimal grab and lift. Due to the positioning of the docking space, the vertical lift of the battery pack assembly is minimized. It also provides optimal passive air cooling.

Docking and Undocking Process:-
The charged battery pack assembly is wheeled towards the vehicle using the telescopic handle and positioned adjacent to the vehicle floorboard so that the battery pack wheel's axis is perpendicular to the vehicle. Retracting the telescopic handle into the battery pack assembly and lifting the assembly using the fixed handle. Hovering it towards the vehicle floorboard and placing it on the slot provided. The Battery Pack is now in a vertical position and the base is fixed.

Pushing the top of the battery pack assembly forward into the slot provided for it. The coil/torsion spring arrangement resistance tilts the battery pack towards the front till it is parallel to the down-tubes of the vehicle chassis, at which point, the lock is engaged to hold this position. Thus engaging the electrical connector simultaneously with the port provide for it.

The battery pack assembly is now connected to the vehicle both physically and electrically and the vehicle is ready to start.

The undocking of the battery pack is possible only when the vehicle is still and the engine is off. Unlocking the docking station either manually or through the electric switch, the coil/torsion spring mechanism automatically lifts the battery pack in the vertical position. Lifting the battery pack from the slot using the fixed handle provided on the top. Placing the pack on the floor and pulling out the telescopic handle of the battery pack assembly. Finally, pulling the battery pack to the power station or storage with the help of a handle and wheels.

As mentioned in the flow diagram of Figure 13, the first step for docking the assembly is positioning the battery pack assembly adjacent to the vehicle floorboard such that the axis of the assembly’s wheels is perpendicular to the vehicle. Retracting the telescopic handle and lifting the assembly using the fixed handle. Hovering it towards the vehicle floorboard and placing it on the slot given for docking. Pushing the top of the Battery Pack further towards the front, receives resistance from the coil/torsion spring arrangement.

The battery pack stays tilted towards the front till it is parallel to the down-tubes of the vehicle chassis, at which point, both the lock and the electrical connector simultaneously get engaged for holding this position, fully connecting the battery pack assembly with the vehicle both physically and electrically.

As mentioned in the flow diagram of figure 14, the battery assembly is removable when the vehicle is at standstill and the power is off. Engaging the stand of the vehicle followed by unlocking the docking station of the Battery Pack assembly through the physical or electrical switch or remotely.

As soon as the docking station in a vehicle is unlocked the coil/torsion spring arrangement automatically positions the battery pack assembly in the vertical position. Lifting the battery pack assembly using the fixed handle given on its top and removing it from the docking slot. Pulling the telescopic handle of the battery pack assembly and transporting it conveniently for charging.

,CLAIMS:We claim-

1. A battery pack assembly (101) comprising a casing (101a), a battery enclosed in the battery cell inside the casing; a retractable telescopic handle (102) provided on the rear surface of the casing, a fixed handle (103) provided on the top of the casing, at least two moving wheels (104) rotatably installed under casing; a connection port on one side to electrically connect with the vehicle.

2. The battery pack assembly as claimed in claim 1, wherein the wheels support the battery pack assembly during the movement and transfer of the battery pack assembly.

3. A docking and undocking system in a vehicle for holding and storing the battery pack assembly comprising the docking space (400) positioned within and parallel to the downtubes (front) of the vehicle chassis extending till the bottom part, a door for closing and opening the docking space, and a coil/torsion spring loaded tilting mechanism (300) or motorized ejection system for supporting and assisting the docking and undocking of the battery pack assembly.

4. The docking and undocking system as claimed in claim 3, wherein the door at one end is provided with a hinge part rotatably connecting the lower side of the door with the bottom end of docking space, a locking system on the upper side of the door for fixing it with the upper end of the docking space.

5. The docking and undocking system as claimed in claim 3, wherein the coil/torsion spring mechanism (300) is placed at the bottom of the docking slot extended till the lower portion of the chassis.

6. The docking and undocking system as claimed in claim 3, wherein the coil/torsion spring mechanism comprises an L-shaped brace (301) having one end free to move and connected with the spring (302) on the other end.


7. The docking and undocking system as claimed in claim 6, wherein the free end of the brace (301) is pushed downwards with the weight of the battery fully stretching the spring/coil (302), removal of the weight releases the spring/coil (302) and the brace (301) is retracted upwards with a force assisting in the removal of the battery pack.

8. The docking and undocking system as claimed in claim 5, wherein the coil/torsion spring mechanism (300) automatically ejects the battery pack assembly from its docking station.

9. An electric vehicle comprising a battery docking system wherein the dock for battery pack assembly is positioned within and parallel to the downtubes (front) of the vehicle’s chassis below the handlebar and a spring-loaded base/floor or a motorized ejection system for assisting the battery pack ejection.

Dated this 10th day of January 2023.

(HARIHARAN SUBRAMANIAM)
IN/-A-93
Of SUBRAMANIAM & ASSOCIATES
ATTORNEYS FOR THE APPLICANTS