Electric vehicle battery pack module

Abstract

A system can include a vehicle having a frame. One or more rails can form at least a portion of the frame, and a container is configured to provide torsional stiffness to the chassis. The system can include the container configured to mount to the one or more rails. A plurality of battery pack assemblies can be enclosed within the container. The system can include a power distribution unit (PDU) to which the plurality of battery pack assemblies are connected. The plurality of battery pack assemblies can be configured to provide power to at least one component of the vehicle via the PDU.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to battery pack modules for electric vehicles. BACKGROUND

[0002] Vehicles that operate using battery pack power, such as hybrid vehicles and electric vehicles, are becoming increasingly popular. Such vehicles offer many advantages over vehicles that do not use battery pack power. For example, because such vehicles do not require fuel, they can save the driver money. Such vehicles are also environmentally friendly because they do not emit pollutants. However, some electric vehicles can need to be powered for a large number of components and / or driven for long distances. It can be difficult to provide enough battery pack power for these electric vehicles. Accordingly, improvements in electric vehicle battery packs are desirable. SUMMARY

[0003] The present application is further understood when read in conjunction with the drawings. For the purpose of illustrating the subject matter, exemplary aspects of the subject matter are disclosed in the drawings; however, the presently disclosed subject matter is not limited to the disclosed implementations.

[0004] Systems and methods for electric vehicle battery pack modules are disclosed herein. A system can include a vehicle having a frame. One or more rails can form at least a portion of the frame. The system can include a container configured to be mounted to the one or more rails. A plurality of battery pack components can be enclosed within the container. The system can include a power distribution unit (PDU) to which the plurality of battery pack components are connected. The plurality of battery pack components can be configured to provide power to at least one component of the vehicle via the PDU.

[0005] A method can include mounting a container to one or more rails. The one or more rails form at least a portion of a frame of a vehicle. A plurality of battery pack components can be inserted within the container. A PDU can be connected to the plurality of battery pack components. The plurality of battery pack components can be configured to provide power to at least one component of the vehicle via the PDU.

[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that solve any or all disadvantages with any part of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0007] The present application is further understood when read in conjunction with the drawings. For the purpose of illustrating the subject matter, exemplary aspects of the subject matter are disclosed in the drawings; however, the presently disclosed subject matter is not limited to the disclosed implementations. In the drawings:

[0008] Figure 1 An example electric vehicle chassis system including a battery pack module is shown.

[0009] Figure 2 An example electric vehicle battery pack module is shown.

[0010] Figure 3 Another example electric vehicle battery pack module is shown.

[0011] Figure 4 Another example electric vehicle battery pack module is shown.

[0012] Figure 5 An example battery pack for use in an electric vehicle battery pack module is shown.

[0013] Figure 6 An example electric vehicle battery pack module including a shelf is shown.

[0014] Figure 7 An example battery pack for use in an electric vehicle battery pack module is shown.

[0015] Figure 8 Connection of a battery pack for use in an electric vehicle battery pack module is shown.

[0016] Figure 9 An example side view of an electric vehicle battery pack module is shown.

[0017] Figure 10 Example components of an electric vehicle system that can be powered by an electric vehicle battery pack module are shown.

[0018] Figure 11 Example electric vehicle battery pack modules of different sizes are shown.

[0019] Figure 12 An example method for assembling an electric vehicle battery pack module is shown.

[0020] Figure 13 Another example method for assembling an electric vehicle battery pack module is shown.

[0021] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. All descriptions and annotations in the figures and all contents therein are incorporated by reference herein as if fully set forth herein. All references are incorporated by reference herein as if fully set forth herein. Aspects of the disclosure will now be described in detail with reference to the drawings, where like reference numerals refer to like elements throughout. DETAILED DESCRIPTION

[0022] The present disclosure can be more readily understood by reference to the following detailed description, taken in conjunction with the accompanying drawings and examples, which constitute a part of this disclosure. It is to be understood that the present disclosure is not limited to the particular devices, methods, applications, conditions or parameters described and / or shown herein, and that the terminology used herein is for the purpose of describing particular examples by way of example only and is not intended to be limiting of the claimed disclosure.

[0023] Disclosed herein are aspects of a system for an electric vehicle battery pack module and a method for assembling such an electric vehicle battery pack module. Figure 1 A chassis system 100 for an electric vehicle is shown. The system 100 includes a first module 102, a second module 104, and a third module 106. The first module 102 can include a cradle for a front axle, suspension, and steering of the electric vehicle. The first module 102 can additionally include auxiliary modules associated with one or more accessories of the electric vehicle. The third module 106 can include a cradle for a rear axle and suspension of the electric vehicle.

[0024] The second module 104 can be an electric vehicle battery pack module. The electric vehicle battery pack module can be a large structural battery pack package configured to provide power to at least one component of the electric vehicle. For example, the electric vehicle battery pack module can include one or more battery pack packages configured to provide power to at least one component of the electric vehicle. The at least one component can be located in the first module 102 or the third module 106. For example, the at least one component can include at least one component including a main drive inverter, an electric motor, a steering pump, an AC compressor, a DC-DC converter, a cabin heater, a cooling system, a charger, an air compressor, an auxiliary inverter, and / or any other component of the electric vehicle. Exemplary electric vehicle battery pack modules will be discussed in greater detail below with respect to Figures 3-7

[0025] The second module 104 is configured to be connected to and interposed between the first module 102 and the third module 106. In some examples, the second module 104 can be bolted to the first module 102 and the third module 106 such that the second module is positioned between the first module 102 and the third module 104.

[0026] ​In other examples, the second module 104 can be connected to a frame rail passing through the first module 102 and the third module 106, such that the second module 104 is positioned between the first module 102 and the third module 106. For example, the second module 104 can be positioned between the first module 102 and the third module 106, such that the frame rail passes through the second module 104. In this way, the vehicle's frame rail can be used to suspend the second module 104. By connecting the second module 104 to existing frame rails, rail manufacturers are able to integrate the second module 104 into existing chassis without requiring time-consuming or costly chassis redesign.

[0027] In some exemplary embodiments, the size of the second module 104 can be selected to maximize the number of battery packs that can be assembled within the second module 104. For example, the length of the second module 104 can be 80 to 100 inches, the width can be 80 to 100 inches, and the height can be 20 to 40 inches. The second module 104 can include, for example, one, two, three, four, five, six, seven, eight, nine, or any other number of battery packs, or the batteries can be directly integrated to form a large battery pack. However, it should be understood that the second module 104 can have any other suitable size that allows a sufficient number of battery packs to be incorporated within the second module 104.

[0028] As described above, the second module 104 can be an electric vehicle battery pack module bolted to the frame rails of the chassis. Figure 2 An example electric vehicle battery pack module 200 is shown. The electric vehicle battery pack module 200 includes a container 202 configured to be mounted to a frame track 206 (i.e., a C-shaped channel) forming at least a portion of the frame of the electric vehicle. The electric vehicle can be any vehicle, including trucks, vans, or trailers. The electric vehicle battery pack module 200 includes a cover 210 configured to cover the top of the opening in the container 202.

[0029] The electric vehicle battery pack module 200 includes multiple battery pack components 207a-c enclosed within a container 202.

[0030] In some cases, the plurality of battery pack assemblies 207a-c are configured to connect to a power distribution unit (PDU). In some cases, the plurality of battery pack assemblies 207a-c are configured to provide power to at least one component of the electric vehicle via the PDU. The PDU to which the plurality of battery pack assemblies 207a-c connect can be located in the auxiliary module (i.e., in the first module 102). Optionally, the PDU can instead be located inside the container 202. The PDU 212 can be included inside the container 202. For example, the PDU 212 can include connections to the electric motor and / or inverter of the electric vehicle. By including the PDU 212 inside the container 202, the PDU in the auxiliary module can be eliminated, thereby reducing weight and lowering cost.

[0031] The plurality of battery pack assemblies 207a-c can each include a plurality of battery packs. For example, the battery pack assembly 207a includes battery packs 208a-c, the battery pack assembly 207b includes battery packs 208d-f, and the battery pack assembly 207c includes battery packs 208g-i. Each of the battery packs 208g-i can have a substantial weight. For example, each of the battery packs 208g-i can weigh about 1000 pounds. The plurality of battery pack assemblies 207a-c can be separated from each other by the interior vertical walls of the container 202. The container 202 can be mounted to the frame rails 206 by bolting the upper portions of the interior vertical walls of the container 202 to the frame rails 206.

[0032] In some examples, aspects include an electric vehicle battery pack module 200 having a layer of material 204 connected to at least one exterior side or end wall of the container 202. The layer of material can be configured to protect the plurality of battery pack assemblies 207a-c from damage. For example, the layer of material can be configured to protect the plurality of battery pack assemblies 207a-c from damage during an impact. The layer of material 204 can have any thickness. For example, the layer of material 204 can have a thickness of one inch, two inches, three inches, four inches, or five inches. The layer of material 204 can be, for example, one or more crush beams. The layer of material 204 can be riveted, bolted, and / or adhered to the two exterior end walls of the container 202.

[0033] In some cases, the rail-mounted containers disclosed herein improve the strength of the chassis by providing additional structural rigidity. Disclosed herein is a container wall that exceeds twice the height of a conventional frame rail, such a container is configured to increase the strength of the chassis by the large vertical members of the container. Truck frames typically use cross members to provide torsional rigidity. This ladder configuration reduces lateral loads from a twisted frame. By including large monolithic packs in the center of the truck and even on the rails, the container provides additional torsional rigidity as the two large vertical members of the enclosure are oriented transverse to the vehicle axis.

[0034] In some cases, the outer shell is at least partially constructed of a composite material that can provide a strong structure that is light in weight but provides high strength.

[0035] Figure 3 Aspects of an electric vehicle battery pack module 300 are shown. The electric vehicle battery pack module 300 includes a container 302 configured to mount to a frame rail 306 (i.e., a C-shaped channel) that forms at least a portion of a frame of an electric vehicle. The electric vehicle can be any vehicle, including a truck, van, or trailer. The electric vehicle battery pack module 300 includes a plate 310 configured to fit into an open bottom of the container 302.

[0036] The electric vehicle battery pack module 300 includes a plurality of battery pack assemblies 307a-c mounted to the plate 310. The plate 310 including the mounted battery pack assemblies 307a-c can be lifted to fit into the open bottom of the container 302 such that the battery pack assemblies 307a-c are enclosed within the container 302.

[0037] The plurality of battery pack assemblies 307a-c can be connected to a PDU. The PDU can or can not be part of the container or can or can not be physically connected to the container. The plurality of battery pack assemblies 307a-c provide power to at least one component of the electric vehicle via the PDU. The plurality of battery pack assemblies 307a-c can be connected to a power distribution unit (PDU). The plurality of battery pack assemblies 307a-c can be directly connected to provide power to at least one component of the electric vehicle via the PDU. The PDU to which the plurality of battery pack assemblies 307a-c are connected can be located in an auxiliary module (i.e., in the first module 102). Optionally, the PDU can instead be located inside the container 302, for example on the plate 310. The PDU 312 can be included inside the container 302. For example, the PDU 312 can include connections to the electric motor and / or inverter of the electric vehicle. By including the PDU 312 inside the container 302, the PDU in the auxiliary module can be eliminated, thereby reducing weight and lowering cost.

[0038] Each of the plurality of battery pack assemblies 307a-c can include a plurality of battery pack packs. For example, battery pack assembly 307a includes battery pack packs 308a-c, battery pack assembly 307b includes battery pack packs 308d-f, and battery pack assembly 307c includes battery pack packs 308g-i. Each of the battery pack packs 308g-i can have a substantial weight. For example, each of the battery pack packs 308g-i can weigh about 1000 pounds. The plurality of battery pack assemblies 307a-c can be separated from each other by the interior vertical walls of the container 302. The container 302 can be mounted to the frame rails 306 by bolting the upper portions of the interior vertical walls of the container 302 to the frame rails 306. For example, the container 302 can be mounted to the frame rails 306 such that the battery pack assemblies 307a-c are enclosed within the container 302 prior to lifting the deck 310 including the mounted battery pack assemblies 307a-c into the open bottom of the container 302.

[0039] In some examples, the electric vehicle battery pack module 300 includes a layer of material 304 connected to at least one exterior side or end wall of the container 302. The layer of material can be configured to protect the plurality of battery pack assemblies 307a-c from damage. For example, the layer of material can be configured to protect the plurality of battery pack assemblies 307a-c from damage during an impact. The layer of material 304 can have any thickness. For example, the layer of material 304 can have a thickness of one inch, two inches, three inches, four inches, or five inches. The layer of material 304 can be connected to, for example, two exterior end walls of the container 302.

[0040] In some examples, the plurality of battery pack assemblies 307a-c can be configured to be removed from the container 302 by lowering the deck 310 including the mounted plurality of battery pack assemblies 307a-c from the open bottom of the container 302. In this way, the plurality of battery pack assemblies 307a-c can be easily removed and / or replaced as needed.

[0041] In some examples, the second module 104 can be an electric vehicle battery pack module that is assembled and dropped onto an existing frame rail. Figure 4 Another example electric vehicle battery pack module 400 is shown. The electric vehicle battery pack module 400 includes a container 402 that is configured to be lowered over a frame rail 406 (i.e., a C-channel) that forms at least a portion of a frame of an electric vehicle. The electric vehicle can be any vehicle, including a truck, a van, or a trailer. The electric vehicle battery pack module 400 includes a cover 410 that is configured to cover an open top of the container 402.

[0042] The electric vehicle battery pack module 400 includes a plurality of battery pack assemblies 407a-c mounted to a bottom surface of the container 402. The container 402 including the mounted battery pack assemblies 407a-c can be lowered on the frame rail 406. The plurality of battery pack assemblies 407a-c can be separated from each other by the vertical walls of the container 402. The container 402 can be lowered on the frame rail 406 such that the vertical walls of the container 402 fit on the frame rail 406. After the container 402 including the mounted battery pack assemblies 407a-c is lowered on the frame rail 406, the cover 410 can be lowered on the container 402 such that the battery pack assemblies 407a-c are enclosed between the container 402 and the cover 402.

[0043] The plurality of battery pack assemblies 407a-c can each include a plurality of battery packs. For example, the battery pack assembly 407a includes battery packs 408a-c, the battery pack assembly 407b includes battery packs 408d-f, and the battery pack assembly 407c includes battery packs 408g-i. Each of the battery packs 408g-i can have a substantial weight. For example, each of the battery packs 408g-i can weigh about 1000 pounds. The plurality of battery pack assemblies 407a-c can be connected to a PDU. The plurality of battery pack assemblies 407a-c provide power to at least one component of the electric vehicle via the PDU.

[0044] In some examples, the electric vehicle battery pack module 400 includes a layer of material 404 connected to at least one outer side or end wall of the cover 410. The layer of material can be configured to protect the plurality of battery pack assemblies 407a-c from damage. For example, the layer of material can be configured to protect the plurality of battery pack assemblies 407a-c from damage during an impact. The layer of material 404 can have any thickness. For example, the layer of material 404 can have a thickness of one inch, two inches, three inches, four inches, or five inches.

[0045] In some examples, the electric vehicle battery pack module 400 includes cover plates 413a-b. The cover plates 413a-b can be bolted between the vertical walls of the container 402 to cover the openings between the vertical walls of the container 402. The cover plates 413a-b can prevent the openings between the vertical walls of the container 402 from being filled with dirt, leaves, debris, etc. The cover plates 413a-b can additionally or alternatively provide additional structural support to the container 402. For example, the cover plates 413a-b can prevent the container 402 from collapsing on itself.

[0046] As described above with respect to the electric vehicle battery pack module 400, the plurality of battery pack assemblies 407a-c can each include a plurality of battery packs. For example, the battery pack assembly 407a includes battery packs 408a-c, the battery pack assembly 407b includes battery packs 408d-f, and the battery pack assembly 407c includes battery packs 408g-i. Each of the battery packs 408g-i can have a substantial weight. For example, each of the battery packs 408g-i can weigh about 1000 pounds. The plurality of battery pack assemblies 407a-c can be connected to a PDU. The plurality of battery pack assemblies 407a-c provide power to at least one component of the electric vehicle via the PDU. Figures 2-4As discussed, an electric battery pack module can include a plurality of battery pack assemblies. Each of the plurality of battery pack assemblies can include a plurality of battery pack packs or modules. In some cases, the battery packs are long and thin and can provide a structural support "blade" battery. The battery pack packs or modules include one or more blade batteries. The battery pack packs in each of the plurality of battery pack assemblies can be bolted together. Figure 5 An example battery pack pack is shown bolted together to form a battery pack assembly. Figure 5 A view 500 illustrating a front end of a battery pack assembly formed by bolting together battery pack packs 508a-c, a view 502 illustrating a side of a battery pack assembly formed by bolting together battery pack packs 508a-c, and a view 504 illustrating a back end of a battery pack assembly formed by bolting together battery pack packs 508a-c are shown. Those skilled in the art and having ordinary skill in the art will recognize that an excess of securing means can be used in the attachment packs and that these attachments will be within the scope of the present disclosure.

[0047] The battery pack packs 508a-c can be bolted together using solid vertical support plates 505a-d. Referring to view 502, the sides of the battery pack packs 508a-c can be bolted together using vertical support plates 505a-b. For example, battery pack pack 508b can be stacked on top of battery pack pack 508c and vertical support plate 505b can be bolted to the side of battery pack pack 508b and the side of battery pack pack 508c in order to connect battery pack packs 508b-c. Likewise, battery pack pack 508a can be stacked on top of battery pack pack 508b and vertical support plate 505a can be bolted to the side of battery pack pack 508a and the side of battery pack pack 508b in order to connect battery pack packs 508a-b. Referring to view 504, vertical support plate 505d can be bolted to the back end of battery pack pack 508b and the back end of battery pack pack 508c in order to further connect battery pack packs 508b-c. Likewise, vertical support plate 505c can be bolted to the back end of battery pack pack 508a and the back end of battery pack pack 508b in order to further connect battery pack packs 508a-b. However, as shown in view 502, vertical support plates can not be used on the front end of the battery pack assembly as electrical and water connections on the front end of the battery pack assembly can need to be accessible.

[0048] Additional securing schemes and devices can include solid vertical support plates on which each of the plurality of battery pack packs in a battery pack assembly can be stacked. Figure 6An example electric vehicle battery pack module 600 including shelves is shown. The electric vehicle battery pack module 600 includes a container 602 configured to be mounted to a frame rail 606 (i.e., a C-shaped channel) forming at least a portion of a frame of an electric vehicle. The electric vehicle battery pack module 600 includes a cover 610 configured to cover an open top of the container 602.

[0049] The electric vehicle battery pack module 600 includes a plurality of battery pack assemblies 607a-c enclosed within the container 602. The plurality of battery pack assemblies 607a-c can be connected to a power distribution unit (PDU). The plurality of battery pack assemblies 607a-c provide power to at least one component of the electric vehicle via the PDU. Optionally, connections 612 can be included inside the container 602. For example, the connections 612 can include connections to an electric motor and / or an inverter of the electric vehicle.

[0050] The plurality of battery pack assemblies 607a-c can each include a plurality of battery pack packs. For example, the battery pack assembly 607a includes battery pack packs 608a-c, the battery pack assembly 607b includes battery pack packs 608d-f, and the battery pack assembly 607c includes battery pack packs 608g-i. The plurality of battery pack assemblies 607a-c can be separated from each other by interior vertical walls of the container 602. The container 602 can be mounted to the frame rail 606 by bolting upper portions of the interior vertical walls of the container 602 to the frame rail 606.

[0051] A plurality of shelves 613a-i can be bolted within the container 602. For example, the plurality of shelves 613a-i can be bolted between the interior vertical walls of the container 602. Each of the plurality of shelves 613a-i can be configured to hold a battery pack pack 608a-i. For example, the shelf 613a can be configured to hold the battery pack pack 608a, the shelf 613b can be configured to hold the battery pack pack 608b, the shelf 613c can be configured to hold the battery pack pack 608c, the shelf 613d can be configured to hold the battery pack pack 608d, the shelf 613e can be configured to hold the battery pack pack 608e, the shelf 613f can be configured to hold the battery pack pack 608f, the shelf 613g can be configured to hold the battery pack pack 608g, the shelf 613h can be configured to hold the battery pack pack 608h, and the shelf 613i can be configured to hold the battery pack pack 608i. The plurality of shelves 613a-i can each be capable of supporting a weight of at least one battery pack pack. For example, in battery pack packs each weighing 1000 pounds, each of the plurality of shelves 613a-i can be capable of supporting a weight of at least 1000 pounds.

[0052] In some examples, the electric vehicle battery pack module 600 includes a layer of material 604 connected to at least one outer side or end wall of the container 602. The layer of material can be configured to protect the plurality of battery pack assemblies 607a-c from damage. For example, the layer of material can be configured to protect the plurality of battery pack assemblies 607a-c from damage during an impact. The layer of material 604 can have any thickness. For example, the layer of material 604 can have a thickness of one inch, two inches, three inches, four inches, or five inches. The layer of material 604 can be connected to, for example, two outer end walls of the container 602.

[0053] Any suitable battery pack can be used in any of the battery pack assemblies described above with respect to Figures 2-6 Figure 7 An isometric view of an example battery pack 700 is shown. The battery pack 700 can be used in any of the battery pack assemblies described above with respect to Figures 2-6 The battery pack 700 includes a battery stack and a housing 702 that encloses the battery stack. The battery stack can include a plurality of layers including a cathode having an active coating, a separator, and an anode having an active coating. The plurality of layers can be wound to form a jellyroll structure or can be stacked to form a stacked battery structure. The plurality of layers can be enclosed within the housing 702 and immersed in an electrolyte.

[0054] The battery pack 700 includes an anode terminal 712 and a cathode terminal 710. The anode terminal 712 and the cathode terminal 710 can extend from the housing 702. The anode terminal 712 and the cathode terminal 710 can be connected to the battery stack. For example, the anode terminal 712 can be connected to an anode layer of the plurality of layers in the battery stack. Likewise, the cathode terminal 710 can be connected to a cathode layer of the plurality of layers in the battery stack.

[0055] In some examples, the battery pack 700 includes water cooling connections 713a-b that extend from the housing 702. The connection 713a can be an input nozzle and the connection 713b can be an output nozzle. The connections 713a-b can be connected to a thermal control unit located in an auxiliary module (i.e., in the first module 102). A coolant can move between the thermal control unit and the connections 713a-b in order to sufficiently heat and cool the battery pack 700.

[0056] In some examples, the battery pack 700 includes a ledge 704. The ledge 704 can be used to bolt the battery pack 700 to other battery packs in a battery pack assembly. For example, as described above with respect to Figure 5 a solid vertical support plate can be bolted to the ledge 704 in order to connect the battery pack 700 to another battery pack in a battery pack assembly.

[0057] Figure 8 ​A front view of an example battery pack 700 is shown. As described above, the battery pack 700 includes an anode terminal 712 and a cathode terminal 710. The anode terminal 712 and cathode terminal 710 extend from the housing 702. The battery pack includes a manual service disconnect (MSD) 802. The MSD 802 is a manual maintenance protection switch with a high-voltage interlock function. When pulled out, the MSD 802 is configured to disconnect the battery pack 700 and protect it from short circuits. (As mentioned above...) Figure 5 As discussed, a vertical support plate may not be used on the front end of the battery pack assembly 700, and terminals 712 and 710, as well as MSD 802, may need to be accessible.

[0058] Figure 9 A front view of an exemplary electric vehicle battery pack module 900 is shown. The electric vehicle battery pack module 900 can be any of the electric vehicle battery pack modules described above (i.e., modules 200, 300, 400, 600). The electric vehicle battery pack module 900 includes at least one battery pack assembly 907. The battery pack assembly 907 includes a plurality of battery packs 908a-c. The plurality of battery packs 908a-c can be stacked and bolted together, as described above. Figure 5 Optionally, multiple battery packs 908a-c can be stacked on a support bolted to the inside of container 902, as described above. Figure 6 The container 902 can be any container described above (i.e., container 202 with lid 210, container 302 with plate 310, or container 402 with lid 410 and plates 413a-b).

[0059] In some examples, the electric vehicle battery pack module 900 includes a manual service disconnect (MSD) 906. The MSD 902 is a manual maintenance protection switch with a high-voltage interlock function. When pulled out, the MSD 902 is configured to disconnect the electric vehicle battery pack module 900 and protect it from short circuits. The electric vehicle battery pack module 900 includes a charging connector 909. The charging connector 909 can be mounted to at least one outer wall (e.g., the front end) of the container 902. The charging connector 909 is configured to supply power from an external power source to the battery pack assembly 907 to recharge the battery pack assembly 909. The electric vehicle battery pack module 900 may include a space 915 for electrical connections. For example, the space 915 may extend approximately three to five inches beyond the battery pack assembly 907.

[0060] In some examples, the electric vehicle battery pack module 900 includes connector boards 911, 913. The connector board 911 can be bolted to the container 902. The connector board 911 can be used to connect the electric vehicle battery pack module 900 to one or more components of an electric vehicle, such as a drive system and / or auxiliary modules. For example, the connector board 911 can be used to provide low voltage power from the electric vehicle battery pack module 900 to one or more components of an electric vehicle, such as a drive system and / or auxiliary modules. The connector board 913 can be used to connect the electric vehicle battery pack module 900 to one or more other components of an electric vehicle, such as an electric motor and / or an inverter.

[0061] As discussed above with respect to Figure 7 Each battery pack in the electric vehicle battery pack module 900 can include a water cooling connection extending from the housing. The connection can be connected to a thermal control unit located in an auxiliary module (i.e., in the first module 102). Coolant can move between the thermal control unit and the connection in order to sufficiently heat and cool each battery pack. The electric vehicle battery pack module 900 can include a connector that connects the thermal control unit to each battery pack in the electric vehicle battery pack assembly 900.

[0062] Figure 10 A diagram 1000 depicting various components of an electric vehicle that can be powered by any of the electric vehicle battery pack modules described above with respect to Figures 1-9 These components are not limiting and the electric vehicle battery pack modules described above with respect to Figures 1-9 may power different or additional components of an electric vehicle. Components that can be powered by any of the electric vehicle battery pack modules described above include: an AC compressor, a steering pump, a cabin heater, a DC-DC converter, an auxiliary inverter, an air compressor, a battery pack cooler, and / or an on-board charger. Other components not depicted, such as a main drive inverter and / or an electric motor, can additionally or alternatively be powered by any of the electric vehicle battery pack modules described above.

[0063] Figure 11Electric vehicle battery pack modules are shown on two different trucks 1100 and 1102. The electric vehicle battery pack modules are located between the front of the front and rear axles of both trucks 1100 and 1102. However, trucks 1100 and 1102 have different wheelbases (i.e., the distance between the front and rear axles). For example, truck 1102 has a longer wheelbase than truck 1100. Trucks with longer wheelbases, such as truck 1102, can often include a sleeper and can be used to drive longer distances. Due to the longer wheelbase, truck 1102 can include a larger electric vehicle battery pack module than truck 1101. Due to the larger electric vehicle battery pack module, truck 1102 can be able to drive longer distances than truck 1100.

[0064] There are now a variety of popular truck models. Each of these truck models has its own unique styling and size constraints. The electric vehicle battery pack modules described above with respect to Figures 1-9 The electric vehicle battery pack modules described above can be used with each of these different styled trucks. For example, if a truck includes steps for a driver to enter the vehicle, these steps can be bolted to the outside of the electric vehicle battery pack module. One styling difference that exists between these different truck models is the frame rail spread (i.e., the distance between the frame rails). To accommodate these varying frame rail spreads, the vertical walls in the above-described containers can have to be customized for each of the different frame rail spreads. Alternatively, the vertical walls in the containers can be spaced apart at a standard size and a bulkhead can be utilized to adjust for varying frame rail spreads.

[0065] Figure 12 A method 1200 for assembling a battery pack power system is shown. At operation 1202, a container can be installed onto one or more rails. The one or more rails can form at least a portion of a frame of a vehicle (e.g., an electric vehicle). The container can be any of the containers described above (i.e., container 202, container 302, or container 402). For example, the vehicle can be a truck, a van, or a trailer. Installing the container onto the one or more rails can include bolting a portion of the container, such as one or more vertical walls in the container, to the one or more rails prior to inserting the plurality of battery pack assemblies into the container. Alternatively, installing the container onto the one or more rails can include lowering the container onto the one or more rails prior to inserting the plurality of battery pack assemblies into the container.

[0066] At operation 1204, after the container is installed to the one or more rails, the plurality of battery pack assemblies can be inserted into the container. In embodiments, the plurality of battery pack assemblies can be installed to a board, and inserting the plurality of battery pack assemblies into the container can include lifting the board, with the plurality of battery pack assemblies installed thereto, into the open bottom of the container. In other embodiments, the plurality of battery pack assemblies can be inserted into the container by stacking them in one or more cavities of the container, which has been lowered onto the one or more rails.

[0067] Conventional battery pack enclosures in a container do not provide structural strength, so the modules themselves just act as large weights in the system. In some examples, the container disclosed herein, which is fixed between the first module and the third module, replaces the rails and eliminates the weight of the rails, while also increasing the strength of the chassis by providing additional structural rigidity. A container wall is disclosed herein that is more than twice the height of a conventional frame rail, and such a container is configured to increase the strength of the chassis by the large vertical members of the container. Truck frames typically use cross members to provide torsional rigidity. This trapezoidal configuration reduces lateral loads from a twisted frame. By including a single large monolithic pack that connects the first module and the third module in the center of the truck, or by including a single large monolithic piece pack on the rails that connect the first module and the third module, the container provides torsional rigidity because the two large vertical members of the enclosure are oriented transverse to the vehicle axis.

[0068] In some cases, the enclosure is at least partially constructed of a composite material, which can provide a strong structure that is light in weight but provides high strength.

[0069] At operation 1206, a layer of material can be connected to at least one side of the container. The layer of material is configured to protect the plurality of battery pack assemblies from damage during an impact. The layer of material can have any thickness. For example, the layer of material can have a thickness of one inch, two inches, three inches, four inches, or five inches. The layer of material can be, for example, one or more extruded beams. The layer of material can be riveted, bolted, and / or adhered to the two exterior end walls of the container.

[0070] At operation 1208, a charging connector can be installed to at least one exterior wall of the container. The charging connector can be configured to provide power to the plurality of battery pack assemblies, for example, from an external power source, to recharge the plurality of battery pack assemblies.

[0071] At operation 1210, a power distribution unit (PDU) can be connected to the plurality of battery pack assemblies. The plurality of battery pack assemblies can be configured to provide power to at least one component of the vehicle via the PDU. As described above, the PDU can be located in the container or can alternatively be located in an auxiliary module of the vehicle. The at least one component can include a main drive inverter, an electric motor, a steering pump, an AC compressor, a DC-DC converter, a cabin heater, a cooling system, a charger, an air compressor, an auxiliary inverter, and / or any other component of the vehicle.

[0072] Figure 13 A method 1300 for assembling a battery pack power system is shown. At operation 1302, a plurality of shelves can be installed within a container. The container can be any of the containers described above (i.e., the container 202, the container 302, or the container 402). For example, the plurality of shelves can be bolted to the interior of the container, for example, between the interior vertical walls of the container. Each of the plurality of shelves can be configured to hold a battery pack. Each of the plurality of shelves can be capable of supporting a weight of at least one battery pack. For example, in a battery pack weighing 1000 pounds each, each of the plurality of shelves can be capable of supporting a weight of at least 1000 pounds.

[0073] At operation 1304, the plurality of battery pack assemblies can be inserted into the container prior to installing the container onto one or more rails that form at least a portion of a frame of a vehicle, such as an electric vehicle. For example, the vehicle can be a truck, a van, or a trailer. In one embodiment, inserting the plurality of battery pack assemblies into the container can include stacking the plurality of battery pack packs on a bottom surface of the container and bolting them together, for example, using a vertical plate. In other embodiments, the plurality of battery pack assemblies can be inserted into the container by stacking the plurality of battery pack assemblies in one or more cavities of the container prior to lowering the container onto the one or more rails. In other embodiments, inserting the plurality of battery pack assemblies into the container can include stacking the plurality of battery pack packs on the plurality of shelves such that each battery pack pack is supported by one or more of the shelves.

[0074] At operation 1306, the container can be installed onto the one or more rails. Installing the container onto the one or more rails can include bolting a portion of the container, such as one or more vertical walls in the container, to the one or more rails prior to inserting the plurality of battery pack assemblies into the container. Alternatively, installing the container onto the one or more rails can include lowering the container onto the one or more rails after inserting the plurality of battery pack assemblies into the container.

[0075] At operation 1306, a material layer can be connected to at least one side of the container. The material layer is configured to protect the plurality of battery pack assemblies from damage during an impact. The material layer can have any thickness. For example, the material layer can have a thickness of one inch, two inches, three inches, four inches, or five inches. The material layer can be, for example, one or more extruded beams. The material layer can be riveted, bolted, and / or adhered to the two exterior end walls of the container.

[0076] At operation 1308, a charging connector can be mounted to at least one exterior wall of the container. The charging connector can be configured to provide power to the plurality of battery pack assemblies, for example, from an external power source, to recharge the plurality of battery pack assemblies.

[0077] At operation 1310, a power distribution unit (PDU) can be connected to the plurality of battery pack assemblies. The plurality of battery pack assemblies can be configured to provide power to at least one component of the vehicle via the PDU. As described above, the PDU can be located in the container, or can alternatively be located in an auxiliary module of the vehicle. The at least one component can include a main drive inverter, an electric motor, a steering pump, an AC compressor, a DC-DC converter, a vehicle cabin heater, a cooling system, a charger, an air compressor, an auxiliary inverter, and / or any other component of the vehicle.

[0078] As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). The words “include,” “including,” and “includes” and “contain,” “containing,” and “contains” mean including, but not limited to. As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0079] As used herein, the recitation of two or more parts or components “coupled” or “connected” shall mean that the parts are either directly or indirectly connected to one another in that the connection is, through one or more intermediate parts or components, as long as there is some linkage—no matter how tenuous—between the connected items. As used herein, “directly coupled” means that two elements are in direct contact with one another. As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to be relatively immovable relative to one another in the direction indicated, unless otherwise noted. Directional phrases used herein, such as, but not limited to, top, bottom, side, ground, and derivatives thereof (e.g., top- most, bottom-most, right, left, upper, lower, front, back, rear, etc.), relate to the orientation of the elements shown in the drawings and are not limiting

[0080] The drawings can not be to scale and can not precisely reflect the structural or performance characteristics of any given implementation and should not be interpreted as defining or limiting the range of values or properties encompassed by example implementations.

[0081] While the system and method have been described in connection with various embodiments thereof, a person skilled in the art will understand that modifications in the embodiments can be made without departing from the broad inventive concept thereof. Accordingly, it is intended that the present disclosure not be limited to the particular embodiments disclosed, but that such embodiments are illustrative only of the scope of the present disclosure which is defined by the appended claims. Furthermore, as used in the specification and appended claims, the singular forms "a," "an" and "the" include plural references unless the context clearly dictates otherwise. The term "plurality" as used herein means more than one. When a range of values is expressed, another example includes from one particular value and / or to another particular value. Similarly, when a value is expressed as an approximation using the antecedent "about," it is understood that the particular value forms another example. All ranges are inclusive and combinable.

[0082] As used in the specification and appended claims, a range can be expressed herein as from "about" one particular value, and / or to "about" another particular value. Unless otherwise expressly stated, no method disclosed in the specification is intended to be interpreted as requiring its steps to be performed in a particular order. Thus, if a method claim is interpreted to require a particular order, that interpretation is not to be understood as requiring that steps be performed in that particular order, unless expressly stated in the claim or specification.

[0083] It will be appreciated that, for clarity, certain features of the present disclosure that have been described in the context of separate examples can also be provided in combination in a single example. Conversely, various features of the present disclosure that are, for brevity, described in the context of a single example, can also be provided separately or in any sub-combination. Furthermore, reference to values stated in ranges includes each and every value within that range.

Claims

1. A battery pack container mounting system to frame rails, comprising: a vehicle having substantially parallel frame rails forming at least a portion of a chassis; a container having an open top and at least two interior vertical wall members configured such that the frame rails pass through end walls of the container; a removable cover configured to cover the open top of the container and the frame rails; the container configured to mount between the frame rails; a plurality of battery pack assemblies within the container; and wherein the container height is configured to add strength and torsional rigidity to the chassis.

2. The system of claim 1, further comprising a layer of material connected to at least one side of the container, the layer of material configured to protect the plurality of battery pack assemblies from damage during an impact.

3. The system of claim 1, wherein each of the plurality of battery pack assemblies comprises at least one battery pack pack stacked and bolted together.

4. The system of claim 1, further comprising a plurality of shelves mounted within the container, and wherein each of the plurality of battery pack assemblies comprises a plurality of battery pack packs stacked on the plurality of shelves.

5. The system of claim 1, wherein the container height is at least twice the frame rail height.

6. The system of claim 1, wherein the container is configured to mount to the frame rails by bolting an upper portion of each vertical wall member to an adjacent frame rail.

7. The system of claim 1, further comprising a charging connector mounted to at least one exterior wall of the container, the charging connector configured to provide power from a power source to the plurality of battery pack assemblies to recharge the plurality of battery pack assemblies.

8. The system of claim 1, wherein the vehicle is a truck, van, or trailer.

9. A method for adding torsional rigidity to a chassis, the method comprising: mounting a container having interior vertical wall members between frame rails, wherein the frame rails form at least a portion of a chassis; inserting a plurality of battery pack assemblies within the container; wherein the container is at least twice the frame rail height; wherein the frame rails extend through end walls of the container; wherein the container provides torsional rigidity to the chassis; and wherein the container is mounted to the frame rails by bolting an upper portion of a vertical wall of one of the frame rails adjacent to the frame rail to the vertical wall and perpendicularly into one of the frame rails.

10. The method of claim 9, further comprising: connecting a layer of material to at least one side of the container, the layer of material configured to protect the plurality of battery pack assemblies from damage during an impact.

11. The method of claim 9, wherein each of the plurality of battery pack assemblies comprises a plurality of battery pack packs, and wherein inserting the plurality of battery pack assemblies within the container comprises stacking the plurality of battery pack packs on a bottom surface of the container and bolting them together. ​ 12. The method of claim 9, further comprising: installing a plurality of shelves within the container, wherein each of the plurality of battery pack assemblies comprises a plurality of battery pack packs, and wherein inserting the plurality of battery pack assemblies within the container comprises stacking the plurality of battery pack packs on the plurality of shelves.

13. The method of claim 9, wherein the plurality of battery pack assemblies installed within the container are installed into one of an open bottom and an open top of the container.

14. The method of claim 9, wherein installing the container to the frame rails comprises lowering the container onto the frame rails.

15. The method of claim 9, further comprising configuring the battery pack assemblies to supply power to at least one component of a vehicle.

16. The method of claim 15, wherein the at least one component comprises at least one of a power distribution unit, a main drive inverter, an electric motor, a steering pump, an AC compressor, a DC-DC converter, a cab heater, a cooling system, a charger, an air compressor, and an auxiliary inverter.

17. The method of claim 9, further comprising: installing a charging connector to at least one exterior wall of the container, the charging connector configured to provide power from a power source to the plurality of battery pack assemblies to recharge the plurality of battery pack assemblies.

18. The method of claim 13, wherein the plurality of battery pack assemblies can be installed or replaced without removing the container from the frame rails.

19. A battery pack container installation system to frame rails, comprising: a vehicle having generally parallel frame rails forming at least a portion of a chassis; a generally rectangular container having an open top and at least two interior vertical wall members configured such that the frame rails pass through a pair of end walls of the container; a removable cover configured to cover the open top of the container and the frame rails; the container configured to be installed between the frame rails and secured to each frame rail by the vertical wall members; and a plurality of battery pack assemblies within the container.

20. The system of claim 19, further comprising a layer of material connected to at least one side of the container, the layer of material configured to protect the plurality of battery pack assemblies from damage during an impact.

21. The system of claim 19, wherein each of the plurality of battery pack assemblies comprises a plurality of battery pack packs stacked and bolted together.

22. The system of claim 19, further comprising a plurality of shelves installed within the container, and wherein each of the plurality of battery pack assemblies comprises a plurality of battery pack packs stacked on the plurality of shelves.

23. The system of claim 19, wherein the container height is at least twice the frame rail height.

24. The system of claim 19, wherein the container is configured to be installed to add torsional stiffness to the chassis. ​ 25. A rail-mounted battery pack container installation system comprising: a vehicle having generally parallel rails forming at least a portion of a chassis; a generally rectangular container having an open top and at least two interior vertical wall members configured such that the rails pass through a pair of end walls of the container; a removable cover configured to cover the open top of the container and the rails; the container configured to be installed between the rails and secured to each rail by the vertical wall members; a plurality of battery pack assemblies within the container; and wherein the plurality of battery pack assemblies can be installed or replaced without removing the container from the rails.

26. The rail-mounted battery pack container installation system of claim 25, wherein the vehicle is at least one of a van, a truck, and a trailer.

Images