Battery mounting system

Abstract

A battery replacement assembly and a method for operating a battery replacement assembly. The assembly comprises a receiving frame and a battery block insertable into the receiving frame, and a mechanical connection mechanism between the receiving frame and the battery block. The mechanical connection mechanism includes slots and projections arranged to cooperate with each slot. Each slot and corresponding projection belongs to the receiving frame on one side and to the battery block on the other. All slots extend longitudinally parallel to a first axis from a first end to a second end, and the first end of each slot communicates with an opening parallel to a second axis perpendicular to the first axis. Each projection engages and moves within the corresponding opening and corresponding slot to insert the battery block into the receiving frame in a second direction parallel to the second axis and a first direction parallel to the first axis relative to the receiving frame, and the mechanical connection mechanism includes at least one stop mechanism for stopping the movement of the battery block in the first direction relative to the receiving frame when the projection is in a stop position within the slot. The mechanical connection mechanism further includes a retaining mechanism for holding the battery block in a direction opposite to the first direction when the projection is in a stop position within the slot. The assembly further includes an electrical connection mechanism having a first connector attached to the battery block and a second connector attached to the receiving frame. The first and second connectors are arranged to interconnect as the battery block moves in the first direction.

Description

Technical Field

[0001] The present disclosure generally relates to a battery attachment system.

Background Art

[0002] As a method to rapidly improve the use of electric devices such as electric vehicles, interest in battery replacement technology has been increasing, and many problems have arisen in the handling and operation of battery blocks that supply power to such devices. The handling and operation of battery blocks usually involve removing a depleted battery block from the device, moving the depleted battery block to a dedicated battery storage area, retrieving a charged battery block, and returning and attaching the charged battery block to the device.

Summary of the Invention

Problems to be Solved by the Invention

[0003] Since battery blocks can weigh up to several hundred kilograms, it is desirable to have a highly reliable battery block attachment system that can safely insert such charged battery blocks into electric devices.

Means for Solving the Problems

[0004] One aspect of the present disclosure relates to a battery replacement assembly. The battery replacement assembly comprises a receiving frame and a battery block insertable into the receiving frame, and a mechanical connection mechanism between the receiving frame and the battery block, the mechanical connection mechanism comprising n slots and n projections arranged to cooperate with each slot, where n is an integer and at least 2. Each slot and corresponding projection belongs to the receiving frame on one side and to the battery block on the other. All slots extend longitudinally parallel to a first axis from a first end to a second end, and the first end of each slot communicates with an opening parallel to a second axis perpendicular to the first axis. Each projection is configured to engage and move within the corresponding opening and corresponding slot in order to continuously insert the battery block into the receiving frame in a second direction parallel to the second axis and a first direction parallel to the first axis relative to the receiving frame. The mechanical connection mechanism includes at least one stop mechanism for stopping the movement of the battery block in a first direction relative to the receiving frame when the projection is in a stop position in the slot, and the mechanical connection mechanism further includes a retaining mechanism for holding the battery block in a direction opposite to the first direction when the projection is in a stop position in the slot. The battery replacement assembly also includes an electrical connection mechanism having a first connector attached to the battery block and a second connector attached to the receiving frame, the first and second connectors being arranged to interconnect as the battery block moves in the first direction.

[0005] Furthermore, the stopping mechanism may include at least one second end of the slot.

[0006] Furthermore, each slot may include a first edge that opens to a corresponding mouth at at least one first end of the slot, and the retaining mechanism may include a boss projecting from the first edge to at least one of the slots, the boss being located between at least one second end of the slot and the mouth. The boss may be located adjacent to the mouth.

[0007] Furthermore, the retaining mechanism may include a first movable element elastically biased to protrude at least partially into at least one of the slots between a first end and a second end of at least one of the slots.

[0008] Furthermore, the holding mechanism may include a second movable element that can be positioned between the battery block and the receiving frame when the battery block is inserted into the receiving frame. The second movable element may be movable in a second direction relative to the battery block between a battery holding position and a battery release position. The second movable element may be elastically biased toward the holding position in a direction opposite to the second direction.

[0009] Furthermore, the holding mechanism may include only the first movable element, only the second movable element, or a combination thereof.

[0010] Furthermore, at least two slots may have their respective second ends further extended in a third direction parallel to the second axis and opposite to the second direction, so that each projection can be further configured to move in the third direction relative to the receiving frame within at least two slots in order to insert the battery block into the receiving frame.

[0011] Furthermore, each opening may have a width parallel to the first axis, and the width may gradually decrease from the opening end of the opening to the slot.

[0012] Furthermore, n may be at least 4, and the n slots may form at least a first pair of slots and a second pair of slots, the slots of the first pair may be aligned parallel to the first axis, and the second pair may be aligned parallel to the first axis.

[0013] Furthermore, each of the first pair of slots may have its second end further extended in a third direction parallel to the second axis and opposite to the second direction.

[0014] Furthermore, the first pair of slots may be spaced apart from the second pair of slots in the first direction.

[0015] Furthermore, all slots may belong to either the receiving frame or the battery block, all protrusions may belong to the other of the receiving frame or the battery block, and all slots may extend in a first direction from a first end to a second end.

[0016] Furthermore, all slots may belong to the receiving frame, and all protrusions may belong to the battery block.

[0017] Furthermore, the receiving frame may include two frame sides extending parallel to the first axis, and the battery block may include two battery block sides extending parallel to the first axis. Slots may be formed on the frame sides, and projections may extend from the battery block sides.

[0018] Furthermore, the receiving frame may include two frame sides extending parallel to the first axis, and the battery block may include two battery block sides extending parallel to the first axis. The receiving frame may have a first crossbar fixed to the two frame sides, and the battery block may have a front side facing the first crossbar when the battery block is inserted into the receiving frame, and a first connector may be provided on the front side of the battery block, and a second connector may be provided on the first crossbar.

[0019] Furthermore, the first connector can be elastically coupled to the front of the battery block.

[0020] Furthermore, the second connector can be elastically coupled to the transverse member.

[0021] Furthermore, the receiving frame may have a second crossbar fixed to two frame sides, and the battery block may have a rear side opposite to the front side. The rear side of the battery block may face the second crossbar when the battery block is inserted into the receiving frame. The holding mechanism may include a second movable element coupled to the second crossbar. The second movable element may be positioned between the battery block and the receiving frame when the battery block is inserted into the receiving frame. The second movable element may be movable in a second direction relative to the battery block between a battery holding position and a battery release position. The second movable element may be elastically biased toward the battery holding position in a direction opposite to the second direction.

[0022] Further embodiments relate to a vehicle having a vehicle frame and a battery replacement assembly as defined above, with or without the additional features defined above. The receiving frame may be integrated with the vehicle frame, the first axis may be substantially horizontal when the vehicle is in use, and the second axis may extend substantially vertically upward when the vehicle is in use.

[0023] Further embodiments relate to a receiving frame for a battery replacement assembly as defined above, with or without the additional features defined above. The receiving frame may comprise two frame sides extending parallel to a first axis and a first crossbar fixed to the two frame sides, a second connector may be provided on the first crossbar, and slots may be formed on the frame sides.

[0024] Further embodiments relate to a battery block for a battery replacement assembly as defined above, with or without the additional features defined above. The battery block may have two battery block sides extending parallel to a first axis, and the battery block may have a first connector provided on the front of the battery block, and projections may extend from the battery block sides.

[0025] A further aspect relates to a method of operating a battery replacement assembly. The battery replacement assembly may be as defined above, regardless of the presence or absence of the additional features defined above. A method including inserting a battery block into a receiving frame by using a mechanical connection mechanism between the receiving frame and the battery block. The mechanical connection mechanism includes n slots and n protrusions arranged to cooperate with the slots respectively, where n is an integer and at least 2. Each slot and the corresponding protrusion belong to either the receiving frame or the battery block. All slots extend longitudinally parallel to a first axis from a first end to a second end, and the first end of each slot communicates with a mouth opening parallel to a second axis perpendicular to the first axis. Inserting includes engaging and moving each protrusion within the corresponding mouth opening and corresponding slot to continuously insert the battery block into the receiving frame in a second direction parallel to the second axis and a first direction parallel to the first axis with respect to the receiving frame. Inserting includes establishing an electrical connection mechanism between a first connector attached to the battery block and a second connector attached to the receiving frame, and the first connector and the second connector are arranged to interconnect when the battery block moves in the first direction. Inserting includes stopping the movement of the battery block in the first direction with respect to the receiving frame via at least one stop mechanism when the protrusion is in a stop position within the slot, and holding the battery block in a direction opposite to the first direction by a holding mechanism when the protrusion is in a stop position within the slot.

[0026] Furthermore, in the method, at least two slots may further extend their respective second ends in a third direction parallel to the second axis and opposite to the second direction, and inserting may further include moving each protrusion in the at least two slots in the third direction with respect to the receiving frame.

[0027] Furthermore, in the method, at least two slots may each extend their respective second ends further in a third direction parallel to the second axis and opposite to the second direction, and the insertion may further include moving each protrusion in a third direction with respect to the receiving frame within at least two slots.

[0028] Furthermore, in the method, inserting may include lifting the battery block in the second direction in order to engage each protrusion within a corresponding mouth opening.

[0029] Furthermore, in the method, n is at least 4, all slots belong to the receiving frame, and all protrusions belong to the battery block. The slots may form at least a first pair of slots and a second pair of slots. The first pair of slots may be aligned parallel to the first axis, and the second pair may be aligned parallel to the first axis. The first pair of slots may be spaced apart from the second pair of slots in the first direction.

[0030] In a further aspect, a method of operating a battery replacement assembly can be used with, or as part of, the battery replacement assembly as defined above, regardless of the presence or absence of the additional features defined above.

[0031] Additional application areas will become apparent from the description herein. The description and specific examples in the summary are for illustrative purposes only and are not intended to limit the scope of the present disclosure.

[0032] Here, some embodiments of the present disclosure will be described by way of example only, with reference to the accompanying drawings. The same reference numerals represent the same elements or the same type of elements in all the drawings.

Brief Description of the Drawings

[0033] [Figure 1] A simplified perspective view of a vehicle including a battery replacement assembly in an exemplary embodiment is illustrated. [Figure 2] A simplified perspective view of a battery replacement assembly in an exemplary embodiment, with the battery block positioned outside the receiving frame, is shown. [Figure 3a] A simplified perspective view of a battery replacement assembly in an exemplary embodiment, with the battery block positioned adjacent to the receiving frame, is shown. [Figure 3b] A simplified perspective view of a battery replacement assembly in an exemplary embodiment is shown, with the battery block positioned in an intermediate insertion position within the receiving frame. [Figure 3c] A simplified perspective view of a battery replacement assembly in an exemplary embodiment, with the battery block fully inserted into the receiving frame, is shown. [Figure 3d] In a simplified perspective view of the battery replacement assembly in an exemplary embodiment, with the battery block fully inserted into the receiving frame, an exemplary alternative to the assembly shown in Figure 3c is illustrated. [Figure 4a] A simplified front view of a battery replacement assembly in an exemplary embodiment is shown, with the battery block positioned outside the receiving frame. [Figure 4b] A simplified front view of a battery replacement assembly in an exemplary embodiment is shown, with the battery block positioned in the insertion position within the receiving frame. [Figure 4c] A simplified front view of the battery replacement assembly in an exemplary embodiment, with the battery block fully inserted into the receiving frame, is shown. [Figure 5a] In a simplified front view of the battery replacement assembly in an exemplary embodiment, with the battery block fully inserted into the receiving frame on one side, an exemplary alternative example of the assembly shown in Figure 4c is illustrated. [Figure 5b] A simplified front view of the assembly shown in Figure 5a for battery replacement in an exemplary embodiment, with the battery block fully inserted into the receiving frame on both sides, is shown. [Figure 6] A simplified perspective view of the battery replacement assembly, showing the details of the receiving frame with the battery block fully inserted into the receiving frame, is illustrated. [Figure 7] A simplified top view of the assembly shown in Figure 6, which is an exemplary embodiment, is shown. [Figure 8] A simplified top view of an exemplary battery block holding mechanism for holding a battery block within a receiving frame in an exemplary embodiment is shown. [Figure 9] A simplified cross-sectional perspective view AA of an exemplary battery block holding mechanism, as shown in Figure 8, is illustrated. [Figure 10] A simplified front view of a battery replacement assembly with an example of another battery block retention mechanism in an exemplary embodiment is shown. [Figure 11] A simplified front view of the assembly shown in Figure 10 is provided, in an exemplary embodiment, with the battery block fully inserted into the receiving frame but not held in place. [Figure 12] A simplified perspective view illustrates the details of the holding mechanism in Figure 10 or Figure 11 in an exemplary embodiment. [Figure 13] An exemplary flowchart illustrating a method for operating a battery replacement assembly in an exemplary embodiment is shown. [Figure 14] Figure 13 illustrates the optional steps of the method shown. [Modes for carrying out the invention]

[0034] The above overview, as well as the following detailed descriptions of specific examples, will be better understood when read in conjunction with the accompanying drawings. In this specification, elements or steps listed in the singular and beginning with the words "a" or "an" should be understood not to exclude multiple elements or steps unless such exclusion is explicitly stated. Terms such as "first," "second," and "third" are used merely as labels and are not intended to impose numerical requirements on the subject. Furthermore, unless explicitly stated to the contrary, embodiments "equipping" or "having" elements or multiple elements having a particular characteristic may include additional elements that do not possess that characteristic.

[0035] In the drawings, the same reference numeral indicates identical or similar elements unless otherwise specified. For ease of explanation and clarity, the dimensions of each element or specific parts comprising an element are exaggerated, omitted, or schematic in the drawings. Therefore, the dimensions of each component may not fully reflect their actual dimensions. Where a detailed description of a relevant known function or configuration would be deemed likely to unnecessarily obscure the essence of this disclosure, such description is omitted.

[0036] Referring here to Figure 1, which illustrates a simplified perspective view of a vehicle 1 or vehicle chassis, which may each have a vehicle frame 2 or vehicle chassis frame and a battery replacement assembly 15 as further illustrated in Figure 2. The battery replacement assembly 15 comprises a receiving frame which may have four sides 4, 6, 7, 8 and a battery block 5 which at least a portion of which is insertable into the receiving frame. The receiving frame may have a hollow contour, and the battery block 5 may have at least a portion of which is sized to fit into the hollow contour of the receiving frame. The receiving frame may be coupled to the vehicle chassis frame by one or more elastic elements 10, 3. The elastic elements may be silent blocks. The battery replacement assembly 15 has a mechanical connection mechanism between the receiving frame and the battery block 5. The mechanical connection mechanism may be configured to guide the battery block 5 within the receiving frame. The battery replacement assembly 15 has an electrical connection mechanism 9 which may be configured to electrically connect the battery block 5 to the receiving frame when the battery block 5 is inserted into the receiving frame.

[0037] One exemplary embodiment of the battery replacement assembly 15 is illustrated in a simplified perspective view in Figure 2. The battery replacement assembly 15 is shown with the battery block 5 positioned outside the receiving frame. The mechanical connection mechanism between the receiving frame and the battery block 5 may be formed by four slots 16, 18, 23, 34 in the receiving frame and four protrusions 31, 36 (only two shown) belonging to the battery block 5 and positioned to cooperate with the slots 16, 18, 23, 34, respectively. The mechanical connection mechanism may also include n slots 16, 18, 23, 34 and n protrusions 31, 36 (only two shown) positioned to cooperate with the slots 16, 18, 23, 34, respectively, where n is an integer and at least 2. Optionally, n may be at least 4 as shown in Figure 2, where the n slots 16, 18, 23, 34 form at least a first pair of slots and a second pair of slots. The first pair of slots 34, 16 may be aligned parallel to the first axis X, and the second pair of slots 18, 23 may also be aligned parallel to the first axis X. Alternatively, instead of as shown in Figure 2, the slots 16, 18, 23, 34 may be formed on the battery block 5, and the projections 31, 36 may be formed on the receiving frame. Thus, each slot 16, 18, 23, 34 and the corresponding projections 31, 36 belong to either the receiving frame or the battery block 5. In other words, all slots 16, 18, 23, 34 may belong to either the receiving frame or the battery block 5, and all projections 31, 36 may belong to either the receiving frame or the battery block 5. The slots form at least a first pair of slots and a second pair of slots, the first pair of slots aligned parallel to the first axis X, and the second pair of slots aligned parallel to the first axis X.

[0038] As shown in Figure 2, all slots 16, 18, 23, and 34 may each extend longitudinally parallel to the first axis X from a first end to a second end, and the first end of each slot communicates with openings 42, 44, and 47 parallel to the second axis Z which is perpendicular to the first axis X. When the battery replacement assembly 15 is mounted to the vehicle 1 or vehicle chassis, the receiving frame may be integrated with the vehicle frame 2 or vehicle chassis frame, the first axis X may be substantially horizontal when the vehicle is in use, and the second direction Z may extend substantially vertically upward when the vehicle is in use. The receiving frame may include two frame sides 17 and 24 extending parallel to the first axis X, and the battery block 5 may include two battery block sides 32 (only one shown) extending parallel to the first axis X. The receiving frame may have a first crossbar 21 fixed to two frame sides 17, 24, and the battery block 5 may have a front side 37 that faces the first crossbar when the battery block 5 is inserted into the receiving frame. The receiving frame may have a second crossbar 26 fixed to two frame sides 17, 24, and the battery block 5 may have a rear side 30 opposite to the front side 37. The rear side 30 of the battery block 5 may face the second crossbar 26 when the battery block 5 is inserted into the receiving frame. The battery block 5 may have a top surface 35 extending parallel to a second axis Z, and one or more edges 33 may be formed between the top surface 35 of the battery block 5 and at least one of the sides 30, 37, 32 of the battery block 5.

[0039] The battery replacement assembly 15 is further illustrated in the exemplary simplified perspective views of Figures 3a, 3b, and 3c, illustrating the continuous insertion of the battery block 5 into the receiving frame. Corresponding exemplary simplified front views to the simplified perspective views of Figures 3a, 3b, and 3c are illustrated in Figures 4a, 4b, and 4c.

[0040] Figures 3a and 4a illustrate the battery replacement assemblies 40, 90 with the battery block 5 positioned adjacent to the receiving frame. To insert the battery block 5 into the receiving frame, each projection 31, 36 engages and moves in a second direction Z1, 41 parallel to the second axis Z within the corresponding mouth openings 42, 44, 47, 91, 92, 95, 97 and the corresponding slots 45, 48, 49, 50. Each mouth may have a width parallel to the first axis X, and the width may gradually decrease from the opening end of the mouth to the slots 45, 48, 49, 50. Each slot 45, 48, 49, 50 may have an upper edge 45, 48, 49, 50 extending longitudinally parallel to the first axis X between the first and second ends of the slot 45, 48, 49, 50. The upper edge may have a surface to restrict the movement of each projection 31, 36 in the second direction Z1, 41 within the corresponding slots 45, 48, 49, 50. As shown in Figure 4a, the battery block 5 may have a first connector 94, and the receiving frame may have a second connector 96. The first connector 94 and the second connector 96 may be arranged to interconnect as the battery block moves in the first direction X1, 61, as shown in Figures 4d and 4c.

[0041] Figures 3b and 4b illustrate exemplary battery replacement assemblies 60, 100 with the battery block 5 positioned in an intermediate insertion position, in which case each projection 31, 36 is located within the corresponding slots 45, 48, 49, 50. To fully insert the battery block 5 into the receiving frame, each projection 31, 36 may be moved in a first direction X1, 61 relative to the receiving frame within the corresponding slots 45, 48, 49, 50. Each slot may have a lower edge 62, 64 opposite to the upper edge. The lower edges 62, 64 may extend longitudinally between the first and second ends 11, 112 of the slot in a direction parallel to the first axis X. The lower edges 62, 64 may have surfaces to restrict the movement of each projection 31, 36 in the direction opposite to the second direction Z1, 41 within the corresponding slots 45, 48, 49, 50.

[0042] Figures 3c and 4c illustrate illustrative diagrams of the battery replacement assemblies 70, 110 with the battery block 5 fully inserted into the receiving frame, in which the first connector 94 and the second connector 96 are connected to each other. When the projections are in the stopping positions 71, 72 in the slots 45, 48, 49, 50, movement of the battery block 5 in the first direction X1, 61 relative to the receiving frame is stopped via a stopping mechanism. The stopping mechanism may include the second ends 111, 112 of at least one of the slots 45, 48, 49, 50.

[0043] Figures 3d, 5a, and 5b show further examples 80, 120, and 130 of battery replacement assemblies with a battery block 5 fully inserted into a receiving frame. Unlike the assemblies described above illustrated in Figures 3c and 4c, the further examples 80, 120, and 130 have at least two slots 82 (only one shown) of the slots 45, 48, 49, and 50, each having a second end 120 that extends further in a third direction Z2, 81 parallel to a second axis Z and opposite to a second direction Z1, 41. To insert the battery block 5 into the receiving frame, projections 31 (only one shown) corresponding to extension slots 82 (only one shown) may move further in the third direction Z2, 81 relative to the receiving frame within at least two extension slots 82, towards their respective extended second ends 120. As already described, slots 45, 48, 49, and 50 can form at least a first pair of slots and a second pair of slots. One of the pairs may be formed by an extended slot 82, and the second pair may be formed by non-extended slots. In this specification, an extended slot refers to a slot 82 having an extended second end 120 as described above, and a non-extended slot refers to a slot that does not have an extended second end.

[0044] Furthermore, each of the first pair of extension slots 82 may have its second end further extended in a third direction Z2, 81 parallel to the second axis Z and opposite to the second direction Z1. The first pair of slots may be spaced apart from the second pair of slots in the first direction X1, 61. The extension slots 82 of the first pair may be aligned parallel to the first axis X, and the second pair of slots may also be aligned parallel to the first axis X. As shown in Figure 2, there may be a total of four slots 45, 48, 49, 50. Alternatively, there may be more than four slots 45, 48, 49, 50 in total, and more than two extension slots 82 each extending their second end 120 in a third direction Z2, 81. Figure 5b illustrates a combination of a pair of extension slots 82 and a pair of non-extension slots provided within the receiving frame, and shows a simplified front view of the battery block 5 fully inserted within the receiving frame (and thus showing only one slot of each pair). The pairs of extension slots 82 and the pairs of non-extension slots may each have portions extending longitudinally from their respective first ends aligned coaxially 134 parallel to the first axis X, as shown in Figure 2. The respective second ends 120 of the pairs of extension slots 82 and the respective second ends of the pairs of non-extension slots 111, 112 may be aligned coaxially 133 forming an angle 131 with the first axis X.

[0045] The angle 131 may fall between 0 and 40 degrees. The angle 131 may be any of the angles 1, 2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40 or more. The angle 131 may also be 2 degrees or less. One advantage of such a mechanism is that when the battery block 5 is fully inserted into the receiving frame, the projections 31, 36 can be held by the second ends 120, 11, 112 of the slots 45, 48, 49, 50, respectively. This can prevent the battery block 5 from moving along the first axis X when the vehicle 1 is in use, if the receiving frame is integrated with the vehicle frame.

[0046] The receiving frame described above, illustrated in Figure 2, may include two frame sides 17, 24 extending parallel to the first axis X. Figure 6 illustrates an example of a receiving frame 140 in detail in a simplified perspective view. As shown in Figure 6, at least one of the frame sides 17, 24, 144 may be at least partially hollow 141. Each of the sides 17, 24, 144 may have at least one inserted support member 142, 143. In Figure 6, only one of the hollow frame sides 144 is shown, the other is not shown, illustrating an example in which two support members 142, 143 may be located within the hollow of the not shown frame side. In one example, each of the frame sides 17, 24, 144 may have two inserted support members 142, 143. Each of the support members 142, 143 may be press-fitted or otherwise fixed to their respective positions within each frame side 17, 24, 144. Each of the support members 142 and 143 may be made of a block of material. Each of the support members 142 and 143 may have at least one slot therein that can be configured to slidably support at least one of the projections 31 and 36 so that it can move within at least one slot of the support member for inserting the battery block 5 into the receiving frame. The slots formed in the support members 142 and 143 may substantially correspond to the slots 45, 48, 49, and 50 provided in the receiving frame. The slots formed in the support members 142 and 143 may have a smaller width than the slots 45, 48, 49, and 50 provided in the receiving frame. Alternatively, the slots formed in the support members 142 and 143 may be the slots 45, 48, 49, and 50 provided in the receiving frame. In such a case, the receiving frame may have at least one notch provided on each of the hollow frame sides 17, 24, and 144 for arranging at least one support member 142, 143. The at least one notch may be provided in a fourth direction Y1 parallel to a third axis Y which is perpendicular to both the first axis X and the second axis Z.At least one notch may at least partially penetrate the frame sides 17, 24, and 144, so that the slots of each support member 142, 143 positioned within the notch can fully accommodate at least one of the projections 31, 36 so that it can move within at least one slot of the support member for inserting the battery block 5 into the receiving frame. Each of the support members 142, 143 may be configured to slidably support at least one of the projections 31, 36 within at least one slot formed therein. In one example illustrated in Figure 7 as a simplified top view of the battery replacement assembly 150 shown in Figure 6, four support members 158, 156, 142, and 143 may be provided, two on each of the frame sides 17, 24, and 144. However, there may be more or fewer than two support members 158, 156, 142, and 143 provided on each of the frame sides 17, 24, and 144.

[0047] The battery block 5 may have four protrusions 31, 36 (only two are shown), each of which may have substantially conical portions 151, 152, 154, 155 adjacent to and extending outward from each battery block side 153, 157 in a direction parallel to the third axis Y. As defined above, the battery block sides 153, 157 extend parallel to the first axis X. The diameters of the substantially conical portions 151, 152, 154, 155 may gradually decrease such that the diameter of the first end of the substantially conical portion 151, 152, 154, 155 is larger than the diameter of the second end of the substantially conical portion 151, 152, 154, 155 on the opposite side of the first end. The first ends of the substantially conical portions 151, 152, 154, and 155 may be adjacent to the respective battery block sides 153, 157, and the second ends of the substantially conical portions 151, 152, 154, and 155 may be further away from the respective battery block sides 153, 157 than the first ends of the substantially conical portions 151, 152, 154, and 155. The substantially conical portions 151, 152, 154, and 155 may further comprise cylindrical portions adjacent to and extending from the second ends of the substantially conical portions 151, 152, 154, and 155. The cylindrical portions may be positioned to slidably interact with the corresponding slots of the respective receiving frames. One advantage of such a mechanism is that the substantially conical portions 151, 152, 154, and 155 can provide guide supports for inserting the battery block 5 into the receiving frame. The guide support portion may be provided to guide the battery block 5 inward within the support members 158, 156, 142, 143 toward the respective slots 45, 48, 49, 50. The cylindrical portions 151, 152, 154, 155 cooperate with the corresponding slots to support and guide the movement of at least one of the projections 31, 36 so as to be slidable within that corresponding slot.

[0048] As shown in Figure 7 and as described above, the battery block 5 may have a front side 37 and a rear side 30. The front side 37 and the rear side 30 each extend parallel to the second axis Z. The front side 37 may be connected to the ends of the frame sides 17, 24, and 144, and the rear side may be connected to the end opposite to the frame sides 17, 24, and 144. The first connector 94 may be provided on the front side 37 of the battery block 5. The first connector 94 may be elastically coupled to the front side 37 of the battery block 5. The second connector 96 may be provided on the first cross member 21. The second connector 96 may be elastically coupled to the first cross member 21.

[0049] In one example illustrated in Figure 7, two of the four illustrated support members 158, 156, 141, and 143, namely support members 142 and 158, are equipped with a retaining mechanism for holding the battery block 5 in a direction opposite to the first direction X1, 61 when the projections 31, 36 are in the stopping positions 71, 72 within the slots of the support members 158, 156, 141, and 143. Alternatively, one or more of the support members 158, 156, 141, and 143 may be equipped with a retaining mechanism. Support members 142 and 158 equipped with a retaining mechanism may be aligned parallel to the first axis X, as shown in Figure 7.

[0050] Figure 8 provides a simplified top view of an exemplary battery block retaining mechanism 160 for holding a battery block 5 within a receiving frame. The retaining mechanism 160 may comprise at least one of support members 158, 156, 142, and 143, each support member housing a first movable element 164 movably mounted therein. At least one of the support members 158, 156, 142, and 143 may have a cavity within the body 161 of at least one of the support members 158, 156, 142, and 143. The first movable element 164 may be housed within the cavity 162. The cavity 162 may define at least partial movement of the first movable element 164. The first movable element 164 may move in direction 166 relative to the at least one support member 158, 156, 142, and 143 to which it is mounted. The first movable element 164 can move in a direction 166 within and relative to a cavity 162 of at least one support member 158, 156, 142, 143 to which it is mounted. The first movable element 164 can move between a retained position and a released position. The first movable element 164 can be elastically biased toward the retained position. In the retained position, the first movable element 164 can at least partially protrude into the slot of the support member in which it is housed. In the retained position, the first movable element 164 can at least partially protrude into the slot between the first and second ends of the slot. This allows the first movable element 164 to prevent the movement of each projection in at least one direction while it is in the slot in the retained position. In one example, the holding position may be set such that when each projection is fully inserted into its respective slot, the portion of the first movable element 164 that protrudes into its slot holds each projection in the stopping position, as shown in Figure 9, which illustrates a simplified cross-sectional perspective view AA of the exemplary battery block holding mechanism 170 of Figure 8. The first movable element 164 may be elastically biased toward the holding position in a direction opposite to the second direction X1, 61. The first movable element 164 may be elastically biased toward the second direction X1, 61 by an elastic member 165 which may be formed of at least one of a spring, rubber, elastomer, or any other elastic element.The first movable element 164 can move between a holding position and a release position within the support members 158, 156, 141, and 143. The guide element 163 can guide the movement of the first movable element 164 within the cavities of each of the support members 158, 156, 141, and 143.

[0051] Another example of a battery block retaining mechanism 194 for holding the battery block 206 within a receiving frame is illustrated in Figures 10 and 11. Figure 10 shows a simplified front view of the battery replacement assembly 190 with the battery block 206 fully inserted and held within the receiving frame. Furthermore, Figure 10 also illustrates an exemplary battery block moving assembly 195 for inserting the battery block 206 into the receiving frame. The battery block moving assembly 195 and its interaction with the battery block 206 may be described in Japanese Patent Application EP 3694014 A1, filed February 6, 2019, entitled “Battery Block Moving Assembly,” which is incorporated herein by reference. The battery block moving assembly 195 may have an upper surface 201 configured to support the battery block 206 thereon, and a movable pin 197 extending from the upper surface 201 and configured to move the battery block 206 along the upper surface 201 in a direction parallel to a first axis X. The upper surface 201 may include optional rollers 198, 199 configured to support a battery block so as to be able to roll thereon.

[0052] The receiving frame may be as shown and described in detail in Figure 2, and may have first cross members 21, 203, second cross members 26, 211, and two frame sides 17, 24, 205. As shown in Figures 10 and 11, the battery block holding mechanism 194 may include at least one second movable element 192 and its connecting portion 210. The second movable element 192 may be movable relative to the connecting portion 210 in a direction parallel to the second axis Z. As shown in Figures 10 and 11, the second movable element 192 may be positioned between the battery block 206 and the second cross member 211 when the battery block is inserted into the receiving frame. The second movable element 192 may be movable in a direction parallel to the second axis Z 191 between the battery block 206 holding position and the battery block 206 release position. The second movable element 192 may be elastically biased toward the battery block 206 holding position. As shown in Figure 12, the second movable element 192 may be elastically biased toward the battery block 206 holding position by at least one elastic member 231, 234 (two shown), each elastic member may be formed of at least one of a spring, rubber, elastomer, or any other elastic element.

[0053] The connecting portion 210 may be coupled to the receiving frame. More specifically, the connecting portion 210 may be coupled to the second cross member 211 of the receiving frame. The connecting portion 210 may be rigidly coupled to the receiving frame or rigidly coupled to the second cross member 211 of the receiving frame. The second movable element 192 may include a battery stop portion 209 configured to engage with the battery block 206 when the second movable element 192 is in the battery block 206 holding position and the battery block 206 is inserted into the receiving frame. The battery stop portion 209 may be configured to engage with at least one portion of the rear side surface 30 of the battery block 206, the top surface 35 of the battery block 206, or a portion of both the top surface 35 and the rear side surface 30 of the battery block 206. The battery stop portion 209 of the second movable element 192 may have a shape substantially complementary to the at least portion of the battery block 206 with which it is configured to engage. In one example shown in Figure 12, the battery stop portion 209 of the second movable element 192 may have L-shaped portions 235, 236 that are complementary to the corner portions of the substantially rectangular parallelepiped shape that form the battery block 206.

[0054] Thus, when the second movable element 192 is in the battery block 206 holding position, the battery stop portion 209 of the second movable element 192 may be configured to engage with at least a portion of the rear surface 30 to hold the battery block 206 in a direction opposite to the first direction X1,61 parallel to axis X. Advantageously, when the second movable element 192 is in the battery block 206 holding position, the battery stop portion 209 may be configured to engage with both at least a portion of the rear surface 30 of the battery block 209 and at least a portion of the top surface 35 of the battery block 209 to hold the battery block 206 in a direction opposite to the first direction X1,61 parallel to axis X and in a second direction Z1 parallel to the second axis Z.

[0055] As described in detail with respect to Figures 3c and 4c, the battery block 206 may be held in the receiving frame at one end via a stop mechanism. The stop mechanism may include a second end of at least one of the slots. The battery block 206 may then be held in the receiving frame at the opposite end via a battery stop portion 209 of the stop mechanism of the second movable element 192. More specifically, the front side 37 of the battery block 206 may be held in the receiving frame via a stop mechanism, and the rear side 30 of the battery block 206 may be held in the receiving frame via a battery stop portion 209 of the second movable element 192. In this manner, when the battery block 206 is inserted into the receiving frame, the battery block 206 can be fixed in each receiving frame in both the first direction X1, 61 and the direction opposite to the first direction X1, 61.

[0056] Referring to Figure 11, a simplified front view of the battery replacement assembly 220 is shown with the battery block 206 fully inserted into the receiving frame but not held in place. Compared to Figure 10, the second movable element 192 is shown moving in a second direction Z1, 223 to the battery block 206 release position. The second movable element 192 or its battery stop portion 209 may be configured not to engage with the battery block 206 when the second movable element 192 is in the battery block release position. The second movable element 192 may be actuated by a battery release element 194 between the battery block 206 holding position and the battery block 206 release position. The battery release element 194 may have a portion 233 shown in Figure 12, configured to apply force to one end 193 of the movable element 192 in a second direction Z1 parallel to the second axis Z. This allows the battery release element 194 to counteract the elastic bias of the second movable element 192 toward the battery block 206 holding position. In one example, the battery release element 194 may be formed by a projection 232 made of any other material, which may be made of a metal plate as shown in Figure 12, or extending in directions Z1, 223 from the upper surface 201 of the battery block moving assembly 195. When the battery block moving assembly 195 is moved toward the receiving frame in a second direction Z1, the second movable element 192 can be actuated via the battery release element 194 from the battery block 206 holding position to the battery block 206 release position. One advantage of such a mechanism is that moving the battery block moving assembly 195 toward the receiving frame in a second direction Z1 disengages the battery stop portion 209 of the second movable element 192, thereby releasing the battery block 206.

[0057] We now move to Figure 13, which illustrates an exemplary flowchart 250 of a method for operating a battery replacement assembly. The steps of this method are described with reference to the example of the battery replacement assembly described and illustrated in any one of Figures 1 to 12, but those skilled in the art will understand that this method may be performed on other systems. The steps of the flowcharts described herein are not exhaustive and may include other steps not shown. The steps described herein may be performed in an alternative order.

[0058] The operation method of the battery replacement assembly includes inserting the battery block into the receiving frame by using a mechanical connection mechanism between the receiving frame and the battery block. The mechanical connection mechanism includes n slots 16, 18, 23, 34 and n protrusions 31, 36 arranged to cooperate with the slots 16, 18, 23, 34, respectively, where n is an integer and may be at least 2. Each slot and corresponding protrusion may belong to the receiving frame on one side and to the battery blocks 5, 206 on the other side. Alternatively, n may be at least 4, in which case all slots 16, 18, 23, 34 may belong to the receiving frame and all protrusions may belong to the battery blocks 5, 206. Furthermore, the slots 16, 18, 23, 34 may form at least a first pair of slots and a second pair of slots. The slots of the first pair may be aligned parallel to a first axis X, and the slots of the second pair may be aligned parallel to the first axis X. The first pair of slots may be spaced apart from the second pair of slots in the first direction X1, 61. All slots 16, 18, 23, 34 extend longitudinally parallel to the first axis X from a first end to a second end 111, 112, respectively. The first end of each slot may communicate with openings 42, 44, 47, 91, 92, 95, 97 parallel to the second axis Z which is perpendicular to the first axis X.

[0059] Insertion of the battery block 5,206 into the receiving frame may be initiated in step 251 by engaging each projection 31, 36 within the corresponding openings 42, 44, 47, 91, 92, 95, 97. Next, in step 252, insertion proceeds by continuously moving each projection 31, 36 within the corresponding openings and slots in a second direction Z1 parallel to the second axis Z and a first direction X1, 61 parallel to the first axis X relative to the receiving frame. In step 253, an electrical connection is formed between a first connector 94 attached to the battery block 5,206 and a second connector 96, 202 attached to the receiving frame. The first connector 94 and the second connectors 96, 202 may be positioned to interconnect as the battery block 5,206 moves in the first direction X1, 61. In step 254, when the projections 31 and 36 are in the stopping positions 71 and 72 within the slots, the movement of the battery blocks 5 and 206 relative to the receiving frame in the first direction X1 and 61 can be stopped by at least one stopping mechanism. The battery blocks 5 and 206 can then be held in the receiving frame in the direction opposite to the first direction X1 and 61 by the holding mechanisms 170 and 194 within the receiving frame when the projections are in the stopping positions within the slots.

[0060] As shown in Figure 14, the method 250 for operating the battery replacement assembly may further include the step 260 of lifting the battery blocks 5, 206 in a second direction Z1 to engage each of the projections 31, 36 within the corresponding openings.

[0061] Slots 16, 18, 23, and 34 may further extend their respective second ends 111, 112 in a third direction Z2, 81 parallel to the second axis Z and opposite to the second direction Z1, and insertion of the battery block into the receiving frame may further include the step of moving each projection in the third direction Z2, 81 relative to the receiving frame within at least two slots.

[0062] It should be understood that the above description is illustrative and not limiting. For example, the above examples (and / or embodiments thereof) may be used in combination with each other. In addition, many modifications may be made without departing from the scope in order to adapt a particular situation or material to the teachings of the various examples of this disclosure. The dimensions and types of materials described herein are intended to define the parameters of the various embodiments of this disclosure, but the embodiments are not limiting and are illustrative embodiments. By considering the above description, many other embodiments will become apparent to those skilled in the art. Therefore, the scope of the various embodiments of this disclosure should be determined by referring to the entire scope of the appended claims and the equivalents thereof.

[0063] This specification uses examples to disclose various embodiments of the disclosure, including the best mode, and to enable a person skilled in the art to carry out various embodiments of the disclosure, including the manufacture and use of any device or system and the execution of any incorporated method. The scope of the various embodiments of the disclosure is defined by the claims and may include other examples that a person skilled in the art may conceive. Such other examples are intended to be within the claims if they have structural elements that are not different from the language of the claims, or if they include equivalent structural elements that are substantially different from the language of the claims.

Claims

1. A battery replacement assembly, The aforementioned assembly is A receiving frame and a battery block (5, 206) that can be inserted into the receiving frame, A mechanical connection mechanism between the receiving frame and the battery block, the mechanical connection mechanism comprising n slots (16, 18, 23, 34) and n projections (31, 36) arranged to cooperate with each slot, where n is an integer and at least 2, each slot and corresponding projection belonging to the receiving frame on one side and the battery block on the other, each slot extending longitudinally parallel to a first axis (X) from a first end to a second end (111, 112), the first end of each slot communicating with openings (42, 44, 47, 91, 92, 95, 97) parallel to a second axis (Z) perpendicular to the first axis (X), and each projection connecting the battery block to the receiving frame A mechanical connection mechanism is configured to engage and move within corresponding openings and corresponding slots for continuous insertion into the receiving frame in a second direction (Z1, 41, 223) parallel to the second axis (Z) and a first direction (X1, 61) parallel to the first axis (X), wherein the mechanical connection mechanism includes at least one stop mechanism for stopping the movement of the battery block in the first direction (X1) relative to the receiving frame when the projection is in a stop position (71, 72) within the slot, and the mechanical connection mechanism further comprises a retaining mechanism (170, 194) for holding the battery block in the direction opposite to the first direction (X1) when the projection is in the stop position within the slot, An electrical connection mechanism having a first connector 94 attached to the battery block and a second connector (96, 202) attached to the receiving frame, wherein the first connector and the second connector are arranged to interconnect when the battery block moves in the first direction (X1), A battery replacement assembly equipped with [a specific feature].

2. The assembly according to claim 1, wherein the stopping mechanism includes the second end of at least one of the slots.

3. The assembly according to claim 1 or 2, wherein the retaining mechanism includes a first movable element (164) elastically biased to protrude at least partially into at least one slot between the first and second ends of at least one of the slots.

4. The assembly according to any one of claims 1 to 3, wherein the retaining mechanism comprises a second movable element (192) positioned between the battery block and the receiving frame when the battery block is inserted into the receiving frame, the second movable element being movable relative to the battery block in a second direction (Z1) between a battery block retaining position and a battery block release position, and the second movable element being elastically biased toward the battery block retaining position in a direction opposite to the second direction (Z1).

5. The assembly according to any one of claims 1 to 4, wherein at least two slots are further configured to have their respective second ends extending in a third direction (Z2) parallel to the second axis (Z) and opposite to the second direction (Z1), so that each of the projections moves in the third direction (Z2) relative to the receiving frame within the at least two slots for the insertion of the battery block into the receiving frame.

6. The assembly according to any one of claims 1 to 5, wherein each opening has a width parallel to the first axis (X), and the width gradually decreases from the opening end of the opening to the slot.

7. The assembly according to any one of claims 1 to 6, wherein n is at least 4, and the n slots form at least a first pair of slots and a second pair of slots, the slots of the first pair are aligned parallel to the first axis (X), and the second pair is aligned parallel to the first axis (X).

8. The assembly according to claim 7, wherein each of the first pair of slots has its second end further extended in a third direction (Z2, 81) parallel to the second axis (Z) and opposite to the second direction (Z1), and the first pair of slots is spaced apart from the second pair of slots in the first direction (X1).

9. The assembly according to any one of claims 1 to 8, wherein all of the slots belong to one of the receiving frame and the battery block, all of the projections belong to the other of the receiving frame and the battery block, and all of the slots extend in the first direction (X1) from the first end to the second end.

10. The assembly according to claim 9, wherein all of the slots belong to the receiving frame and all of the protrusions belong to the battery block.

11. The assembly according to claim 10, wherein the receiving frame includes two frame sides (17, 24, 144) extending parallel to the first axis (X), and the battery block comprises two battery block sides (153, 157) extending parallel to the first axis (X), the slot is formed in the frame side, and the projection extends from the battery block side.

12. The assembly according to any one of claims 1 to 11, wherein the receiving frame includes two frame sides extending parallel to the first axis (X), the battery block has two battery block sides extending parallel to the first axis (X), the receiving frame has a first cross member (21, 203) fixed to the two frame sides, the battery block has a front side (37) facing the first cross member when the battery block is inserted into the receiving frame, the first connector is provided on the front side of the battery block, and the second connector is provided on the first cross member.

13. The assembly according to claim 12, wherein the first connector is elastically coupled to the front surface of the battery block.

14. The assembly according to claim 12 or 13, wherein the second connector is elastically coupled to the first transverse member.

15. The assembly according to any one of claims 12 to 14, wherein the receiving frame has second transverse members (21, 211) fixed to the two frame sides, the battery block has a rear side (30) opposite to the front side, and the rear side of the battery block faces the second transverse member when the battery block is inserted into the receiving frame.

16. A vehicle (1) having a vehicle frame (2) and an assembly according to any one of claims 1 to 15, wherein the receiving frame is integral with the vehicle frame, the first axis (X) is substantially horizontal when the vehicle is in use, and the second direction (Z1) extends substantially vertically upward when the vehicle is in use.

17. A receiving frame for assembly according to any one of claims 12 to 15, The two frame sides extending parallel to the first axis (X), The first horizontal member fixed to the two frame sides, The second connector provided on the first horizontal member, Equipped with, The aforementioned slot is formed on the side surface of the frame, Receiving frame for assembly.

18. A battery block (5) for an assembly according to any one of claims 12 to 15, wherein the first connector is provided on the front side surface of the battery block, and the projection extends from the side surface of the battery block.

19. A method for operating a battery replacement assembly, the method comprising the steps of inserting a battery block (5, 206) into a receiving frame using a mechanical connection mechanism between the receiving frame and the battery block, the mechanical connection mechanism comprising n slots (16, 18, 23, 34) and n projections (31, 36) arranged to cooperate with each of the slots, where n is an integer and at least 2, and each of the slots and corresponding projections is one part belonging to the receiving frame and the other part belonging to the battery block, and all of the slots extend longitudinally parallel to a first axis (X) from a first end to a second end (111, 112), and the first end of each slot communicates with an opening (42, 44, 47, 91, 92, 95, 97) parallel to a second axis (Z) perpendicular to the first axis (X), The insertion step is, The steps include moving each projection by engaging it within the corresponding opening and corresponding slot in order to continuously insert the battery block into the receiving frame in a second direction (Z1, 41, 233) parallel to the second axis (Z) and a first direction (X1, 61) parallel to the first axis (X), A step of forming an electrical connection mechanism between a first connector (94) attached to the battery block and a second connector (96, 202) attached to the receiving frame, wherein the first connector and the second connector are arranged to interconnect when the battery block moves in the first direction (X1), The steps include stopping the movement of the battery block in the first direction (X1) relative to the receiving frame via at least one stopping mechanism when the projection is in the stopping position (71, 72) within the slot, When the projection is in the stop position within the slot, the holding mechanism (170, 194) holds the battery block in the receiving frame in a direction opposite to the first direction (X1), Methods that include...

20. At least two slots further extend their respective second ends in a third direction (Z2, 81) parallel to the second axis (Z) and opposite to the second direction (Z1), and the insertion step is, The step of moving each of the aforementioned protrusions in the third direction (Z2) relative to the receiving frame within the at least two slots, The method according to claim 19, further comprising:

21. The aforementioned insertion step is, The step of lifting the battery block in a second direction (Z1) in order to engage each of the aforementioned protrusions within the corresponding openings, The method according to claim 19 or 20, further comprising:

22. The method according to any one of claims 19 to 21, wherein n is at least 4, all of the slots belong to the receiving frame, and all of the protrusions belong to the battery block.

23. The method according to claim 22, wherein the slots form at least a first pair of slots and a second pair of slots, the slots of the first pair are aligned parallel to the first axis (X), the second pair is aligned parallel to the first axis (X), and the first pair of slots is spaced apart from the second pair of slots in the first direction (X1).

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