EP-4737152-A1 - A MOUNTING FRAME ARRANGEMENT FOR ELECTROCHEMICAL POWER UNITS AND A SYSTEM

EP4737152A1EP 4737152 A1EP4737152 A1EP 4737152A1EP-4737152-A1

Abstract

The present disclosure relates to a mounting frame arrangement (30) for securing at least one electrochemical power unit (20, 20a to 20n) to a chassis (2) of a vehicle (1), wherein the mounting frame arrangement comprises: a coupling interface (35) for attachment of the mounting frame arrangement to the chassis; and a docking interface (40) configured to dock the at least one electrochemical power unit (20a) to the mounting frame arrangement, wherein the docking interface comprises a cooling system interconnection interface (50) for the at least one electrochemical power unit, and an electrical connection interconnection interface (55, 58) for the at least one electrochemical power unit.

Inventors

HU, Wenting
Roy, Sanchayan

Assignees

Volvo Truck Corporation

Dates

Publication Date: 20260506
Application Date: 20241029

Claims (15)

A mounting frame arrangement (30) for securing at least one electrochemical power unit (20, 20a to 20n) to a chassis (2) of a vehicle (1), wherein the mounting frame arrangement comprises: - a coupling interface (35) for attachment of the mounting frame arrangement to the chassis; and - a docking interface (40) configured to dock the at least one electrochemical power unit (20a) to the mounting frame arrangement, wherein the docking interface comprises a cooling system interconnection interface (50) for the at least one electrochemical power unit, and an electrical connection interconnection interface (55, 58) for the at least one electrochemical power unit.
The mounting frame arrangement of claim 1, wherein the docking interface comprises a positioning supporting arrangement (90) for the at least one electrochemical power unit, the positioning supporting arrangement being configured to guide the at least one electrochemical power unit into a docking position relative to the mounting frame arrangement.
The mounting frame arrangement of claim 2, wherein the positioning supporting arrangement comprises one or more guide pins (92, 92a to 92n) for guiding the at least one first electrochemical power unit into the docking position relative to the mounting frame arrangement.
The mounting frame arrangement of any previous claims, wherein the mounting frame arrangement comprises a plurality of chambers (80, 80a, 80b, 80c) for individual accommodation of a first internal coolant conduit (65) in a first chamber, a second internal coolant conduit (64) in a second chamber, and an electric cable arrangement (66) in a third chamber.
The mounting frame arrangement of claim 4, wherein the electrical connection interconnection interface comprises a high-voltage (HV) interconnection interface for the at least one electrochemical power unit and a low-voltage (LV) interconnection interface (58, 58a, 58b) for the at least first electrochemical power unit, and wherein the HV interconnection interface and the LV interconnection interface are arranged in separate chambers of the mounting frame arrangement.
The mounting frame arrangement of any previous claims, further comprising a fastening system (70) configured to mechanically connect the at least one electrochemical power unit to the mounting frame arrangement.
The mounting frame arrangement of any previous claims, wherein the coupling interface is configured to couple the mounting frame arrangement to one or more longitudinal sides (4, 5) of a frame structure (3) of the chassis.
The mounting frame arrangement of any previous claims, further comprising an inlet (61) for coolant, an outlet (62) for coolant, and an electrical connection interface (63).
The mounting frame arrangement of any previous claims, wherein the at least one electrochemical power unit is provided in the form of a battery module comprising battery cells, or wherein the at least one electrochemical power unit is provided in the form of a fuel cell system comprising fuel cells.
The mounting frame arrangement of any previous claims, wherein the mounting frame arrangement is an extruded profile structure.
The mounting frame arrangement of any previous claims, wherein the at least one electrochemical power unit is a first electrochemical power unit (20a), and wherein the mounting frame arrangement further comprises a corresponding docking interface (40b) configured to dock a second electrochemical power unit (20b) to the mounting frame arrangement.
The mounting frame arrangement of claim 11, wherein the docking interface (40a) is arranged on an upper side (31) of the mounting frame arrangement so as to dock the first electrochemical power unit to the upper side, and the corresponding docking interface (40b) is arranged on a lower side (32) of the mounting frame arrangement so as to dock the second electrochemical power unit to the lower side.
The mounting frame arrangement of claim 11, wherein the docking interface (40a) and the corresponding docking interface (40a) are arranged on a lower side (32) of the mounting frame arrangement so as to dock the first electrochemical power unit and the second electrochemical power unit to the lower side of the mounting frame arrangement.
An electrical energy storage system (10) comprising at least a first electrochemical power unit, a second electrochemical power unit and a mounting frame arrangement according to any one of the previous claims.
A vehicle (1) comprising a mounting frame arrangement (30) according to any previous claims 1 to 13 and/or an electrical energy storage system according to claim 14.

Description

TECHNICAL FIELD The disclosure relates generally to a mounting frame arrangement for electrochemical power units of a vehicle. In particular aspects, the disclosure relates to electrical energy storage systems for vehicles. The disclosure can be applied to heavy-duty vehicles, such as trucks, buses, and construction equipment, among other vehicle types. Although the disclosure may be described with respect to a particular vehicle, the disclosure is not restricted to any particular vehicle. The disclosure may also be applicable to marine vehicle applications. Additionally, the disclosure may be used in a number of different types of electric-powered vehicles such as fully electrical vehicles, partly electrical vehicles e.g. hybrid vehicles and vehicles having an internal combustion engine and an electrical machine, fuel cells and an electrical machine etc. BACKGROUND In the field of electrochemical power units, such as batteries and fuel cells for vehicles, various systems have been developed for storing and connecting power units to the electric propulsion system. Electrochemical power units are typically responsible for powering the vehicle itself and for supplying energy to auxiliary electrical systems. As vehicle electrification progresses, the demand for reliable, high-capacity energy storage solutions continues to increase. An electrochemical power unit typically comprises multiple battery cells or fuel cells, connected in series or parallel, forming an integrated system capable of delivering the required energy. A challenge in such systems involves improving the placement of the power units within the vehicle. Although advancements have been made in the design of power unit systems, there remains a need to further improve the integration of electrochemical power units in vehicles. SUMMARY According to a first aspect of the disclosure, there is provided a mounting frame arrangement for securing at least one electrochemical power unit to a chassis of a vehicle. The mounting frame arrangement comprises a coupling interface for attachment of the mounting frame arrangement to the chassis; a docking interface configured to dock the at least one electrochemical power unit to the mounting frame arrangement. Moreover, the docking interface comprises a cooling system interconnection interface for the at least one electrochemical power unit; an electrical connection interconnection interface for the at least one electrochemical power unit. The disclosure is at least partly based on the insight that integrating electrochemical power units into a vehicle requires a system that may not only provide a stable mechanical interface but also facilitates the secure and efficient transfer of coolant, electrical power, and/or signals between the power units and the relevant sub-systems. In addition, it has been observed that hitherto known prior art systems may not adequately account for the separation of cooling and electrical systems or may pose risks in terms of electrical interference and water leakage. The first aspect of the disclosure may seek to improve the integration of multiple electrochemical power units in vehicles, while addressing challenges related to the safe transfer of power, signals, and coolant. More specifically, the disclosure may seek to contribute to a more reliable mechanical attachment while minimizing, or at least reducing, risks associated with thermal-electrical interference and potential water ingress over the lifetime of the electrochemical power units. By facilitating easier assembly, disassembly, and aftermarket access, the disclosure also addresses the need for operational efficiency in the handling of such systems. A technical benefit may include an improved mounting of one or more electrochemical power units to a chassis of a vehicle, such as a heavy-duty vehicle. The multi-functional docking interface arranged in the mounting frame arrangement ensures that the complementary interface of the electrochemical power unit can be securely docked to the mounting frame arrangement. By incorporating both the coupling interface and the docking interface, the mounting frame arrangement is configured to serve as an intermediate load-bearing system that extends between the electrochemical power unit and the chassis, effectively acting as the primary load-bearing structure. In this manner, the mounting frame arrangement allows for more efficient distribution of forces and facilitates the transfer of power and coolant through the system. Additionally, the mounting frame arrangement may simplify assembly and disassembly processes, enabling quick access to cooling and electrical interfaces, which can be particularly beneficial for aftermarket maintenance. The mounting frame arrangement is particularly useful for an electric-powered vehicle, such as an electric truck, electric bus or the like, i.e. a full electric vehicle. However, the mounting frame arrangement may likewise be installed in a partly ele