Connector for battery frame of vehicle

Abstract

A connector 200 for a battery frame (100, figure 1) of a vehicle comprises a side rail connection portion 201 extending in a longitudinal direction and configured to be secured to a longitudinally ext

Description

TECHNICAL FIELD The present disclosure relates to a connector for a battery frame of a vehicle. Aspects of the invention relate to a connector for a battery frame of a vehicle, a battery frame comprising a connector, a battery assembly comprising a battery frame, and a vehicle comprising a battery frame ora battery assembly. BACKGROUND A battery for an electric vehicle is typically supported in a battery frame structure provided in the vehicle. It is known to provide a battery frame comprising longitudinally extending side rails forming part of an outer perimeter of the battery frame, and a number of laterally extending battery support rails that are connected to the side rails. During use of the vehicle, the battery frame may experience relatively large forces. In some situations, a force may urge a battery support rail perpendicularly into a connected side rail. This may cause the battery support rail and / or the side rail to fracture, bend or buckle, compromising the structural integrity of the battery frame. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a connector for a battery frame of a vehicle, a battery frame comprising a connector, a battery assembly comprising a battery frame, and a vehicle comprising a battery frame or a battery assembly as claimed in the appended claims. According to an aspect of the present invention there is provided a connector for a battery frame of a vehicle, the connector comprising: a side rail connection portion extending in a first direction and configured to be secured to a side rail of the battery frame; a support rail connection portion extending in a second direction different to the first direction and configured to be secured to an end portion of a battery support rail of the battery frame; and a coupling member connected between the side rail connection portion and the support rail connection portion, wherein the coupling member extends in both of the first and second directions to transfer a force from the support rail connection portion to the side rail connection portion. Accordingly, the direction of the force transferred from the battery support rail to the side rail is changed to have a component, or a larger component, along the side rail, thereby reducing the magnitude of the force imparted directly into the side rail by the battery support rail, reducing the risk of damage to the side rail. According to an aspect of the present invention there is provided a connector for a battery frame of a vehicle, the connector comprising: a side rail connection portion extending in a longitudinal direction and configured to be secured to a longitudinally extending side rail of the battery frame; a support rail connection portion extending in a lateral direction perpendicular to the longitudinal direction and configured to be secured to an end portion of a laterally extending battery support rail of the battery frame; and a coupling member connected between the side rail connection portion and the support rail connection portion, wherein the coupling member extends in both of the lateral and longitudinal directions to transfer a force from the support rail connection portion to the longitudinally extending side rail connection portion. Accordingly, the direction of the force transferred from the battery support rail to the side rail is changed to have a component, ora larger component, parallel to the side rail, thereby reducing the magnitude of the force imparted perpendicularly into the side rail by the battery support rail, reducing the risk of damage to the side rail. According to another aspect of the present invention there is provided a battery frame of a battery assembly in a vehicle, the battery frame comprising: a side rail; a battery support rail; and a connector according to the preceding aspect connecting the battery support rail to the side rail. Accordingly, if the battery support rail is forced towards the side rail, the structural integrity of the battery frame is maintained. According to another aspect of the present invention there is provided a battery assembly comprising: a battery frame according to the preceding aspect; and one or more battery cells supported by the battery support rail. Accordingly, if the battery support rail is forced towards the side rail, the battery cells are held in place due to the structural integrity of the battery frame being maintained. According to another aspect of the present invention there is provided a vehicle comprising a battery frame, or a battery assembly, according to the above aspects. Accordingly, the vehicle can continue to operate if the battery support rail is forced towards the side rail due to the structural integrity of the battery frame being maintained. In an embodiment, the force transferred from the support rail connection portion to the side rail connection portion may comprise a lateral force. Accordingly, the risk of damage to the side rail caused by the force is reduced even if the force is perpendicular to the side rail. In an embodiment, the side rail connection portion may comprise a longitudinally extending load transfer face for transferring load to the side rail, and the force from the support rail connection portion may be transferred to the longitudinally extending load transfer face. Accordingly, load may be effectively transferred the side rail in the longitudinal direction, thereby reducing the risk of damage to the side rail. In an embodiment, the load transfer face may be adapted to spread out the force from the support rail connection portion along a part of the side rail. Accordingly, load may be transferred to the side rail over a relatively large area, thereby reducing the risk of damage to the side rail. In an embodiment, the coupling member may comprise a first wing and / or a second wing. Accordingly, the wings provide an effective structure for modifying the force transferred from the battery support rail to the side rail. In an embodiment, the first and second wings may diverge from each other in a direction from the side rail connection portion towards the support rail connection portion. Accordingly, the wings provide an effective structure for changing the direction of the force transferred from the battery support rail to the side rail, for example from lateral to longitudinal. In an embodiment, the first wing and / or the second wing may be connected to the side rail connection portion at an angle non-perpendicularto the side rail connection portion. Accordingly, the force may be transferred to the side rail in a direction having a component in the longitudinal direction. In an embodiment, the first wing may be connected between a first portion of the support rail connection portion and a first portion of the side rail connection portion. Accordingly, a structure is provided to effectively connect the first wing between the support rail connection portion and the side rail connection portion. In an embodiment, the second wing may be connected between a second portion of the support rail connection portion and a second portion of the side rail connection portion. Accordingly, a structure is provided to effectively connect the second wing between the support rail connection portion and the side rail connection portion. In an embodiment, the first portion and the second portion of the support rail connection portion may be parallel and spaced apart such that they are securable to opposing sides of the support rail. Accordingly, a structure is provided to securely connect the first and second wings to the support rail. In an embodiment, at least one of the first and second wings may have a variable thickness. Accordingly, a structure having an effective physical shape for transferring load is provided. In an embodiment, at least one of the first and second wings may comprise a reinforced portion at the area of connection to the side rail connection portion. Accordingly, a more robust structure is provided. In an embodiment, the coupling member may comprise one or more resilient members adapted to at least partly absorb the force from the support rail connection portion. Accordingly, a structure is provided in which the force from the battery support rail is at least partly absorbed such that a relatively small load is imparted to the side rail. In an embodiment, the coupling member may comprise one or more of the following: one or more flexible portions; one or more non-linear shaped portions; one or more curved portions; and one or more compressible portions. Accordingly, an effective structure is provided for transferring, spreading and / or absorbing load. In an embodiment, the battery support rail may be disposed perpendicular to the side rail. Accordingly a structure is provided in which the side rail and the battery support rail are perpendicular, increasing the overall rigidity of the structure. In an embodiment, the battery support rail and the side rail may be configured with a gap therebetween. Accordingly, a structure is provided in which some relative movement between the battery support rail and the side rail can be accommodated before the battery support rail impacts the side rail. 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 anyway 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: Figure 1 shows a battery frame for a vehicle in accordance with an embodiment of the invention; Figure 2 shows a connector for connecting a battery support rail of the battery frame of Figure 1 to a side rail of the battery frame of Figure 1; and Figure 3 shows a vehicle in accordance with an embodiment of the invention. DETAILED DESCRIPTION Figure 1 shows a battery frame 100 for a vehicle in accordance with an embodiment of the invention. Referring to Figure 1, the battery frame 100 comprises an outer perimeter 101 including side rails 103, end rails 105 and corner portions 107. The battery frame 100 also comprises a number of battery support rails 109 connected at each of their ends to respective opposite sides of the outer perimeter 101, in particular opposing side rails 103 of the battery frame 100. The battery support rails 109 are configured to support one or more battery cells (not shown). The side rails 103 are arranged in a first direction and the battery support rails 109 are arranged in a second direction. The first and second directions may be perpendicular directions. For example, the side rails 103 may be arranged in a longitudinal direction and the battery support rails 109 may be arranged in a lateral direction. The battery frame 100 and the one or more battery cells together form a battery assembly. Figure 2 shows a part of the battery frame 100 of Figure 1 in more detail. In particular, Figure 2 shows a connector 200 for connecting a battery support rail 109 of the battery frame 100 of Figure 1 to a side rail 103 of the battery frame 100. Referring to Figure 2, the connector 200 is disposed between a first end of a battery support rail 109 and a first side rail 103. The connector 200 is configured for connecting the first end of the battery support rail 109 to the first side rail 103. A similar connector may be provided at a second end of the battery support rail 109 to connect the second end of the battery support rail 109 to a second side rail at the opposite side of the battery frame 100. Yet further connectors may be provided to connect other battery support rails to the side rails. As shown in Figure 2, the battery support rail 109 is disposed perpendicularly to the side rail 103. In some circumstances, for example during impact of the vehicle containing the battery frame 100 with another vehicle or other object, the battery frame 100 may experience relatively large forces. These may include a force along the direction of the battery support rail 109 that may urge an end of the battery support rail 109 into the side rail 103 to which the battery support rail 109 is connected. This may cause the side rail 103 and / or the battery support rail 109 to fracture, bend or buckle, compromising the structural integrity of the battery frame 100. According to various embodiments of the present invention, the connector 200 is adapted to reduce or eliminate potential damage to the side rail 103 and / or the battery support rail 109, for example according to one or more of the following. In certain embodiments, the connector 200 is adapted to change a direction of the force transferred between the battery support rail 109 and the side rail 103, so that the force is transferred at least partially along a direction parallel to the side rail 103. In certain embodiments, the connector 200 is adapted to spread out the force transferred between the battery support rail 109 and the side rail 103, so that the force is transferred to the side rail 103 over a relatively large area. In certain embodiments, the connector 200 is adapted to at least partially absorb the force transferred between the battery support rail 109 and the side rail 103, so that the force experienced by the side rail 103 is relatively small. The connector 200 comprises a side rail connection portion 201, a support rail connection portion 203, and a coupling member 205. The side rail connection portion 201 is configured to be secured to the side rail 103 of the battery frame 100. The support rail connection portion 203 configured to be secured to an end portion of the battery support rail 109 of the battery frame 100. The coupling member 205 is connected between the side rail connection portion 201 and the support rail connection portion 103. Accordingly, the side rail connection portion 201 and the support rail connection portion 203 are provided to secure the connector 200 to the side rail 103 and battery support rail 109, respectively, while the coupling member 205 is provided to modify the force transferred between the battery support rail 109 and the side rail 103. As described above, the force may be modified, for example, by changing the direction of the force, spreading out the force and / or absorbing the force. The side rail connection portion 201 may comprise any suitable form. In some embodiments, if the side rail 103 extends in a first (e.g. longitudinal) direction then the side rail connection portion 201 may also extend in the first direction, although embodiments are not limited to this case. For example, the side rail connection portion 201 may comprise a longitudinally extending load transfer face (e.g. a plate) for transferring load to the side rail 103. Accordingly, the force from the support rail connection portion 203 is transferred to the longitudinally extending load transfer face. In some embodiments, the load transfer face may be adapted to spread out the force from the support rail connection portion 203 along a part of the side rail 103. For example, this may be achieved by providing the load transfer face in the form of a plate or other suitable type of extended body. The side rail connection portion 201 may be secured to the side rail 103 in any suitable manner, for example by welding or fixed using any suitable type of fastener(s) (e.g. bolts and / or screws). In some embodiments, the side rail connection portion 201 may be formed integrally with the coupling member 205. For example, the side rail connection portion 201 may be formed from one end of the coupling member 205, or may be formed from an extended portion of one end of the coupling member 205. In other embodiments, the side rail connection portion 201 may be a separate component from the coupling member 205. In this case, the side rail connection portion 201 may be secured to one end of the coupling member 205 in any suitable manner, for example by welding or fixed using any suitable type of fastener(s) (e.g. bolts and / or screws). The support rail connection portion 203 may comprise any suitable form. In some embodiments, if the battery support rail 109 extends in a second (e.g. lateral) direction different from (e.g. perpendicular to) the first direction, then the support rail connection portion 203 may also extend in the second direction, although embodiments are not limited to this case. In some embodiments, the support rail connection portion 203 may comprise one or more extended portions (e.g. plates, protrusions, flaps, and the like) configured to be secured to one end of the battery support rail 109. For example, an extended portion may be secured to a side, top, bottom and / or end face of the battery support rail 109. Figure 2 shows an example in which the extended portions comprise two flaps that are secured to respective opposite sides of one end of the battery support rail 109. The support rail connection portion 203 may be secured to the battery support rail 109 in any suitable manner, for example by welding or fixed using any suitable type of fastener(s) (e.g. bolts and / or screws). In some embodiments, the support rail connection portion 203 may be formed integrally with the coupling member 205. For example, the support rail connection portion 203 may be formed from one end of the coupling member 205, or may be formed from an extended portion of one end of the coupling member 205. In other embodiments, the support rail connection portion 203 may be a separate component from the coupling member 205. In this case, the support rail connection portion 203 may be secured to one end of the coupling member 205 in any suitable manner, for example by welding or fixed using any suitable type of fastener(s) (e.g. bolts and / or screws). As described above, the coupling member 205 is provided between the battery support rail 109 and the side rail 103 to modify a force transferred between the battery support rail 109 and the side rail 103, for example by changing the direction of the force, spreading out the force and / or absorbing the force. The coupling member 205 may be provided in any suitable form. In some embodiments, the coupling member 205 may extend in both of a first (e.g. longitudinal) direction and a second (e.g. lateral) direction to transfer a force from the support rail connection portion 203 to the side rail connection portion 201. The first and second directions may be directions in which the side rail 103 and the battery support rail 109 are oriented, respectively. In some embodiments, the coupling member 205 may comprise one or more wings that extend between the support rail connection portion 203 and the side rail connection portion 201. In the example shown in Figure 2, the coupling member 205 comprises a first wing and a second wing, although any suitable number of wings may be provided in various embodiments. The first wing may be connected between a first portion of the support rail connection portion 203 and a first portion of the side rail connection portion 201. The second wing may be connected between a second portion of the support rail connection portion 203 and a second portion of the side rail connection portion 201. As shown in Figure 2, the first portion and the second portion of the support rail connection portion 203 may be parallel and spaced apart such that they are securable to opposing sides of the battery support rail 109. The wings may diverge from each other in a direction from the side rail connection portion 201 towards the support rail connection portion 203. One or more of the wings may be connected to the side rail connection portion 201 at an angle non-perpendicular to the side rail 103. This arrangement helps to transfer the force from the battery support rail 109 to the side rail 103 in a direction including a component that is parallel to the side rail, so that the force is directed at least partly along the direction of the side rail 103. In some embodiments, at least one of the wings has a variable thickness. In some embodiments, at least one of the wings comprises a reinforced portion at the area of connection to the side rail connection portion 201 providing greater robustness. In some embodiments, the coupling member 205 comprises one or more resilient members adapted to at least partly absorb the force transferred from the support rail connection portion 203 to the side rail connection portion 201. For example, a resilient member may comprise a spring or any other suitable compressible element. In some examples, some or all of the coupling member 205 may comprise a compressible material, thereby providing a resilient member. In some examples, some or all of the coupling member 205 may be flexible, thereby providing a resilient member. In some embodiments, the coupling member 205 may comprise one or more of: one or more flexible portions; one or more non-linear shaped portions; one or more curved portions; and one or more compressible portions. In some embodiments, the battery support rail 109 and the side rail 103 may be configured with a gap therebetween. Accordingly, when the battery support rail 109 is urged towards the side rail 103 by a force, some relative movement between the battery support rail 109 and the side rail 103 is allowed before the battery support rail 109 impacts the side rail 103. In some embodiments, the coupling member 205 may be capable of absorbing some or all of the force before impact occurs, thereby reducing or eliminating the force of the impact. According to the structure described above, a load resulting from a force (e.g. a lateral force) exerted by the battery support rail 109 towards the side rail 103 is transferred to the side rail 103 via the support rail connection portion 203, coupling member 205 and side rail connection portion 201. The load may be transferred at least partly along a direction (e.g. longitudinal direction) in which the side rail 103 is disposed. The load may be spread over a relatively large area of the side rail 103. The load may be at least partially absorbed by the coupling member 205. Accordingly, the risk of the side rail 103 and / or the battery support rail 109 being damaged as a result of the force / load is reduced, helping to maintain the structural integrity of the battery frame 100. Figure 3 shows a vehicle in accordance with an embodiment of the invention. The vehicle 300 comprises a battery frame, for example the battery frame 100 shown in Figure 1. The battery frame comprises a side rail, a battery support rail and a connector, for example the side rail 103 of Figures 1 and 2, the battery support rail 5 109 of Figures 1 and 2, and the connector 200 of Figure 2. The connector 200 connects the battery support rail 109 to the side rail 103 as described above. The vehicle 300 also comprises a number of battery cells (not shown) supported by the battery frame 100. The battery frame 100 and the battery cells together form a battery assembly of the vehicle 300. 10 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.

Claims

1. A connector for a battery frame of a vehicle, the connector comprising:a side rail connection portion extending in a longitudinal direction and configured to be secured to a longitudinally extending side rail of the battery frame;a support rail connection portion extending in a lateral direction perpendicular to the longitudinal direction and configured to be secured to an end portion of a laterally extending battery support rail of the battery frame; anda coupling member connected between the side rail connection portion and the support rail connection portion,wherein the coupling member extends in both of the lateral and longitudinal directions to transfer a force from the support rail connection portion to the longitudinally extending side rail connection portion.

2. A connector according to claim 1,wherein the side rail connection portion comprises a longitudinally extending load transfer face for transferring load to the side rail, andwherein the force from the support rail connection portion is transferred to the longitudinally extending load transfer face.

3. A connector according to claim 2, wherein the load transfer face is adapted to spread out the force from the support rail connection portion over a part of the side rail.

4. A connector according to claim 1,2 or 3, wherein the coupling member comprises first and second wings that diverge from each other in a direction from the side rail connection portion towards the support rail connection portion.

5. A connector according to claim 4, wherein the first and second wings are connected to the side rail connection portion at an angle non-perpendicularto the side rail connection portion.

6. A connector according to claim 4 or 5, whereinthe first wing is connected betweena first portion of the support rail connection portion, anda first portion of the side rail connection portion; andthe second wing is connected betweena second portion of the support rail connection portion, anda second portion of the side rail connection portion,wherein the first portion and the second portion of the support rail connection portion are parallel and spaced apart such that they are securable to opposing sides of the battery support rail.

7. A connector according to claim 4, 5 or 6, wherein at least one of the first and second wings has a variable thickness.

8. A connector according to any of claims 4 to 7, wherein at least one of the first and second wings comprises a reinforced portion at the area of connection to the side rail connection portion.

9. A connector according to any preceding claim, wherein the coupling member comprises one or more resilient members adapted to at least partly absorb the force from the support rail connection portion.

10. A connector according to any preceding claim, wherein the coupling member comprises one or more of the following:one or more flexible portions;one or more non-linear shaped portions;one or more curved portions; andone or more compressible portions.

11. A battery frame of a battery assembly in a vehicle, the battery frame comprising:a side rail;a battery support rail; anda connector according to any preceding claim connecting the battery support rail to the side rail.

12. A battery frame according to claim 11, wherein the battery support rail is disposed perpendicular to the side rail.

13. A battery frame according to claim 11 or 12, wherein the battery support rail and the side rail are configured with a gap therebetween.

14. A battery assembly comprising:a battery frame according to claim 11,12 or 13; and one or more battery cells supported by the battery support rail.

15. A vehicle comprising a battery frame according to claim 11,12 or 13, or a battery assembly according to claim 14.Application No: GB2412913.2 Examiner: Dr Steven ChadwellClaims searched: 1-15Date of search: 7 February 2025Patents Act 1977Amended Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance v A 1-15 US 2023 / 0318106 Al (HASE et al.) see whole document, especially figures 1-7 X 1-15 WO 2023 / 032646 Al (KOBE STEEL LTD) see whole document, especially figures 32-36 &60-61 X 1-15 US 2021 / 0020877 Al (CHEN) see whole document, especially figures 2-6, 9 &10 X 1-3,9-15 US 2024 / 0030537 Al (SABHAPATHI et al.) see figures 2-3 &9-10, and paragraphs [0041]-[0044]Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if P Document published on or after the declared priority date but combined with one or more other documents of same category. before the filing date of this invention. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:International Classification:Subclass Subgroup Valid From HO IM 0050 / 289 01 / 01 / 2021 B60L 0050 / 64 01 / 01 / 2019 HO IM 0050 / 204 01 / 01 / 2021Subclass Subgroup Valid From HO IM 0050 / 238 01 / 01 / 2021 HO IM 0050 / 242 01 / 01 / 2021 HO IM 0050 / 244 01 / 01 / 2021 HO IM 0050 / 249 01 / 01 / 2021 HO IM 0050 / 291 01 / 01 / 2021

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