Vehicle

Abstract

The invention relates to an electric vehicle having an electric motor and a bag that can be used to store energy, the vehicle being provided with at least two passenger seats comprising a first seat and a second seat, located behind the front seat and configured to face backwards, and the bag having a transverse module configured to extend between the first seat and the second seat perpendicular to the longitudinal axis direction of the vehicle.

Description

Technical Field

[0001] This invention relates to an electric vehicle with an energy storage pack that can be used to provide energy to drive and propel the electric traction motor of the electric vehicle. More specifically, this invention relates to a motor vehicle that optimizes passenger space and increases the volume of the energy storage pack without sacrificing vehicle dynamics or range. This invention also relates to the energy storage pack and its configuration. Background Technology

[0002] Battery-powered electric vehicles typically have a high-voltage battery pack. A high-voltage battery pack contains thousands of low-voltage cells arranged to meet the needs of a single vehicle. The battery pack contains cells that, through electrical configuration and mechanical assembly, provide the high voltage needed to supply energy that allows the electric vehicle to travel a suitable distance between recharges. For example, a Nissan Leaf manufactured around 2010 would have an initial range of approximately 70 miles, while a Tesla Model S manufactured around 2021 would have an initial range of approximately 200 miles—in each case, the energy storage capacity of the battery pack has a dominant influence on that range.

[0003] Gasoline has a volumetric energy density of 35 MJ / L and diesel 38.6 MJ / L, compared to 0.9 MJ / L for a state-of-the-art lithium-ion battery pack (Tesla Model 3). Once energy conversion efficiency and the overall propulsion system volume are taken into account, the internal combustion engine has a volumetric energy density of approximately 3.0 MJ / L, compared to 0.6 MJ / L for a battery electric vehicle (these figures are based on a comparison of two mid-sized models: the Audi A4 and the Tesla Model 3). The energy storage device required within an internal combustion engine would require approximately 65 liters plus 170 liters for other parts of the propulsion system (engine, transmission, intake, and exhaust). An equivalent battery energy storage device for an electric vehicle would require approximately 1170 liters plus an additional 120 liters for other parts of the propulsion system. Since volume is a major constraint for passenger cars, the volume available for a battery pack in a mid-sized vehicle is limited to approximately 400 liters. The downside is that the range between refueling (recharging) is 600 km for the best battery electric vehicle (Tesla Model 3 Long Range in WLTP cycle), compared to 1380 km for a similarly sized internal combustion engine vehicle (Audi A4 TDi in WLTP cycle).

[0004] Battery pack volume will continue to be a significant constraint on battery pack energy levels and vehicle range. Battery packs typically range from 150L in small cars (A-class) to 460L in large luxury cars, a significant difference compared to the 35L fuel tanks of traditional small cars and the 100L fuel tanks of large luxury cars. Once energy conversion efficiency and differences in propulsion system component volume are taken into account, the energy of a battery pack is roughly 480 liters compared to those fuel tanks, which requires a relatively large amount of packaging space within the same vehicle.

[0005] Table 1 shows the interior volume of a conventional vehicle, based on the US EPA classification and the conventional volume of propulsion systems.

[0006]

[0007] Table 1

[0008] Interior space is a critical constraint for passenger vehicles. Figure 1a shows a schematic plan view of a conventional passenger vehicle 2 with a body 4, two axles 6, and wheels 8 at each end of the axles 6. The “front bay” of the vehicle 2 extends from the area of ​​the front tires 8 to the front of the vehicle (on the left, as shown), while the “rear bay” 12 extends from the area of ​​the rear tires 8 to the rear of the vehicle (on the right, as shown). Between the front bay 10 and the rear bay 12, between the axles 6 of the vehicle, is the “cabin area” 12. Along the edges of the vehicle are collision layers, such as buffer zones 16. Critical components, such as batteries, tend to be located away from the collision layers to reduce the likelihood of damage in a crash.

[0009] The area for storing batteries or their accessories is generally described as being located in one or more of seven areas, as shown in Figure 1a and described along the longitudinal axis as follows: the front bay area 10, which is the space under the hood or engine cover of the vehicle, typically located between the front of the vehicle and the engine compartment bulkhead, and which encloses the electric motor and (if possible) luggage; the front floor area 18, which is located between the engine compartment bulkhead and the front seats, and is the area where the front passengers place their feet and stretch their legs; the front seat area 20, which is the area under the front passenger seats; the rear floor area 22, which is the area between the front seat area 22 and the rear seat area 24, and is the area where the rear passengers place their feet; the passageway area 26, which typically extends along the central longitudinal axis between the front passenger seats and is located below the rear seat area 24; the rear seat area 24 is the area located below the rear passenger seat area 24; and the rear bay area 12 is commonly referred to as the "boot" or "trunk" of the vehicle and extends from the rear seat area to the rear of the vehicle.

[0010] One of the earliest mass-produced electric vehicles was the hybrid Toyota Prius (from 1997), illustrated in Figure 1b. The battery pack 28 is located in the rear bay 12 or luggage area. The Toyota Prius has an internal combustion engine 30 (ICE) and a control module 32 in the front bay 10. Vehicles without an internal combustion engine (no ICE), created and mass-produced by manufacturers for public road use and developed in the last decade, tend to employ one of the three battery pack layouts described below.

[0011] H-type: Primarily a floor-based battery pack layout, it has a larger vertical volume in both the front and rear seating areas, specifically below the first and second rows of passenger seats, resembling the two vertices of the letter H, and with part of the battery pack extending at the lowest point between the front and / or rear floor areas. H-type battery packs are suitable for vehicle platforms using internal combustion engine derivatives because body-in-white (BIW) requires less redevelopment. An example of a vehicle with an H-type battery layout is the 2010 Nissan Leaf (RTM). While the H-type layout utilizes the space under the passengers, it ultimately raises the vehicle because there is no sacrifice in rear luggage space or passenger height. Therefore, the entire front area of ​​the car is enlarged to accommodate the battery pack without sacrificing passenger headroom. In this example, the manufacturer chose not to raise the car, thus accepting a lower battery volume.

[0012] T-type: A dominant layout utilizing the rear seat area or rear bay, i.e., the space behind the second-row passengers (the horizontal part of the letter T), providing additional battery pack volume between passengers in the aisle area (the apex of the letter T). T-type layouts can be used on shared platforms, such as the first version of the Chevrolet Volt, or on dedicated vehicle platforms, such as the Audi A8 eConcept. T-type layouts allow for increased battery pack volume and do not compromise the height of the front seats by using longitudinal space between passengers. However, the rear passenger seats are raised in the rear seat area, similar to early versions of the Chevrolet Volt (RTM), or alternatively, when the battery pack is enclosed in the rear bay of the sports car, the rear seats cannot be enclosed, similar to the Rimac Concept 1 (RTM).

[0013] Underfloor type: This type of battery pack typically requires a dedicated vehicle platform and forms a planar volume of equal depth beneath the floor, across the cabin area, i.e., between the axles, similar to a "flatbed" or "skateboard." Examples of vehicles with underfloor battery packs include the Porsche Taycan (RTM), Tesla Model S (RTM), Jaguar I-Pace (RTM), Chevrolet Volt (RTM), and Audi e-Tron (RTM). Underfloor type battery packs offer greater volume, especially in long-wheelbase vehicles with larger interior volumes, but they have a direct impact on vehicle height and the front end area. An example of an underfloor type battery pack configured within a vehicle is shown in Figure 1c.

[0014] Figure 1d illustrates the time trend of battery packs by way of example, from left to right: first-generation Chevrolet Volt Electric T-type battery pack, second-generation Chevrolet Volt Electric T-type battery pack, first-generation Chevrolet Spark Electric H-type, and Chevrolet Bolt Electric underfloor type battery pack.

[0015] Figure 1e is a table showing the approximate volume (liters) of the battery in different vehicle models, and the volume distribution in the front bay area 10, front floor area 18, front seat area 20, rear floor area 22, passageway area 26, rear seat area 24, and rear bay area 12. It can be understood that as vehicle segment and size increase, the total battery volume tends to increase, and this is achieved using under-floor type battery packs.

[0016] Figure 1f The table shows the impact of underfloor battery configurations on vehicle height, ground clearance, headroom, and the remaining vertical packing space, which is important for interior space. A significant comparison can be made between the Porsche 911 (RTM) and Taycan (RTM). While the Taycan's height is not significantly higher than the 911, the proportion of height allocated to the battery module has a greater impact on the remaining vertical height, and therefore may impose stricter constraints. For example, the Taycan has a gap in the rear panel area for the battery module to accommodate rear passenger feet.

[0017] Passenger comfort is a priority for manufacturers of electric traction motor-driven vehicles, and placing an underfloor type battery pack imposes significant impacts on vehicle height and / or design constraints for passenger placement, similar to the gaps in the Porsche Taycan's underfloor battery. H-type battery packs require greater vehicle height, while T-type battery packs reduce the available space for rear passengers (e.g., Chevrolet Volt Electric (RTM)) or require full utilization of rear passenger space (e.g., Rimac Concept 1 (RTM)).

[0018] Each known battery pack layout affects at least one of the following: vehicle body design, interior layout, passenger space, and vehicle height. This ultimately results in a larger front end area and higher fuel consumption due to reduced aerodynamic performance, and ultimately, vehicle range (which electric vehicle manufacturers strive to maximize). At highway speeds, the front end area and towing efficiency become even more critical, having the greatest impact on reducing electric vehicle range—that is, doubling speed quadruples towing capacity.

[0019] The battery pack layout further impacts vehicle performance, as its structural requirements influence the placement of the battery pack, affecting factors such as weight, material strength, torsional stiffness, and crash performance.

[0020] H-type and T-type battery packs are typically packaged to minimize changes to the standard body-in-white configuration of existing vehicles, which requires a compromise between battery volume and encroachment on passenger / storage space.

[0021] Underfloor battery packs, typically used on skateboarding platforms, offer a larger battery volume. While this results in increased vehicle height, it minimizes impact on passenger capacity and storage space. However, these underfloor battery packs are long, wide, and shallow in depth, meaning they occupy a significant amount of space. The cells within the pack are not structural, therefore the casing must be rigid enough to maintain its shape. Neither the battery pack nor the vehicle can be stretched or bent. Furthermore, if the underfloor battery pack is inserted into a BIW or skateboarding platform, the holes for receiving the pack will need to be reinforced to prevent stretching. Therefore, a compromise is to increase the vehicle's weight to maintain strength and crashworthiness.

[0022] This invention was made in this context. The invention attempts to overcome the problems of known battery pack layouts and conventional seat configurations. Other objects of the invention will become clear from the following description. Summary of the Invention

[0023] This invention generally relates to an electric vehicle having an electric motor and a battery pack for storing energy, the vehicle being configured with: at least two passenger seats, including a forward-facing first seat and a second seat positioned behind the first seat, such as a front seat, and configured to face rearward, wherein the battery pack is configured to have a lateral module configured to extend between the first and second seats along a direction perpendicular to the longitudinal axis of the vehicle. The first and second seats are located in adjacent rows and, because they face opposite directions, form a gap therein, and the lateral module of the battery pack extends at least partially across a portion of the width of the vehicle between the adjacent rows. The lateral module extends in a vertical direction and is therefore configured to optimize the volume of the gap between the adjacent rows. The lateral module may extend at least above the seat cushion and / or at the buttocks point of the seat in the row. The vehicle may have space for configuring to accommodate one or more modules. Alternatively, the seats are arranged back-to-back and facing a direction perpendicular to the direction of operation, and the modules and space can extend longitudinally. The lateral module is configured to extend between the first and second seats in a direction perpendicular to the longitudinal axis of the vehicle across a portion of the width of the vehicle located between the adjacent seats. The height of the lateral module extends along a vertical direction between the lowest surface and the highest surface of the lateral module, the lowest surface of the lateral module being below the lowest point of the first seat adjacent to the battery pack, and the highest surface of the lateral module being above at least one of the following: the top of the seat back of the first and second seats being higher than the highest height of the seat cushion of the first seat in the first row and / or the second seat in the second row; the average height of the seat cushion of the first seat in the first row and / or the second seat in the second row; or the hip point of the seats in the first and / or second rows.

[0024] The example describes a vehicle with an electric motor and a pack for storing energy. The vehicle is configured with a first seat facing forward and / or a second seat facing rearward; and a space / compartment for housing the battery pack, wherein the space is configured to be integrated with the vehicle structure and / or body and located behind the first seat; and extends laterally across the vehicle in a direction substantially perpendicular to the longitudinal axis, wherein the height of the space extends vertically between the lowest point of the space (located below the lowest point of the first seat and / or the second seat) and the highest point of the space (located above at least the highest point of the seat cushion of the first seat and / or the second seat). This space, or other spaces, can be configured to house longitudinal modules, front-end modules, or rear-end modules. The first seat can be a front seat, such as the front row seats in the vehicle. The first seat can be a passenger seat. The second seat can be a rear seat, immediately following the front seats.

[0025] The height of the space extends vertically between the lowest point of the space (located below the hip points of the first and / or second seats) and the highest point of the space (located above at least the hip points of the first and / or second seats). The lowest point of the space may be the floor or bottom of the vehicle body or the vehicle chassis.

[0026] The height of the space may extend vertically to a point exceeding the maximum height of the front and / or rear tires. The lowest point of the space may be below the maximum height of the front and / or rear tires. The lowest point of the space may be below the height of the front and / or rear axle.

[0027] The space can function as a torsion-resistant box structure. The space can be configured as a cage. The cage can be opened. The space may include reinforcing features such as supports, brackets, and mesh, and these features can be connectably configured. The space can be connected to the vehicle side and / or floor and / or chassis structure. The space can be bolted to the vehicle body or chassis.

[0028] The space is configured to receive a module. The module can be movably connected to the space. The connection can be located on the uppermost and / or lowermost surface of the module.

[0029] The vehicle may have a first seat and a second seat facing each other in a direction, and the space extends between the first seat and the second seat. The vehicle may be configured to have at least two passenger seats with backrests, including a first seat configured to face forward, and a second seat positioned behind and adjacent to the first seat and configured to face rearward, wherein the space is configured to extend across the width of the vehicle between the first seat and the second seat, and wherein the height of the space, in the vertical direction, is above at least one of the following: the top of the backrests of the first seat and the second seat; the highest height of the seat cushion of the first seat in the first row and / or the second seat in the second row; the average height of the seat cushion of the first seat in the first row and / or the second seat in the second row; and the buttock point of the seats in the first row and / or the second row.

[0030] The space can be integrated with the vehicle, for example, at least one of the pillars and the space at least partially form a structural ring or an enclosure structure surrounding the interior of the vehicle, and the space is preferably integrated with at least one of the vehicle's A-pillar, B-pillar, C-pillar, and D-pillar. The space can be formed as part of the vehicle's roll cage. The space can be configured to be connected to or formed as part of a trapezoidal chassis.

[0031] The space can be integrated with the vehicle and configured as a load path, wherein external forces applied to the vehicle pass directly through the space. The space is configured to absorb energy from a collision pulse upon impact. The space may be configured with absorption features, such as folded areas.

[0032] The space may have an opening configured to detachably receive and secure the package within it. The opening may be located within the vehicle floor or chassis. The opening may be sized to accommodate a complete module, such as a transverse module. The opening may extend vertically to one side of the space or be located on one side of the space. The perimeter of the opening may be composed of straight lines. At least one side of the opening may be non-straight.

[0033] The vehicle may include a battery pack, which is detachably secured within the space by an accessory connecting at least one of (i) the lowest peripheral edge of the battery pack to the vehicle floor or chassis, and (ii) the highest region of the battery pack to the space. The accessory securing the battery pack within the space may include an elastic element. For example, an elastic element such as a rubber bushing can be used to reduce noise and vibration.

[0034] The space may have walls configured to include at least one of the following: a cage including supports that act as loading paths and are configured to provide a reinforced enclosure structure for the battery pack; metal sheets, such as steel sheets; reinforcing ribs formed within the metal sheets, such as steel sheets; and the reinforcing ribs being connected to the metal sheets, such as steel sheets.

[0035] The battery pack is at least partially enclosed by an encapsulation layer having walls and / or a base, the walls and / or base being configured to include at least one of the following: a cage including supports that act as load paths, configured to provide a reinforced enclosure structure for the battery pack; a metal sheet, such as a steel sheet; reinforcing ribs formed within the metal sheet, such as the steel sheet; and the reinforcing ribs being connected to the metal sheet, such as the steel sheet. The battery pack may include one or more of lateral modules, longitudinal modules, front modules, or rear modules.

[0036] The battery pack is releasably secured within the space. It can be configured to close the opening of the space to seal the battery pack. The encapsulation layer of the battery pack reinforces the space, and the battery pack, connected to and secured within the encapsulation layer, forms part of the vehicle structure together with the encapsulation layer and includes at least one load path. The battery pack can be sealed to the encapsulation layer, and the battery pack may include reinforcing elements configured to protect the battery cells and / or reinforce the walls of the sealing layer. One or more surfaces of the space, particularly the surface closing the opening, can be shaped to suppress resonance and / or increase strength. For example, this can be achieved by having, for example, wavy ribs and / or reinforcing features, and / or an arcuate cross-section.

[0037] The height of the space may extend vertically between the lowest point and the highest point of the space, the lowest point of the space being below the hip point of the first seat and / or the second seat, and the highest point of the space being at least above the hip point of the first seat and / or the second seat.

[0038] The space and / or module can increase the rigidity and / or strength of the vehicle. The housing of the module, such as the lateral module, can include at least one of cages, precast panels, pillars, supports, lattices, and honeycomb structures. The lateral and longitudinal elements of the space and / or module, such as pillars or supports, can be at least one of: folded, extruded, flattened, cast, or made of 3D-printed material, such as iron or plastic.

[0039] The lateral module and / or the space extends across the width of the vehicle in an offset direction, such as asymmetric. The space and / or the lateral module may have two or more surfaces whose tangents extend in different planes, for example, they may include stepped or curved profiles.

[0040] In another example, a module with a battery pack includes at least one of the following: a rack, a bracket, and space for housing the energy cells, the module being configured as a torque box. The module can be configured to cooperate with the space of a vehicle. The structural integrity can be the same whether or not it has the energy cells.

[0041] In another embodiment, the vehicle is equipped with an electric motor, such as a traction motor, and a battery pack for storing energy. The vehicle has at least two passenger positions, including a first seat and a second seat located behind the first seat, such as a front seat, and configured to face rearward. The battery pack has a lateral module extending between the first and second seats along a direction perpendicular to the longitudinal axis of the vehicle. The first seat can be a front seat, such as the front row seats in a vehicle. The first seat can be a driver's seat. The second seat can be a rear seat, located in the row immediately behind the front seats.

[0042] The height of the lateral module extends vertically between the lowest point of the lateral module and the highest point of the space. The lowest point of the lateral module is below the hip point of the first seat and / or the second seat, and the highest point of the space is at least above the hip point of the first seat and / or the second seat. The lowest point of the lateral module may be located in the floor area or in the base area of ​​the body-in-white or the vehicle chassis.

[0043] The height of the lateral module may extend vertically to a point above the highest point of the front and / or rear tires. The lowest point of the lateral module may be a point below the highest point of the front and / or rear tires. The lowest point of the lateral module may also be a point below the height of the front and / or rear axle.

[0044] The lateral module can be configured between adjacent rows of seats, one row facing forward in a first direction, and the other row facing backward in the opposite direction, such as rearward. The rows of seats can be arranged in the longitudinal direction of the vehicle. Rearward-facing seats can face the rear of the vehicle and be parallel to the vehicle's longitudinal axis. Rearward-facing seats can be configured not to be aligned with the vehicle's longitudinal axis. Although the invention includes a battery pack between adjacent seats configured to face different directions, such as rows of seats, adjacent rows can be a first row and a second row, i.e., front seats and rear seats.

[0045] Different seating arrangements are available and include, but are not limited to: two seats arranged along the longitudinal axis, having a first seat and a second seat, the first seat being positioned facing forward of the vehicle, and the second seat being positioned behind and adjacent to the first seat, the second seat facing rearward, for example in a back-to-back layout; three seats arranged along the longitudinal axis, having a first seat in the first row facing forward of the vehicle and two seats in the second row facing rearward, the second row being adjacent to and behind the first row; three seats arranged along the longitudinal axis, having two seats in the first row facing forward of the vehicle and a third seat in the second row facing rearward, the second row being adjacent to and behind the first row; four seats arranged along the longitudinal axis, having two seats in the first row facing forward of the vehicle. The vehicle has three or more rows of seats, each with one or more seats, and at least two rows of seats facing opposite directions, for example, in a back-to-back layout; the vehicle has three or more rows of seats, each with one or more seats, and at least two rows of seats facing to the side; and the vehicle has three or more rows of seats, each with one or more seats, and at least two rows of seats aligned with the longitudinal axis of the vehicle.

[0046] The vehicle can only be powered by electricity, which comes from energy stored in a battery configured to output current. Further or alternatively, an additional energy source can be used to generate electricity, such as a hydrogen fuel source and an electrolysis system that converts stored hydrogen into current to drive a traction motor. The vehicle can also be driven solely by non-combustion methods.

[0047] The vehicle may be equipped with a drive mechanism and / or an energy management system configured to receive and process stored energy to drive the drive mechanism and / or retrieve the stored energy. The system may include an energy conversion module for managing the reception of electrical power from an external source to charge the vehicle's battery pack. The energy conversion module manages the energy delivery from the battery pack to the traction motor. The energy conversion module can manage the energy delivery from any source (e.g., regenerative braking) to charge the vehicle's battery pack.

[0048] The vehicle may further include a longitudinal module configured to extend along the longitudinal axis of the vehicle; extend perpendicular to the transverse module; and extend at least partially between the front seats and the rear seats. The longitudinal axis may be the central longitudinal axis of the vehicle. The front seats may be located on one side of the longitudinal axis of the vehicle.

[0049] The longitudinal axis may be the center of the vehicle, and the vehicle may be configured to have: at least two front seats separated by the longitudinal axis; and / or at least two rear seats separated by the longitudinal axis. At least one front seat and at least one rear seat may at least partially face different directions. At least one seat in the first row and at least one seat in the second row may at least partially face different directions, for example, opposite directions. The distance between the front seats and the rear seats may be less than the maximum dimension of the front seats or the rear seats in the longitudinal direction. Each seat may have a foot area, wherein each foot area may have a maximum foot space dimension in the longitudinal direction of the vehicle.

[0050] In the longitudinal direction of the vehicle, the seats can be divided by a space defined between the rear surfaces of the front seats, the rear surfaces of the rear seats, and the floor of the vehicle. The seats can have a maximum tilt angle. The maximum tilt angle of the seats can be determined by the lateral module. The maximum dimension of the space between the front and rear seats in the longitudinal direction of the vehicle can be less than the maximum space occupied by at least one of the front and rear seats in the longitudinal direction of the vehicle. The longitudinal length of the base of the lateral module can be between approximately 20% and approximately 41% of the wheel base distance of the vehicle. The length of the front seats can be between approximately 45 and 60 centimeters. The maximum distance between adjacent rows of seats in the longitudinal direction can be approximately 50 centimeters, or approximately 30 centimeters, or less than approximately 25 centimeters.

[0051] Although this example relates to a vehicle interior having a transverse module between adjacent rows of seats, the shape of which can improve the performance of the vehicle in which it is configured, this example may also relate to a battery pack having a transverse module as described and defined in the claims, and / or a method of configuring a vehicle having a transverse module as described and defined in the claims.

[0052] In another example, a vehicle with a traction motor and a battery pack for energy storage is involved, the battery pack having a transverse module extending perpendicularly to the longitudinal axis of the vehicle, wherein at least a portion of the cross-section of the transverse module is quadrilateral. The transverse module may be defined by the outer edge of an encapsulation layer, which may have a truncated pyramidal shape based on the quadrilateral. The transverse module may have at least two side portions configured to extend vertically toward an intersection point above the transverse module and taper at their apex. The side portions extending vertically toward the intersection point above the transverse module may be sides facing the front and rear of the vehicle, and / or sides facing the sides of the vehicle. The transverse module may be an isosceles trapezoid. The transverse module may have a front side facing the front of the vehicle and a rear side facing the rear. Because the transverse module extends between adjacent rows of seats, the front and rear sides may be tilted to complement or match the nearest surface of the seat. The center of gravity in the vertical direction may be lower than the center point of the cross-section in the vertical direction. The upper surface of the transverse module in the longitudinal direction is shorter than the length of the base of the transverse module. The length of the highest portion of the lateral module may be between about 10% and about 50% of the base length of the lateral module, and preferably between about 20% and about 40% of the base length of the lateral module, and more preferably between about 25% and about 35% of the base length of the lateral module.

[0053] In the longitudinal direction, the lateral module may widen towards the front of the vehicle and narrow towards the rear of the vehicle, and / or the lateral module may widen towards the bottom of the vehicle and narrow towards the top of the vehicle. The sides of the lateral module may be shaped to fit the features of the vehicle, such as wheel arches.

[0054] The battery pack may further include a longitudinal module connected to the lateral module; the longitudinal module is configured to extend along the longitudinal axis from the lateral module toward the front of the vehicle. The connection may be mechanical and / or electrical. The longitudinal module may have a cross-section that is at least partially trapezoidal. The upper surface of the longitudinal module is shorter laterally than the width of its base. The width of the topmost part of the longitudinal module in the lateral direction may be between approximately 10% and approximately 50% of the width of the base of the longitudinal module, more preferably between approximately 20% and approximately 40%, and even more preferably between approximately 25% and approximately 35% of the width of the base of the longitudinal module.

[0055] The battery pack may be equipped with a rear module connected to the lateral module, the rear module being configured to extend rearward from the lateral module. The connection may be mechanical and / or electrical. The battery pack may be equipped with a front module, the front module being encapsulated in the front bay of the vehicle and connected to the battery pack. The connection may be mechanical and / or electrical. The rear module may be wider towards the front of the vehicle and narrower towards the rear of the vehicle. The rear module may be configured to extend along the longitudinal axis between the rear seats; and / or extend beneath the rear seats.

[0056] The bottom surface of the longitudinal module and the bottom surface of the transverse module can be configured to extend at the same level within the vehicle. The height of the transverse module can be at least one of the following: the maximum height of the lowest position of the top of the front or rear seat, or less than 100 mm; at least higher than the maximum height of the seat cushion in the first and / or second row; or lower than the lowest edge of the window opening closest to the battery pack.

[0057] The vehicle may be configured to have at least one of the following parameters: having a transverse module with a volume ranging from approximately 3791 to approximately 11231; the length of the battery pack, including a longitudinal module, the transverse module, and the rear module, being between approximately 88% and 92% of the wheelbase; the length of the base of the transverse module being between approximately 26% and approximately 41% of the wheelbase length in the longitudinal direction; and within the vehicle having the transverse and longitudinal modules, the transverse module may be between approximately 275% and approximately 720% of the volume of the longitudinal module, and / or the longitudinal module's... Approximately 150% and approximately 350% of the height; when the battery pack extends beyond the area below the front seat passenger, the hip point of the front seat passenger is between approximately 31% and approximately 41% of the vehicle height; when the area where the battery pack can be configured in the vehicle, and the height of the vehicle, the packing efficiency is (i) the volume per square meter of the battery pack, which is the average track width of the vehicle multiplied by the wheelbase, and (ii) when the volume per square meter of the battery pack relative to the height of the vehicle is also taken into account, then the battery pack is configured to be between approximately 144 L / m². 2 and approximately 2651 / m 2 , and / or approximately 2941 / m and approximately 8851 / m.

[0058] In summary, the example here differs from known vehicles and has improved features, which may include:

[0059] The increased energy storage volume can be achieved through the shape and configuration of the lateral modules of the energy battery pack, which have a higher height compared to other modules. This increased height can be achieved by placing lateral modules between adjacent rows of seats, such as the front and rear seats, where the rear seats face rearward and away from the front of the vehicle. The rear seats may face to one side or rearward, for example, in a back-to-back configuration, thus obstructing legroom for rear passengers. In this placement, the lateral modules can extend across the width of the vehicle, for example, between adjacent rows of front and rear seats. The lateral modules can be configured to extend above the buttocks of the front and rear seat passengers, located in the row below the front seats. That is, the lateral modules extend vertically to a height above the highest point of the seat cushion where the passengers will sit.

[0060] Enhanced safety is achieved because the battery pack can be centrally positioned, reducing the perimeter of the battery pack exposed on one side of the vehicle, such as around a crash buffer zone. A vehicle with a battery pack can have a crash buffer zone, and the battery pack can be shaped so that it does not extend into the buffer zone, or the peripheral surface of the battery pack exposed to the crash buffer zone is minimized. This example allows for a larger battery pack volume while minimizing the battery pack's exposure to the vehicle's exterior.

[0061] Better collision performance is achieved because the interfaces between the modules of the battery pack are at least shaped to offset forces to prevent damage from longitudinal forces and / or include energy absorption characteristics. The modules of the battery pack may be shaped to prevent damage caused by collisions and may include at least one of the following: an interface shape that guides the modules away from each other to offset the force of a collision pulse; a rotatable interface; and an energy absorption component.

[0062] A better travel distance is achieved by reducing the front area of ​​the vehicle. This also improves fuel efficiency, which can be achieved by lowering the hip point of the passengers, since there is no module encased under the passengers causing their seating position to be raised, and thus allowing for a lower overall vehicle height.

[0063] The battery pack layout results in better packaging, which reduces the weight of the vehicle.

[0064] These examples can be located within a vehicle that includes one or more of these improved features. The vehicle may be equipped with two or more lateral modules and / or spaces. For example, it is known that a battery pack with only a flat, panel-like floor can benefit from having lateral modules extending between the first and second rows of seats, wherein the second row of seats faces rearward, for example, towards the rear of the vehicle. The vehicle in this example can be an electrically driven vehicle with an electric traction motor. The vehicle and / or battery pack in this example illustrate, by way of example, the purpose of using batteries or cells located within each module or section forming the battery pack.

[0065] According to the guidance of this invention, those skilled in the art will understand that aspects of the invention are interchangeable and transferable among those described, and can be combined to provide a more preferred aspect of the invention. A further aspect of the invention will be understood through the following description. Attached Figure Description

[0066] The known vehicle layout is illustrated above with reference to Figures 1a to 1f. To facilitate understanding of the invention, the remaining figures are referenced by way of example, wherein:

[0067] Figures 2a to 2f The vehicle is shown in various views, including a side view, a plan view, and a perspective view. The vehicle has a battery pack with lateral modules and shows passengers sitting next to the battery pack.

[0068] Figures 3a to 3d Showing Figure 2b The diagram shows the layout of the different battery packs, along with a side view of each battery pack for reference.

[0069] Figures 4a to 4c It showed similar Figure 3c Cross-sectional diagrams of vehicles of different sizes with varying battery packs and layouts;

[0070] Figures 5a to 5c A perspective view and schematic cross-section show a lateral battery module, as well as an example of the cell layout of the module within the battery pack, which has shaped sides.

[0071] Figures 6a to 6c A schematic cross-sectional view of a battery pack is shown, which has features to prevent damage to the battery pack in the event of a frontal or rear-end collision.

[0072] Figure 7a A schematic side view of the vehicle with a battery pack is shown, while Figure 7b and 7c They were displayed respectively Figure 7a Side view and Figure 7aA side view of the battery pack, for reference;

[0073] Figures 8a to 8f These are different parts of the same table, which together provide the size information of the battery pack in this example, when various sizes are achieved, for example, by using actual data, calculations, and displays in combination of the reference numerals in Figure 7;

[0074] Figure 9 is a perspective view of the body-in-white of a known vehicle, where the load path is shown using arrows along the corresponding structural members;

[0075] Figures 10a and 10b are perspective views of the white body of the vehicle showing structural components;

[0076] Figure 11 Based on the three-dimensional diagram of the car in this example, and the forces acting on the car in the X, Y, and Z planes, and the input forces from the road surface as indicated by the arrows;

[0077] Figure 12a and 12b Each shows a perspective view of a known vehicle with an underfloor type battery pack located under the vehicle before installation and a vehicle configured according to this example, wherein the battery pack is shown located under the vehicle before installation;

[0078] Figure 13 A 3D sketch of the internal structure of the horizontal module;

[0079] Figures 14a to 14c The diagram shows the internal structure of the battery pack's cells, the encapsulation layers of the lateral modules, and the space between all these components before they are nested together.

[0080] Figure 15 It is another arrangement of the transverse modules, which extends across the width of the vehicle in an offset manner, showing both with and without a body-in-white shell; and

[0081] Figure 16 It is a collection of side views of different cars, with overlapping compartments.

[0082] Similar reference numerals indicate similar features. Detailed Implementation

[0083] Figures 2a to 2eThis passenger vehicle 100, with an example configuration, is a structurally proportional representation of the example, derived from CAD data. The vehicle in this example has an electric traction motor 102 for driving wheels 104 and an associated energy conversion module 106 for converting energy from and to a battery pack configured to store energy. The module provides electrical energy to drive the electric motor 102. Each vehicle in this example may include such an energy conversion module 106, which manages the reception of electricity from an external source to charge the vehicle's battery pack and subsequently manages the energy supply from the battery pack to the traction motor. Although not shown in this example, an internal combustion engine may optionally be equipped to drive at least one wheel of the vehicle or to drive a generator to generate electrical energy stored in the battery pack. However, the applicant's intention is to provide an improved battery pack configuration and / or an improved vehicle layout for vehicles with non-internal combustion engines, configured to accommodate a battery pack with a larger volume to increase energy storage capacity and thus increase the range of vehicles without IEC.

[0084] exist Figure 2a In this vehicle, the body 108 has a front portion 110 and a rear portion 112, a front axle 114a and a rear axle 114b, and wheels 104 and tires are provided at both ends of the axles. Figures 2a to 2c In each figure, the front passenger 116 (95th percentile male) is shown seated in the front seat 118, facing the front of the vehicle. Further, the rear passenger 120 (95th percentile male) is shown seated between the front passenger 116 and the rear seat 122 at the rear of the vehicle, with both the rear seat and the rear passenger facing the rear of the vehicle 112. Optionally, the rear seats are configured to accommodate the 95th percentile male – some vehicle types, such as sports cars with a 2+2 configuration, have rear seats that are rarely used and are therefore configured to accommodate the 50th percentile male, an example of which is shown in [figure not provided]. Figure 2d and 2e middle.

[0085] Figure 2f Showing Figure 2d and 2e Passengers sit around the battery pack in their seats, wherein one row of passenger seats, in this example the front seats, is located outside the space occupied by the battery pack. That is, the first row of passenger seats does not have a battery pack located beneath them. In this way, the hip point of the seats can be lowered. In this example, the second row of seats adjacent to the first row and facing rearward is positioned above a portion of the battery pack. However, the rear module is optional and / or can be configured to extend between rear passengers, so that their seats also do not have a battery pack located beneath them.

[0086] The front seats 118 and rear seats 122 are positioned back-to-back so that the passengers face opposite directions. In this example, the front seats 118 are positioned such that the front passenger sits approximately midway between the front axle 114a and the rear axle 114b of the vehicle. The rear seats are positioned in the area of ​​the rear axle. Figures 2a to 2c In the example, the rear seat and the passenger's hip point (HP) 124 are such that HP 124 is located in front of the rear axle 114b and the passenger's legs will extend beyond the rear axle towards the rear of the vehicle. Figure 2b 2c and 2d are displayed accordingly. Figure 2a The floor plan and front view of the vehicle are shown, and in all these drawings only show two passengers, 116 and 120, to provide a clear view of the battery pack used for storing energy in the vehicle. Although the vehicle can have only two seats, the vehicle shown can be placed in a four-seat configuration of "2+2", with two front seats and two rear seats, and additional seats (not shown) can be placed in the mirror position.

[0087] The battery pack in this example has two modules—a lateral module 126 and a longitudinal module 128. The lateral module is configured to extend between the front seats 118 and the rear seats 122, i.e., between the two front passenger seats (although only one front passenger is shown for clarity), and between the two rear seats (although only one front passenger is shown for clarity). The lateral module 126 is configured to extend between the opposing front and rear passenger seats shown in Figures 26 to 2c, from one side of the vehicle to the other. The lateral module 126 can extend from one side of the vehicle to the other. The lateral module can be confined within a crash pack enclosure. The longitudinal module 128 of the battery pack extends perpendicularly to the lateral module 126 along the longitudinal axis of the vehicle toward the front of the vehicle. The longitudinal module can extend along the longitudinal axis of the vehicle between the front passenger seats. The lateral and longitudinal modules 126, 128 may include respective sub-modules. The modules and sub-modules may contain individual cells, such as battery cells.

[0088] The battery pack shown extends longitudinally from the front to the rear, from an area adjacent to the vehicle's bulkhead to an area adjacent to the rear axle. The longitudinal module extends from the bulkhead to an area level with the backrests of the front seats, where it intersects the vehicle floor. After this point, facing the rear of the vehicle, the transverse module extends to an area level with the rear axle.

[0089] Both the longitudinal module 128 and the transverse module 126 have bottom surfaces configured such that they are at the same level as the bottom of the vehicle, typically the floor of the body-in-white or the bottom of the vehicle chassis. The base of the longitudinal module may be at the same height as the transverse module. The height of the longitudinal module 128 may be consistent along its length. The height of the longitudinal module may be between approximately 100 mm and approximately 500 mm, and optionally between approximately 200 mm and approximately 400 mm, and preferably approximately 350 mm. The height of the longitudinal module may be between approximately 5% and approximately 45% of the vehicle depth, and optionally between approximately 14% and approximately 35%, and preferably between approximately 25% and approximately 35% of the vehicle depth. The height of the longitudinal axis may vary to accommodate other features of the vehicle. For example, the height of the partition area may be reduced, gradually decreased, or stepped down to accommodate the vehicle's instrument panel.

[0090] The height of the transverse modules, which are related to the longitudinal modules (when provided), can vary depending on the size and configuration of the vehicle. For example, the following discussion... Figures 8a to 8f The values ​​in the figures represent a nominal configuration where the longitudinal module has a height of 350 mm and the lateral module is 55% of the vehicle depth – thus the lateral module is between approximately 175% and approximately 225% of the height of the longitudinal module. However, having a lower longitudinal module (approximately 100 mm) and a higher lateral module (approximately 70% of the vehicle depth) results in the lateral module being between approximately 750% and approximately 1000% of the height of the longitudinal module.

[0091] The height of the lateral module can be the maximum height of the front and rear seatbacks. The maximum height of the seatbacks can include the head protection device, which can be integrated with the seat.

[0092] Figures 2a to 2d An example is shown where four passengers can be arranged as two facing forward at the front and two facing backward at the rear, with two front seats separated by a longitudinal axis and two rear seats separated by a longitudinal axis. Different contemplated configurations are within the scope of the invention, such as equipping at least one front seat and at least one rear seat facing backward. In this configuration, the longitudinal axis may extend along a non-central axis of the vehicle. When equipped with a single center seat or three front seats, two longitudinal axis modules may be equipped, extending along one side of the seats. Figures 2a to 2dIn this example, each front seat is provided with a rear seat adjacent to and behind the front seat, so that they are back-to-back. However, the front and rear seats do not need to be aligned. Therefore, at least one front seat and at least one rear seat can be configured at least partially as follows: offset in the lateral direction; having rearward-facing rear seats that include a series of positions from the side facing the vehicle to the rear of the vehicle; and back-to-back.

[0093] For example, a microcar may be equipped with a configuration in which the vehicle has only two seats, which are aligned facing opposite directions and have a lateral module for a battery pack disposed between the two seats, as described herein. The two seats are aligned centrally within the vehicle. Such a vehicle may have the lateral module and optionally a front module and / or optionally a rear module. Although the lateral module here is intended to provide an increased battery pack volume as an option to replace the underfloor battery pack, the vehicle may be equipped with both an underfloor battery pack and the lateral module.

[0094] The lateral modules of the battery pack are configured in a gap or in space 134, between the rear surfaces of the front and rear seats. This gap 134 is therefore configured because the front and rear seats are opposite each other and the seats have a ramp. Figure 2a The minimum dimension of the cross-section of the gap 134 can be determined by the limits of the recline of the front seat and the rear seat, for example, until the upper part of the front seat contacts the upper part of the rear seat. Even when the front seat and the rear seat are reclined and in contact, a gap exists between them. This gap is a three-dimensional space, and the three-dimensional space is defined in cross-section by… Figure 2a The floor of the vehicle shown is defined by the rear surfaces of the front and rear seats; and as in Figure 2b The plan view shown is defined by the body of the vehicle at the side.

[0095] To accommodate the shape of the vehicle body, the transverse module in the longitudinal direction can be wider at the front of the vehicle and narrower at the rear, such as... Figure 2b As shown, and / or the lateral module in the vertical direction is wider at the base and narrower at the top facing the vehicle, as... Figure 2cAs shown. To avoid any doubt, the applicant has positioned the rear seats rearward to create a gap in which the lateral modules can be encapsulated. The battery pack may be shaped to maximize its volume within the gap by having at least one of the following: lateral faces, i.e. those facing the front and rear of the vehicle, extending non-perpendicularly to each other, for example, inclined to form a triangle or quadrilateral in cross-section; the ends of the lateral modules, i.e. those closest to the sides of the vehicle, extending at an angle and non-perpendicularly to the longitudinal axis of the vehicle; and the ends of the lateral modules, i.e. those closest to the sides of the vehicle, configured to extend to each other, such that they gradually decrease or are otherwise configured to adapt to the shape of the vehicle, which may include adaptation to wheel arches.

[0096] The lateral module 126 may at least partially form a triangular prism shape, having three sides and two end faces. To accommodate the ideal mathematical shape, the prism needs to be smaller than the gap or space between the seats, thus leaving unused space. In practice, the module may be constructed to have a portion in cross-section that is at least substantially triangular or quadrilateral in shape. The triangular prism may have an upper portion of shape, such as a flat top, which may be referred to as the lateral upper portion. The lateral upper portion extends in the top region of the seat back. The minimum dimension at the top of the lateral module may be close to or proportional to the size of the module's minimum battery cell. The shape of the vehicle may have curved sides, and therefore the ends of the lateral module may be tilted or angled to utilize available space. The shape of the battery pack may be between an ideal triangular prism and a three-dimensional shape that occupies most of the space in the gap. The lateral module 126 may take the shape of a truncated quadrilateral pyramid.

[0097] The lateral module of the battery pack can function as an internal partition because its height can extend to at least 75% of the height of the front seats, and preferably to the full height of the front seats. The front seats can extend even higher, theoretically reaching the height of the vehicle's interior ceiling. The battery pack can be configured as a partition wall between the front passenger area and the rear passenger area. The lateral module can be configured to extend vertically to the lowest point of the nearest opening (e.g., a window). The height of the lateral module can be between approximately 50% and approximately 70% of the vehicle depth. As described below... Figures 8a to 8f The examples in the table set the vehicle depth to 55% for each vehicle example.

[0098] The battery pack 107 can be configured to adapt to different vehicle sizes and seating configurations, and each module is configured for a given configuration. Figures 3a to 3d Showing Figure 2bThe plan view of the different battery pack configurations shown is as follows: A vehicle 100 with only a battery pack 107 of the transverse module 126, located between the front and rear seats, wherein the rear seats face rearward. This may be suitable if the vehicle has, for example, a short wheelbase (distance between axles) and minimal space to accommodate the longitudinal module and / or rear module (see...). Figure 3a The vehicle has a battery pack with a transverse module 126 located between the back-to-back front and rear seats, and an optional longitudinal module 128 extending from the transverse module toward the front of the vehicle between the individual front seats (see...). Figure 3b A battery pack having a horizontal module 126 and an optional vertical module 128, such as Figure 3a and 3b In addition, an optional rear module 130 may be suitable if the vehicle has space to accommodate the lateral module 130, for example, in a SUV under the rear seats and / or between the rear seats (see [link to SUV description]). Figure 3c ); and has a battery pack with a lateral module 126, an optional longitudinal module 128, and an optional rear module 130, such as Figure 3c In addition, an optional front module 132 may be suitable if the vehicle has a rear-wheel-drive electric traction motor and therefore has space in the front to accommodate further battery pack volume and energy storage (see...). Figure 3d ).

[0099] As shown in these figures, modules 126, 128, 130, and 132 can be shaped to fit the shape of the vehicle, for example, the front of the longitudinal module and the rear of the rear module gradually decrease in size, as do the sides of the transverse module, which in this case takes into account the rear wheel arches of the vehicle.

[0100] The rear module may have at least one of the following: a rearward, i.e., side facing the rear of the vehicle, extending non-vertically toward a point on the rear module, for example, inclined to form a wedge shape; the side of the rear module forming an angle relative to the longitudinal axis of the vehicle; and the ends laterally closest to the side of the vehicle being configured to extend toward each other.

[0101] The rear module may be wider facing the front of the vehicle and narrower facing the rear. The rear seats may be elongated seats, i.e., a single seat cushion is configured to accommodate two or more passengers, and the rear module may extend horizontally and flatly under the elongated seat. However, if the vehicle is equipped with two individual rear seats, the rear module may be configured to extend along the longitudinal axis of the vehicle under and / or between the individual rear seats.

[0102] The longitudinal module can also be shaped to optimize the use of the space between the front seats and the space at the frontmost part of the vehicle adjacent to the partition. The longitudinal module can also be shaped to optimize its volume in the gap by having at least one of the following: a non-perpendicular front, i.e., the surface closest to the partition, for example, angled to form a gradually narrowing front end that houses the dashboard or an important display screen above the vehicle; and sides, i.e., those surfaces closest to the front seats, angled and extending non-perpendicularly to the longitudinal axis of the vehicle, thus allowing for a larger volume and minimal intrusion into the passenger space.

[0103] Figures 4a-4c The positions of seats 118 and 122, passengers 116 and 120, and battery pack 107 are shown in a schematic cross-section within three types of vehicles 100 with different sizes and purposes. Each vehicle shows a battery pack 107 with a longitudinal module 128, a transverse module 126, and a rear module 130. An electric traction motor 102 is used to drive wheels 104 mounted on the front and rear axles 114a and 114b. Passengers are shown seated in the front and rear seats.

[0104] Figure 4a The sports car shown features a "2+2" seating configuration, with an overall low height and seats positioned even lower within the vehicle, resulting in a lower passenger hip point (HP) of 124. In the plan view, Figure 4a With Figure 3c Comparable layouts. In general, for better performance and efficiency, a lower chassis height can be achieved and provides a smaller front end area, resulting in increased travel, for example. As mentioned above... Figures 2a to 3c As described, the front and rear seats face opposite directions. The battery pack's risk module is configured to accommodate the space between the front and rear seats—thus having a wide base in cross-section and being configured vertically to narrow towards the top of the vehicle. In the example shown, the highest point of the lateral module is located in the area above the seat back or the top of the front and rear seats. Between the two seats, a longitudinal module extends from the lateral module toward the front of the vehicle—this allows the hip point 124 of seats 118, 122 or passengers 116, 120 to be lowered, since there are no components of the battery pack 107 below the front seats. In this example, as shown, the sports car has front seats that typically accommodate the 95th percentile male, while the rarely used rear seats are often smaller and typically accommodate the 50th percentile male. The rear module is configured to extend from the lateral module toward the rear of the vehicle. The rear module can be configured to extend from the lateral module toward the rear axle. However, by extending upward from a higher point in the lateral module, the rear module can be enclosed above the rear axle—a side view schematic of an example of this layout is shown. Figures 6a to 6bInside, the battery pack 107 can be placed between the vehicle's axles. The lateral modules extend vertically beyond the height of the longitudinal modules to provide additional storage volume for the battery pack. This is because the increased height of the lateral modules 126 of the battery pack 107, combined with the opposite seating arrangement, provides more space for the battery pack and can accommodate rear passengers without sacrificing comfort, such as reduced legroom, or without requiring compromises in the battery pack layout, such as specially shaped underfloor batteries to accommodate the feet of rear seat passengers, similar to the Porsche Taycan.

[0105] Figure 4b Display and Figure 4a The layout is fairly standard, except that the car shown is a small car, such as a B-segment car with a longer wheelbase. The lateral module 126 extends vertically between the seats, with its highest point located in the area at the top of the seatbacks. The longitudinal module 128 extends between the front seats and is lower in height to provide a more spacious cabin feel. In this example, the 95th percentile male is shown in both the front and rear sections, and the rear module 130 extends under the rear seats, which could be elongated bench seats.

[0106] Figure 4c The car shown is a larger vehicle, such as the E-Class with three rows of seats. In this example, the 95th percentile male is shown in the front seats. The second row of seats faces rearward, occupied by the 95th percentile male, and is positioned away from the front seats, creating a gap there. The lateral module 126 of the battery pack extends between the front seats 118 and the second row of seats 122. The third row of seats 136 is located at the rear of the vehicle and faces forward. The longitudinal module 128 extends from the lateral module located between the front seats toward the front of the vehicle, and the rear module extends from the lateral module between the second rows of seats toward the rear of the vehicle.

[0107] While the examples of battery packs provided here are intended to illustrate the increased volume in different configurations and across a range of vehicle sizes, this teaching can be applied to any vehicle by varying the dimensions of the battery pack according to the vehicle size—for example, a larger vehicle can accommodate wider lateral and longitudinal modules. Figure 4c An additional expansion module 138 is included, which adds extra volume to the battery pack. The expansion module 138 can be added to any of the modules to increase the volume of any of the following: the transverse module 126, the longitudinal module 128, the rear module 130, or the front module. This configuration depends on the vehicle.

[0108] While the example here allows the vehicle to be configured with a low hip point 124, or Seating Register Position (SgRP), which thus allows for a reduction in the front area of ​​the vehicle, the battery pack 107 configuration can be used, for example, in conjunction with an underfloor battery pack. Although the hip point may be raised to increase the volume of the battery pack, the sacrifice in vehicle height can increase storage space and improve travel.

[0109] Figures 2a to 4c The example shows a vehicle 100 with a battery pack 107 having a transverse module 126, a longitudinal module 128, and / or a rear module 130 extending towards the rear of the vehicle. In each example, the transverse module 126 is shown to have at least a portion of a generally triangular or trapezoidal shape in cross-section. That is, the uppermost part of the transverse module narrows or gradually decreases in size towards a point above the transverse module. In practice, the ends of the transverse module adjacent to the side of the vehicle may also gradually decrease in size towards the top. In three dimensions, the transverse module may have at least a partially truncated rectangular pyramid shape. The volume of the transverse module in the shape of a truncated rectangular pyramid can be constructed such that it is quadrilateral, for example, a shape used to accommodate the side of the vehicle in the wheel arch area.

[0110] Figures 2a to 2d The cell 150 is shown by way of example as a module that can be assembled into a battery pack, the cells being packaged and stacked together. Figures 5a to 5c An example of the shape of a horizontal module 126 is shown, which is the encapsulation layer inside which the module's battery cells are packaged. Figure 5a This is an example of the shape of the encapsulation layer 140, which is designed to maximize the use of the space 134 or gap located between the front and rear seats. It can be sized and / or adjusted to fit the available space within the vehicle. In this example, the battery pack encapsulation layer 140 has a quadrilateral pyramidal form of a lateral module – the base has length a and width a', and its upper portion has length b and width b'. It has a height V in the vertical direction of the vehicle. The example shown has six sides – a crown or upper surface 142, an occupancy area 144, two sides 146, and front and rear 148. The lateral module 126 is configured to extend vertically from the occupancy area 144 to the crown 142. In the example shown, the crown has a flat surface, although this can be rounded or pointed. The example also shows edges extending parallel in the lateral direction, although these can be non-parallel. The example shows longitudinal edges extending horizontally in the longitudinal direction, although these can be non-parallel.

[0111] Figures 5b to 5cThe image shows an encapsulation layer 140 for a horizontal module, configured to encapsulate battery cells 150. This encapsulation layer and cell arrangement can be used equally in vertical modules 128, rear modules 130, front modules 132, or extension modules 138. The encapsulation layer can be fitted to substantially surround the module, as shown in the image. Figure 5a The encapsulation layer is a truncated quadrilateral pyramid, configured to do so with minimal surface area. More specifically, the encapsulation layer can be a case where it surrounds the battery cells within the module. This is the most likely scenario if the battery cells within the module do not have a shape or form that allows them to fit together seamlessly with the encapsulation layer at the interface. In this case, the encapsulation layer can be configured to extend across the space between the battery cells. The encapsulation layer can be a physical layer that substantially surrounds the battery cells, such as a layer of steel, or the encapsulation layer can be at least partially defined by a shape surrounding an overall outer edge that encircles the cross-section of the module. The encapsulation layer can be a combination of a part of the module and a part of the vehicle. The encapsulation layer can be a perimeter shape defined by the shortest distance around the perimeter of the module's cross-section.

[0112] The space within the module's encapsulation layer that is not used by the battery cells can accommodate at least one of the following: fixing devices, fasteners, reinforcements, insulation materials, cooling mechanisms, and electrical connections, such as busbars. Therefore, maximizing the volume of the battery pack is important.

[0113] Figure 5b The diagram shows cell 150, cell pairs 152, and two submodules consisting of four sets of cells 154 and eight sets of cells 156, forming part of the battery pack. The submodules can have any number of cells. Adjacent to the cells and submodules, a trapezoidal physical encapsulation layer 140 is fitted with the cells 150 to demonstrate that the cells can be encapsulated within the encapsulation layer. The encapsulation layer can be seen bridging the gaps between the cells to substantially minimize the length of the cross-sectional perimeter. Adjacent physical encapsulation layers, where the same number of cells are arranged, do not have physical encapsulation layers – this can be achieved because the cells and submodules can be connectably configured to use, for example, brackets for self-support. The physical encapsulation layer can be provided solely for protection. In practice, the encapsulation layer can be the body of a vehicle in which the module is mounted, or the encapsulation layer can be a vehicle component with defined gaps in which the battery pack is configured. Figure 5c It shows a segment of the module with the longest length, and in this example, it provides a battery pack.

[0114] Battery cell 150 can be like... Figure 5b and 5c The cell is cylindrical as shown. Alternatively, the cell may be in the shape of... Figures 2a to 2dThe cells can be cubic or pocket-shaped. A module can contain cylindrical cells, cubic cells, and / or a mixture of pockets. Based on the teachings herein, it can be understood that the cell configuration is an example and other configurations can be arranged within the encapsulation layer of the battery pack module.

[0115] Within the cross-section, the encapsulation layer of the transverse module has a wide base and narrows towards the top of the vehicle. This is not only advantageous for filling the gap between the back-to-back front and rear seats, but the shape also provides further beneficial features, including at least: a lower center of gravity than a cubic module for the same height and volume; wiring for cooling and / or connectors or internal bus connections using the gaps between the cells; and a lighter weight compared to a cubic module of the same height and volume, as the triangular or quadrilateral shape is inherently more robust and requires less reinforcement or strengthening. The internal structure may include components that support the cells and / or reinforce the module or battery pack's strength. For example, the racks may be arranged in a shape arrangement, such as a triangular or honeycomb configuration.

[0116] The lateral module 126 is described as having an ideal shape, such as a truncated quadrilateral pyramid - but based on the teachings here, it can be understood that features can be added to the lateral module or virtually any module, wherein: protrusions are provided to increase volume to, for example, occupy ineffective areas within the vehicle, such as unused space; and / or recesses to improve visibility between the front and rear of the vehicle.

[0117] As described above, the wide base and height of the lateral module not only provide stability to the module, but also provide a significant amount of storage space within the encapsulation layer 140. The left-hand configuration is part of the battery pack, which additionally includes the longitudinal module and the rear module.

[0118] For small vehicles such as smart cars or Volkswagen UP (RTM), the lateral module may be the only module in the battery pack. In such small vehicles, the wide base and truncated pyramid shape can lower the center of gravity and improve stability, especially in the event of a collision, compared to a similarly sized cubic module of the same height. However, to maximize the vehicle's range, modules such as longitudinal modules and / or rear modules are important for providing additional volume for the energy cells.

[0119] As described above Figures 3a to 3c The central position of the battery pack inside the vehicle increases the average distance between the periphery of the battery pack enclosure 140 and the edge of the vehicle body 108, or the collision buffer zone 16. In the example provided here, the end of the lateral module is the battery pack portion closest to the external body of the vehicle. Compared to, for example, a battery pack of the underfloor type, the end of the lateral module defines a lower percentage of the overall periphery of the battery pack exposed to side impacts.

[0120] The impact pulse from a frontal or rear-end collision with the vehicle is not only significant for the lateral module 126, improving stability during the collision, but also for the longitudinal module 128 and the rear module 130. During a collision, the forces acting on the mass of the lateral and rear modules can be managed to prevent the battery pack modules from impacting, or otherwise crushing or damaging, another module in the battery pack. Conventional methods for maintaining the integrity of the battery pack involve adding reinforcement, such as extra layers of metal plates or thicker metal plates or additional fasteners. In contrast to known methods, and to minimize the vehicle's weight, the quadrilateral shape of the lateral modules has non-perpendicular sides, which can be used to guide forces within the battery pack during a collision. Figure 6a It shows having with Figures 3c to 4c A battery pack with a similar layout, wherein the battery pack has three modules: a longitudinal module, a transverse module, and a rear module. Figure 6a The rear module can optionally be positioned adjacent to the transverse module on the ground, although it can also be placed at the same level as the longitudinal module. Compared to the transverse module, the height of the longitudinal module and the rear module can be adjusted to accommodate the features of the vehicle.

[0121] exist Figure 6a In the middle, the joint between the longitudinal and transverse modules is angled to the joint between the transverse and rear modules. The encapsulation layer 140 of the module can also be angled. The angled joints are complementary, thus guiding the movement of the module caused by a forward or rearward impact force in the vertical direction, which is mainly along the longitudinal axis of the vehicle, thereby reducing any longitudinal impact force between the modules and thus at least partially weakening or redirecting the impact force from a frontal or rear-end collision.

[0122] exist Figure 6b In this process, a material 158 having energy-absorbing and / or low-friction surfaces is configured in... Figure 6a The angled joints between the modules. This material can be used to absorb energy and prevent contact between modules, and / or facilitate movement in the vertical direction, thus deflecting longitudinal forces from impacts from the front or rear.

[0123] Figure 6c This illustrates another module setup for mitigating the effects of frontal or rearward impacts, primarily along the vehicle's longitudinal axis. In this example, a transverse module connects the longitudinal and rear modules via a pivot point, allowing the connected modules to rotate around the pivot. The longitudinal and rear modules are closest to the transverse module, and as they rotate 160 degrees around the pivot point, their surfaces are shaped to accommodate the movement between the modules in the battery pack. Figure 6cAs shown, the pivot connection axis extends laterally across the vehicle's entry page, and the modules can rotate about the pivot connection axis. Arrows indicate the direction of rotation of the modules along the pivot connection. An optional energy absorber 158 is shown configured between the modules. This energy absorber can be configured at the front and / or rear. The energy absorber can be configured to be at least partially located between the faces of the modules that will contact each other upon impact. The energy absorber can be configured as a component of the vehicle's seat, vehicle trim, or other vehicle trim component. Additionally or optionally, a torque bar 162 can be configured within the pivot connection to control the rate of relative steering of the modules. Additionally or optionally, one or more shock absorbers can be provided between or within each module of the battery pack, configured to manage the stiffness of the battery pack by managing movement therebetween, and / or configured to manage the stiffness of the vehicle.

[0124] Although Figures 2a to 4c Examples of the present invention are generally described. Figures 7a to 7c An example of a vehicle battery pack providing the layout of the present invention is shown, and a "reference" is provided to allow comparison of different vehicle sizes or sections, which are representative of vehicles currently on the market. Figures 8a to 8f The comparison displays parameters taken from manufacturer data, measurement data, estimated values, and calculations in separate tables – via reference. Figures 7a to 7c The features and accompanying diagrams support the understanding of how the vehicle and battery pack can be adapted for the vehicle. Because many passenger and seating positions are possible in some of the examples presented here, and Figures 7a to 8f This provides support for at least some of the possible configurations by way of example only.

[0125] Figure 7a The diagram shows a tram 100, defined by a body 108 and front and rear axles 114a, 114b, with length, width, and height. A front electric traction motor 102 is connected to the front axle, and a rear motor is connected to the rear axle. The tram has an energy conversion module 106 for managing energy going to and from the tram, as well as energy going to and from the traction motor. Although not shown in these figures, the tram may include, for example, a front-mounted steering system, independent rear suspension, and a rear frame beam. The tram is shown above the ground, which serves as a reference surface indicated by dashed lines located below the wheels. The tram has ground clearance, front and rear axle distance, front track width, rear track width, and interior width. The reference point for all dimensions is the centerline of the front axle at the ground.

[0126] Figure 7aThe side front view shows two seats and a male silhouette at the 95th percentile in each seat. A battery pack 107 with a transverse module 126, a longitudinal module 128, and a rear module 130 is shown, as can be seen, located between the vehicle's axles 114a and 114b. The longitudinal module of the battery pack may extend along the vehicle's aisle section and may optionally be referred to as an aisle module.

[0127] Although details are not shown, the wheel and tire 104 have dimensions including: front tire width, front tire profile and front rim diameter, which allow the front tire outer diameter to be estimated by calculation; and rear tire width and rear rim diameter, which allow the front tire outer diameter to be estimated by calculation.

[0128] like Figure 7a As shown and in Figures 8a to 8f The table lists passenger positions and ergonomic seating positions, described by the front passenger, which also provides a direct naming convention where: X is the longitudinal dimension, extending from the front to the rear of the vehicle; Y is the lateral dimension, extending from one side of the vehicle to the other; and Z is the vertical dimension, extending from the top to the bottom of the vehicle. Figures 8a to 8f The reference standard for all measurements is located at Figure 7a The centerline of the front axle at the ground level of CRRC. Figures 7a to 7c The letters in parentheses next to the reference numerals in the figures refer to their respective dimensions – for example, A(x) refers to the position of the ball of a foot and “X” is the distance from the center line of the front axle on the ground in the longitudinal direction.

[0129] Figure 7a The passenger positions and seating positions are indicated, and the following are shown: the position of the forefoot of the front passenger at position A(x); the position of the heel of the front passenger at position B(z); the longitudinal distance from the heel B(z) to the seating reference point (SgRP, which is the hip point), the SgRP position from reference numerals -D(x) and E(z); the vertical distance F(z) from the heel B(z) to SgRP; the vertical distance G(z) from the ground line of the vehicle to SgRP; the distance H(x) from SgRP to the back of the front seat; and the seat depth I(x).

[0130] The seat width is not displayed. Figure 7a In the middle, although in Figure 8a This column shows an example of 550mm and also displays the position value. Figure 7b and 7c They are respectively Figure 7a Side and end views of the battery pack. Values ​​for the positions of different examples are listed in... Figure 8e and 8fThe following parameters are included: the distance J(x) from the front axle to the position of the front surface of the battery pack; the distance K(x) from the front axle to the rearmost position of the battery pack; the overall length L of the battery pack; the length M of the upper surface of the longitudinal module (channel) from the front of the battery pack to the junction with the transverse module; the length N of the lower surface of the longitudinal module (channel) from the front of the battery pack to the junction with the transverse module; the width O of the longitudinal module, which is set to a value of 300 mm for all but two examples to emphasize the importance of the transverse module in the battery pack; the height P of the longitudinal module, which is set to a value of 350 mm for all but two examples to emphasize the importance of the transverse module in the battery pack; the length AA of the rear module; the width AB of the rear module; and the height AC of the rear module, which is set to a value of 350 mm for all but two examples to emphasize the importance of the transverse module in the battery pack. All other examples except for one are set to a value of 2300mm to emphasize the importance of the lateral module in the battery pack; the distance Q(x) from the front axle to the front edge of the lateral module; the angle R between the front of the lateral module and the ground; the angle S between the rear of the lateral module and the ground; the height T of the lateral module, which for all examples is nominally set to 55% of the vehicle depth to emphasize the importance of the lateral module in the battery pack; the longitudinal distance U(x) from the reference point to the highest point of the front edge of the lateral module; the longitudinal length V of the top of the lateral module; the longitudinal distance W(x) from the reference point to the highest point of the rear edge of the lateral module; the longitudinal distance X(x) from the reference point to the rear edge of the lateral module; the length Y of the base of the lateral module; and the width W of the lateral module in the lateral direction.

[0131] According to the teachings here, a vehicle can be equipped with a battery pack having lateral modules. While the applicant believes that a battery pack with a combination of lateral and longitudinal modules is suitable for lowering the hip point (HP) or for the SgRP of sports cars that traditionally have a lower driving height, using a battery pack with lateral modules provides ample storage capacity for any vehicle, and using longitudinal modules allows the SgRP to be positioned relatively lower within the vehicle.

[0132] Figure 8a The battery packs were considered for use in a range of different vehicle sizes, including: sub-A segment vehicles such as the "SMART" (RTM); A segment vehicles such as the Volkswagen UP (RTM); B segment vehicles such as the Audi A1 (RTM) or Volkswagen Polo (RTM); C segment vehicles such as the Audi A3 (RTM) or Volkswagen Golf (RTM); D segment vehicles such as the Audi A4 (RTM); E segment vehicles such as the Audi A6 (RTM) or Volkswagen Passat (RTM); F segment vehicles such as the Audi A8 (RTM) or Volkswagen Phaeton (RTM); sporty C segment vehicles such as the Audi TT (RTM); and standalone custom examples of sporty C segment vehicles.

[0133] The proportions of many parameters and values ​​can be obtained through... Figures 8a to 8f The dimensions of each vehicle in the table are used to determine the dimensions, and the context can be referenced. Figures 7a to 7c Let's understand this using an example layout. Providing lateral modules with prismatic or pyramidal shapes improves module stability and offers inherent improvements. With the current and rear seats facing opposite directions, vehicles with this type of lateral module benefit from improved layout and internal encapsulation. The main factors affecting battery pack volume are the vehicle's wheelbase, vehicle height, and the height of the lateral modules. Although vehicle sizes vary across different market segments... Figures 8a to 8f It demonstrates how lateral modules and / or configurations between back-to-back front and rear seats can be achieved to improve the layout.

[0134] use Figures 7a to 8f The example represents the size of most electric vehicles, and the improved layout can provide at least one of the following configurations:

[0135] - Lateral modules, ranging in volume from approximately 3791 to approximately 5991, when the height (dimension T) is approximately 55% of the vehicle's depth (i.e., vehicle height minus ground clearance). At approximately 55% of the depth, if the lateral modules are configured within a battery pack containing both longitudinal and lateral modules, then the lateral modules account for approximately 68% to approximately 83% of the battery pack volume. This is the most significant contribution of lateral modules in small sub-A-segment vehicles. Increasing the height of the lateral modules to approximately 70% of the depth can increase the volume of the lateral modules alone to between approximately 3921 and approximately 8981 (which is between approximately 78% and 84% of the battery pack volume). Increasing the height of the lateral module to approximately 80% of its depth can increase the volume of the lateral module alone by between approximately 3781 and approximately 11231 (which is between approximately 80% and 86% of the battery pack volume). The height of the lateral module within the vehicle depends on the vehicle's configuration requirements, but this is understandable; for a range of vehicle sizes, when configured in combination with the longitudinal module and / or rear module, the lateral module can occupy between approximately 3791 and approximately 11231 and approximately 68% to approximately 86% of the battery pack volume. The longitudinal and rear modules can be optional, but this helps to demonstrate the benefits of configuring the lateral module here. Although not described in detail, the front module located between the vehicle's bulkhead and the front can add additional volume to the battery pack.

[0136] When longitudinal, transverse, and rear modules are included, the length of the battery pack is influenced by the length of the vehicle's wheelbase (longitudinal direction) and the necessary clearance space. Thus, the length of the battery pack can be between approximately 88% and approximately 92% of the wheelbase (size L).

[0137] - The length (dimension Y) of the base of the transverse module can be between approximately 26% and approximately 41% of the wheelbase length. Specifically, when the height of the transverse unit is approximately 55% of the vehicle's depth, then the length of the base of the transverse module can be between approximately 26% and approximately 33% of the wheelbase length.

[0138] Between. When the height of the lateral unit is approximately 80% of the vehicle's depth, the length of the base of the lateral module can be between approximately 26% and approximately 41% of the wheelbase length. When the height of the lateral unit is approximately 70% of the vehicle's depth, the length of the base of the lateral module can be between approximately 32% and approximately 39% of the wheelbase length.

[0139] - The horizontal and vertical modules (channels) can be the largest components of the battery pack. In the example,

[0140] The longitudinal module has a height of approximately 350 mm. The transverse module can be between approximately 275% and approximately 700% of the volume of the longitudinal module, and between approximately 150% and approximately 350% of the height of the longitudinal module. Specifically, when the height of the transverse unit is approximately 55% of the vehicle depth, then the transverse module can be between approximately 275% and approximately 500% of the volume of the longitudinal module, and between approximately 157% and approximately 225% of the height of the longitudinal module. When the height of the transverse unit is approximately 80% of the vehicle depth, then the transverse module can be between approximately 400% and approximately 720% of the volume of the longitudinal module, and between approximately 250% of the height of the longitudinal module.

[0141] Between approximately 350%.

[0142] - Considering that the lateral and longitudinal modules (channels) can be the largest components of the battery pack, the decisive role of the lateral module can be further understood when the lateral module has a height of approximately 200mm. In this case, when the height of the lateral unit is approximately 55% of the vehicle depth, then the lateral module can be between approximately 500% and approximately 875% of the volume of the longitudinal module, and between approximately 300% and approximately 400% of the height of the longitudinal module. When the height of the lateral unit is approximately 80% of the vehicle depth, then the lateral module can be between approximately 700% and approximately 1300% of the volume of the longitudinal module, and between approximately 450% and approximately 650% of the height of the longitudinal module.

[0143] -When the battery pack is configured as follows Figures 2a to 3c As shown, it does not have an underfloor type battery pack.

[0144] The front passenger's hip point—SgRP—can then be between approximately 31% and 41% of the vehicle height. These figures can fluctuate depending on the customized configuration of each vehicle, but it is reduced compared to an equivalent vehicle with an underfloor type battery pack that raises the passenger and therefore SgRP height. The battery pack is particularly effective when combined with rear-facing seats located behind the front seats, minimizing both the vehicle's SgRP and overall height—however, when used in conjunction with an underfloor type battery pack, the overall energy storage capacity of the vehicle can be enhanced.

[0145] When considering the area where the battery pack can be placed within the vehicle and the vehicle's height, the packing efficiency can be calculated by taking into account the battery pack volume per square meter (wheelbase * average vehicle path) and the battery pack volume relative to the vehicle's height. Specifically, when the lateral unit height is 55% of the vehicle depth, the battery pack can provide approximately 144 L / m². 2 and approximately 1871 / m 2 Between approximately 2941 m and approximately 5641 m. When the lateral unit height is 70% of the vehicle depth, the battery pack can provide between approximately 1731 m. 2 and approximately 2421 / m 2 Between approximately 3021 m and approximately 7461 m. When the lateral unit height is 80% of the vehicle depth, the battery pack can provide between approximately 1681 m. 2 and approximately 2651 / m 2 Between, and between approximately 2931 / m and approximately 8851 / m. Figures 7a to 8f The examples provided can be applied to known vehicles. However, the shapes and figures given are indications of the range of examples. Modifications and adjustments can be made, based on the teachings here, to optimize the form of the battery pack or its integration within the vehicle, thereby substantially achieving the same volume and proportions as presented in the examples here. Due to the tolerances and minor adjustments that can be made based on the teachings here, the percentage figures given are approximations, such as "approximately".

[0146] Figures 2a to 6b For example, the lowest or bottom surface of the battery pack module extends in the same plane, and this configuration allows the battery pack to be positioned as low as possible within the vehicle. Therefore, the SgRP (space travel ratio) of the front and / or rear passengers can be minimized because there is no battery pack beneath these passengers. Consequently, this allows the front area of ​​the vehicle to be minimized, thereby increasing travel by reducing aerodynamic drag. However, the battery pack modules can be positioned at different heights to accommodate other vehicle features, such as the rear axle, thus raising the base of the rear module relative to the bases of the longitudinal and / or lateral modules. Furthermore, the battery pack described herein can be combined with existing battery pack configurations, such as under-floor type batteries.

[0147] Examples of battery packs in different passenger vehicles have been shown, and according to the description herein, the battery packs can be adapted to larger passenger vehicles, including, but not limited to, Volkswagen (RTM) minibuses or Mercedes-Benz Sprinter (RTM) minibuses.

[0148] If vehicle height is not limited and the battery pack volume is maximized to maximize range, then a lateral module can be mounted on an underfloor type module that extends across the vehicle floor between the axles. In this configuration, the lateral module extends between the front and rear seats, with the rear seats facing rearwards. An additional longitudinal module can be provided to extend between the front seats. An additional rear module can be provided to extend between or under the rear seats.

[0149] Besides reducing the height of the seat's hip point, often referred to as SGRP, the battery pack and seating arrangement can improve the safety of rear passengers in the event of a frontal collision, as rear passengers are rear-facing. In vehicles equipped with lateral modules, these modules can be configured to improve the vehicle's structural performance. The lateral modules of the battery pack, along with components therein, such as the encapsulation layer, act as torsion boxes, and are configured to improve the vehicle's rigidity.

[0150] Figure 9 uses arrows to illustrate some load paths through typical vehicle structural members. As shown, the highest arrow indicates a force applied to the roof at a 25-degree angle, which occurs during a rollover event and applies force across the vehicle's roof structure. Similarly, arrows pointing to the sides of the vehicle indicate force and load paths on or through the vehicle in a direct (90-degree) or indirect (63-degree) side impact collision. The arrows also show the frontal impact force and subsequent load paths through the vehicle's structure. Although three sets of arrows are shown, those skilled in the art will understand that the vehicle's structural components work together to provide overall structural integrity.

[0151] Figures 10a and 10b use labels to name individual structural components within a typical vehicle of the same type. Four perspective views are provided to show the structural components from different angles. While not all identical types are labeled, each type of structural component is labeled. Figure 10a includes: seat transverse members; roof beams; B-pillars and door rings; bumper beams; rear beams; underbody beams; rocker arm inner and outer sides (these are also commonly referred to as "sills"); A-pillar inner and outer sides; front beams; and ski-mount beams. Figure 10b also includes: seat transverse members; roof beams; front beams; and ski-mount beams. Figure 10b additionally includes: kick-up walls; reinforcements; underbody tunnel reinforcements; torque boxes; crash boxes; and dashboard transverse members.

[0152] By comparing the corresponding locations in Figure 9 with the positions of the structural members, the complexity and connectivity within the body-in-white can be understood. During a collision, the impact force generates a "crash pulse" that travels through the vehicle along the structural members and their connections. Equally important are the forces exerted on the vehicle through the wheels during dynamic driving conditions or a collision, which generate torque around at least one of the x-axis (rollover), y-axis (bumping), and z-axis (lateral swaying) within the body.

[0153] The structural efficiency of a vehicle is determined by the balance between weight, strength, material selection, and the impact structure used for energy absorption and torsional and bending stiffness. The structural efficiency of the BIW in Figures 10a and 10b is an illustrative example, and those skilled in the art will understand that no modifications to the vehicle can be made without compromise. For example, in addition to the floor tunnel extension, the bottom reinforcement members are shown extending forward and laterally under the vehicle; the floor forging and seat lateral members significantly contribute to structural integrity during an impact event. These members also significantly contribute to the torsional and bending stiffness of the vehicle body.

[0154] Optional B IW (Body-In-Warehouse) systems that accommodate underfloor battery packs, such as skateboard-type platforms, require packaging the battery pack, which houses numerous structural components. Therefore, modifications are needed to achieve structural integrity in order to avoid increasing vehicle suspension height and maintain torsional and bending stiffness. Furthermore, in vehicles with underfloor battery packs, the floor is generally not considered a significant structural component, as it is undesirable for the partitions and floor area to bear high strains to prevent intrusion into the battery pack during a collision. Once installed in the vehicle, the battery pack provides a useful, and sometimes significant, contribution to the vehicle's torsional and bending stiffness. Due to the limited use of structural components in the floor (typically limited to seat transverse members), vehicles with underfloor battery packs tend to have high lateral stiffness, and the battery pack needs to provide the necessary lateral stiffness once installed. To provide lateral stiffness, the underfloor battery pack requires high stiffness in its casing and numerous transverse structural members. The battery casing and structural members typically account for 18% to 28% of the weight of the underfloor battery pack. The structural integrity of the underfloor battery pack requires higher strength to provide high lateral stiffness and reduce intrusion into the battery pack during side impacts.

[0155] In comparison, the performance requirements for the lateral module 126, which is configured to provide a constraint mechanism for the battery module or cell, are lower, enabling a useful weight reduction. This is because the compartment 170 provides the main structural performance. Optionally, the encapsulation layer 140 of the lateral module can contribute to the vehicle's torsional or bending stiffness, and therefore the encapsulation layer 140 and the lateral module can be significantly lighter than a similarly sized underfloor battery pack. The weight reduction from the lateral module and encapsulation layer can typically be 6% to 16% of the total weight, depending on the vehicle and battery pack dimensions.

[0156] Figure 11 The BIW (Bend-In-Wave) is shown, including vertical arrows indicating input forces typically received from the ground, while curved arrows show the bending and torsional reaction moments resulting when the vehicle body is subjected to forces approximately along its axis. As indicated by the vertical arrows, varying widths indicate asymmetrical forces acting on the vehicle suspension, resulting in net side-to-side torque and net front-to-rear torque from the front axle to the rear axle. These forces arise from responses to road surface irregularities, potholes, speed bumps, cornering, etc. Net side-to-side torque is considered the torque input, and torsional stiffness refers to the displacement of the vehicle body relative to the torque input. Net front-to-rear torque is considered the bending input, and bending stiffness refers to the displacement of the vehicle body relative to the bending input. Torque and bending stiffness (two static stiffnesses and dynamic mode characteristics) are critical considerations for vehicle handling performance and particularly relate to noise and vibration performance. Structural members located at the front, rear, and top of compartment 170 and / or transverse module 126 are represented by struts 170a, shown in this example as a support-type structure. Additionally or alternatively to strut 170a, a wall, typically a sheet metal firewall / bulge type configuration, can be configured to connect the body side and / or strut 170a, creating a structure that greatly resists the torsional bending forces encountered by the vehicle during use. Compartments and / or struts and / or bulkheads can act to resist bending inputs. Compartments are integrated parts of the body structure and can be either permanently connected or connected to movable fasteners. The shape, size, and material selection of structural members, along with the body structure and other structural members, are designed to meet the specific design requirements of the body. Compartments add additional mechanical restraint to the sides of the vehicle, thus reducing displacement caused by forces acting on the BIW structure. Due to the open structure of this configuration, this additional restraint is particularly beneficial on large vehicles such as minibuses or vehicles with multiple door openings on each side. The connection between the transverse module 126 and the compartment can be achieved via fasteners 176. Each fastening point further enhances the torsional and bending stiffness of the body.

[0157] The compartment is integrated with the vehicle body in this way, thereby improving crashworthiness and enhancing passenger protection in all impact scenarios. In particular, the compartment 170 is configured to ensure that the lateral module 126 battery pack experiences low-level intrusion during a collision event to prevent leakage, breakage, fire, and explosion. This compartment acts as a housing for energy storage, such as hydrogen or batteries.

[0158] The width of the transverse module 126 can be less than the total width of the compartment, which is comparable to the width of the vehicle – example dimensions can be understood from the table in Figure 8, where the width of the transverse module (dimension Z) is less than the width of the vehicle. The gap between the ends of the compartment 170 and the ends of the transverse module 126 inside can provide bending areas. Not only does the compartment provide structural integrity in the event of a side impact (e.g., from two external vehicles or a collision with a utility pole), which results in large lateral forces acting on the side of the vehicle, but the cells within the transverse module can also be separated from the sides. However, the strength of the compartment 170 can be achieved by the encapsulation layer 140 of the transverse module through at least one of the following: (i) a tight fit with the compartment such that the gap between them is less than 50 mm, and preferably less than 30 mm, and preferably less than 10 mm; and (ii) fasteners 176 between the encapsulation layer and the compartment.

[0159] Compartments can improve crashworthiness and passenger protection in specific crash scenarios. One such scenario involves a side-impact collision between a low-chassis-height vehicle, to which these examples apply, and another vehicle with a higher chassis-height, such as a light van with a robust ladder frame. In conventional vehicles, the collision is likely to occur at the midpoint of the B-pillar, which is the weakest point, thus increasing the possibility of protrusions entering the passenger compartment. In vehicles with a 170° transverse compartment that extends vertically through the vehicle and connects to the side, such as to the B-pillar, the structural integrity of the vehicle is improved in such a crash.

[0160] In general, compartment 170 can be connected to the body-in-white of the conventional body, as well as at least one of the body side, body pillars, door rings, floor, seat lateral members, floor reinforcements, rocker arm, which contributes to structural integrity in the event of a side impact.

[0161] The compartment 170 and lateral module 126 provide the vehicle with numerous structural features. The compartment is connected to the side of the vehicle. This connection on the side of the vehicle can extend from the lowest horizontal level of the vehicle, the floor, or the bottom of the passenger compartment, and can extend upwards. The highest point of the connection on the side of the vehicle can be above at least one of the following: the top of the backrest of the first and / or second seat; the highest height of the seat cushion in the first seat of the first row and / or the second seat of the second row; the average height of the seat cushion in the first seat of the first row and / or the second seat of the second row; and the hip point of the seats in the first and / or second rows.

[0162] This compartment, either alone or in combination with a lateral module, can act as a torsion box, connecting to the bottom and / or sides of the vehicle to improve its torsional and bending stiffness. The compartment can be located at at least one pillar of the vehicle, such as pillar A, pillar B, or pillar C. This compartment can improve the lateral stiffness of the vehicle body, especially where passenger and / or battery protection is required, or in areas where the vehicle has openings and relatively weak structures, such as in a van. In other words, the compartment can enhance side-impact stiffness, reducing passenger cell intrusion and / or improving protection of the battery pack from side-impact intrusion during a side impact.

[0163] While vehicle design incorporates performance considerations, such as crashworthiness, vehicle development, including the significant weight of the battery pack, leads to increased weight due to the need for additional structural strength to accommodate the battery pack and its weight. Therefore, it is important to efficiently house the battery pack to minimize weight and cost increases without compromising torsional and / or lateral stiffness. Compartment 70 not only improves vehicle stiffness but also minimizes the need for higher-standard materials with greater strength and extensive modifications to structural components.

[0164] Underfloor-mounted batteries offer an alternative to lateral modules, such as those found in "skateboard" platforms, but they impact vehicle stiffness and weight. Using compartment 170 and lateral modules 126 allows for the use of conventional vehicle structures with minimal modifications and improved performance compared to underfloor-mounted battery packs. This is because underfloor-mounted battery pack setups require additional frontal protection to safeguard the pack in frontal offset impacts, where forces transmitted during an impact need to be channeled along longitudinal support members at the front of the vehicle into the lower side members and structures surrounding door openings. Adapting to open body structures requires members with significant cross-sectional dimensions to support the structure, which has sufficient force transmission into the side members.

[0165] The use of an underfloor battery arrangement increases the mechanical requirements for both the vehicle body structure and the battery pack as independent structures. The vehicle body structure needs sufficient structural integrity when the battery pack is not installed to allow for vehicle assembly and battery relocation for vehicle or battery pack maintenance. Similarly, when not installed within the vehicle, the battery pack must have sufficient structural integrity to allow it to be lifted and transported. These requirements exceed those for the vehicle body and battery pack as a combined unit. One or more of the following requirements are added to the vehicle body and battery pack as independent structures: additional structural elements; increased cross-sectional dimensions; increased material thickness; and increased material specifications.

[0166] Conversely, the compartments and transverse modules 126 taught here allow for minimal or no modification to the vehicle's body-in-white structural components. That is, the original structure and support structure of the vehicle, including the compartments, allow for a design that follows a conventional arrangement, where forces from the longitudinal members at the front of the body are transmitted not only to the side members and door opening structures, but also to the vehicle floor and passageway structures. This arrangement results in a highly efficient support mechanism with smaller cross-sectional dimensions, lower standard and lower specification materials – leading to weight and cost savings.

[0167] Similar to the above, except in the case of a rear offset impact: for a battery arrangement under the floor, the forces transmitted during an impact event need to be directed along the longitudinal support members at the front of the vehicle into the lower side members and the structure surrounding the door openings – this arrangement necessitates members with significantly larger cross-sectional dimensions in the open body structure to provide sufficient force transmission to the support structure into the side members. Displacement of the battery pack in front of and / or between the second-row seats allows the vehicle support mechanism to follow a conventional arrangement, where forces from the longitudinal members at the rear of the vehicle are transmitted not only into the side members and door opening structures but also into the vehicle floor and passageway structures. This arrangement results in a very efficient support mechanism with smaller cross-sectional dimensions, lower standard, and lower specification materials – leading to weight and cost savings.

[0168] As described here, the dimensions of the compartment 170 and the transverse module 126, and their integration into the vehicle interior, place different requirements on the body and battery pack. The compartment has an opening 172 that is relatively smaller than the body structure. Using the example from Figure 8, which provides examples of transverse modules of different sizes for different vehicles, it can be understood that the area at the base of the transverse module (determined by coordinates Y and Z) is within 0.777m. 2 Up to 1.21m 2 The volume of the lateral module varies within a range; the volume per square meter varies from 433 liters to 506 liters per square meter; and taking into account the area defined by the vehicle's width and wheelbase, the base of the lateral module varies within a range of 20% to 25% of said area. These examples demonstrate the adverse impact minimization of the lateral module on the vehicle structure and the volume of the lateral module relative to its occupied area – all of which can be compared to the requirements of similar underfloor type battery packs in skateboard platforms.

[0169] For example, the lateral module included in a large F-Class vehicle would have an L*W*H module size of approximately 800mm*1500mm*700mm, assuming a battery pack volume of 0.84m³. 3 And it occupies an area of ​​1.2m 2 The result was 0.71 / m 2In comparison, the Tesla Model S (RTM) has a module size of approximately 800mm*1500mm*700mm (L*W*H), assuming a battery pack volume of 0.455m³. 3 And it occupies an area of ​​4.134m. 2 The result was 0.111 / m 2 .

[0170] Compared to the area occupied by the vehicle between the wheelbases, for a given material specification or cross-sectional size, the relative size of the area occupied by the opening 127 allows for greater relative floor stiffness, resulting in lower levels of noise, vibration, and roughness. Another advantage of reducing the maximum size of the flat panel is that it can lead to lower costs for production tooling and measuring instruments.

[0171] As a result of the effective volume required by floor space, the further vehicle performance flexibility achievable here is the ability to use larger diameter wheel and tire assemblies on the vehicle, which can achieve lower rolling resistance. Furthermore, the increase in vehicle weight can influence the use of wider tires, thus increasing the volume required to cover the wheel and tire assemblies. Over the past 20 years, the volume required to cover the wheel and tire assemblies has increased by approximately 20%. For example, the 2000 Range Rover had a maximum in-service tire diameter of 756 mm and a maximum in-service tire width of 277 mm. In comparison, the 2020 Range Rover has a corresponding maximum in-service tire diameter of 801 mm and a maximum in-service tire width of 302 mm. The maximum volume corresponding to each wheel and tire assembly has increased from 124 liters to 151 liters. The space required to cover the wheel and tire assemblies and to provide spacing for them directly impacts the available space for passengers and the battery pack. When the battery pack is located under the vehicle floor, the reduced space available for the battery pack when large wheels and tires are in use necessitates creating additional space for it, which can be achieved either by extending the wheelbase or increasing the height of the battery pack. Both of these methods of increasing space reduce vehicle energy efficiency due to higher aerodynamic drag and / or greater vehicle weight.

[0172] Referring to those identified in Figures 10a and 10b, we now discuss the impact on the structural components of a typical vehicle. Different vehicle types have different performance requirements, so the impact on each component is discussed by way of example. Therefore, the focus is on the impact on the lateral modules of a vehicle with a 170-degree compartment. Based on the component-to-component approach, this is compared to a vehicle with an underfloor type battery pack.

[0173] On vehicles with compartment 170, the roof beam and seat lateral members can remain. Some structural components adhere to conventional body structure requirements, necessitating modifications to increase cross-sectional dimensions and / or material specifications and / or shape solely to support the additional mass of the lateral modules in the tram, resulting in a mass increase of approximately 10% to 24% compared to vehicles with internal combustion engines. Components requiring conventional modifications include: A-pillars (internal and external); B-pillars and door rings; crash boxes; dashboard lateral members; floor; floor tunnel; front beams; rear beams; rocker arm internal and external; roof beams; seat lateral members; ski floor beams; torsion boxes; and lower body beams. Depending on the vehicle type, the lower body tunnel reinforcement can be omitted, as compartment 170 provides its function. The kick-up wall can also be omitted, as compartment 170 provides its function.

[0174] Conversely, vehicles with underfloor type batteries eliminate the need for ski-floor beams, lower body beams, and underbody channel reinforcements to accommodate the battery. The primary function of these components is structural, particularly to accommodate impact loads and improve bending stiffness. A secondary function is to improve noise and vehicle handling (NVH) through increased floor stiffness, which is transmitted to torque boxes, rocker arms, A-pillars, B-pillars, roof beams, door rings, and the battery pack structure. Their elimination has a cascading effect on other structural components.

[0175] In vehicles with underfloor type batteries, numerous structural components require modification, including: the interior and exterior of the A-pillar; the interior and exterior of the rocker arm; the rear transverse member; the B-pillar and door rings; the front torque box; and the roof beam. These components require significantly increased cross-sectional size and / or material specifications and flatness to accommodate at least (i) the increased load from frontal impacts transmitted from the torque box into the A-pillar and door rings; (ii) the increased load from side impacts transmitted along the rocker arm and door rings into the A-pillar as a result of removing underfloor reinforcements; and (iii) the additional mass of the battery pack compared to I CE (typically a 16% to 30% increase in mass). Furthermore, modifications are needed to accommodate fatigue loads (typically 400 kg to 900 kg) from the suspended underfloor type battery pack, originating from the rocker arm (the battery pack is also typically suspended on the dashboard transverse member, torque box, and rear transverse member of the cabin). In vehicles with underfloor type 28 batteries, structural components that require modifications to accommodate the additional mass compared to ICE include: the rear beam, the crash box, and the front beam.

[0176] In vehicles with underfloor Type 28 batteries, the kick plate above the battery pack is typically smaller in cross-sectional dimensions to make room for the battery pack. This reduction in size decreases the ability to transfer loads in a side collision. For example, the Porsche Taycan (RTM) has a kick plate that rises above the floor and can be larger than in conventional vehicles to accommodate secondary stacks of battery cells or the battery management system located below the kick plate. Lateral components of the dashboard also typically have reduced dimensions in the longitudinal direction to free up space for the battery pack.

[0177] In vehicles with underfloor type 28 batteries, the floor is redundant because the battery pack is integrated into the vehicle's structural performance, and the floor's primary function is largely reduced to support internal components. Compared to conventional vehicles, seat lateral members are typically reduced in height for aerodynamic reasons to help keep the overall vehicle height as low as possible while providing sufficient headroom for passengers. The consequence of reducing the height of the seat lateral members is that it reduces their ability to transfer loads in side impacts, thus requiring rocker arms, door rings, pillars, roof beams, and the battery pack to absorb a larger portion of the side impact load.

[0178] Further redundant structural components, typically omitted in vehicles with underfloor battery packs, are floor access channels used to perform structural impact safety functions. This function is required within the battery pack structure.

[0179] Typically, in vehicles with underfloor type battery packs, the key difference lies in the high load and strain levels resulting from the attachment being located beneath the vehicle floor, due to the presence of large, heavy objects that often extend across a significant portion of the vehicle's width. These high load and strain levels are particularly concentrated at the corners of the battery pack, from impacts to other verified load conditions. Furthermore, many structural functions of the floor and other structural members very close to the floor (e.g., underfloor rails) are transferred to the battery pack housing and internal structural members, as these are incompatible with underfloor type battery packs. The battery pack structure and rocker tend to have large cross-sectional dimensions and / or high standards to provide structural protection for side impacts.

[0180] Having an underfloor type 28 battery requires additional structural components. These include:

[0181] The lower battery pack shield is configured to prevent objects from penetrating it when impacting the underside of the vehicle, while also providing additional rigidity to the battery casing. This shield is typically made of 6mm aluminum or 1.5mm steel – adding significant weight due to the need to protect a large area.

[0182] The internal transverse and internal longitudinal members of the battery pack are configured to provide: lateral connections, and thus load paths from the sides of the battery pack housing to provide stiffness primarily in the event of a side impact; additional torque and bending stiffness to the battery pack; mounting points for cells or modules (which the longitudinal members can serve); and a stopping function for cells or modules in the event of an impact.

[0183] Battery pack casings are made of steel or aluminum. If aluminum is used, they tend to be formed by extrusion or casting to form front, side and rear components with high wall thickness and internal reinforcement to meet the strain level requirements in the event of an impact, as well as the verification and fatigue load from fatigue events. If steel is used, they tend to be formed by a combination of compression forming and roll forming, using high-strength steel to meet the strain level requirements in the event of an impact, as well as the verification and fatigue load from fatigue events.

[0184] The battery pack is integrated with the vehicle via connectors at the dashboard transverse members, torque box, rocker arm, and rear transverse members, with approximately 10-20 connectors on each side. Due to the high verification and fatigue load at the corners of the battery pack, there are more connectors at the corners to maintain the integrity of the connectors.

[0185] In summary, the integration of underfloor type battery packs with the vehicle body adds approximately 10% torsional and bending stiffness. Assuming a conventional battery pack housing and structural components have a mass between 60 kg and 200 kg, depending on the battery and vehicle dimensions, the additional stiffness provided by battery pack and body integration is low compared to the stiffness achievable by more optimized body reinforcement with similar mass. This is primarily due to the long span, and the low height of the battery pack results in a low moment of inertia, or "I-value."

[0186] The battery-powered vehicle is designed with transverse modules 126 and compartments 170, preferably extending vertically from the floor area above the seat cushions and / or hip points. This allows the BIW design and structure to follow conventional vehicle body structure designs to protect passengers and the battery. While the compartment 170 structure can enhance the load, front and rear impact loads will largely follow conventional vehicle paths. The side impact load path differs in that the flat / transverse members in front of, behind, and above the battery pack provide high-rigidity load paths, allowing some structural functions of the following items to be transferred to these flats: rocker arms, A-pillars, B-pillars, door rings, dashboard crossbeams, seat transverse members, underfloor passage reinforcements, and kick-up stands.

[0187] Although the compartment is described using the traditional BIW (Body IW) structure, it can be at least partially configured as an integrated component of a monocoque chassis, such as a carbon fiber monocoque chassis. A monocoque chassis can be defined as a single body component that integrates other parts of the vehicle. Preferably, the compartment connects to the side of the vehicle's BIW or monocoque.

[0188] Furthermore, the concentration of the battery pack within a smaller footprint allows for higher structural stiffness in the battery structure. Due to the shorter span of the lateral battery pack, it is at least 50% larger than an underfloor battery pack of equivalent volume. Combined with the increased height, this allows for a very high moment of inertia. When the battery pack is mechanically connected to rockers located in front, behind, and above the battery pack, on the sides of the vehicle body, and importantly, to flat / lateral members, the higher structural stiffness of the battery pack makes a significant contribution to the vehicle's torsional and bending stiffness.

[0189] Figure 12a The floor-mounted battery pack 28 shown is placed beneath the BIW and can be installed within the BIW. The planar shape of the battery pack 28 prevents it from intruding into the cabin space, thus avoiding a significant reduction in passenger or luggage space. Figure 12b The image shows a cavity for housing the battery pack 28, with alignment for mounting the battery pack.

[0190] Figure 12c Showing Figure 12a The vehicle has a compartment 170 and an opening 172 for receiving transverse modules 126. The compartment is sized to accommodate transverse modules 126. In the example shown, the opening 172 is located at the bottom of the vehicle. Optionally, the opening can be provided on the side of the vehicle or inside the vehicle, so that the transverse modules can be inserted accordingly in the horizontal or vertical direction. A cage with supports 170a can define the compartment. The supports can form supports that extend laterally across the BIW. Supports that extend vertically on the side of the BIW can also be provided. Further, the supports can form diagonal cross-shaped supports located between the two sides of the BIW. Additionally or optionally, the walls 170b of the compartment can be formed of sheet material, such as carbon fiber or steel plate. The compartment forms an integrated structural part of the vehicle. The compartment acts as a cavity or recess in which the transverse modules can be stored.

[0191] The cavity for receiving the battery pack 126 is shown in the display Figure 12d In the middle, the lateral module 126 is shown configured on the support 174 having fasteners 176. The fasteners are shown surrounding the outer edge of the opening 172. The encapsulation layer 140 may also include fasteners for securing the lateral module to the compartment 170.

[0192] Figure 13A perspective sketch of the interior of a transverse module without encapsulation layer 140 is shown, allowing the internal structure to be understood. Built on support 174 is a series of racks 178 connected by brackets 180, which create sub-compartments 182 for holding cells 50, or battery packs that clamp the cells, as described above. Figures 5a to 5c As described herein, linear sub-compartments are shown by way of example, and additionally or optionally, they may have triangular, circular, or hexagonal shapes. The cells or battery packs may be protected by a frame 178, a support 180, and a casing 140, or a combination thereof. The cells and / or battery packs may also be configured within a protective housing. Figure 12d As shown, fastener 176 is assembled around the outer edge of the support to connect to the BIW. Fasteners are also provided on the upper surface of the transverse module 126 and / or the encapsulation layer 140 to connect to the compartment 170 inside the vehicle.

[0193] Figures 14a to 14c It is a perspective view of the compartments 170 and modules 126 with visible internal structure and battery cells. Figure 14a This is a perspective view of the components of the internal structure of compartment 170, encapsulation layer 140, and transverse module 126, including: fasteners 176, shelves 178 and brackets 180, and individual battery cells 150, 152, 154, and 156. When assembled, these components are nested together inside the vehicle during use. The compartment may be defined by pillars 17a and / or walls 170b, which may be equipped with a reinforcing structure 170c. This structure is equipped to increase the rigidity of the wall 170b, which has a large surface area. Compartment 17 is shown independently, although it may be connected to the vehicle side and / or floor. In this example, the compartment is connected to the floor and forms wall 170b with structure 170c. Before being fastened by fasteners 176, transverse module 126 with supports 174 is positioned to be installed into the compartment, the supports 174 serving as a base, shelf, and bracket. The encapsulation layer of the transverse module is optional and is not shown. The encapsulation layer of the transverse module can be combined with the compartment via, for example, bracket 80. The structure of the transverse module can be similar to that of the compartment, having equivalent structural features in the form of sheet metal, such as steel plate, for the support column 170a and / or wall 170b. Figure 14a This setup is suitable for bottom-supporting the transverse module 126 as a whole. Large battery packs, such as transverse modules, are heavy, and installation may require lifting the battery pack into the compartment or lowering the vehicle from the four-post lift onto the battery pack, which is placed on a trolley below the floor. To facilitate installation, the compartment and / or transverse module can be configured with alignment features so that fastening features, such as bolts located at the top and / or bottom of the transverse module, engage with the highest and / or lowest outer edges of the compartment.

[0194] Figure 14b A configuration is shown in which compartment 170 and the lateral module are integrated into one unit, and battery cells or battery packs 150, 152 are installed from one side of the compartment. Battery cells can be individually inserted into rack 178. This configuration avoids the need for holes 172 in the vehicle floor. Furthermore, the vehicle's range can be easily adjusted by providing a customized number of battery cells. For example, (i) a city vehicle may only require two racks to be fully charged with battery cells, which can be the two lowest racks; however, (ii) such a city vehicle may optionally rent or lease additional battery cells if a longer range is required, and the racks can be fully charged with battery cells.

[0195] exist Figure 14c In this configuration, it is possible to customize the number of battery cells 150, 152, 154, and 156 in the transverse module 126, wherein the compartment 170 has an opening 172 located below the vehicle and the transverse module with a shelf 178 and a bracket 180 is inserted from below. (See reference...) Figure 14b Not all racks need to be fully charged with cells, as documented. For reference, a complete set of 150 cells is shown adjacent to the horizontal module before installation.

[0196] In summary, compartment 170 is connected to the vehicle and provides inherent strength by acting as a torque box and improving the structural strength of the vehicle itself. Support 174 of the lateral module 140 is configured to close opening 172 and enhance the compartment's strength through an assembly called the torque box. Furthermore, the lateral module's encapsulation layer 140 can be detachably connected to compartment 170, thus connecting the compartment to the upper and lower portions of the lateral module, resulting in at least one of the lateral module encapsulation layer 140, shelf 178, and bracket 180 adding strength to the compartment – ​​effectively creating a double-layer torque box. Finally, battery cells / packs 150, 152, 154, and 156, configured as structural shells or structural attachments, can further enhance the strength of the lateral module. The battery cells / packs can be connected to the lateral module. That is, the combination of the chair and one or more of the modules provides greater strength than the sum of the components.

[0197] In a vehicle having compartment 170, the compartment and / or lateral module 126 may include additional structural members:

[0198] - The internal transverse members of the battery pack, such as struts 180, encapsulation layers 140, or sub-compartments 182, are configured to provide: assembly points for cells or modules (e.g., longitudinal modules can perform this function); and stopping functions for cells or modules in the event of a frontal or rear-end impact. Due to the presence of flat / transverse members and support structures at the front, rear, and top of the battery pack, which provide structural support for each additional stack of cells / modules, the following functions become secondary: providing lateral connections and thus providing a load path from the sides of the battery pack housing to primarily provide stiffness in the event of a side impact; and adding torsional and bending stiffness to the battery pack. As a result, the cross-sectional dimensions of the internal transverse members of the battery pack can be smaller than those of an optional battery pack (e.g., an underfloor type battery pack).

[0199] - Internal longitudinal members of the battery pack, such as struts 180, encapsulation layers 140, or sub-compartments 182, are configured to provide: assembly points for cells or modules (this function can be performed by lateral modules); and stopping functions for cells or modules in the event of a side impact. To a lesser extent than underfloor type battery packs, the internal longitudinal members provide longitudinal connections, and thus the load path from the front to the rear lateral members of the battery pack housing also contributes to this structural function, serving as a battery pack support structure for each additional stack of cells / modules. As a secondary function, the internal longitudinal members also add torsional and bending stiffness to the battery pack.

[0200] - The lower battery pack shield, such as support 174, can be configured to withstand penetration from objects impacting the underside of the vehicle, while providing additional rigidity to the battery housing. This shield can have significantly different dimensions compared to underfloor type battery pack shields, typically made of approximately 6mm thick aluminum or approximately 1.5mm thick steel, because the compartment opening 172 is smaller than that of a flat-pack battery pack in an underfloor type vehicle system.

[0201] - The battery pack housing, such as the encapsulation layer 140, is typically formed of steel and / or aluminum, but has a thinner internal cross section compared to an equivalent volume of underfloor battery packs. This is because the transverse battery pack within the vehicle is better integrated with the structural functions provided by the flat / transverse members through the front, rear and top of the battery pack, enabling lower structural requirements.

[0202] - A battery pack support structure, such as a strut 180 or a rack 178, is provided for each additional stack of cells / modules. This structure can be fitted to each additional stack of cells / modules to support the weight of the cells or modules. This support structure can be mechanically connected to the underlying structure and provides the ability to mechanically connect to the front, rear, and upper flat / lateral members of the battery pack, enabling a high degree of integration between the battery pack and the vehicle. Through this mechanical connection, the front, rear, and upper flat / lateral members of the battery pack can also contribute to supporting the weight of the cells or modules.

[0203] - Battery pack integration with the vehicle can include fasteners at multiple points on the body surface on the flat / transverse members in front of, behind, and above the battery pack. Battery pack integration with the body adds torsional and bending stiffness to the vehicle. Transverse battery packs contribute more to vehicle stiffness due to their higher stiffness for the same volume compared to underfloor battery packs, and due to the better distribution of mechanical connections across the battery pack body. A traditional transverse battery pack casing, including structural members, can have a mass of 30kg to 120kg. The additional stiffness provided by battery pack integration with the body is likely limited compared to the additional stiffness achievable if the body were stiffened by optimizing the placement of a similar mass. As cells or modules evolve to be used as structural members, where batteries may withstand limited strain levels and still require fracture protection, the structural characteristics of transverse battery packs are improved, providing a useful improvement to vehicle torsional and bending stiffness, with deterministic improvements in underfloor battery packs due to reduced span and higher battery pack height (moment of inertia).

[0204] - A flat / lateral member, such as strut 180 or strut 17a, positioned above the battery pack, provides lateral connection at the vehicle side, door rings, and / or between strut A or strut B, areas typically subject to high strain during side impacts. The form and shape of the flat / lateral member will depend on the individual application, but its primary function remains to connect to the vehicle side to provide a load path for lateral forces during side impacts, to counteract torque forces caused by road inputs, and to provide mounting points for the battery pack housing. This structural element may be attached to the battery housing, i.e., encapsulation layer 140 or strut 180, to increase the rigidity of the integrated structure and to provide support for additional stacking of cells or modules.

[0205] - A flat / lateral member located behind the battery pack provides lateral connection at the vehicle side, between rocker arms and door rings and / or A-pillars or B-pillars, in areas typically experiencing high strain during a side impact. The form and shape of the flat / lateral member will depend on the individual application, but its primary function remains to connect to the vehicle side to provide a load path for lateral forces during a side impact, to resist torque forces caused by road input, and to provide a mounting point for the battery pack housing. This structural element may be attached to the battery housing, which is encapsulated by a 140mm layer, to improve the rigidity of the integrated structure.

[0206] - A flat / lateral member located in front of the battery pack provides lateral connection at the vehicle side, rocker arm and door ring, and / or A-pillar or B-pillar, areas typically experiencing high strain during a side impact. The form and shape of the flat / lateral member will depend on the individual application, but its primary function remains to connect the vehicle side to provide a load path for lateral forces during a side impact and to resist torque forces caused by road input, as well as to provide mounting points for the battery pack housing. This structural element may be connected to the battery pack housing at multiple points to increase the stiffness of both elements. Floor channels connect to the structural element to further enhance the stiffness of both elements.

[0207] The aforementioned compartment 170 is described only by means of the transverse module 126. Based on the teachings herein, the structural elements and features illustrated by compartment 170 and transverse module 126 can be used / adapted to any one of the longitudinal module 128, rear module 130, and front module 132, or a combination thereof. For example, the required occupancy area and corresponding opening will correspond to... Figures 3a to 3d The occupied area shown in the image.

[0208] Additional modules, such as longitudinal module 128, not only increase the volume of the battery pack, but the compartments also provide additional strength to the vehicle by acting as floor passages. The extrusion forging of the floor panel and the lateral seat members both contribute to torsional and bending stiffness. The compartments used in the longitudinal modules also function as structural members for frontal and rear-impact performance.

[0209] Each of the horizontal module 126, the vertical module 128, the rear module 130, and the front module 132 may have its own battery pack 126 and encapsulation layer 170 as described above, or the battery packs may be combined into a single unit. Each module may have its own opening 172.

[0210] Figure 15The diagram shows compartment / lateral modules 126 and 170 extending across the width of the vehicle, between a first seat facing forward and occupied by passengers and a second seat facing rearward, just behind it. The lateral module can be described as dividing the passenger compartment into a front and rear section. Overall, there are five seats in the rear, but only four passengers are shown. The lateral module 126 has front and rear modules or portions extending below adjacent seats / passengers, providing additional volume to the lateral module 126. The lateral module extends from below the lowest point of the first and / or second seats to the highest point of the compartment, which is at least above the highest height of the backrests of the first and / or second seats. The lateral module extends across the width of the vehicle in an offset manner. It can have a stepped or curved shape. That is, it can be described as non-linear or asymmetrical. Depending on the purpose of the vehicle, the configuration of the lateral module can be compensated to accommodate different passenger or cargo needs. In this particular example, the layout is suitable for London taxis, where only passengers sit in the front, while up to five passengers sit in the rear compartment.

[0211] Figure 16 The side view shows different vehicle types, including the overlapping shapes of compartment / lateral modules 126, 170 on the side of each vehicle at a location that allows the compartment to provide at least additional structural integrity to the vehicle under discussion. For example, among other improvements, the compartment can extend between the B pillars to improve the crashworthiness of the passenger compartment. As shown, the compartment can be configured in passenger cars, commercial vans, and heavy-duty cargo vehicles of the tractor-trailer type. In accordance with the teachings herein, modules 126, 128, 130, 132 and / or the compartment can be adapted to different vehicle types, such as those containing vehicles arranged as follows: two seats back-to-back in a straight line; a first seat facing forward and back-to-back with at least two other seats, which can be individual seats or bench seats; two seats facing forward and at least two adjacent seats arranged back-to-back; the first seat facing a direction perpendicular to the direction of travel and the second adjacent seat arranged back-to-back facing the opposite direction to the first seat, such that the modules and compartments extend in the longitudinal direction of the vehicle.

[0212] The foregoing description is merely a few examples, and various modifications can be made within the spirit of the invention, extending to equivalent features of the described features.

[0213] For example, many of the vehicles shown there demonstrated two seats and two passengers. Those skilled in the art will understand that, depending on the type and function of the vehicle, more seats can be provided.

[0214] While different embodiments of this disclosure are described and shown herein, those skilled in the art will readily conceive of many other ways and / or structures for performing the functions and / or obtaining the results and / or one or more advantages described herein, and each of these variations and / or modifications is considered to fall within the scope of this disclosure. More generally, those skilled in the art will readily understand that all parameters, dimensions, materials, and / or configurations will depend on the specific application or the application to which the teachings of this disclosure are intended. Those skilled in the art will understand, or can clearly appreciate, that many equivalent ways of the specific embodiments described herein can be used without going beyond ordinary experimentation. Therefore, it is understood that the foregoing embodiments are shown by way of example only, and that the invention may be practiced in ways other than those specifically described and claimed within the scope of the appended claims and their equivalents. The invention refers to each individual feature, system, article, material, and / or method described herein. Furthermore, any two or more such features, systems, articles, materials, and / or methods are included within the scope of the invention if such features, systems, articles, materials, and / or methods are not inconsistent with each other.

[0215] Unless otherwise expressly stated, the indefinite articles “a” and “an” used in this specification and claims shall be understood to mean “at least one”. The term “and / or” used in this specification and claims shall be understood to mean “one or both” of elements so combined, i.e., elements that appear together in some cases and separately in others. Other elements may optionally appear, whether related to or unrelated to those specifically identified by the clause “and / or”, unless clearly indicated otherwise. Thus, as a non-limiting example, when used in conjunction with open-ended language such as “comprising,” reference to “A and / or B” may, in one embodiment, mean A without B (optionally including elements other than B); in another embodiment, mean B without A (optionally including elements other than A); in yet another embodiment, mean both A and B (optionally including other elements); and so on.

[0216] As used herein and in the claims, “or” may be understood to have the same meaning as “and / or” as defined above. For example, when the items in the list are separated, “or” or “and / or” should be interpreted as inclusive, that is, including at least one / a, as well as more than one of some or a list of elements, and, optionally, additional unlisted items. Only terms that clearly indicate the opposite, such as “only one of them” or “exactly one of them,” or when used in the claims, “consisting of…”, will specify that it includes an exact one of some or a list of elements. Generally, the term “or” as used herein should be interpreted only as indicating an exclusive option (i.e., “one or the other but not both”). When preceded by an exclusive term, such as “one of both,” “one of them,” “only one of them,” “exactly one of them,” “substantially constitutes…”, when used in the claims, should have its usual meaning as it is used in the field of patent law.

[0217] As used in this specification and claims, the term "at least one / a" when referring to a list of one or more elements may be understood to mean selecting at least one element from one or more elements in the list, but does not necessarily include at least one of every and all possible elements specifically listed in the list, and does not exclude any combination of elements in the list. This definition also allows elements to be presented optionally, whether or not they are related to the specifically indicated term "at least one / a" in addition to those specifically specified in the list. Therefore, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B", or, equivalently, "at least one of A and / or B") may in one embodiment mean at least one, optionally including more than one, while B is not present (and optionally including other elements besides B); in another embodiment, mean at least one, optionally including more than one, B, while A is not present (and optionally including other elements besides A); in yet another embodiment, mean at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements), and so on.

[0218] In the claims and the foregoing description, all transitional terms, such as “comprising,” “including,” “with,” “having,” “containing,” “involving,” “holding,” etc., shall be understood as open-ended, i.e., including but not limited to. Only the transitional terms “consisting of…” and “substantially consisting of…” shall be closed or semi-closed transitional terms, respectively, as explained in Section 2111.03 of the Patent Examination Procedure in the U.S. Patent Office Manual. The use of common terms such as “first,” “second,” “third,” etc., to define elements of a claim in the claims does not imply any priority, order of precedence, or that one claim element is in order of precedence over another, or the chronological order of the actions of a method, but is merely used as identifiers to distinguish one claim element with a certain name from another element with the same name (but as common terms) to differentiate claim elements.

[0219] The invention also exists in any single feature described or implied herein, or in any combination of such features shown or implied in the figures, or in any higher form of such features or combinations.

Claims

1. A vehicle (100) having an electric motor and an energy storage pack (107, 126), the vehicle being configured with: at least two passenger seats (118, 122) each having a backrest, including a first seat (118) configured to face forward and a second seat (122) located behind and adjacent to the first seat and configured to face backward, wherein, The package (107, 126) has a transverse module (126) configured to extend between the first seat and the second seat along a direction perpendicular to the longitudinal axis of the vehicle; The lateral module (126) is configured to extend transversely across a portion of the width of the vehicle located between adjacent seats in a direction perpendicular to the longitudinal axis of the vehicle (100) between the first seat (118) and the second seat (122). The height of the lateral module (126) extends in the vertical direction between the following two: The bottom surface of the lateral module is located below the lowest point of the first seat adjacent to the package, and The highest surface of the horizontal module is located above the following: The top of the backrests of the first seat (118) and the second seat (122); The maximum height of the seat cushion of the first seat (118) in the first row and / or the second seat (122) in the second row; The average height of the seat cushions of the first seat in the first row and / or the second seat in the second row; and, The hip point (124) of the first seat in the first row and / or the second seat in the second row.

2. The vehicle (100) according to claim 1, further comprising a longitudinal module (128) configured to: extend along the longitudinal axis of the vehicle; extend in a direction perpendicular to the transverse module (126); and extend at least partially between at least two first seats (118).

3. The vehicle (100) according to claim 1, wherein, The first seat (118) is located on one side of the longitudinal axis of the vehicle.

4. The vehicle (100) according to claim 1 or 3, wherein, The longitudinal axis is the center of the vehicle, and the vehicle has: at least two first seats separated by the longitudinal axis; and / or at least two second seats separated by the longitudinal axis.

5. The vehicle (100) according to claim 1, wherein, At least one first seat (118) and at least one second seat (122) are arranged back to back, at least partially.

6. The vehicle (100) according to claim 1, wherein, The maximum distance between the first seat and the second seat is less than the maximum dimension of the first seat or the second seat in the longitudinal direction.

7. The vehicle (100) according to claim 1, wherein, The second seat is a long bench seat.

8. The vehicle (100) according to claim 2, wherein, The package (107) further includes a longitudinal module (128) connected to the transverse module (126), the longitudinal module being configured to extend from the transverse module toward the front of the vehicle along the longitudinal axis.

9. The vehicle (100) according to claim 2, wherein, The package (107) has a rear module (130) connected to the lateral module, the rear module being configured to extend rearward from the lateral module.

10. The vehicle (100) according to claim 9, wherein, The rear module (130) is configured to extend between the second seats and be in line with the longitudinal module; and / or extend below the second seats.

11. The vehicle (100) according to claim 2, wherein, The lowest surface of the longitudinal module (128) and the lowest surface of the transverse module (126) extend at the same height in the vehicle.

12. The vehicle (100) according to claim 1, wherein, The height (T) of the lateral module is at least one of the following: the maximum height of the lowest position of the top of the first seat or the second seat, or at most less than 100 mm; or at least greater than the maximum height of the seat cushion of the first row and / or the second row of seats. And below the lowest edge of the window closest to the package (107).

13. The vehicle (100) according to claim 1, wherein, The bottom surface of the bag is level with at least one bottom surface of the vehicle.

14. The vehicle (100) according to claim 13, wherein, At least one bottom of the vehicle is the floor of the body-in-white, or the bottom of the vehicle chassis.

15. The vehicle (100) according to claim 1, wherein, The length (V) of the uppermost part of the transverse module (126) in the longitudinal direction is between 10% and 50% of the length of the bottom (Y) of the transverse module.

16. The vehicle (100) according to claim 1, wherein, The length (V) of the uppermost part of the transverse module (126) in the longitudinal direction is between 20% and 40% of the length of the bottom (Y) of the transverse module.

17. The vehicle (100) according to claim 1, wherein, The length (V) of the uppermost part of the transverse module (126) in the longitudinal direction is between 25% and 35% of the length of the bottom (Y) of the transverse module.

18. The vehicle (100) according to claim 9, wherein, The vehicle has a flat, plate-shaped underfloor battery pack and at least one of the transverse module, the longitudinal module, the front module, and the rear module.

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