Device for attaching a battery system component to a vehicle

Abstract

Device for attaching a battery system component (18) to a vehicle (12), the device comprising: a mounting plate (40) configured to be detachably attached to the vehicle (12), the battery system component (18) being attached to the mounting plate (40); and a mounting plate suspension (42) attached to the mounting plate (40), the mounting plate suspension (40) being configured to be detachably attached to the vehicle (12); the mounting plate (40) further comprising: one or more fastening elements (44) configured to be attached to the vehicle (12) by a detachable fastening means (22); and the mounting plate suspension (42) further comprising: a rigid support element (42) attached to the mounting plate (40) and detachably attached to the vehicle (12);wherein the rigid support element (42) further comprises: a first end (46a) which is attached to a first surface (40a) of the mounting plate (40) by fasteners; and a second end (46b) which is attached to the vehicle (12) by a removable fastener (22), the second end (46b) being opposite to the first end (46a); and wherein the rigid support element (42) further comprises: a trapezoidal rigid support element (42), wherein the first end (46a) of the trapezoidal rigid support element is attached to the mounting plate (40) and the second end (46b) of the trapezoidal rigid support element is attached to a vehicle body floor liner (24) of the vehicle (12) by a removable fastener (22); wherein the vehicle body floor liner (24) further comprises: an access plate (28b) which provides access to the battery system component (18).

Description

introduction

[0001] The present description relates to an apparatus and a system for mounting battery system components on a vehicle.

[0002] To increase performance and simplify manufacturing, battery electric vehicles and hybrid electric vehicles can be equipped with battery storage systems configured to provide electrical energy to operate the vehicle's electromechanical components and systems. Battery storage systems can be housed in a sealed container to ensure the structure and environmental / electrical isolation of the battery system. However, current battery storage systems can be large and heavy and require specialized equipment for installation in the vehicle during vehicle manufacturing. In addition, current battery storage systems may require the entire storage system to be removed from the vehicle to perform service and / or maintenance on the battery system.In addition, current packaging devices for battery systems may require significant modifications to the vehicle structure to accommodate the large and / or heavy container.

[0003] Therefore, while current battery packaging systems and devices serve their purpose, there is a need for a new and improved system and device for securing a battery system component to a vehicle. Description

[0004] According to several aspects, a device for attaching a battery system component to a vehicle is provided. The device may include a mounting plate configured to be removably attached to the vehicle. The battery system component is attached to the mounting plate. The device may further include a mounting plate hanger attached to the mounting plate. The mounting plate hanger is configured to be removably attached to the vehicle.

[0005] In another aspect of the present description, the mounting plate may further include one or more fasteners configured to be secured to the vehicle with a removable fastener.

[0006] In another aspect of the present description, the one or more fasteners are attached to a cross body member of the vehicle with the removable fastener.

[0007] In another aspect of the present description, the battery system component may further comprise a battery module having one or more battery cells.

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

[0009] In another aspect of the present description, the mounting plate suspension may further comprise a rigid support member secured to the mounting plate and removably attached to the vehicle.

[0010] In another aspect of the present description, 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 with a removable fastener. The second end is opposite the first end.

[0011] In another aspect of the present description, the rigid support member may further comprise a trapezoidal rigid support member. The first end of the trapezoidal rigid support member is secured to the mounting plate, and the second end of the trapezoidal rigid support member is secured to a vehicle body floor pan of the vehicle with a removable fastener.

[0012] In another aspect of the present description, the vehicle body floor pan may further include an access panel that allows access to the battery system component.

[0013] In another aspect of the present description, the device may further comprise a liner disposed between the battery system component and the vehicle. The liner is configured to isolate the battery system component from the vehicle.

[0014] According to several aspects, a system for securing a battery system component to a vehicle is provided. The system may include a vehicle body floor pan 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 cross-body members, each of the plurality of cross-body members having a first end, a second end, and a first surface. The first end of each of the plurality of cross-body members is secured to the second surface of the body floor pan such that the first surface of each of the plurality of cross-body members is substantially perpendicular to the second surface of the body floor pan.The system may further include a mounting module removably mounted between two of the plurality of cross-body members, the mounting module including a mounting plate having a first surface. The mounting module may further include a mount for the mounting plate having a first end and a second end. The first end is attached to the first surface of the mounting plate. The second end is configured to be removably attached to the second surface of the floor panel of the vehicle body. The system may further include the battery system component attached to the first surface of the mounting plate.

[0015] In another aspect of the present description, each of the plurality of cross-body members may further include one or more apertures in the first surface of each of the plurality of cross-body members. Each of the one or more apertures allows the passage of one or more electrical or liquid conductors for electrical or liquid connection to the battery system component.

[0016] In another aspect of the present description, the vehicle body floor pan may further comprise one or more access panels disposed on the first surface of the vehicle body floor pan. The one or more access panels provide access to one or more electrical or liquid conductors.

[0017] In another aspect of the present description, the mounting plate may further include one or more fasteners configured to be attached to the second end of one or more of the plurality of vehicle body cross members with removable fasteners.

[0018] In another aspect of the present description, the mounting plate suspension may further comprise a trapezoidal rigid support member. A first end of the trapezoidal rigid support member is attached to the first surface of the mounting plate, and a second end of the trapezoidal rigid support member is attached to the second surface of the vehicle body floor pan with a removable fastener.

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

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

[0021] According to several aspects, an apparatus for securing a battery system component to a vehicle is provided. The apparatus may include a mounting module having a mounting plate with a first surface. The battery system component is secured to the first surface. The apparatus may further 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 floor pan of the vehicle body.

[0022] In another aspect of the present description, the mounting plate suspension may further comprise a trapezoidal rigid support member. A first end of the trapezoidal rigid support member is secured to the first surface of the mounting plate, and a second end of the trapezoidal rigid support member is secured to the vehicle body floor pan with a removable fastener.

[0023] In another aspect of the present description, the mounting module may further comprise at least two mounting plate hangers attached to the first surface of the mounting plate. The battery system component is 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 present description. It should be understood that the description and specific examples are for illustrative purposes 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 illustrative purposes only and are not intended to limit the scope of this description in any way. Fig. 1 is a schematic diagram of a system for attaching a battery system component to a vehicle according to an exemplary embodiment; Fig. 2 is an exploded perspective view of the system for securing a battery system component to a vehicle according to an exemplary embodiment; Fig. 3 is an assembled perspective view of the system for securing a battery system component to a vehicle according to an exemplary embodiment; Fig. 4 is an assembled bottom perspective view of the system for attaching a battery system component to a vehicle, according to an exemplary embodiment; Fig. 5 is a perspective view of a mounting module with a first exemplary battery system component according to an exemplary embodiment; Fig. 6 is a perspective view of a mounting module with a second exemplary battery system component according to an exemplary embodiment; Fig. 7 is a top perspective view of a portion of the system for securing a battery system component to a vehicle according to an exemplary embodiment; and Fig. Figure 8 is an enlarged view of the composite perspective view of Fig. 3 according to an exemplary embodiment. Detailed description

[0026] The following description is merely exemplary and is not intended to limit the present disclosure, application, or uses.

[0027] In aspects of the present description, a new and improved battery storage system for battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and / or hybrid electric vehicles (HEVs) is provided. The battery storage system is packaged to be structurally and environmentally / electrically isolated. Advantageously, the new and improved battery storage system of the present description reduces the weight of the vehicle. This is because the new and improved battery storage system of the present description utilizes the existing vehicle structure to provide structure for the battery storage system.This contrasts with conventional sealed battery containers, which are larger and heavier and require specialized equipment and skills for installation during vehicle assembly and removal / reinstallation during maintenance. Furthermore, 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. Accordingly, the present disclosure provides a new and improved battery storage system with a modular design for attaching batteries and battery system components to a vehicle.

[0028] In Fig. 1 is a schematic diagram of a system for attaching a battery system component to a vehicle, generally designated by the reference numeral 10. The system 10 is illustrated in a cross-sectional view of an example vehicle 12. Although a passenger car is depicted, the vehicle 12 may be any type of vehicle without departing from the scope of the present description. In an exemplary embodiment, the system 10 is disposed on the underside of the vehicle 12. More specifically, the system 10 is integrated into a body of the vehicle 12, as will be explained in more detail below.

[0029] The Fig. 2 to 4 show an exploded perspective view of the system 10 in Fig. 2, a composite perspective view of the system 10 in Fig. 3 and a composite perspective bottom view of the system 10 in Fig. 4. The system 10 generally includes a vehicle body 14, a mounting module 16, a battery system component 18, and a liner 20. The Fig. 2-4 show an embodiment with three mounting modules 16, three battery system components 18, and three liners 20. However, it is understood that embodiments with any number of mounting modules 16, battery system components 18, and liners 20 fall within the scope of the present description. In addition, the system 10 is shown with a plurality of fasteners 22. For the purposes of the present description, the plurality of fasteners 22 includes removable fasteners, such as screws, bolts, and / or the like. The plurality of fasteners 22 are configured to engage nuts, threads, and / or the like to establish a releasable connection between two objects. It is understood that the location, type, and size of the Fig. 2 to 4 are merely exemplary and that the Fig. 2 to 4 are not necessarily to scale.

[0030] The vehicle body 14 includes a body floor pan 24 and a plurality of body cross members 26. The body floor pan 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) may be attached to the vehicle body floor pan 24. In an exemplary embodiment, the vehicle floor pan 24 has a first surface 24a and a second surface 24b. The first surface 24a of the vehicle body floor pan 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 body floor pan 24 is penetrated by a plurality of access openings 28a that allow access from the first surface 24a (i.e., the interior of the vehicle 12) to the battery system component 18, as will be explained in more detail below.The vehicle body floor pan 24 may further include a plurality of access panels 28b disposed on the first surface 24a to cover the plurality of access openings 28a. In one non-limiting example, the plurality of access panels 28b are removably attached with the fasteners 22. In one exemplary embodiment, the fasteners 22 holding the plurality of access panels 28b may be removed from the first surface 24a (i.e., the interior of the vehicle 12). In another exemplary embodiment, the fasteners 22 holding the plurality of access panels 28b may be removed from the second surface 24b (i.e., the exterior of the vehicle 12). It should be understood that the number, size, shape, and location of the access panels 28b shown in FIGS. Fig. 2 to 4 are merely exemplary and that the plurality of access openings 28a and the access plates 28b Fig. 2 to 4 are not necessarily to scale. In one non-limiting example, the vehicle body floor pan 24 is made of a sheet metal and / or a composite material (e.g., steel, aluminum, carbon fiber, and / or the like).

[0031] The plurality of cross body members 26 provide additional structural support for the vehicle body floor pan 24. In an exemplary embodiment, each cross body member 26 has a first end 30a, a second end 30b, and a first surface 32. In one non-limiting example, the first end 30a of each cross body member 26 is attached to the second surface 24b of the vehicle body floor pan 24 such that the first surface 32 of each cross body member 26 is substantially perpendicular to the second surface 24b of the vehicle body floor pan 24. As used herein, "substantially perpendicular" means that an angle measured between the first surface 32 of each cross body member 26 and the second surface 24b of the vehicle body floor pan 24 is approximately ninety degrees (90°) within a predetermined tolerance (e.g., ±10%).

[0032] In one non-limiting example, the first end 30a is secured to the second surface 24b of the vehicle body floor pan 24 with a weld, an angled bracket and fasteners, and / or the like. In an exemplary embodiment, each cross-body member 26 has one or more apertures 34 in at least the first surface 32 of each cross-body member 26 that allow connection to the battery system component 18, as will be explained in more detail below. It is understood that the number, size, shape, and location of the apertures 34 provided in the Fig. 2 to 4 are merely exemplary and that the Fig. 2 to 4 are not necessarily to scale. It should be noted that the number, size, shape and location of the Fig. The plurality of vehicle body cross members 26 illustrated in Figures 2 through 4 are merely exemplary. By way of non-limiting example, the plurality of vehicle body cross members 26 are constructed from a sheet metal and / or a composite material (e.g., steel, aluminum, carbon fiber, and / or the like).

[0033] Fig. 5 shows a perspective view of the mounting module 16 with a first exemplary battery system component 18a. The mounting module 16 is used to receive the battery system component 18 (e.g., the first exemplary battery system component 18a) and to 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 fasteners 44. The one or more fasteners 44 are configured to be attached to the second end 30b of the body cross members 26 with the fasteners 22.In an exemplary embodiment, the one or more fastening elements 44 are through-holes or threaded holes in at least the first surface 40a of the mounting plate 40 and are arranged proximal to one or more edges or corners of the mounting plate 40. It is understood that the number, size, shape, and location of the fastening elements 44 shown in FIG. Fig. 5 shown fastening elements 44 are merely exemplary and that Fig. 5 is not necessarily to scale. In one non-limiting example, the mounting plate 40 is made of a sheet metal and / or a composite material (e.g., steel, aluminum, carbon fiber, and / or the like).

[0034] The mounting plate hanger 42 provides additional structural support and secures the mounting plate 40 to the vehicle body 14. In an 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 attached to the first surface 40a of the mounting plate 40. In one 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 attached to the first surface 40a of the mounting plate 40 with fasteners. 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 body floor pan 24 using fasteners 22.In an exemplary embodiment, the mounting plate hanger 42 is a rigid support member made from a metal and / or composite material (e.g., steel, aluminum, carbon fiber, and / or the like), a sheet metal, an extrusion, a tube, a box, and / or the like. In a 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 attached proximally to one or more edges of the mounting plate 40. It should be understood that the number, size, shape, and position of the mounting plate hangers 42 shown in FIG. Fig. 5 shown mounting plate hangers 42 are merely exemplary and that Fig. 5 is not necessarily to scale. In some embodiments, additional mounting plate hangers 42 are provided depending on the needs of a particular application, battery system component 18, and / or the like.

[0035] With further reference to Fig. 5, the first exemplary battery system component 18a is shown with the attachment module 16. In one exemplary embodiment, the first exemplary battery system component 18a includes a battery module 48 having one or more battery cells 50. In one non-limiting example, the battery module 48 stores and delivers 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 parallel to provide increased voltage and / or current carrying capacity. It is understood that the one or more battery cells 50 may comprise any type of battery cell chemistry and form factor, including, for example, cylindrical battery cells.

[0036] The first exemplary battery system component 18a further includes one or more electrical or liquid conductors 52 for connecting (i.e., electrical and / or liquid connection) between adjacent battery system components 18 (as shown in Fig. 3). In one non-limiting example, the one or more electrical or fluid conductors 52 include, for example, electrical bus bars, electrical cables, coolant lines, air ducts, gas vent ducts, and / or the like. The one or more electrical or fluid conductors 52 extend through the one or more apertures 34 to establish electrical and / or fluid communication between adjacent battery system components 18. In one exemplary embodiment, the one or more electrical or fluid conductors 52 may be mounted from one or more of the plurality of access openings 28a. In another exemplary embodiment, the one or more electrical or fluid conductors 52 may be mounted from the exterior (i.e., the underside) of the vehicle 12.It should be understood that the type, quantity, size, shape, routing and location of the one or more electrical or liquid conductors 52 are merely exemplary and that . Fig. 5 is not necessarily to scale.

[0037] In Fig. Figure 6 is a perspective view of the fastening module 16 as described above with reference to Fig. 5, with a second exemplary battery system component 18b. In an exemplary embodiment, the second exemplary battery system component 18b is a battery disconnect unit (BDU) 54.

[0038] The BDU 54 is used to control the connection and disconnection of one or more battery modules 48 from other systems of the vehicle 12. In an exemplary embodiment, the BDU 54 includes a BDU control unit, a BDU sensor, and a BDU switch. In one non-limiting example, the BDU control unit uses the BDU sensor to monitor battery system metrics (e.g., voltage, current, temperature, and / or the like) and to detect adverse conditions (e.g., overvoltage or overcurrent conditions, thermal runaway, and / or the like). In response to detecting adverse conditions, the BDU control unit actuates the BDU switch to disconnect the battery system from other systems of the vehicle 12. In another non-limiting example, the BDU control unit receives inputs from an external device (e.g.,an emergency stop switch, a wired / wireless interface, and / or similar) and actuates the BDU switch to isolate the battery system based at least in part on the inputs from the external device.

[0039] The second exemplary battery system component 18b further includes one or more electrical or liquid conductors 52 for connecting (i.e., electrical and / or liquid connection) between adjacent battery system components 18. In one non-limiting example, the one or more electrical or liquid conductors 52 include, for example, electrical bus bars, electrical cables, coolant lines, air ducts, gas vent ducts, and / or the like. The one or more electrical or liquid lines 52 extend through the one or more apertures 34 to establish electrical and / or liquid connection between adjacent components of the battery system 18. It is understood that the type, quantity, size, shape, routing, and location of the one or more electrical or liquid lines 52 are merely exemplary and that Fig. 6 is not necessarily to scale.

[0040] Fig. Figure 7 shows a top perspective view of a portion of the base pan 24. The top perspective view is shown with the access panel 28b removed, illustrating access to the one or more electrical conductors or fluid conductors 52 through the access opening 28a. Access to one or more electrical conductors or fluid conductors 52 may be provided through the access opening 28a for service, maintenance, testing, assembly / disassembly, and / or the like.

[0041] With reference to the Fig. 2-6, the battery system component 18 in the context of the present description is any component of an electrical system of the vehicle 12, in particular any component of an energy storage system of the vehicle 12. Two examples of battery system components 18 are described above with reference to the Fig. 5 and Fig. 6 (i.e., the first example battery system component 18a and the second example battery system component 18b). In general, the battery system component 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 extinguishing devices, thermal runaway prevention / mitigation devices, etc.), and / or the like. The battery system component 18 is attached to the first surface 40a of the mounting plate 40.In one non-limiting example, the battery system component 18 is secured to the mounting plate 40 with one or more clamps, fasteners, and / or the like.

[0042] In Fig. Figure 8 is an enlarged view 56 of the composite perspective view of Fig. 3. With further reference to the Fig.2-3 and 8, the liner 20 is used to insulate the battery system component 18 and / or the mounting module 16 from the vehicle body 14 and to contain and / or channel gases escaping from the battery system component 18. The liner 20 is configured to perform one or more of the following functions: electrical, thermal, chemical, environmental, and physical insulation and / or protection of the battery system component 18. In one exemplary embodiment, the liner 20 is disposed over the battery system component 18 and forms a barrier between the battery system component 18 and the vehicle body 14 when the system 10 is assembled. In another exemplary embodiment, the liner 20 is a coating disposed on the second surface 24b of the vehicle body floor pan 24 and one or more surfaces of the plurality of vehicle body cross members 26.In some examples, the liner 20 includes apertures for the one or more electrical or fluid conduits 52 and / or the plurality of access openings 28a. In one non-limiting example, the liner 20 is a blow-molded polymer structure. In another non-limiting example, the liner 20 is a curable coating that adheres to the vehicle body 14 and cures after being applied to the vehicle body 14. It should be noted that the size, shape, and location of the liner 20 are merely exemplary in nature.

[0043] The system 10 and mounting module 16 of the present description offer several advantages. By utilizing the existing vehicle structure, such as the vehicle body 14, to provide the structure for the components of the battery system 18, the need for additional material and, therefore, additional weight due to structural components is reduced. Furthermore, by providing the mounting module 16 as a modular device, installation and maintenance can be performed on individual mounting modules 16, reducing the need to handle large and / or heavy components. The access openings 28a and the access panels 28b allow for servicing of the electrical lines or the fluid lines 52 without removing the mounting modules 16. The liner 20 insulates and protects the components of the battery system 18.Due to the modular design of system 10, the present description is adaptable, scalable, and suitable for use with many types of battery system components and many vehicle body designs. For example, 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, system 10 is adaptable for use with various current and future battery chemistries and energy system technologies and topologies.

[0044] The description of the present disclosure is merely exemplary, and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present description.

Claims

[1] A device for attaching a battery system component to a vehicle, the device comprising: a mounting plate configured to be removably attached to the vehicle, wherein the battery system component is attached to the mounting plate; and a mounting plate hanger attached to the mounting plate, the mounting plate hanger being configured to be removably attached to the vehicle. [2] The device of claim 1, wherein the mounting plate further comprises: one or more fasteners configured to be secured to the vehicle with a removable fastener. [3] The apparatus of claim 2, wherein the one or more fasteners are attached to a vehicle body cross member of the vehicle with the removable fastener. [4] The apparatus of claim 1, wherein the battery system component further comprises: a battery module with one or more battery cells. [5] The apparatus of claim 1, wherein the battery system component further comprises: a battery separation unit (BDU). [6] The apparatus of claim 1, wherein the mounting plate suspension further comprises: a rigid support element attached to the mounting plate and removably mounted to the vehicle. [7] The device of claim 6, wherein the rigid support member further comprises: a first end attached to the mounting plate; and a second end secured to the vehicle by a removable fastener, the second end being opposite the first end. [8] The device of claim 7, wherein the rigid support member further comprises: a trapezoidal rigid support member, the first end of the trapezoidal rigid support member being secured to the mounting plate and the second end of the trapezoidal rigid support member being secured to a vehicle body floor pan of the vehicle with a removable fastener. [9] The apparatus of claim 8, wherein the vehicle body floor pan further comprises: an access panel that provides access to the battery system component. [10] The device of claim 1, further comprising: a liner disposed between the battery system component and the vehicle, the liner configured to isolate the battery system component from the vehicle.

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