AU2021206878A1

AU2021206878A1 - Stackable units

Info

Publication number: AU2021206878A1
Application number: AU2021206878A
Authority: AU
Inventors: Andrew Dale Holmes; David John Treanor
Original assignee: Redei Innovations Pty Ltd
Current assignee: Redei Innovations Pty Ltd
Priority date: 2021-07-22
Filing date: 2021-07-22
Publication date: 2023-02-09
Also published as: WO2023000032A1

Abstract

P1777AU00 ABSTRACT A stackable unit 1 comprising upper interlocking features 7 and lower interlocking features 9. The lower interlocking features are shaped to move in a horizontal direction into interlocking engagement with the upper interlocking features of an 5 identical stackable unit to restrain the stackable unit transverse to the horizontal direction relative to the identical stackable unit. The stackable unit is an electrical unit. 1/2 1 3 5 FIGURE 1 FU 9o 00 FIGURE 1

Description

1/2

1

3

FIGURE 1

9o

00

FU FIGURE 1

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STACKABLE UNITS FIELD

The invention relates to stackable units.

The invention will be described with reference to batteries by way of example only.

BACKGROUND

Battery systems for light commercial applications and applications such as domestic battery-solar systems typically comprise multiple batteries. Very often, these batteries are mounted in a rack or placed on shelves.

SUMMARY

The present inventors have recognised that significant efficiencies can be realised by providing a battery in the form of a stackable unit. In particular, the rack and/or shelves might be eliminated. To this end, the present inventors have invented an advantageous stackable unit, variants of which may well be usefully employed in contexts remote from batteries.

One aspect of the invention provides a stackable unit comprising

upper interlocking features; and

lower interlocking features;

wherein the lower interlocking features are shaped to move in a horizontal direction into interlocking engagement with the upper interlocking features of an identical stackable unit to restrain the stackable unit transverse to the horizontal direction relative to the identical stackable unit; and

the stackable unit is an electrical unit, e.g. a battery.

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The stackable unit preferably comprises a housing. The housing preferably comprises the upper interlocking features and/or the lower interlocking features. Optionally, the housing comprises one or more tubular portions. Preferably, the one or more tubular portions comprises the upper interlocking features and/or the lower interlocking features. Optionally, the housing comprises end pieces. Preferably, the one or more tubular portions comprises ends mutually spaced in the horizontal direction and closed by the end pieces.

Another aspect of the invention provides a stackable unit comprising a housing;

the housing comprising

end pieces;

one or more tubular portions; and

fasteners;

the one or more tubular portions comprising

extrusion portions;

upper interlocking features;

lower interlocking features; and

ends mutually spaced in a horizontal direction and closed by the end pieces;

wherein the lower interlocking features are shaped to move in the horizontal direction into interlocking engagement with the upper interlocking features of an identical stackable unit to restrain the stackable unit transverse to the horizontal direction relative to the identical stackable unit; and

the fasteners are engaged with the extruded portions to fasten the end pieces to each of the ends.

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Preferably, the end pieces are plates and/or the one or more tubular portions comprise fastener receivers by which the end pieces are fastened to the tubular portion. Most preferably, the housing predominantly consists of the end pieces and one of the one or more tubular portions.

The stackable unit may comprise extrusion portions, or the extrusion portions, defining the upper interlocking features and the lower interlocking features. Preferably, at least one of the one or more tubular portions comprises two or more panel members each mutually connecting two of the extrusion portions.

Preferably, at least one of the one or more tubular portions predominantly consists of a respective extrusion. Most preferably, the housing is predominantly metallic.

The stackable unit may be shaped to define one or more gaps thermally separating most of a bottom of the stackable unit from a top of the identical stackable unit.

Optionally, the stackable unit comprises an upper fastener receiver and lower fastener receiver arranged such that the lower fastener receiver and the upper fastener receiver of the identical stackable unit are fastenable to a connecting piece to resist relative movement in the horizontal direction.

Another aspect of the invention provides a stack of the stackable units.

Preferably, a connecting piece is fastened to each of a vertically-adjacent two of the stackable units to resist relative movement in the horizontal direction.

Another aspect of the invention provides a mounting plate for mounting the stackable unit. Preferably, the mounting plate is mountable on a cargo floor of a vehicle. Optionally, it comprises features co-operable with the lower interlocking features.

Another aspect of the invention provides a vehicle carrying the stackable unit. The vehicle preferably comprises features co-operable with the lower interlocking features to restrain the stackable unit.

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Another aspect of the invention provides a method of making the stackable unit. The preferably comprises making the housing. The making may comprise extruding.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a perspective view of a stackable unit;

Figure 2 is a perspective view of a stack;

Figure 3 is a schematic elevation of another stack;

Figure 4 is a front view of interlocked features;

Figure 5 is a front view of an extruded portion;

Figure 6 is a perspective view of another extruded portion; and

Figure 7 is a schematic elevation of a vehicle.

DESCRIPTION OF EMBODIMENTS

The stackable unit 1 comprises an extruded aluminium casing 3 and end plates 5. The casing 3 has a tubular form that runs horizontally and has ends capped by the plates 5.

The unit 1 comprises upper interlocking features 7 and lower interlocking features 9. In this case, the features 7, 9 comprise T-rails and complementary T-slots. The interlocking features 7, 9 are mutually complementary whereby the unit 1 can be slid horizontally (in a direction parallel to the length of the tube 3) to bring its lower interlocking features 9 into interlocking engagement with the upper interlocking features 7' of an underlying unit 1'. This interlocking restrains the unit 1 relative to the unit 1' in all directions transverse to lengthwise. The tube 3 comprises six fastener receivers opening from each end of the tube 3. The mounting plate 5 comprises an array of six screw-holes complementary to the screw-receivers. Screws (not shown) pass through these holes and engage the extrusion (or more specifically the screw-

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receivers of the extrusion) to fix the end plates 5 to the ends of the tube. In this way, the stackable unit becomes a strong, self-supporting box.

In this example, there are six screws arrayed around the perimeter of the plate 5. Other fasteners and/or a different number of fasteners are possible. By way of example, blind rivets may be inserted and expanded to engage interiors of fastener receiving formations of the extrusion. In principle, the plate 5 might be attached with only one fastener (or indeed could be attached by other means) or by a small number of fasteners along one edge of the extrusion. More preferably, the end plate is attached with at least two fasteners spaced about the profile of the tubular portion to support the tubular portion against vertical collapse.

In this example, each T-rail 7' has its own "head" which is received and captured within a corresponding portion of the T-slot 9. Other shapes are possible, e.g. the head might have a bulbous form. In this example, each T-rail/complementary T-slot combination individually restrains against movement, although there are other options. Whereas in this example the unit 1 has a T-rail 7 on each side, in another example of the unit, each side may have its own L-shaped rail oriented in an opposite direction to the L-shaped rail at the other side. In this way, the two L-shaped rails and the corresponding two lower interlocking portions co-operate, as a group, to restrain against movement transverse to the lengthwise direction.

In this example, the tube 3 and end plates 5 together define substantially all of an exterior of the unit 1 and the unit 1 is co-operable with substantially identical stackable units 1', 1".

Other variants are possible. By way of example, a single stackable unit might be made up of two mutually different units 1A, 1B stacked one on top of the other. For the avoidance of doubt, the combination of units 1A, 1B is a stackable unit as the terminology is used herein. The stackable units 1A, 1B might be mutually connected in a manner akin to the connection between units 1, 1', although there are other options. By way of example, each of the units 1A, 1B might have its own tubular housing, in which case the mutually aligned ends of the tubular housing at one end of the combination 1A, 1B might be capped by a single end plate. This example of the

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unit 1 is a battery. The tube 3 and end plates 5 together constitute a housing which houses the cells of the battery. The housing is fully enclosed. The electrical connectors are mounted on the end plate 5. In this case, the electrical connectors are keyed. An indicator panel, which provides an indication of the state of charge of the battery, also opens from the end plate 5.

In this example, the end plate 5 is formed of aluminium sheet, although there are other options. By way of example, the end plate 5 might be replaced by an end piece formed of injection-moulded plastic and having a more elaborate shape. That said, the housing is preferably fire-resistant, and is most preferably predominantly metallic. The metallic construction is not only fire-resistant but also assists to dissipate heat. This is particularly advantageous in the context of batteries that generate heat when charged and discharged. Similar benefits can be realised in the context of other electrical units such as amplifiers and power distribution systems for stage lighting, etc.

The unit 1 is advantageously shaped to define air gaps 11 between the vertically adjacent modules 1, 1' in the stack, whereby these two modules are, mostly, thermally separated. This limits the transference of heat from one module to the other and provides additional surface area for dissipating heat. In this example, the air gap 11 is achieved by a downwardly-proud spacing portion 11a at each transverse end of the unit 1 and an upwardly-proud spacing portion 11b' on top of the underlying unit 1'. The spacing portions 11b' sit in abutment with each other. This particular spacing arrangement is symmetric, although asymmetric options are possible. Most preferably, unit 1 is shaped to define a gap mostly separating it from a horizontally adjacent unit in a stack.

For many applications, the interlocking forms may provide for a sufficiently stable stack, although for additional restraint (particularly to suit mobile applications), additional restraints are preferred. Any convenient restraint to restrain relative movement in the lengthwise direction is possible. Preferably, the restraint comprises a connecting piece connecting adjacent units. In this case, the connecting piece 13 takes the form of a simple square plate penetrated by a square array of holes complementary to the four screw-holes at the juncture of four units in a stack. In this

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way, the simple plate and four screws mutually restrains the four units with respect to each other and also holds the units' end plates on.

Figure 1 illustrates a variant of the unit 1 comprising a one-piece extruded tube 3 comprising the interlocking features 7 and an integral panel portion 15 therebetween. Instead of an integral panel portion, other versions of the unit may comprise a panel member. Figure 4 illustrates an extruded corner profile 17 complementary to corner profile 17'. The profile is generally L-shaped and defines a grip 17a opening from the end of each arm of the L. The grips 17a are configured to receive and grip the edge of a panel member in the form of a piece of aluminium sheet. The profile 17 further defines spacing portion 17b, lower interlocking portion 17c and fastener receivers 17d. The fastener receivers are preferably openings. In this case they are extruded channels.

The disclosed mode of construction is highly scalable. The unit 1 can be scaled up without the need to invest in additional extrusion tools, simply by parting off the tube 3 at a longer length. Units comprising the profile 17 can be scaled up in the same way and also scaled up by simply varying the dimensions of the panel members. In the context of large profile units, extruded connector 21 may be fitted between two panel members. In this example, the connector 1 comprises a pair of inlets 21a opening away from each other to receive about coplanar panel members. The connector 21 further comprises a fastener receiver 21b and loop 21c. The loop 21c might receive a rod of a securing mechanism.

The extruded portions might simply be extruded and parted-off. Alternatively, they may be subject to a post-extrusion operation, e.g. a material removal operation such as drilling or machining. The post extrusion operation may be to create one or more mounting points, e.g. within a housing. In one example of the connector 21 an end portion (e.g. an about 25mm long end portion) of the loop 21c is machined away so that the loop 21c opens inside the housing to provide an anchor point inside the housing. Optionally, a screw may engage the anchor point (whereby the open end of the loop 21c serves as a fastener receiver). More preferably a threaded rod runs through the loop 21c and is engaged by nuts e.g. inside and outside the housing.

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Advantageously, two such connectors 21 might sit along opposite walls of a housing to define a pair of anchor points. Those anchor points may be mutually connected by a connecting member to reinforce the housing and/or carrying housed components, e.g to carry battery cells.

Figure 6 schematically illustrates a vehicle 23 comprising a mounting plate 25 carrying a module 27 akin to the module 1. The mounting plate 25 and module 27 are shown in exaggerated scale for the sake of clarity. Preferred variants of the stackable unit are dimensioned to be safely carried by a single human.

The mounting plate 25 is configured to be fixed to the cargo-carrying floor, in this case the floor of the vehicle's flat bed, and further comprises T-rails akin to the T-rails 7' to restrain the unit 27. Preferably, the unit 27 is also restrained in the lengthwise (i.e. rail-wise) direction, e.g. unit 1 might be bracketed between stops fixed relative to the cargo-carrying bed. One of these stops might be part of the mounting plate 25 (e.g. an integral part). Another might be placed after the unit 27 is placed. Preferred forms of the mounting plate are a simple bolt in fit to any convenient vehicle, e.g. in the cargo-carrying floor at the rear of a station wagon or the rear of a van, although there are other options. Indeed, other variants of the concept might be implemented without a mounting plate as such, e.g. T-rails might be separately installed at any convenient point in or on a vehicle.

The invention is not confined to the examples disclosed herein. Whilst various portions are preferably formed by extrusion, those portions might be replaced by portions of substantially uniform cross-section formed by other means, such as by pultrusion or wire cutting. Whilst the unit 1 has a housing, a housing-less stackable battery unit comprising a cell-carrying frame that defines the interlocking features would be useful.

The term "comprises" and its grammatical variants has a meaning that is determined by the context in which it appears. Accordingly, the term should not be interpreted exhaustively unless the context dictates so.

Claims

P1777AU00 9 CLAIMS

1. A stackable unit comprising

upper interlocking features; and

lower interlocking features;

the stackable unit is an electrical unit.

2. The stackable unit of claim 1 wherein the stackable unit is a battery.

3. The stackable unit of claim 1 or 2 comprising a housing;

wherein the housing comprises

the upper interlocking features; and

the lower interlocking features.

4. The stackable unit of claim 3 wherein

the housing comprises one or more tubular portions; and

the one or more tubular portions comprise

the upper interlocking features;

the lower interlocking features.

5. The stackable unit of claim 4 wherein

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the housing comprises end pieces; and

the one or more tubular portions comprises ends mutually spaced in the horizontal direction and closed by the end pieces.

6. A stackable unit comprising a housing;

the housing comprising

end pieces;

one or more tubular portions; and

fasteners;

the one or more tubular portions comprising

extrusion portions;

upper interlocking features;

lower interlocking features; and

ends mutually spaced in a horizontal direction and closed by the end pieces;

7. The stackable unit of claim 5 or 6 wherein the end pieces are plates.

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8. The stackable unit of claim 5, 6 or 7 wherein the one or more tubular portions comprise fastener receivers by which the end pieces are fastened to the tubular portion.

9. The stackable unit of any one of claims 5 to 8 wherein the housing predominantly consists of

the end pieces; and

one of the one or more tubular portions.

10. The stackable unit of anyone of claims 4 to 9 comprising extrusion portions, or the extrusion portions, defining the upper interlocking features and the lower interlocking features;

wherein at least one of the one or more tubular portions comprises two or more panel members each mutually connecting two of the extrusion portions.

11. The stackable unit of any one of claim 4 to 9 wherein at least one of the one or more tubular portions predominantly consists of a respective extrusion.

12. The stackable unit of any one of claims 3 to 11 wherein the housing is predominantly metallic.

13. The stackable unit of any one of claims 1 to 12 shaped to define one or more gaps thermally separating most of a bottom of the stackable unit from a top of the identical stackable unit.

14. The stackable unit of any one of claims 1 to 13 comprising an upper fastener receiver and lower fastener receiver arranged such that lower fastener receiver and the upper fastener receiver of the identical stackable unit are fastenable to a connecting piece to resist relative movement in the horizontal direction.

15. A stack of stackable units each in accordance with any one of claims 1 to 14.

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16. The stack of claim 15 comprising a connecting piece fastened to each of a vertically-adjacent two of the stackable units to resist relative movement in the horizontal direction.

17. A mounting plate for mounting the stackable unit of any one of claims 1 to 14;

wherein the mounting plate is mountable on a cargo floor of a vehicle and comprises features co-operable with the lower interlocking features.

18. A vehicle carrying the stackable unit of any one of claims 1 to 14;

the vehicle comprising features co-operable with the lower interlocking features to restrain the stackable unit.

19. A method of making the stackable unit of any one of claims 3 to 12;

wherein the method comprises making the housing; and

the making comprises extruding.