Battery module locking structure and method

Abstract

Battery module locking structures and methods are provided. Methods and systems are provided for securing a battery module in a vehicle. The method includes providing a compartment in a vehicle adjacent to a vehicle component; inserting a battery module into the compartment, where the battery module has a wall, and where the wall is separated from the vehicle component by a gap; and actuating the locking means to move from the idle configuration to an active configuration in which the locking means extends between the battery module and the vehicle component to prevent movement of the battery module relative to the vehicle component.

Description

Technical Field

[0001] This disclosure generally relates to electric vehicles, including all-electric and hybrid electric configurations. More specifically, aspects of this disclosure relate to the mounting architecture of battery packs for battery electric vehicles (BEVs). Background Technology

[0002] Vehicles typically consist of a chassis frame and a main structure, designed to support multiple vehicle components and contribute to the vehicle's rigidity and strength performance. Examples of frame configurations can include trapezoidal frames, monocoque (i.e., semi-monocoque) frames, peripheral frames, etc. Many frames include opposing side rails or rocker panels connected via multiple transverse members. A corresponding front rail may project forward from the rocker panel via a front transverse member, and a corresponding rear rail may project rearward from the rocker panel via a rear transverse member.

[0003] The engine and front suspension are typically supported by the front rail beam and adjacent lateral members. The fuel tank and rear suspension are typically supported by the rear rail beam and adjacent lateral members. The sill plates and associated lateral members typically support the floor pan, passenger seat, main pillars, and many other components and features.

[0004] Recently, vehicles have come to include hybrid vehicles powered by a combination of batteries and internal combustion engines. Additionally, all-electric vehicles, or battery electric vehicles (BEVs), can operate solely on a battery pack. Such vehicles typically support the weight of the battery on the chassis frame and in various locations with sufficient storage space. To maintain desired road clearance, the battery is usually located above the chassis frame. Furthermore, batteries in a single vehicle may require various shapes and sizes to utilize available storage space.

[0005] Accordingly, improvements in battery storage are needed for the structure of BEVs and related structures to support and secure the battery after installation, while also facilitating installation and removal. Furthermore, other desirable features and characteristics of this disclosure will become apparent from the accompanying drawings and the foregoing technical and background information, based on the following detailed description and appended claims. Summary of the Invention

[0006] In one embodiment, a method for securing a battery module in a vehicle includes: providing a compartment adjacent to a vehicle component in the vehicle; inserting the battery module into the compartment, wherein the battery module has a wall and wherein the wall is spaced apart from the vehicle component by a gap; and actuating a locking device to move from a passive configuration to an active configuration, in which the locking device extends between the battery module and the vehicle component to prevent movement of the battery module relative to the vehicle component.

[0007] In some embodiments, the method further includes: actuating a locking device to move from an active configuration to an idle configuration by retracting the locking device from the gap; and removing the battery module from the compartment.

[0008] In some embodiments of the method, the locking device is installed on a vehicle component.

[0009] In some embodiments of the method, the vehicle component is a crossbeam.

[0010] In some embodiments of the method, the crossbeam defines an internal volume, and the locking device is located within the internal volume in an idle configuration.

[0011] In some embodiments of the method, the crossbeam includes an upper end, the battery module includes a laterally extending upper tab, and inserting the battery module into the compartment includes contacting the laterally extending upper tab with the upper end, and supporting the battery module with the crossbeam when the locking device is in an idle configuration.

[0012] In some embodiments of the method, the actuating locking device includes an actuator that manipulates a device placed on the crossbeam.

[0013] In some embodiments of the method, manipulating the appliance actuator includes rotating the appliance actuator about an axis parallel to the compartment.

[0014] In some embodiments of the method, the vehicle component is a first vehicle component; the compartment is positioned adjacent to the first vehicle component and a second vehicle component; the wall is a first wall, and the battery module further includes a second wall; the gap is a first gap located between the first wall and the first vehicle component; the second gap is located between the second wall and the second vehicle component; the locking device is a first locking device that contacts the first wall of the battery module in an active configuration; and the method includes actuating a second locking device to move from an idle configuration to an active configuration, in which the second locking device extends between the battery module and the vehicle component to prevent movement of the battery module relative to the vehicle component.

[0015] In some embodiments, the method further includes pressing the battery module between the first locking device and the second locking device when the first locking device and the second locking device are moved to their respective active configurations.

[0016] In some embodiments of the method, the first wall is a first sidewall; the second wall is a second sidewall opposite to the first sidewall; the first end wall and the second end wall connect the first sidewall and the second sidewall; the first end wall and the second end wall are separated by a side length; the first sidewall and the second sidewall are separated by an end length; and the side length is greater than the end length.

[0017] In another embodiment, a housing system for a battery module in a vehicle is provided, and the housing system includes: a compartment adjacent to a vehicle component in the vehicle, the compartment being configured to receive a battery module having a gap between the battery module and the vehicle component; and a locking device configured to move from an idle configuration to an active configuration, in which the locking device extends between the battery module and the vehicle component to prevent movement of the battery module relative to the vehicle component.

[0018] In some embodiments of the housing system, the locking device is configured to move from an active configuration to an idle configuration in which the locking device is not located in the gap.

[0019] In some embodiments of this housing system, locking devices are mounted to vehicle components.

[0020] In some embodiments of the housing system, the vehicle component is a crossbeam, wherein the crossbeam defines an internal volume, and wherein the locking device is located in the internal volume in an idle configuration.

[0021] In some embodiments of the housing system, the crossbeam includes an upper end, wherein the battery module includes a laterally extending upper tab configured to be located on the upper end.

[0022] In some embodiments of the housing system, the locking device includes a device actuator positioned on a crossbeam, and the locking device and the device actuator are rotatable about an axis parallel to the compartment.

[0023] In some embodiments of the housing system, the vehicle component is a first vehicle component; the compartment is positioned adjacent to the first vehicle component and a second vehicle component; the gap is a first gap located between the battery module and the first vehicle component; the second gap is located between the battery module and the second vehicle component; the locking device is a first locking device; and the housing system includes a second locking device configured to move from an idle configuration to an active configuration, in which the second locking device extends between the battery module and the vehicle component to prevent the battery module from moving relative to the vehicle component.

[0024] In another embodiment, a vehicle includes: an electric propulsion system; a battery module; a battery module compartment adjacent to a vehicle component and configured to receive the battery module, with a gap between the battery module and the vehicle component; and a locking device configured to move from an idle configuration to an active configuration, in which the locking device extends between the battery module and the vehicle component to prevent movement of the battery module relative to the vehicle component.

[0025] In some embodiments of the vehicle, the locking device is configured to move from an active configuration to an idle configuration, in which the locking device is retracted from the gap; the locking device is mounted to a vehicle component; the vehicle component is a crossbeam defining an internal volume and including an upper end; the locking device is located within the internal volume in the idle configuration; the battery module includes a laterally extending upper tab configured to be located on the upper end; the locking device includes a device actuator positioned on the crossbeam; and the locking device and the device actuator are rotatable about an axis parallel to the battery module compartment. Attached Figure Description

[0026] The present disclosure will be described below with reference to the following figures, wherein the same numerals denote the same elements, and wherein:

[0027] Figure 1 This is a schematic top view of an embodiment of a vehicle having a powertrain and a battery module according to various embodiments, the battery module using a battery array configured to generate and store electrical energy.

[0028] Figure 2 According to various embodiments Figure 1 The schematic top perspective exploded view of the battery module shown shows a cooling plate configured to distribute coolant flow for managing heat transfer from the battery array to the environment.

[0029] Figure 3 The diagram illustrates a battery module in a battery compartment (such as in) according to various embodiments. Figure 1 A top-down view of the position of the vehicle (in the vehicle).

[0030] Figure 4 The diagram illustrates the battery compartment (such as in) according to various embodiments. Figure 1 A top view of the location of the locking mechanism, which is in an idle configuration, adjacent to the battery module in the vehicle.

[0031] Figure 5 It is an active configuration in contact with the battery module according to various embodiments. Figure 4 A top view of the locking mechanism.

[0032] Figure 6It is an idle configuration according to various embodiments. Figure 4 A side view of the locking mechanism.

[0033] Figure 7 It is in an active configuration according to various embodiments, Figure 5 A side view of the locking mechanism.

[0034] Figure 8 The diagram illustrates the battery compartment (such as in) according to various embodiments. Figure 1 A top view of the location of the locking mechanism, which is in an idle configuration, adjacent to the battery module in the vehicle.

[0035] Figure 9 It is an active configuration in contact with the battery module according to various embodiments. Figure 8 A top view of the locking mechanism.

[0036] Figure 10 It is an idle configuration according to various embodiments. Figure 8 A side view of the locking mechanism.

[0037] Figure 11 It is in an active configuration according to various embodiments, Figure 9 A side view of the locking mechanism.

[0038] Figure 12 This is a flowchart illustrating a method for securing a battery in a battery compartment of a vehicle according to various embodiments. Detailed Implementation

[0039] The following detailed description is merely exemplary in nature and is not intended to limit the application and use of the embodiments described herein. Furthermore, it is not intended to be bound by any express or implied theory presented in the foregoing introduction, summary of the invention, or the following detailed description.

[0040] This document describes embodiments of the present disclosure in terms of functional and / or logic block components and various processing steps. Connecting lines shown in the various figures contained herein are intended to illustrate exemplary functional relationships and / or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of the present disclosure.

[0041] For the purposes of this description, unless expressly denied, the use of the singular includes the plural and vice versa; the terms “and” and “or” should be both connective and selective; and the words “including,” “contains,” “comprising,” “containing,” “having,” etc., should mean “including but not limited to.” Furthermore, approximate words such as “about,” “almost,” “substantially,” “generally,” “roughly,” etc., may be used herein in the sense of “being, near, or almost being,” or “within 0-5%,” or “within acceptable manufacturing tolerances,” or logical combinations thereof. As used herein, a component “configured” to perform the specified function is capable of performing the specified function without alteration, rather than merely having the potential to perform the specified function after further modification. In other words, when explicitly configured to perform the specified function, the described hardware is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function.

[0042] The embodiments described herein provide a method for securing a battery module within the battery compartment of a vehicle, while simultaneously facilitating the installation and removal of the battery module when needed. Specifically, a locking device is located within the vehicle and can be moved between an idle configuration and an active configuration. In the idle configuration, the locking device is removed from the battery compartment, while in the active configuration, the locking device extends into the battery compartment, contacts the battery module, and applies force to the battery module.

[0043] In some embodiments, the locking device is actuated from a location easily accessible to a technician, above a vehicle component adjacent to the battery compartment. Furthermore, actuation may include simply rotating a shaft included in or connected to the locking device. This provides a simplified process with limited design impact on other functions.

[0044] Manufacturing and installation require a loading clearance between the battery module and vehicle components to ensure safe and reliable loading. During dynamic loading conditions, this clearance allows relative movement between the battery module and vehicle components, which can lead to impacts and failure modes such as delamination of the battery cells from the battery module structure. Embodiments herein provide methods to selectively and reversibly eliminate the clearance between the vehicle components and the battery module. Specifically, some embodiments provide a rotating or reversibly extending locking device to eliminate the clearance between the battery module and adjacent vehicle components.

[0045] Therefore, methods are provided to eliminate the spacing between components in an assembly in order to reduce or eliminate the relative movement between those components during dynamic loading, such as when the vehicle accelerates, decelerates, or especially when the vehicle descends or ascends vertically due to uneven terrain.

[0046] In some embodiments, the locking device is rotated after the battery module is loaded into the structure. The rotation of the locking device fills the gap between the battery module and the vehicle components. This process is reversible, allowing the module to be removed for maintenance.

[0047] In some embodiments, the locking device is extended after the battery module is loaded into the structure. The extension of the locking device fills the gap between the battery module and the vehicle components. The locking device can be deformable, allowing it to fill a variable initial gap. This process is reversible, thus enabling the module to be removed for maintenance.

[0048] In some embodiments, the systems and methods described herein are provided for: maintaining the existing nominal loading spacing required for manufacturing during installation, selectively filling the gap between the battery module and vehicle components after installation, and this is reversible so that the battery module can be removed for servicing.

[0049] Referring to the accompanying drawings, where similar reference numerals correspond as far as possible to similar or analogous parts throughout the various drawings, Figure 1 Electric vehicle 10 is shown in the image.

[0050] Cross-reference Figures 1-2 The vehicle 10 has a powertrain or electric propulsion system 12. Figure 1 The electric vehicle 10 is represented as an automobile, such as any of several different types of automobiles, such as, for example, sedans, vans, trucks, sport utility vehicles (SUVs), etc. In some implementations, vehicle 10 may include motorcycles or other land-based vehicles (such as rail locomotives), or non-land-based vehicles (such as aircraft, spacecraft, ships, etc.), and / or one or more other types of mobile platforms (e.g., robots and / or another mobile platform). In other implementations, the battery module described below may alternatively be part of and / or coupled to any number of other types of mobile or non-mobile platforms and / or other systems, such as buildings, infrastructure, secondary uses, home power, non-automobile, and / or other platforms and / or other systems.

[0051] The propulsion system 12 includes a power source 14 configured to generate power source torque for propelling the vehicle 10 relative to the road surface 18 via drive wheels 16. The power source 14 is depicted as an electric motor-generator. The propulsion system 12 may also include an additional power source 20, such as an internal combustion engine. Power sources 14 and 20 can work together to power the vehicle 10. The vehicle 10 also includes a programmable electronic controller 21 and a battery module 22. The battery module 22 may include one or more battery segments 24, such as cells or arrays, configured to generate and store electrical energy to power the power sources 14 and 20. Each battery segment 24 in the battery module 22 generates and stores electrical energy through a heat-generating electrochemical reaction. The operation of the propulsion system 12 and the battery module 22 can generally be regulated by the electronic controller 21.

[0052] like Figure 1 As shown, battery module 22 is located within battery compartment 23. Battery compartment 23 is an open space defined by other vehicle components, in which battery module 22 can be located and supported. In some embodiments, the top of battery module 22 is fixed to the vehicle component, while the bottom of battery module 22 is not directly supported. Therefore, battery module 22 is suspended from the vehicle component.

[0053] like Figure 2 As shown, battery segment 24 has a first side surface 24-1, a second side surface 24-2, a top surface 24-3, and a bottom surface 24-4. Battery module 22 includes a first side plate or sidewall 26, a second side plate or sidewall 28, and a cover or top wall 30 attached to the first and second side plates. The first side plate 26, the second side plate 28, and the cover 30 are configured to define battery segment 24 on the respective first side surface 24-1, second side surface 24-2, and top surface 24-3. Additionally, as... Figure 2 As shown, an epoxy resin layer 31 may be applied to the bottom surface 24-4 of the battery section 24. The battery module 22 also includes a bottom wall 32 or a base plate 32. In some embodiments, the base plate 32 is a plate cooling plate 32 configured to manage heat transfer from the battery section 24 to the environment. The cooling plate 32 is attached to first and second side plates 26, 28, thereby defining the battery section 24 on the bottom surface 24-4. The cooling plate 32 may be additionally attached to the bottom surface 24-4 of the battery section 24 via the epoxy resin layer 31.

[0054] like Figure 2 As indicated, each side panel 26 and 28 is formed with an outwardly extending tab 25. During installation in the vehicle 10, the tab 25 can be positioned and secured to an adjacent vehicle component, as described below. Thus, when installed in the vehicle 10, the battery module 22 can be supported by the tab 25.

[0055] Cooling plate 32 is configured to receive the flow of circulating coolant passing through it to remove heat generated by battery section 24. For this purpose, as... Figure 2 As shown, the cooling plate 32 includes a coolant inlet 36. The cooling plate 32 also includes a coolant outlet 40. The coolant passage is arranged to be in direct fluid communication with the coolant inlet 36 and / or the coolant outlet 40.

[0056] like Figure 2 As shown, the cooling plate 32 may have a clamshell structure 58. The clamshell structure 58 may include two sub-plates 58-1 and 58-2, which are fused together and configured to define corresponding coolant channels.

[0057] Figure 3 This is a top view schematic diagram of a portion of a battery module 22 received within a portion of one or more battery compartments 23. Note that the tab 25 and the top wall or cover 30 are not shown. Figure 3 The first battery module 122 and the second battery module 222 are identified in the diagram. The first battery module 122 and the second battery module 222 can be considered as parts of a single battery module 22, or they can be considered as separate modules.

[0058] As shown, the boundary of the battery compartment 23 is formed by vehicle components 210. For example, vehicle components 210 may include adjacent systems to which the battery module is not structurally connected, and adjacent structural components to which the battery is structurally connected. For example, as shown, two crossbeams 215 may extend through the battery compartment 23. In some embodiments, tabs (not shown) may rest on and be secured to the top surface of the crossbeams 215. In other words, the battery module 22 may be structurally connected to the crossbeams 215.

[0059] Interface 219 is defined at the junction of battery compartment 23 and vehicle component 210.

[0060] like Figure 3 As shown, each battery module 22 includes a first end plate or end wall 27 and a second end plate or end wall 29. The first end wall 27 and the second end wall 29 connect to a first side wall 26 and a second side wall 28. As shown, the outer surface of the first end wall 27 is separated from the outer surface of the second end wall 29 by a side length 260, and the outer surface of the first side wall 26 is separated from the outer surface of the second side wall 28 by an end length 270. In some embodiments, the side length 260 is greater than the end length 270.

[0061] For example, the side length 260 can be from 0.5 to 2 meters, such as 1.2 meters. The end length 270 can be significantly smaller, such as from 50 to 500 millimeters (mm).

[0062] like Figure 3As shown, the gap 230 is located between the battery module 22 and the vehicle component 210. The gap 230 facilitates the installation of the battery module 22 into the compartment 23 without being obstructed by the vehicle component 210.

[0063] Figure 3 The first gap 231 is located between the first sidewall 26 of the first battery module 221 and the vehicle component 211 (which may be a crossbeam 215), and the second gap 232 is located between the second sidewall 28 of the first battery module 221 and the vehicle component 212 (which may be a crossbeam 215).

[0064] like Figure 3 As shown, vehicle component 212 (such as crossbeam 215) can be located between two battery modules (such as modules 122 and 222). As shown, the sidewall 26 of module 222 is 322 away from the sidewall 28 of module 122. The width of crossbeam 215 is less than the distance 322, such that gap 230 is located between crossbeam 215 and modules 122 and 222.

[0065] Clearance 230 is also provided between end wall 27 and vehicle component 210, between end wall 29 and vehicle component 210, and / or bottom wall. Figure 3 (Not shown in the text) and vehicle component 210. As mentioned above... Figure 2 As indicated, the laterally extending tab 25 can contact and be secured to the upper surface of the vehicle component 210 to support the battery module 22 in the compartment 23.

[0066] While gap 230 facilitates installation, the absence of additional structural contact between battery module 22 and vehicle component 210, besides tab 25, could lead to undesirable results. For example, the weight of battery module 22 and the high speed of the vehicle can cause it to exhibit significant momentum during vehicle use. In some embodiments, the battery module may weigh more than 200 pounds, more than 300 pounds, or more than 400 pounds, such as approximately 450 pounds. During acceleration or deceleration, the momentum of the unsupported bottom of the battery module can cause it to oscillate. If not stopped or damped, the battery module may swing back and forth like a pendulum. Such oscillation can result in repeated impacts between battery module 22 and vehicle component 210, and can lead to delamination or other detrimental structural effects on battery module 22.

[0067] After understanding Figure 3 With regard to the relative positions of the battery module 22, compartment 23, and vehicle component 210 as explained in the figure, the following figures illustrate the use of locking devices in the housing system to prevent undesirable movement of the battery module 22 relative to the vehicle component 210.

[0068] Figure 4This is a top view of the housing system 100, and Figure 6 This is a side view schematic diagram, focusing on the vehicle component 210 in the form of a crossbeam 215 located between two battery modules 122 and 222 in compartment 23.

[0069] Cross-reference Figure 4 and Figure 6 Vehicle component 210 has an outer surface 216 defining an internal volume 218. The outer surface 216 of vehicle component 210 is separated by gaps 230 from the sidewall 26 (i.e., interface 219) of battery module 222 and from the sidewall 28 (i.e., interface 219) of battery module 122. The outer surface 216 is formed with openings 217. (As shown...) Figure 6 As further shown, the bottom wall 32 of each battery module 22 is kept at a distance from the lower vehicle component 210 by a gap 230.

[0070] Figure 4 and Figure 6 The diagram shows a housing system 100 including a locking device 300. Figure 4 and Figure 6 In the idle configuration 300', the locking device 300 is located within the internal volume 218 of the vehicle component 210. Specifically, no part of the locking device 300 is located within the gap 230.

[0071] exist Figure 4 and Figure 6 In this device, the locking device 300 includes a device actuator 310, which can be manipulated to move the locking device 300 from an idle configuration 300' to an active configuration. Furthermore, the locking device 300 includes a shaft 320 and a lateral extension member 330. The shaft 320 is rotatable about an axis 305. Figure 4 and Figure 6 In this configuration, the appliance actuator 310, shaft 320, and lateral extension member 330 are fixed together and rotate together about axis 305.

[0072] The lateral extension member 330 can be a cam, an eccentric disk, or other shape configured to convert rotational motion into linear motion. For example, as... Figure 6 As shown, the lateral extending member 330 extends in the direction toward each sidewall 26, 28 (i.e., in...). Figure 6 (In the plane) extending a distance of 333. Figure 4 In the figure, the lateral extension member 330 extends a distance 334 in a direction parallel to each sidewall 26, 28. As shown, the distance 334 is greater than the distance 333. Furthermore, the distance 334 is greater than the distance 322 between modules 122 and 222.

[0073] Figure 6The diagram illustrates tabs 25 extending laterally from modules 122 and 222, which can extend over and rest on vehicle component 210. Furthermore, tabs 25 can be secured to vehicle component 210, such as via removable fasteners. Typically, battery module 22 can be supported by at least four tabs 25, two on each opposite side. For longer battery modules, more than four tabs 25 can provide structural connections to vehicle component 210.

[0074] Figure 6 The diagram also shows the outer surfaces of the top wall 30 and the bottom wall 32 at a distance of 265 from each other from the module height. In some embodiments, the module height 265 can be 100 to 400 millimeters (mm), such as 200 to 300 mm, such as about 250 mm.

[0075] Figure 5 and Figure 7 The figure shows the housing system 100 in which the locking device 300 is in the active configuration 300”. Figure 5 This is a top view of the housing system 100, and Figure 7 This is a side view schematic diagram, focusing on the vehicle component 210 in the form of a crossbeam 215 located between two battery modules 122 and 222 in compartment 23.

[0076] Cross-reference Figure 5 and Figure 7 The actuator 310 is manipulated and rotated about axis 305 from an idle configuration to an active configuration 300. In some embodiments, the actuator 310 may be a handle, nut, or other fastener head that can be manipulated by hand or tool and rotated about axis 305.

[0077] In the active configuration 300”, the lateral extension member 330 extends laterally through the opening 217 in the crossbeam 215 and into the gap 230 until it contacts and presses against the sidewalls 26 and 28 of modules 222 and 122. In the active configuration 300”, the friction between the crossbeam 215 and the shaft 320 can keep the locking device 300 in place.

[0078] Shaft 320 can rotate in the opposite direction to retract the lateral extension member 330 from the gap 230 and receive the lateral extension member 330 within the internal volume 218 of the vehicle component 210, thereby returning to Figure 4 and Figure 6 300' of idle configuration.

[0079] like Figures 4-7As shown, the locking device 300 may have an asymmetrical shape, such as a cam, about an axial center, such that a 90-degree rotation causes the locking device 300 to fill the gap between the battery module 22 and the adjacent vehicle structure. In some embodiments, the locking device 300 includes a deformable lateral extension member 330, such that the lateral extension member 330 can fill a wide range of gaps by “flattening” after contacting mating parts of the battery module 22 (i.e., the walls or plates of the battery module 22). In some embodiments, the lateral extension member 330 is formed of a selected material and has a selected geometry, which is combined to adjust the strain / force curve of the deformation. In some embodiments, the locking device 300 and / or the lateral extension member 330 are integrated into the vehicle component 210 defining the battery compartment 23 and are extended into place to reduce the gap with or contact the battery module 22. In some embodiments, locking device 300 and / or lateral extension member 330 are integrated into battery module 22 and extended into place to reduce the distance from or contact with vehicle component 210 defining battery compartment 23.

[0080] Now for reference Figures 8-11 The figure shows the housing system 100.

[0081] Figure 8 This is a top view of the housing system 100, and Figure 10 This is a side view schematic diagram, focusing on the vehicle component 210 in the form of a crossbeam 215 located between two battery modules 122 and 222 in compartment 23.

[0082] Cross-reference Figure 8 and Figure 10 Vehicle component 210 has an outer surface 216 defining an internal volume 218. The outer surface 216 of vehicle component 210 is separated by gaps 230 from the sidewall 26 (i.e., interface 219) of battery module 222 and from the sidewall 28 (i.e., interface 219) of battery module 122. The outer surface 216 is formed with openings 217. (As shown...) Figure 10 As further shown, the bottom wall 32 of each battery module 22 is kept at a distance from the lower vehicle component 210 by a gap 230.

[0083] Figure 10 The diagram illustrates tabs 25 extending laterally from modules 122 and 222, which can extend over and rest on vehicle component 210. Furthermore, tabs 25 can be secured to vehicle component 210, such as via removable fasteners. Typically, battery module 22 can be supported by at least four tabs 25, two on each opposite side. For longer battery modules, more than four tabs 25 can provide structural connections to vehicle component 210.

[0084] Figure 10 The diagram also shows that the outer surfaces of the top wall 30 and the bottom wall 32 are 265 units apart from each other at the module height.

[0085] Figure 8 and Figure 10 The diagram shows a housing system 100 including a locking device 300. Figure 8 and Figure 10 In the idle configuration 300', the locking device 300 is located within the internal volume 218 of the vehicle component 210. Specifically, no part of the locking device 300 is located within the gap 230.

[0086] exist Figure 8 and Figure 10 In this device, the locking device 300 includes a device actuator 310, which can be manipulated to move the locking device 300 from an idle configuration 300' to an active configuration. Furthermore, the locking device 300 includes a shaft 320 and a lateral extension member 330. The shaft 320 is rotatable about an axis 305. Figure 8 and Figure 10 In this configuration, the appliance actuator 310 and the shaft 320 are fixed together and rotate together about axis 305. The lateral extension member 330 may be fixed to the shaft 320 and rotate together with the shaft 320. Alternatively, the shaft 320 may pass through the lateral extension member 330 and may rotate freely independently of the lateral extension member 330.

[0087] The lateral extension member 330 is a device that converts longitudinal forces (along axis 305) into lateral forces (perpendicular to axis 305). For example, the lateral extension member 330 may be a leaf spring device, a structural balloon, or other device that converts compressive forces in the longitudinal direction into expansive forces in the lateral direction. In some embodiments, the lateral extension member 330 converts longitudinal compressive forces into radial forces extending in all directions (including toward sidewalls 26 and 28). In other embodiments, the lateral extension member 330 converts longitudinal compressive forces into linear forces toward sidewalls 26 and 28, i.e., non-radial forces. In each case, the surfaces 332 of the lateral extension member 330 are driven outward from each other and contact sidewalls 26 and 28.

[0088] like Figure 10 As shown, in the idle configuration, the lateral extension member 330 extends in the direction toward each sidewall 26, 28 (i.e., in...). Figure 10 (In the plane) the extension distance is 333.

[0089] Figure 10The housing system 100 is also illustrated, including a movable compression block 340 and a fixed compression block 350. A threaded connection is provided between a shaft 320 and the compression block 340. The shaft 320 can pass through the fixed compression block 350, but the shaft 320 is not connected to the fixed compression block 350. As a result, rotation of the actuator 310 and the shaft 320 causes movement of the movable compression block 340. Specifically, from Figure 8 and Figure 10 The idle configuration 300', the rotation of shaft 320 will cause the movable compression block 340 to move toward the fixed compression block 350.

[0090] Figure 9 and Figure 11 The figure shows the housing system 100 in which the locking device 300 is in the active configuration 300”, i.e., after the movable compression block 340 moves toward the fixed compression block 350. Figure 9 This is a top view of the housing system 100, and Figure 11 This is a side view schematic diagram, focusing on the vehicle component 210 in the form of a crossbeam 215 located between two battery modules 122 and 222 in compartment 23.

[0091] Cross-reference Figure 9 and Figure 11 The actuator 310 is actuated and rotates about axis 305 from an idle configuration to an active configuration 300. For example, the actuator 310 may be a handle, nut, or other fastener head that can be actuated by a tool and rotated about axis 305.

[0092] When moved to the active configuration 300", the lateral extension member 330 is compressed longitudinally (i.e., along axis 305) and expanded laterally or radially. In the active configuration 300", the lateral extension member 330 extends laterally through the opening 217 in the crossbeam 215 and into the gap 230 until the surface 332 contacts and presses against the sidewalls 26 and 28 of modules 222 and 122. In the active configuration 300", friction between the crossbeam 215 and the shaft 320 can hold the locking device 300 in place.

[0093] Shaft 320 can rotate in the opposite direction to move the movable compression block 340 away from the fixed compression block 350 and remove the compressive force on the lateral extension member 330. Therefore, the lateral extension member 330 retracts from the gap 230 and is received within the internal volume 218 of the vehicle component 210, thus returning to its original position. Figure 8 and Figure 10 300' of idle configuration.

[0094] like Figures 8-11As shown, the locking device 300 may be a reversible and deformable device that can expand by applying a load orthogonal to the lateral expansion direction and retract laterally when the load is removed. In some embodiments, the lateral extension member 330 is shaped like a hollow bulb, a leaf spring, or another suitable geometry. The lateral extension member 330 is compressible between a threaded movable compression block 340 and a fixed compression block 350. During rotation of the shaft, the threaded engagement between the shaft 320 and the movable compression block 340 causes the movable compression block 340 to move relative to the fixed compression block 350, thereby causing the lateral extension member 330 to expand or retract in a direction orthogonal to the load. In some embodiments, the lateral extension member 330 can fill a wide range of gaps by being deformable and flattening after contacting mating parts (i.e., the walls or plates of the battery module 22). In some embodiments, the locking device 300 is integrated into a vehicle component 210 adjacent to the battery compartment 23 and is extended into place to reduce the gap with or contact the battery module 22. In some embodiments, the locking device 300 is integrated into the battery module 22 and extended in place to reduce the distance from or contact with the vehicle component 210 adjacent to the battery compartment 23.

[0095] Cross-reference Figure 3 , Figures 4-7 as well as Figures 8-11 It is understood that the battery module 22 can be located between two vehicle components 210 provided with locking devices 300. Therefore, manipulating each locking device 300 into the active configuration 300” presses the battery module 22 between the laterally extending members 330 from opposite sides of the module 22. Furthermore, more than one locking device 300 can be provided along the length of the battery module 22, such that each battery module 22 can be contacted by at least four locking devices 300 in the active configuration 300”, with two locking devices on each opposite side. Longer battery modules 22 can be provided with six, eight, ten, or more locking devices 300, which are arranged to secure the battery module 22 in place and resist movement relative to the vehicle regardless of acceleration / deceleration.

[0096] It should be noted that, although Figures 4-7 and Figures 8-11 The figure shows the contact between the locking device 300 and the side walls 26 and 28 of the battery module 22, but in some embodiments, the end wall or bottom wall of the battery module 22 may be contacted and pressed by the locking device 300.

[0097] Figure 12This is a flowchart illustrating a method 1200 for positioning a battery module in a vehicle. As shown, at action block 1205, method 1200 includes providing a battery compartment 23 for the vehicle and a housing assembly 100 in an idle configuration 300'.

[0098] Method 1200 can continue at action frame 1215, wherein the battery module 22 is installed in the battery compartment 23. For example, the battery module 22 can be lowered into the compartment 23 until the tab 25 rests on the structural vehicle component 210. Subsequently, the tab 25 can be secured to the structural vehicle component 210, such as by means of removable fasteners.

[0099] With the battery module 22 fixed in place in the battery compartment 23, method 1200 can continue at action frame 1225, wherein the locking device 300 is actuated to move the locking device 300 to a corresponding active configuration 300". In the active configuration 300", the lateral extension member 330 of the locking device 300 contacts a selected wall of the battery module 22 and applies a lateral force thereto. For example, a compressive lateral force can be applied to the opposing side walls 26 and 28 of the battery module 22. As a result, relative movement of the battery module 22 relative to the vehicle component 210 is prevented or suppressed.

[0100] At action frame 1235, method 1200 includes operating vehicle 10. When operating vehicle 10, locking device 300 prevents movement of battery module 22 relative to vehicle component 210. More specifically, locking device 300 prevents impact between battery module 22 and vehicle component 210, even if a large inertial force is applied to battery module 22.

[0101] At action frame 1245, method 1200 may include actuating the locking device 300 to an idle configuration 300'. As described above, the locking device easily retracts and is no longer in contact with the battery assembly 22, and is removed from the battery compartment 23. As a result, the battery compartment 23 is provided with full clearance to facilitate the removal of the battery module 22 when needed.

[0102] At action frame 1255, method 1200 may include removing battery module 22 from battery compartment 23. For example, battery module 22 may be removed for diagnostics and / or replacement. Method 1200 may then be repeated at action frame 1205.

[0103] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the exemplary embodiments or multiple exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiments or multiple exemplary embodiments. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A method for securing a battery module in a vehicle, the method comprising: A compartment is provided adjacent to vehicle components in the vehicle; The battery module is inserted into the compartment, wherein the battery module has a wall, and wherein the wall is separated from the vehicle component by a gap; as well as The locking device is actuated to move from an idle configuration to an active configuration, in which the locking device extends between the battery module and the vehicle component to prevent the battery module from moving relative to the vehicle component.

2. The method according to claim 1, further comprising: Actuate the locking device to move it from the active configuration to the idle configuration by retracting the locking device from the gap; as well as Remove the battery module from the compartment.

3. The method of claim 1, wherein the locking device is installed on the vehicle component.

4. The method according to claim 3, wherein: The vehicle component is a crossbeam; The crossbeam defines the internal volume; The locking device is located within the internal volume in the idle configuration; The crossbeam includes an upper end; The battery module includes a laterally extending upper protrusion; Inserting the battery module into the compartment includes contacting the upper end with the laterally extending upper tab, and supporting the battery module with the crossbeam when the locking device is in the idle configuration; Actuating the locking device includes manipulating a device actuator positioned on the crossbeam; as well as Manipulating the appliance actuator includes rotating the appliance actuator about an axis parallel to the compartment.

5. The method according to claim 1, wherein: The vehicle component is a first vehicle component; The compartment is positioned adjacent to both the first vehicle component and the second vehicle component; The wall is a first wall, and the battery module further includes a second wall; The gap is a first gap located between the first wall and the first vehicle component; The second gap is located between the second wall and the second vehicle component; The locking device is a first locking device that contacts the first wall of the battery module in the active configuration; as well as The method includes actuating a second locking device to move from an idle configuration to an active configuration, in which the second locking device extends between the battery module and a vehicle component to prevent the battery module from moving relative to the vehicle component.

6. The method of claim 5, further comprising pressing the battery module between the first locking device and the second locking device when the first locking device and the second locking device are moved to their respective active configurations.

7. The method according to claim 5, wherein: The first wall is the first side wall; The second wall is the second sidewall that is opposite to the first sidewall; The first end wall and the second end wall connect the first side wall and the second side wall; The first end wall and the second end wall are separated by the side length; The length of the ends separating the first sidewall from the second sidewall; as well as The side length is greater than the end length.

8. A housing system for a battery module in a vehicle, the housing system comprising: A compartment adjacent to a vehicle component in the vehicle, the compartment being configured to receive the battery module, with a gap between the battery module and the vehicle component; as well as A locking device configured to move from an idle configuration to an active configuration, in which the locking device extends between the battery module and a vehicle component to prevent the battery module from moving relative to the vehicle component.

9. The housing system according to claim 8, wherein: The locking device is configured to move from the active configuration to the idle configuration, in which the locking device is not located in the gap; The locking device is installed on the vehicle component; The vehicle component is a crossbeam; The crossbeam defines the internal volume; The locking device is located within the internal volume in the idle configuration; The crossbeam includes an upper end; The battery module includes a laterally extending upper tab, which is configured to be located on the upper end; The locking device includes a device actuator positioned on the crossbeam; as well as The locking device and device actuator are rotatable about an axis parallel to the compartment.

10. The housing system according to claim 9, wherein: The vehicle component is a first vehicle component; The compartment is positioned adjacent to both the first vehicle component and the second vehicle component; The gap is a first gap located between the battery module and the first vehicle component; The second gap is located between the battery module and the second vehicle component; The locking device is a first locking device; as well as The housing system includes a second locking device configured to move from an idle configuration to an active configuration, in which the second locking device extends between the battery module and a vehicle component to prevent the battery module from moving relative to the vehicle component.

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