ELECTRIC VEHICLE WITH STEERING COLUMN EXTENDING THROUGH BATTERY PACK

An electric vehicle and a powertrain for an electric vehicle are disclosed. According to an embodiment, an electric vehicle includes a steering system with a steering column, and a battery pack having a battery enclosure and a plurality of battery modules housed within the battery enclosure. The battery enclosure defines a slot that extends from at least a top surface of the battery enclosure to receive the steering column.

TECHNICAL FIELD

The present disclosure relates generally to electric vehicles and, in particular embodiments, to powertrain components of electric vehicles.

BACKGROUND

Electric vehicles comprise different powertrain components than traditional combustion engine vehicles. For example, instead of having a fuel tank and a combustion engine, an electric vehicle comprises a battery pack and an electric motor. Due to the sizes and weights of the electric vehicle powertrain components, consideration is needed when locating and positioning them in relation to each other, as well as other components of the electric vehicle. The strength and rigidity of the electric vehicle should also be considered when locating and positioning the powertrain components.

By way of example, for an electric snowmobile, further consideration is needed when locating a battery pack and electric motor in relation to a chassis and suspension system.

SUMMARY

Some embodiments of the present disclosure provide a battery pack that is configured and implemented as a structural element in an electric vehicle. For example, the battery enclosure of the battery pack may serve at least two functions in the electric vehicle. The first function is protecting and/or encapsulating other battery components, such as one or more battery cells, one or more battery modules and/or one or more battery controllers, for example. The second function is providing strength and rigidity to the electric vehicle by receiving loads from the suspension system, seat and/or steering system, for example. In this way, the battery pack may reduce the number, size and/or weight of other structural components in the electric vehicle, and increase the overall structural efficiency of the electric vehicle.

According to one example, an electric vehicle is provided that comprises a suspension system, a seat, a steering system, an electric motor and a battery pack. The battery pack may comprise one or more battery modules to provide power to the electric motor and a battery enclosure may house the one or more battery modules. The battery enclosure is a structural element of the electric vehicle to receive loads from at least two of the suspension system, the seat and the steering system of the electric vehicle.

In some examples, the battery enclosure transfers the loads received, at least partially, to a center of mass of the electric vehicle. Alternatively or additionally, the battery enclosure transfers the received loads, at least partially, to a chassis of the electric vehicle. According to another example, the battery enclosure defines a front portion and a rear portion. The front portion may receive loads from at least one of the suspension system (e.g., a front suspension of the electric vehicle) and the steering system. The rear portion may receive loads from at least the seat.

In some examples, the electric vehicle comprises a chassis defining a front brace structure, the battery enclosure connected to the front brace structure to receive loads from the front brace structure. Optionally, multiple different surfaces of the battery enclosure (e.g., front, top, side and/or bottom surfaces) are connected to the front brace structure. The suspension assembly may include a shock absorber that is connected to the front brace structure.

In some examples, the battery enclosure is connected to the steering system to receive loads from the steering system.

In some examples, the electric vehicle is a snowmobile.

According to one example, a battery enclosure for an electric vehicle is provided. The battery enclosure being a structural element of the electric vehicle and comprising a rear portion for connection to a rear portion of a chassis of the electric vehicle, the rear portion of the battery enclosure configured to receive loads from a seat of the electric vehicle; and a front portion for connection to a front portion of the chassis of the electric vehicle, the front portion of the battery enclosure configured to receive loads from a front suspension of the electric vehicle.

In some examples, the battery enclosure is configured to transfer loads received from the seat and/or the front suspension, at least partially, to a center of mass of the electric vehicle. In some examples, the battery enclosure is configured to transfer loads received from the seat and/or the front suspension, at least partially, to a chassis of the electric vehicle. In some examples, the front portion is to receive loads from a steering system of the electric vehicle and, optionally, to transfer those loads, at least partially, to a center of mass of the electric vehicle.

In some examples, the battery enclosure comprises a carbon fiber composite material. Alternatively or additionally, the battery enclosure comprises a glass fiber reinforced plastic material. The battery enclosure may have a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa. In some examples, the battery enclosure houses at least two electric battery modules and, optionally, provides a water-tight housing for the at least two electric battery modules.

In some examples, the electric vehicle is a snowmobile. In some examples, the rear portion of the battery enclosure is adapted for connection to a tunnel of the snowmobile, and the front portion of the battery enclosure is adapted for connection to a front brace structure of the snowmobile.

According to a further example, the battery enclosure transfers the loads received, at least partially, to a center of mass of the electric vehicle. In another example, the battery enclosure transfers the loads received, at least partially, to a chassis of the electric vehicle. According to another example, the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from a front suspension of the electric vehicle. According to another example, the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from the steering system and the rear portion receiving loads from the seat.

According to one example, a snowmobile is provided comprising a chassis that comprises a rear tunnel and a front brace structure adapted to receive loads from a front suspension system of the snowmobile. The snowmobile further comprises a battery enclosure defining a tunnel portion and a front portion, the tunnel portion being connected to the rear tunnel of the chassis and the front portion being connected to the front brace structure of the chassis. The battery enclosure receives loads from the front suspension system of the snowmobile through the front brace structure and transfers the loads from the front suspension system to at least one of the rear tunnel and a center of mass of the electric vehicle through a body of the battery enclosure.

In some examples, the battery enclosure is further connected to the front brace structure at a bottom surface. In some examples, a steering mount is connected to the front portion of the battery enclosure for connection to a steering column, the steering mount transferring loads from the steering column into the body of the battery enclosure. In some examples, a seat is connected to the tunnel portion of the battery enclosure, wherein loads from the seat are received by and transferred into the body of the battery enclosure. In some examples the front portion of the battery enclosure defines a first height and the tunnel portion of the battery enclosure defines a second height, the first height being greater than the second height. In some examples, the front portion of the battery enclosure defines a first width and the tunnel portion of the battery enclosure defines a second width, the first width being greater than the second width. In some examples, the front suspension system comprises at least one coil over spring and damper assembly. In some examples, at least one coil over spring and damper assembly is connected between a pair of skis and the front brace structure. In some examples, the battery enclosure comprises a carbon fiber composite material. In some examples, the battery enclosure comprises an injection molded glass fiber reinforced plastic material. In some examples, the tunnel portion of the battery enclosure is connected to the rear tunnel of the chassis via two or more right side blocks and two or more left side blocks. In some examples, the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 Gpa and equal to or less than 70 Gpa. In some examples, the battery enclosure comprises a cover and a floor. In some examples the battery enclosure houses at least two electric battery modules for supplying electricity to the electric motor. In some examples, the battery modules comprise one or more pouch battery cells.

According to one example, a battery enclosure for an electric snowmobile is provided. The battery enclosure comprises a tunnel portion adapted for connection to a rear tunnel of a snowmobile chassis, a front portion adapted for connection to a front brace structure of the snowmobile chassis. The battery enclosure is configured to receive loads from a front suspension system of the snowmobile through the front brace structure and transfers the loads from the front suspension system to at least one of the rear tunnel and a center of mass of the electric vehicle through a body of the battery enclosure.

In one example, the battery enclosure is configured for connection to a steering column via a steering mount for receiving loads from the steering column into the body of the battery enclosure. In some examples, the battery enclosure is configured for connection to a seat of the electric vehicle for receiving loads from the seat into the body of the battery enclosure. In some examples, the front portion of the battery enclosure defines a first height and the tunnel portion of the battery enclosure defines a second height, the first height being greater than the second height. In some examples, the front portion of the battery enclosure defines a first width and the tunnel portion of the battery enclosure defines a second width, the first width being greater than the second width. In some examples, the battery enclosure comprises a carbon fiber composite material. In some examples, the battery enclosure comprises an injection molded glass fiber reinforced plastic material. In some examples, the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa. In some examples, the battery enclosure comprises a cover and a floor.

According to one example, an electric vehicle is provided that comprises a straddle-seat, a chassis, a suspension system and a battery pack configured as a structural element that receives loads from the suspension system. In one example, the battery pack comprising a battery enclosure coupled to the suspension system to transfer, at least partially, loads from the suspension system through a body of the battery enclosure to the chassis. In one example, a brace structure transfers loads between the suspension system and the battery enclosure. In one example, the straddle-seat is mounted directly to the battery pack. In one example, the electric vehicle is a snowmobile.

Some embodiments of the present disclosure provide a battery pack that defines a slot to accommodate and receive a steering column of the electric vehicle. In this way, the steering column can extend through the battery pack. Optionally, the slot may be provided in a battery enclosure of the battery pack. The steering column may connect handlebars of the electric vehicle to one or more steering arms, which allows the electric vehicle to be steered and controlled. Advantageously, the slot may allow the steering column to be substantially straight, rather than be bent to avoid the battery pack. A straight steering column may be stronger, easier to manufacturer, and provide a better ride quality than a bent steering column.

One example provides an electric vehicle. The electric vehicle includes a battery pack having a battery enclosure, the battery enclosure defines a slot that extends downwards from a top surface of the battery enclosure for receiving a steering column of the electric vehicle.

In one example, the slot extends downwards from the top surface of the battery enclosure to a front side surface of the battery enclosure. In another example, the slot extends downwards from the top surface of the battery enclosure to a bottom surface of the battery enclosure. In one example, the width of the slot varies along a length, a top end of the slot being wider than a bottom end of the slot.

In one example, the slot divides the front portion of the battery enclosure into a first side and a second side, wherein each of the first side and second side is suitable for housing one or more electric battery modules. In one example, the slot is positioned substantially centrally with respect to a first side wall and a second side wall of the battery enclosure.

In one example, the battery enclosure is a structural component suitable for receiving loads from the steering column and transferring the loads to a chassis. In one example, a straight steering column passes through the slot.

Another example provides a snowmobile. The snowmobile includes a chassis that comprises a rear tunnel, a front brace structure, and a battery enclosure defining a tunnel portion and a front portion, the tunnel portion being connected to the rear tunnel of the chassis and the front portion being connected to the front brace structure, wherein the front portion of the battery enclosure defines a slot that extends downwards from a top surface of the battery enclosure for receiving a steering column of the snowmobile.

In one example, the slot extends downwards from the top surface of the battery enclosure to a front side surface of the battery enclosure. In one example, the slot extends downwards from the top surface of the battery enclosure to a bottom surface of the battery enclosure. In one example, the slot defines a first side wall, a second side wall and a bottom surface, wherein the bottom surface of the slot extends at an angle of between 30-60 degrees with respect to a substantially horizontal longitudinal axis of the snowmobile. In one example, a width of the slot is between 30 millimeters (mm) and 60 mm. In one example, the width of the slot varies along a length, a top end of the slot being wider than a bottom end of the slot.

In one example, the slot divides the front portion of the battery enclosure into a first side and a second side, wherein each of the first side and second side is suitable for housing one or more electric battery modules. In one example, the slot is positioned substantially centrally with respect to a first side wall and a second side wall of the battery enclosure. In one example, the battery enclosure is a structural component suitable for receiving loads from the steering column and transferring the loads to the chassis. In one example, a straight steering column passes through the slot.

In one example, a top of the steering column is above the top surface of the battery enclosure and a bottom of the steering column is below a bottom surface of the battery enclosure and is attached to a steering mechanism that controls a direction of a right front ski and a left front ski for the snowmobile. In one example, an upper steering mount is attached to the top surface of the battery enclosure and is configured to support an upper portion of the steering column and provide a stiffness to the upper portion of the steering column.

In one example, the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa, and wherein the stiffness of the battery enclosure corresponds with the stiffness that the upper steering mount provides to the upper portion of the steering column.

In one example, the upper steering mount comprises a right upper steering mount and a left upper steering mount attached to a pipe having an axis aligned with an axis of the steering column, and wherein the steering column passes through the pipe and is supported by the pipe. In one example, the steering column passes through the slot at an angle with respect to an axis of the steering column and a substantially horizontal longitudinal axis of the snowmobile that is equal to or greater than 30 degrees and equal to or less than 60 degrees. In one example, the slot is centered between a right side wall and a left side wall of the front portion of the battery enclosure, and wherein a right side stack of one or more batteries are between a first side wall of the slot and a first side wall of the front portion of the battery enclosure, and wherein a left side stack of one or more batteries are between a second side wall of the slot and a second side wall of the front portion of the battery enclosure.

In one example, the front portion of the battery enclosure has a width in a direction transverse to a substantially horizontal longitudinal axis of the snowmobile in a direction between the front end and the back end of the snowmobile that is greater than a width of the tunnel portion of the battery enclosure, and wherein the tunnel portion of the battery enclosure includes a row of one or more batteries aligned along the substantially horizontal longitudinal axis of the snowmobile between the front end and the rear end of the snowmobile.

Another example provides a battery enclosure for an electric vehicle. The batter enclosure includes a rear portion, and a front portion, the front portion of the battery enclosure defining a slot that extends downwards from a top surface of the battery enclosure for receiving a steering column of the electric vehicle.

In one example, the slot extends downwards from the top surface of the battery enclosure to a front side surface of the battery enclosure. In one example, the slot extends downwards from the top surface of the battery enclosure to a bottom surface of the battery enclosure. In one example, the slot defines a first side wall, a second side wall and a bottom surface, wherein the bottom surface of the slot extends at an angle of between 30-60 degrees with respect to a substantially horizontal longitudinal axis of the electric vehicle. In one example, a width of the slot is between 30 millimeters (mm) and 60 mm. In one example, the slot divides the front portion of the battery enclosure into a first side and a second side, wherein each of the first side and second side is suitable for housing electric battery modules. In one example, the slot is positioned substantially centrally with respect to a first side wall and a second side wall of the battery enclosure. In one example, the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa.

In one example, the tunnel portion of the battery enclosure includes a row of one or more batteries in a direction between the front portion of the battery enclosure and the tunnel portion of the battery enclosure. In one example, the battery enclosure comprises a carbon fiber composite material. In one example, the battery enclosure comprises an injection molded glass fiber reinforced plastic material.

In one example, the electric vehicle is a snowmobile.

According to one example, an electric vehicle is provided that comprises a steering system comprising a steering column and a battery pack comprising a battery enclosure and a plurality of battery modules housed within the battery enclosure, the battery enclosure defining a slot that extends from at least a top surface of the battery enclosure to receive the steering column.

In some examples, the slot is substantially straight and/or a portion of the steering column received by the slot is substantially straight.

In some examples, the slot extends from the top surface of the battery enclosure to a front side surface of the battery enclosure. Alternatively or additionally, the slot extends from the top surface of the battery enclosure to a bottom surface of the battery enclosure.

In some examples, the steering system comprises a handlebar attachment coupled to an upper portion of the steering column. The steering system may also or instead comprise at least one steering arm coupled to a lower portion of the steering column. The electric vehicle may comprise at least one ski assembly coupled to the at least one steering arm.

In some examples, the slot divides a portion of the battery enclosure into a first side and a second side, wherein each of the first side and the second side houses one or more of the plurality of electric battery modules. The slot may be positioned substantially centrally with respect to a first side wall and a second side wall of the battery enclosure. The slot may define a bottom surface, the bottom surface extending at an angle of between 30-60 degrees with respect to a substantially horizontal longitudinal axis of the electric vehicle. A width of the slot may be between 30 millimeters (mm) and 60 mm.

In some examples, the steering system comprises a mount coupled to the top surface of the battery enclosure to support an upper portion of the steering column. The battery enclosure may be a structural component suitable for receiving loads from the steering column and transferring the loads to a chassis of the electric vehicle.

In some examples, the electric vehicle is a straddle-seat vehicle comprising a straddle-seat, such as a snowmobile. The straddle-seat may be coupled to the battery pack.

According one example, an electric snowmobile is provided that comprises a chassis comprising a rear tunnel and a front brace structure; a steering system comprising a steering column; and a battery enclosure defining a tunnel portion and a front portion, the tunnel portion being connected to the rear tunnel of the chassis and the front portion being connected to the front brace structure, wherein the front portion of the battery enclosure defines a slot that extends downwards from a top surface of the battery enclosure for receiving the steering column. The electric snowmobile may also comprise at least one ski assembly connected to the steering system.

According to one example, a battery pack for an electric vehicle is provided that comprises a plurality of battery modules and a battery enclosure housing the plurality of battery module and defining a slot to receive a steering column of the electric vehicle that extends from a top surface of the battery enclosure. The battery enclosure may define a rear portion, a front portion first side and a front portion second side, the front portion first side and the front portion second side being separated by the slot. Each of the rear portion, the front portion first side and the front portion second side may house at least one stack of battery modules.

Some embodiments of the present disclosure provide an electric motor that is positioned and mounted on a chassis of an electric vehicle to provide a space efficient configuration and better manage loads. For example, the electric motor may be positioned within a mid-bay of an electric snowmobile, between a rear tunnel and a front end of the electric snowmobile and below a battery pack. The electric motor may also or instead be adjacent to a front wall of the rear tunnel. This position may place the electric motor in proximity to, and substantially horizontal to, a transmission of the electric snowmobile for space efficiency. Further, a simply supported transmission plate may be used to mount and stabilize the electric motor. The transmission plate may be connected at one end to the rear tunnel and at another end to a front brace structure. These connection points of the transmission plate may be generally aligned with at least some loads exerted by the electric motor and/or the transmission on the transmission plate. In this way, the transmission plate may be configured to better manage the loads without bending and may be lighter than other transmission plates not utilizing such a configuration.

One example provides an electric vehicle. The electric vehicle includes a chassis defining a rear portion and a front portion, a transmission mounted to a rear portion of the chassis, and a battery enclosure mounted on top of the rear portion of the chassis. An electric motor mounted below the battery enclosure and between a front side of the rear chassis and a front end of the electric vehicle.

In one example, the electric motor is oriented generally horizontally relative to the transmission. In one example, the electric vehicle includes a transmission drive shaft and a motor drive shaft spaced apart along a longitudinal axis of the electric vehicle.

In one example, the rear portion of the chassis is a rear tunnel and the front portion of the chassis is a front brace structure, wherein a transmission plate attached to the electric motor is connected at a first end to the rear tunnel and at a second end to the front brace structure. In one example, the electric vehicle is a snowmobile.

Another example provides a snowmobile. The snowmobile includes a chassis that comprises a rear tunnel, a battery enclosure mounted to the rear tunnel, and an electric motor mounted below the battery enclosure and adjacent to a front side of the rear tunnel.

In one example, the chassis further defines a mid-bay and a front brace structure, the mid-bay being located between the rear tunnel and the front brace structure, wherein the electric motor is positioned within the mid-bay. In one example, the mid-bay comprises a transmission plate positioned substantially parallel to a first side edge of the rear tunnel. In one example, transmission plate is attached at a first end to the first side edge of the rear tunnel and at a second end to a component of the front brace structure. In one example, the transmission plate is further attached to a front plate of the electric motor.

In one example, the snowmobile further comprises a transmission, wherein the electric motor is mounted proximate to the transmission by the transmission plate. In one example, the transmission plate includes a U-shaped opening that extends downwards from a top side of the transmission plate, and wherein the electric motor is attached to both sides of the U-shaped opening such that a drive shaft of the electric motor extends through the U-shaped opening. In one example, a component of the front brace structure is mounted to an underside of the battery enclosure and to the transmission plate.

In one example, the electric motor includes an electric motor drive gear and the transmission includes a transmission gear, and wherein a drive belt is connected between the electric motor drive gear and the transmission gear such that an angle of a top portion of the drive belt between the electric motor drive gear and the transmission gear with respect to a substantially horizontal longitudinal axis of the snowmobile is equal to or less than 20% and equal to or greater than −20%. In one example, the snowmobile further includes a drive belt idler pulley that contacts a bottom surface of the bottom portion of the drive belt, and wherein the top portion of the drive belt is connected directly between the electric motor drive gear and the transmission gear.

Another example provides an electric snowmobile. The electric snowmobile includes a transmission mounted within an interior of a rear tunnel of the snowmobile and proximate to a rear suspension of a track of the snowmobile, and a battery enclosure mounted to the rear tunnel. The electric motor is mounted below the battery enclosure and between a front side of the rear tunnel and a front end of the snowmobile.

In one example, a transmission is provided, wherein the electric motor is mounted directly to the transmission by a transmission plate, and wherein the transmission plate is mounted to the rear tunnel of the snowmobile. In one example, the transmission plate includes a U-shaped opening that extends downwards from a top side of the transmission plate, and wherein the electric motor is attached to the transmission plate at an interior of the transmission plate such that a drive shaft of the electric motor extends through from the interior to an exterior of the U-shaped opening of the transmission plate.

In one example, the electric motor includes an electric motor drive gear and the transmission includes a transmission gear, and wherein a drive belt is connected between the electric motor drive gear and the transmission gear such that an angle of a top portion of the drive belt between the electric motor drive gear and the transmission gear with respect to a substantially horizontal longitudinal axis of the snowmobile is equal to or less that 20% and equal to or greater than −20%.

According to one example, an electric vehicle is provided that comprises a chassis comprising a rear portion and a front portion, and a suspension system comprising a front suspension coupled to the front portion of the chassis and a rear suspension coupled to the rear portion of the chassis. A battery pack is mounted at least partially on top of the rear portion of the chassis. An electric motor, powered by the battery pack, is mounted below the battery pack and between the rear portion of the chassis and a front end of the electric vehicle. The electric vehicle may also include a straddle-seat coupled to the battery pack. The electric vehicle may be a snowmobile.

In some examples, the electric vehicle comprises a transmission mounted to the rear portion of the chassis and coupled to the electric motor. The electric motor may be positioned substantially horizontally relative to the transmission. The electric vehicles may include a drive linkage (which is optionally a component of the transmission) to couple the transmission to the electric motor. The drive linkage may comprise a drive belt and/or a drive chain. In some examples, an angle of a portion of the drive linkage extending between the electric motor and the transmission with respect to a substantially horizontal longitudinal axis of the electric vehicle is between 11.3 degrees and −11.3 degrees.

In some examples, the rear portion of the chassis comprises a rear tunnel and the front portion of the chassis comprises a front brace structure and the electric vehicle comprises a transmission plate coupled to the electric motor. A first end of the transmission plate is connected to the rear tunnel and a second end of the transmission plate is connected to the front brace structure. The first end and the second end of the transmission plate may be spaced apart along a substantially horizontal longitudinal axis of the electric vehicle. The transmission plate may comprise a slot extending downwards from a top side of the transmission plate, and a drive shaft of the electric motor extends through the slot of the transmission plate.

According to one example, an electric snowmobile is provided that comprises a chassis comprising a rear tunnel; a battery pack mounted to the rear tunnel; and an electric motor, powered by the battery pack, mounted below the battery pack and adjacent to a front side of the rear tunnel.

In some examples, the chassis comprises a mid-bay and a front brace structure, the mid-bay being located between the rear tunnel and the front brace structure, wherein the electric motor is positioned within the mid-bay. Optionally, the electric vehicle comprises a transmission plate coupled to the electric motor. A first end of the transmission plate may be connected to the rear tunnel and a second end of the transmission plate may be connected to the front brace structure. The first end and the second end of the transmission plate may be spaced apart along a substantially horizontal longitudinal axis of the electric snowmobile. Further, the transmission plate may comprise a slot extending downwards from a top side of the transmission plate, and a drive shaft of the electric motor may extend through the slot of the transmission plate.

In some examples, the electric snowmobile comprises a transmission mounted to the rear tunnel of the chassis and coupled to the electric motor. The electric motor may be positioned substantially horizontally relative to the transmission. A drive linkage may couple the transmission to the electric motor. An angle of a portion of the drive linkage extending between the electric motor and the transmission with respect to a substantially horizontal longitudinal axis of the electric vehicle may be between 11.3 degrees and −11.3 degrees.

According to one example, an electric snowmobile is provided that comprises a chassis comprising a rear tunnel; a transmission mounted within an interior of a rear tunnel; a battery pack mounted to the rear tunnel; and an electric motor, powered by the battery pack, mounted adjacent to a front side of the rear tunnel and substantially horizontally relative to the transmission.

According to one example, an electric vehicle is provided that comprises a straddle-seat, a chassis, and a battery pack coupled to the straddle-seat to passively transfer heat to the straddle-seat. The battery pack may support the straddle-seat to receive loads from the straddle-seat. In some examples, the battery pack comprises a battery enclosure, the straddle-seat is mounted to the battery enclosure, and the battery enclosure is configured to transfer, at least partially, loads from the straddle-seat through a body of the battery enclosure to the chassis. In some examples, the straddle-seat is configured to receive radiant heat generated during discharge of the battery pack. Optionally, the electric vehicle is a snowmobile.

DETAILED DESCRIPTION

The present disclosure relates, in part, to electric vehicles. In one or more examples illustrated herein, an electric vehicle is a powersport vehicle such as an electric snowmobile. It is recognized that although a snowmobile is used in some examples, the present disclosure also applies to other electric vehicles, including other electric powersport vehicles (e.g., electric all-terrain vehicles (ATV), utility task vehicles (UTV), personal watercraft, side-by-side vehicles, motorcycles, etc.). In some examples, the electric vehicle is a straddle-seat electric vehicle, which is a vehicle where the seat is straddled by a rider, such as a snowmobile, personal watercraft or ATV, among others.

In some embodiments, an electric vehicle includes a battery pack that is configured as a structural element. For example, the battery pack may receive loads from a suspension system and/or other components of the electric vehicle during operation of the electric vehicle. Utilizing the battery pack as a structural element results in dynamic advantages in operation of the electric vehicle and an ergonomic advantage to the electric vehicle riders.

FIG. 1is a block diagram illustrating components of an electric vehicle100according to one example of the present disclosure. The electric vehicle100includes a chassis110(or frame), a suspension system112and a battery pack114, among other components that are not shown. The battery pack114is configured as a structural element that receives loads from at least the suspension system112, indicated at115a, and may transfer loads, at least partially, from the suspension system112, through the battery pack114to the chassis110, indicated at115b. As will be described in more detail below, the battery pack114may be further configured to receive loads from all or some of the seating of the electric vehicle100and a steering column, among other components or mechanisms of the electric vehicle100, and transfer those loads, at least partially, to the chassis110.

In some examples, the battery pack114may transfer loads to the center of mass (or center of gravity) of the electric vehicle100. The center of mass (CM) may correspond to a location on or within the chassis110; however, this need not always be the case. The center of mass may also or instead correspond to other components of the electric vehicle100such as the battery pack114, for example. The transfer of received loads from the battery pack114to the center of mass may result from the battery pack114being a structural element that adds strength and/or rigidity to the electric vehicle100. The transfer of load in an electric vehicle may be considered the transfer of inertia from a linear and/or rotational acceleration. By way of example, when the electric vehicle100travels over a bump, the suspension system112may experience a linear and/or rotational acceleration as the suspension system112is forced upwards by the bump. The acceleration may be transferred as a load to the center of mass via the battery pack114. When the load reaches the center of mass, it may be considered to act on the entire electric vehicle100, forcing the electric vehicle100upwards.

It should be noted that although the battery pack114is a structural element of the electric vehicle100, forces may also be transferred directly from the suspension system114to the chassis110(or center of mass) without transiting the battery pack114. For example, the suspension system112and the center of mass may be connected via other linkages that can transfer loads. The proportions of loads that are transferred via the battery pack114may depend on the rigidity of the battery pack relative to other linkages between the suspension system112and the center of mass.

In the illustrated example, the battery pack114comprises a battery enclosure116housing one or more battery modules119. The battery enclosure116may protect the battery module119from external impacts, water and/or other debris. In one example, it is the battery enclosure116that is coupled to the suspension system112for receiving and transferring loads between the other vehicle components. A brace structure118that forms part of the chassis110may be present to transfer loads between the battery enclosure116and the suspension system112.

FIG. 2is a front view of an electric vehicle embodied as an electric snowmobile120, according to one example of the present disclosure. The snowmobile120is illustrated with one or more elements removed to aid in describing the remaining elements of the snowmobile120. For example, in one or more figures, various body panels of the snowmobile120(e.g., the hood) are removed, the endless track is removed and/or the snowmobile seat is removed.

The snowmobile120includes a chassis122(or frame), a battery pack124and a suspension system126. The chassis122provides a load bearing framework for the snowmobile120. The suspension system126connects the chassis122to the endless track and/or skis of the snowmobile120, and provides the steering/handling of the snowmobile120. The suspension system126may also provide shock absorption to improve ride quality for a user. The chassis122and/or suspension system126may be formed from, inter alia, metal, metal alloys, plastics and/or composites, for example.

As described above with respect toFIG. 1, the battery pack124comprises a battery enclosure128that houses one or more battery modules therein. In one example, the battery pack124, and more specifically the battery enclosure128, forms a structural element of the snowmobile120and is configured to receive, partially absorb and transfer loads from other snowmobile components, including the suspension system126, the seating (not shown inFIG. 2), and/or a steering system150, to the vehicle's center of mass and/or to the chassis122.

The battery enclosure128is made of a material that provides sufficient structural support to the snowmobile120, or another electric vehicle, such that it acts as a structural element of the vehicle. The material of the battery enclosure128has a stiffness sufficient for receiving and absorbing loads, as well as transmitting loads between the vehicle components (e.g., the suspension system126, seating and steering system150) and the vehicle's center of mass and/or the chassis122. The battery enclosure128may provide sufficient structural support to replace traditional support members such as braces, tubes and linkages, thus facilitating a more lightweight, compact, cost-efficient and/or ergonomic design for the snowmobile120.

In one example, the battery enclosure128is made of a carbon fiber composite material. Optionally, the carbon fiber composite material may have a thickness of 2-3 millimeters with an elastic modulus (i.e., stiffness) rating of at least 60 GPa. In other examples, the material has a stiffness rating between 10 GPa and 70 GPa.

In another example, the battery enclosure128is made of a material such as a polymer or a loaded polymer. In one example, the battery enclosure128is made of a glass fiber reinforced polymer (plastic) using an injection molding process, for example. In one example, the polymer incudes glass fiber reinforcement that provides stiffness to the battery enclosure128. For example, the polymer may include between 20-40% glass fiber content, and in another non-limiting example, 30% glass fiber content. In another example, the material of the battery enclosure128has a stiffness rating of at least 10 times the stiffness of a suspension spring element (i.e., a shock absorber). In another example, the material of the battery enclosure128has a stiffness that can range from 3 GPa without any fiber reinforcement to approximately 13 GPa with a 40% fiber reinforcement. It is recognized that other combinations of material and fiber reinforcement may be used based on the type of material and fiber used, and design requirements for a given application.

Other materials that the battery enclosure128may be made from are also contemplated. For example, the battery enclosure128may be made in whole or in part from metal or metal alloys.

The battery enclosure128may be formed in a single piece, or multiple pieces that are secured together. For example, the battery enclosure128may include a floor (not shown) that may be a relatively flat plate that is secured to the chassis122and a lid that connects to the floor in order to create a cavity for housing the electric battery module(s). In another example, the battery enclosure128may be made of two halves that connect at a central seam. In other examples, the battery enclosure128could be made of a bucket and a top cover; or there could be a floor, a ring-like central portion and a cover or lid.

It is also recognized that in areas where additional support is needed, the thickness of the material can be increased to provide additional stiffness. For example, reinforcement ribs can be injection molded into the material shape and thickness using the same material. In this manner, additional support and stiffness can be selectively provided to desired areas of the battery enclosure while still injection molding the same material throughout the process.

In one example, in addition to being a structural element that is able to receive, absorb and/or transfer loads received from the suspension system126, the steering system150and/or the seating, the battery enclosure128is also designed to withstand impact and damage that may be experienced during use of the snowmobile120. In a further example, the battery enclosure128is designed to protect the electric battery from the elements, and when sealed, may provide a water-tight enclosure that is closed to water and foreign debris ingress. In this manner, the battery enclosure128may provide sufficient protection such that the electric battery module(s) can be housed directly within the battery enclosure128.

In one example, the battery enclosure128might not be completely sealed to the elements and the electric battery module(s) may be provided within a non-structural watertight enclosure that is then, in-turn, housed within the structural battery enclosure128. The battery enclosure128may include an exoskeleton that provides a relatively lightweight yet rigid shape to at least partially protect the battery modules, while also acting as a structural element of the snowmobile120. For example, the exoskeleton may include a honeycomb lattice structure. Another enclosure, such as a watertight bag or container, for example, may provide the battery modules with protection from the elements.

Advantageously, the battery enclosure128may provide both housing of the battery modules (e.g., water-tight encapsulation and/or protection) and structural support. Combining this functionality in the battery enclosure128may reduce the size and/or weight of the chassis122, for example, and enable a more lightweight, compact, cost-efficient and/or ergonomic design of the snowmobile120. For example, implementing the battery enclosure128as a structural element may eliminate the need for other structural components that add strength and rigidity to the snowmobile120.

FIG. 3is a side view of the snowmobile120andFIG. 4is another side view of the snowmobile120. As shown inFIGS. 3 and 4, the snowmobile120includes a front end102, a rear end104(or back end), a top106and a bottom108. The snowmobile also includes two sides. One or more longitudinal axis, transverse axis and vertical axis may be defined for the snowmobile120. A longitudinal axis generally extends between the front end102and the rear end104of the snowmobile120, and corresponds to a typical horizontal direction of travel for the snowmobile120. A vertical axis extends in the vertical direction between the top106and bottom108when the snowmobile120is oriented for operation, i.e., with the suspension system122supporting the snowmobile120on the ground. A transverse axis extends horizontally between the two sides of the snowmobile120.

As also shown inFIGS. 2 to 4, the chassis122of the snowmobile120includes a rear tunnel130and a front brace structure132. The front brace structure132is connected to and configured to receive loads from the suspension system126. The front brace structure132includes a first top brace134and a second top brace136. The rear tunnel130and/or the front brace structure132may be made from metal, metal alloys, plastics and/or composite materials, for example.

The suspension system126may be coupled to the battery enclosure128, either directly or indirectly through the chassis122, and more specifically through at least the front brace structure132. In one example, the suspension system126may comprise a front suspension system that includes a first suspension leg138and a second suspension leg140. The first suspension leg138includes a first shock absorber142and is coupled to a first ski assembly144. The second suspension leg140includes a second shock absorber146and is coupled to a second ski assembly148. The first top brace134is coupled between the battery enclosure128and the first suspension leg138. The second top brace136is coupled between the battery enclosure128and the second suspension leg140. The first suspension leg138and the second suspension leg140may also include other structural components, such as one or more wishbone arms and/or one or more anti-roll bars, that may be connected to the front brace structure132and/or to other portions of the chassis122.

The shock absorbers142,146may each comprise a coil over spring and damper assembly, a hydraulic or pneumatic piston assembly, or any other type of shock assembly known to those skilled in the art. The shock absorbers142,146are connected either directly or indirectly between their respective ski assemblies144,148and the front brace structure132of the chassis122.

As shown inFIGS. 3 and 4, the suspension system126includes a back or rear suspension system180(which may also be referred to as a “skid” or “rear skid”) to support the real tunnel130. The rear suspension system180may include one or more skid rails to support an endless track that provides traction to drive the snowmobile120. The rear suspension system180may also include a front control arm, a rear control arm and one or more shock absorbers that connect the slide rails to the rear tunnel130.

Also illustrated inFIG. 2is the steering system150having handlebar attachment154coupled to an upper portion of the steering column152. The handlebar attachment154may enable handlebars to be rigidly coupled to the steering column152and enable a user to rotate the steering column152to turn the snowmobile120during use.

The steering system150also includes a steering assembly156coupled to the first and second ski assemblies144,148. The steering assembly156includes a first steering arm157(or steering link) and a second steering arm159. The first steering arm157connects a lower portion of the steering column152to the first ski assembly144and the second steering arm159connects the lower portion of the steering column152to the second ski assembly148. The connections between the steering column, the steering arms157,159and the ski assemblies144,148may be rotatable and/or pivotable (e.g., using ball joints) to accommodate rotation of the steering column152and/or motion of the suspension legs138,140. In some examples, the steering arms157,159might not be directly coupled to the steering column152. A rack and pinion assembly might be implemented between the steering column152and the steering arms157,159. In this way, the steering arms157,159might be indirectly coupled to the steering column. Similarly, the steering arms157,159might also or instead be indirectly coupled to the ski assemblies144,148.

The steering column152is securely and rotatably coupled to the battery enclosure128at a location160via a steering mount. The steering column152may extend at least partially through the battery enclosure128. In one example, the steering column152freely rotates within a tunnel or slot162defined by the battery enclosure128during steering of the snowmobile120. One or more examples of the steering system150are described in further detail elsewhere herein.

Reference is now made toFIG. 3andFIG. 4. As indicated above, the chassis122comprises the rear tunnel130and the front brace structure132. The battery pack124is illustrated positioned, at least partially, over the rear tunnel130. The battery enclosure128of the battery pack124defines a tunnel portion200(or rear portion) and a front portion202. In one example, the tunnel portion200(or rear portion) is connected to the rear tunnel130of the chassis122, and the front portion202is connected to the front brace structure132. In one example, the tunnel portion200may be generally rectangular shaped with one or more chamfered edges, although other shapes are also possible, including an elongated dome shape, or a truncated prismatic shape, among other possibilities. The tunnel portion200is connected to the rear tunnel130of the chassis122at connection points or blocks204. The tunnel portion200may be rigidly connected to the rear tunnel130via mechanical fasteners such as nuts and bolts, rivets, staples, etc. In some embodiments, a bottom portion or floor of the battery enclosure128may be connected to the rear tunnel130more permanently via welding, soldering or adhesion among other possibilities. In such a case, an upper portion or lid of the battery enclosure128may then be rigidly fastened to the floor via mechanical fasteners, a friction fit, a snap fit or any other suitable removable fastening mechanism.

As shown inFIG. 2, the front portion202of the battery enclosure128may be generally rectangular shaped and is located towards the front of snowmobile120. In some cases, the front portion202may have one or more chamfered edges. In one example, front portion202of the battery enclosure128has different width and height dimensions from tunnel portion200of the battery enclosure128, such that there is a clear visual demarcation between the tunnel portion200and the front portion202of the battery enclosure128. However, in other embodiments, the front portion202may have only a different height or a different width from the tunnel portion200, and not both. In still further embodiments, the front portion202may have the same height and width as the tunnel portion200along an entire length of the battery enclosure128, such that there is no distinct visual demarcation between the tunnel portion200and the front portion202. In still further embodiments, the battery enclosure128may gradually increase in height and/or width from the rear of the tunnel portion200to the front of the front portion202. The battery enclosure128may have any shape or configuration that is suitable for housing one or more battery modules and attaching to the tunnel130and front brace structure132of the electric vehicle.

FIG. 5Ais a partial side view of the snowmobile120. With reference toFIG. 5A, in one example, the front portion202of the battery enclosure128defines a first height206and the tunnel portion202of battery enclosure128defines a second height208. As illustrated, the first height206and the second height208are generally measured along a vertical axis of the snowmobile120. In one example, the first height206is greater than the second height208. In other examples, the first height206is less than the second height208. In one example, the front portion202of battery enclosure128defines a first width210and the tunnel portion202of battery enclosure128defines a second width212. As shown, the first width210and the second width212are generally measured along a transverse axis of the snowmobile120. In one example, the first width210is greater than the second width212. In other examples, the first width210is less than the second width212.

In one example, battery pack124has an approximate overall length (along a longitudinal axis) of 1563 mm, width of 596 mm, and height of 437 mm. It is recognized that the overall length, width and height of battery pack124may vary based on the design of snowmobile120. In another example, the approximate overall length of battery pack124is in a range of 750-2000 mm, the width is in a range of 450 mm-600 mm, and the height is in a range of 350-550 mm.

FIG. 6is a top front perspective view of the snowmobile120. The battery enclosure128includes the tunnel portion200positioned over rear tunnel130, and the front portion202positioned at or in proximity to the front of the rear tunnel130.

In one or more examples, it is recognized that the battery enclosure128may provide one single internal cavity for the battery module(s) of the electric battery, or multiple segmented internal cavities that can separate the different battery module(s) of the electric battery. There may be cutouts in the segmenting walls for enabling electrical interconnection of the battery modules.

In one example, the battery enclosure128may be one overall component made up of a floor and a cover or lid. In another example, the battery enclosure128may comprise multiple separate battery enclosure components that each have a floor and cover or lid. The separate enclosure components may comprise two separate enclosure components (for example, the tunnel portion200and the front portion202may each form a separate distinct battery enclosure component). Alternatively, the battery enclosure128could be divided up differently, and into even more than two separate battery enclosure components. The separate battery enclosure components can be positioned on the chassis122in the same configuration as described for a single battery enclosure (i.e., in the same position as shownFIG. 3), or the different individual battery enclosure components could be positioned differently in relation to the rear tunnel130and front brace structure132of the chassis122. In one example, the front portion202may be positioned in a mid-bay region in horizontal alignment with the rear tunnel130and the motor is positioned above the front portion202of the battery enclosure128. The separate battery enclosure components may be unconnected when installed on an electric vehicle, or the separate battery enclosure components could be connected together with brackets, etc. The electric battery module(s) housed within the separate battery enclosure components would be electrically interconnected.

As described above, multiple battery enclosures may be used and operably connected together. The multiple battery enclosures may allow for a more optimal weight distribution. In one example, as batteries get smaller and more powerful it may be beneficial to locate the batteries in a number of enclosures to improve ergonomic design and performance of the electric vehicle.

In one example, the battery enclosure128may house only the electric battery modules (and possibly wiring/electronics and supporting structures for the battery modules) of the electric battery. In another example, the battery enclosure128may house the electric battery as well as other components of the electric vehicle, such as battery management controllers, thermal management systems, a motor assembly, etc.

FIG. 7Ais an enlarged partial perspective view of section A ofFIG. 6showing the battery enclosure128front portion202. The front portion202includes a top surface300, a front surface302, a first side surface304, a second side surface306, and a bottom surface308. It should be noted that the top surface300is not limited to a single flat surface. For example, the top surface300may be formed from multiple surfaces disposed at the top of the battery enclosure128. There may also or instead be multiple top surfaces of the battery enclosure128. Similar comments apply to the front surface302, the first side surface304, the second side surface306and the bottom surface308.

The front brace structure132may be coupled to the battery enclosure128at one or more of the top surface300, the front surface302, the first side surface304, the second side surface306and the bottom surface308. In one example, the front brace structure132is coupled to battery enclosure128at least partially at the top surface300. In another example, the front brace structure132is coupled to the battery enclosure128at least partially at the front surface302. In another example, the front brace structure132is coupled to the battery enclosure128at least partially at a front edge330formed by the top surface300and the front surface302. The front brace structure132may also or instead be coupled to the battery enclosure128at the bottom surface308.

In one example, the front brace structure132is rigidly coupled to the battery enclosure128at four connection points for transferring load to the battery enclosure128. The front brace structure132includes the first top brace134and the second top brace136. The first top brace134includes a first end320and a second end322. The second top brace136includes a first end324and a second end326. The first top brace134is connected to battery enclosure128at the first end320. In one example, the first end320of first top brace134is connected to both the top surface300and the front surface302at the front edge330(at a first connection location332). The second top brace136is connected to the battery enclosure128at the first end324. In one example, the first end324of the second top brace136is connected to both the top surface300and the front side surface302at the front edge330(at a second connection location334). In one example, the first connection location332is spaced apart from the second connection location334along the front edge330, identified as top space336. The top space336is shown as distance between the first connection location332and the second connection location334along a lateral axis of the snowmobile120.

In one example, the second end322of first top brace134is connected to the front surface302and/or to the bottom surface308of the battery enclosure128(at a third connection location342) via one or more linkages. In one example, the second end326of second top brace136is connected to the front surface302and/or to the bottom surface308(at a fourth connection location344) via one or more linkages. Optionally, the third connection location342and/or the fourth connection location344is at a front bottom edge340formed by the front surface302and the bottom surface308of the battery enclosure128. In one example, the third connection location342is spaced apart from the fourth connection location344along the front bottom edge340, identified as bottom space346. The bottom space346is shown as distance between the third connection location342and the fourth connection location344along a lateral axis of the snowmobile120. In one example, bottom space346is wider than top space336. In another example, top space336is wider than bottom space346. In yet another example, the top space336is approximately equal to the bottom space346.

In one example, the front brace structure132includes a cross brace structure350. The cross brace350extends between the first top brace134and the second top brace136. The cross brace350provides bracing between the first top brace134and the second top brace136at the second end322and the second end326. In one example, the cross brace350is connected to the second end322at a joint member352. The cross brace350is connected to the second end326at a joint member354.

FIG. 7Bis an enlarged partial view of the fourth connection location344, indicated at321. Referring toFIG. 7B, the second top brace136is connected to the battery enclosure128at the second end326through the joint member354and a mechanical linkage325.

As outlined above, the front portion202of the battery enclosure128is coupled to the front brace structure132. In the example shown inFIG. 7A, the first top brace134and the second top brace136of the front brace structure132are connected to front portion202of the battery enclosure128. More specifically, in the example shown, the four connection points332,334,342,344provide a secure and rigid connection between the front brace structure132and battery enclosure128. This provides for the transferring of loads between suspension system126and the battery pack124. The connection points332,334,342,344may implement, inter alia, mechanical fasteners (e.g., nuts, bolts, screws and rivets), welds, adhesives, snap-fit connections and any combination thereof to form rigid connections.

It is recognized that other design configurations and connections may exist between the front brace structure132and the battery enclosure128, in order for the battery enclosure128to be connected to and receive loads from suspension system126. In one example, there are fewer than four connection points between front brace structure132and the battery enclosure128. In one example, there are more than four connection points between the front brace structure132and battery enclosure128. The surfaces and/or edges of the battery enclosure128on which the connection points are located are also not limited. For example, the front brace structure may also or instead be coupled to the first side surface304and/or to the second side surface306. The connection points may be fixed or removable. The structure of the front brace structure132may take on many different forms and remain within the scope of the present disclosure.

In one example, loads or forces imparted by the steering system150, and more specifically by the steering column152, of the electric vehicle are received by the battery enclosure128of the battery pack124. These loads are partially absorbed by the battery enclosure128and/or transferred to the vehicle's center of mass and/or chassis122through the battery pack124.

FIG. 11is an enlarged partial perspective view of the snowmobile120. In the example shown inFIG. 11, the steering system150comprises a steering mount430that includes a first side mount452and a second side mount454attached to the front portion202of the battery enclosure128. The first side mount452and/or the second side mount454may implement, inter alia, one or more mechanical fasteners, welds, adhesives, snap-fit connections and any combination thereof to rigidly connect to the battery enclosure. A member424extends between first side mount452and second side mount454, and operates to hold the steering column152to the battery enclosure128. The member424also allows steering column152to rotate during operation of the steering system150.

In one example, the member424includes a pipe member having an axis aligned with an axis of the steering column152. In operation, the steering column152passes through the pipe member and is supported by the pipe member.

As the operator of the snowmobile120steers and maneuvers the vehicle, loads are transferred from the steering column152to the steering mount430, which in turn transfers loads from the steering column152to the battery pack124, and specifically the battery enclosure128. The battery enclosure128may absorb some of those loads and/or transfer the loads from the steering column152to the vehicle's center of mass and/or the chassis122.

FIG. 12is a partial side view of a snowmobile500, according to one example of the present disclosure. Snowmobile500is similar to the snowmobile120previously detailed herein. Snowmobile500includes battery pack124having battery enclosure128.

The battery enclosure128includes the tunnel portion200and the front portion202. The tunnel portion200includes a tunnel portion front end506and a tunnel portion back end508. The tunnel portion200is located over and secured to the chassis rear tunnel130. The front portion202is located near the front of the snowmobile500, at the tunnel portion front end506.

The snowmobile500includes a seat510and a backrest512. As illustrated, the snowmobile seat510is a straddle-seat that is to be straddled by a rider, i.e., with a leg positioned on either side of the seat510. The seat includes a cushion522.

The battery pack124provides structural support for the snowmobile500seating, which may comprise one or both of a snowmobile seat510and backrest512. In one example, the snowmobile seat510and backrest512are mounted directly to the battery pack enclosure128. In one example, the seat510is mounted to the battery pack enclosure128via brackets (not shown) such that a space is provided between the tunnel portion200of the battery pack enclosure128and the seat510. In another example, the seat510is mounted to the battery pack enclosure128such that at least a portion of a bottom surface of the seat510is in direct contact with a surface of the tunnel portion200of the battery pack enclosure128. The seat510is connected to the tunnel portion200of the battery enclosure128, and extends from the front portion202at the tunnel portion front end506to the tunnel portion back end508. Battery enclosure128is a structural element of the snowmobile that supports seat510and optionally the backrest512. Further, the battery enclosure128tunnel portion200receives loads transmitted from the seat510and partially absorbs and/or transfers those loads to the vehicle's center of mass and/or the chassis122due to one or more riders positioned on the seat510or the result of operation of the snowmobile500over various snow terrain.

In some examples, heat generated by the battery pack124may be transferred through the battery enclosure128and into the seat510. This heat may be generated during discharge of the battery pack124to power an electric motor and/or other systems of the snowmobile500. The heat may be transferred passively to the seat510via radiation, conduction and/or convection, for example. Transfer of the heat into the seat510may warm the cushion522and, optionally, an operator seated on the cushion522. In this way, by mounting the seat510onto the battery pack124, heat generated by the battery pack124may provide a more pleasant experience for the operator in cold conditions. This heat might otherwise be lost into the ambient environment. Further, because an operator may straddle the battery pack124when riding the snowmobile500, heat generated by the battery pack124may radiate out the lateral sides of the battery enclosure128and warm the legs of the operator.

The seat backrest512is supported by the battery enclosure128tunnel portion200. In one example, the seat backrest512is mounted directly to the battery enclosure128at the tunnel portion back end508. The seat back rest512includes a bracket524. The bracket524is generally L-shaped, including a generally vertical first leg526and a generally horizontal second leg528. A cushion of the backrest512may be attached to the first leg526. The second leg528is attached to the tunnel portion200. The seat510may extend rearward beyond a top surface of the battery enclosure tunnel portion200and be supported by the second leg528. Seat loads (e.g., by a rider during operation of the snowmobile) are received by the battery pack124, and specifically the battery enclosure128, via connection points between the seat510and the battery pack124. Additionally, seat loads are transferred during use from the seat backrest512to the battery pack124at locations where the seat backrest512is connected to the battery pack124.

In one example, the seat510is rigidly fastened at four places onto the battery pack124. There may be two plastic hooks (not shown) on the top surface of the tunnel portion back end508of the battery enclosure128that mate with corresponding slots located on the bottom of the seat510(i.e., the seat pan). Additionally, there may be two aluminum tabs on a fore portion of the seat pan (one on each side) that fasten the seat510to the battery enclosure128. In one example, the seat510is rigidly fastened to the battery pack124via the seat pan using screw holes with threaded inserts on the lid of the battery enclosure128. Other types of connections between the seat510and the battery enclosure128are also possible.

In one example, the seat backrest512is fully supported by the battery enclosure128. In contrast, typical backrests are mounted directly to a snowmobile chassis. With the battery enclosure128being used to fully support the seat backrest512, additional storage area is available on the rear tunnel130for cargo or other utility use. In one example, the backrest512is a separate component independently and directly attached to the battery pack124using one or more mechanical fasteners, welds, adhesives, snap-fit connections and any combination thereof, for example. In another example, the seat backrest512is at least partially part of or an extension of the seat510.

Loads imparted on the snowmobile seating (i.e., one or both of the seat510and the backrest512), are received directly by the battery pack124, and specifically the battery enclosure128. The battery enclosure128may absorb some of those loads and/or transfer the loads from the seating to the vehicle's center of mass and/or the chassis130.

In operation, as the snowmobile120,500is driven across a varied terrain, loads are transferred from the suspension system126(e.g., the first suspension leg138and the second suspension leg140) through the front brace structure132(e.g., through the corresponding first top brace134and the second top brace136) to the battery enclosure128. Likewise, loads are transferred from the seating (e.g., the seat510and the backrest512) and the steering system150to the battery enclosure128. The battery enclosure128acts as a structural element, and after receiving the loads then transfers the loads through the body of the battery enclosure128to the vehicle's center of mass and/or to the rear tunnel130. In one or more examples described herein, loads are transferred to the rear tunnel130since the center of mass of the vehicle is located at the rear tunnel130. As such, it is recognized that the loads are transferred to the center of mass located within the rear tunnel130.

FIG. 5Bis a block diagram illustrating a load path of a snowmobile (e.g., the snowmobile120,500), according to one example of the present disclosure. The load path is also illustrated inFIG. 5A. The load path is illustrated using arrows220,222,224,226and228. In one example, as the snowmobile120,500moves over a given terrain or snow profile, load is transferred from the suspension system126(via the first suspension leg138and the second suspension leg140) to the front brace structure132(via the first top brace134and the second top brace136); load is then transferred from the front brace structure132(via first the top brace structure134and second the top brace structure136) to the battery enclosure128(e.g., to the front surface302of the battery enclosure128); and the load is then transferred, at least partially, from the battery enclosure128(via the front portion202and the tunnel portion200) to the chassis122including the rear tunnel130.

Traditional electric powersport vehicles, such as combustion engine snowmobiles, often have curved steering columns and/or complex linkages connecting the steering column to their steering assembly. This is a result of the steering column having to avoid interference with the combustion engine, which is typically housed in the front portion of the snowmobile.

In some embodiments, an electric vehicle includes a battery pack design that accommodates a straight steering column. Such battery pack designs may leverage the modular nature of battery pack components. For example, battery modules and/or other components of a battery pack may be arranged within the battery pack to form a slot to receive the steering column.

It should be noted that battery packs and enclosures without a slot for receiving a steering column are also contemplated and are included within the scope of the present disclosure.

Reference is now made toFIG. 8.FIG. 8is a partial front view of the battery enclosure128and the chassis122of the snowmobile120. In one example, the battery enclosure128front portion202may define a slot162. The slot162is illustrated as a substantially straight channel or groove in the front portion202of the battery enclosure128. The slot162extends downward from the top surface300of the battery enclosure128for receiving the steering column152of the snowmobile120. In this way, the steering column152is able to at least partially pass through the battery enclosure128. The straight slot162defined within the battery enclosure128enables the electric vehicle to use a linear, substantially straight, steering column152and a relatively uncomplex connection between the steering column152and the steering assembly156.

In one example, the slot162extends from the top surface300of battery enclosure128to a front surface302of the battery enclosure128. The slot162may be at least partially formed by the front surface302. In another example, the slot162extends downwards from the top surface300of the battery enclosure128to the bottom surface308of the battery enclosure128. The slot162may at least partially pass through the bottom surface308.

In one example, the slot162is generally geometrically shaped. For example, the slot162can be partially circular, oval or square shaped in cross-section. In other examples, the slot162is not geometrically shaped. The slot162may have an open side along its length. In other embodiments, the slot162can be defined as a wholly or partially enclosed slot extending through the battery enclosure128. In one or more examples, the slot162may take on the form of a tunnel, pipe, or tubular member.

FIG. 9is a cross-sectional view of the slot162taken along the line9-9inFIG. 8. In one example, the slot is generally U-shaped in cross-section. The slot162is defined by a first side wall400, a second side wall402, and a bottom surface404. Additional walls and/or surfaces may also be present in other slot designs. In one example, the bottom surface404has an angle along its length that generally matches an angle of the steering column152.FIG. 10is a diagram illustrating an angle of the bottom surface404relative to a substantially horizontal longitudinal axis of the snowmobile120indicated at410. With reference toFIG. 10, the bottom surface404of the slot162extends at an angle of between 30 degrees and 60 degrees with respect to the horizontal longitudinal axis410. In one example, the substantially horizontal longitudinal axis410of the electric snowmobile is defined by a top surface of rear tunnel130.

A width412of the slot162is defined by the distance between the first sidewall400and the second sidewall402. In one example, the width412of slot162is between 30 millimeters and 60 millimeters. The width of slot162may vary along its length. In one example, the width of slot162is wider at a top end of the slot162than at a bottom end of slot162. In another example, the width412of slot162is substantially constant along its length with first sidewall400being substantially parallel to second sidewall402.

Referring back toFIG. 8, in one example, the slot162divides the front portion202of battery enclosure128into two sides, defined as a front portion first side420and a front portion second side422. In one example, the slot162is positioned substantially centrally with respect to the first side surface304and the second side surface306, such that the slot162divides the front portion202of the battery enclosure into two halves. Alternatively, the slot162may not be positioned centrally, such that the front portion first side420and front portion second side422are of different sizes. In operation, the front portion first side420and the front portion second side422each house one or more electric battery modules. In one example, the front portion first side420and the front portion second side422each house a stack of battery modules. In other examples, at least one of the front portion first side420and the front portion second side422contain or house one or more components of the battery pack124other than a battery module, such as a battery controller and/or heating/cooling ducts, for example.

As described above, the slot162is configured such that a substantially straight steering column152passes through the slot162. The steering system150includes the steering mount430that operably couples the steering column152to the battery enclosure128to support the upper portion of the steering column152. In some examples, the steering mount430couples to the steering column152to the top surface300of the battery enclosure. The first side mount452is attached on the front portion first side420at a top end of the slot162and the second side mount454is attached on the front portion second side422on an opposite side of the slot162from the first side mount452. The steering mount430allows the steering column152to operate within the slot162while providing structural support to the steering column152within steering system150. For example, the steering mount430may provide support and structural stiffness to the steering column162. The steering mount430is coupled to the battery enclosure128at a position that enables the steering column152to be received within the slot162. The steering mount430may provide a structural stiffness to the snowmobile handlebars, and in turn, an improved experience to a snowmobile operator. The steering mount430may also transfer loads from the steering system150to the battery enclosure128.

FIG. 13is a partial side view of a snowmobile600, according to one example of the present disclosure. The snowmobile600is similar to the snowmobile120and snowmobile500previously described herein.FIG. 13depicts the battery pack124positioned on the chassis122. An electric battery is housed within the battery enclosure128of the battery pack124. The electric battery comprises multiple electric battery modules714. Both the tunnel portion200and the front portion202of battery enclosure128contain the battery modules714to power snowmobile120.

The snowmobile600illustrates one example of the relative locations of the battery pack124and an electric motor assembly610on the snowmobile chassis122. By arranging the locations of the battery pack124and the electric motor assembly610appropriately, the location of center of mass612can be improved. This provides for a better snowmobile ride experience and better snowmobile performance. For example, too much weight forward can result in poor snowmobile traction and acceleration. With too much weight backward, there can be a loss of snowmobile steering and control. As such, it is desirable to locate the center of mass and weight distribution to improve both snowmobile control and performance.

The snowmobile600includes a rear portion of the chassis122having rear tunnel130. A portion of the battery enclosure128is mounted on the rear tunnel130. The electric motor assembly610is mounted below the battery enclosure128and adjacent a front side620of the rear tunnel130. The chassis122further defines a mid-bay630. The mid-bay630is located between the rear tunnel130and the front brace structure132. In some embodiments, the mid-bay630may form part of the front brace structure132. In one example, the electric motor assembly610is positioned within the mid-bay630. The electric motor assembly610includes a drive shaft operably aligned with the snowmobile drive transmission640. The drive transmission640may include a drive linkage to drivingly couple to the electric motor assembly610. In one example, the drive transmission640is a belt drive system and/or a chain drive system. As such, it is efficient to have the motor assembly610located within the mid-bay630in the lower front area of chassis122. In this configuration, the motor assembly610and drive transmission640are efficiently mounted right next to each other on the snowmobile chassis122.

Further examples of the electric motor assembly610being within the mid-bay630is described in further detail later in this specification.

The battery pack124includes a tunnel battery pack710and a mid-bay battery pack712. The tunnel battery pack710is generally corresponds to the tunnel portion200of the battery pack124and the mid-bay battery pack712generally corresponds to the front portion202of the battery pack124. Each battery pack710and712includes a plurality of the battery modules714. The battery modules714are one of the heaviest design elements of snowmobile600. The location of battery packs710and712, and therefore distribution of the battery modules714over the chassis122, aids in desired weight distribution across the snowmobile600. The tunnel battery pack710is located above the rear tunnel130(and below the snowmobile seat). The mid-bay battery pack712is located above the front end of rear tunnel130within mid-bay630and above the electric motor assembly610. This may provide a shifted and improved location of the center of mass612, resulting in a snowmobile with improved weight distribution and balance, and overall snowmobile performance.

The battery pack124includes the battery enclosure128having a lid or cover and floor. The battery cover operates primarily to protect the battery modules and as a structural element to transfer loads from the suspension system126to the snowmobile chassis122. The battery pack floor primarily operates to support the battery modules714within the battery pack124.

FIGS. 14 to 17illustrate one example of the battery pack124, including the battery modules714. For ease of illustration, the battery pack124is shown with the battery enclosure lid removed for a view of the internal structure of the battery pack124.

FIG. 14is a front top perspective view of the battery pack124, according to one example of the present disclosure.FIG. 14shows the battery modules714that make up an electric battery within the battery pack124. The battery pack124includes the battery enclosure128that houses the battery modules714. The battery enclosure128includes a battery pack cover or lid716(shown removed) and a battery pack support floor718. The battery pack support floor718holds and supports the battery modules714. Further, the battery modules714are securely retained within the battery pack124by a battery support structure720.

The battery pack124comprises a plurality of battery stacks740, where each stack is retained within a cartridge assembly742. Each battery stack740is made up of two or more battery modules and retained within a cartridge assembly742. In one example, the tunnel battery pack710is made up of four battery stacks744. Each battery stack744includes two battery modules714stacked together within a cartridge assembly742. As such, the tunnel battery pack710includes eight total battery modules714. The battery stacks744are positioned on the battery pack support floor718. The battery support structure720aids in maintaining each battery stack744in a desired location on support floor718. The battery support structure720operates to maintain a desired spacing between individual battery stacks740, and also maintain spacing between the battery stacks740and the battery enclosure.

In one example, a mid-bay battery pack712is made up of two battery stacks748. One battery stack748is disposed in the front portion first side420and the other battery stack748is disposed in the front portion second side422. Each battery stack748includes three battery modules714stacked together within a cartridge assembly742. As such, the mid-bay battery stack712includes six total battery modules714. The battery stacks748are positioned on battery pack support floor718. Battery support structure720aids in maintaining each battery stack748in a desired location on support floor718. Battery support structure720operates to maintain a desired spacing between individual battery stacks748, and also maintain spacing between the battery stacks748and the battery enclosure128. In one example, the battery support structure420is part of the battery enclosure128. In one example, the spacing between battery stacks748located within mid-bay battery pack712is also dependent on the space requirements for slot162to accommodate the snowmobile steering column.

In one example, the battery support structure720is made of a rigid material, such as a rigid polymeric material. In one example, individual members of battery support structure720are generally tubular shaped members.

In one example, each battery module714is generally rectangular shaped. The battery modules714within the battery stacks744are orientated in a direction different than the battery modules714positioned within battery stacks744. In one example, the battery modules714within battery stack744are orientated perpendicular to an orientation of the battery modules714contained within battery stacks748. In other embodiments, all of the battery modules714are oriented in the same direction.

FIG. 15is a top view of the battery pack124ofFIG. 14, further illustrating the battery support structure720and the battery stacks740.FIG. 16is a side view of the battery pack124further illustrating the tunnel battery pack710and the mid-bay battery pack712.FIG. 17is a front view of the battery pack124, further illustrating the mid-bay battery stack748.

Each battery module714contained within the battery pack124is made of one or more battery cells. In one example, the battery modules are lightweight ‘pouch” battery modules, where each battery module includes two or more pouch battery cells. The battery cells may be prismatic battery cells. In one example, the prismatic battery cells are lithium-ion prismatic battery cells. One or more examples of a battery stack, a battery cartridge, battery module and battery cooling panel assembly, including pouch battery modules and pouch battery cells, suitable for use in the present electric vehicle are disclosed in U.S. patent application Ser. No. 17/091,777 titled Battery Cooling Panel for Electric Vehicles filed Nov. 6, 2020, the entire contents of which are incorporated herein by reference.

In some embodiments, the positions of a battery pack, an electric motor and/or a transmission on a chassis of an electric vehicle are selected to provide a more space-efficient design, better manage loads from the electric motor, and/or to improve the location of the center of mass of the electric vehicle. In one example, an electric vehicle includes a chassis defining a rear portion and a front portion. A transmission may be mounted to a rear portion of the chassis and a battery pack may be mounted on top of the rear portion of the chassis. An electric motor may be mounted below the battery enclosure and between a front side of the rear portion of the chassis and a front end of the electric vehicle. In this way, the transmission and the electric motor may be proximate to each other underneath the battery pack to conserve space.

Further, the electric motor may be positioned generally horizontally relative to the transmission. In one example, the electric vehicle includes a transmission drive shaft and a motor drive shaft spaced apart along a longitudinal axis of the electric vehicle. The motor drive shaft may be coupled to the transmission drive shaft via a drive linkage such as a drive belt, for example. A portion of the drive linkage extending between the transmission drive shaft and the motor drive shaft may be substantially horizontal (e.g., substantially parallel to a longitudinal axis of the electric vehicle).

A transmission plate may be attached to the electric motor to provide structural stability to the electric motor. The transmission plate may be connected at a first end to the rear portion of the chassis and at a second end to the front portion of the chassis in a generally horizontal manner. In this way, the transmission plate may be simply supported along a longitudinal axis of the electric vehicle. The transmission plate may also be supported parallel to the portion of the drive linkage extending between the transmission drive shaft and the motor drive shaft. This configuration of the transmission plate may improve rigidity and enable the transmission plate to better manage tensile and rotational loads from the electric motor and drive belt.

FIGS. 18 to 22illustrate one example of an electric motor assembly610.FIG. 18is a partial perspective view of the electric motor assembly610positioned within a snowmobile. The electric motor assembly610is mounted below the battery enclosure128and adjacent to a front side620of the rear tunnel130. In this way, the electric motor assembly610is positioned in front of the rear tunnel130. The motor assembly610is also positioned generally horizontally relative to the longitudinally extending rear tunnel130.

Mounting the electric motor assembly610below the battery pack124can help provide more space for the battery pack124. For example, the battery pack124may extend along the length of the rear tunnel130without being limited in size by the electric motor assembly610and/or other components. This may enable larger battery packs with greater capacities to be used. Further, mounting the battery pack124on top of the rear tunnel130may shift the center of mass of the snowmobile towards the rear suspension, which may improve traction and overall ride quality.

The snowmobile chassis122includes the rear tunnel130. The chassis122also includes a mid-bay and the front brace structure132, the mid-bay being located between the rear tunnel130and the front brace structure132. The electric motor assembly610is positioned within the mid-bay.

The electric motor assembly610is shown coupled to a drive transmission800. The drive transmission800may transfer power from the electric motor assembly610to an endless track of the snowmobile. In one example, the electric motor assembly610is coupled to the drive transmission800via a belt drive system810. A chain drive system may also or instead be used. The electric motor assembly610is positioned substantially horizontally relative to the drive transmission800. For example, the electric motor assembly610and the drive transmission800may occupy the same horizontal plane and/or be aligned along a longitudinal axis of the snowmobile.

FIG. 19is an enlarged partial perspective view of the motor assembly610.FIG. 19further illustrates the position of electric motor assembly610on the chassis122. A transmission plate812is positioned between the belt drive system810and the motor assembly610. In one example, the transmission plate812is positioned substantially parallel to a first side edge814of the rear tunnel130. The transmission plate812includes a first end820and a second end822, which spaced apart along a substantially horizontal longitudinal axis of the snowmobile. The transmission plate812is attached at the first end820to the first side edge814of rear tunnel130, and at the second end822to a component of the front brace structure132. In this way, the transmission plate812is simply supported by the chassis122at its first end820and its second end822. Additionally, the transmission plate812is attached to a front plate824of the motor assembly610. The second end822of the transmission plate812is coupled to the front brace structure at connection points813, which may be bolt holes that correspond to bolt holes on the font brace structure132to form a rigid bolted connection. A rigid bolted connection may also be implemented between the first end820of the transmission plate812and the first side edge814of rear tunnel130, and/or between the transmission plate812and the front plate824of the motor assembly610. Other forms of rigid connections, including welds, snap fit connections and/or friction fit connections, for example, may also be implemented in the connections to the transmission plate812.

The configuration and coupling of the transmission plate812to the chassis122may provide a rigid support for the motor assembly810and improved handling of transmission loads from the belt drive system810. For example, tensile and rotational loads from the motor assembly610and belt drive system810may be managed without bending or other deformation of the transmission plate812. The configuration and coupling of the transmission plate812to the chassis122may also allow for a lighter transmission plate since the transmission plate812is supported at both ends. In contrast, if only one end of the transmission plate812is connected to the chassis122, the significant bending could occur do to loads from the motor assembly610and belt drive system810.

FIG. 20is a partial side view of the electric motor assembly610. In one example, the electric motor assembly610is mounted proximate to the drive transmission800by the transmission plate812. The electric motor assembly610includes a motor drive shaft830. The drive transmission800includes a transmission drive shaft832. The motor drive shaft830and the transmission drive shaft832extend parallel to each other along transverse axes. The transmission drive shaft832and the motor drive shaft830are spaced apart from each other along a longitudinal axis of the electric vehicle. The motor drive shaft830is operably coupled to the transmission drive shaft832via the belt drive system810.

The transmission plate812includes a U-shaped slot809(or opening) that extends downwards from a top side of the transmission plate812. The electric motor assembly610drive shaft830extends through the U-shaped slot809. In one example, the electric motor assembly610is attached to both sides of the U-shaped slot809at an interior of the transmission plate812such that the motor drive shaft830extends through the U-shaped slot809from an interior to an exterior of the U-shaped slot. The U-shaped slot809may aid in mounting of the motor assembly610to the chassis122by enabling the motor assembly610to be lowered downwards into position in the mid-bay, with the drive shaft830positioned within the U-shaped slot809. The electric motor assembly610may then be coupled to the transmission plate812. An additional plate (not shown) may cover the U-shaped slot809once the motor assembly610is positioned within the snowmobile120that may aid in managing torque loads from the motor.

In one example, the electric motor assembly610includes an electric motor drive gear coupled to the motor drive shaft830and the drive transmission800includes a transmission gear860coupled to the transmission drive shaft832. The belt drive system810includes a drive belt811. The drive belt811is connected between the electric motor drive gear and the transmission gear860. In other embodiments, another drive linkage such as a drive chain, for example, may be connected between the electric motor drive gear and the transmission gear860. In some examples, an angle of a portion of the drive belt811extending between the electric motor drive gear and the transmission gear860with respect to the substantially horizontal longitudinal axis of the snowmobile is equal to or less than 20% (or 11.3 degrees) and equal to or greater than −20% (or −11.3 degrees). As illustrated, this portion of the drive belt811is a top portion of the drive belt811connected directly between the electric motor drive gear and the transmission gear860. A drive belt idler pulley862contacts a bottom surface of the bottom portion of the drive belt811.

In other embodiments, the drive belt idler pulley862may contact a top portion of the drive belt811and the bottom portion of the drive belt811may be connected directly between the electric motor drive gear and the transmission gear860. An angle of the bottom portion of the drive belt811with respect to a substantially horizontal longitudinal axis of the snowmobile may be equal to or less than 20% (or 11.3 degrees) and equal to or greater than −20% (or −11.3 degrees).

Advantageously, positioning the electric motor assembly610substantially horizontally to the drive transmission810may reduce the distance between the electric motor assembly610and the drive transmission810, thereby potentially providing an efficient utilization of space and/or a reduction in the complexity and cost of the belt drive system810. Further, positioning the electric motor assembly610and the drive transmission810such that the top portion of the drive belt811extends substantially parallel a horizontal longitudinal axis of the snowmobile helps ensure that some loads exerted on the transmission plate812are also along the horizontal longitudinal axis of the snowmobile. The transmission plate812is supported at either end820,822along this longitudinal axis, and may therefore better manage loads from the belt drive system810and electric motor assembly610.

FIG. 21andFIG. 22further illustrate the electric motor assembly610.FIG. 21is another partial side view of the electric motor assembly610, andFIG. 22is a partial perspective view of the electric motor assembly610. The electric motor assembly610is shown positioned immediately adjacent the front side620of rear tunnel130. In the embodiment shown, the electric motor assembly610does not extend the entire width of the rear tunnel130. As such, the electric motor850may remain substantially unsupported, or supported by sheet metal with minimal structural support, at the end opposite from the motor drive shaft830. The electric motor assembly610incudes a motor850coupled to an inverter852. The inverter852is directly coupled to the motor850, and contained within a common housing854. The electric motor assembly610having the inverter852integrated into the same housing provides for efficient locating of the motor assembly610in the chassis mid-bay in front of the rear tunnel130. One motor assembly including a motor coupled to an inverter, suitable for use in the present electric vehicle, is disclosed in U.S. Patent Application No. 63/135,466 (Attorney Docket No. T1670.109.101/TPA013), titled DRIVE UNIT FOR ELECTRIC VEHICLE, filed Jan. 8, 2021, the entire contents of which are incorporated herein by reference.

Although specific examples have been illustrated and described herein, a variety of alternate and/or equivalent implementations may be substituted for the specific examples shown and described without departing from the scope of the present disclosure. This disclosure is intended to cover any adaptations or variations of the specific examples discussed herein.

It should be noted that, as used herein, the phrase “at least one of A and B” includes any combination of A and/or B. For example, the phrase “at least one of A and B” encompasses only A, only B, and A and B together. Similar comments apply to the phrase “at least two of A, B and C”.

Various example embodiments of the present disclosure will now be provided.

An electric vehicle comprising, an electric motor, a battery pack comprising: one or more battery modules for providing power to the electric motor; and a battery enclosure housing the one or more battery modules, the battery enclosure being a structural element of the electric vehicle for receiving loads from at least two of a suspension system, a seat and a steering system of the electric vehicle.

The electric vehicle of example embodiment 1, the battery enclosure transferring the loads received, at least partially, to a center of mass of the electric vehicle.

The electric vehicle of any one of example embodiments 1 or 2, the battery enclosure transferring the loads received, at least partially, to a chassis of the electric vehicle.

The electric vehicle of any one of example embodiments 1 to 3, wherein the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from a front suspension of the electric vehicle.

The electric vehicle of any one of example embodiments 1 to 3, wherein the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from the steering system and the rear portion receiving loads from the seat.

The electric vehicle of any one of example embodiments 4 or 5, wherein the electric vehicle comprises a chassis defining a tunnel portion and a front brace structure, the tunnel portion connected to the rear portion of the battery enclosure and the front brace structure connected to the front portion of the battery enclosure.

The electric vehicle of any one of example embodiments 1 to 6, wherein the electric vehicle is a snowmobile.

A battery enclosure for an electric vehicle, the battery enclosure being a structural element of the electric vehicle and comprising: a rear portion adapted for connection to a rear portion of a chassis of the electric vehicle, the rear portion of the battery enclosure configured to receive loads from a seat of the electric vehicle; and a front portion adapted for connection to a front portion of the chassis of the electric vehicle, the front portion of the battery enclosure configured to receive loads from a front suspension of the electric vehicle.

The battery enclosure of example embodiment 8, wherein the battery enclosure is configured to transfer loads received from the seat and the front suspension, at least partially, to a center of mass of the electric vehicle.

The battery enclosure of one of example embodiments 8 or 9, wherein the battery enclosure is configured to transfer loads received from the seat and the front suspension, at least partially, to a chassis of the electric vehicle.

The battery enclosure of example embodiment 9, the front portion further adapted for receiving loads from a steering system of the electric vehicle and transferring those loads, at least partially, to a center of mass of the electric vehicle.

The battery enclosure of any one of example embodiments 8 to 11, wherein the electric vehicle is a snowmobile.

The battery enclosure of example embodiment 12, wherein the rear portion of the battery enclosure is adapted for connection to a tunnel of the snowmobile, and the front portion of the battery enclosure is adapted for connection to a front brace structure of the snowmobile.

A snowmobile comprising: a chassis that comprises: a rear tunnel; and a front brace structure adapted to receive loads from a front suspension system of the snowmobile; a battery enclosure defining a tunnel portion and a front portion, the tunnel portion being connected to the rear tunnel of the chassis and the front portion being connected to the front brace structure of the chassis; wherein the battery enclosure receives loads from the front suspension system of the snowmobile through the front brace structure and transfers the loads from the front suspension system to at least one of the rear tunnel and a center of mass of the electric vehicle through a body of the battery enclosure.

The snowmobile of example embodiment 14, wherein the battery enclosure is further connected to the front brace structure at a bottom surface.

The snowmobile of one of example embodiments 14 or 15, wherein a steering mount is connected to the front portion of the battery enclosure for connection to a steering column, the steering mount transferring loads from the steering column into the body of the battery enclosure.

The snowmobile of any one of example embodiments 14 to 16, further comprising a seat connected to the tunnel portion of the battery enclosure, wherein loads from the seat are received by and transferred into the body of the battery enclosure.

The snowmobile of any one of example embodiments 14 to 17, wherein the front portion of the battery enclosure defines a first height and the tunnel portion of the battery enclosure defines a second height, the first height being greater than the second height.

The snowmobile of any one of example embodiments 14 to 18, wherein the front portion of the battery enclosure defines a first width and the tunnel portion of the battery enclosure defines a second width, the first width being greater than the second width.

The snowmobile of any one of example embodiments 14 to 19, wherein the front suspension system comprises at least one coil over spring and damper assembly.

The snowmobile of example embodiment 20, wherein the at least one coil over spring and damper assembly is connected between a pair of skis and the front brace structure.

The snowmobile of any one of example embodiments 14 to 21, wherein the battery enclosure comprises a carbon fiber composite material.

The snowmobile of any one of example embodiments 14 to 21, wherein the battery enclosure comprises an injection molded glass fiber reinforced plastic material.

Example embodiment 24. The snowmobile of any one of example embodiments 14 to 23, wherein the tunnel portion of the battery enclosure is connected to the rear tunnel of the chassis via two or more right side blocks and two or more left side blocks.

The snowmobile of any one of example embodiments 14 to 24, wherein the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa.

The snowmobile of any one of example embodiments 14 to 25, wherein the battery enclosure comprises a cover and a floor.

The snowmobile of any one of example embodiments 14 to 26, further comprising an electric motor, wherein the battery enclosure houses at least two electric battery modules for supplying electricity to the electric motor.

The snowmobile of example embodiment 27, wherein the at least two electric battery modules comprise one or more pouch battery cells.

A battery enclosure for an electric snowmobile, the battery enclosure comprising: a tunnel portion adapted for connection to a rear tunnel of a snowmobile chassis; a front portion adapted for connection to a front brace structure of the snowmobile chassis, wherein the battery enclosure is configured to receive loads from a front suspension system of the snowmobile through the front brace structure and transfers the loads from the front suspension system to at least one of the rear tunnel and a center of mass of the electric vehicle through a body of the battery enclosure.

The battery enclosure of example embodiment 29, configured for connection to a steering column via a steering mount for receiving loads from the steering column into the body of the battery enclosure.

The battery enclosure of example embodiment 29, configured for connection to a seat of the electric vehicle for receiving loads from the seat into the body of the battery enclosure.

The battery enclosure of any one of example embodiments 29 to 31, wherein the front portion of the battery enclosure defines a first height and the tunnel portion of the battery enclosure defines a second height, the first height being greater than the second height.

The battery enclosure of any one of example embodiments 29 to 32, wherein the front portion of the battery enclosure defines a first width and the tunnel portion of the battery enclosure defines a second width, the first width being greater than the second width.

The battery enclosure of any one of example embodiments 29 to 33, wherein the battery enclosure comprises a carbon fiber composite material.

The battery enclosure of any one of example embodiments 29 to 34, wherein the battery enclosure comprises an injection molded glass fiber reinforced plastic material.

The battery enclosure of any one of example embodiments 29 to 35, wherein the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa.

The battery enclosure of any one of example embodiments 29 to 36, wherein the battery enclosure comprises a cover and a floor.

A straddle-seat electric vehicle, comprising; a chassis including a suspension system; and a battery pack configured as a structural element that receives loads from the suspension system.

The straddle-seat electric vehicle of example embodiment 38, the battery pack comprising a battery enclosure coupled to the suspension system for transferring, at least partially, loads from the suspension system through a body of the battery enclosure to the chassis.

The straddle-seat electric vehicle of example embodiment 38, comprising a brace structure that transfers loads between the suspension system and the battery enclosure.

The straddle-seat electric vehicle of example embodiment 38, further comprising a straddle seat, the straddle seat being mounted directly to the battery pack.

The straddle-seat electric vehicle of example embodiment 39, wherein the straddle-seat vehicle is a snowmobile.

An electric vehicle, comprising: a battery pack having a battery enclosure, the battery enclosure defines a slot that extends downwards from a top surface of the battery enclosure for receiving a steering column of the electric vehicle.

The electric vehicle of example embodiment 43, wherein the slot extends downwards from the top surface of the battery enclosure to a front side surface of the battery enclosure.

The electric vehicle of example embodiment 43, wherein the slot extends downwards from the top surface of the battery enclosure to a bottom surface of the battery enclosure.

The electric vehicle of example embodiment 43, wherein the width of the slot varies along a length, a top end of the slot being wider than a bottom end of the slot.

The electric vehicle of example embodiment 43, wherein the slot divides the front portion of the battery enclosure into a first side and a second side, wherein each of the first side and second side is suitable for housing one or more electric battery modules.

The electric vehicle of example embodiment 43, wherein the slot is positioned substantially centrally with respect to a first side wall and a second side wall of the battery enclosure.

The electric vehicle of example embodiment 43, wherein the battery enclosure is a structural component suitable for receiving loads from the steering column and transferring the loads to a chassis.

The electric vehicle of example embodiment 43, wherein a straight steering column passes through the slot.

A snowmobile, comprising: a chassis that comprises: a rear tunnel; and a front brace structure; a battery enclosure defining a tunnel portion and a front portion, the tunnel portion being connected to the rear tunnel of the chassis and the front portion being connected to the front brace structure, wherein the front portion of the battery enclosure defines a slot that extends downwards from a top surface of the battery enclosure for receiving a steering column of the snowmobile.

The snowmobile of example embodiment 51, wherein the slot extends downwards from the top surface of the battery enclosure to a front side surface of the battery enclosure.

The snowmobile of example embodiment 51, wherein the slot extends downwards from the top surface of the battery enclosure to a bottom surface of the battery enclosure.

The snowmobile of example embodiment 51, wherein the slot defines a first side wall, a second side wall and a bottom surface, wherein the bottom surface of the slot extends at an angle of between 30-60 degrees with respect to a substantially horizontal longitudinal axis of the snowmobile.

The snowmobile of example embodiment 51, wherein a width of the slot is between 30 millimeters (mm) and 60 mm.

The snowmobile of example embodiment 55, wherein the width of the slot varies along a length, a top end of the slot being wider than a bottom end of the slot.

The snowmobile of example embodiment 51, wherein the slot divides the front portion of the battery enclosure into a first side and a second side, wherein each of the first side and second side is suitable for housing one or more electric battery modules.

The snowmobile of example embodiment 51, wherein the slot is positioned substantially centrally with respect to a first side wall and a second side wall of the battery enclosure.

The snowmobile of example embodiment 51, wherein the battery enclosure is a structural component suitable for receiving loads from the steering column and transferring the loads to the chassis.

The snowmobile of example embodiment 51, wherein a straight steering column passes through the slot.

The snowmobile of example embodiment 51, wherein a top of the steering column is above the top surface of the battery enclosure and a bottom of the steering column is below a bottom surface of the battery enclosure and is attached to a steering mechanism that controls a direction of a right front ski and a left front ski for the snowmobile.

The snowmobile of example embodiment 51, wherein an upper steering mount is attached to the top surface of the battery enclosure and is configured to support an upper portion of the steering column and provide a stiffness to the upper portion of the steering column.

The snowmobile of example embodiment 62, wherein the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa, and wherein the stiffness of the battery enclosure corresponds with the stiffness that the upper steering mount provides to the upper portion of the steering column.

The snowmobile of example embodiment 62, wherein the upper steering mount comprises a right upper steering mount and a left upper steering mount attached to a pipe having an axis aligned with an axis of the steering column, and wherein the steering column passes through the pipe and is supported by the pipe.

The snowmobile of example embodiment 51, wherein the steering column passes through the slot at an angle with respect to an axis of the steering column and a substantially horizontal longitudinal axis of the snowmobile that is equal to or greater than 30 degrees and equal to or less than 60 degrees.

The snowmobile of example embodiment 51, wherein the slot is centered between a right side wall and a left side wall of the front portion of the battery enclosure, and wherein a right side stack of one or more batteries are between a first side wall of the slot and a first side wall of the front portion of the battery enclosure, and wherein a left side stack of one or more batteries are between a second side wall of the slot and a second side wall of the front portion of the battery enclosure.

The snowmobile of example embodiment 51, wherein the front portion of the battery enclosure has a width in a direction transverse to a substantially horizontal longitudinal axis of the snowmobile in a direction between the front end and the back end of the snowmobile that is greater than a width of the tunnel portion of the battery enclosure, and wherein the tunnel portion of the battery enclosure includes a row of one or more batteries aligned along the substantially horizontal longitudinal axis of the snowmobile between the front end and the rear end of the snowmobile.

A battery enclosure for an electric vehicle, comprising: a rear portion; and a front portion, the front portion of the battery enclosure defining a slot that extends downwards from a top surface of the battery enclosure for receiving a steering column of the electric vehicle.

The snowmobile of example embodiment 68, wherein the slot extends downwards from the top surface of the battery enclosure to a front side surface of the battery enclosure.

The snowmobile of example embodiment 68, wherein the slot extends downwards from the top surface of the battery enclosure to a bottom surface of the battery enclosure.

The battery enclosure of example embodiment 68, wherein the slot defines a first side wall, a second side wall and a bottom surface, wherein the bottom surface of the slot extends at an angle of between 30-60 degrees with respect to a substantially horizontal longitudinal axis of the electric vehicle.

The battery enclosure of example embodiment 68, wherein a width of the slot is between 30 millimeters (mm) and 60 mm.

The battery enclosure of example embodiment 68, wherein the slot divides the front portion of the battery enclosure into a first side and a second side, wherein each of the first side and second side is suitable for housing electric battery modules.

The battery enclosure of example embodiment 68, wherein the slot is positioned substantially centrally with respect to a first side wall and a second side wall of the battery enclosure.

The battery enclosure of example embodiment 68, wherein the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa.

The battery enclosure of example embodiment 68, wherein the tunnel portion of the battery enclosure includes a row of one or more batteries in a direction between the front portion of the battery enclosure and the tunnel portion of the battery enclosure.

The battery enclosure of example embodiment 68, wherein the battery enclosure comprises a carbon fiber composite material.

The battery enclosure of example embodiment 68, wherein the battery enclosure comprises an injection molded glass fiber reinforced plastic material.

The battery enclosure of example embodiment 68, wherein the electric vehicle is a snowmobile.

An electric vehicle, comprising: a chassis defining a rear portion and a front portion; a transmission mounted to a rear portion of the chassis; a battery enclosure mounted on top of the rear portion of the chassis; and an electric motor mounted below the battery enclosure and between a front side of the rear chassis and a front end of the electric vehicle.

The electric vehicle of example embodiment 81, wherein the electric motor is positioned generally horizontally relative to the transmission.

The electric vehicle of example embodiment 81, wherein a transmission drive shaft and a motor drive shaft are spaced apart along a longitudinal axis of the electric vehicle.

The electric vehicle of example embodiment 81, wherein the rear portion of the chassis is a rear tunnel and the front portion of the chassis is a front brace structure, wherein a transmission plate attached to the electric motor is connected at a first end to the rear tunnel and at a second end to the front brace structure.

The electric vehicle of example embodiment 81, wherein the electric vehicle is a snowmobile.

A snowmobile, comprising: a chassis that comprises a rear tunnel; a battery enclosure mounted to the rear tunnel; and an electric motor mounted below the battery enclosure and adjacent to a front side of the rear tunnel.

The snowmobile of example embodiment 86, wherein the chassis further defines a mid-bay and a front brace structure, the mid-bay being located between the rear tunnel and the front brace structure, wherein the electric motor is positioned within the mid-bay.

The snowmobile of example embodiment 87, wherein the mid-bay comprises a transmission plate positioned substantially parallel to a first side edge of the rear tunnel.

The snowmobile of example embodiment 88, wherein the transmission plate is attached at a first end to the first side edge of the rear tunnel and at a second end to a component of the front brace structure.

The snowmobile of example embodiment 89, wherein the transmission plate is further attached to a front plate of the electric motor.

The snowmobile of example embodiment 90, further comprising a transmission, wherein the electric motor is mounted proximate to the transmission by the transmission plate.

The snowmobile of example embodiment 91, wherein the transmission plate includes a U-shaped opening that extends downwards from a top side of the transmission plate, and wherein the electric motor is attached to both sides of the U-shaped opening such that a drive shaft of the electric motor extends through the U-shaped opening.

The snowmobile of example embodiment 89, wherein the component of the front brace structure is mounted to an underside of the battery enclosure and to the transmission plate.

The snowmobile of example embodiment 91, wherein the electric motor includes an electric motor drive gear and the transmission includes a transmission gear, and wherein a drive belt is connected between the electric motor drive gear and the transmission gear such that an angle of a top portion of the drive belt between the electric motor drive gear and the transmission gear with respect to a substantially horizontal longitudinal axis of the snowmobile is equal to or less than 20% and equal to or greater than −20%.

The snowmobile of example embodiment 89, further comprising a drive belt idler pulley that contacts a bottom surface of the bottom portion of the drive belt, and wherein the top portion of the drive belt is connected directly between the electric motor drive gear and the transmission gear.

An electric snowmobile, comprising: a transmission mounted within an interior of a rear tunnel of the snowmobile and proximate to a rear suspension of a track of the snowmobile; a battery enclosure mounted to the rear tunnel; and an electric motor mounted below the battery enclosure and between a front side of the rear tunnel and a front end of the snowmobile.

The electric snowmobile of example embodiment 96, further comprising a transmission, wherein the electric motor is mounted directly to the transmission by a transmission plate, and wherein the transmission plate is mounted to the rear tunnel of the snowmobile.

The electric snowmobile of example embodiment 97, wherein the transmission plate includes a U-shaped opening that extends downwards from a top side of the transmission plate, and wherein the electric motor is attached to the transmission plate at an interior of the transmission plate such that a drive shaft of the electric motor extends through from the interior to an exterior of the U-shaped opening of the transmission plate.

The electric snowmobile of example embodiment 97, wherein the electric motor includes an electric motor drive gear and the transmission includes a transmission gear, and wherein a drive belt is connected between the electric motor drive gear and the transmission gear such that an angle of a top portion of the drive belt between the electric motor drive gear and the transmission gear with respect to a substantially horizontal longitudinal axis of the snowmobile is equal to or less that 20% and equal to or greater than −20%.