FIELD OF THE INVENTION

The present invention relates generally to battery enclosures for use in electric vehicles. More specifically, it relates to the structures and components that generally make up the enclosure such that the battery for the vehicle is protected from structural damage and prevented from overheating during vehicle operation.

BACKGROUND OF THE INVENTION

Automobile vehicles in general are comprised of many different structural and functional components. In some instances, they may generally be described in relation to a body or cabin, which are designed to enclose the passengers, and the various electrical, mechanical and structural systems, subsystems and components that allow the vehicle to operate. In traditional automobile design, the body and various functional systems and components are inextricably intertwined. For example, mechanical linkages directly interconnect the steering and brake systems between the wheels and the passenger, and elements such as the motor, transmission system, and cooling systems are disposed in a front enclosure that extends upward into the body of the vehicle. Additional structural components may serve to house certain functional elements essential for vehicle operation.

Recent advances in electric motor and battery technologies have made electric vehicles practical to manufacture. Electric vehicles have a number of advantages over conventional internal combustion vehicles, including the dramatically reduced footprint of the drive train components. Further advancements in signal processing and drive-by-wire technologies means that it is now possible to produce vehicle platforms containing all the necessary functional components of a vehicle. Furthermore, with the advancement of electric vehicles, batter enclosures serve a key element in the overall structure and function of the vehicle. However, despite the potential these advancements represent most electric vehicles being produced today continue to incorporate designs that have been traditionally used in internal combustion engines. This can be particularly true for the framework and layout of many of the features including the drive motors. Electric vehicle batteries pose unique problems for the advancement in vehicles which necessarily require unique solutions.

SUMMARY OF THE INVENTION

Many embodiments are directed to a battery enclosure for use in an electric vehicle. Many embodiments include a battery enclosure that has multiple structural elements forming a basic framework of the enclosure including:A pair of longitudinal side rails each with an elongated body with a forward end and a rear end and with external and internal sides;A forward and a rear support element each with an elongated body with opposing ends and disposed laterally between each of the side rails and connected to each of the two side rails where each of the opposing ends connects to a respective internal side of the side rails, and wherein the forward support element is disposed at the forward end and the rear support element is disposed at the rear end thereby creating a space therebetween; andA plurality of lateral support structures having elongated bodies with opposing ends and disposed between the side rails in a longitudinal direction such that the space is divided by the lateral support structures and wherein each of the side rails, forward and rear support elements, and lateral structures serve to provide strength to the battery enclosure as well as act as support features for a plurality of internal battery components disposed within the divided spaceA plurality of individual battery modules disposed within the space between the support elements and structures wherein each of the plurality of battery modules are individually connected to one or more support elements.

Other embodiments include one or more longitudinal support members each having an elongated body with a first end and a second end, wherein the first end is connected to a center portion of one of the forward support element or the rear support element and wherein the second end is connected to a center portion of a lateral support structure.

Still other embodiments include a top plate and a bottom plate wherein the top plate is secured to a top portion of each of the side rails, the forward and rear support elements, and each of the plurality of lateral support structures, and wherein the bottom plate is secured to a bottom portion of each of the side rails, the forward and rear support elements, and each of the plurality of lateral support structures.

In yet other embodiments, the battery enclosure has a plurality of temperature control elements, wherein each of the plurality of temperature control elements is disposed between at least two of the plurality of battery modules such that the plurality of temperature control elements receive heat energy from the battery modules.

In still yet other embodiments, the temperature control elements are cooling elements.

In other embodiments, the plurality of temperature control elements are connected to a vehicle temperature control system such that the heat energy received is transferred to the vehicle temperature control system.

In still other embodiments, the plurality of battery modules are disposed parallel to and perpendicular to a longitudinal axis of framework comprised of at least the longitudinal side rails and the front and rear support elements.

In yet other embodiments, the battery enclosure has a plurality of auxiliary components that complement the function of the plurality of battery modules and are interconnected therewith such that the plurality of auxiliary components can transfer energy from the plurality of battery modules to other components in a vehicle structure.

In still yet other embodiments, the auxiliary components are connected to the plurality of battery modules via wire buses.

In other embodiments, wherein the plurality of auxiliary components are selected from a group consisting of power management devices, cooling elements, and battery disconnects.

In still other embodiments, each of the plurality of lateral support structures have at least one opening disposed within the elongated body such that the opening extends between two external sides of the elongated body such that the wire busses pass can through the at least one opening to connect the plurality of battery modules and auxiliary components.

In yet other embodiments, the bottom plate comprises a sacrificial impact layer such that an impact to the bottom plate does not damage the bottom plate beyond the sacrificial impact layer.

In still yet other embodiments, the bottom plate comprises a plurality of support ridges such that each of the ridges extend inward towards the space and are configured to engage with and support each of the plurality of individual battery modules.

In other embodiments, the top plate has a plurality of connection points disposed on an outer surface.

In still other embodiments, the battery enclosure has a plurality of battery support elements connected to at least one of the longitudinal side rails and/or at least one of the plurality of lateral support structures and wherein each of the plurality of battery support elements has a flange extending inward towards the space and cooperatively engages with at least one of the plurality of battery modules.

In yet other embodiments, each of the battery modules can be individually removed and/or replaced as needed.

Other embodiments include an electric vehicle platform with a battery enclosure in accordance with the embodiments described herein.

Additional embodiments and features are set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the disclosure. A further understanding of the nature and advantages of the present disclosure may be realized by reference to the remaining portions of the specification and the drawings, which forms a part of this disclosure.

