Battery mounting system

Abstract

A battery mounting system includes a battery case 34 and a mounting bracket 36. The mounting bracket has a first part (66, Figure 4) for connection to an elongate support (64, Figure 4) and a second p

Description

Title — Battery Mounting System The present invention relates to a battery case and mounting, in particular for use with a hoist for loading an individual or a mobility scooter or similar assistive device into and out of a vehicle. Assistive hoists and lifting devices for passenger vehicles are known. Typically, the hoist mechanisms comprise pivoting lifting arms and swing into and out of a vehicle. Motors or actuators are typically provided to power at least the lifting action, and power for these motors or actuators is typically taken from the vehicle’s internal power source, by wiring the hoist mechanism into the vehicles electrical system. Increasingly, there is a desire for a separate / dedicated battery to be provided with a hoist assembly. In recent years access to the internal vehicle battery has become more and more restricted. This is particularly the case for hybrid or fully electric vehicles, where the increased reliance on the internal battery for operation of the vehicle, and the requirement for a constant / reliable power delivery, means that manufacturers do not want any ancillary devices potentially placing additional drain on the battery. Avoiding the need to wire a hoist or similar into the vehicle's electrical system also helps to minimise modification of the vehicle during installation. Avoiding or minimising vehicle modification has a number of benefits for both the installer and the customer. Drilling or cutting into a vehicle offers a range of potential risks including electrocution if electrical components are damaged and harmful dust from composite materials. Vehicle modifications also require a longer install time and greater knowledge and training for the installer, particularly when the vehicle electrical system is involved. Reducing or avoiding this may, in some cases, avoid the need for a professional installer altogether. Finally, end users can be understandably resistant to cutting and / or drilling in their new car. If the product later needs to be removed from a vehicle, remedial work and / or new interior panels are generally needed, increasing cost and / or reducing the resale value of the vehicle. Dedicated batteries do, however, have disadvantages. Being separate from the vehicle's electrical system means that the charge in a separate battery or battery pack need to be managed by the user independently of the vehicle's battery. A secure mounting is also required to ensure that they remain securely in place during use, including in the event of an impact or accident. Ideally, the mounting should be adjacent the hoist assembly and / or any associated drive motors to remain accessible to a user and to minimise the amount of wiring or cabling required. However, it is not always easy to find a suitable location to mount a battery without additional permanent modification of a vehicle. According to a first aspect of the invention there is provided a battery mounting system as defined in the appended claim 1. Further optional features are recited in the associated dependent claims. The battery mounting system advantageously opens the possibility of mounting a dedicated battery to a hoist mounting frame, potentially at a number of possible positions (helping to ensure it is within easy reach of a user), regardless of the specific mounting frame design. This simplifies the use of a dedicated battery. The mounting system additionally simplifies the attachment and removal of a battery pack for charging or potentially when moving between vehicles, because no physical clip or latch needs to be manipulated. A vertical orientation of the battery pack is an important safety concern, particularly where there is no physical latch between the battery case and mounting bracket, and the pivoting connection provide by the mounting bracket ensures that this vertical orientation can be maintained regardless of where the mounting bracket is secured to a frame. A dedicated external battery pack and mounting system allows new or existing products to be used without the need to wire into a vehicle during installation, and also avoids the need for all future products to be developed with inbuilt power supplies. The battery mounting system as claimed comprises a battery case and a mounting bracket. The mounting bracket comprises a first part for connection to an elongate support and a second part joined to the first part via a pivot point. The battery case comprises a sleeve, with an open end and a closed end opposite the open end, for receiving the second part of the mounting bracket. The second part of the mounting bracket comprises a ferromagnetic material, and a magnet is provided adjacent the closed end of the sleeve. The open end of the sleeve may comprise a chamfered edge to provide a lead-in feature and simplify mounting of the battery case on the mounting bracket. The second part of the mounting bracket may comprise an elongate flat plate of ferromagnetic material. The flat plate may be completely smooth on both sides. A simple design of this type helps to ensure that the sleeve can receive the second part of the mounting bracket in either of two orientations, ie so that the main body of the battery case can be positioned on either side of the second part of the mounting bracket. The pivot point between the first and second parts of the mounting bracket may comprise a single bolt or similar fixing. The first part of the mounting bracket may comprise an open channel section shaped to receive and partly surround an elongate support. For example, a bracket for securing to a frame member of typical square cross-section could have a channel shaped and sized to receive the frame member and surround it on three sides. The channel could provide an interference fit with the frame member and / or grub screws could be provided to secure the channel in place. The first part of the mounting bracket may be formed from a flat / sheet material bent to provide the open channel section. One side of the open channel section may extend for a distance greater than the thickness of said elongate support to provide an extended limb extending to a flat portion on which the pivot point is provided. The extended limb thus provides an offset between said elongate support and the pivot point. For example, the extended limb could have a length of ~70mm measured from the base of the open channel. This would provide an offset of ~45mm beyond a standard 25mm square section frame member at which the pivot point could be provided on a flat portion. The flat portion may be provided at 90° to the extended limb. For example, a sheet material could be bent to form the open channel section as previously described and then bent back at 90° to provide the flat section. The length of the extended limb may be similar to the thickness of the battery case. This allows the body of the battery case to be aligned with a frame member when mounted so that it doesn't protrude beyond the frame. It will be understood that the required offset will depend on the dimensions of a specific battery case and the thickness of a frame member to which the mounting bracket is secured, however the overall length of the extended limb would still be similar to the thickness of the battery case. For example, a mounting bracket for a battery case of ~45mm thickness would require an extended limb of ~45mm regardless of whether it is mounted to a standard 25mm section frame member or to a larger section, for example 35mm. The battery case may comprise a power indicator, for example in the form of display lights, possibly activated by a button or other user input. The battery case is formed from a plastics material such as polycarbonate, or from a similar tough durable material. Robust and / or tamper resistant fixings may be used to ensure that the battery or cells are securely protected and inaccessible to an end user. The battery case may house a plurality of battery cells arranged to ensure that the battery case maintains a slim profile. For example, at least a part of the battery case may be no thicker than 50mm and / or have a perimeter of no more than 300mm so that a user can wrap their had around the battery case to simplify gripping and handling. The invention also provides a battery case or a mounting bracket for a battery mounting system as previously described. Practicable embodiments of the invention are described in further detail below with reference to the accompanying drawings, of which: Figure 1 shows an example mounting frame for a hoist assembly; Figure 2 shows a battery mounting system according to the present invention; Figure 2A shows an opposite face of the battery case from Figure 2; Figure 3 shows the interior of a sleeve portion of the battery case of Figure 2: Figure 4 shows the mounting bracket from Figure 2 in isolation; Figure 5 shows a first configuration of the assembled battery case and mounting bracket; Figure 5A shows a cross section as indicated in Figure 5; and Figure 6 shows a second configuration of the assembled battery case and mounting bracket. It is conventional to provide a mounting frame to securely fix a hoist assembly into a vehicle. Some heavy-duty hoists rated to lift up to 200kg, so that they can lift full sized mobility scooters into the load space of a passenger vehicle, so a reliable secure mounting to the vehicle is important. An example mounting frame 2 for a heavy-duty hoist is shown in Figure 1. The hoist assembly is largely omitted from the view of Figure 1, but briefly comprises a liting arm attached at a lower pivot bracket 4 and a linear actuator attached at an upper pivot bracket 6 to a vertical support 8. The linear actuator also attached to the lifting arm and is powered by motor to raise and lower the lifting arm as required. The vertical support 8 is mounted to a pivot post 10 at one edge of the mounting frame 2, to allow the hoist assembly to pivot horizontally relative to the mounting frame 2 and thus swing into or out of a vehicle load space. In the example shown, this movement of the hoist assembly is controlled by a horizontal linear actuator 12 powered by an electric motor 14. The vertical support 8 is received on first and second pins 16,18 on the pivot post 10 so that the lifting arm can be easily removed from the mounting frame 2 when needed. The mounting frame 2 is formed from 25mm square mild steel box section, and has an A-frame structure essentially comprising the vertical pivot post 10, a horizontal member 20 and a first diagonal member 22 between the two. Several other bracing and fixing frame members 24,26,28,30, including a second diagonal member 24, are also provided for strength and to provide appropriately positioned fixing brackets 32 for securing the mounting frame 2 to the wall and floor of a vehicle load space. As noted above, there is an increasing desire for hoists to be powered by their own separate / dedicated power supply rather than the vehicle battery. Ideally, the mounting point for any dedicated battery should be adjacent the hoist assembly and / or any associated drive motors. The hoist mounting frame 2 meets both of these key requirements for mounting a separate / external battery pack. However, it can be seen from Figure 1 that several parts of the mounting frame 2 are adjacent other components, such as the vertical support 8 of the hoist assembly or the horizontal linear actuator 12 and its motor 14. This prevents or limits access to these parts of the mounting frame 2 when a hoist assembly is in place, making them unsuitable. The first and second diagonal members 22,24 remain largely unobstructed, providing better potential mounting locations for a battery or other component associated with the hoist Although the A-frame design shown in Figure 1 is fairly standard, modifications often need to be made to a mounting frame 2 to suit a specific make or model of vehicle. In particular, the angles of the first and second diagonal members 22,24 may have to be varied to avoid obstructions and ensure that fixing bracket 32 is appropriately positioned for fixing to a secure structural position on the side wall of a vehicle. The increased use of new composite materials in vehicles can also make it harder to find structural places suitable to support lifting devices. These same composite materials can also be toxic and / or require specialist protective equipment when being cut or drilled, further limiting the number of mounting options. The locations of the batteries used in hybrid or electric vehicles is becoming more varied as battery technology and car design evolves. Several batteries are often spread around the vehicle to enhance weight distribution for improved handling, and the information on precise locations of batteries is often not available to third parties. If a battery is ruptured, for example by an installer when drilling a mounting hole or cutting an opening for cable routing, then the installer could receive a 3-phase shock and a chemical fire could occur. As a result, it is increasingly desirable to minimise vehicle modifications during installation, and providing an external / dedicated power source helps to achieve this goal. The risk of drilling into an internal battery also further limits the choice of mounting positions, making modification of a mounting frame more likely, or in some cases requiring a completely bespoke mounting to minimise or eliminate drilling in certain areas. Figure 2 shows an exploded view of a battery case 34 and mounting bracket 36 according to the present invention. The battery case 34 houses a number of cells to provide a battery pack for powering a hoist or similar. The battery case 34 is formed from a polycarbonate material, although various other high impact plastics would also be suitable. A cable gland 38 for an output cable projects from one side at a first end, and a power indicator button 40 and display 42 are provided in a recessed area 44 on one face of the battery case 34. Pressing the button 40 illuminates a sequence of lights on the display 42 to indicate to a user how much charge remains in the battery pack. This clear charge indicator allows a user to easily monitor the charge state to ensure that there is sufficient charge before setting off and prevents unnecessary removal of the battery pack for charging. Figure 2A shows the opposite face 45 of a first end of the battery case 34. The face 45 is smooth and flat along the length of the battery case, and a charging port 39 can be seen on a side of the case 34 to opposite the cable gland 38 at the first end. Positioning the cable gland 38 and charging port 39 to the side(s) of the battery case 34 allows the battery case 34 to sit flat to the side of a vehicle, taking up less space. lt also allows the battery case 34 to be stored in a front door pocket or cup holder without bending the cable. The entire battery case 34 has been designed to comply with EU standard |P64 for environmental protection, meaning that it is dust tight and ‘splash proof’. This is achieved by use of a band seal or round rubber washers between fixings and an |P64 rated cable gland 38 and charging port cover. The protection ensures that the battery pack will continue to function in the event that rain enters the load space of a vehicle or if the case otherwise gets wet though accidental misuse or mishandling. The general robust construction, including the chosen materials, strengthening ribs within the battery case 34 and recessed area 44 for the button 40 and display 42 further help to mitigate the risk of damage if the battery pack is dropped or suffers any other impact. The battery case 34 has also been specifically designed to account for users of lower dexterity. The general shape of the battery case 34 is slim enough that a user can wrap their hand around the body to ensure a secure grip. This has been achieved through the use of bespoke batteries / cells within the battery case 34 which could be arranged as needed to maintain a slim profile, with a thickening only where necessary (e.g. at the first end to provide a location for the cable gland 38 and charging port 39). The outer dimensions of the battery case as shown are approximately 252x82x44mm in the thinnest region of the body. The thickness increases to around 52mm at the first end to accommodate the features refenced above, and to provide some space for the cells to 'breath’ within the battery case 34 and avoid overheating. Since the additional thickness is only at one end of the battery case 34 a user can still grip comfortably around the majority of the case 34. This slim / sleek design is also of benefit when securing the battery case 34 to a mounting bracket secured to an A-frame (discussed below) and / or when storing in a door pocket or cup holder. It should be understood that other sizes, in particular to accommodate larger or higher capacity batteries, could be provided. However, maintaining a slim design is important for storage and handling. For example, the abovementioned dimensions of 252x82x44mm mean that the outer perimeter of the battery case 34 measures 252mm. This allows a user to wrap their hand around at least three sides of the battery case 34 when handling, which is particularly beneficial for those with reduced grip strength or dexterity. The battery case 34 comprises a sleeve 46 to receive a part of the bracket 36 and secure the battery case 34 thereto. The sleeve 46 is shown separated from the remainder of the battery case 34 in Figure 2, but is secured in place in use by four screws 48 extending from within the body of the battery case 34. Once assembled, the screw heads are thus inaccessible to a user. Just four further fixings are used to secure the body of the battery case 34 together, and all have ‘anti-tamper’ heads to prevent access by a user. An additional fixing screw 50 secures a neodymium magnet 52 in place within the sleeve 46, as can be better seen in Figure 3. Figure 3 shows an underside of the sleeve 46 in isolation. A neodymium magnet 52 and its fixing screw 50 can be clearly seen in exploded view at the end of a channel 54 formed in the underside of the sleeve 46. The end of the channel 54 is rounded to correspond with the shape of the magnet 52. Several strengthening ribs 56 can also be seen as part of the moulding. Brass threaded inserts 58,60 are provided in holes to receive the screws 48 extending from the body of the battery case and the fixing screw 50 for the neodymium magnet 52. The inserts provide better and more durable connections, and thus better security, than self tapping screws driven directly into the plastic of the sleeve 46. An opposite end of the channel 54 to the magnet 52 is open to allow a part of the mounting bracket 36 to be inserted. A chamfer 62 is provided to create a lead-in feature which helps to guide the components together during use. With reference to Figure 2, the sleeve 46 is attached to the body of the battery case 34 with the magnet 52 positioned toward the first end, and the open end of the channel 54 at a second end, opposite the first end. The outer wall of the sleeve 46 aligns with the part of the main body containing the power indicator button 40 and display 42 to help maintain the overall slim and sleek design. Figure 4 shows the mounting bracket 36 attached to a length of 25mm square steel section 64. The mounting bracket comprises two main parts. A first part 66 of the mounting bracket 36 comprises a bent steel member shaped to provide an open channel 68 dimensioned to fit snugly around the square steel section 64 where it can be secured in place by grub screws (not shown). The open channel 68 simplifies the initial positioning of the mounting bracket 36 and allows its attachment to a frame member after the frame 2 has been constructed and secured in place within a vehicle. The first part 66 of the mounting bracket 36 extends from one side of the channel 68 beyond the width / thickness of the steel section 64, and is then bent back at 90 degrees to provide a flat portion 70 to which a second part 72 of the mounting bracket by a single bolt 74. The flat portion 70 and bolt 74 are therefore offset from the square steel section 64. The second part 72 of the mounting bracket 36 is a flat piece of steel dimensioned to fit within the channel 54 in the sleeve 46 of the battery case. In the example shown the second part is 110mm in length and 30mm wide, and is formed of steel with a 4mm thickness, although it will be appreciated that other dimensions are possible to suit a larger or smaller battery case. A rounded end 76 is provided to correspond to the rounded end of the channel 54 and the magnet 52. The use of a single screw or bolt 74 to secure the first and second parts 66,72 of the mounting bracket 36 together means that the second part 72 can be pivoted relative to the first part 66 by loosening the bolt 74. It will be understood that the square steel section 64 shown in Figure 4 could be a part of a frame member 10,20,22,24,26 from the mounting frame 2 of Figure 1. In particular, the square steel section 64 could be a part of the first or second diagonal member 22,24. As already discussed, the diagonal members 22,24 are typically less obstructed and thus suitable for mounting a bracket. However, since the angle of diagonal members can vary between installations, a common / fixed attachment is unsuitable, because it could not then be guaranteed that the battery case 34 would sit vertically on the second part 72 of the mounting bracket 36. A vertical mounting of the battery case 34 is an important safety concern. Sudden acceleration or deceleration forces experienced during a crash could cause the battery case 34 to detach from the mounting bracket 36, particularly since there is no physical catch or latch locking the battery case 34 onto the mounting bracket 36. Ensuring a vertical mounting helps to ensure that battery pack remains securely in place, and even if detached avoids the heavy battery pack being thrown towards the driver or other vehicle occupants in such circumstances. The single screw or bolt 74 allows the second part 72 of the mounting bracket 36 to rotate relative to the first part 66, either before or after installation, and then be fixed at a desired angle. This ensures that the second part 72 of the mounting bracket 36 can always be aligned vertically, regardless of where on a hoist mounting frame 2 the first part 66 of the mounting bracket 36 is attached. The screw / bolt 74 provides a full range of movement from +90° to -90°, meaning that mounting to vertical fame members is also a possibility. This provides maximum freedom when locating the mounting bracket 36, ensuring that there will always be a location that suits, regardless of the A frame design. Figure 5 shows a first configuration of the battery case 34 attached to the mounting bracket 36. As shown in Figure 5, the length of steel section 64 is substantially horizontal, so the first and second parts 66,72 of the mounting bracket 36 are aligned, and the battery case 34 is positioned perpendicular to the length of steel section 64. The cross section of Figure 5A shows that the offset provided by the first part 66 of the mounting bracket 36 means that the thickness of the battery case 34 is aligned with the steel section 64. As a result, the battery case 34 as a whole is, in use, largely flush with a mounting frame 2 and does not extend into the load space of the vehicle. The flush mounting also helps to ensure that the actuator, which rotates on the mounting frame 2, does not clash with the battery during use. The slim design of the battery case 34 discussed above is also of benefit here. Figure 5A also illustrates the lead-in chamfer 62 at the open end of the channel 54 shown in Figure 3, and the location of the magnet 52 at the other end of the channel 54. The lead-in chamfer 62 helps to guide the second part 72 of the mounting bracket 36 into the channel 54, simplifying mounting of the battery case 34 to the mounting bracket 36. The magnet 52 then attracts the steel of the second part 72 to help ensure that the battery case 34 is fully engaged with the mounting bracket 36, and then retains them securely together in use. The use of a magnet 52 rather than a physical clip / latch or similar is beneficial because it maintains the battery case 34 in position and avoids unwelcome rattling during transit, but does not require a user to manipulate any physical clip or similar mechanism in order to release or remove the battery case 34 from the mounting bracket 36. A user simply has to overcome the magnetic force and move / slide the battery case 34 along the second part 72 of the mounting bracket 36. The lack of any manipulation is particularly significant for users with low dexterity. An alternative configuration of the battery case 34 and mounting bracket 36 is shown in Figure 6. In the alternative configuration, the length of steel section 64 is angled at 45°. The mounting bracket 36 nonetheless maintains the battery case 34 in a vertical orientation because the 45° angle now seen between parts 66,72 of the mounting bracket 36 compensates for the angle of the steel section 64. In the majority of situations, the battery case 34 will be mounted to frame members that are substantially horizontal or at around 45°. However, the mounting bracket 36 allows for any deviation from the angles to be easily accommodated, and even allows freedom to potentially choose mounting positions on frame members far outside this range, by allowing full adjustment of the angle between parts 66,72 of the mounting bracket. As previously described, mounting bracket 36 provides a full range of movement from +90° to -90°. However, it can be seen from Figure 6 that adjusting for larger angles may risk the battery case 34 clashing with a frame member adjacent the mounting bracket 36. The simple design of the second part 72 of the mounting bracket 36 and the use of a magnet 52 rather than a latch or catch to retain the battery case 34 in place mean that the battery case 34 can be flipped from the position shown in Figure 6 and can still engage reliably with the mounting bracket 36 without compromising the security of the connection. When ‘flipped’, the same offset provided by the first part 66 of the mounting bracket 36 now ensures that the battery case 34 can bypass a frame member, allowing greater angles between the first and second parts 66,72 of the mounting bracket 36, including a 90° angle as would be needed to align the battery case 34 with a vertical frame member. In addition, mounting frames are typically mounted as close to a side of the load space as possible so as minimise lost load space. Since the battery case can be slid onto the mounting bracket either way, the battery can be positioned in the orientation that gives the best balance of an accessible but unobtrusive fitting. Various small modifications to the described embodiment would also be apparent to a skilled reader. As such, it is emphasised that the forgoing description is provided by way of example only, and is not intended to limit the scope of protection as defined with reference to the appended claims.

Claims

1. A battery mounting system comprising a battery case and a mounting bracket, the mounting bracket comprising a first part for connection to an elongate support and a second part joined to the first part via a pivot point, and the battery case comprising a sleeve for receiving the second part of the mounting bracket, the sleeve comprising an open end and a closed end opposite the open end, wherein the second part of the mounting bracket comprises a ferromagnetic material, and wherein a magnet is provided adjacent the closed end of the sleeve.

2. A battery mounting system according to claim 1, wherein the open end of the sleeve comprises a chamfered edge.

3. A battery mounting system according to claim 1 or 2, wherein the second part of the mounting bracket comprises an elongate flat plate of ferromagnetic material.

4. A battery mounting system according to any preceding claim, wherein the pivot point between the first and second parts of the mounting bracket comprises a single bolt.

5. A battery mounting system according to any preceding claim, wherein the first part of the mounting bracket comprises an open channel section shaped to receive and partly surround an elongate support.

6. A battery mounting system according to claim 5, wherein the first part of the mounting bracket is formed from a flat / sheet material bent to provide the open channel section.

7. A battery mounting system according to claim 5 or 6, wherein one side of the open channel section comprises an extended limb having a lengthgreater than the thickness of said elongate support and extending to a flat portion offset from said elongate support on which the pivot point is provided.

8. A battery mounting system according to claim 7, wherein the flat portion is provided at 90° to the extended limb.

9. A battery mounting system according to claim 7 or 8, wherein the length of the extended limb is similar to the thickness of the battery case.

10. A battery mounting system according to any preceding claim, wherein the battery case comprises a power indicator.

11. A battery mounting system according to any preceding claim, wherein the battery case is formed from a plastics material.C\J12. A battery mounting system according to claim 11, wherein the battery case is formed from polycarbonate.i—co

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