Patent Description:
Electrification of vehicles is becoming increasingly common and may take the form of battery electric vehicles, powered exclusively by electrical energy stored in the vehicle, or hybrid vehicles, which are powered by a combination of electrical energy stored in the vehicle and an internal combustion engine. In both cases, these vehicles are, at least in part, propelled using electrical energy and so may be referred to as electric vehicles.

Electrical energy may be stored in the vehicle using one or more voltaic cells, or additionally or alternatively may be stored using one or more super capacitors. Such electrical energy storage means are referred to as a battery or battery module. The weight and complexity of such a battery however, has a strong influence on the overall cost and range of the vehicle, and due to the nature of storing electrical energy at voltages exceeding the once typical 12V, it is necessary to balance the need to protect the battery from damage in use, whilst not becoming excessively heavy or complicated.

One such way to protect the battery is to encase it in a housing means, such as a battery module housing, in which the electrical energy storage means for powering the vehicle may be received. The battery housing means must typically be able to protect the electrical energy storage means housed therein from contact with dirt or water from the road or whatever surface the vehicle is being used on. The housing must also retain the energy storage means therein in a way as to protect and support the energy storage means, to mitigate against any damage that may otherwise be caused by an impact to the housing during vehicle operation. Typically the battery module housing, once assembled, is fitted to the vehicle, secured thereto via dedicated fixing points provided on the vehicle body, frame and/or chassis.

Furthermore, it is known to provide vehicles with a separate chassis or frame and body. As vehicles are becoming increasingly more complicated and sophisticated they often require a significant number of component parts, such as suspension components, seating components, instrumentation and cooling systems that must all be provided means for securing them to the body and/or the chassis or frame. As such, vehicles with greater parts complexity are typically more time consuming and expensive to manufacture and maintain and require a number of different raw materials and tooling for manufacture and assembly, which can lead to an undesirable increase in vehicle weight which has an adverse affect on vehicle efficiency.

A pertinent battery module is known from <CIT>.

Aspects and embodiments of the invention provide a battery module housing and a vehicle.

According to the invention, there is provided a battery module housing for an electric vehicle, the battery module housing comprising:.

According to another aspect of the invention, there is provided a battery module housing for an electric vehicle, the battery module housing comprising:.

In an example, the battery module housing is load bearing and is arranged to support the load of the energy storage means and at least one suspension component of the vehicle, the suspension component being attached to the battery module housing via the hard-point. In an example, the battery module housing is further arranged to support the load of at least one seat for supporting a vehicle occupant. In an example, the suspension assembly comprises at least one of: a wheel; a continuous track assembly; or ski. In an example, the suspension assembly comprises at least one of: a swing arm, pivotably attached to said hard-point via a pivot; a steering mechanism, configured to permit the user to change the direction of travel of the vehicle in use; a head-stock, arranged to provide a pivotable attachment for a steering mechanism; a telescopic fork assembly pivotably attached to the hard-point via the headstock; or braking means, arranged to apply a braking force between the vehicle and the wheel or continuous track in use.

Advantageously, a single structure or component, namely the battery module housing, can be used for multiple functions. The battery module housing may advantageously function to house and optionally support and protect energy storage means, such as one or more voltaic cells and/or super capacitors, whilst also functioning as a major structural component of the electric vehicle. This advantageously reduces parts complexity and therefore costs and also keeps overall mass of an electric vehicle incorporating the battery module housing to a minimum, leading to more efficient operation of the electric vehicle. As used herein, the term shelving matrix means a component comprising one or more shelves for receiving said energy storage means thereon. The shelving matrix may comprise only a single shelf or may comprise multiple shelves. The shelving matrix may comprise one or more partitions that divide the one or more shelves into sections. The one or more partitions may be substantially perpendicular to said one or more shelves. In other embodiments, the shelving matrix may comprise no partitions.

In some embodiments, the monocoque is one or both of a chassis and a body of the electric vehicle. Advantageously, this means that a single structure or component, namely, the battery module housing, can function both to house and optionally support and protect the energy storage means, such as one or more cells, whilst also functioning as a major structural component of the electric vehicle. In use, such a battery module housing may advantageously bear the overall weight of the electric vehicle and, may additionally bear the weight of any vehicle occupant(s). This advantageously reduces manufacturing materials and therefore costs and also reduces overall mass of the electric vehicle, leading to more efficient vehicle operation.

In some embodiments, the front suspension assembly comprises a steering assembly and the battery module housing comprises a front through aperture defining a headtube through and about which a steering mechanism of the steering assembly operates.

In some embodiments, said monocoque comprises:.

The body component defines a chamber therein, for receipt of the shelving matrix and energy storage means. The cover plate may close an opening in the body component to close the chamber. The cover plate may comprise a sealing member arranged to seal the energy storage means into the chamber in use and prevent ingress of dirt or water from the road or other surface on which the vehicle is being operated. Optionally, said body component is a unitary component, closeable by said removable cover plate. In some embodiments, said body component may be a unitary, integrally formed component. The body component may, in some embodiments, comprise a composite material, or may comprise a casting of a metal or metal alloy.

Advantageously, a removable cover plate provides quick and easy access to an internal part, or chamber, of the monocoque. This means that energy storage means, such as one or more cells or super capacitors, can quickly and easily be inserted, removed or replaced from the shelving matrix within the monocoque. This advantageously reduces assembly and maintenance time for an electric vehicle incorporating the battery module housing.

Optionally, the removable cover plate is positioned at a side surface of the monocoque. Optionally, said the body component and the removable cover plate are arranged to fit together at a top of the monocoque, when in use as part of an electric vehicle, distal from a contact point between a wheel, continuous track or ski of the vehicle and a ground surface on which the vehicle is standing. Alternatively, when the monocoque is closed by said removable cover plate, the body component and the removable cover plate are arranged to fit together at a rear of the monocoque. In this sense, rear surface means a surface of the monocoque, when in use as part of an electric vehicle, distal from a front surface arranged to face in the direction of normal travel of the electric vehicle. The cover plate may be releasably fixable to the unitary, integrally formed body component. Advantageously, by providing the removable cover plate at a top or rear surface of the monocoque, an internal part or chamber of the monocoque can easily be accessed.

In some embodiments, the removable cover plate comprises at least one busbar for providing an electrical terminal for said energy storage means. The at least one busbar may be a metallic strip or bar. Advantageously, the at least one busbar can carry substantial electric current over a relatively short distance and serves to keep losses due to electrical resistance to a minimum. By incorporating the one or more busbars into the removable cover plate, pressure can be applied to ensure a good electrical connection between the busbars and the energy storage means, such as one or more cells received by the shelving matrix. In some embodiments, the one or more busbars comprise a flat strip, a solid bar or rod, a hollow tube or a braided wire. Advantageously, such shapes allow for more efficient heat dissipation, due to a high ratio of surface area to cross sectional area. In some embodiments, the busbars are supported on an insulator or are completely surrounded by an insulator. In some embodiments, the cover plate comprises an insulator supporting an electrical connector, electrically coupled to the busbar, and arranged to provide means for connecting the electrical storage means to at least one of an electrical charging socket, an inverter, or an electric traction motor.

In some embodiments, said shelving matrix comprises at least one shelf for providing a partition to define a compartment either side thereof, within the monocoque. The at least one shelf, within the monocoque, may extend substantially from a front end of the monocoque to a rear end of the monocoque, wherein the front end and the rear end are aligned along a longitudinal axis of the monocoque. Advantageously, this enables an internal part or chamber of the monocoque to be divided into chamber and provides support means for the energy storage means, such as one or more cells, received by the shelving matrix.

Optionally, the battery module housing comprises a clearance zone at an end of each at least one shelf. Said clearance zone may be a gap at an edge or an end of the at least one shelf for receiving a part of a energy storage means, such as a string of cells. Advantageously, a clearance zone allows the battery module housing to receive a string of cells, which cells may be distributed throughout a plurality of compartments within the battery module, without breaking connection of the string of cells. The cells may completely occupy the plurality of compartments within the battery module. Alternatively, the cells may occupy only some of the plurality of compartments within the battery module.

In some embodiments, said shelving matrix is integrally formed with said monocoque.

In some embodiments, said shelving matrix is mechanically attached to said monocoque.

In some embodiments, said shelving matrix may be bolted to said monocoque.

In some embodiments, the battery module housing comprises at least one cooling channel. Said at least one cooling channel advantageously provides means for mitigating or preventing overheating. This may be especially advantageous in extended and/or heavy operating conditions, and especially where the vehicle is being operated in areas of relatively high ambient temperatures.

Optionally, said at least cooling channel is integral with said monocoque. Optionally, said at least one cooling channel is integral within said shelving matrix. The at least one cooling channel may comprise a cavity formed in a shelf of said shelving matrix. Advantageously, this prevents the need for additional materials or components to provide a cooling means to mitigate or prevent overheating.

Optionally, said monocoque comprises at least one aperture for providing fluid communication between said at least one cooling channel and an environment external the monocoque.

Optionally, a first of said at least one aperture is arranged at a front of the monocoque and a second of said at least one aperture is arranged at a rear of the monocoque. The front of the monocoque and the rear of the monocoque may be aligned along a longitudinal axis. Advantageously, this allows air to flow into and out of said at least one cooling channel without need to provide additional means to exhaust air out the battery module. Advantageously, this encourages airflow through said at least one cooling channel when the vehicle is in motion substantially in a direction aligned with, along, or coaxial with said longitudinal axis.

Optionally, the battery module housing further comprises a battery cooling pack having a heat exchanger supported on an external surface of the monocoque and arranged to be in fluid communication with the at least one cooling channel and configured to cool the energy storage means in use. In an example, the battery cooling pack comprises a heat exchanger, containing a coolant in fluid communication with the at least one cooling channel; and a fan arranged to force air through the heat exchanger to facilitate the removal of heat from the coolant, and wherein the cooling pack is mounted to exterior formations provided on the monocoque and those exterior formations form at least a part of a cowling around the heat exchanger and the fan, the cowling being arranged to duct air from the fan through the heat exchanger.

In the case of the front and rear suspension assemblies, they may comprise any of: a wheel; a continuous track; or a ski, and further comprise suitable connection means for connecting the suspension assembly thereto. The front connection means may additionally or alternatively be arranged to receive a vehicle steering mechanism. The vehicle steering mechanism may comprise a headstock or headtube. The front connection means may be at a front of the monocoque and the rear connection means may be at a rear of the monocoque. The front of the monocoque and the rear of the monocoque may be aligned along a longitudinal axis. The rear connection means may comprise an aperture in the monocoque. The front connection means may comprise an aperture in the monocoque. Optionally, said rear suspension assembly comprises a rear swing arm pivotably connected to the monocoque via mounting means comprising a swing arm bearing. Optionally, the front suspension assembly comprises a front swing arm. The front swing arm may comprise a hub centre steering system. Advantageously, by connecting one or both of the front and rear suspension assemblies to the battery module housing through connection means in the monocoque, the monocoque can function as a pivot point for each of the suspension assemblies. In some embodiments, one or both of the front and rear swing arms comprise a composite material, such as carbon fibre reinforced resin. In some embodiments, one or both of the front and rear swing arms comprise a metal or metal alloy, such as fabricated aluminium, or an alloy thereof.

In some embodiments, said battery module housing comprises lateral damping control means for providing suspension, when the battery module housing is in use with an electric vehicle, and the vehicle is cornering. Optionally, said lateral damping control means comprises said monocoque being arranged to control lateral flexion. In some embodiments, said being arranged to control lateral flexion comprises the monocoque having one or both of a shape and one or more mechanical properties being tailored to maintain lateral flexion within a desired range of lateral flexion. Advantageously, the battery module housing provides means for controlling and therefore managing lateral damping, advantageously overcoming the requirement for providing a separate component to control lateral damping of the electric vehicle when cornering.

In some embodiments, said monocoque may be formed in any three dimensional shape. Said monocoque may be formed by modular construction. Said monocoque may be adapted to maintain lateral flexion within a desired range of lateral flexion and with pre-defined lateral flexion characteristics, regardless of the shape of the monocoque. Said monocoque may be adapted to withstand a variety of twisting forces, regardless of the shape of said monocoque. Bending and torsional forces will be applied to the monocoque from the front and/or rear suspension assemblies when the vehicle is in use. Resistance to and control of these forces is essential to ensure the vehicle handling characteristics are predictable and reliable.

In some embodiments, said monocoque comprises a composite material. Advantageously, composite materials are lightweight, meaning that an electric vehicle comprising the battery module housing can operate at increased efficiency. Said composite material may be a carbon fibre reinforced resin. Advantageously, a composite material enables the monocoque to act as a heatsink. A composite material also advantageously enables the provision of a lightweight shelving matrix, without compromising on strength. In other embodiments, said monocoque comprises a metal or metal alloy. The metal may be aluminium. In other embodiments, said monocoque comprises both a composite material and a metal or metal alloy.

In some embodiments, said shelving matrix comprises a composite material. Advantageously, composite materials are lightweight, meaning that an electric vehicle comprising the battery module housing can operate at increased efficiency. Said composite material may be a carbon fibre reinforced resin. A composite material also enables the provision of a lightweight shelving matrix, without compromising strength. In other embodiments, said shelving matrix comprises a metal or metal alloy. Advantageously, the material used for the shelving matrix has good thermal conductivity properties to enable the shelving matrix to act as a heatsink to draw heat away from the electrical energy storage means. The metal may be aluminium. In other embodiments, said shelving matrix comprises both a composite material and a metal or metal alloy.

In some embodiments, said battery module housing further comprises an energy storage means. In some embodiments, the energy storage means comprises one or more cells or super capacitors housed within the battery module housing. Optionally, said one or more cells comprises a string of cells. Optionally, said one or more super capacitors comprises a string of super capacitors. Optionally, the energy storage means comprises both a string of cells and a string of super capacitors. In some embodiments, the one or more cells and/or one or more super capacitors occupies substantially all of the battery module housing. In some embodiments, the one or more cells or one or more super capacitors occupies only a part of the battery module housing. In some embodiments, the one or more cells occupy less than <NUM>% of a volume within the battery module housing. In some embodiments, the one or more super capacitors occupy less than <NUM>% of a volume within the battery module housing.

In some embodiments, an internal wall of the monocoque and an edge or edges of the shelving matrix comprise cooperative lugs and detents. Advantageously, this helps to retain said shelving matrix within the monocoque in a desired position.

Optionally, said shelving matrix is retained within said monocoque by means of adhesion. This may be provided by an adhesive material, or by bonding webbing. Alternatively, said shelving matrix is retained within said monocoque by means of one or more soldered or welded joins. Advantageously, this helps to retain said shelving matrix within the monocoque in a desired position.

In some embodiments, one or both of the monocoque and the shelving matrix are manufactured by any one of: bladder moulding, compression moulding, autoclave moulding, mandrel wrapping, wet layup, chopper gun forming, filament winding, pultrusion and resin infusion. In some embodiments, one or both of the monocoque and the shelving matrix are manufactured by 3D printing, such as stereolithography (SLA), selective laser sintering (SLS), fused deposition modelling (FDM), electron beam melting (EMB), selective laser melting (SLM) or digital light processing (DLP).

According to another aspect of the invention, there is provided vehicle comprising the battery module housing as described above. The vehicle may be an electric vehicle or a hybrid electric vehicle. Optionally, said vehicle is a two-wheeled vehicle. Optionally, said two-wheeled vehicle is a motorcycle, such as an electric motorcycle. Optionally, said vehicle is a three or more wheeled vehicle. In some embodiments, said vehicle is a four wheeled vehicle. In some embodiments, said four wheeled vehicle is a car or a quad bike or an all terrain vehicle (ATV). In some embodiments, said vehicle does not comprise wheels. Optionally, said vehicle comprises one or more continuous tracks, such as an elastomeric track or a metal track. Optionally said vehicle comprises one or more skis, snowboards or blades. Advantageously, a vehicle incorporating the battery module housing as above described may benefit from reduced parts complexity due to the battery module housing's ability to perform multiple functions, such as load bearing functions, housing, protecting and supporting a energy storage means and acting as a hard-point for the vehicle suspension.

One or more embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings, in which:.

<FIG> shows a vehicle <NUM> according to an embodiment of the invention. Vehicle <NUM> is an electric vehicle and comprises energy storage means (not shown), for storing electrical energy therein for, at least partially, propelling the vehicle <NUM>. In some embodiments, vehicle <NUM> is a plug in hybrid electric vehicle (PHEV) that may be recharged by connecting vehicle <NUM> to an external source of electric power. The energy storage means may comprise one or more cells. The cells may be voltaic cells comprising rechargeable batteries such as lithium-ion or lithium-polymer batteries. Other battery chemistries are useful.

Additionally or alternatively, the cells may be super capacitors, or may comprise a combination of super capacitors and rechargeable batteries as may be desirable for a given vehicle application or function. The energy storage means may be charged with electrical power by electrical connection to a charging station external to the vehicle, or may be charged, at least in part by energy recovered by regenerative braking by a vehicle powertrain in use as are both well known in the art. The vehicle is propelled, at least in part, by a vehicle powertrain comprising an electric traction motor powered by the electricity stored in the energy storage means.

In the embodiment illustrated in <FIG>, the vehicle <NUM> is a two-wheeled vehicle or motorcycle. The vehicle <NUM> comprises a first wheel <NUM> at the front of the vehicle and a second wheel <NUM> at the rear of the vehicle. The two wheels <NUM>, <NUM> are arranged in alignment along a longitudinal axis <NUM> of the vehicle <NUM>, such that the first wheel <NUM> is forward of the second wheel <NUM>. As shown in the Figure, the first wheel <NUM> is at a front <NUM> of the vehicle and second wheel <NUM> is at a rear <NUM> of the vehicle. The first wheel <NUM> is used for steering the motorcycle. Other embodiments of motorcycle <NUM> may be envisaged, such as a tricycle comprising three wheels, with two rear wheels separated along a transverse axis of the vehicle <NUM> and a single front wheel, or alternatively, two front wheels separated along a transverse axis of the vehicle <NUM> and a single rear wheel. Indeed, other embodiments of vehicle <NUM> may be envisaged, such as a quad bike or ATV, which may have four wheels. In other embodiments, vehicle <NUM> does not comprise wheels and instead comprises some other component for providing ground engaging traction means, such as one or more continuous tracks, which may be an elastomeric track or a metal track. In other embodiments the vehicle comprises one or more skis, snowboards or blades.

The vehicle <NUM> comprises a seat unit <NUM>, which provides a surface <NUM>, on which a user may sit during vehicle operation. The seat unit <NUM>, in the example shown, is provided at a top <NUM> of the vehicle <NUM>. The vehicle <NUM> also comprises a steering mechanism or steering assembly (not shown) comprising steering input means, such as handlebars (as shown in <FIG>). The steering assembly may further comprise a telescopic fork or alternatively comprise a hub centre steering assembly (as is shown in the example of <FIG>).

The vehicle <NUM> comprises a battery module housing <NUM> from which the wheels <NUM>, <NUM> are suspended via one or more intermediate components known as suspension assemblies. The suspension assemblies may comprise forks (not shown) or one or more swing arm(s) <NUM>, <NUM> as is shown in the example of the motorcycle of <FIG>. The wheels <NUM>, <NUM> and intermediate components for suspending the wheels <NUM>, <NUM> from the battery module housing <NUM> define a front suspension assembly and a rear suspension assembly, respectively. In some embodiments, the battery module housing <NUM> comprises a front connection means comprising a front mounting point or through aperture <NUM> and a rear connection means comprising a rear mounting point or through aperture <NUM>, for receiving the one or more intermediate components of the front and rear suspension assemblies, respectively. In this way, the battery module housing <NUM> may provide hard-points for mounting the suspension assemblies to the battery module <NUM>, these hard-points may act as a pivot point of the vehicle <NUM>. In some embodiments, front and rear suspension assemblies comprise front and rear swing arm assemblies, respectively. The front wheel assembly may also comprise a steering assembly, such as a hub centre steering assembly or a headstock or headtube.

In some embodiments, one or both of the front and rear swing arms <NUM>, <NUM> comprise a composite material, such as carbon fibre reinforced resin. In some embodiments, one or both of the front and rear swing arms <NUM>, <NUM> comprise a metal or metal alloy. In some embodiments, the front mounting point or through aperture <NUM> is arranged to receive or provide a headstock or headtube. The battery module housing <NUM> may comprise any of fixing points, pivots, bearings or inserts, for attaching auxiliary components of the vehicle <NUM> to the battery module housing <NUM>, such as the headstock or headtube. The bearings or inserts may comprise metal or metal alloy.

The energy storage means (not shown) may be suspended within the battery module housing <NUM>. The battery module housing <NUM> may also house any one or more of: a motor, which may be an electric traction motor; an inverter; or a battery management system (BMS). The battery module housing <NUM> may also house other electronic systems of the vehicle <NUM>. The battery module housing <NUM> is a primary load bearing structural component of the vehicle. In use, the battery module housing <NUM> is able to bear a combined load of the vehicle and any vehicle occupant(s) and any cargo to be carried. The battery module housing <NUM> must be able to achieve this without buckling, bending, fracturing or otherwise experiencing mechanical failure. In some embodiments, this is achieved by providing the battery module housing <NUM> with a stiffness within or exceeding a predefined range, said range being sufficient to support the rider and vehicle weight. In some embodiments, the battery module housing <NUM> controls flexion and torsion in one or more directions, as will later be described. The battery module housing <NUM> may prohibit flexion and torsion in one or more directions. Appropriate battery module housing <NUM> geometry to provide sufficient mechanical properties to at least enable the battery module housing <NUM> to function as a primary load bearing structural component of the vehicle <NUM> may be determined using finite element analysis (FEA) or other mathematical and/or computational modelling techniques. In some embodiments, the battery module housing <NUM> may be formed in any three dimensional shape. The appropriate mechanical properties as above described may be obtained by other means, such as by appropriate material selection and treatments.

In an embodiment, such as that illustrated in <FIG> and indeed in the embodiments illustrated in <FIG>, the battery module housing <NUM> is both a body of the vehicle and a chassis or frame of the vehicle. In other embodiments, the battery module housing <NUM> may be only one of a body or a chassis or frame of a vehicle. In some embodiments, the battery module housing <NUM> comprises a metal or metal alloy, such as aluminium, or an aluminium alloy. In some embodiments, the battery module housing <NUM> comprises a composite material, such as carbon fibre reinforced epoxy resin.

The battery module housing <NUM> comprises a monocoque <NUM> and a shelving matrix (shown in detail in <FIG> and <FIG>). As used herein, the term shelving matrix means a component comprising one or more shelves for receiving said energy storage means thereon. The shelving matrix may comprise only a single shelf or may comprise multiple shelves. The shelving matrix may comprise one or more partitions that divide the one or more shelves into sections. The one or more partitions may be substantially perpendicular to said one or more shelves. In other embodiments, the shelving matrix may comprise no partitions. The monocoque <NUM> functions as a structural shell of the battery module housing <NUM>, for carrying loads, including at least tensile and compressive loads. In the embodiments illustrated in <FIG>, monocoque <NUM> provides both a frame function and a body function of the vehicle <NUM>. In other words, monocoque <NUM> is an integral chassis-body component of the vehicle <NUM>. The shelving matrix may be integrally formed with the monocoque <NUM>. In some embodiments, the monocoque comprises one or both of a metal/metal alloy, such as fabricated aluminium and a composite material, such as carbon fibre reinforced resin.

The monocoque <NUM> may comprises any one of a variety of shapes. In the embodiments illustrated in <FIG>, the monocoque <NUM> comprises a three dimensional (3D) polygon, having a number of straight edges and flat faces. However in some embodiments, the monocoque <NUM> may comprise one or both of curved edges and curved faces. In some embodiments, the monocoque <NUM> may comprise one or both of: a mixture of curved and straight edges and a mixture of flat and curved faces. Indeed, it will be appreciated that straight edges and flat faces are not essential features of the monocoque <NUM>.

In some embodiments, as illustrated in <FIG> and <FIG>, the monocoque <NUM> comprises a body component <NUM> and a cover plate <NUM>. The body component <NUM> may be a unitary, integrally formed component. The cover plate <NUM> may be a removable cover plate. The body component may be substantially hollow to define an internal portion, chamber or cavity therein. In some embodiments, the body component <NUM> comprises an opening <NUM>, which opening is closeable by the cover plate <NUM>, which may be releasably secured to the body component <NUM> by means of screws, an adhesive, or other fastening means. In some embodiments, body component <NUM> comprises a ledge 206a for receiving the cover plate <NUM>. Ledge 206a may be provided around at least a part of a perimeter of the opening <NUM>. Ledge 206a may slightly within the body component <NUM>, so that when the cover plate <NUM> is received on the ledge 206a, the cover plate <NUM> is substantially flush with an outer face or outer faces of the body component <NUM>. A sealing member (not shown) may be provided between the removable cover plate <NUM> and the ledge 206a, arranged to provide, when the cover plate is secured to the monocoque, an effective seal against the ingress of dirt or water from the road or other surface on which the vehicle is operating and the interior of the monocoque <NUM>. The sealing member may be formed from EPDM, PU or other suitable elastomer. The cover plate <NUM> enables access to an interior portion of the monocoque <NUM> and to the shelving matrix therein. This allows energy storage means received by the shelving matrix to easily be inserted, removed, replaced or serviced as required.

With reference to <FIG>, said opening <NUM> of the body component <NUM> may be located at a rear <NUM> of the battery module housing <NUM>, so that when the body component <NUM> of the monocoque <NUM> is closed by the cover plate <NUM>, the cover plate <NUM> is positioned at a rear surface of the monocoque <NUM>. In some embodiments, as illustrated by <FIG>, said opening <NUM> of the body component <NUM> may be located at a top <NUM> of the battery module housing <NUM>, so that when the body component <NUM> of the monocoque <NUM> is closed by the cover plate <NUM>, the cover plate <NUM> is positioned at a top surface of the monocoque <NUM>. In some embodiments, as illustrated by <FIG>, said opening <NUM> of the body component <NUM> may be located at a side of the battery module housing <NUM>, so that when the body component <NUM> of the monocoque <NUM> is closed by the cover plate <NUM>, the cover plate <NUM> is positioned at a side surface of the monocoque <NUM>. In an embodiment (not shown), the monocoque <NUM> may further comprise a separate, storage volume for storing of items such as gloves, keys, sunglasses, wallet, tools or the like as may be useful to the vehicle user. This storage volume is accessible via a lockable cover plate, hinged to the monocoque and located in an upper surface of the monocoque so as to be conveniently accessible to the vehicle user.

In some embodiments, at least one internal face of the monocoque <NUM> comprises one or more busbars <NUM> for providing an electrical terminal for said energy storage means. The one or more busbars <NUM> may comprise any one or more of: a flat strip, a solid bar, a solid rod, a hollow tube and a braided wire. In some embodiments, an internal face on each of a pair of ends, which ends may be opposing ends, each comprise one or more busbars <NUM> for providing an electrical terminal for said energy storage means. In the embodiment illustrated in <FIG> and <FIG>, a front internal face <NUM> at a front <NUM> end of the monocoque <NUM> comprises a plurality of busbars <NUM> and cover plate <NUM> closes the body component <NUM> of the monocoque <NUM> at a substantially opposite, rear <NUM> end of the monocoque <NUM>. As illustrated in <FIG>, a face <NUM> of cover plate <NUM> also comprises a plurality of busbars <NUM>. In use, when the body component <NUM> is closed by the cover plate <NUM> and the cover plate is fastened in place, a clamping force is exerted by the cover plate on the energy storage means contacting and extending between both the busbars <NUM> on face <NUM> and the busbars <NUM> on face <NUM>. This results in a good electrical connection and sealing of the internal volume of the body component <NUM>.

In addition to a monocoque <NUM>, battery module housing <NUM> comprises a shelving matrix within the monocoque <NUM>. In some embodiments, the shelving matrix comprises one or both of a metal/metal alloy, such as fabricated aluminium and a composite material, such as carbon fibre reinforced resin. The shelving matrix may provide additional structural support to the monocoque <NUM>. The shelving matrix is arranged to receive an energy storage means, which may, in some embodiments, be a string of cells. The energy storage means may occupy more than one shelf of the shelving matrix. The energy storage means may occupy substantially all of the shelves of the shelving matrix. The energy storage means may occupy only a part of a shelf of the shelving matrix. The shelving matrix may support and retain the energy storage means within the battery module housing <NUM>. The shelving matrix may comprise shock absorbing means so as to protect the energy storage means received by the shelving matrix from damage, such as due to impact to the vehicle. Shock absorbing means may be provided in the form of padding or cladding on the shelving matrix. Additionally or alternatively, shock absorbing means may be provided in the form of deformable support elements (not shown), positioned between the shelving matrix and the monocoque <NUM>. These deformable elements are configured to be replaceable sacrificial mounting elements that, in the event of a vehicle impact, deform, allowing a small amount of relative movement between the shelving matrix and the monocoque, absorbing energy in the process of deformation. In other embodiments, shock absorbing means may be provided by the monocoque <NUM>, such as padding or cladding on an internal face or faces of the monocoque. The shelving matrix comprises one or more shelves <NUM>, as illustrated in <FIG> and <FIG>. The shelves <NUM> of the shelving matrix may be substantially parallel. The shelves <NUM> of the shelving matrix may extend substantially across a plane of the monocoque <NUM>, from a first, front <NUM> end of the monocoque <NUM>, to a second, rear <NUM> end of the monocoque, as illustrated in <FIG>.

In some embodiments, the shelving matrix may comprise a lattice structure of shelves <NUM> and walls or partitions. With reference to <FIG>, in some embodiments, shelving matrix <NUM> comprises one or more shelves <NUM> and one or more sidewalls <NUM>. The sidewalls <NUM> may be substantially parallel to each other. The one or more sidewalls <NUM> may be substantially perpendicular to the one or more shelves <NUM>, so as to define one or more open topped compartments <NUM> of the shelving matrix <NUM>. Where more than one shelf <NUM> is provided, the shelves may be substantially parallel to one another, as illustrated by <FIG>, to define one or more additional compartments <NUM>. The compartments <NUM>, <NUM> may be distributed in a grid like pattern.

In some embodiments, the shelving matrix <NUM> may comprise one or more clearance zones. A clearance zone may provide clearance to separate the energy storage means from one or both of the front and rear connection means, which in some embodiments, comprise through apertures <NUM>, <NUM>, and are arranged to provide mounting means for the front and rear suspension assemblies respectively.

With reference to <FIG>, in some embodiments, the shelving matrix may only extend throughout an area <NUM> within the monocoque, as indicated by the hatched region of the monocoque <NUM> of <FIG>. The shelving matrix does not extend into the front and rear clearance zones <NUM>, <NUM> provided at the front <NUM> and rear <NUM> of the battery module housing <NUM>, respectively. Front and rear clearance zones <NUM>, <NUM> therefore enable substantially unimpeded connection of front and rear wheel assemblies to the battery module housing <NUM> via front and rear connection means, which may be, in some embodiments, through apertures <NUM>, <NUM>, respectively. The front and rear clearance zones <NUM>, <NUM> therefore may be arranged to provide sacrificial crumple zones to further protect the shelving matrix <NUM> and energy storage means in the event of a vehicle impact.

The front suspension assembly may comprise a headstock or headtube (not shown). The front suspension assembly may include a steering assembly. The front through aperture <NUM>, may be arranged to receive the headstock therethrough, or may itself define a headtube through and about which a steering mechanism of the steering assembly of the front suspension assembly may operate. The front and rear clearance zones <NUM>, <NUM> also enable an energy storage means to be distributed on multiple shelves <NUM> without breaking an electrical connection. The clearance zones <NUM>, <NUM> may enable a string of cells to be threaded along multiple rows in an S-like pattern.

Referring again to <FIG>, in some embodiments, the shelving matrix <NUM> comprises at least one cooling means such as a cooling channel <NUM>, as illustrated by <FIG>. The at least one cooling channels <NUM> may comprise a through cavity.

The at least one cooling channel <NUM> may be integral with the shelving matrix, such as formed within one or both of a side wall <NUM> and a shelf <NUM>, such as illustrated by <FIG> and <FIG>. The at least one cooling channels <NUM> may be coaxial with a shelf <NUM> in which it is integrally formed within. In some embodiments, the monocoque <NUM> comprises at least one aperture <NUM> for providing fluid communication between the at least one cooling channel <NUM> and an environment external to the monocoque <NUM>. A first of such apertures <NUM> may be provided substantially at the front <NUM> of the monocoque <NUM> and a second of such apertures <NUM> may be provided substantially at a rear <NUM> of the monocoque <NUM>. In some embodiments, as illustrated in <FIG>, <FIG>, <FIG> and <FIG>, a plurality of such apertures <NUM> are provided substantially at the front <NUM> of the monocoque <NUM> and a plurality of apertures <NUM> are provided substantially at the rear <NUM> of the monocoque <NUM>. In this way, air can flow from an environment external to the vehicle, through the aperture or apertures <NUM> substantially at the front <NUM> of the monocoque <NUM>, into the monocoque <NUM>, through at least one of the at least one cooling channels <NUM> and through the aperture or apertures <NUM> substantially at the rear <NUM> of the monocoque <NUM>, to the external environment, thereby cooling contents within the battery module housing <NUM>. This may be especially advantageous in extended and/or heavy operating conditions. It is envisaged that excess heat is transferred away from the energy storage means via thermally conductive surfaces or elements in the shelves <NUM> and that the shelves are cooled whilst the energy storage means are substantially sealed within their compartments <NUM>, <NUM>, so that they cannot become contaminated by dust or water entrained in the cooling air. This is especially advantageous where the vehicle is being operated in areas of relatively high ambient temperatures and where conditions are wet or dusty.

In an alternative embodiment (not shown), the battery module housing <NUM> further comprises a battery cooling pack having a heat exchanger supported on an external surface of the monocoque <NUM>. The cooling pack contains a coolant (which may be a liquid or gas) in fluid communication between the heat exchanger and the cooling channels <NUM> and is configured to convey excess heat away from the energy storage means in use. In an example, the battery cooling pack comprises a heat exchanger and a fan arranged to force cooling air through the heat exchanger and the monocoque <NUM> has external formations in the form of a partial or complete duct or cowl, arranged to support the heat exchanger and the fan and provide a cowling therefor to guide air from the fan through the heat exchanger so as to maximise cooling pack performance.

The vehicle <NUM> comprises suspension assemblies arranged to support the weight of the vehicle and user and to permit a range of relative movement between the vehicle and the aforementioned wheel, track and/or ski. These suspension assemblies comprise attachment means for securing the suspension assembly to the monocoque <NUM> and, distal from the attachment means, are provided with mounting means to which are mounted the wheel, track or ski as may be desired. Between the mounting means and the monocoque is provided a spring-damper assembly arranged to provide controlled relative movement between the vehicle and the mounting means. The spring-damper assembly provide the vehicle with vertical damping means <NUM> (as shown in <FIG> and <FIG>) for providing damping along a substantially vertical axis (not shown).

However, for some arrangements of vehicle <NUM>, especially those with only two wheels, the user will lean the vehicle <NUM> whilst cornering. During cornering, these vehicles may approach an orientation in which a lateral axis <NUM> of the vehicle, such as illustrated by <FIG>, approaches an orientation almost perpendicular to a driving surface on which the vehicle is operating. In those scenarios, the effectiveness of vertical damping means <NUM> can be diminished and another solution is required. In some embodiments, the battery module housing <NUM> comprises lateral damping control means for controlling damping when the vehicle is cornering. The lateral damping control means may control damping along the lateral axis <NUM>. As described above, battery module housing <NUM> is a primary load bearing structural component of the vehicle <NUM> and, in some embodiments, controls flexion and torsion in one or more directions. The monocoque <NUM> is therefore, in some embodiments, adapted to control lateral flexion. In some embodiments, being adapted comprises the monocoque having one or both of a shape and one or more mechanical properties being arranged to control to permit lateral flexion within a desired range. Appropriate battery module housing <NUM> geometry to provide sufficient mechanical properties to at least enable the battery module housing <NUM> to function as a lateral damping control means of the vehicle <NUM> may be determined using finite element analysis (FEA) or other mathematical and/or computational modelling techniques. In some embodiments, said battery module housing <NUM> may be formed in any three dimensional shape. The battery modular housing <NUM> may be adapted to maintain lateral flexion within a desired range of lateral flexion and with desired dynamic response characteristics, regardless of the shape of the battery module housing <NUM>. This may instead be achieved by appropriate material selection. Said battery module housing <NUM> may be adapted to withstand a variety of twisting forces, regardless of the shape of said monocoque. This may instead be achieved by appropriate material selection. The battery module housing <NUM> may be formed by a modular construction.

To manufacture the battery module housing <NUM>, the monocoque <NUM> and shelving matrix <NUM> may be manufactured concurrently. In some embodiments, the monocoque <NUM> and the shelving matrix <NUM> are independently manufactured and the shelving matrix <NUM> is then fitted within the monocoque <NUM>. In some embodiments, such as that illustrated in <FIG>, the shelving matrix <NUM> may comprise a first shelving matrix part 700c and a second shelving matrix part 700d. The first and second shelving matrix parts 700c, 700d may be fitted together to form the shelving matrix <NUM>. The first and second shelving matrix parts 700c, 700d may be fitted together by a variety of methods, such as by an adhesive, by soldering or welding, by fastening means such as screws, or by a mechanical connection, such as lugs and detents formed in adjoining shelving matrix parts 700c, 700d. One or more cooling channels may be formed in the shelving matrix <NUM>, by a method such as a gas forming technique.

The shelving matrix <NUM> may be retained within the monocoque <NUM> by bonding the shelving matrix <NUM> to an internal wall of the monocoque <NUM>. This may be achieved using an adhesive or bonding webbing, or another suitable method for bonding components together, such as soldering or welding. Alternatively, the shelving matrix <NUM> may be retained within the monocoque <NUM> by a mechanical connection, such as an internal lug or lugs protruding from an internal wall of the monocoque <NUM> for engaging with one or more edges of the shelving matrix <NUM>. The one or more edges of the shelving matrix <NUM> may be an edge of a shelf <NUM>. In some embodiments, the one or more edges of the shelving matrix may be provided with an auxiliary extension or accessory, such as lugs, detents or clips, for engaging the internal lug or lugs protruding from the internal wall of the monocoque <NUM>.

In some embodiments, monocoque <NUM> comprises a first clamshell part 700a and a second clamshell part 700b. To assemble the battery module housing <NUM>, a shelving matrix <NUM> may be fitted to one of the clamshell parts 700a, 700b. The other of the clamshell parts 700a, 700b may then be fitted to the first of the clamshell parts, over and around the shelving matrix <NUM>, thereby enclosing the shelving matrix <NUM> within the monocoque <NUM>. The first and second clamshell parts 700a, 700b may be fitted together by a variety of methods, such as by an adhesive, by soldering or welding, by fastening means such as screws, by a mechanical connection, or by any combination of these methods. When the two clamshell parts 700a, 700b are fitted together a seal is formed between the two clamshell parts to prevent ingress of dirt and or water into the battery module housing <NUM>.

In some embodiments, monocoque <NUM> comprises a first clamshell part 700a and a second clamshell part 700b. To assemble the battery module housing <NUM>, a first part of the shelving matrix <NUM> may be fitted to the first clamshell part 700a and a second part of the shelving matrix <NUM> may be fitted to the second clamshell part 700b. The first and second clamshell parts may then be brought together and secured. The first and second clamshell parts 700a, 700b and the first and second parts of the shelving matrix <NUM> may be fitted together by a variety of methods, such as by a pressed connection fitting, an adhesive, by soldering or welding, by fastening means such as screws, by a mechanical connection, or by any combination of these methods.

In some embodiments, one or both of the monocoque <NUM> and the shelving matrix <NUM> comprise a composite material such as carbon fibre reinforced resin. In those embodiments, the monocoque <NUM> and/or the shelving matrix <NUM> may be formed by any of: bladder moulding, compression moulding, autoclave moulding, mandrel wrapping, wet layup, chopper gun forming, filament winding, pultrusion and resin infusion.

In some embodiments, one or both of the monocoque <NUM> and the shelving matrix <NUM> are manufactured by 3D printing, such as stereolithography (SLA), selective laser sintering (SLS), fused deposition modelling (FDM), electron beam melting (EMB), selective laser melting (SLM) or digital light processing (DLP).

Claim 1:
A battery module housing (<NUM>) for an electric vehicle (<NUM>), comprising:
a monocoque (<NUM>); and
a shelving matrix (<NUM>) within the monocoque (<NUM>), the shelving matrix (<NUM>) for receiving an energy storage means,
wherein the monocoque (<NUM>) is a structural component of the electric vehicle (<NUM>),
characterised in that:
the monocoque (<NUM>) comprises a rear connection means (<NUM>) for receiving a rear suspension assembly and a front connection means (<NUM>) for receiving a front suspension assembly;
the rear suspension assembly comprises a rear swing arm (<NUM>) and a spring-damper assembly arranged between the rear swing arm (<NUM>) and the monocoque (<NUM>), and wherein the spring-damper assembly is configured to control the movement of the swing arm (<NUM>) relative to the battery module housing (<NUM>); and
the front suspension assembly comprises a front swing arm (<NUM>) and a spring-damper assembly arranged between the front swing arm (<NUM>) and the monocoque (<NUM>), and wherein the spring-damper assembly is configured to control the movement of the front suspension assembly relative to the battery module housing (<NUM>).