Battery system mounting device for vehicle

Abstract

An apparatus for securing a battery system component to a vehicle may include a mounting plate configured to be removably secured to the vehicle. The battery system component is fixed to the mounting plate. The apparatus may also include a mounting plate hanger secured to the mounting plate. The mounting plate hanger is configured to be removably secured to a vehicle.

Description

Technical Field

[0001] The present disclosure relates to an apparatus and system for mounting battery system components to a vehicle. Background Art

[0002] To improve performance and ease of manufacturing, battery-powered electric vehicles and hybrid electric vehicles may be equipped with a battery storage system that is configured to provide electrical energy to power the vehicle's electromechanical components and systems. The battery storage system may be enclosed in a sealed container to provide structural and environmental / electrical isolation for the battery system. However, current battery storage systems may be large and heavy, requiring specialized equipment to be installed on the vehicle during vehicle manufacturing. In addition, current battery storage systems may require the entire storage system to be removed from the vehicle in order to repair and / or maintain the battery system. Furthermore, current battery system packaging arrangements may require significant modifications to the vehicle structure in order to accommodate the large and / or heavy container.

[0003] Therefore, while current battery packaging systems and apparatuses achieve their intended purposes, a need remains for a new and improved system and apparatus for securing battery system components to a vehicle. Summary of the Invention

[0004] According to several aspects, the present disclosure provides an apparatus for securing a battery system component to a vehicle. The apparatus may include a mounting plate configured to be removably secured to the vehicle. The battery system component is secured to the mounting plate. The apparatus may also include a mounting plate bracket secured to the mounting plate. The mounting plate bracket is configured to be removably secured to the vehicle.

[0005] In another aspect of the present disclosure, the mounting plate may further include one or more attachment features configured to be secured to the vehicle using removable fasteners.

[0006] In another aspect of the present disclosure, one or more attachment features are secured to a body cross member of a vehicle using removable fasteners.

[0007] In another aspect of the present disclosure, the battery system component may further include a battery module including one or more battery cells.

[0008] In another aspect of the present disclosure, the battery system component may further include a battery disconnect unit (BDU).

[0009] In another aspect of the present disclosure, the mounting plate hanger may further include a rigid support member secured to the mounting plate and removably secured to the vehicle.

[0010] In another aspect of the present disclosure, the rigid support member may further include a first end secured to the mounting plate. The rigid support member may further include a second end secured to the vehicle using a detachable fastener. The second end is opposite the first end.

[0011] In another aspect of the present disclosure, the rigid support member may further include a trapezoidal rigid support member having a first end secured to the mounting plate and a second end secured to the vehicle's underbody using a detachable fastener.

[0012] In another aspect of the present disclosure, the underbody may further include an access door for accessing battery system components.

[0013] In another aspect of the present disclosure, the device may further include a gasket disposed between the battery system component and the vehicle, wherein the gasket is configured to isolate the battery system component from the vehicle.

[0014] According to several aspects, the present disclosure provides a system for securing a battery system component to a vehicle. The system may include a vehicle body comprising a vehicle floor having a first surface and a second surface. The first surface is parallel to the second surface. The vehicle body may further include a plurality of vehicle cross members, each of the plurality of vehicle cross members having a first end, a second end, and a first surface. The first end of each of the plurality of vehicle cross members is secured to the second surface of the vehicle floor such that the first surface of each of the plurality of vehicle cross members is substantially perpendicular to the second surface of the vehicle floor. The system may further include a mounting module removably secured between two of the plurality of vehicle cross members, the mounting module comprising a mounting plate having a first surface. The mounting module may further include a mounting plate bracket having a first end and a second end. The first end is secured to the first surface of the mounting plate. The second end is configured to be removably secured to the second surface of the vehicle floor. The system may further include a battery system component secured to the first surface of the mounting plate.

[0015] In another aspect of the present disclosure, each of the plurality of body cross members may further include one or more penetrations in the first surface of each of the plurality of body cross members. Each of the one or more penetrations allows one or more electrical conductors or fluid conductors to pass therethrough for electrical or fluid connection to the battery system components.

[0016] In another aspect of the present disclosure, the underbody may further include one or more access doors disposed on the first surface of the underbody, wherein the one or more access doors are used to access the one or more electrical conductors or fluid conductors.

[0017] In another aspect of the present disclosure, the mounting plate may further include one or more attachment features configured to be secured to the second end of one or more of the plurality of body cross members using removable fasteners.

[0018] In another aspect of the present disclosure, the mounting plate bracket may further include a trapezoidal rigid support member having a first end secured to the first surface of the mounting plate and a second end secured to the second surface of the vehicle body floor using a detachable fastener.

[0019] In another aspect of the present disclosure, the battery system component may further include at least one of: (i) a battery module including one or more battery cells, and (ii) a battery disconnect unit (BDU).

[0020] In another aspect of the present disclosure, the system may further include a gasket disposed between the battery system component and the vehicle body, wherein the gasket is configured to isolate the battery system component from the vehicle body.

[0021] According to several aspects, the present disclosure provides an apparatus for securing a battery system component to a vehicle. The apparatus may include a mounting module comprising a mounting plate having a first surface. The battery system component is secured to the first surface. The apparatus may also include a mounting plate hanger having a first end and a second end. The first end is secured to the first surface of the mounting plate. The second end is configured to be removably secured to a vehicle underbody.

[0022] In another aspect of the present disclosure, the mounting plate bracket may further include a trapezoidal rigid support member having a first end secured to the first surface of the mounting plate and a second end secured to the vehicle body floor using a detachable fastener.

[0023] In another aspect of the present disclosure, the mounting module may further include at least two mounting plate hangers fixed to the first surface of the mounting plate. The battery system components are disposed between the at least two mounting plate hangers on the first surface of the mounting plate.

[0024] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0026] Figure 1 is a schematic diagram of a system for securing battery system components to a vehicle according to an exemplary embodiment;

[0027] Figure 2is an exploded perspective view of a system for securing battery system components to a vehicle according to an exemplary embodiment;

[0028] Figure 3 is an assembled perspective view of a system for securing battery system components to a vehicle according to an exemplary embodiment;

[0029] Figure 4 is an assembled bottom perspective view of a system for securing battery system components to a vehicle according to an exemplary embodiment;

[0030] Figure 5 is a perspective view of a mounting module having a first exemplary battery system component according to an exemplary embodiment;

[0031] Figure 6 is a perspective view of a mounting module with a second exemplary battery system component according to an exemplary embodiment;

[0032] Figure 7 is a top perspective view of a portion of a system for securing a battery system component to a vehicle according to an exemplary embodiment; and

[0033] Figure 8 According to an exemplary embodiment Figure 3 An enlarged view of the assembly perspective view of FIG. DETAILED DESCRIPTION

[0034] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0035] In aspects of the present disclosure, a new and improved battery storage system for a battery electric vehicle (BEV), a plug-in hybrid electric vehicle (PHEV) and / or a hybrid electric vehicle (HEV) is provided. The battery storage system employs packaging to provide structural and environmental / electrical isolation. Advantageously, the new and improved battery storage system of the present disclosure reduces the weight of the vehicle. This is because the new and improved battery storage system of the present disclosure utilizes the existing vehicle structure to provide structure for the battery storage system. This is in stark contrast to larger, heavier conventional sealed battery containers that require specialized equipment and skills to install during vehicle assembly and require removal / reinstallation during maintenance. In addition, the use of sealed battery containers may require redesign of the vehicle body structure to accommodate the size, shape and weight of such sealed battery containers. Therefore, the present disclosure provides a new and improved battery storage system having a modular design for securing batteries and battery system components to the vehicle.

[0036] refer to Figure 1, a schematic diagram of a system for securing battery system components to a vehicle is shown and generally designated by the reference numeral 10. The system 10 is shown in a cross-sectional view of an exemplary vehicle 12. While a passenger vehicle is shown, it should be understood that the vehicle 12 may be any type of vehicle without departing from the scope of the present disclosure. In the exemplary embodiment, the system 10 is disposed on the underside of the vehicle 12. More specifically, the system 10 is integrated with the body of the vehicle 12, as will be discussed in greater detail below.

[0037] Now refer to Figure 2-Figure 4 , Figure 2 shows an exploded perspective view of the system 10, Figure 3 shows an assembled perspective view of the system 10, and Figure 4 An assembled bottom perspective view of the system 10 is shown. The system 10 generally includes a vehicle body 14, a mounting module 16, battery system components 18, and a liner 20. Although Figure 2-Figure 4 An embodiment including three mounting modules 16, three battery system components 18, and three gaskets 20 is shown, but it should be understood that embodiments including any number of mounting modules 16, battery system components 18, and gaskets 20 are within the scope of the present disclosure. In addition, the system 10 is shown as having a plurality of fasteners 22. It is within the scope of the present disclosure that the plurality of fasteners 22 include removable fasteners (e.g., screws, bolts, and / or the like). The plurality of fasteners 22 are configured to engage with nuts, threads, and / or the like to form a removable fastener between two objects. It should be understood that Figure 2-Figure 4 The locations, types, and sizes of the various fasteners 22 shown are merely exemplary in nature, and Figure 2-Figure 4 Not necessarily drawn to scale.

[0038] The vehicle body 14 includes a vehicle floor panel 24 and a plurality of vehicle cross members 26. The vehicle floor panel 24 provides structure to the vehicle body 14 and provides a floor surface for the interior of the vehicle 12. Interior components of the vehicle 12 (e.g., seats of the vehicle 12) can be mounted to the vehicle floor panel 24. In an exemplary embodiment, the vehicle floor panel 24 has a first surface 24a and a second surface 24b. The first surface 24a of the vehicle floor panel 24 faces the interior of the vehicle 12, and the second surface 24b faces the exterior of the vehicle 12. In an exemplary embodiment, the vehicle floor panel 24 is penetrated by a plurality of access openings 28a that allow access to the battery system components 18 from the first surface 24a (i.e., the interior of the vehicle 12), which will be discussed in more detail below. The vehicle floor panel 24 may also include a plurality of access doors 28b disposed on the first surface 24a to cover the plurality of access openings 28a. In a non-limiting example, the plurality of access doors 28b are removably secured with fasteners 22. In an exemplary embodiment, the fasteners 22 that retain the plurality of access doors 28b are removable from the first surface 24a (i.e., the interior of the vehicle 12). In another exemplary embodiment, the fasteners 22 that retain the plurality of access doors 28b are removable from the second surface 24b (i.e., the exterior of the vehicle 12). It should be understood that Figure 2-Figure 4 The number, size, shape, and location of the various access openings 28a and access doors 28b shown are merely exemplary in nature and Figure 2-Figure 4 In non-limiting examples, the underbody 24 is made of sheet metal and / or a composite material (eg, steel, aluminum, carbon fiber, and / or the like).

[0039] A plurality of cross-body members 26 provide additional structural support to the underbody panel 24. In the exemplary embodiment, each cross-body member 26 has a first end 30a, a second end 30b, and a first surface 32. In a non-limiting example, the first end 30a of each cross-body member 26 is secured to the second surface 24b of the underbody panel 24 such that the first surface 32 of each cross-body member 26 is substantially perpendicular to the second surface 24b of the underbody panel 24. Within the scope of this disclosure, "substantially perpendicular" means that the angle measured between the first surface 32 of each cross-body member 26 and the second surface 24b of the underbody panel 24 is approximately ninety degrees (90°) within a predetermined tolerance (e.g., ±10%).

[0040] In a non-limiting example, the first end 30a is secured to the second surface 24b of the underbody 24 using welding, angle brackets and fasteners, and / or the like. In the exemplary embodiment, each body cross member 26 has one or more penetrations 34 in at least the first surface 32 of each body cross member 26 to allow for connection to the battery system components 18, as will be discussed in greater detail below. It should be understood that Figure 2-Figure 4The number, size, shape, and location of the one or more penetrations 34 shown are merely exemplary in nature and Figure 2-Figure 4 It is not necessarily drawn to scale. Figure 2-Figure 4 The number, size, shape, and location of the illustrated plurality of cross-body members 26 are merely exemplary in nature. In non-limiting examples, the plurality of cross-body members 26 are made of sheet metal and / or composite materials (e.g., steel, aluminum, carbon fiber, and / or the like).

[0041] refer to Figure 5 , shows a perspective view of a mounting module 16 with a first exemplary battery system component 18a. The mounting module 16 is used to accommodate a battery system component 18 (e.g., a first exemplary battery system component 18a) and secure the battery system component 18 to the vehicle body 14. In an exemplary embodiment, the mounting module 16 includes a mounting plate 40 and a mounting plate hanger 42. In an exemplary embodiment, the mounting plate 40 has at least a first surface 40a and one or more attachment features 44. The one or more attachment features 44 are configured to be attached to the second end 30b of the vehicle body cross member 26 using a fastener 22. In an exemplary embodiment, the one or more attachment features 44 are through holes or threaded holes in at least the first surface 40a of the mounting plate 40, which are disposed adjacent to one or more edges or corners of the mounting plate 40. It should be understood that Figure 5 The number, size, shape, and location of the one or more attachment features 44 shown are merely exemplary in nature, and Figure 5 In non-limiting examples, the mounting plate 40 is made of sheet metal and / or a composite material (eg, steel, aluminum, carbon fiber, and / or the like).

[0042] The mounting plate hanger 42 is used to provide additional structural support and secure the mounting plate 40 to the vehicle body 14. In the exemplary embodiment, the mounting plate hanger 42 has at least a first end 46a and a second end 46b. The first end 46a of the mounting plate hanger 42 is secured to the first surface 40a of the mounting plate 40. In a non-limiting example, the first end 46a is welded to the first surface 40a of the mounting plate 40. In another non-limiting example, the first end 46a is secured to the first surface 40a of the mounting plate 40 using a fastener. The second end 46b of the mounting plate hanger 42 includes a through hole, a threaded hole, a captive nut, and / or the like for removably securing the second end 46b to the second surface 24b of the vehicle underbody 24 using the fastener 22. In the exemplary embodiment, the mounting plate hanger 42 is a rigid support member fabricated from a metal and / or composite material (e.g., steel, aluminum, carbon fiber, and / or the like) sheet, extrusion, tubing, box, and / or the like. In one non-limiting example, the mounting plate hanger 42 is a trapezoidal rigid support member. In an exemplary embodiment, one or more mounting plate hangers 42 are secured adjacent one or more edges of the mounting plate 40. It should be understood that Figure 5 The number, size, shape, and location of the mounting plate hangers 42 shown are merely exemplary in nature and Figure 5 In some embodiments, additional mounting plate brackets 42 are included as needed for a particular application, battery system components 18, and / or the like.

[0043] Continue to refer Figure 5 , a first exemplary battery system component 18a is shown with a mounting module 16. In one exemplary embodiment, the first exemplary battery system component 18a includes a battery module 48 that includes one or more battery cells 50. In one non-limiting example, the battery module 48 stores and provides electrical energy in the form of direct current (DC). In one exemplary embodiment, the one or more battery cells 50 (e.g., lithium-ion battery cells) are electrically connected in series and / or in parallel to provide increased voltage and / or current carrying capacity. It should be understood that the one or more battery cells 50 may include battery cells of any chemistry and form factor, including, for example, cylindrical battery cells.

[0044] The first exemplary battery system component 18a also includes one or more electrical or fluid conductors 52 for connecting adjacent battery system components 18 (e.g., Figure 3As shown), the one or more electrical conductors or fluid conductors 52 are interconnected (i.e., electrically and / or fluidically connected) between the battery system components 18. In one non-limiting example, the one or more electrical conductors or fluid conductors 52 include, for example, electrical bus bars, cables, coolant lines, air ducts, exhaust ducts, and / or the like. The one or more electrical conductors or fluid conductors 52 pass through the one or more penetrations 34 to provide electrical and / or fluid connections between adjacent battery system components 18. In one exemplary embodiment, the one or more electrical conductors or fluid conductors 52 may be assembled from one or more of the plurality of access ports 28a. In another exemplary embodiment, the one or more electrical conductors or fluid conductors 52 may be assembled from the outside (i.e., the underside) of the vehicle 12. It should be understood that the type, quantity, size, shape, wiring, and location of the one or more electrical conductors or fluid conductors 52 are merely exemplary in nature, and Figure 5 Not necessarily drawn to scale.

[0045] refer to Figure 6 , as referenced above Figure 5 The perspective view of the mounting module 16 is shown with a second exemplary battery system component 18b. In one exemplary embodiment, the second exemplary battery system component 18b is a battery disconnect unit (BDU) 54.

[0046] The BDU 54 is used to control the connection and disconnection of one or more battery modules 48 with other systems of the vehicle 12. In an exemplary embodiment, the BDU 54 includes a BDU controller, a BDU sensor, and a BDU switch. In a non-limiting example, the BDU controller uses the BDU sensor to monitor battery system indicators (e.g., voltage, current, temperature, and / or similar indicators, etc.) and detect adverse conditions (e.g., overvoltage or overcurrent conditions, thermal runaway, and / or similar conditions, etc.). In response to detecting an adverse condition, the BDU controller actuates the BDU switch to isolate the battery system from other systems of the vehicle 12. In another non-limiting example, the BDU controller receives input from an external device (e.g., an emergency shutdown switch, a wired / wireless interface, and / or the like), and actuates the BDU switch to isolate the battery system based at least in part on the input from the external device.

[0047] The second exemplary battery system component 18b also includes one or more electrical or fluid conductors 52 for interconnecting (i.e., electrically and / or fluidically connecting) adjacent battery system components 18. In one non-limiting example, the one or more electrical or fluid conductors 52 include, for example, electrical bus bars, cables, coolant lines, air ducts, exhaust ducts, and / or the like. The one or more electrical or fluid conductors 52 pass through the one or more penetrations 34 to provide electrical and / or fluid connections between adjacent battery system components 18. It should be understood that the type, number, size, shape, routing, and location of the one or more electrical or fluid conductors 52 are merely exemplary in nature, and Figure 6 Not necessarily drawn to scale.

[0048] refer to Figure 7 , shows a top perspective view of a portion of the base plate 24. The top perspective view is shown with the access door 28b removed, illustrating access through the access opening 28a for accessing one or more electrical or fluid conductors 52. The access opening 28a can be used to access the one or more electrical or fluid conductors 52 for repair, maintenance, testing, assembly / disassembly, and / or the like.

[0049] Reference again Figure 2-Figure 6 , within the scope of this disclosure, a battery system component 18 is any component of the electrical system of the vehicle 12, and more specifically, any component of the energy storage system of the vehicle 12. Figure 5 and Figure 6 Two examples of battery system components 18 are discussed (i.e., a first exemplary battery system component 18a and a second exemplary battery system component 18b). Generally speaking, the battery system components 18 may include any component of the electrical system of the vehicle 12, including, but not limited to, battery modules, battery cells, BDUs, power electronics (e.g., fuses, contactors, converters, inverters, etc.), battery management systems (BMS), battery cooling system components (e.g., pumps, hoses, radiators, coolant reservoirs, etc.), battery heating system components, battery safety system components (e.g., fire suppression equipment, thermal runaway prevention / mitigation equipment, etc.), and / or the like. The battery system components 18 are secured to a first surface 40a of a mounting plate 40. In one non-limiting example, the battery system components 18 are secured to the mounting plate 40 using one or more brackets, fasteners, and / or the like.

[0050] refer to Figure 8 , showing Figure 3 An enlarged view of the assembled perspective view 56. Again referring to Figure 2-Figure 3 and Figure 8The gasket 20 is used to isolate the battery system components 18 and / or mounting modules 16 from the vehicle body 14 and to contain and / or direct gasses vented from the battery system components 18. The gasket 20 is configured to provide one or more of electrical, thermal, chemical, environmental, and physical isolation and / or protection for the battery system components 18. In one exemplary embodiment, the gasket 20 is positioned above the battery system components 18, thereby providing a barrier between the battery system components 18 and the vehicle body 14 when the system 10 is assembled. In another exemplary embodiment, the gasket 20 is a coating disposed on the second surface 24b of the vehicle body floor 24 and one or more surfaces of the plurality of vehicle body cross members 26. In some examples, the gasket 20 includes penetrations for one or more electrical or fluid conductors 52 and / or a plurality of access openings 28a. In one non-limiting example, the gasket 20 is a blow-molded polymer structure. In another non-limiting example, the gasket 20 is a curable coating that adheres to the vehicle body 14 and cures after application. It should be understood that the size, shape, and location of the gasket 20 are merely exemplary in nature.

[0051] The system 10 and mounting modules 16 of the present disclosure provide several advantages. By utilizing existing vehicle structure, such as the vehicle body 14, to provide structure for the battery system components 18, the need for additional material and the resulting added weight due to the structural components is reduced. Furthermore, by providing the mounting modules 16 as modular devices, installation and maintenance can be performed on separate mounting modules 16, thereby reducing the need for handling large and / or heavy components. The access openings 28a and access doors 28b allow for servicing of the electrical conductors or fluid conductors 52 without removing the mounting modules 16. The liner 20 isolates and protects the battery system components 18. Due to the modular design of the system 10, the present disclosure is adaptable, scalable, and applicable to a variety of types of battery system components and a variety of vehicle body designs. For example, the system 10 can be scaled to provide a specific amount of battery system energy storage based on vehicle size, customer needs, and / or the like. Furthermore, the system 10 is applicable to a variety of current and future battery chemistries and power system technologies and topologies.

[0052] The description of the present disclosure is merely exemplary in nature, and variations that do not depart from the gist of the present disclosure are intended to fall within the scope of the present disclosure. Such variations should not be regarded as a departure from the spirit and scope of the present disclosure.

Claims

1. A device for securing a battery system component to a vehicle, the device comprising: a mounting plate configured to be removably secured to the vehicle, wherein the battery system component is secured to the mounting plate; and A mounting plate hanger is secured to the mounting plate, wherein the mounting plate hanger is configured to be removably secured to the vehicle.

2. The device according to claim 1, wherein The mounting plate further comprises: One or more attachment features configured to be secured to the vehicle using removable fasteners.

3. The device according to claim 2, wherein The one or more attachment features are secured to a body cross member of the vehicle using the removable fastener.

4. The device according to claim 1, wherein The battery system components also include: A battery module includes one or more battery cells.

5. The device according to claim 1, wherein The battery system components also include: Battery disconnect unit BDU.

6. The device according to claim 1, wherein The mounting plate rack further comprises: A rigid support member is secured to the mounting plate and is removably secured to the vehicle.

7. The device according to claim 6, wherein The rigid support member further comprises: a first end secured to the mounting plate; and A second end is secured to the vehicle using a removable fastener, wherein the second end is opposite the first end.

8. The device according to claim 7, wherein The rigid support member further comprises: A trapezoidal rigid support member wherein a first end of the trapezoidal rigid support member is secured to the mounting plate and a second end of the trapezoidal rigid support member is secured to the underbody of the vehicle using a removable fastener.

9. The device according to claim 8, wherein The vehicle body bottom panel further comprises: An inspection door is used to inspect the battery system components.

10. The apparatus according to claim 1, further comprising: A gasket is disposed between the battery system component and the vehicle, wherein the gasket is configured to isolate the battery system component from the vehicle.

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