Polyurethane/polyurea elastomer coated steel battery box for hybrid electric vehicle applications

• US 6,189,635 B1
• Filed: 03/09/1998
• Issued: 02/20/2001
• Est. Priority Date: 03/09/1998
• Status: Expired due to Term

• Current Assignee: International Truck Intellectual Property Co. LLC (Volkswagen AG)
• Original Assignee: Navistar International Transportation Corp. (Volkswagen AG)
• Inventors: Donley, Harl, Lasecki, Michael P., Jenks, Jeffrey D., Schuler, Nathan L.
• Primary Examiner(s): Johnson, Brian L.
• Assistant Examiner(s): DRAPER, DEANN L
• Application Number:
  US09/041,362
• Time in Patent Office: 1,079 Days
• Field of Search: 180/68.5, 180/65.2, 180/65.1, 429/164, 429/61
• US Class Current: 180/68.5
• CPC Class Codes: B60R 16/04 Arrangement of batteries

Abstract

A battery box with a lid and a tray assembly for batteries for a hybrid electric vehicle. The lid and tray assembly are made of steel with an internal and external spray coating of an elastomer with high electrical resistance properties. Batteries are mounted in the tray assembly and enclosed by the lid. The elastomer coating on the tray assembly and the lid provides a non-electrically conductive interior and exterior surface for increased service safety. The steel base material of the tray assembly and the lid provides shielding from electromagnetic interference and radio frequency interference associated with the high voltages required to operate electric motors in hybrid electric vehicles. Additionally, the tray assembly has vents designed to optimize cooling of the batteries.

Claims

1. A battery box for a mobile vehicle with batteries of a fixed height, and a chassis with frame rails, comprising:

(a) a tray assembly for holding the batteries;

(b) a lid for installation onto said tray assembly to enclose the batteries and both said tray and said lid are made of steel;

(c) a means for attachment to a frame rail of the chassis; and

(d) both said tray assembly and said lid being coated with an elastomer with high electrical resistance.

2. The battery box of claim 1, wherein:

(a) said elastomer coating is a combination Polyurethane and Polyurea elastomer.

3. The battery box of claim 2, wherein:

(a) said elastomer coating is from one sixteenth to one eighth of an inch thick.

4. The battery box of claim 3, wherein said tray assembly is comprised of:

(a) a horizontal bottom shelf;

(b) a vertical back side engaged to said bottom shelf;

(c) a vertical forward face and a vertical rear face, each engaged to said bottom shelf and said back side;

(d) a forward vent in said forward face and a rear vent in said rear face; and

(e) said forward vent and said rear vent positioned at a height below the fixed height of a battery on said bottom shelf.

5. The battery box of claim 4, wherein:

(a) said bottom shelf of said tray assembly has drain holes.

6. The battery box of claim 5, wherein:

(a) said forward vent and said rear vent each have vent covers; and

(b) each said vent cover is comprised of two flaps, one flap directed downward and inward to the batteries within said tray assembly and a second flap directed downward and outward from the tray assembly.

7. The battery box of claim 6, additionally comprising:

(a) hold down braces and hold down bolts to prevent the batteries from moving within said tray assembly; and

(b) battery spacers for insertion between the batteries and between said hold down braces and the batteries to provide air flow channels between sets of the batteries.

8. The battery box of claim 7, wherein said air flow channels are at least 0.25 inches wide.

9. The battery box of claim 8, wherein said frame rail attachment means is comprised of:

(a) attachment plates engaged to a bottom surface of said bottom shelf of said tray assembly; and

(b) said attachment plates are engageable to hangers on the frame rail of the vehicle.

10. A mobile hybrid electric vehicle, comprising:

(a) a chassis with two frame rails;

(b) hangers engaged to one of said frame rails;

(c) an electric motor en d to said chassis;

(d) batteries of a fixed height for providing electric power to said motor; and

(e) a battery box, comprising;

(i) a tray assembly for holding said batteries;

(ii) a lid for installation onto said tray assembly to enclose said batteries and

(iii) both said tray assembly and said lid being coated with an elastomer with high electrical resistance;

(iv) said tray assembly having a horizontal bottom shelf with a bottom surface;

(iv) attachment plates engaged to said bottom surface; and

(v) said attachment plates engaged to said hangers on said frame rail.

11. The hybrid electric vehicle of claim 10, wherein:

(a) said elastomer coating is a combination Polyurethane and Polyurea elastomer.

12. The hybrid electric vehicle of claim 11, wherein:

(a) said elastomer coating is from one sixteenth to one eighth of an inch thick.

13. The hybrid electric vehicle of claim 12, with said tray assembly additionally comprising:

(a) a vertical back side engaged to said bottom shelf;

(b) a vertical forward face and a vertical rear face, each engaged to said bottom shelf and said back side;

(c) a forward vent in said forward face and a rear vent in said rear face; and

(d) said forward vent and said rear vent positioned at a height below said fixed height of one of said batteries on said bottom shelf.

14. The hybrid electric vehicle of claim 13, wherein:

(a) said bottom shelf has drain holes.

15. The hybrid electric vehicle of claim 14, wherein:

(a) said forward vent and said rear vent each have vent covers; and

(b) each said vent cover is comprised of two flaps, one flap directed downward and inward to the batteries within said tray assembly and a second flap directed downward and outward from the tray assembly.

16. The hybrid electric vehicle of claim 15, wherein:

(a) hold down braces and hold down bolts to prevent said batteries from moving within said tray assembly; and

(b) battery spacers for insertion between said batteries and between said hold down braces and said batteries to provide air flow channels between sets of the batteries.

17. The hybrid electric vehicle of claim 16, wherein said air flow channels between said sets of said batteries are at least 0.25 inches wide.