A mounting system for a plurality of battery modules needed to form a battery pack includes a battery tray with a combination of fixed and detachable retainers that enable insertion/removal of individual battery modules from the battery pack, both during assembly of the battery pack and later in con
A mounting system for a plurality of battery modules needed to form a battery pack includes a battery tray with a combination of fixed and detachable retainers that enable insertion/removal of individual battery modules from the battery pack, both during assembly of the battery pack and later in conjunction with service during its operation. The battery tray may be disposed on a base plate for added support, as well as integration of more than one battery tray and associated modules into a battery pack. A cover may be added to for additional support and protection of the battery modules. Where multiple battery trays are integrated on a base plate, the battery trays may be oriented on the base plate in different directions. The battery mounting system may be used in a motor vehicle or other applications that use a battery pack.
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1. A battery mounting system, comprising: a battery tray having a base, a retainer side and an attachment side opposed across a width thereof, the battery tray having a length operative to receive a plurality of battery modules, the retainer side having a retainer extending at least partially along
1. A battery mounting system, comprising: a battery tray having a base, a retainer side and an attachment side opposed across a width thereof, the battery tray having a length operative to receive a plurality of battery modules, the retainer side having a retainer extending at least partially along a length of the tray, the attachment side having an attachment structure extending at least partially along the length of the tray, the retainer operative to engage a first retention surface associated with each of the plurality of battery modules;the attachment structure comprising a plurality of spaced bores that are located in a raised portion of the attachment structure, the raised portion comprising a plurality of raised pockets and the bores are associated with the pockets. 2. The battery mounting system of claim 1, wherein the retainer comprises an inwardly and upwardly extending tapered wall having a taper angle. 3. The battery mounting system of claim 2, wherein the retainer also comprises a plurality of spaced gussets joining the tapered wall and the base along the length of the battery tray. 4. The battery mounting system of claim 1, wherein the battery tray has a rib extending lengthwise along the base. 5. The battery mounting system of claim 1, wherein the base has a plurality of spaced cut-outs located along the length. 6. The battery mounting system of claim 1, wherein each of the pockets has an upper surface that tapers outwardly and downwardly toward the attachment side. 7. The battery mounting system of claim 1 further comprising a base plate having an upper surface and a lower surface, wherein a lower surface of the battery tray is disposed on the upper surface of the base plate. 8. The battery mounting system of claim 7, further comprising a plurality of lateral ribs disposed on the lower surface of the base plate. 9. The battery mounting system of claim 1, further comprising a cover operative to be disposed on the upper surface of the base plate and enclose the plurality of battery modules. 10. The battery mounting system of claim 1, further comprising a resilient sheet attached to an upper surface of the battery tray. 11. The battery mounting system of claim 1, further comprising a plurality of resilient sheets disposed on an upper surface of the battery tray, wherein a first resilient sheet is disposed proximate the retainer at least partially along a length of the first resilient sheet and a second sheet is disposed proximate the attachment structure at least partially along a length of the second sheet. 12. The battery mounting system of claim 11, wherein the retainer comprises an inwardly and upwardly extending tapered wall, and the first resilient sheet is disposed on the tapered wall. 13. The battery mounting system of claim 1, further comprising a plurality of retainer plates each having a retainer end and an attachment end, the retainer end having a clamp retainer and the attachment end having an clamp attachment structure, the clamp attachment structure operative for detachable attachment to the attachment structure of the battery tray through a connector. 14. The battery mounting system of claim 13, wherein the clamp retainer comprises an inwardly and upwardly extending tapered wall having a taper angle. 15. The battery mounting system of claim 2, further comprising a plurality of retainer plates each having a retainer end and an attachment end, each retainer end having a clamp retainer and each clamp attachment end having a clamp attachment structure, each clamp attachment structure operative for detachable attachment to the attachment structure of the battery tray through a connector. 16. The battery mounting system of claim 15, wherein the clamp retainer comprises an inwardly and upwardly extending clamp tapered wall having an installed taper angle. 17. The battery mounting system of claim 16, wherein the taper angle and the installed taper angle are the same. 18. The battery mounting system of claim 15, further comprising a resilient sheet disposed on the clamp tapered wall. 19. A battery mounting system, comprising: a battery tray having a base, a retainer side and an attachment side opposed across a width thereof, the battery tray having a length operative to receive a plurality of battery modules, the retainer side having a retainer extending at least partially along the length of the tray, the attachment side having an attachment structure extending at least partially along the length of the tray, the retainer operative to engage a first retention surface associated with each of the plurality of battery modules, the battery tray having at least one strengthening rib extending longitudinally along the battery tray, the at least one strengthening rib being disposed between the retainer side and the attachment side, the battery tray further having a plurality of openings extending therethrough that are disposed between the at least one strengthening rib and the retainer side, the battery tray further having a plurality of openings extending therethrough that are disposed between the at least one strengthening rib and the attachment side;a base plate having an upper surface and a lower surface, wherein a lower surface of the battery tray is disposed on the upper surface of the base plate; anda plurality of retainer plates each having a clamp retainer end and a clamp attachment end, the clamp retainer end having a clamp retainer operative to engage a second retention surface associated with each of the plurality of battery modules. 20. The battery mounting system of claim 19, further comprising a cover operative to be disposed on the upper surface of the base plate and enclose the plurality of battery modules. 21. The battery mounting system of claim 19, further comprising a resilient sheet attached to an upper surface of the battery tray. 22. The battery mounting system of claim 19, further comprising a plurality of lateral ribs disposed on the lower surface of the base plate. 23. The battery mounting system of claim 19, wherein the retainer comprises an inwardly and upwardly extending tapered wall having a first taper angle and the clamp retainer comprises an inwardly and upwardly extending tapered wall having a second taper angle. 24. The battery mounting system of claim 19, further comprising a corrosion resistant and electrically insulating coating applied to exposed portions of the battery tray, the base plate and the plurality of retainer plates. 25. The battery mounting system of claim 19, wherein the base plate has a T-shape. 26. The battery mounting system of claim 19, wherein the plurality of openings extending through the battery tray that are disposed between the at least one strengthening rib and the retainer side have a plurality of sizes and a plurality of shapes. 27. The battery mounting system of claim 19, wherein the plurality of openings extending through the battery tray that are disposed between the at least one strengthening rib and the attachment side have a plurality of sizes and a plurality of shapes.
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Waters John E. (Fishers IN) Harris Brent A. (Alexandria IN) Gresley Ross A. (Anderson IN) Boys William E. (Anderson IN) Brouns Daniel R. (Indianapolis IN), Electric vehicle battery pack.
Lent, Steven; Yang, Heekook; Merriman, Robert; Garascia, Michael P., Battery module mounting assembly and method for mounting a battery module to a base plate.
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