Battery assembly kit for a vehicle battery assembly

The fixing system with an elongate member and flange compresses the plate element against the crossmember, addressing adhesive detachment issues and enabling secure, late-stage attachment and removal of components, while providing an effective seal, thus improving assembly efficiency and fluid prevention.

GB2643750APending Publication Date: 2026-03-04JAGUAR LAND ROVER LTD
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Patent Information

Authority / Receiving Office
GB · GB
Patent Type
Applications
Current Assignee / Owner
Filing Date
2024-08-30
Publication Date
2026-03-04

AI Technical Summary

Technical Problem

Existing vehicle battery assembly methods face issues with non-mechanical fixings, such as adhesives, detaching or deforming during assembly stages, leading to gaps and complicating the assembly process, and there is a need for secure and efficient attachment of auxiliary components without compromising the adhesive bond.

Method used

A fixing system with an elongate member having a first and second attachment portion and a flange that compresses the plate element against the crossmember, ensuring even curing of adhesives and allowing auxiliary components to be attached and removed without disturbing the adhesive bond, featuring threaded engagement for secure joints and a sealing surface for fluid prevention.

Benefits of technology

Ensures consistent contact for adhesive curing, allows late-stage attachment and removal of auxiliary components, and provides an effective under-head seal, enhancing assembly security and fluid prevention.

✦ Generated by Eureka AI based on patent content.

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Abstract

A vehicle battery assembly kit 128 comprising a frame 122 having a crossmember 120 with a hole (Fig. 3, 152); a plate 126 with a hole (Fig. 3, 150); a fixing 102 comprising an elongate member 104 with
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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, and a method of assembling a battery assembly kit for a vehicle battery assembly. BACKGROUND A vehicle battery assembly is configured to house and support one or more components of the vehicle battery assembly. The vehicle battery assembly may include a battery frame including at least one crossmember, a housing within which the battery frame is housed, a lid or plate element, and auxiliary components (e.g., a battery electricity module or a high voltage junction box). In a first stage of assembling the vehicle battery assembly, the plate element may be attached to the crossmembers using a non-mechanical fixing (e.g., an adhesive). In a second stage of assembling the vehicle battery assembly, the auxiliary components may be attached to the crossmembers of the battery frame, and optionally the plate element, using a mechanical fixing. Attaching the auxiliary components to the crossmembers, in this way, compresses the plate element against the crossmember, enabling the non-mechanical fixing, disposed between the plate element and the crossmember, to cure / set. In an absence of compression between the plate element and crossmember, during the first stage of assembling the vehicle battery assembly, it is desirable to ensure the non-mechanical fixing is secure, prior to the second stage of assembling the vehicle battery assembly, to help avoid issues, for example, arising from the plate element and the crossmembers detaching from one another, deforming the plate element and / or complicating the second stage of assembling 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, and a method of assembling a battery assembly kit for a vehicle battery assembly, as claimed in the appended claims. According to an aspect there is provided a fixing for a vehicle battery assembly, the fixing including: an elongate member including: a first attachment portion for coupling a plate element to a battery frame; and a second attachment portion for coupling an auxiliary component of the vehicle battery assembly to the battery frame; and a flange disposed between the first attachment portion and the second attachment portion, wherein the flange includes an abutment surface adjoining the flange to the first attachment portion, wherein the abutment surface is configured to abut the plate element, in use. 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: an elongate member including: a first attachment portion for coupling the plate element to the at least one crossmember; and a second attachment portion for coupling an auxiliary component of the vehicle battery assembly to the battery frame; and a flange disposed between the first attachment portion and the second attachment portion, wherein the flange includes an abutment surface, wherein in an assembled configuration of the battery assembly kit: the plate element is disposed adjacent to the at least one crossmember; the first attachment portion is received in the receiving hole of the plate element, such that the abutment surface abuts the plate element; and the first 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. Advantageously, the fixing first attaches the plate element to the underlying crossmember. In doing so, the abutment surface of the flange 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 any nonmechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, can evenly cure / set without the formation of gaps. This arrangement also allows the use of a quick curing adhesive. Advantageously, the provision of the second attachment portion of the fixing allows auxiliary components of the vehicle battery assembly to be attached to the crossmembers of the battery frame, and optionally, the plate element, after the non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, has cured / set. In this manner, the auxiliary component(s) can be attached to the crossmembers without compromising any non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember. This arrangement allows the auxiliary component to be attached to the crossmembers and / or plate element at a later stage of assembling the vehicle battery assembly. Advantageously, the provision of the second attachment portion of the fixing also allows the auxiliary component of the vehicle battery assembly to be removed from the crossmembers of the battery frame, and optionally, the plate element without compromising any non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember. For example, the auxiliary component can be removed during servicing of the vehicle battery assembly. Advantageously, the abutment surface of the flange provides a sealing surface to which a sealant can be applied. This arrangement allows for an under-head seal to be created at an interface between the fixing and the plate element, helping seal potential fluid flow paths into the vehicle battery assembly. In an embodiment, one or more of the first attachment portion and second attachment portion may be threaded. Advantageously, the threaded first attachment portions and second attachment portions ensure a secure joint is provided between the fixing and the crossmember, and the fixing and the auxiliary component of vehicle battery assembly, respectively. That is, one or more of the first attachment portions and the second attachment portions can be engaged with the crossmember and the auxiliary component, respectively. Advantageously, the use of a threaded engagement portion provides control over the applied torsion, during assembly. In this manner, during assembly, the fixing (or a retainer member coupled thereto) can be rotated until the plate element is suitably engaged with the at least one crossmember, such that the plate element and the crossmember may be adhered to one another. In an embodiment, the battery assembly kit may include a first retainer member, wherein in the assembled configuration the first retainer member secures the first attachment portion to the at least one crossmember. In an embodiment, the first retainer member is disposed on the at least one crossmember. In an embodiment, the second attachment portion may include a tool receiving portion extending from an end of the second attachment portion, the tool receiving portion may be configured to receive a tool for torquing the fixing, wherein in the assembled configuration, the fixing is arranged in a torqued position, such that the first attachment portion is secured to the at least one crossmember. In an embodiment, the battery assembly kit may include an auxiliary component, wherein the auxiliary component may include a receiving hole, wherein in the assembled configuration the second attachment portion is received in the receiving hole of the auxiliary component. Advantageously, the provision of the second attachment portion of the fixing allows the auxiliary component of the vehicle battery assembly to be attached to the crossmembers of the battery frame, and optionally, the plate element after a nonmechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, has cured / set. Advantageously, the provision of the second attachment portion of the fixing also allows the auxiliary component to be removed from the crossmembers of the battery frame, and optionally, the plate element, without compromising the non-mechanical fixing (e.g., an adhesive) disposed between the plate element and the crossmember. For example, the auxiliary component can be removed during servicing of the vehicle battery assembly. In an embodiment, the auxiliary component may be a battery electronics module or a high voltage junction box. In an embodiment, the battery assembly kit may include a second retainer member, wherein in the assembled configuration the second retainer member is connected to the second attachment portion of the elongate member to inhibit removal of the auxiliary component from the battery frame. In an embodiment, the first retainer member and / or the second retainer member may be a nut or a tapped hole. In an embodiment, a diameter of the flange may be larger than a diameter of the receiving hole of the at least one crossmember and the diameter of the receiving hole of plate element. In an embodiment, the flange may be annular and may extend about a circumference of the elongate member. In an embodiment, the flange may be integral with the elongate member. 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 of the flange and the plate element. Advantageously, the provision of a sealant, disposed at the interface between the abutment surface of the flange and the plate element, helps seal potential fluid flow paths into the vehicle battery assembly. This under-head seal may be more effective than other sealing methods, for example, the provision of a sealing element disposed 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 including the vehicle battery assembly of the invention. According to another aspect of the invention, there is provided a method of assembling a battery assembly kit for a vehicle battery assembly, the method including: fixing a plate element to at least one crossmember of a battery frame, wherein fixing the plate element to the at least one crossmember includes: providing a fixing including: an elongate member including: a first attachment portion for coupling the plate element to the at least one crossmember; and a second attachment portion for coupling an auxiliary component of the vehicle battery assembly to the battery frame; and a flange disposed between the first attachment portion and the second attachment portion, wherein the flange includes an abutment surface; inserting the first attachment portion of the elongate member into a receiving hole of the plate element, such that the abutment surface abuts the plate element; and inserting the first attachment portion into a receiving hole of the at least one crossmember and securing the first attachment portion to the at least one crossmember, such that the abutment surface compresses the plate element against the at least one crossmember. Advantageously, the fixing first attaches the plate element to the underlying crossmember. In doing so, the abutment surface of the flange 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 any nonmechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, can evenly cure / set without the formation of gaps. This arrangement also allows the use of a quick curing adhesive. Advantageously, the provision of the second attachment portion of the fixing allows auxiliary components of the vehicle battery assembly to be attached to the crossmembers of the battery frame, and optionally, the plate element, after the non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, has cured / set. In this manner, the auxiliary component(s) can be attached to the crossmembers without compromising any non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember. This arrangement allows the auxiliary component to be attached to the crossmembers and / or plate element at a later stage of assembling the vehicle battery assembly. Advantageously, the provision of the second attachment portion of the fixing also allows the auxiliary component of the vehicle battery assembly to be removed from the crossmembers of the battery frame, and optionally, the plate element without compromising any non-mechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember. For example, the auxiliary component can be removed during servicing of the vehicle battery assembly. Advantageously, the abutment surface of the flange provides a sealing surface to which a sealant can be applied. This arrangement allows for an under-head seal to be created at an interface between the fixing and the plate element, helping seal potential fluid flow paths into the vehicle battery assembly. In an embodiment, the method may include providing an adhesive disposed between the plate element and the at least one crossmember. In an embodiment, the method may include providing a sealant disposed at an interface between the abutment surface of the flange and the plate element. Advantageously, the provision of a sealant, disposed at the interface between the abutment surface of the flange and the plate element, helps seal potential fluid flow paths into the vehicle battery assembly. This under-head seal may be more effective than other sealing methods, for example, the provision of a sealing element disposed within the interior of the vehicle battery assembly. In an embodiment, the method may include inserting the second attachment portion into a receiving hole of an auxiliary component of the vehicle battery assembly. Advantageously, the provision of the second attachment portion of the fixing allows the auxiliary component of the vehicle battery assembly to be attached to the crossmembers of the battery frame, and optionally, the plate element after a nonmechanical fixing (e.g., an adhesive), disposed between the plate element and the crossmember, has cured / set. Advantageously, the provision of the second attachment portion of the fixing also allows the auxiliary component to be removed from the crossmembers of the battery frame, and optionally, the plate element, without compromising the non-mechanical fixing (e.g., an adhesive) disposed between the plate element and the crossmember. For example, the auxiliary component can be removed during servicing 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, by way of example only, with reference to the accompanying drawings, in which: FIG. 1 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. 2 illustrates a perspective view of the fixing of the battery assembly kit of FIG. 1; FIG. 3 illustrates a perspective view of part of a crossmember of a battery frame and a plate element of the battery assembly kit; FIG. 4 illustrates a perspective view of part of the fixing of FIGs. 1 and 2 and the crossmember of FIG. 3 in an assembled configuration; FIG. 5 illustrates a perspective view of part of an auxiliary component of the vehicle battery assembly; FIG. 6 illustrates a side view of a vehicle battery assembly an assembled configuration and including the auxiliary component of FilG. 5, a first retainer member, and a second retainer member; FIG. 7 illustrates a section view of the vehicle battery assembly of FIG. 6; FIG. 8 illustrates a plan view of a vehicle battery; FIG. 9 illustrates a perspective view of a vehicle including a vehicle battery assembly; and FIG. 10 illustrates a method of assembling a vehicle battery assembly. DETAILED DESCRIPTION FIG. 1 to FIG. 7 illustrate elements of a battery assembly kit 128 for a vehicle battery assembly 802 (as shown in FIG. 8) in accordance with an embodiment of the invention. The battery assembly kit 128 for a vehicle battery assembly 802 includes a battery frame 122 including at least one crossmember 120. The, or each, crossmember 120 of the battery frame 122 may be configured to provide structural integrity to the vehicle battery assembly 802. The crossmember 120 may also support components of the vehicle battery assembly 802, such as battery modules 806 (as described in relation to FIG. 8). The battery frame 122 may include any number of crossmembers 120, depending on the structural requirements of the battery frame 122, for example, one, two or more crossmembers. In this example, FIG. 3 shows part of a single crossmember 120. FIG. 3 illustrates a part of the crossmember 120. The crossmember 120 of the battery assembly kit 128 may be an elongate member (only a section of which is shown in FIG. 3), including a central portion 148 extending along a length of the elongate member and flanges 144 extending laterally from the central portion 148. The central portion 148 includes at least an upper tier 142 and a lower tier 146, where each of the tiers are connected to one another. The flanges 144 of the crossmember 120 are disposed either side of the upper tier 142 of the central portion 148, and are integral with the upper tier 142. The upper tier 142 is not round, as illustrated in FIG 3, but extends it its illustrated plane in two dimensions, The crossmember 120 includes a receiving hole 152 for receiving a fixing. As shown in FIG. 3, the receiving hole 152 is disposed in a surface of the upper tier 142. There may be any number of receiving holes 152 disposed along the length of the crossmember 120, depending on the required number of fixing points. The battery assembly kit 128 includes a thin plate element 126. In this example, the plate element 126 of the battery assembly kit 128, like the upper tier 142 of the cross member, is not necessarily round as illustrated in FIG.3, but may be configured to cover the entire vehicle battery assembly 802, (as described in relation to FIG. 8) such that components of the vehicle battery assembly 802 are protected from damage. Indeed, the plate element 126 may constitute a lid or cover, and in some instances, the plate element 126 is thin-gauged. The plate element 126 includes a receiving hole 150 for receiving a fixing. As shown in FIG. 3 and FIG. 4, the plate element 126 is disposed adjacent to the crossmember 120. More specifically, the plate element 126 is disposed adjacent to the surface of the upper tier 142 of the crossmember 120. The plate element 126 may extend across an extent (i.e., a width and / or a length) of the crossmember 120. In some instances, the plate element 126 may extend further than the extents of the crossmember 120, such that the plate element 126 covers further components of the vehicle battery assembly 802, including battery modules 806 and further crossmembers 804 (as described in relation to FIG. 8). The battery assembly kit 128 includes a fixing 102. FIG. 1 and FIG. 2 illustrate the fixing 102 of the battery assembly kit 128. The fixing includes an elongate member 104. The elongate member 104 includes a first attachment portion 106 for coupling the plate element 126 to the crossmember 120. The first attachment portion 106 is positioned at a first end of the elongate member 104. The elongate member 104 includes a second attachment portion 108 for coupling an auxiliary component 116 of a vehicle battery assembly 802 to the battery frame 122. The second attachment portion 108 is positioned at a second end of the elongate member 104. The elongate member 104 includes a flange 110 disposed between the first attachment portion 106 and the second attachment portion 108. In this instance, the flange 110 is disposed at a mid-point along a length of the elongate member 104, such that the first attachment portion 106 and the second attachment portion 108 are substantially equal in length. In other instances, the flange 110 may be disposed at any point along the length of the elongate member 104, such that the first attachment portion 106 and the second attachment portion 108 are of different lengths. The flange 110 extends outwardly in a direction perpendicular to the longitudinal axis of the elongate member 104. In this example, the flange 110 is integral with the elongate member 104. As shown in FIG. 2, in particular, the flange 110 is annular and extends about a circumference of the elongate member 104. The diameter of the flange 110 is larger than the diameter of the receiving hole 152 of the crossmember 120, and the diameter of a receiving hole 150 of plate element 126 (as described in relation to FIG. 3 and FIG. 4). In other instances, the flange 110 may be discontinuous about the circumference of the elongate member 104. For example, the flange 110 may include radial portions extending from the elongate member 104. The radial portions may be spaced from one another about the elongate member 104. The flange 110 includes an abutment surface 112 adjoining the flange 110 to the first attachment portion 106. In this way, the abutment surface 112 is a lower surface of the flange 110. Advantageously, the abutment surface 112 of the flange 110 provides a sealing surface to which a sealant can be applied. This arrangement allows for an under-head seal to be created at an interface 118 between the fixing 102 and the plate element 126, helping seal potential fluid flow paths into the vehicle battery assembly 802. As shown in FIG. 1, in particular, in this example, each of the first attachment portion 106 and the second attachment portion 108 include a frustoconical portion 132, 134 (or a tapered portion) disposed at ends 138, 140 of the first attachment portion 106 and the second attachment portion 108, respectively. The frustoconical portion 132 of the first attachment portion 106 is configured to facilitate insertion of the first attachment portion 106 into the receiving hole 150 of the plate element 126 and the receiving hole 152 of the crossmember 120. The frustoconical portion 134 of the second attachment portion 108 is configured to facilitate insertion of the second attachment portion 108 into a receiving hole 154 of the auxiliary component 116 of the vehicle battery assembly 802. In this example, the second attachment portion 108 includes a tool receiving portion 136 extending from an end 138 of the second attachment portion 108. The tool receiving portion 136 of the second attachment portion 108 is configured to receive a tool for torquing (or rotating) the fixing 102 (as described in relation to FIG, 6 and FIG. 7), wherein in the assembled configuration, the fixing 102 is arranged in a torqued position, such that the first attachment portion 106 is secured to the crossmember 120. As shown in FIG. 1 and FIG. 2, an external surface of the tool receiving portion 136 may be shaped so as to correspond to the shape of the tool for torquing the fixing 102. In other examples, the tool receiving portion 136 may include a recess shaped so as to correspond to the shape of the tool for torquing the fixing 102. In some instances, one or more of the first attachment portion 106 and second attachment portion 108 may be threaded. The threaded first attachment portion 106 and threaded second attachment portion 108 may be configured to engage with a corresponding internal thread. To assemble the battery assembly kit 128, the plate element 126 is brought into engagement with the crossmember 120, and as shown in FIG. 4, the first attachment portion 106 is received in the receiving hole 150 of the plate element 126, such that the abutment surface 112 abuts the plate element 126. The first attachment portion 106 is also received in the receiving hole 152 of the crossmember 120 and secured to the crossmember 120, such that the abutment surface 112 compresses the plate element 126 against the crossmember 120. In the assembled configuration, the receiving hole 150 of the plate element 126 aligns with the receiving hole 152 of the crossmember 120, such that a continuous bore extends through both the plate element 126 and cross member 120. Advantageously, the fixing 102 first attaches the plate element 126 to the underlying crossmember 120. In doing so, the abutment surface 112 of the flange 110 bears against the plate element 126, compressing the plate element 126 against the underlying crossmember 120 and ensuring consistent contact between the plate element 126 and the crossmember 120. This arrangement helps ensure that any non-mechanical fixing (e.g., an adhesive), disposed between the plate element 126 and the crossmember 120, can evenly cure / set without the formation of gaps. This arrangement also allows the use of a quick curing adhesive. As shown in FIG. 5 to FIG. 7, the battery assembly kit 128 may further include an auxiliary component 116. The auxiliary component 116 may be a component that is configured to facilitate operating the vehicle battery assembly 802. For example, the auxiliary component 116 may be a battery electronics module ora high voltage junction box. As shown in FIG. 5, in particular, the auxiliary component 116 includes a receiving hole 154 disposed in a surface of the auxiliary component 116. For example the receiving hole 154 may be present in a lug or flange of the auxiliary component 116. In the assembled configuration, the receiving hole 154 of auxiliary component 116 aligns with the receiving hole 152 of the crossmember 120 and receiving hole 150 of the plate element 126. The diameter of the receiving hole 154 of the auxiliary component 116 may substantially correspond, though be larger than, the diameter of the second attachment portion 108. The diameter of the flange 110 of the fixing 102 is larger than the diameter of the receiving hole 154 of the auxiliary component 116. Advantageously, the provision of the second attachment portion 108 of the fixing 102 allows the auxiliary component 116 of the vehicle battery assembly 802 to be attached to the crossmembers 120 of the battery frame 122, and optionally, the plate element 126 after a non-mechanical fixing (e.g., an adhesive), disposed between the plate element 126 and the crossmember 120, has cured / set. This arrangement allows the auxiliary component 116 to be attached to the crossmember 120 and / or plate element 126 at a later stage of assembly of the vehicle battery assembly 802. Further still, the provision of the second attachment portion 108 of the fixing 102 also allows the auxiliary component 116 to be removed from the crossmembers 120 of the battery frame 122, and optionally, the plate element 126 without compromising the non-mechanical fixing (e.g., an adhesive), disposed between the plate element 126 and the crossmember 120. For example, the auxiliary component 116 can be removed during servicing of the vehicle battery assembly 802. As further shown in FIG. 6 and FIG. 7, in this example, the battery assembly kit 128 may include a first retainer member 124, wherein in the assembled configuration the first retainer member 124 secures the first attachment portion 106 to the crossmember 120. In addition, the battery assembly kit 128 may include a second retainer member 114, wherein in the assembled configuration the second retainer member 114 is connected to the second attachment portion 108 to secure the auxiliary component 116 to the battery frame 122. In this example, the first retainer member 124 is disposed on the crossmember 120. More specifically, the first retainer member 124 is disposed on an underside of the upper tier 142 of the crossmember 120. The first retainer member 124 may be integral with the crossmember 120 or, alternatively, the first retainer member 124 may be releasably connectable to the crossmember 120. The first retainer member 124 and the second retainer member 114 may be releasably connectable to the fixing 102, such that in the assembled configuration the first retainer member 124 and the second retainer member 114 are releasably connected to the fixing 102. Where the first attachment portion 106 and the second attachment portion 108 are threaded, the first retainer member 124 and the second retainer member 114 may include an internal thread. The first retainer member 124 and second retainer member 114 may be a nut or a tapped hole. In the assembled configuration, the thread of the first attachment portion 106 may be connected to the internal thread of first retainer member 124. Following insertion of the second attachment portion 108 into a receiving hole 154 of the auxiliary component 116, the thread of the second attachment portion 108 may be connected to the internal thread of the second retainer member 114. Advantageously, the threaded first attachment portion 106 and threaded second attachment portion 108 ensure a secure joint is provided between the fixing 102 and the crossmember 120, and the fixing 102 and the auxiliary component 116 of vehicle battery assembly 802, respectively. That is, the first attachment portion 106 and the second attachment portion 108 can be engaged with the crossmember 120 and the auxiliary component 116, respectively. Further still, the use of a threaded engagement portion provides control over the applied torsion, during assembly. In this manner, during assembly, the fixing 102 (or a retainer member coupled thereto) can be torqued (or rotated) until the plate element 126 is suitably engaged with the at least one crossmember 120, such that the plate element 126 and the crossmember 120 may be adhered to one another. The battery assembly kit 128 may include a sealant, wherein in the assembled configuration, the sealant is disposed at the interface 118 between the abutment surface 112 of the flange 110 and the plate element 126. The abutment surface 112 may be configured with grooves, ridges, or undulations for containing and / or directing the sealant at the interface 118 between the abutment surface 112 and the plate element 126. Advantageously, the provision of a sealant, disposed at the interface 118 between the abutment surface 112 of the flange 110 and the plate element 126, helps seal potential fluid flow paths into the vehicle battery assembly 802. This under-head seal is more effective than other sealing methods, for example, the provision of a sealing element disposed within the interior of the vehicle battery assembly 802. The battery assembly kit 128 may also include an adhesive. In the assembled configuration the adhesive is disposed between the plate element 126 and the crossmember 120. The plate element 126, and optionally, the crossmember 120 may be configured with grooves, ridges, or undulations for containing and / or directing the adhesive between the plate element 126 and the crossmember 120. When the second retainer member 114 is tightened to press against the auxiliary component 116 about its bore 154, it may press a peripheral flange of the auxiliary component against the plate element 126 and without any abutment of the auxiliary component against the flange 110 of the fixing 102. This provides a wide, stable connection of the auxiliary component 116 to the cross member 122. On the other hand, an internal flange of the auxiliary component 116 may contact the flange 110 of the fixing 102 before, or simultaneously with, the peripheral flange abutting the plate 126, whereby the pressure on the plate 126 exerted by the peripheral flange may be limited. As discussed in relation to FIG. 1 and FIG. 2, the second attachment portion 108 includes a tool receiving portion 136 extending from an end 138 of the second attachment portion 108. The tool receiving portion 136 of the second attachment portion 108 may receive a tool for torquing (or rotating) the fixing 102. Rotating of the fixing 102 facilitates connecting the thread of the first attachment portion 106 and the internal thread of the first retainer member 124. In this way, the first attachment portion 106 is secured to the crossmember 120. Alternatively, the first retainer member 124 may, itself, be rotated in respect of the first attachment portion 106, such that the thread of the first attachment portion 106 is connected to the internal thread of the first retainer member 124. Torquing (or rotating) the fixing 102 or the first retainer member 124, in this manner, compresses the first retainer member 124 against the crossmember 120 which, in turn: compresses the crossmember 120 against the plate element 126, and compresses the plate element 126 against the abutment surface 112 of the flange 110. Compressing the components of the battery assembly kit 128, in this manner, may improve the efficacy of the sealant, disposed between the abutment surface 112 and the plate element 126, and the adhesive, disposed between the plate element 126 and the crossmember 120. The second retainer member 114 may be connected to the second attachment portion 108 by disposing the second retainer member 114 on the second attachment portion 108, and in turn, torquing (or rotating) the second retainer member 114 in respect of the second attachment portion 108. Torquing (or rotating) the second retainer member 114 in this manner compresses the second retainer member 114 against the auxiliary component 116, which, in turn: compresses the auxiliary component 116 against the plate element 126, and in turn, compresses the plate element 126 against the crossmember 120. Compressing the components of the battery assembly kit 128, in this manner, may improve the efficacy of the adhesive, disposed between the plate element 126 and the crossmember 120. FIG. 8 illustrates a vehicle battery assembly 802 in accordance with an embodiment of the invention. The vehicle battery assembly 802 includes the battery assembly kit 128 in the assembled configuration. As shown in FIG. 8, in this example, the vehicle battery assembly 802 includes multiple battery assembly kits 128, each battery assembly kit 128 spaced from one another across the extent of the vehicle battery assembly 802. In other instances, the vehicle battery assembly 802 may include only one battery assembly kit 128. The plate element 126 of the battery assembly kit 128 covers the extent (i.e., width and / or length) of the vehicle battery assembly 802. The crossmembers 120 of the battery assembly kit 128 (indicated in dashed line) are disposed inwardly of the plate element 126, as described in relation to FIG. 3 and FIG. 4. The vehicle battery assembly 802 may include further crossmembers 804, which are similarly disposed inwardly of the plate element 126. The further crossmembers 804 may be connected to the plate element 126, but not coupled with the auxiliary component 116. The vehicle battery assembly 802 may include further components, including battery modules 806. The battery modules 806 are disposed inwardly of the plate element 126 of the battery assembly kit 128. The battery modules 806 may include any of cells, coolant circuits, or battery electronics. As shown in FIG. 8, the battery modules 806 may be disposed between crossmembers 120 of the battery assembly kits 128. The battery modules 806 may span between crossmembers 120, such that battery modules 806 are supported by crossmembers 120. In some instances, the vehicle battery assembly 802 may have a two-tier configuration, such that the battery modules 806 include upper battery modules (not shown) and lower battery modules (not shown). FIG. 9 illustrates a vehicle 902 in accordance with an embodiment of the invention. The vehicle 902 includes the vehicle battery assembly 802. The vehicle battery assembly 802 may be the vehicle battery assembly 802 described in relation to FIG. 8. The vehicle battery assembly 802 may be connected to a vehicle body of the vehicle 902 using mechanical fixings, or by any other means known in the art. For example, a mechanical fixing, coupling the vehicle battery assembly 802 to the vehicle body, may be connected to other receiving holes (not shown) of the plurality of receiving holes of the crossmember 120 of the battery assembly kit 128. The vehicle battery assembly 802 may be configured to distribute electrical power to the vehicle 902, enabling functions of the vehicle 902, including: movement of the vehicle 902, and operation of entertainment systems of the vehicle 902. As shown in FIG. 9, in this example, the vehicle 902 is an automobile (e.g., a car), however, the vehicle 902 may be a boat, plane, or any other vehicle 902 suitable to be used in conjunction with the vehicle battery assembly 802. FIG. 10 illustrates a method 1008 of assembling a vehicle battery assembly 802 in accordance with an embodiment of the invention. The method 1008 of assembling a vehicle battery assembly 802 includes a first step 1002 of: fixing a plate element 126 to at least one crossmember 120 of a battery frame 122. For example, the at least one crossmember 120 may be a single crossmember 120. Fixing the plate element 126 to the crossmember 120 includes: providing a fixing 102 including: an elongate member 104 including: a first attachment portion 106 for coupling the plate element 126 to the crossmember 120; and a second attachment portion 108 for coupling an auxiliary component 116 of the vehicle battery assembly 802 to the battery frame 122; and a flange 110 disposed between the first attachment portion 106 and the second attachment portion 108, wherein the flange 110 includes an abutment surface 112 adjoining the flange 110 to the first attachment portion 106. In some instances, the step 1002 of the method 1008 may further include providing an adhesive disposed between the plate element 126 and the crossmember 120. Optionally, the step 1002 of the method 1008 may further include providing a sealant disposed at an interface 118 between the abutment surface 112 of the flange 110 and the plate element 126. The method 1008 includes a further step 1004 of inserting the first attachment portion 106 of the elongate member 104 into a receiving hole 150 of the plate element 126, such that the abutment surface 112 abuts the plate element 126. The method 1008 includes a further step 1006 of inserting the first attachment portion 106 into a receiving hole 152 of the crossmember 120 and securing the first attachment portion 106 to the crossmember 120, such that the abutment surface 112 compresses the plate element 126 against the crossmember 120. In some instances, the battery assembly kit 128 includes a first retainer member 124. In such instances, the method 1008 may include the further step of connecting the first attachment portion 106 to the first retainer member 124 to inhibit removal of the fixing 102 from the battery frame 122. 5 In some instances, the method 1008 may further include the further step of providing an auxiliary component 116 of the vehicle battery assembly 802; and inserting the second attachment portion 108 into a receiving hole 154 of the auxiliary component 116 of the vehicle battery assembly 802. The auxiliary component may be a battery electronics module or a high voltage junction box. In some instances, the fixing 102 includes a second retainer member 114. In such instances, the further step of the method 1008 may include connecting the second attachment portion 108 to the second retainer member 114 to inhibit 10 removal of the auxiliary component 116 from the battery frame 122. 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 128, vehicle battery assembly 802, and vehicle 902 may differ from that illustrated in the figures. For example, the plate element 126 may be 15 omitted from the battery assembly kit 128, such that, in the assembled configuration, the first attachment portion 106 is only received in the receiving hole 152 of the crossmember 120.

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:an elongate member comprising:a first attachment portion for coupling the plate element to the at least one crossmember; anda second attachment portion for coupling an auxiliary component of the vehicle battery assembly to the battery frame; anda flange disposed between the first attachment portion and the second attachment portion, wherein the flange comprises an abutment surface,wherein in an assembled configuration of the battery assembly kit:the plate element is disposed adjacent to the at least one crossmember;the first attachment portion is received in the receiving hole of the plate element, such that the abutment surface abuts the plate element; andthe first 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.

2. A battery assembly kit according to claim 1, wherein one or more of the first attachment portion and second attachment portion is threaded.

3. A battery assembly kit according to claim 1 or 2, wherein the battery assembly kit comprises a first retainer member, wherein in the assembled configuration the first retainer member secures the first attachment portion to the at least one crossmember.

4. A battery assembly kit according to any one of claims 1 to 3, wherein the second attachment portion comprises a tool receiving portion extending from an end of the second attachment portion, the tool receiving portion configured to receive a tool for torquing the fixing, wherein in the assembled configuration the fixing is arranged in a torqued position, such that the first 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 battery assembly kit further comprises an auxiliary component, wherein the auxiliary component comprises a receiving hole, wherein in the assembled configuration the second attachment portion is received in the receiving hole of the auxiliary component.

6. A battery assembly kit according to claim 5, wherein the battery assembly kit comprises a second retainer member, wherein in the assembled configuration the second retainer member is connected to the second attachment portion of the elongate member to secure the auxiliary component to the battery frame.

7. A battery assembly kit according to any one of claims 1 to 6, wherein a diameter of the flange is larger than a diameter of the receiving hole of the at least one crossmember and the diameter of the receiving hole of plate element.

8. A battery assembly kit according to any one of claims 1 to 7, wherein the flange is annular and extends about a circumference of the elongate member.

9. A battery assembly kit according to any one of claims 1 to 8, wherein the flange is integral with the elongate member.

10. A battery assembly kit according to any one of claims 1 to 9, 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.

11. A battery assembly kit according to any one of claims 1 to 10, wherein the battery assembly kit comprises a sealant, wherein in the assembled configuration the sealant is disposed at an interface between the abutment surface of the flange and the plate element.

12. A vehicle battery assembly comprising the battery assembly kitof any one of claims 1 to 11 in the assembled configuration.

13. A vehicle comprising the vehicle battery assembly according to claim 12.

14. A method of assembling a vehicle battery assembly, the method comprising:fixing a plate element to at least one crossmember of a battery frame, wherein fixing the plate element to the at least one crossmember comprises:providing a fixing comprising:an elongate member comprising:a first attachment portion for coupling the plate element to the at least one crossmember; anda second attachment portion for coupling an auxiliary component of the vehicle battery assembly 802() to the battery frame; anda flange disposed between the first attachment portion and the second attachment portion, wherein the flange comprises an abutment surface;inserting the first attachment portion of the elongate member into a receiving hole of the plate element, such that the abutment surface abuts the plate element; andinserting the first attachment portion into a receiving hole of the at least one crossmember and securing the first attachment portion to the at least one crossmember, such that the abutment surface compresses the plate element against the at least one crossmember.

15. A method according to claim 14, wherein the method comprises inserting the second attachment portion into a receiving hole of an auxiliary component of the vehicle battery assembly.15

Citation Information

Patent Citations

  • A battery box

    CN115020898B