Patent Application
20240313315
A typical side-by-side vehicle provides transportation for passengers seated in a side-by-side manner. Some side-by-side vehicles may be equipped with cargo carrying rear beds (or decks), roll bars, etc. depending on use and application.
Traditional side-by-side vehicles use internal combustion engines and gas tanks for fuel-based propulsion, and such vehicles are not intended to accommodate electric motors and rechargeable batteries for propulsion. Moreover, electric motors and rechargeable batteries impose different requirements/challenges, e.g., for operation, for installation, accessibility, safety, heat management, weight distribution, etc.
An improved technique involves a battery box for an electric off-road vehicle. Such a battery box richly and reliably stores and provides electric power to an electric motor for off-road vehicle propulsion. Along these lines, such a battery box protects a set of batteries against a harsh environment where moisture, dirt, etc. would otherwise impact operation. Moreover, the protection provided by such a battery box alleviates the need to use battery-related components (e.g., a battery management system or BMS, a DC/DC converter, a motor controller, etc.) that are individually rated/upgraded for harsh environments. Rather, standard rated components may be used while still enjoying protection against moisture, dirt, and so on. In accordance with certain embodiments, such a battery box is particularly well-suited for protecting a set of batteries from harsh conditions, for installation as a single assembly on a vehicle, is arranged to position batteries and related componentry for improved accessibility, is provisioned to provide operator safety, is configured for effective heat management, is suitable for operating a centrally-located differential, combinations thereof, etc.
One embodiment is directed to a battery box assembly. The battery box assembly includes a metallic skeleton. The battery box assembly further includes an insulative inner layer coupled with the metallic skeleton. The insulative inner layer faces an inner space defined by the metallic skeleton. The battery box assembly further includes an insulative outer layer coupled with the metallic skeleton. The insulative outer layer facing outwardly from the metallic skeleton.
In some embodiments, the battery box assembly further includes a set of inner walls disposed within the inner space and coupled with the insulative inner layer, the set of inner walls separating the inner space into multiple cavities.
In some embodiments, the set of inner walls separates the inner space into (i) a set of battery cavities constructed and arranged to house respective sets of battery modules and (ii) a component cavity constructed and arranged to house a set of electrical components configured to transfer power to and from the sets of battery modules.
In some embodiments, the insulative outer layer defines a bottom and a set of exterior walls that extend from the bottom. Further, the battery box assembly further includes a lid constructed and arranged to couple with the set of exterior walls. The lid, the bottom, and the set of exterior walls enclose the inner space when the lid is coupled with the set of exterior walls.
In some embodiments, the set of battery cavities includes at least two battery cavities. Further, the set of inner walls includes a first inner wall and a second inner wall. The first inner wall separates the at least two battery cavities from each other. The second inner wall separates the component cavity from the set of battery cavities. The second inner wall extends further from the bottom than the first inner wall to inhibit airflow between the component cavity and the set of battery cavities.
In some embodiments, the battery box assembly further includes a metallic plate constructed and arranged to couple with the lid and further couple with a set of upper frame members of an off-road vehicle to prevent the insulative outer layer from colliding with the set of upper frame members during a deflection event.
In some embodiments, the battery box assembly further includes a set of metallic fasteners constructed and arranged to couple with the metallic plate and the metallic skeleton. Additionally, the metallic plate and the set of metallic fasteners are constructed and arranged to connect the metallic skeleton to a chassis ground of the off-road vehicle.
In some embodiments, the battery box assembly further includes an interlock assembly constructed and arranged to couple with the metallic plate and maintain the sets of battery modules in a low voltage configuration when the lid is decoupled from the set of exterior walls.
In some embodiments, the lid, the bottom, and the exterior walls are constructed and arranged to form a watertight enclosure for the inner space when the lid is coupled with the set of exterior walls. Additionally, the battery box assembly further includes a pressure release assembly constructed and arranged to reduce pressure within the inner space when the lid is coupled with the set of exterior walls.
In some embodiments, a set of mounting members disposed within the compartment cavity constructed and arranged to mount the set of electrical components, the set of electrical components including a motor controller, a battery management system (BMS), and a DC/DC converter.
In some embodiments, the insulative inner layer defines a floor that mimics at least one top portion of a battery module. The floor is constructed and arranged to interface with at least one bottom portion of the sets of battery modules to vertically stack the sets of battery modules.
In some embodiments, the battery box assembly further includes a heat exchanger constructed and arranged to transfer heat from the component cavity to the set of battery cavities to warm the respective sets of battery modules.
In some embodiments, the battery box assembly further includes an electrical connections port coupled with the insulative outer layer, the electric connection port being constructed and arranged to provide access to the set of electrical components.
In some embodiments, the insulative outer layer includes a polymeric coating constructed and arranged to electrically and thermally insulate the inner space.
Another embodiment is directed to an off-road vehicle. The off-road vehicle includes a frame. The off-road vehicle further includes an electric motor coupled with one or more ground engaging members. The off-road vehicle further includes a battery box assembly disposed over the frame and constructed and arranged to provide power to the electric motor, the battery box assembly including:
In some embodiments, the battery box assembly further includes a set of inner walls disposed within the inner space and coupling with the insulative inner layer, the set of inner walls separating the inner space into (i) a set of battery cavities constructed and arranged to house respective sets of battery modules and (ii) a component cavity constructed and arranged to a set of electrical components configured to transfer power to and from the set of battery modules. Additionally, the set of battery cavities are disposed closer to a center of the off-road vehicle than the component cavity to provide the sets of battery modules closer to the center of the off-road vehicle.
Yet another embodiment is directed to a method of providing a battery box assembly. The method includes providing a metallic skeleton. The method further includes coupling an insulative inner layer with the metallic skeleton. The insulative inner layer facing an inner space defined by the metallic skeleton. The method further includes coupling an insulative outer layer with the metallic skeleton. The insulative outer layer facing outwardly from the metallic skeleton.
In some embodiments, the method further includes, after installing the respective sets of battery modules and installing the set of electrical components, inserting the battery box assembly into an off-road vehicle to provide the off-road vehicle with the sets of battery modules and the set of electrical components simultaneously.
Other embodiments are directed to apparatus, devices, and related componentry. Some embodiments are directed to various vehicles, equipment, assemblies, systems, sub systems, internal structures/configurations/arrangements, methods, and so on, which involve a battery box.
This Summary is provided merely for purposes of summarizing some example embodiments so as to provide a basic understanding of some aspects of the disclosure. Accordingly, it will be appreciated that various example embodiments disclosed herein are merely examples and should not be construed to narrow the scope or spirit of the disclosure in any way. Other embodiments, aspects, and advantages will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments.
The foregoing and other features and advantages will be apparent from the following description of particular embodiments, as illustrated in the accompanying drawings, in which like reference characters refer to the same or similar parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments.
Improved techniques are directed to battery boxes and off-road vehicles that utilize such battery boxes. Such battery boxes richly and reliably store and provide electric power to electric motors for off-road vehicle propulsion. Along these lines, such battery boxes protect batteries against harsh environments where moisture, dirt, etc. would otherwise impact operation. In accordance with certain embodiments, such battery boxes are particularly well-suited for protecting batteries from harsh conditions, for installation as single assemblies on vehicles, are arranged to position batteries and related componentry for improved accessibility, are provisioned for operator safety, are configured for effective heat management, are suitable for operating centrally-located differentials, combinations thereof, and so on.
It should be appreciated that the protection provided by such a battery box alleviates the need to use battery-related components (e.g., a battery management system or BMS, a DC/DC converter, a motor controller, etc.) that are individually rated/upgraded for harsh environments. Rather, standard rated components may be used while still enjoying protection against moisture, dirt, and so on.
The individual features of the various embodiments, examples, and implementations disclosed within this document can be combined in any desired manner that makes technological sense. Furthermore, the individual features are hereby combined in this manner to form all possible combinations, permutations and variants except to the extent that such combinations, permutations and/or variants have been explicitly excluded or are impractical. Support for such combinations, permutations and variants is considered to exist within this document. Such modifications and enhancements are intended to belong to various embodiments of the disclosure.
Certain portions of the electric vehicle 100 (e.g., exterior panels, doors, a hood, a cargo bed, etc.) may have been omitted from these figures for simplicity and/or to better show other details of the electric vehicle 100.
As best shown in
As best shown in
In some embodiments, the top plate 160 defines an opening 164 that allows a portion of a lid of the battery box 110 to extend therethrough. In some embodiments, the top plate 160 is constructed and arranged to reduce a load on the subcradle underneath it.
In some embodiments, the top plate 160 is metallic and is constructed and arranged to serve as an extension of chassis ground (e.g., by coupling the battery box 110 with the vehicle frame 130). Accordingly, the top plate 160 both holds the top of the battery box 110 in place as well as provides electrical protection.
In some embodiments, the battery box 110 and/or the top plate 160 are equipped with an interlock device 166. As will be described in greater detail below, in some embodiments, the interlock device 166 is constructed and arranged to disable certain electrical features when the interlock device 166 is removed (e.g., to then remove the metallic plate and access the battery box) to provide a safeguard to a user of the electric vehicle 100.
As best shown in
In some embodiments, the cargo bed 170 is coupled with the vehicle frame 130 above the battery box 110 and is constructed and arranged to pivot relative to the vehicle frame 130 to provide access to the battery box 110.
As best shown in
During an example installation operation, the battery box 110 is lowered onto or dropped in from above the vehicle frame 130 in an assembly/production line manner. In some embodiments, the top plate 160 is then installed over the battery box 110 to secure the battery box 110 to the upper portion 132 of the vehicle frame 130. Further, in some embodiments, the electric motor 120 and/or other electrical components are then simply plugged into ports on the exterior of the battery box 110. Further, other componentry may be installed (e.g., the cargo bed 170, the ducting 190, combinations thereof, etc.).
As shown, the electric powertrain 180 includes a centrally located differential (center differential 210) constructed and arranged to interface with the electric motor 120. In some embodiments, the electric motor 120 and center differential 210 connect to a front differential 212 and a rear differential 214 via respective driveshafts 220, 222 as shown in
As shown in
Such a configuration enables the electric motor 120 to be positioned more centrally in the vehicle as well as enables the battery box 110 to be positioned more to the rear (e.g., as shown in
It should be understood that the electric powertrain 180 is provided for example purposes, and variations may be made without departing from the spirit and scope of the present disclosure.
Certain portions of the battery box 110 (e.g., a lid, battery modules, other componentry, etc.) may have been omitted from these figures for simplicity and/or to better show other details of the battery box 110.
As best shown in
In some embodiments, the lid 320 is constructed and arranged to cover an inner space of the body 310. Further, in some embodiments, the top plate 160 (
It should be appreciated that, in some embodiments, the battery box 110 is constructed and arranged to provide high voltage (e.g., 60 volts or higher) for electric propulsion when the battery box 110 is sealed. Nevertheless, the battery box 110 is further constructed and arranged to safely isolate the circuitry to protect human operators.
In some embodiments, a control panel is provided on the side of the battery box 110 in a region of the vehicle that is easily accessible. Further, in some embodiments, one or more interlock devices is provided on the lid/plate/control panel to transfer the electrical components/battery from a high voltage configuration to a low voltage configuration if the lid is removed.
Additionally, the battery box 110 provides rich and robust water maintenance to keep the battery box components dry. Accordingly, in some embodiments, the battery box components themselves do not need to be modularized/protected/higher-durability-rated due to battery box protection. Thus, the individual components may be standard (or lower) rated. Additionally, such features enable a reduction in space requirements, cost, complexity (e.g., in manufacturing, maintenance, etc.), and so forth.
In some embodiments, the battery box 110 is constructed and arranged to position the battery modules at the forward end of the battery box 110 so that the battery modules are located close to the electric motor 120 and/or an engine compartment of the electric vehicle 100. In some embodiments, the battery modules are organized in one or more stacks that include four battery modules per stack. Positioning the stacks near the electric motor 120 and/or the engine compartment is advantageous for positioning more of the weight closer to vehicle center (e.g., between the axles 230, 232 (
In some embodiments, the compartments are separated so that heat and/or fluid transfer from one side to the other is restricted (although vents may be provided to control the transfer of heat if desired). Furthermore, in some embodiments, heat is recouped from various components such as a motor controller, a BMS, a DC/DC converter, etc. and used to regulate temperature within the battery box 110 as well as provided to external locations as needed. Accordingly, in some embodiments, the battery box 110 is provisioned with and/or serves as a battery module and/or a heat producing component module.
As best shown in
In some embodiments, the set of fasteners 316 is constructed and arranged to couple the lid 320 and the body 310 along with a clasp 318 (or similar continuity detection device). As will be discussed in further detail below, in some embodiments, the clasp 318 is constructed and arranged to facilitate lid removal detection, e.g., to protect a user from high voltage.
As shown best in
It should be understood that the battery cavities 330 and/or the component cavity 340 are provided for example purposes, and in some embodiments, more or fewer cavities are provided. Further, in some embodiments, the battery box 110 houses more or fewer battery modules, houses battery modules horizontally, combinations thereof, etc.
In some embodiments, the battery cavities 330 are positionable towards the center of the electric vehicle 100 so that the sets of battery modules 332 are located near a desired center of gravity. In some embodiments, the component cavity 340 is positionable rearward of the battery compartment.
As best shown in
In some embodiments, this insulating barrier is made of plastic (or rubber, etc.). For example, in some embodiments, the insulating barrier between the battery stacks is solid plastic. In some embodiments, the insulating barrier provided without metal reinforcement.
In some embodiments, at least part of the first inner wall 360 does not contact the lid 320 when the lid 320 is installed. In this manner, the first inner wall 360 permits heat venting between the battery cavities 330 during operation.
As best shown in
In some embodiments, the second inner wall 370 is high enough to completely separate the battery stacks from the other components so that the second inner wall 370 prevents airflow between the compartments when the lid 320 is positioned thereon (e.g., the second inner wall 370 completely separates the battery cavities 330 from the component cavity 340).
In some embodiments, the BMS 346 is constructed and arranged to mount on a reinforced bulkhead separating the component cavity 340 from the battery cavities 330, which puts it in a position adjacent the sets of battery modules 332 to shorten the wiring therebetween while still maintaining electrical and/or heat isolation.
In some embodiments, the DC/DC converter 348 and/or the motor controller 344 are constructed and arranged to mount on an outer wall of the component cavity 340, e.g., so that fluid heat exchangers may be utilized to cool these components and the fluid ports can be located at the periphery where it is easy to access and install. Similarly, in some embodiments, an electrical interface is positioned on an outer wall of the component cavity 340, e.g., to provide easy access during installation and maintenance.
As will be discussed in greater detail below, in some embodiments, at least a portion of the lid 320 projects upwardly to accommodate larger components (such as the BMS 346 (see, e.g.,
In some embodiments, the second inner wall 370 is extends further from a bottom (or floor) of the battery box 110 than the first inner wall 360 between the sets of battery modules 332, e.g., to allow air to cross (or circulate) between the sets of battery modules 332.
As best shown in
In some embodiments, the motor controller 344 is constructed and arranged to provide instructions to the electric motor 120 for vehicle propulsion.
In some embodiments, the BMS 346 is constructed and arranged to provide control between the battery modules and outside world, e.g., to allow proper voltage and current for vehicle operation.
In some embodiments, the DC/DC converter 348 is constructed and arranged to act similarly to an alternator on a gas engine that receives a high voltage input and provides a lower voltage output (e.g., 12v).
In some embodiments, the battery cavities 330 are oriented closest to the seating area 140 of the electric vehicle 100, and the component cavity 340 is farthest from the seating area 140. Such an orientation provides certain advantages such as placing the batteries nearest to the passengers for possible heat sharing, placing non-battery components away from the seats for easier access, and so on.
It should be appreciated that, in accordance with certain embodiments, placing the sets of battery modules 332 in the front of the battery box 110 adjacent the seating area 140 helps keep weight towards a middle (or center) of the electric vehicle 100. Further, in accordance with certain embodiments, placing the set of electrical components 342 in the rear of the battery box 110 away from the seating area 140 allows for easy accessibility when connecting/disconnecting outside components to the battery box 110.
Moreover, it should be appreciated that the above-described orientation is particularly well suited for the electric vehicle 100 in which the rear differential (i.e., the differential in the back that operates the rear wheels) takes up space underneath.
In some embodiments, the set of fasteners 316 are constructed and arranged to attach the lid 320 to the battery box body 310. In some embodiments, the set of fasteners 316 are further constructed and arranged to extend through the top plate 160 so that the lid 320 is sandwiched between the top plate 160 and the battery box body 310, as shown in
As best shown in
As best shown in
It should be understood that the raised portion 410 may be omitted in certain embodiments. Moreover, the battery box 110 may take other shapes and geometries.
In some embodiments, the lid 320 and/or the second inner wall 370 (e.g., at the region that interfaces with the lid 320) defines a gap to allow for passage of a busbar and/or other connections extending between compartments of the battery box 110 (e.g., between the component cavity 340 and the battery cavities 330).
In some embodiments, the interlock device 166 is a high voltage interlock (HVIL) constructed and arranged to protect against inadvertent access to high voltage. In some embodiments, the interlock device 166 is attached to a connecting object 510 (e.g., a bolt, a connector, etc.) on the top plate 160 and/or the lid 320 of the battery box 110. In some embodiments, interlock device 166 is constructed and arranged to act as a service disconnect (or inductor) that current flows through during operation.
In some embodiments, the interlock device 166 constructed and arranged to be wired in-between (or connect) two separate sets of battery modules 332. In some embodiments, the interlock device 166 is constructed and arranged to split the separate sets of battery modules 332 into two <60-volt segments when the interlock device 166 is removed and the battery box 110 is opened. In these embodiments, it may be viewed that the threshold for high voltage is 60 v, so by doing this, the sets of battery modules 332 are separated into two circuits less than 60 v when opened, thus making the battery box 110 safer. Other thresholds and/or voltage levels are suitable for use as well.
During example operation, the interlock device 166 prevents a user from opening the lid 320 without breaking an interlock circuit 520. Along these lines, if a user attempts to remove the plate and removes the interlock, a break in the interlock circuit 520 causes the battery box circuitry to shut down (e.g., the battery box 110 transitions to a safe state). Accordingly, in some embodiments, the user cannot take the lid 320 off and access the batteries in a high voltage configuration. In this manner, the interlock device 166 protects users (human operators) from accidentally working with high voltage.
Along these lines, the sensing circuitry 522 detects whether there is a break in the interlock circuit 520. If not, the componentry within the battery box 110 remains in a high voltage configuration (or state) in order to deliver electric power for propulsion. However, if the interlock circuit 520 is broken, the componentry within the battery box 110 transitions to a safe configuration, e.g., a lower voltage configuration or a disabled state, to prevent injury. Accordingly, if the interlock device 166 is removed or if there is otherwise a break in the interlock circuit 520, the interlock device 166 places the circuitry within the battery box 110 in a safe state.
Along these lines, as best shown in
In some arrangements, the heat management componentry 610 is constructed and arranged to heat the sets of battery modules 332 (in the battery cavities 330) using heat from other components (e.g., the set of electrical components 342 in the component cavity 340). Other heat management configurations are suitable as well.
In some embodiments, the electric vehicle 100 has control features (e.g., vents, valves, etc.) that provide an ability to open or close and thus direct the heat to different locations, such as the sets of battery modules 332, outside, inside a vehicle cab, combinations thereof, etc. Along these lines, in some embodiments, the vehicle is equipped with the ducting 190 (e.g., molded features) (
In an example heat exchange operation, water (or some other heat transfer fluid) flows into the battery box 110 for heat exchange and out. In some embodiments, electrical components (e.g., the motor controller 344 and the DC/DC converter 348) provide heat during operation, and such heat is removed and used elsewhere in the electric vehicle 100 where needed/desired. In some embodiments, heat captured from within the battery box 110 is used to heat occupants and/or other vehicle components.
It should be appreciated that, in conventional vehicles, electric components may be normally air cooled and left exposed (e.g., simply mounted to a vehicle chassis or body panel). However, in accordance with certain embodiments, these same components are used within the battery box 110. Additionally or alternatively, in some embodiments, the battery box 110 houses certain components over components with higher ingress protection (IP) ratings (or similar ratings for industrial enclosures). That is, such components do not need to be upgraded, etc. Rather, the components are used within the battery box 110 and water cooled thus enabling the components to run properly within an enclosed environment without overheating. Moreover, using a water heat exchanger enables the heat to warm the sets of battery modules 332 and/or other components in cold settings.
As best shown in
As best shown in
In some embodiments, the metallic skeleton 710 enables extension of the chassis ground to the battery box components. For example, in some embodiments, the set of fasteners 316 (
In some embodiments, mounting holes penetrate one or both of the insulating layers 720, 730 to engage threaded hardware of the metallic skeleton 710. Accordingly, when the battery box 110 is fastened to the vehicle frame 130, the metallic skeleton 710 connects to the chassis ground of the electric vehicle 100. In some embodiments, the body 310 is provisioned with a designated ground post for connection with the vehicle frame 130.
In some embodiments, the battery box body 310 uses reinforced plastic molded over perforated metal. In some embodiments, a polymeric coating provides heat/electrical isolation between the two compartments, and protects against the exterior environment (e.g., dust, water, etc.). In some embodiments, the utilization of plastic makes the body 310 watertight and temperature insulating and protects the sets of battery modules 312 from shorting out internally. That is, the body 310 provides water tightness and insulation from outside and inside. In some embodiments, the polymeric coating is nylon and/or ABS with fiber reinforcement. In some embodiments, carbon fiber, fiberglass, etc. is also used, e.g., to provide structural support to the body 310.
In some embodiments, features are molded into the battery box 110. For example, in some embodiments, at least a portion of the bottom (or floor) of the battery box 110 has a side facing the interior that mirrors one or more battery modules to facilitate battery module stacking. For example, in some embodiments, a bottom of the battery box 110 (e.g., a floor of the insulative inner layer 720) is provided with mounting features that are shaped like the top of a battery module so that the battery stacks are easily fixed in place.
In some embodiments, the battery box 110 is constructed and arranged to eliminate or minimize redundant brackets. That is, in some embodiments, the battery box 110 supports retrofitting with different brackets to replace or upgrade components such as the converter, etc. In such embodiments, the inner portion of the bottom and/or sides are less customized for simplicity, other uses, repurposing, and so on.
In some embodiments, the body 310 provides a bolt pattern to match that of the vehicle frame 130. This enables the bottom of the battery box 110 to richly and reliably mount to the subframe.
In an example manufacturing operation, the battery box 110 starts with the metallic skeleton 710 which is then covered (or encased) by the inner insulating layer 720 and the outer insulating layer 730.
In some embodiments, the battery box 110 itself is first formed by stamping/shaping the metallic skeleton 710. As shown in
In some embodiments, the first inner wall 360 and the second inner wall 370 (
Other processes may be used to form the battery box body 310. Along these lines, in accordance with other embodiments, the battery box body 310 is an injection molded structure with metal inserts. For example, in some embodiments, metal connectors are welded to the metallic skeleton 710, and then cast in plastic. Next, metal brackets are added to the inside of interior battery box space to hang components. Then, the supports and additional hardware are installed before installing the components.
In some embodiments, after the components are installed, the battery box 110 is provided as a subassembly to an assembly line. Along these lines, in some embodiments, the battery box 110 is dropped in from above the vehicle frame 130 so that it rests on the cradle structure 150 positioned at the bottom of the vehicle frame 130 (
It should be understood that variations may be made without departing from the spirit and scope of the present disclosure. For example, in some embodiments, the battery box 110 is loaded on the vehicle frame 130 from a side of the vehicle frame 130 or lifted from below the vehicle frame 130.
In some embodiments, the interface section 810 includes a set of electrical connection ports that provide access to the internally disposed circuitry in low voltage state (see, e.g.,
In some embodiments, the interface section 810 further includes a manual service disconnect (MSD) 820 that plugs into a connection panel of the interface section 810. In some embodiments, the MSD 820 enables a user to break the interlock circuit 510 (
In some embodiments, one or more connectors include an interlock to sense when connections (e.g., to cables) are present. In some embodiments, while the battery box 110 is fully assembled, the sets of battery modules 332 connect to provide a high voltage output. In some embodiments, the interface section 810 (e.g., connections adjacent to the manual service disconnect 820) provides CAN bus access (e.g., for control/status/etc.), charging access, 12V access, and 3-phase power to the electric motor 120.
It should be understood that the connector ports are provided for example purposes, and in some embodiments, more or fewer connector ports are provided.
While various embodiments of the present disclosure have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present disclosure as defined by the appended claims.
For example,
Certain portions of the electric vehicle 900 (e.g., exterior panels, doors, a hood, a cargo bed, etc.) may have been omitted from these figures for simplicity and/or to better show other details of the electric vehicle 900.
In some embodiments, the electric vehicle 900 includes a vehicle frame 930 constructed and arranged to be used for traditional internal combustion engine and hybrid electric vehicle models.
In some embodiments, the battery box 910 is constructed and arranged to house a set of batteries and a set of electric components (e.g., a BMS and a motor controller) in a way that protects these components while still accommodating the positioning of drivetrain components such as a driveshaft 906 that are common on each model, thereby reducing cost.
In some embodiments, the battery box 910 is provided at least partially under seats 940. In some embodiments, the battery box 910 is constructed and arranged to house the batteries 912 and other components 914 (e.g., the BMS and the motor controller). In some embodiments, the battery box 910 is constructed and arranged to protect the components from the environment and is shaped to also accommodate other vehicle components such as the driveshaft that extends between a front differential 982 and a rear differential 984. Accordingly, the batteries 912 are maintained as low as possible (e.g., to have a low center of gravity) without interfering with other components of the electric vehicle 900, such as a driveshaft that is used on the other vehicle types, thereby allowing for the use of some common drivetrain components/configurations.
In some embodiments, the batteries 912 and the other components 914 (e.g., the BMS, the motor controller, and wiring) are housed within the battery box 910. As shown in
As shown, in some embodiments, the electric motor 920, the batteries 912, and/or the other components 914 are positioned partially under the seats 940 at a forward end. Further as shown, these components are positioned partially under a conventional cargo bed portion 970 at a rearward end. In some embodiments, the cargo bed portion 970 includes a pivot point 972 constructed and arranged to pivot upward to provide access to the batteries 912, the BMS, and/or the motor controller through an upper/rear portion of the vehicle frame 930.
As another example,
Similar to the battery box 110 (
However, unlike the battery box 110, in some embodiments, the battery box 1010 positions the battery compartment closest to a seating area 1020 of the electric vehicle 1000, and the component compartment farthest from the seating area 1020. Such an orientation provides certain advantages such as placing the batteries nearest to the passengers for possible heat sharing, placing non-battery components away from the seats for easier access, and so on.
It should be appreciated that, in accordance with certain embodiments, placing the battery modules in the rear of the battery box 1010 adjacent the seating area helps keep weight towards the middle of the electric vehicle 1000. Further in accordance with certain embodiments, placing the other components in the front of the battery box 1010 away from the seating area allows for easy accessibility when connecting/disconnecting outside components to the battery box 1010.
Certain portions of the electric vehicle 1000 (e.g., exterior panels, doors, a hood, a cargo bed, etc.) may have been omitted from these figures for simplicity and/or to better show other details of the electric vehicle 1000.
Some embodiments are directed to an off-road vehicle which includes a frame and a differential coupled with the frame. The differential is constructed and arranged to operate a rear axle (or a rear differential that operates the rear axle). The off-road vehicle further includes a battery box being disposed over the frame between the differential and the rear axle area. The battery box includes a container, and a set of batteries disposed within the container. The set of batteries is constructed and arranged to provide electric power to an electric motor that provides drive to the differential.
In some arrangements, the frame defines a seating area to seat passengers in a side-by-side arrangement above the differential.
In accordance with certain embodiments, a housing for a S×S vehicle's battery compartment is positionable towards the center of the vehicle so that it locates near the desired center of gravity. In some embodiments, the housing includes a second compartment rearward of the battery compartment constructed and arranged to house other components such as a battery management system (BMS), an electric motor controller, and a DC/DC converter. In some embodiments, the BMS is arranged on a reinforced bulkhead separating the two compartments, which puts it in a position adjacent the battery stacks to shorten the wiring therebetween while still maintaining electrical/heat isolation. In some embodiments, the DC/DC converter and the motor controller are positioned on outer walls so that fluid heat exchangers may be utilized to cool these components, and the fluid ports can be located at the periphery where it is easy to access and install. Similarly, in some embodiments, an electrical interface is positioned on an outer wall of the second compartment to provide easy access during installation and maintenance.
In some embodiments, compartment 1 houses one or more stacks of battery cells positioned at the forward end of the box so that they are positioned closed to the electric motor and the engine compartment. In some embodiments, this configuration includes 4 battery modules per stack. Positioning the stacks near the motor and engine compartment is advantageous by positioning more of the weight closer to vehicle center (between axles).
In some embodiments, compartment 2 houses a BMS, a motor controller, a DC/DC converter, solenoids, and chargers. In some embodiments, these components have the ability to generate heat, so arranging them in a separate compartment rearward of the batteries allows for the heat to be managed.
In some embodiments, the BMS is mounted on the internal wall (bulkhead) positioned adjacent to the battery compartment to streamline the connections therebetween. In some embodiments, the internal wall and the exterior walls are reinforced with a metal skeleton that provides additional structural support to these components.
In some embodiments, the DC/DC converter and the motor controller are typically air cooled but are provided with a heat exchanger (with cooling fluid channels) positioned between the components and the wall to transfer heat from the second compartment.
Some embodiments are directed to an off-road vehicle which includes a frame that defines a seating area to seat passengers in a side-by-side arrangement and a rear axle area to support a rear axle. The off-road vehicle further includes a cargo carrying assembly coupled with the frame, the cargo carrying assembly being constructed and arranged to carry cargo. The off-road vehicle further includes a battery box being disposed over the frame between the seating area and the rear axle area, and underneath at least a portion of the cargo carrying assembly. The battery box includes a container, and a set of batteries disposed within the container. The set of batteries is constructed and arranged to provide electric power for the off-road vehicle.
In some arrangements, the off-road vehicle further includes a cradle assembly constructed and arranged to attach to the frame to form a battery box cradle that supports at least a portion of the battery box once the battery box is installed onto the off-road vehicle.
In some arrangements, the off-road vehicle further includes a metallic plate section constructed and arranged to attach to the frame over the battery box, the metallic plate section being constructed and arranged to constrain deflection of a top portion of the battery box during deflection events encountered by the off-road vehicle.
In some arrangements, the battery box further includes componentry that supports operation of the set of batteries. Additionally, the set of batteries are disposed within the container in a set of battery locations. Furthermore, the componentry is disposed within the container in a componentry location. Also, the set of battery locations is closer to the seating area than the componentry location.
Some embodiments are directed to a battery box which includes a container, a set of batteries disposed within the container, and an interlock that places the set of batteries in a high voltage configuration when the interlock couples with the container and a low voltage configuration when the interlock is removed from the container.
In some arrangements, the container includes a first section and a second section. Additionally, the interlock prevents the first section and the second section from being separated from each while the interlock couples with the container, and allows the first section and the second section to be separated from each while the interlock is removed from the container.
Other embodiments are directed to an off-road electric vehicle which includes a frame that defines a seating area to seat passengers in a side-by-side arrangement. The off-road electric vehicle further includes an electric propulsion system supported by the frame, the electric propulsion system being constructed and arranged to provide vehicle propulsion using electric power. The off-road electric vehicle further includes a battery box supported by the frame. The battery box includes:
Some embodiments are directed to a battery box container which includes a bottom, a set of exterior walls extending from the bottom, and a lid constructed and arranged to engage with the set of exterior walls to enclose an inner space within which heat from componentry residing within the inner space is contained.
In some arrangements, the set of exterior walls defines an inlet port that provides fluid access into the inner space, and an outlet port that provides fluid access from the inner space.
In some arrangements, the battery box container further includes a motor controller mounting plate disposed within the inner space. The motor controller mounting plate is constructed and arranged to support a motor controller and thermally couple with the motor controller to manage heat generated by the motor controller.
In some arrangements, the battery box container further includes a DC/DC converter plate disposed within the inner space, the DC/DC converter mounting plate being constructed and arranged to support a DC/DC converter and thermally couple with the DC/DC converter to manage heat generated by the DC/DC converter.
In some arrangements, the battery box container further includes a set of conduits interconnecting the motor controller mounting plate and the DC/DC converter plate with the inlet port and the outlet port.
In accordance with certain embodiments, a S×S vehicle is provisioned with a first compartment for batteries and a second compartment for components such as a BMS, an electric motor controller, and a DC/DC converter. In some embodiments, these items (e.g., the BMS, the DC/DC converter, and/or the motor controller) produce heat that can be applied to the batteries or other parts of the vehicle depending on operating conditions. Typically, the DC/DC converter and the electric motor controller are air cooled components. However, certain embodiments include placing them in a protective and sealed housing and utilizing a different heat transfer system. Along these lines, in certain embodiments, a heat exchanger (e.g., a fluid system) is used to cool the DC/DC converter and the electric motor controller. In some embodiments, the heat transferred from these items is selectively used to heat the battery stacks and/or the passenger compartment as needed. In some embodiments, if no heat is needed, the heat is transferred to the environment. In some embodiments, the heat exchanger (with cooling fluid channels) is positioned between components and the wall to provide an ability to transfer heat from the second compartment.
In some embodiments, a physical barrier between the first compartment containing batteries and the second compartment helps prevent transfer of heat when heat is not desired. In some embodiments, a box bellow allows for controlled expansion and contraction of the gas housed within the box due to heat or other by allowing the bellow to expand or collapse based on the boxes needs (when heat is not desired). In some embodiments, the larger heat producing items in compartment 2 (with BMS/DC/DC converter/electric motor controller) are water cooled and the coolant passes through the box through plumbing (bulkhead fittings) to a heat exchanger. In some embodiments, that heat exchanger is designed to have the heat directed: 1) to the atmosphere 2) to the battery compartment (provide heat in cold weather) 3) occupant compartment or 4) some combination of those options. In some embodiments, the heat is transferred via fluid lines to a heat exchanger positioned in the battery compartment, or via air heated by a heat exchanger and routed to the battery compartment and/or the passenger compartment. It should be appreciated that positioning the batteries adjacent the passenger compartment simplifies the ducting for heating the passenger compartment.
Some embodiments are directed to a battery box container which includes a metallic skeleton, and an insulative inner layer coupled with the metallic skeleton. The insulative inner layer faces an inner space defined by the metallic skeleton. The battery box container further includes an insulative outer layer coupled with the metallic skeleton, the insulative outer layer facing outwardly from the metallic skeleton.
In some arrangements, the battery box container further includes a set of inner walls disposed with the inner space and coupling with the insulative inner layer. The set of inner walls separate the inner space into multiple cavities.
In some arrangements, the metallic skeleton and insulative layers form a bottom and a set of exterior vertical walls that extend from the bottom. Additionally, the set of inner walls extend vertically from the bottom to divide the inner space into the multiple cavities.
In some arrangements, the battery box container further includes a lid constructed and arranged to engage with the set of exterior walls. The lid, the bottom and the set of exterior walls enclose the inner space when the lid engages with the set of exterior walls.
In some arrangements, the set of inner walls separates the inner space into (i) a set of battery cavities for holding respective sets of batteries and (ii) a component cavity for holding components that support operation of the set of batteries.
In some arrangements, the set of inner walls inhibit air flow between each of battery cavity and the component cavity. Additionally, the set of inner walls allows air flow between the sets of battery cavities.
In some arrangements, the battery box container further includes a diaphragm constructed and arranged to accommodate pressure changes among the multiple cavities.
In some embodiments, the battery box container includes a burst plate (or blow-off valve), e.g., to allow sudden large changes of pressures to escape as opposed to destroying the box. In some embodiments, the burst plate includes springs constructed and arranged to keep the battery box sealed when a pressure within the battery box is below a certain threshold. In some embodiments, the springs are constructed and arranged to allow the burst plate to move away from the box in a controlled manner, e.g., to allow for a rapid and sudden increase in pressure.
It should be appreciated that on a conventional side-by-side (S×S) vehicle, individual components are commonly spread across a chassis of the vehicle. For such a vehicle, each component is rated for harsh environments.
Along these lines, S×S vehicles are used in harsh conditions where moisture can be a concern. An electric powertrain can become very complicated and expensive if each individual item must be rated for such conditions. Mounting of the individual components across the chassis and connecting them in a way that maintains the ratings can also be difficult. Certain embodiments disclosed herein alleviate those concerns by providing a protective housing that allows lower rated components to be operated in harsh environments.
In accordance with certain embodiments, a metal reinforced polymer box houses battery stacks and other components such as the battery management system, electric motor controller, and the DC/DC converter. The electric motor is positioned underneath the passenger seat and the box is positioned rearward of the motor/passenger compartment slightly forward of the rear differential/axle. The box is also positioned underneath the cargo bed, which allows for easy installation of the box/components.
In some embodiments, an electric side-by-side vehicle is built on a frame that may also be used for traditional internal combustion engine and hybrid electric vehicle models. In some embodiments, the battery box houses the batteries, battery management system, and motor controller in a way that protects these components while still accommodating positioning of the drivetrain components, such as the driveshaft, that are common on each model, thereby reducing cost.
In some embodiments, the box extends across the width of the vehicle underneath the seat at the forward end and under the cargo bed at the rearward end. In some embodiments, the batteries are housed on outboard sides of the box, and the portion of the box in the middle of the vehicle that is positioned between the batteries is raised to form a tunnel or hat section therebetween. In some embodiments, this raised portion is where the BMS and the motor controller are located. In some embodiments, the driveshaft extends through the tunnel and underneath the BMS and motor controller. Therefore, the same driveshaft is able to be used in a configuration that is common across the different models.
In accordance with certain embodiments, the battery box housing protects the batteries, BMS, and motor controller in a way that can accommodate conventional drivetrain components.
A contemporary configuration of a four-wheel drive vehicle consists of an internal combustion engine attached to a transaxle, that is located at the rear of the vehicle, through a continuously variable transmission (CVT) which powers the rear wheels directly through a set of gears, while also driving the front wheels via a driveshaft that exits the transaxle towards the front of the side-by-side vehicle and into a differential that splits the power out to the wheels. In some cases, this layout can be flipped with the engine in the front of the vehicle (e.g., with everything reversed). In either scenario, it is possible to switch the vehicle into two-wheel drive by decoupling the differential.
Another contemporary configuration of a four-wheel drive vehicle consists of two transaxles, one per set of wheels (front and rear), with their own respective motors attached and the ability to power each set of wheels either collectively or independently.
In contrast with contemporary configurations of a four-wheel drive vehicle, certain embodiments disclosed herein are directed to an improved powertrain layout centrally locates a powerplant (e.g., a gas engine, electric motor, or hybrid mixture of both) that is used to drive either a transaxle or differential. Exiting from this centrally located transaxle/differential is a configuration of drive shafts fore and aft of the vehicle so that power can be transmitted into a rear and/or front differential, thus splitting up the power and sending it out to their respective wheel sets.
There are a number of benefits from this unique configuration. In some embodiments, in this configuration, there is an ability to either engage both front and rear or any number of wheel sets simultaneously. For example, some embodiments engage both front and rear wheel sets for four-wheel drive (e.g., where only four wheels exist). Additionally, some embodiments engage only the rear and/or front wheel seats via differentials that are selectively engaged or disengaged (e.g., electrically or mechanically) for rear-wheel drive or front-wheel drive. The advantages of these options allow for additional maneuverability.
For example, certain embodiments have an ability to apply rear braking while dragging the vehicle with the front wheel sets only. This currently does not exist in a contemporary gas configuration. Rather, the contemporary gas configuration only decouples and recouples an axle opposite of another axle having the engine attached.
Further, some embodiments have an ability to disconnect the centrally located differential/transaxle and/or the front and rear differentials simultaneously, e.g., to allow for an idle scenario for an electrically powered vehicle. Advantageously, this affords the option of running a power take-off (PTO) for driving hydraulic pumps, for example.
Some embodiments allow for the mass production of a two-wheel drive vehicle while also allowing for an option of allowing for a four-wheel drive option. Regardless of the application, this four-wheel drive configuration eliminates the loss of half of available horsepower during an axle-slipping event in an electric powertrain application. Along these lines, in contemporary four-wheel drive motor powered golf car, a respective motor and a respective transaxle are located at each set of wheels. For example, a contemporary 5-horsepower motor in the front and another contemporary 5-horsepower in the rear would have 10 total horsepower available at the ground. The moment slipping occurs at any one of the respective transaxles, the contemporary golf car loses that axle's ability to transmit power to the ground. This would lower available power to 5-horsepower. In contrast with the contemporary golf car, certain embodiments are directed to a centrally located configuration. This configuration enables all horsepower to still be available to a remaining axle if one of the axles began slipping.
Some embodiments are provisioned with the following:
The individual features of the various embodiments, examples, and implementations disclosed within this document can be combined in any desired manner that makes technological sense. Furthermore, the individual features are hereby combined in this manner to form all possible combinations, permutations and variants except to the extent that such combinations, permutations and/or variants have been explicitly excluded or are impractical. Support for such combinations, permutations and variants is considered to exist within this document. Such modifications and enhancements are intended to belong to various embodiments of the disclosure.
This application claims priority to and the benefit of earlier-filed U.S. Application No. 63/452,784, filed on Mar. 17, 2023, and entitled “Battery Box for Off-Road Vehicles”, the contents and teachings of which are hereby incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63452784 | Mar 2023 | US |
