Patent Publication Number: US-2023163400-A1

Title: Vehicle battery pack tray with multiple access points

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to battery systems for electric vehicles, and more particularly to a vehicle battery pack with multiple doors or hatches enabling access to an interior of an otherwise sealed electric vehicle battery. 
     BACKGROUND 
     Electrical vehicles are becoming increasingly popular as consumers look to decrease their environmental impact and improve air quality. Instead of a traditional internal combustion engine, electric vehicles include one or more electric motors, powered by a rechargeable battery pack. Conventional electric vehicle battery packs are typically constructed of multiple components, including a plurality of battery modules, electrical current transmission systems, temperature control systems, safety systems, battery management systems, and one or more structural supports. 
     Conventional construction techniques begin with an empty battery tray, which represents a bottom and typically one or more sides of a structural vessel, representing a compartment, configured to contain the other components of the battery pack. Often the battery tray includes one or more structural supports (e.g., cross members, etc.), providing structural support to the battery pack, as well as surfaces within the battery tray compartment on which other components of the battery pack can be affixed. The various components, including the temperature control system (e.g., cooling panels, etc.) and plurality of battery modules can be positioned within the compartment and secured in place. Electrical current transmission systems, battery management systems, and safety systems are also positioned within the compartment. A lid or cover is then positioned on the battery tray, thereby sealing the compartment. 
     Sealing the battery compartment serves to isolate the components positioned within the battery tray from the outside environment, which in turn inhibits the intrusion of moisture and corrosion inducing chemicals (e.g., oxygen, road salt, etc.), and inhibits fluid within the compartment from leaking out, for example in the event of a battery module failure. Although sealing of the battery compartment has proved useful for its intended purpose, there is occasionally a need to access components within the sealed compartment. Current techniques of gaining access to the sealed compartment typically include removal of the lid or cover, which is typically affixed to the tray with a combination of fasteners and adhesive. As the lid or cover typically encompasses the entire top surface of the battery pack, after installation in a vehicle, the battery pack must be removed from a vehicle (e.g., uncoupled from a vehicle frame) before the lid or cover can be removed. Accordingly, gaining access to the sealed compartment of a battery pack can be a labor-intensive endeavor. The present disclosure addresses this concern. 
     SUMMARY OF THE DISCLOSURE 
     Embodiments of the present disclosure provide vehicle battery packs and methods of construction comprising multiple access or service lids, enabling selective access to an otherwise sealed compartment containing various components of the battery pack, thereby enabling components within the battery pack (e.g., battery modules, battery management systems, etc.) to be serviced without a need to remove the entire battery pack from a vehicle. In some embodiments, the multiple access or service lids can be sealed with a flange and adhesive gasket arrangement to ensure proper sealing of the battery pack, while enabling repeated access to the sealed compartment through the multiple axis or service lids. 
     One embodiment of the present disclosure provides a vehicle battery pack for electric vehicle, including a battery tray defining a battery compartment configured to house at least one of plurality of battery modules or individual battery cells, a current transmission system, a temperature regulation system, a safety system, a battery management system, and a current management system, a cover configured to operably coupled to the battery tray, thereby sealing the battery compartment, the cover defining two or more access doors, and two or more service lids operably coupleable to the cover, thereby selectively providing access to the battery compartment through the two or more access doors. 
     In one embodiment, the two or more access doors are positioned on an aft portion of the cover. In one embodiment, the cover defines a foot well for a backseat of the electric vehicle. In one embodiment, the two or more access doors are positioned aft of the foot well. In one embodiment, the two or more service lids are accessible by removal of the backseat. In one embodiment, the two or more service lids are secured to the cover via a plurality of fasteners. In one embodiment, the vehicle battery pack further includes an adhesive gasket positioned between each service lid and the cover, the adhesive gasket providing a seal between each service lid and the cover. 
     Another embodiment of the present disclosure provides a selectively sealable vehicle battery pack for electric vehicle configured to enable selective access to components within the battery pack, without a need to remove the battery pack from a vehicle in which it is installed, including a vessel defining a compartment configured to house at least one of plurality of battery modules or individual battery cells, a current transmission system, a temperature regulation system, a safety system, a battery management system, and a current management system, a cover configured to operably coupled to the vessel, thereby sealing the compartment, the cover defining two or more access doors, and two or more service lids operably coupleable to the cover, thereby selectively providing access to the battery compartment through the two or more access doors. 
     In one embodiment, the two or more access doors are positioned on a portion of the cover positioned beneath a back seat of the electric vehicle. In one embodiment, the cover defines a foot well for a backseat of the electric vehicle. In one embodiment, each of the service lids are substantially rectangular in shape. In one embodiment, each of the service lids define a U-shaped channel arranged around a perimeter of the service lid. In one embodiment, the U-shaped channel defines a plurality of apertures are configured to receive a corresponding plurality of fasteners. In one embodiment, the two or more service lids are secured to the cover via a plurality of fasteners. In one embodiment, each of the service lids is constructed through a process of stamping sheet metal. In one embodiment, the battery pack further includes an adhesive gasket positioned between each service lid and the cover, the adhesive gasket providing a seal between each service lid and the cover. In one embodiment, a central portion of each service lid is shaped to accommodate one or more components of the battery pack partially protruding through the two or more access doors. In one embodiment, at least one of a battery management system or a current management system positioned within the compartment is accessible by removal of the two or more access doors. In one embodiment, removal of the two or more access doors enables a user to at least one of perform diagnostics, change a fuse, reset a replay, or perform software updates to the battery pack. 
     Another embodiment of the present disclosure provides a vehicle battery pack for electric vehicle, the vehicle battery pack, including a battery tray defining a battery compartment configured to house at least one of plurality of battery modules or individual battery cells, a current transmission system, a temperature regulation system, a safety system, a battery management system, and a current management system, a cover configured to operably coupled to the battery tray, thereby sealing the battery compartment, the cover defining a foot well for a backseat to the electric vehicle and two or more access doors, wherein the two or more access doors are positioned aft of the foot well, two or more substantially rectangular service lids operably coupleable to the cover, thereby selectively providing access to the battery compartment through the two or more access doors, wherein each of the service lids define a U-shaped channel arranged around a perimeter of the service lid, the channel defining a plurality of apertures configured to receive a corresponding plurality of fasteners, wherein the two or more service lids are secured to the cover via the plurality of fasteners, an adhesive gasket positioned between each service lid and the cover, the adhesive gasket providing a seal between each service lid and the cover, wherein the two or more service lids are accessible by removal of the backseat of the vehicle. 
     The summary above is not intended to describe each illustrated embodiment or every implementation of the present disclosure. The figures and the detailed description that follow more particularly exemplify these embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which: 
         FIG.  1    is a perspective view depicting a vehicle battery pack comprising multiple access lids for positioning in an electric vehicle, in accordance with an embodiment of the disclosure. 
         FIG.  2    is a perspective view of a vehicle battery pack tray loaded with a plurality of battery pack components, in accordance with an embodiment of the disclosure. 
         FIG.  3 A  is a perspective view of a battery pack including a lid defining multiple access points to access battery components within the battery compartment, in accordance with an embodiment of the disclosure. 
         FIG.  3 B  is a perspective view of the battery pack of  FIG.  3 A , wherein the multiple access points are sealed by respective lids, in accordance with an embodiment of the disclosure. 
         FIG.  4 A  is a perspective view of a vehicle including a battery pack having multiple access doors sealed by respective lids, in accordance with an embodiment of the disclosure. 
         FIG.  4 B  is a perspective view of the vehicle of  FIG.  5 A , in which additional panels are installed over the respective lids, in accordance with an embodiment of the disclosure. 
         FIG.  5    is a close-up, perspective view depicting a battery pack access door, in accordance with an embodiment of the disclosure. 
         FIG.  6 A  is a top perspective view of a battery pack access lid, in accordance with an embodiment of the disclosure. 
         FIG.  6 B  is a bottom perspective view of the battery pack access lid of  FIG.  4 A . 
         FIG.  7 A  is a plan view of a battery pack access lid, in accordance with an embodiment of the disclosure. 
         FIG.  7 B  is a lateral cross-sectional view of the battery pack access lid of  FIG.  5 A . 
         FIG.  7 C  is a longitudinal cross-sectional view of the battery pack access lid of  FIG.  5 A . 
         FIG.  8    is a partial, cross-sectional, perspective view depicting an interaction between a service led and a cover of the battery pack, in accordance with an embodiment of the disclosure. 
     
    
    
     While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof shown by way of example in the drawings will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims. 
     DETAILED DESCRIPTION 
     Referring to  FIG.  1   , a vehicle battery pack  100  comprising multiple access or service lids  102 A/B enabling selective access to an otherwise sealed compartment containing various components of the battery pack, is depicted in accordance with an embodiment of the disclosure. As depicted in  FIG.  1   , in some embodiments, the battery pack  100  can include a battery tray  104 , defining a compartment into which components of the battery pack can be positioned. A cover  106  can be affixed to the battery tray  104 , thereby sealing the battery compartment. Thereafter, the assembled battery pack  100  can be mounted to the frame and/or chassis of a vehicle  108 , which in some embodiments can be positioned adjacent to a cabin floor  110  of the vehicle  108 , thereby maintaining a low center of gravity. 
     Various embodiments of the present invention will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Various directions and orientations, such as “upward,” “downward,” “top,” “bottom,” “upper,” “lower”, etc. are generally described herein with reference to the drawings in the usual gravitational frame of reference, regardless of how the components may be oriented during assembly. 
     With additional reference to  FIG.  2   , a battery tray  104 , which can represent a bottom and one or more sides of a structural vessel  112  defining a compartment  114 , is depicted in accordance with an embodiment of the disclosure. In some embodiments, the battery tray  104  can include one or more structural supports, such as cross member  120 A-C, which can provide structural support to the battery pack  100 , as well as surfaces within the compartment  114  on which other components of the battery pack can be affixed. 
     A variety of components can be packed into the compartment  114  before the cover  106  (as depicted in  FIG.  1   ) is affixed to a top surface  116  of the battery tray  104 , thereby sealing the compartment  114  their within. In some embodiments, the components can include a plurality of battery modules  122 , electrical current transmission systems  124 , temperature control systems  126 , safety systems  128 , battery management systems  130  (including current management systems  132 ), and the like. Once the components have been positioned in the compartment  114 , the cover  106  can be affixed to the top surface  116  via a plurality of fasteners  118 , adhesive, or a combination thereof. 
     Although sealing of the battery compartment  114  is effective in inhibiting the introduction of corrosion inducing chemicals and moisture, as well as inhibiting the leakage of fluids in the event of a battery module failure, occasionally technicians may require access to the battery compartment  114 , for example to address a faulty battery module  122 , reset battery management systems  130 , change a fuse or relay on a current management system  132 , or the like. In an effort to reduce the labor intensive endeavor of removing the entire battery pack  100  from the vehicle  110  in order to remove the cover  106 , embodiments of the present disclosure provide multiple service lids  102 A/B enabling selective access to the sealed compartment  114 . 
     For example, as depicted in  FIGS.  3 A- 4 B , a vehicle battery pack  100  comprising a cover  106  defining one or more access doors  134 A/B selectively sealed by service lids  102 A/B, is depicted in accordance with an embodiment of the disclosure. In some embodiments, the one or more access doors  134 A/B can be positioned on an aft portion of the cover  106 . For example in one embodiment, the cover  106  can define a rear foot well  136  for passengers positioned in a rear or backseat  138  of the vehicle  108  (as depicted in  FIG.  1   ). The one or more access doors  134 A/B and service lids  102 A/B can be positioned aft the rear foot well  136 , so as to be positioned beneath the rear seat  138 . In some embodiments, one or more panels  139 A-C can be operably coupled to a frame  141  of the vehicle  108 , thereby providing an access point to the service lids  102 A/B. 
     A variety of components can be positioned within the battery compartment  114  for access through the one or more access doors  134 A/B. For example, as depicted, in one embodiment at least one of the battery management system  130  or current management system  132  can be accessible through the one or more access doors  134 A/B, thereby enabling a user to remove and replace components, change fuses, perform diagnostics or software updates, etc. Further, in some embodiments, the one or more access doors  134 A/B can be positioned to enable user to access one or more battery modules  122 , current transmission systems  124 , temperature regulation systems  126 , and safety systems  128  among other components of the battery pack  100 . 
     With additional reference to  FIG.  5   , access to the battery compartment  114  can be gained without a need to remove the entire battery pack  100  from the vehicle  108 . For example, in some embodiments, the one or more access doors  134 A/B can be accessed by removal of the rear seat  138 , thereby exposing the service lids  102 A/B. Thereafter, the service lids  102 A/B, which can be secured to the cover  106  via a plurality of fasteners  140  and adhesive  146 , can be removed thereby providing selective access to the battery compartment  114 . 
     With additional reference to  FIG.  6 A /B, respective top and bottom perspective views of an example service lid  102  are depicted in accordance with an embodiment of the disclosure. In some embodiments, each service lid  102  can have a substantially rectangular perimeter  142 , which in some embodiments can include filleted or rounded corners. In some embodiments, the service lid  102  can define a channel  144 , for example having a generally U-shaped cross-section, in proximity to the perimeter  142 . In addition to providing structural support to the service lid  102 , the channel  144  can provide a proper spacing for the fasteners  140  for operable coupling to the cover  106 . In embodiments, a plurality of apertures  145  configured to receive respective fasteners  140 , can be defined along the channel  144 . 
     With additional reference to  FIGS.  7 A-C , a top plan view and respective cross-sectional views of the service lid  102  are provided in accordance with an embodiment of the disclosure. In some embodiments, a central portion  150  of the service lid  102  can be shaped to accommodate components of the battery pack  100  partially protruding out of the battery compartment  114  through the access door  134 . For example, in some embodiments, a portion of the battery management system  130 /current management system  132  can protrude slightly outwardly, with the service lid  102  shaped and sized to provide sufficient clearance, while ensuring a proper seal of the access door  134  to the cover  106 . Construction of the service lid  102  to accommodate a variety of shapes can be performed according to a number of different methods, for example, in one embodiment, the service lid  102  can be stamped from a stock of sheet metal; although other methods of construction are also contemplated. 
     With additional reference to  FIG.  8   , in some embodiments, a gasket or adhesive  146  can be positioned inboard of the channel  144  on a bottom surface  148  of the service lid  102 , thereby providing a fluid tight seal between the service lid  102  and the cover  106 . For example, in one embodiment, the battery pack  100  can be sealed with an adhesive gasket  146 , with the channel  144  and fasteners  140  arranged to maintain a small gap or clearance for proper compression of the gasket  146 , thereby enabling repeated access to the battery compartment  114  for servicing. In some embodiments, the service lid  102  can be configured to enable In some embodiments, the fasteners  140 A/B, which can be in the form of a two-part bolt/nut combination, can be tightened to a specific torque requirement (e.g., 13 Nm, etc.) to ensure proper compression of the gasket  146  against the cover  106 . 
     The invention is further illustrated by the following embodiments: 
     A vehicle battery pack for an electric vehicle, comprising: a battery tray defining a battery compartment configured to house at least one of plurality of battery modules or individual battery cells; a cover configured to operably coupled to the battery tray, thereby sealing the battery compartment, the cover defining two or more access doors; and two or more service lids operably coupleable to the cover, thereby selectively providing access to the battery compartment through the two or more access doors. 
     A system or method according to any embodiment, wherein removal of the two or more access doors enables a user to at least one of perform diagnostics, change a fuse, reset a replay, or perform software updates to the battery pack. 
     A system or method according to any embodiment, wherein each of the service lids are substantially rectangular in shape. 
     A system or method according to any embodiment, wherein the two or more access doors are positioned on an aft portion of the cover. 
     A system or method according to any embodiment, wherein the cover defines a foot well for a backseat of the electric vehicle. 
     A system or method according to any embodiment, wherein the two or more access doors are positioned aft of the foot well. 
     A system or method according to any embodiment, wherein the two or more access doors are positioned on a portion of the cover positioned beneath a back seat of the electric vehicle. 
     A system or method according to any embodiment, wherein the two or more service lids are secured to the cover via a plurality of fasteners. 
     A system or method according to any embodiment, further comprising an adhesive gasket positioned between each service lid and the cover, the adhesive gasket providing a seal between each service lid and the cover. 
     A system or method according to any embodiment, wherein each of the service lids define a U-shaped channel arranged around a perimeter of the service lid. 
     A system or method according to any embodiment, wherein the U-shaped channel defines a plurality of apertures are configured to receive a corresponding plurality of fasteners. 
     A system or method according to any embodiment, wherein each of the service lids is constructed through a process of stamping sheet metal. 
     A system or method according to any embodiment, wherein a central portion of each service lid is shaped to accommodate one or more components of the battery pack partially protruding through the two or more access doors. 
     A system or method according to any embodiment, wherein the battery tray is further configured to house at least one of a current management system, current transmission system, a temperature regulation system, a safety system, and a battery management system. 
     An electric vehicle comprising the battery pack according to any embodiment. 
     Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions. 
     Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted. 
     Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended. 
     Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein. 
     For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.