Patent Description:
The use of alternative fuels for vehicles is becoming more prevalent. Natural gas powered automobiles produce less harmful emissions than do automobiles powered by traditional fossil fuels. A growing trend is the use of electrical motors for propulsion.

Electric drive systems have become ubiquitous for small passenger vehicles. However, long wait time to charge batteries is an obstacle to wider adoption of electric drive systems.

In <CIT> there is described a vehicle having a body forming a passenger compartment. The vehicle also has a chassis supporting the body. The chassis includes a frame structure having a pair of side rails connected by a plurality of rigid cross rails and defining a plurality of bays between the cross rails. The vehicle additionally has a battery pack including a plurality of electrical storage devices stored in a battery housing. The battery housing defines a plurality of channels. The vehicle further includes a fastening mechanism attaching the battery housing directly to the plurality of cross rails with at least a portion of the battery housing in the plurality of bays and the plurality of cross rails in the plurality of channels.

An aspect of the present invention provides a battery assembly for an electric vehicle. Another aspect of the present invention provides a method of equipping a vehicle with a battery assembly designed for easy and quick exchange of battery assemblies enabling a vehicle to resume driving much more quickly than traditional charging permits.

According to a first aspect of the present invention there is provided a battery assembly for an electric vehicle, wherein the battery assembly comprises the features of claim <NUM>.

In some variations, at least a portion of the one or more battery units is disposed in the first lateral portion. In some variations, at least a portion of the one or more battery units is disposed in the second lateral portion. In some variations, at least a portion of the one or more battery units is disposed in the first lateral portion and in the second lateral portion.

In another embodiment the housing comprises a W-shaped housing.

The housing can be configured to be exposed to the road beneath the electric vehicle when the battery assembly is coupled to the frame member of the electric vehicle.

The mounting system can comprise a first component coupled with the housing and a second component configured to be coupled with the frame member. The first component can be configured to be releasably coupled to the second component. In this context, the releasable coupling can be one that facilitates quick exchange of the battery assembly for another, fully charged, battery assembly.

Where provided the second component of the mounting system can be configured to be coupled with a lateral portion of, e.g., an outwardly facing side of, the frame member.

When provided, the first component of the mounting system can include one or more brackets disposed on one or both of a first inside surface of the first lateral portion and on a second inside surface of the second lateral portion.

Where provided, the brackets of the mounting system can include U-shaped members configured to be disposed around the second component of the mounting system.

In some embodiments, the housing is configured to be coupled to the mounting system from beneath the vehicle. The housing can be moved transversely to the long axis of the vehicle, e.g., between forward and rearward wheels of the vehicle. The housing can be moved longitudinally along the long axis of the vehicle, e.g., under an axle between driver side and passenger side wheels coupled with the axle.

According to a second aspect of the present invention there is provided a method of equipping a vehicle with a battery assembly comprising the steps of claim <NUM>.

The battery assembly and method of equipping a vehicle with a battery assembly may be better understood from the following detailed description when read in conjunction with the accompanying schematic drawings, which are for illustrative purposes only. The drawings include the following figures:.

This application is directed to electric vehicle components and assemblies. The components described and claimed herein can be used in vehicles that are powered solely by electric motor(s) and in vehicles that are powered by a combination of power sources including electric motors and fossil fuels, e.g., natural gas fuel systems.

<FIG> illustrates a vehicle <NUM> with a fossil fuel system <NUM> disposed within an enclosure behind a cab <NUM>. The fuel system <NUM> can power a combustion engine. The vehicle <NUM> can be powered by an electric motor (not shown) as dsiclosed herein. In one arrangement, the truck has multiple distinct energy sources that are capable of operating independently. In certain arrangements, the truck has no combustion engine and uses an electric motor for its propulsion power.

<FIG> illustrates a side view of a vehicle <NUM>. The vehicle <NUM> has a cab <NUM> and a vehicle frame for loading cargo <NUM>. The vehicle <NUM> has an electric drive system and at least one battery to power the electric drive system. The fossil fuel system <NUM> is shown in dash line, indicating that in this example such a system is optional and may not be present.

In <FIG>, a first battery assembly <NUM> is located under the cab <NUM> and a second battery assembly <NUM> is located under the cargo frame <NUM>. In certain arrangements, the truck has no battery to power its electric drive system under the cab <NUM>, and instead has one or more battery assemblies under the cargo area of the vehicle. In certain arrangements, the truck has no battery to power its electric drive system under the cargo frame <NUM> and instead has one or more battery assemblies forward of the cargo area, e.g., under the cab <NUM>.

In <FIG>, the two batteries <NUM>, <NUM> are coupled to a beam <NUM> that is fixed to the cargo frame <NUM> and/or a frame of the cab <NUM>. The beam <NUM> is a structural member that bears the load of the cargo frame <NUM> and also supports other components directly or indirectly, such as the wheels and axles. The beam <NUM> is sometimes referred to herein as a rail or frame rail. In certain arrangements, a battery to power the vehicle's electric drive system is fixed to a frame of the cab <NUM>.

Referring to <FIG>, the second battery assembly <NUM> is sized such that the second battery assembly <NUM> does not overlap the wheels <NUM>, <NUM>, <NUM> of the truck. <FIG> shows that if the battery assembly <NUM> is forward of the rear wheels <NUM>, <NUM>, the width dimension of a housing of the battery assembly <NUM> can be greater than the distance <NUM> between the inside of the inner wheels. Generally, the battery assembly <NUM> will not be wider than the distance <NUM> between the outer sides of the outermost wheels.

<FIG> illustrates a bottom view of the vehicle <NUM>. The truck has at least one beam (or frame rail) <NUM> installed under the cab <NUM> and the cargo frame <NUM>. The beam <NUM> extends generally along a longitudinal direction of the vehicle <NUM> for holding the cargo frame <NUM> and other systems such as the wheels and axles, suspension, exhaust, as well as one or both of the battery assemblies <NUM>, <NUM>. Referring to <FIG>, the beam <NUM> extends to overlap a first rear-wheel axle <NUM> adjacent to or immediately neighboring the front-wheel axle <NUM>. The beam <NUM> does not extend beyond the front-wheel axle <NUM> or beyond the first rear-wheel axle <NUM> in some arrangements. In certain arrangements, the beam <NUM> extends to overlap all of the axles <NUM>, <NUM>, <NUM> or does not overlap any of the axles <NUM>, <NUM>, <NUM> when viewed from the bottom. <FIG> shows that the battery assemblies <NUM>, <NUM> are located in a space between the front-wheel axle <NUM> and the rear-wheel axle <NUM> adjacent to or immediately neighboring the front-wheel axle <NUM> in one example.

<FIG> illustrates a rear view of the vehicle <NUM>. The beam <NUM> is installed under the cargo frame <NUM> between rear wheels <NUM>. The battery assembly <NUM> is coupled to the beam <NUM> using mounting systems <NUM>, <NUM>. In certain arrangements, the clearance <NUM> below the rear axles <NUM>, <NUM> is greater than the height <NUM> of the battery assembly <NUM> such that the battery assembly <NUM> can move under the rear axles <NUM>, <NUM> and between the rear wheels <NUM> for exchanging battery assemblies. Manners of securing the first battery <NUM> or the second battery <NUM> to the <NUM> are discussed below in connection with <FIG>, <FIG> and <FIG>.

<FIG> is a schematic view of an electric drive system. The vehicle <NUM> uses at least one motor <NUM> for propulsion. At least one battery assembly <NUM>, <NUM> of the vehicle <NUM> provides power in the form of electric current to drive the motor <NUM>. The vehicle <NUM> comprises an electric current conveyance system <NUM> for connecting the battery assembly <NUM>, <NUM> and the motor <NUM>. The vehicle <NUM> has a transmission system (not shown) to deliver torque generated by the motor <NUM> to one or more wheel driving axles, e.g., to the axle <NUM>.

<FIG> is a perspective view of the battery assembly <NUM>. <FIG> illustrates the battery assembly <NUM> coupled with the beam <NUM>. <FIG> is a top view of the battery assembly <NUM> coupled with the beam <NUM>.

Referring to <FIG>, the battery assembly <NUM> includes a housing <NUM> and at least one mounting system <NUM>, <NUM> for coupling the battery assembly <NUM> to the beam <NUM>. The housing <NUM> comprises a first lateral portion <NUM>, a second lateral portion <NUM>, and a central portion <NUM> interposed between the lateral portions <NUM>, <NUM>. The central portion <NUM> does not extend as far in the vertical direction as the lateral portions <NUM>, <NUM>. A space <NUM> is provided between the lateral portions <NUM>, <NUM> to receive the beam <NUM> as illustrated in <FIG> and <FIG>. The space <NUM> can be disposed between an inward facing surface of the first lateral portion <NUM> and an inward facing surface of the second lateral portion <NUM>. The inward facing surfaces can be surfaces that face toward a central vertical longitudinal plane of the vehicle <NUM> when the battery assembly <NUM> is mounted thereto. In other words, the inward facing surfaces can be closer to the central vertical longitudinal plane than are outward surfaces of the first and second lateral portions <NUM>, <NUM> which face away from that central vertical longitudinal plane.

The housing <NUM> of the battery assembly <NUM> is generally symmetrical about a central plane A-A. The mounting system <NUM> and the mounting system <NUM> are also symmetrical about the central plane A-A. In certain embodiments, the battery assembly <NUM> is asymmetrical about the plane A-A, and the mounting system <NUM> connected to the first lateral portion <NUM> and the mounting system <NUM> connected to the second lateral portion <NUM> have different configurations.

At least one mounting system <NUM> is provided in a recess <NUM> between the central portion <NUM> and the second lateral portion <NUM>. The recess <NUM> can include a bight formed by the housing <NUM>. The bight can be formed in a concave periphery on the top side of the housing <NUM>. The bight can include a more complex shape such as two U-shaped or concave portions on opposite sides of a central vertical plane of the housing <NUM>. The mounting system <NUM> includes a first member <NUM> fixed to a wall of the housing <NUM> (e.g., to a wall of the second lateral portion <NUM>) that is facing the beam <NUM> and a second member or component <NUM> for connecting the first member <NUM> to the beam <NUM>. In some embodiments, when the battery <NUM> is lifted to a position where the first member <NUM> of the mounting system <NUM> is at a level of the beam, the second member <NUM> is fixed to the beam by fastening a bolt (that is accessible from the space <NUM>). In certain embodiments, the second member <NUM> is fixed to the beam using at least one bolt <NUM>, the beam <NUM> has at least one through hole <NUM> for receiving the bolt <NUM>, and the second member <NUM> has at least one screw hole for receiving the bolt <NUM>. In certain embodiments, a procedure to secure the battery assembly <NUM> to the beam comprises: (<NUM>) when the vehicle <NUM> is parked, moving the battery assembly <NUM> on or over the ground to place it under the beam <NUM>; (<NUM>) lifting the battery assembly <NUM> to a set position shown in <FIG> where the through hole <NUM> is aligned with a screw hole of the second member <NUM>; and (<NUM>) fastening the bolt <NUM> to second member <NUM> passing the through hole <NUM>. In various techniques, a motorized screwdriver, impact wrench or other hand tool can access the bolt <NUM> in the space <NUM> over the central portion <NUM> of the battery assembly <NUM>. In another method, the second member <NUM> is secured to the beam <NUM> and the bolt <NUM> may be advanced through any of the holes in the side of the first member <NUM>. More specifically, the bolt <NUM> can be advanced through any of the holes in a direction parallel to the central plane A-A and into the second member <NUM>. An impact wrench or other tool can be used to secure the bolt <NUM> in this direction and in this manner.

<FIG> is a cross sectional view of the battery assembly <NUM> coupled with the frame rails <NUM> of a vehicle as shown in <FIG>. The housing <NUM> of the battery assembly <NUM> contains or encloses a plurality of battery units or cells <NUM>. The housing <NUM> is fixed to the beam (e.g., frame rail) <NUM> using the mounting system <NUM>, <NUM> such that some of the battery units <NUM> are disposed laterally of the frame rails <NUM> and some are disposed between the frame rails <NUM>. More particularly, the mounting system <NUM> enables the frame rails <NUM> to support battery cells over a wide area beneath the vehicle <NUM>, with some battery cells at the central vertical longitudinal plane of the vehicle <NUM>, and some disposed laterally between the central vertical longitudinal plane of the vehicle <NUM> and the frame rails <NUM> and with some of the battery cells disposed laterally between the frame rails <NUM> and the lateral outer extent of the vehicle <NUM>, e.g., such that the frame rails are between at least some of the battery cells <NUM> and the central vertical longitudinal plane of the vehicle <NUM>. Furthermore, battery cells <NUM> are contained in portions of the housing <NUM> corresponding to the mounting systems <NUM>, <NUM> e.g., in the recess <NUM>, at a level of, lateral of, and/or below the mounting systems <NUM>, <NUM> to increase the number of contained battery cells while allowing a vacant space <NUM> between the lateral portions <NUM>, <NUM>.

<FIG> illustrate processes for mounting a battery assembly. A first bracket <NUM> fixed to the beam <NUM> is engaged with a second bracket <NUM> for coupling the lateral portion <NUM> of the housing to the beam. The lateral portion <NUM> and the second bracket <NUM> can be moved from one side of the vehicle <NUM> under the frame rails <NUM> across the central vertical longitudinal plane of the vehicle <NUM> then lifted to be disposed over at least a portion of the first bracket <NUM>. When the battery cell <NUM> is lifted from a set position shown in <FIG> to a lifted position shown in <FIG>, a coupling pin <NUM> of the second bracket <NUM> is elevated above a recess <NUM> of the first bracket <NUM>. When the battery assembly is in a mounted position shown in <FIG>, the coupling pin <NUM> is received in the recess <NUM> of the first bracket <NUM> such that one side of the battery assembly <NUM> is coupled to one of the beams <NUM> of the vehicle. In certain arrangements, subsequent to coupling the lateral portion <NUM> to the beam <NUM> in the mounted position of <FIG>, another mounting system <NUM> connected to the lateral portion <NUM> at the other side of the battery assembly <NUM> is aligned with the beam <NUM> and then secured to the beam <NUM> using a bolt (or other fastening system) to prevent the battery assembly <NUM> from moving relative to the beam <NUM> and to prevent the coupling pin <NUM> from coming out of the recess <NUM>. More details about coupling of the brackets <NUM>, <NUM> can be found in <CIT>.

<FIG> illustrate a process for mounting a battery assembly. A third bracket <NUM> fixed to the beam <NUM> is engaged with a fourth bracket <NUM> for coupling the lateral portion <NUM> of the housing to the beam <NUM>. When the battery assembly <NUM> is lifted from a set position shown in <FIG> to a lifted position shown in <FIG>, a hole <NUM> of the forth bracket <NUM> is elevated over a coupling protrusion <NUM> of the third bracket <NUM>. When the battery assembly is in a mounted position shown in <FIG>, the coupling protrusion <NUM> is inserted to the hole <NUM> of the fourth bracket <NUM> such that the battery assembly <NUM> is coupled to the beam <NUM>. In some arrangements, subsequent to coupling the lateral portion <NUM> to the beam <NUM> in the mounted position of <FIG>, another mounting system <NUM> connected to the lateral portion <NUM> at the other side of the battery assembly <NUM> is aligned with the beam <NUM> and then secured to the beam <NUM> using a bolt (or other fastening system) to prevent the battery assembly <NUM> from moving relative to the beam <NUM> and to prevent the coupling protrusion <NUM> from coming out of the hole <NUM>. More details about coupling of the brackets <NUM>, <NUM> can be found in U. Patent Publication No. <CIT>.

<FIG> shows the fuel system <NUM> mounted to the vehicle <NUM> in a behind-the-cab or back-of-cab configuration. More details of the fuel system <NUM> can be found in US Patent Publication No. <CIT>.

While the present description sets forth specific details of various embodiments, it will be appreciated that the description is illustrative only and should not be construed in any way as limiting. Furthermore, various applications of such embodiments and modifications thereto, which may occur to those who are skilled in the art, are also encompassed by the general concepts described herein.

The above presents a description of battery assemblies and methods contemplated for carrying out the concepts disclosed herein, and of the manner and process of making and using them, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this invention. The assemblies and methods disclosed herein, however, are susceptible to modifications and alternate constructions from that discussed above which are within the scope of the appended claims. Consequently, it is not the intention to limit this invention to the particular embodiments disclosed. On the contrary, the intention is to cover modifications and alternate constructions coming within the scope of the invention as expressed by the following claims, which particularly point out and distinctly claim the subject matter of embodiments disclosed herein.

Claim 1:
A battery assembly (<NUM>) for an electric vehicle, comprising:
a housing (<NUM>) having a first lateral portion (<NUM>), a second lateral portion (<NUM>), and a central portion (<NUM>), the housing (<NUM>) forming an upwardly oriented recess between the first lateral portion (<NUM>) and the second lateral portion (<NUM>);
one or more battery units (<NUM>) disposed within the housing (<NUM>) at least in the central portion (<NUM>); and
a mounting system (<NUM>, <NUM>) disposed at least partially between the first lateral portion (<NUM>) and the second lateral portion (<NUM>), characterized in that
a frame member (<NUM>) extending along a longitudinal direction of the electric vehicle can be disposed between the first lateral portion (<NUM>) and the second lateral portion (<NUM>) and when so disposed can be coupled to the mounting system (<NUM>, <NUM>) between the first lateral portion (<NUM>) and the second lateral portion (<NUM>).