Battery system, housing and vehicle including battery system

A battery system for use in a vehicle is disclosed. The battery system includes a tray having a plurality of battery receptacles. A plurality of batteries are also provided, each battery in the plurality of batteries being received in a battery receptacle. A conductive layer in electrical communication with the plurality of batteries and a terminal for electrically coupling to a vehicle are also provided in the battery system. A cover interlocks with the tray. The cover carries a computer and a diagnostic identification system for the plurality of batteries. A housing for a battery system and a vehicle including a battery system are also disclosed.

FIELD

The present inventions relate to vehicles such as golf cars or carts, utility vehicles and neighborhood electric vehicles. The present inventions more specifically relate to battery systems, housings for battery systems and bodies for such vehicles.

BACKGROUND

Vehicles such as golf cars and carts typically include a frame, a body mounted to the frame, three or four wheels rotatably connected with the frame and a power system operably connected with a wheel drive assembly. Power systems for these vehicles include an electric motor, and one or more batteries, and other electrical components. The batteries may alternatively be coupled to an internal combustion engine.

Power systems common to electric motor powered vehicles, such as a golf car or cart, commonly include multiple batteries that are individually installed and connected in series by a variety of cables. These batteries are individually retained in place with individual battery hold downs that removably attach the battery to the frame of the vehicle. It is also known to provide the individual batteries underneath the seat of such vehicles. Unfortunately, these battery systems are difficult to install and/or replace as individual batteries must be separately installed and electrically connected below the seat, and include multiple parts for installation. Further, such batteries are typically delivered for installation with no electrolyte. As a result, before the batteries are usable, the vent caps must be removed from each battery and each battery filled with fluid. Likewise, ongoing maintenance of the batteries requires each individual battery to be separately filled with electrolyte or other fluid.

SUMMARY

Accordingly, a battery system for use in a vehicle is provided. The battery system includes a tray having a plurality of battery receptacles. A plurality of batteries are also provided, each battery in the plurality of batteries being received in a battery receptacle. A conductive layer in electrical communication with the plurality of batteries and a terminal for electrically coupling to a vehicle are also provided in the battery system. A cover interlocks with the tray. The cover carries a computer and a diagnostic identification system for the plurality of batteries.

A housing for a battery system is also provided. The housing includes a tray having a plurality of receptacles sized to carry batteries, an elevated floor providing an area of clearance below the floor, and apertures in the receptacles in communication with the area of clearance. A cover interlocks with the tray. The cover has a leg which extends and couples to the tray.

A vehicle is also provided. The vehicle has a power system coupled to driven wheels and a battery system docking area. The battery docking area has a drawer to rack system. A battery system is provided which is movable on the drawer to rack system into and out of the docking area. A self-docking plug-in system defined by an electrical coupling of the battery system and the power system is also provided.

These and other features and advantages of devices, systems, and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various examples of embodiments.

It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

A vehicle102is shown inFIG. 1. The vehicle102may include a battery system according to one or more examples of embodiments. The vehicle102in the illustrated examples is a golf car or cart. However, according to various alternative examples of embodiments, the vehicle102may be any variety of types of vehicles including, among others, utility vehicles, all terrain vehicles, neighborhood electric vehicles, and recreational vehicles. The vehicle102may also be other vehicles utilizing multiple batteries. According to one or more examples of embodiments, the vehicle102uses one or more electric motors for locomotive purposes. However, use of the battery system in combination with an internal combustion engine is also contemplated.

Generally, the vehicle102is formed of a frame104, a body106coupled or mounted to the frame, a plurality of wheels108rotatably connected with the frame, and a power system operably connected with a wheel drive assembly to drive one or more wheels108from the plurality of wheels. The vehicle102includes a seat110or seating system. The seating system110may be integral or otherwise attached to the body106, or it may be configured to be removably coupled to the body. Referring toFIG. 2, the power system112generally includes a motor114(such as an electric motor), power components116necessary to operate the motor and/or vehicle, and a battery system116. As indicated, the power system112may also include an internal combustion engine. One or more components of the power system112may be coupled or mounted to the frame104and/or the body106of the vehicle102.

A battery system116for use with the vehicle102and/or power system112is shown inFIGS. 3-15. According to one or more examples of embodiments, the battery system116generally includes a housing118formed of tray120or framework or base and a cover122, a plurality of batteries124, and conductive layer or wiring or a wiring harness126. In various embodiments, the battery system116may also be coupled to a computer128.

As shown inFIGS. 3-5, a battery system116, and in particular the housing118, includes a base, which may be a tray or framework120. The tray120is arranged to position and/or secure one or more of the batteries124of the battery system116during shipping, installation, and/or use.

In the illustrated example shown inFIG. 5, the base or tray120has multiple cavities or receptacles or compartments130configured for positioning multiple batteries124. Six cavities130are shown inFIG. 4. The cavities130are shown as two rows of two, bookended with a single cavity on each side. The cavities130form a battery support area132on the tray120for carrying or supporting the batteries124. The cavities130are surrounded by a frame134. The frame134may also include one or more legs136or feet or other features which raise the floor138of the tray120above the supporting surface, providing space150below. Further, or in the alternative, clearance or space or apertures may be provided on the lower edge of the frame134between the floor138and the supporting surface.

In one or more examples of embodiments, each cavity130or receptacle has a front wall140, end walls142, a rear wall144, and a bottom wall146. The bottom wall146may be provided at the bottom edge of the front, and in rear walls. In other various embodiments, the bottom wall146may be provided away from the bottom edge of the front wall140, end walls142, and/or rear wall144, for instance, to allow air to pass below the battery124. As shown inFIG. 5, one or more of the cavities130or receptacles may have an aperture148, such as for example a partially opened bottom wall, which exposes the bottom of a battery held in the cavity130. The apertures148may be in direct communication with the space150below the floor138of the tray120.

While the cavities130or receptacles are shown inFIG. 5in a particular configuration, it should be appreciated that the cavities130may be provided or configured in any suitable configuration. For example, while six cavities130are shown inFIG. 5, the base or tray120may include any number of cavities. Further, while the cavities130inFIG. 5are shown as two rows of two, bookended with a single cavity on each side, other configurations may be utilized (e.g., a two-by-three configuration or two-by-two bookended one each side by an offset cavity). Likewise, while apertures148are illustrated in the cavities130, the cavities may be provided without apertures or openings, or the aperture may be located in other locations within the cavity or receptacle.

In various embodiments, the base, tray or framework120is integrally formed or connected (e.g. of one-piece construction). However, it should be appreciated that the base, tray or framework120may include separate pieces coupled together (e.g., by brackets, fasteners, plastic fusion, or other now known or future developed means).

One or more batteries124may be received in the base or tray120in the various receptacles130. The batteries124may be provided in the base or tray120in any suitable configuration. The batteries124shown inFIGS. 3-5may include any type of secondary battery (e.g., rechargeable battery). According to one or more examples of embodiments, the batteries124include a lead-acid storage battery. Lead-acid storage batteries may be either sealed (e.g., non-maintenance) or unsealed (e.g., wet). According to one or more examples of embodiments, the lead-acid storage battery is an unsealed lead-acid battery that periodically requires the addition of electrolyte and/or water to maintain a desired volume and/or concentration of either or both. Each battery124includes a positive and a negative terminal for electrically coupling the battery to another device.FIGS. 4-5show six unsealed 8-volt batteries. However, the type, number and voltage of the batteries124may vary according to the intended use or requirements.

In various examples of embodiments, the battery system116includes a conductive layer, wiring harness or wiring126for electrically coupling the batteries124together and/or to the vehicle102(seeFIGS. 4-5). The conductive layer126is in electrical communication with a plurality of batteries124and the power system112or vehicle102. In one example, the batteries124are coupled in series, although alternative arrangements suitable for the purposes of the battery system116may also be acceptable. The conductive layer or wiring harness126may be a single or one-piece wiring harness, wherein the wiring includes connectors152or other members for coupling the positive and negative terminals154of the batteries124to the wiring126. The coupling elements152, as well as the wire or cable126, are formed of or include conductive material for transmission of current. The coupling elements152may be arranged or shaped to be received on a battery terminal154and are spaced along the wiring harness126so as to be positioned over a battery terminal from a battery124carried by the tray120. Accordingly, the wiring harness126has a plurality of coupling elements152interspersed on the cable or wire or conductive layer126, and connected for the desired battery configuration, e.g., in series. As a result, the wiring harness126makes all the necessary electrical contacts with the battery or plurality of batteries124. In various examples of embodiments, the wiring126also includes a positive terminal156and a negative terminal158, or more than one such terminal. The positive and negative terminals156,158may be arranged to be accessible from the exterior of the battery system116, or for example from the battery cover122. In one or more examples of embodiments, the cover provides electrical access to the terminals156,158, either providing physical access to the terminals, or by providing a separate terminal or terminals in electrical communication with the conductive layer terminals156,158. Terminals156,158may be coupled to the power system terminal cables159directly or indirectly via electrical connection with conductive elements in the cover. While the wiring126is shown inFIGS. 4-5as being a single or one-piece wiring harness, it should be appreciated that the wiring or conductive layer126may include any number of components, segments, or pieces.

The wiring harness or conductive layer126may also be linked or coupled to a computer128(FIG. 5), such as, in one example, an on-board computer. For instance, a positive terminal156and a negative terminal158of the wiring126may be coupled to one or more computers126. One or more examples of a computer128are shown inFIG. 5. The computer128may be carried by the cover122of the battery system116, or may alternatively be carried by the tray120. For example, the top portion162of the cover122may carry an on-board computer128. The computer128may be any suitable computer, including for example, an on-board computer, an on-board battery charger computer, a controller, a solenoid, and/or other electrical components. As one of ordinary skill in the art will appreciate, however, the batteries124or wiring126do not need to be coupled to an on-board computer128. Further, it should be appreciated that the batteries124may be coupled to a computer128which is not provided within the battery system housing118. The computer128may be provided for any suitable purpose, including, but not limited to, the following: monitoring the service and condition of batteries124, providing data on use; controlling the battery system116and/or power distribution; controlling on/off; and/or controlling the battery system display.

As shown inFIG. 3-5, in one or more examples of embodiments the battery system116also includes a cover122. The cover122may be disposed on the batteries124. The cover122encloses or covers the batteries124carried by the tray120. In the illustrated example, the cover122extends over the top surface160of the batteries124. The cover122may be releasably or hingedly or pivotably coupled to the base or tray120of the system. The cover122is formed of a top portion162and one or more legs164extending therefrom. In the illustrated example, legs164extend below the top portion162of the cover122from positions proximate to the ends of the top portion162. The leg or plurality of legs164space the cover122a distance away from the tray120. Preferably, the distance corresponds to, at least, the height of the batteries124carried by the tray120. Each leg164may include a flange166or other interlocking member which couples to, or is supported on or near, the base or tray120. The flange166or leg164may couple to the tray120on one or more surfaces, such as a side surface, and may further couple in a corresponding receptor168. For example, a leg164may interlock with the tray120by a snap-fit or friction-fit type arrangement, or in the alternative may interlock via a tongue and groove type arrangement.

The cover122may also optionally include or be associated with a fluid delivery system. The fluid delivery system may be utilized to provide fluid, such as water or electrolyte, to one of the batteries124or multiple batteries, simultaneously or in sequence. As a result, a one-step fluid fill and flood system may be provided in association with or in connection with the cover122. To this end, a fluid port or receptacle, along with a delivery system connected with or connectable to the various batteries124in the battery system116may also optionally be provided in association with the cover122. Further, this system may be arranged to provide a one-step fill system with overflow. The cover122may also include vent caps (not shown), such as vent caps integral to the cover122. In various alternative examples of embodiments, however, the vent caps may be provided separately from the cover122, such as for example by use of single or gang vents.

The cover122may provide access to the terminals156,158of the wiring or wiring harness126. To this end, access openings170may be provided in the cover122. InFIGS. 3-6, access openings170are provided in the top portion162of the cover122. In various alternative examples of embodiments, the cover122includes terminals that are electrically coupled to the wiring harness126and/or terminals of the wiring harness. As a result, a quick-connect coupling mechanism may be provided for coupling to the vehicle positive and negative terminal wiring.

Accordingly, as shown inFIGS. 6-7, a service panel172or compartment may be provided on the top portion162of the cover122. The service panel172may include positive and negative terminals170, or access thereto. Fluid delivery system inlet or inlets or port(s)174may, optionally, be included in the service panel172. The service panel172may also include a diagnostic identification system176. For example, a diagnostic display device176may be used, such as but not limited to an LCD screen, to communicate information regarding the battery system116and may further be coupled to a computer system128, such as an on-board computer system, which controls the display. The information may include any suitable information for operation, maintenance, or general knowledge of the battery or battery system116. For example, the information may include, but is not limited to, the condition or service requirements of the battery system116, or other information from the on-board computer128or detectable from the battery system components. The compartment or service panel172may include a removable or hinged door or cover178for the compartment (seeFIG. 3).

While the service panel172is specifically described above in relation to the top portion162of the cover122, alternative locations for the service panel and other/additional components contained within the service panel may also be acceptable for the purposes provided.

The battery system cover122may be integrally formed or connected, such as by one-piece construction. In one or more examples of embodiments, the cover122is formed by blow molding a plastic material. However, it should appreciated that the cover122may be formed of different materials, by different processes, and/or include separate pieces coupled together (e.g., by brackets, fasteners, plastic fusion, etc.)

In one or more examples of embodiments, the power system112and, in particular the battery system116, is disposed on, and may be at least partially disposed inside the body106of the vehicle102. In one or more examples of embodiments, the base, tray or framework120may be mounted to the vehicle102such as, for example, to the frame104or body106. In various embodiments, the base or tray or framework120may be formed and/or mounted to stiffen or increase rigidity of the vehicle102(e.g. frame, body, or other vehicle component).

As can be seen inFIG. 1, the body106of the vehicle102includes one or more seats110for vehicle occupants. In one or more examples of embodiments, one or more of the seats110may be moved, removed or otherwise adjusted to allow, or provide access to the battery system116. For example, the battery system116may be installed below the seat110or seats of the vehicle102as shown inFIG. 7. In this regard, the battery system116may be installed by any suitable means, examples of which include a lift180or hoist182as shown inFIGS. 8-9. The base or tray120may rest within the battery bay184or receptacle in the vehicle102, and may further be secured or mounted in place within the battery bay184, such as by fasteners secured to the legs or feet136of the battery system base120.

In various alternative examples of embodiments, the cover222of the battery system116may include or be comprised of one or more seats210. As shown inFIGS. 10-12, the cover222and seat210may be coupled or removably coupled together, such as for example, by brackets, fasteners, plastic fusion, or other now known or future developed means. However, the cover222and seat210may integrally formed or connected (e.g., of one-piece construction). The battery system116may also include a seat210on, or as the battery system cover222. In this regard, the battery system116includes a cover222with integrated seats210which can be removed to access the batteries124.

As shown inFIGS. 12-14, the body106of the vehicle102may include an apparatus configured to releasably couple a battery system116to the body106of the vehicle102. In one or more examples of embodiments, the body106of the vehicle102is provided with “drawer-to-rack” system186. The system186in the illustrated embodiment includes a rail188or groove190, or other member(s) such as rollers or a slide rail, which receives a portion of the battery system116. In particular, the battery system116may be mounted on the drawer-to-rack system186, (e.g., slidable on the rail188or groove190). In the illustrated example, a plurality of rails188, such as for example two or three rails or combination of rails and grooves, are provided for slidable coupling or movement of the battery system116. The battery system base220or cover122or222may be provided with a mating apparatus, e.g., a rail or groove or other suitable device, which corresponds to the apparatus on the vehicle body106configured to releasably couple the battery system116which is moveable thereon. A docking area284may also be provided on the body106of the vehicle102which is sized to receive the battery system116and base220. The battery system116is moveable into and out of the docking area284. While the members shown inFIGS. 12-14are slide rails188or grooves190, it should be appreciated that any number of configurations may be utilized to releasably couple the battery system116with seat210to the body106of the vehicle102. For example, the battery system116with seat210may be provided into a compartment designed to releasably couple the system to the body106.

Referring toFIGS. 12-14, a self-docking plug-in system or attachment may also be provided on the body106of the vehicle102for electrically coupling the battery system116to the vehicle. The self-docking system includes, or is defined by a plug arrangement192in a surface of the vehicle body106in proximity to the battery system116. The plug arrangement192of the vehicle102is electrically coupled to the power system112or to the components of the vehicle102operated by a power system112. The battery system116or power system112includes and, thus, the self-docking plug in system is further defined by a corresponding or mating plug arrangement194on a surface of the cover or base of the battery system116which is aligned with the body106plug arrangement192upon installation. The mating plug arrangement192,194is electrically coupled to the conductive layer126of the battery system116, such as for example, to a terminal of plurality of terminals, or may form the terminals. The installed battery system116in the battery bay or docking area284causes the coupling of the mating plug arrangement192,194, thereby electrically coupling the battery system116to the power system112and vehicle102. In the illustrated examples shown inFIGS. 12-14, at least a portion of the self-docking plug-in system192is installed on a wall196of the docking bay284, such that upon sliding of the battery system116, with corresponding plug-in arrangement194aligned, into place on the vehicle102also electrically couples the battery system to the vehicle.

Referring toFIG. 15, in various examples of embodiments, the vehicle102may also include other modular components that may be coupled (e.g., releasably coupled) to the body206. The modular components or trim may include body panels198or plastics, an overhead canopy200, supports for an overhead canopy202, HMI/electronics, seatbacks204, armrests206, structural accessory mounts including, without limitation, golf bag supports, bumpers, etc. In various embodiments, the modular components may improve ease of assembly, and/or repair of the vehicle102. Further, one or more of the components may be coupled to the power system112or battery system116providing an integrated vehicle system.

As indicated in the Figures, many components, such as the cover and base of the power system, the vehicle trim and other panels and components of the vehicle, and the like, are constructed of one or more now known or future developed plastic materials. The various components may be constructed, fabricated, or formed of any number or variation of known or hereafter-developed polymers, copolymers, or other materials including, without limitation, thermoplastics such as for example polyethylene or polypropylene, nylon, fiberglass, fiberglass filled nylon, fiber reinforced polymer (e.g. glass fiber reinforced polymer). Further, these materials may be formed from any number of known or hereafter developed processes including, without limitation, blow-molding, injection molding, gas-assist injection molding, compression molding. It should be appreciated, however, that any or all of the components may be constructed of any known or hereafter developed material or materials suitable for the intended purposes.

In one or more examples of embodiments, the battery system116may be assembled by placement of one or more batteries124in receptacles130of the tray120, coupling the conductive layer to the battery terminals154, optionally connecting a computer128to the conductive layer, and attaching the cover122to the tray120by the mechanisms described hereinabove. The computer may alternatively be coupled to the cover prior to attachment to the conductive layer. The batteries124may be provided in a filled or unfilled state. Accordingly, unfilled batteries may be filled prior to assembling the conductive layer and/or cover to the battery system, or in the alternative may be filled following assembly, such as in some examples following installation in a vehicle. Once the battery system116is assembled, it is installed in a vehicle102as previously described herein.

The vehicle, body, battery system and/or housing described herein include a number of advantages over traditional systems. The battery system provides reduced battery watering effort, time and/or costs as it permits simultaneous watering of multiple batteries. The battery system, as an integrated unit also reduces maintenance effort, time and/or costs, as each battery does not need to be tended individually. Furthermore, the system described herein, including a diagnostic display device, reduces diagnostic effort, time and/or costs because such information is readily available on the battery system cover.

The housing, including base and cover, of the battery system provides improved stiffness and/or rigidity of the frame, body and/or vehicle. The elevated floor and/or clearance or apertures of the tray provide an area below the floor of the tray for air to circulate and assist in cooling the batteries and/or battery system.

The combined battery system includes fewer parts, and results in reduced vehicle, housing and/or battery system volume, as well as reduced vehicle, housing and/or battery system weight. These reductions from the use of the integrated battery system also improve storage and/or comfort in the vehicle.

The battery system provides improved battery and component connections permitting quick connect and disconnect of the battery system from the power system and vehicle. The battery system also provides improved performance. For example, the battery system has improved cooling, improved vehicle range per charge, and improved battery life and/or performance because of the various features identified herein.

Additionally, the integrated system including multiple batteries and associated components described herein reduce shipping effort, time and/or costs; as well as delivery effort, time and/or costs; storage effort, time and/or costs; and installation effort, time and/or costs. Moreover, there are fewer components and/or parts in the integrated battery system, and as a result, fewer stock-keeping units (SKUs) for manufacturers, suppliers, sellers, and purchasers. Furthermore, one or more features of the battery system may be used for other manufacturer purposes, such as for example use of the tray for a shipping pallet.

It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.

While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.