Battery assembly kit for a vehicle battery assembly
A two-stage fixing system with a compressive abutment surface and under-head seal addresses the inefficiencies of existing battery assembly seals, ensuring effective fluid prevention and adhesive curing consistency.
Patent Information
- Application Number
- GB2024011526
- Authority / Receiving Office
- GB · GB
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-08-06
- Publication Date
- 2026-02-11
AI Technical Summary
Existing methods for sealing vehicle battery assemblies are ineffective and can damage internal components, particularly due to water ingress, and often require internal sealing elements that may not provide consistent contact for adhesive curing.
A two-stage fixing system comprising a first fixing element with a receiving portion having a larger cross-sectional dimension than its attachment portion, creating an abutment surface for compressing a plate element against a crossmember, and a second fixing element with an elongate body portion, allowing for an under-head seal and consistent adhesive curing, enhancing the sealing effectiveness.
The system provides a more effective seal against fluid ingress and ensures even curing of adhesives, preventing damage to battery components and improving the assembly's structural integrity.
Smart Images

Figure 00000000_0000_ABST
Abstract
Description
TECHNICAL FIELD The present disclosure relates to a battery assembly kit for a vehicle battery assembly. Aspects of the invention relate to a battery assembly kit, a vehicle battery assembly, a vehicle sub-assembly, a vehicle, and a method of assembling a vehicle sub-assembly. BACKGROUND A vehicle can include several components, including a vehicle battery assembly and a vehicle body. During assembly of a vehicle, the vehicle battery assembly is attached to a component of the vehicle body. Both prior to and following attachment to a component of the vehicle body, it is imperative that the vehicle battery assembly is sealed, so as to prevent damage to internal components of the vehicle battery assembly from water ingress, for example. In known arrangements, sealants are provided internal to the vehicle battery assembly. However, in some instances, sealing the vehicle battery assembly in such a manner can be relatively ineffective and may damage internal components of the vehicle battery assembly. It is an aim of the present invention to address one or more of the disadvantages associated with known arrangements. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a battery assembly kit, a vehicle battery assembly, a vehicle sub-assembly, a vehicle, and a method of assembling a vehicle sub-assembly as claimed in the appended claims. According to an aspect there is provided a fixing for a vehicle battery assembly, the fixing including: a first fixing element including: an attachment portion for attaching the first fixing element to a battery frame; and a receiving portion extending from the attachment portion, wherein, at an interface between the attachment portion and the receiving portion, a cross-sectional dimension of the receiving portion is larger than a cross-sectional dimension of the attachment portion, such that the receiving portion includes an abutment surface at the interface between the receiving portion and the attachment portion; and a second fixing element for attaching a component of a vehicle body to the first fixing element, the second fixing element including an elongate body portion, the receiving portion having an opening for receiving the elongate body portion, wherein in an assembled configuration the elongate body portion is received in the opening ofthe receiving portion. According to an aspect of the present invention there is provided a battery assembly kit for a vehicle battery assembly, the battery assembly kit including: a battery frame including at least one crossmember, the at least one crossmember including a receiving hole; a plate element, the plate element including a receiving hole; a fixing including: a first fixing element including: an attachment portion for attaching the first fixing element to the battery frame; and a receiving portion extending from the attachment portion, wherein, at an interface between the attachment portion and the receiving portion, a cross-sectional dimension of the receiving portion is larger than a cross-sectional dimension of the attachment portion, such that the receiving portion includes an abutment surface at the interface between the receiving portion and the attachment portion; and a second fixing element for attaching a component of a vehicle body to the first fixing element, the second fixing element including an elongate body portion, the receiving portion having an opening for receiving the elongate body portion, wherein in an assembled configuration of the battery assembly kit: the attachment portion is received in the receiving hole of the plate element, such that the abutment surface abuts the plate element; the attachment portion is received in the receiving hole of the at least one crossmember and secured to the at least one crossmember, such that the abutment surface compresses the plate element against the at least one crossmember; and the elongate body portion is received in the opening of the receiving portion. Advantageously, the abutment surface provides a sealing surface to which a sealant can be applied. This arrangement allows an under-head seal to be created at the interface between the abutment surface and the plate element, helping seal potential fluid flow paths into the vehicle battery assembly through the joint. This under-head seal is more effective than other known sealing methods, for example, the provision of a sealing element within the interior of the vehicle battery assembly. Advantageously, the first fixing element first attaches the plate element to the underlying crossmember. In doing so, the abutment surface of the receiving portion bears against the plate element, compressing the plate element against the underlying crossmember, and ensuring consistent contact between the plate element and the crossmember. This arrangement helps ensure that the non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, can evenly cure / set, without the formation of gaps. Advantageously, the provision of a second fixing element allows the battery assembly kit to be attached to a vehicle body using the same fixing, after the non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, has cured / set. As noted above, the ‘two-stage’ fixing improves (1) the construction and sealing of the vehicle battery assembly and (2) the assembly and sealing of the vehicle battery assembly to the vehicle body. In an embodiment, the abutment surface may be at a first end of the receiving portion and the opening may be at a second end of the receiving portion, the second end being opposed to the first end. In an embodiment, the fixing may include a gasket or a friction washer, wherein in the assembled configuration the gasket or friction washer is disposable at the second end of the receiving portion between the second end of the receiving portion and the component of the vehicle body. In an embodiment, the receiving portion may be configured to receive a tool for torquing the first fixing element, and wherein in the assembled configuration the first fixing element is arranged in a torqued position, such that the attachment portion is secured to the at least one crossmember. In an embodiment, the second fixing element may be a bolt. In an embodiment, in the assembled configuration the elongate body portion may be secured to the receiving portion. In an embodiment, the attachment portion may be elongate, and wherein the abutment surface may be oriented perpendicular to a longitudinal axis of the attachment portion. In an embodiment, the attachment portion and receiving portion may be integral to one another. In an embodiment, the battery assembly kit may include an adhesive, wherein in the assembled configuration the adhesive is disposed between the plate element and the at least one crossmember. In an embodiment, the battery assembly kit may include a sealant, wherein in the assembled configuration the sealant is disposed at an interface between the abutment surface and the plate element. Advantageously, the provision of a sealant, disposed at an interface between the abutment surface of the receiving portion and the plate element, helps seal potential fluid flow paths into the vehicle battery assembly through the joint. This under-head seal is more effective than other known sealing methods, for example, the provision of a sealing element within the interior of the vehicle battery assembly. According to another aspect of the invention, there is provided a vehicle battery assembly including the battery assembly kit of the invention in the assembled configuration. According to another aspect of the invention, there is provided a vehicle sub-assembly including the vehicle battery assembly of the invention and a component of a vehicle body having a receiving hole, wherein the elongate body portion is received in the receiving hole of the component of the vehicle body. In an embodiment, the receiving portion may be sized so as to space the plate element from the component of the vehicle body by a predetermined distance. According to another aspect of the invention, there is provided a vehicle including the vehicle subassembly of the invention. According to another aspect of the invention, there is provided a method of assembling a vehicle subassembly, the method including: providing a fixing including: a first fixing element including: an attachment portion for attaching the first fixing element to a battery frame; and a receiving portion extending from the attachment portion, wherein, at an interface between the attachment portion and the receiving portion, a cross-sectional dimension of the receiving portion is larger than a cross-sectional dimension of the attachment portion, such that the receiving portion includes an abutment surface at the interface between the receiving portion and the attachment portion; and a second fixing element for attaching a component of a vehicle body to the first fixing element, the second fixing element including an elongate body portion, the receiving portion having an opening for receiving the elongate body portion, inserting the attachment portion into a receiving hole of a plate element, such that the abutment surface abuts the plate element; inserting the attachment portion into a receiving hole of a crossmember of the battery frame, wherein the attachment portion is secured to the at least one crossmember such that the abutment surface compresses the plate element against the crossmember; inserting the elongate body portion into the receiving hole of the component of the vehicle body; and inserting the elongate body portion into the opening in the receiving portion. Advantageously, the abutment surface provides a sealing surface to which a sealant can be applied. This arrangement allows an under-head seal to be created at the interface between the abutment surface and the plate element, helping seal potential fluid flow paths into the vehicle battery assembly through the joint. This under-head seal is more effective than other known sealing methods, for example, the provision of a sealing element within the interior of the vehicle battery assembly. Advantageously, the first fixing element first attaches the plate element to the underlying crossmember. In doing so, the abutment surface of the receiving portion bears against the plate element, compressing the plate element against the underlying crossmember, and ensuring consistent contact between the plate element and the crossmember. This arrangement helps ensure that the non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, can evenly cure / set, without the formation of gaps. Advantageously, the provision of a second fixing element allows the battery assembly kit to be attached to a vehicle body using the same fixing, after the non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, has cured / set. As noted above, the ‘two-stage’ fixing improves (1) the construction and sealing of the vehicle battery assembly and (2) the assembly and sealing of the vehicle battery assembly to the vehicle body. In an embodiment, the method may include providing an adhesive disposed between the plate element and the crossmember. In an embodiment, the method may include providing a sealant disposed at an interface between the abutment surface and the plate element. Advantageously, the provision of a sealant, disposed at an interface between the abutment surface of the receiving portion and the plate element, helps seal potential fluid flow paths into the vehicle battery assembly through the joint. This under-head seal is more effective than other known sealing methods, for example, the provision of a sealing element within the interior of the vehicle battery assembly, Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, byway of example only, with reference to the accompanying drawings, in which: FIG. 1 illustrates a perspective view of part of a plate element and a crossmember of a battery assembly kit for a vehicle battery assembly in accordance with an embodiment of the invention; FIG. 2 illustrates a side view of a fixing of a battery assembly kit for a vehicle battery assembly in accordance with an embodiment of the invention; FIG. 3 illustrates a perspective view of the fixing of the battery assembly kit of FIG. 2; FIG. 4 illustrates a further perspective view of the fixing of the battery assembly kit of FIG. 2; FIG. 5 illustrates a section view of the fixing of the battery assembly kit of FIG. 2; FIG. 6 illustrates a side view of a vehicle battery assembly in accordance with an embodiment of the invention, the vehicle battery assembly corresponding to a battery assembly kit in an assembled configuration and including a second fixing element; FIG. 7 illustrates a section view of the vehicle battery assembly of FIG. 6; FIG. 8 illustrates a side view of a fixing of a battery assembly kit for a vehicle battery assembly in accordance with a further embodiment of the invention; FIG. 9 illustrates a perspective view of the fixing of the battery assembly kit of FIG. 8; FIG. 10 illustrates a further perspective view of the fixing of the battery assembly kit of FIG. 8; FIG. 11 illustrates a section view of the fixing of the battery assembly kit of FIG. 8; FIG. 12 illustrates a vehicle battery assembly in accordance with an embodiment of the invention, the vehicle battery assembly corresponding to the battery assembly kit in an assembled configuration and including a battery assembly; FIG. 13 illustrates a vehicle sub-assembly in accordance with an embodiment of the invention, the vehicle sub-assembly including a vehicle battery assembly and component of a vehicle body; FIG. 14 illustrates a vehicle in accordance with an embodiment of the invention, the vehicle including a vehicle sub-assembly; and FIG. 15 illustrates a method of assembling a vehicle sub-assembly in accordance with an embodiment of the invention. DETAILED DESCRIPTION FIG. 1 to FIG. 7 illustrate a battery assembly kit 104 for a vehicle battery assembly 1202 in accordance with an embodiment of the invention. The battery assembly kit 104 includes a battery frame 106 including at least one crossmember 108. As shown in FIG. 1, in this example the at least one crossmember 108 is a single crossmember 108, although in other examples the battery frame 106 may include a number of crossmembers, for example two, three or more crossmembers. The crossmember 108 of the battery frame 106 is configured to provide structural integrity to the vehicle battery assembly 1202. The crossmember 108 may support components of the vehicle battery assembly 1202, such as battery modules (as described in relation to FIG. 13). FIG. 1 illustrates a part of the crossmember 108. In this example, the crossmember 108 of the battery assembly kit 104 is an elongate member (only a section of which is shown in FIG. 1), including a central portion 142 extending along a length of the elongate member and flanges 144 extending laterally from the central portion 142. In this example, the central portion 142 includes at least an upper tier 146 and a lowertier 148, with each ofthe tiers being connected to one another. The flanges 144 of the crossmember 108 are disposed either side ofthe upper tier 146 ofthe central portion 142, and are integral with the upper tier 146. The crossmember 108 includes at least one receiving hole 140 configured to receive a fixing 110. As shown in FIG. 1, the receiving hole 140 is disposed in a surface ofthe upper tier 146, and as shown in FIG. 6 and FIG. 7, the receiving hole 140 is configured to receive an attachment portion 116 of a first fixing element 112 of a fixing 110. In some instances, the receiving hole 140 has an internal thread. The diameter ofthe receiving hole 140 ofthe crossmember 108 substantially corresponds to, though is larger than, the diameter ofthe attachment portion 116. The battery assembly kit 104 further includes a plate element 102. The plate element 102 is configured to cover the vehicle battery assembly 1202, such that components ofthe vehicle battery assembly 1202 are protected from damage. The plate element 102 is a lid, and in some instances, the plate element 102 is thin-gauged. As shown in FIG. 1, the plate element 102 is disposed adjacent to the crossmember 108. More specifically, the plate element 102 is disposed adjacent to the surface of the upper tier 146 of the crossmember 108. The plate element 102 extends across an extent (i.e., a width and / or a length) of the crossmember 108. In some instances, the plate element 102 extends further than the extents ofthe crossmember 108, such that the plate element 102 covers further components ofthe vehicle battery assembly 1202, including battery modules and further crossmembers (as described in relation to FIG. 13). The plate element 102 includes a receiving hole 138 disposed in a surface ofthe plate element 102. As shown in FIG. 6 and FIG. 7, the receiving hole 138 ofthe plate element 102 is configured to receive the attachment portion 116 ofthe first fixing element 112 ofthe fixing 110. The diameter ofthe receiving hole 138 ofthe plate element 102 substantially corresponds to, though is larger than, the diameter of the attachment portion 116. As shown in FIG. 1, the receiving hole 138 ofthe plate element 102 aligns with the receiving hole 140 of the crossmember 108, such that a bore extends through both the plate element 102 and the crossmember 108. The battery assembly kit 104 further includes a fixing 110 including a first fixing element 112 and a second fixing element 130. FIG. 2 to FIG. 5 illustrate the first fixing element 112. The first fixing element 112 includes an attachment portion 116 for attaching the first fixing element 112 to the battery frame 106, and a receiving portion 114 for receiving the second fixing element 130 of the fixing 110. As shown in FIG. 2, in this example, the attachment portion 116 is an elongate member. As shown in FIG. 3, the attachment portion 116 is cylindrical. In other instances, the attachment portion 116 is any suitable shape for inserting through both the receiving hole 138 of the plate element 102 and the receiving hole 140 ofthe crossmember 108. The attachment portion 116 includes a frustoconical portion at a first end 120 ofthe attachment portion 116. The frustoconical portion ofthe attachment portion 116 is configured to facilitate insertion ofthe attachment portion 116 into the receiving hole 138 ofthe plate element 102 and the receiving hole 140 ofthe crossmember 108. In some instances, the attachment portion 116 is a threaded connector. As further shown in FIG. 2, the receiving portion 114 extends from the attachment portion 116. More specifically, the receiving portion 114 extends from a second end 150 ofthe attachment portion 116. In this example, the attachment portion 116 and receiving portion 114 are integral to one another. The cross-sectional dimension (e.g., the external diameter) ofthe receiving portion 114 is larger than the cross-sectional dimension (e.g., the external diameter) ofthe attachment portion 116, such that the receiving portion 114 includes an abutment surface 124 at the interface between the receiving portion 114 to the attachment portion 116. The attachment portion 116 is elongate, and the abutment surface 124 is oriented perpendicular to a longitudinal axis ofthe attachment portion 116. The abutment surface 124 is disposed at a first end 152 ofthe receiving portion 114. The external diameter ofthe receiving portion 114 is largerthan the diameter ofthe receiving hole 138 ofthe plate element 102 and the receiving hole 140 ofthe crossmember 108. Advantageously, the abutment surface 124 provides a sealing surface to which a sealant can be applied. This arrangement allows an under-head seal to be created at the interface 118 between the abutment surface 124 and the plate element 102, helping seal potential fluid flow paths into the vehicle battery assembly 1202 through the joint. The receiving portion 114 includes an opening 126 for receiving an elongate body portion 132 ofthe second fixing element 130. The opening 126 is disposed at a second end 154 ofthe receiving portion 114, the second end 154 being opposed to the first end 152 of the receiving portion 114. The opening 126 extends from the second end 154 ofthe receiving portion 114, and extends along a length ofthe first fixing element 112. As shown in FIG. 5, in this example, the opening 126 extends along the length ofthe receiving portion 114 and along at least part of a length ofthe attachment portion 116. The opening 126 substantially corresponds in shape to the elongate body portion 132 of the second fixing element 130. For example, where the elongate body portion 132 is cylindrical, the opening 126 is a cylindrical opening. The diameter of the opening 126 substantially corresponds to, though is larger than, the external diameter of the elongate body portion 132 of the second fixing element 130. In some instances, the opening 126 has an internal thread. As further shown in FIG. 5, the opening 126 includes a tool receiving portion disposed at the second end 154 of the receiving portion 114. The tool receiving portion of the opening 126 is configured to receive a tool for torquing (or rotating) the first fixing element 112 (as described in relation to FIG. 6 and FIG. 7), wherein in the assembled configuration, the first fixing element 112 is arranged in a torqued position, such that the attachment portion 116 is secured to the at least one crossmember 108. FIG. 6 and FIG. 7 illustrate the second fixing element 130 of the battery assembly kit 104. The second fixing element 130 includes an elongate body portion 132, the elongate body portion 132 configured for insertion into the opening 126 of the receiving portion 114 of the first fixing element 112. In some instances, the elongate body portion 132 is a threaded connector. The second fixing element 130 includes a head portion 134 at an end 136 of the elongate body portion 132. The head portion 134 and the elongate body portion 132 of the second fixing element 130 are integral with one another. The head portion 134 includes a tool receiving portion, the tool receiving portion configured to receive a tool for torquing (or rotating) the second fixing element 130. The second fixing element 130 may be a bolt. As shown in FIG. 6 and FIG. 7, the diameter of the head portion 134 is larger than the diameter of the elongate body portion 132, such that the head portion 134 includes an abutment surface at the interface between the head portion 134 and the elongate body portion 132. The abutment surface 124 is perpendicular to the longitudinal axis of the elongate body portion 132. Advantageously, during assembly the first fixing element 112 first attaches the plate element 102 to the underlying crossmember 108. In doing so, the abutment surface 124 of the receiving portion 114 bears against the plate element 102, compressing the plate element 102 against the underlying crossmember 108, and ensuring consistent contact between the plate element 102 and the crossmember 108. This arrangement helps ensure that any non-mechanical fixing (e.g., an adhesive), disposed between the plate element 102 and the crossmember 108, can evenly cure / set, without the formation of gaps. In addition, the provision of a second fixing element 130 allows the battery assembly kit 104 to be attached to a vehicle body 1306 using the same fixing, after the non-mechanical fixing, disposed between the plate element 102 and the crossmember 108, has cured / set. FIG. 6 and FIG. 7 further illustrate a vehicle battery assembly 1202, the vehicle battery assembly 1202 corresponding to the battery assembly kit 104 in an assembled configuration. In the assembled configuration, the attachment portion 116 is received in the receiving hole 138 of the plate element 102 such that the abutment surface 124 abuts the plate element 102. The attachment portion 116 is received in the receiving hole 140 of the crossmember 108 and secured to the crossmember 108. The elongate body portion 132 is received in the opening 126 of the receiving portion 114. As described in relation to FIG. 2 to FIG. 5, in some instances, the attachment portion 116 of the first fixing element 112 is a threaded connector and the receiving hole 140 of the crossmember 108 has an internal thread. In such an instance, in the assembled configuration, the threaded connector is connected to the internal thread, securing the attachment portion 116 to the crossmember 108. The threaded connector is connected to the internal thread by torquing (or rotating) the first fixing element 112. The first fixing element 112 is torqued (or rotated) by engaging a tool with the tool receiving portion of the opening 126. The threaded connector is, in turn, removable from the internal thread, such that the first fixing element 112 is removed from the crossmember 108. In other instances, the attachment portion 116 of the first fixing element 112 is secured to the crossmember 108 via a push-fit configuration, or by any other means known in the art. The battery assembly kit 104 may include an adhesive. In the assembled configuration, the adhesive is disposed between the plate element 102 and the crossmember 108. The plate element 102, and optionally, the crossmember 108 may be configured with grooves, ridges, or undulations for containing and / or directing the adhesive between the plate element 102 and the crossmember 108. The battery assembly kit 104 may include a sealant. In the assembled configuration, the sealant is disposed at an interface 118 between the abutment surface 812 and the plate element 102. The abutment surface 124 may be configured with grooves, ridges, or undulations for containing and / or directing the sealant at the interface 118 between the abutment surface 124 and the plate element 102. Advantageously, the provision of a sealant, disposed at an interface 118 between the abutment surface 124 of the receiving portion 114 and the plate element 102, helps seal potential fluid flow paths into the vehicle battery assembly 1202 through the joint. This under-head seal is more effective than other known sealing methods, for example, the provision of a sealing element within the interior of the vehicle battery assembly 1202. In the assembled configuration, the attachment portion 116 is secured to the crossmember 108 such that the abutment surface 124 compresses the plate element 102. In turn the plate element 102 is compressed against the crossmember 108. Compressing the components of the battery assembly kit 104, in this manner, improves the efficacy of the sealant, disposed between the abutment surface 124 and the plate element 102, and in some instances, the adhesive, disposed between the plate element 102 and the crossmember 108. In some instances, the elongate body portion 132 of the second fixing element 130 is a threaded connector and the opening 126 of the first fixing element 112 has an internal thread. In such an instance, in the assembled configuration, the threaded connector is connected to the internal thread. The threaded connector is connected to the internal thread by torquing (or rotating) the second fixing element 130. The second fixing element 130 is torqued (or rotated) by engaging a tool with the tool receiving portion of the head portion 134 of the second fixing element 130. The threaded connector is, in turn, removable from the internal thread, such that the second fixing element 130 is removed from the first fixing element 112. In other instances, the elongate body portion 132 of the second fixing element 130 is connected to the first fixing element 112 via a push-fit configuration, or by any other means known in the art. As shown in FIG. 6 and FIG. 7, in the assembled configuration, the length of the elongate body portion 132 is largerthan the length of the opening 126 ofthe first fixing element 112, such that the head portion 134 ofthe second fixing element 130 is spaced from the receiving portion 114 ofthe first fixing element 112. FIG. 8 to FIG. 11 illustrate a fixing 804 of a battery assembly kit 104 for a vehicle battery assembly 1202 in accordance with a further embodiment ofthe invention. As shown in FIG. 8 to FIG. 11, the first fixing element 802 includes an attachment portion 806 for attaching the first fixing element 802 to the battery frame 106, and a receiving portion 808 for receiving the second fixing element 130. The attachment portion 806 and the receiving portion 808 are configured in a similar manner to the attachment portion 116 and the receiving portion 114, described in relation to FIG. 2 to FIG. 5. For example, the receiving portion 808 includes an abutment surface 812 disposed at a first end 814 ofthe receiving portion 808. However, as shown in at least FIG. 11, in this example, the height ofthe receiving portion 808 is larger than the height ofthe receiving portion 114, described in relation to FIG. 2 to FIG. 5. The receiving portions 114, 808 are sized so as to space the plate element 102 from a component 1304 ofthe vehicle body 1306 by a predetermined distance (as described in relation to FIG. 13). In this way, the receiving portion 808 spaces the plate element 102 from the component 1304 ofthe vehicle body 1306 by a greater distance than the receiving portion 114, described in relation FIG. 2 to FIG. 5, and will therefore be used in positions where the required space between the plate element 102 and the component 1304 is greater. As further shown in FIG. 11, in this example, an opening 818 ofthe receiving portion 808 has a stepped profile, where the diameter ofthe opening 818 reduces along at least part ofthe length ofthe receiving portion 808. As shown in FIG. 9, in this example, the fixing 804 includes a gasket 810 (or friction washer). In the assembled configuration, the gasket 810 (or friction washer) is disposed at the second end 816 ofthe receiving portion 808, between the second end 816 ofthe receiving portion 808 and the component 1304 ofthe vehicle body 1306. The second end 816 ofthe receiving portion 808 is opposed to the first end 814 ofthe receiving portion 808 The gasket 810 (or friction washer) is configured to seal an interface between a component 1304 of a vehicle body 1306 and the vehicle battery assembly 1202 (as described in relation to FIG. 13). FIG. 12 further illustrates a vehicle battery assembly 1202 in accordance with an embodiment ofthe invention. As shown in FIG. 12, in this example, the vehicle battery assembly 1202 includes multiple battery assembly kits 104 in the assembled configuration, each battery assembly kit 104 spaced from one another across the extent of the vehicle battery assembly 1202. In other instances, the vehicle battery assembly 1202 includes a single battery assembly kit 104 in the assembled configuration. The battery assembly kit 104 may be the battery assembly kit 104 described in relation to FIG. 1 to FIG. 7. In this example, the plate element 102 of the battery assembly kit 104 covers the extent (i.e., the width and / or the length) of the vehicle battery assembly 1202. The crossmembers 108 (indicated in a dashed line) are disposed inwardly of the plate element 102, as described in relation to FIG. 1. The vehicle battery assembly 1202 may include further components, including battery modules 1204. The battery modules 1204 are disposed inwardly of the plate element 102 of the battery assembly kit 104. The battery modules 1204 may include any of cells, coolant circuits, or battery electronics. As shown in FIG. 12, the battery modules 1204 are disposed between crossmembers 108 of the battery assembly kits 104. The battery modules 1204 span between crossmembers 108 of the battery assembly kit 104, such that battery modules 1204 are supported by crossmembers 108. In some instances, the vehicle battery assembly 1202 may have a two-tier configuration, such that the battery modules 1204 include upper battery modules (not shown) and lower battery modules (not shown). FIG. 13 illustrates a vehicle sub-assembly 1302 in accordance with an embodiment of the invention. The vehicle sub-assembly 1302 includes a vehicle battery assembly 1202 and a component 1304 of a vehicle body 1306. The component 1304 of the vehicle body 1306 includes a receiving hole 1308. The elongate body portion 132 is received in the receiving hole 1308 of the component 1304 of the vehicle body 1306. The vehicle battery assembly 1202 may be the vehicle battery assembly 1202, described in relation to FIG. 12. In this example, the component 1304 of the vehicle body 1306 is an undercarriage of the vehicle body 1306. As shown in FIG. 13, the component 1304 of the vehicle body 1306 is disposed between the head portion 134 of the second fixing element 130 and the receiving portion 808 of the first fixing element 802. In this way, the receiving portion 114 is sized so as to space the plate element 102 from the component 1304 of the vehicle body 1306 by a predetermined distance. The component 1304 includes an upper surface 1310 and a lower surface 1312, the upper surface 1310 and the lower surface 1312 being spaced from one another. As further shown in FIG. 13, the receiving hole 1308 is configured to receive the elongate body portion 132 of the second fixing element 130. The diameter of the receiving hole 1308 of the component 1304 substantially corresponds to, though is larger than, the diameter of the elongate body portion 132. The receiving hole 1308 aligns with any of the opening 126 of the first fixing element 112, the receiving hole 138 of the plate element 102, and / or the receiving hole 140 of the crossmember 108, such that a bore extends through the component 1304 of the vehicle body 1306 and the vehicle battery assembly 1202. As described in relation to FIG. 6 and FIG. 7, the diameter of the head portion 134 of the second fixing element 130 is larger than the diameter of the elongate body portion 132. As shown in FIG. 13, the diameter of the receiving hole 1308 is configured such that the diameter of the head portion 134 is larger than the diameter of the receiving hole 1308. In this way, when the elongate body portion 132 is received in the receiving hole 1308, an abutment surface of the head portion 134 abuts an upper surface 1310 of the component 1304 of the vehicle body 1306. The abutment surface of the head portion 134 may include a sealant for sealing an interface between the abutment surface and the upper surface 1310 of the component 1304 of the vehicle body 1306. As described in relation to FIG. 8, in some instances, the fixing includes a gasket or a friction washer, the gasket or friction washer configured to seal an interface between a component 1304 of a vehicle body 1306 and the vehicle battery assembly 1202. In this example, the gasket or friction washer is configured to seal an interface between a lower surface 1312 of the component 1304 and the receiving portion 114 of the battery assembly kit 104. FIG. 14 illustrates a vehicle 1402 in accordance with an embodiment of the invention. The vehicle 1402 includes the vehicle sub-assembly 1302. The vehicle sub-assembly 1302 may be the vehicle sub-assembly 1302 described in relation to FIG. 13. The vehicle sub-assembly 1302 is configured to distribute electrical power to the vehicle 1402, enabling functions of the vehicle 1402, including: movement of the vehicle 1402, and operation of entertainment systems of the vehicle 1402. As shown in FIG. 14, in this example, the vehicle 1402 is an automobile (e.g., a car), however, the vehicle 1402 may be a boat, plane, or any other vehicle 1402 suitable to be used in conjunction with the vehicle subassembly 1302. FIG. 15 illustrates a method 1502 of assembling a vehicle sub-assembly 1302 in accordance with an embodiment of the invention. The method 1502 of assembling a vehicle sub-assembly 1302 includes a first step 1504 of providing a fixing 110 including: a first fixing element 112 including: an attachment portion 116 for attaching the first fixing element 112 to a battery frame 106; and a receiving portion 114 extending from the attachment portion 116. At an interface between the attachment portion 116 and the receiving portion 114, the cross-sectional dimension (e.g., the external diameter) of the receiving portion 114 is larger than the cross-sectional dimension (e.g., the external diameter) of the attachment portion 116, such that the receiving portion 114 includes an abutment surface 124 at the interface between the receiving portion 114 to the attachment portion 116; and a second first fixing element 112 for attaching a component 1304 of a vehicle body 1306 to the first fixing element 112, the second fixing element 130 including an elongate body portion 132, the receiving portion 114 having an opening 126 for receiving the elongate body portion 132. In some instances, the first step 1504 of the method 1502 may include providing an adhesive, and disposing the adhesive between the plate element 102 and the crossmember 108. In some instances, the first step 1504 of the method 1502 may include providing a sealant, and disposing the sealant at an interface 118 between the abutment surface 124 and the plate element 102. The method 1502 includes a further step 1506 of inserting the attachment portion 116 into a receiving hole 138 of a plate element 102, such that the abutment surface 124 abuts the plate element 102. The method 1502 includes a further step 1508 of inserting the attachment portion 116 into a receiving hole 140 of the crossmember 108 of the battery frame 106, wherein the attachment portions 116 is secured to the crossmember 108 such that the abutment surface 124 compresses the plate element 102 against the crossmember 108. In some instances, the attachment portion 116 is a threaded connector, and the receiving hole 140 of the crossmember 108 has an internal thread. The step 1508 of method 1502 may thereby include connecting the threaded connector to the internal thread by torquing (or rotating) the first fixing element 112. The method 1502 includes a further step 1510 of inserting the elongate body portion 132 into the receiving hole 1308 of the component 1304 of the vehicle body 1306. The elongate body portion 132 is inserted into the receiving hole 1308 until the head portion 134 of the second fixing element 130 abuts an upper surface 1310 of the component 1304 of the vehicle body 1306. The method 1502 includes a further step 1512 of inserting the elongate body portion 132 into the opening 126 in the receiving portion 114. In some instances, the elongate body portion 132 is a threaded connector, and the opening 126 has an internal thread. The step 1512 of method 1502 may thereby include connecting the threaded connector to the internal thread by torquing (or rotating) the second fixing element 130. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application. It would be understood by the skilled person that the battery assembly kit 104, the vehicle battery assembly 1202, the vehicle sub-assembly 1302, and the vehicle 1402 may differ from that illustrated in the figures. For example, the fixing 110, described in relation to FIG. 2 to FIG. 5, may include a gasket (or a friction washer). The gasket (or friction washer) may be disposed at a second end 154 of the receiving portion 114. As a further example, the plate element 102 may be omitted from the battery assembly kit 104, such that, in the assembled configuration, the attachment portion 116 of the first fixing element 112 is received in the receiving hole 140 of the crossmember 108.
Claims
1. A battery assembly kit for a vehicle battery assembly, the battery assembly kit comprising:a battery frame comprising at least one crossmember, the at least one crossmember comprising a receiving hole;a plate element, the plate element comprising a receiving hole;a fixing comprising:a first fixing element comprising:an attachment portion for attaching the first fixing element to the battery frame; anda receiving portion extending from the attachment portion, wherein, at an interface between the attachment portion and the receiving portion, a cross-sectional dimension of the receiving portion is larger than a cross-sectional dimension of the attachment portion, such that the receiving portion comprises an abutment surface at the interface between the receiving portion and the attachment portion; anda second fixing element for attaching a component of a vehicle body to the first fixing element, the second fixing element comprising an elongate body portion, the receiving portion having an opening for receiving the elongate body portion,wherein in an assembled configuration of the battery assembly kit:the attachment portion is received in the receiving hole of the plate element, such that the abutment surface abuts the plate element;the attachment portion is received in the receiving hole of the at least one crossmember and secured to the at least one crossmember, such that the abutment surface compresses the plate element against the at least one crossmember; andthe elongate body portion is received in the opening of the receiving portion.
2. A battery assembly kit according to claim 1, wherein the abutment surface is at a first end of the receiving portion and the opening is at a second end of the receiving portion, the second end being opposed to the first end.
3. A battery assembly kit according to claim 2, wherein the fixing comprises a gasket or a friction washer, wherein in the assembled configuration the gasket or friction washer is disposable at the second end of the receiving portion between the second end of the receiving portion and the component of the vehicle body.
4. A battery assembly kit according to any one of claims 1 to 3, wherein the receiving portion is configured to receive a tool for torquing the first fixing element, and wherein in the assembled configuration the first fixing element is arranged in a torqued position, such that the attachment portion is secured to the at least one crossmember.
5. A battery assembly kit according to any one of claims 1 to 4, wherein the second fixing element is a bolt.
6. A battery assembly kit according to any one of claims 1 to 5, wherein in the assembled configuration the elongate body portion is secured to the receiving portion.
7. A battery assembly kit according to any one of claims 1 to 6, wherein the attachment portion is elongate, and wherein the abutment surface is oriented perpendicular to a longitudinal axis of the attachment portion.
8. A battery assembly kit according to any one of claims 1 to 7, wherein the attachment portion and receiving portion are integral to one another.
9. A battery assembly kit according to any one of claims 1 to 8, wherein the battery assembly kit comprises an adhesive, wherein in the assembled configuration the adhesive is disposed between the plate element and the at least one crossmember.
10. A battery assembly kit according to any one of claims 1 to 9, wherein the battery assembly kit comprises a sealant, wherein in the assembled configuration the sealant is disposed at an interface between the abutment surface and the plate element.
11. A vehicle battery assembly comprising the battery assembly kit of any one of claims 1 to 10 in the assembled configuration.
12. A vehicle sub-assembly, the vehicle sub-assembly comprising:the vehicle battery assembly of claim 11; anda component of a vehicle body having a receiving hole, wherein the elongate body portion is received through the receiving hole of the component of the vehicle body.
13. A vehicle sub-assembly according to claim 12, wherein the receiving portion is sized so as to space the plate element from the component of the vehicle body by a predetermined distance.
14. A vehicle comprising the vehicle sub-assembly according to claim 12 or 13.
15. A method of assembling a vehicle sub-assembly, the method comprising:providing a fixing comprising:a first fixing element comprising:an attachment portion for attaching the first fixing element to a battery frame; and a receiving portion extending from the attachment portion, wherein, at an interface between the attachment portion and the receiving portion, a cross-sectional dimension of the receiving portion is larger than a cross-sectional dimension of the attachment portion, such that the receiving portion comprises an abutment surface at the interface between the receiving portion and the attachment portion; anda second fixing element for attaching a component of a vehicle body to the first fixing element, the second fixing element comprising an elongate body portion, the receiving portion having an opening for receiving the elongate body portion, inserting the attachment portion into a receiving hole of a plate element, such that the abutment5 surface abuts the plate element;inserting the attachment portion into a receiving hole of a crossmember of the battery frame, wherein the attachment portion is secured to the at least one crossmember such that the abutment surface compresses the plate element against the crossmember;inserting the elongate body portion into the receiving hole of the component of the vehicle body;10 andinserting the elongate body portion into the opening in the receiving portion.17
Citation Information
Patent Citations
Battery case structure for vehicle
CN111341955A
Battery pack and vehicle with same
CN215911514U
Vehicle body structure
US11813935B2