STRUCTURAL ENCLOSURE FOR PACKAGING POWER ELECTRONICS FOR VEHICLE BATTERY MODULES AND METHODS OF SERVICING AND MANUFACTURING VEHICLES USING SAME

• US 20120312612A1
• Filed: 06/13/2011
• Published: 12/13/2012
• Est. Priority Date: 06/13/2011
• Status: Active Grant

• Current Assignee: EMatrix Energy Systems Inc.
• Original Assignee: ALTE
• Inventors: Harrison, Albert W. III, Mleczko, Dave, Sabin, Scott
• Granted Patent: US 9,108,497 B2
• Time in Patent Office: Days
• US Class Current: 180/68.5
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/0438 Arrangement under the floor
• CPC Class Codes: B60K 2001/0472 from below
• CPC Class Codes: B60Y 2400/61 Arrangements of controllers for electric machines, e.g. inverters
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/264 for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/49815 Disassembling

Abstract

An apparatus for a vehicle is provided that includes a structural enclosure configured to attach to both first and second spaced battery module housings while spanning the gap between the spaced battery module housings. The structural enclosure is configured to support power electronics and is configured to allow connection of the power electronics to the battery modules through the structural enclosure. A method of servicing vehicles and a method of manufacturing vehicles is also provided.

Claims

1. An apparatus for a vehicle having a first battery module in a first battery module housing and a second battery module in a second battery module housing;

wherein the battery module housings are spaced from one another to define a gap therebetween;

wherein control of and power to the battery modules is through power electronics, the apparatus comprising;

a structural enclosure configured to attach to both the first battery module housing and the second battery module housing while spanning the gap between the battery module housings when so attached; and

wherein the structural enclosure is configured to support the power electronics and is configured to allow connection of the power electronics to the battery modules through the structural enclosure.

2. The apparatus of claim 1, wherein the power electronics include at least one electrical connector, at least one power shutoff, and internal power electronics;

and further comprising;

mechanical attachments supported by the structural enclosure at an internal surface of the structural enclosure;

wherein the mechanical attachments are configured to attach to the internal power electronics such that the internal power electronics are enclosed within a cavity defined by the enclosure when attached to the mechanical attachments;

wherein the structural enclosure has at least one external surface at which the structural enclosure supports said at least one power shutoff and said at least one electrical connector external of the cavity; and

wherein the structural enclosure has openings positioned to permit said at least one power shutoff and said at least one electrical connector to operatively connect to said internal power electronics through said structural enclosure when said at least one power shutoff and said at least one electrical connector are supported at said at least one external surface.

3. The apparatus of claim 1, further comprising:

mechanical attachments supported by the structural enclosure at at least one internal surface of the structural enclosure;

wherein the mechanical attachments are configured to attach to the internal power electronics such that the internal power electronics are enclosed within a cavity defined by the enclosure;

wherein the structural enclosure has first and second spaced openings configured to be aligned with the first and the second battery module housings, respectively, when the structural enclosure is attached to both the first battery module housing and the second battery module housing to thereby permit wiring to extend from the internal power electronics to the first and the second battery modules through the first and second laterally-spaced openings.

4. The apparatus of claim 3, wherein the structural enclosure includes walls and a lid;

wherein the lid is moveable from an open position to a closed position to enclose the cavity;

wherein the first and second spaced openings are notches at a perimeter of at least one of the walls; and

wherein the notches are covered when the lid is in the closed position.

5. The apparatus of claim 1, wherein the structural enclosure includes multiple sides partially defining a cavity configured to contain at least some of the power electronics;

wherein at least one of the sides defines an opening; and

wherein the enclosure further includes a lid operatively connected to said at least one of the sides at the opening and movable from an open position permitting access into the cavity and a closed position further defining the cavity and thereby enclosing said at least some of the power electronics within the cavity when at least some of the power electronics are supported by the enclosure.

6. The apparatus of claim 5, further comprising:

a sealing mechanism at an interface between the lid and said at least one of the sides to seal the cavity when the lid is in the closed position.

7. The apparatus of claim 1, wherein the structural enclosure has fastener openings, and further comprising:

multiple fasteners configured to extend through the fastener openings for attaching the structural enclosure to both the first battery module housing and the second battery module housing.

8. The apparatus of claim 1, wherein the vehicle has battery module support structure that supports the battery modules;

and

wherein the structural enclosure is configured to attach to the battery module support structure when the structural enclosure is attached to the battery module housings.

9. The apparatus of claim 1, wherein the vehicle has a longitudinally-extending component;

and wherein the structural enclosure forms a notch so that the structural enclosure is packaged partially around the longitudinally-extending component at the notch when the structural enclosure is attached to the battery module housings.

10. A battery assembly for a vehicle comprising:

a first battery module;

a first battery module housing substantially enclosing the first battery module;

a second battery module;

a second battery module housing substantially enclosing the second battery module;

wherein the battery module housings are spaced from one another to define a gap therebetween;

a structural enclosure attached to both the first battery module housing and the second battery module housing and spanning the gap between the battery module housings;

power electronics configured to control and power the battery modules;

wherein the enclosure defines an internal cavity and supports at least some of the power electronics within the internal cavity; and

wherein the enclosure has openings positioned so that said at least some of the power electronics are operatively connected to the battery modules through the openings of the structural enclosure.

11. The battery assembly of claim 10, further comprising:

battery module support structure that supports the battery modules; and

wherein the structural enclosure is configured to attach to the battery module support structure.

12. The battery assembly of claim 11, wherein the battery assembly is for a rear-wheel drive vehicle that has a driveshaft extending longitudinally;

wherein the structural enclosure has a notch so that the structural enclosure is configured to be packaged partially around the driveshaft at the notch;

wherein the structural enclosure has a rearward-facing panel at which the structural enclosure is attached to the battery module housings; and

wherein the structural enclosure has a bottom-facing panel at which the structural enclosure is attached to the battery module support structure.

13. The battery assembly of claim 11, wherein the battery assembly is for a vehicle that has a longitudinally-extending component;

and wherein the structural enclosure forms a notch so that the structural enclosure is configured to be packagable partially around the longitudinally-extending component at the notch.

14. The battery assembly of claim 11, wherein the structural enclosure with at least some of the power electronics therein is configured to be attachable and removable from the first and the second battery module housings as an integral unit.

15. The battery assembly of claim 11, wherein the power electronics include internal power electronics, at least one electrical connector for providing power to the first and the second battery modules, and at least one power shutoff for preventing power flow to the first and the second battery modules;

and further comprising;

mechanical attachments supported at at least one internal surface of the structural enclosure and configured to attach to the internal power electronics such that the internal power electronics are enclosed within the internal cavity;

wherein the structural enclosure has at least one external surface at which said at least one power shutoff and said at least one electrical connector external are supported at least partially external of the internal cavity; and

wherein the structural enclosure has openings positioned to permit said at least one power shutoff and said at least one electrical connector to operatively connect to said internal power electronics through said structural enclosure.

16. A method of servicing a vehicle comprising:

removing a battery assembly from the vehicle;

wherein the battery assembly includes a first and a second battery module, a first battery module housing substantially enclosing the first battery module, a second battery module housing substantially enclosing the second battery module and spaced from the first battery module housing to define a gap therebetween, and a structural enclosure attached to both the first battery module housing and the second battery module housing while spanning the gap between the battery module housings;

opening a lid of the structural enclosure;

disconnecting wiring connecting power electronics in the structural enclosure to the first battery module and additional wiring connecting the power electronics in the structural enclosure to the second battery module; and

detaching the structural enclosure from the battery modules.

17. A method of manufacturing vehicles comprising:

mounting a first structural enclosure of an inventory of substantially identical structural enclosures to spaced battery module housings on a first vehicle to span between the battery module housings of the first vehicle;

operatively connecting power electronics mounted to said first structural enclosure to battery modules within the battery module housings of the first vehicle;

mounting a second structural enclosure of the inventory of substantially identical structural enclosures to spaced battery module housings on a second vehicle to span between the battery module housings of the second vehicle; and

operatively connecting power electronics mounted to said second structural enclosure to battery modules within the battery module housings of the second vehicle;

wherein the battery modules of the first vehicle are a different size than the battery modules of the second vehicle.

18. The method of claim 17, wherein the power electronics mounted to said first structural enclosure are substantially identical to the power electronics mounted to said second structural enclosure.

19. The method of claim 17, further comprising:

providing the inventory of substantially identical structural enclosures.