CA3113789A1 - Electric vehicle with battery pack as structural element - Google Patents

Abstract

An electric vehicle and a battery enclosure for an electric vehicle are disclosed. The electric vehicle is a straddle-seat electric vehicle, comprising a chassis including a suspension system and a battery pack configured as a structural element that receives loads from the suspension system of the electric vehicle.

Description

ELECTRIC VEHICLE WITH BATTERY PACK AS STRUCTURAL ELEMENT
TECHNICAL FIELD
[0001] The disclosure relates generally to electric vehicles.
BACKGROUND

[0002] Electric vehicles comprise different powertrain components than traditional combustion engine vehicles. For example, instead of having a fuel tank and a combustion engine, an electric vehicle comprises a battery pack and an electric motor. Due to the sizes and weights of the electric vehicle powertrain components, consideration is needed when locating and positioning them in relation to each other, as well as other components of the electric vehicle.

[0003] For an electric snowmobile, further consideration is needed when locating a battery pack and electric motor in relation to a chassis and suspension system.

[0004] For these and other reasons, there is a need for the present invention.
SUMMARY

[0005] According to one example, an electric vehicle is provided that comprise an electric motor and a battery pack. The battery pack comprising one or more battery modules for providing power to the electric motor; and a battery enclosure housing the one or more battery modules. The battery enclosure is a structural element of the electric vehicle for receiving loads from at least two of a suspension system, a seat and a steering system of the electric vehicle.

[0006] According to some examples, the battery enclosure transfers the loads received, at least partially, to a center of mass of the electric vehicle. In another example, the battery enclosure transferring the loads received, at least partially, to a Date Recue/Date Received 2021-03-30 chassis of the electric vehicle. According to another example, the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from a front suspension of the electric vehicle. According to another example, the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from the steering system and the rear portion receiving loads from the seat.

[0007] In some examples, the electric vehicle comprises a chassis defining a tunnel portion and a front brace structure, the tunnel portion connected to the rear portion of the battery enclosure and the front brace structure connected to the front portion of the battery enclosure. In some examples, the electric vehicle is a snowmobile.

[0008] According to one example, a battery enclosure for an electric vehicle is provided. The battery enclosure being a structural element of the electric vehicle and comprising a rear portion adapted for connection to a rear portion of a chassis of the electric vehicle, the rear portion of the battery enclosure configured to receive loads from a seat of the electric vehicle; and a front portion adapted for connection to a front portion of the chassis of the electric vehicle, the front portion of the battery enclosure configured to receive loads from a front suspension of the electric vehicle.

[0009] In some examples, the battery enclosure is configured to transfer loads received from the seat and the front suspension, at least partially, to a center of mass of the electric vehicle. In some examples, the battery enclosure is configured to transfer loads received from the seat and the front suspension, at least partially, to a chassis of the electric vehicle. In some examples, the front portion is further adapted for receiving loads from a steering system of the electric vehicle and transferring those loads, at least partially, to a center of mass of the electric vehicle.
In some examples, the electric vehicle is a snowmobile. In some examples, the rear portion of the battery enclosure is adapted for connection to a tunnel of the snowmobile, and the front portion of the battery enclosure is adapted for connection to a front brace structure of the snowmobile.

[0010] According to a further example, the battery enclosure transfers the loads received, at least partially, to a center of mass of the electric vehicle. In another Date Recue/Date Received 2021-03-30 example, the battery enclosure transferring the loads received, at least partially, to a chassis of the electric vehicle. According to another example, the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from a front suspension of the electric vehicle. According to another example, the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from the steering system and the rear portion receiving loads from the seat.

[0011] According to one example, a snowmobile is provided comprising a chassis that comprises a rear tunnel; and a front brace structure adapted to receive loads from a front suspension system of the snowmobile. The snowmobile further comprises a battery enclosure defining a tunnel portion and a front portion, the tunnel portion being connected to the rear tunnel of the chassis and the front portion being connected to the front brace structure of the chassis. The battery enclosure receives loads from the front suspension system of the snowmobile through the front brace structure and transfers the loads from the front suspension system to at least one of the rear tunnel and a center of mass of the electric vehicle through a body of the battery enclosure.

[0012] In some examples, the battery enclosure is further connected to the front brace structure at a bottom surface. In some examples, a steering mount is connected to the front portion of the battery enclosure for connection to a steering column, the steering mount transferring loads from the steering column into the body of the battery enclosure. In some examples, a seat is connected to the tunnel portion of the battery enclosure, wherein loads from the seat are received by and transferred into the body of the battery enclosure. In some examples the front portion of the battery enclosure defines a first height and the tunnel portion of the battery enclosure defines a second height, the first height being greater than the second height. In some examples, the front portion of the battery enclosure defines a first width and the tunnel portion of the battery enclosure defines a second width, the first width being greater than the second width. In some examples, the front suspension system comprises at least one coil over spring and damper assembly. In some examples, at least one coil over spring and damper assembly is connected between a pair of Date Recue/Date Received 2021-03-30 skis and the front brace structure. In some examples, the battery enclosure comprises a carbon fiber composite material. In some examples the battery enclosure comprises an injection molded glass fiber reinforced plastic material. In some examples, the tunnel portion of the battery enclosure is connected to the rear tunnel of the chassis via two or more right side blocks and two or more left side blocks. In some examples, the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa.
In some examples, the battery enclosure comprises a cover and a floor. In some examples the battery enclosure houses at least two electric battery modules for supplying electricity to the electric motor. In some examples, the battery modules comprise one or more pouch battery cells.

[0013] According to one example, a battery enclosure for an electric snowmobile is provided. The battery enclosure comprises a tunnel portion adapted for connection to a rear tunnel of a snowmobile chassis, a front portion adapted for connection to a front brace structure of the snowmobile chassis. The battery enclosure is configured to receive loads from a front suspension system of the snowmobile through the front brace structure and transfers the loads from the front suspension system to at least one of the rear tunnel and a center of mass of the electric vehicle through a body of the battery enclosure.

[0014] In one example, the battery enclosure is configured for connection to a steering column via a steering mount for receiving loads from the steering column into the body of the battery enclosure. In some examples, the battery enclosure is configured for connection to a seat of the electric vehicle for receiving loads from the seat into the body of the battery enclosure. In some examples, the front portion of the battery enclosure defines a first height and the tunnel portion of the battery enclosure defines a second height, the first height being greater than the second height. In some examples, the front portion of the battery enclosure defines a first width and the tunnel portion of the battery enclosure defines a second width, the first width being greater than the second width. In some examples, the battery enclosure comprises a carbon fiber composite material. In some examples, the battery Date Recue/Date Received 2021-03-30 enclosure comprises an injection molded glass fiber reinforced plastic material. In some examples, the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa.
In some examples, the battery enclosure comprises a cover and a floor.

[0015] According to one example, a straddle-seat electric vehicle is provided that comprises a chassis including a suspension system and a battery pack configured as a structural element that receives loads from the suspension system.
In one example, the battery pack comprising a battery enclosure coupled to the suspension system for transferring, at least partially, loads from the suspension system through a body of the battery enclosure to the chassis. In one example, a brace structure transfers loads between the suspension system and the battery enclosure. In one example, the vehicle comprises a straddle seat, the straddle seat being mounted directly to the battery pack. In one example, the straddle-seat vehicle is a snowmobile.
BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a block diagram of components of an electric vehicle 100, according to one example of the present disclosure.

[0017] Figure 2 is a front perspective view of an electric vehicle that is a snowmobile, according to one example of the present disclosure.

[0018] Figure 3 is a side perspective view of the snowmobile of Figure 2, according to one example of the present disclosure.

[0019] Figure 4 is another side perspective view of the snowmobile of Figure 2, according to one example of the present disclosure.

[0020] Figure 5A is a partial side perspective view of a snowmobile, according to one example of the present disclosure.

[0021] Figure 5B is a block diagram illustrating a load path of a snowmobile, according to one example of the present disclosure.
Date Recue/Date Received 2021-03-30

[0022] Figure 6 is a front top partial perspective view of a snowmobile, according to one example of the present disclosure.

[0023] Figure 7 is a front partial perspective view of a snowmobile, according to one example of the present disclosure.

[0024] Figure 7A is an enlarged partial perspective view of a snowmobile, according to one example of the present disclosure.

[0025] Figure 8 is a front view of a snowmobile, according to one example of the present disclosure.

[0026] Figure 9 is a cross-sectional view of a portion of a battery enclosure, according to one example of the present disclosure.

[0027] Figure 10 is a diagram illustrating part of a battery enclosure, according to one example of the present disclosure.

[0028] Figure 11 is an enlarged partial perspective view of a battery enclosure, according to one example of the present disclosure.

[0029] Figure 12 is a partial side view of a snowmobile, according to one example of the present disclosure.

[0030] Figure 13 is a partial side view of a snowmobile, according to one example of the present disclosure

[0031] Figure 14 is a partial perspective view of a battery pack, according to one example of the present disclosure.

[0032] Figure 15 is a top view of a battery pack, according to one example of the present disclosure.

[0033] Figure 16 is a side view of a battery pack, according to one example of the present disclosure.

[0034] Figure 17 is a front view of a battery pack, according to one example of the present disclosure.

[0035] Figure 18 is a partial perspective view of a motor assembly, according to one example of the present disclosure.

[0036] Figure 19 is a partial perspective view of a motor assembly, according to one example of the present disclosure.
Date Recue/Date Received 2021-03-30

[0037] Figure 20 is a partial side view of a motor assembly, according to one example of the present disclosure.

[0038] Figure 21 is a partial side view of a motor assembly, according to one example of the present disclosure.

[0039] Figure 22 is a partial perspective view of a motor assembly, according to one example of the present disclosure.
DETAILED DESCRIPTION

[0040] In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific examples in which the disclosure may be practiced. It is to be understood that other examples may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims. It is to be understood that features of the various examples described herein may be combined, in part or whole, with each other, unless specifically noted otherwise.

[0041] In one or more examples, the present application discloses an electric vehicle. The electric vehicle includes a battery pack that is configured as a structural element that receives loads from at least a suspension system during operation of the electric vehicle. Utilizing the battery pack as a structural element results in dynamic advantages in operation of the electric vehicle and an ergonomic advantage to the electric vehicle riders. In one or more examples illustrated herein, the electric vehicle is a powersport vehicle, and specifically an electric snowmobile. It is recognized that although a snowmobile is used in the examples, the present disclosure also applies to other electric vehicles, including other electric powersport vehicles (e.g., electric all-terrain vehicles (ATV), utility task vehicles (UTV), personal watercraft, side-by-side vehicles, motorcycles, etc.). In one or more examples illustrated herein, the electric vehicle is a straddle-seat electric vehicle, which is a Date Recue/Date Received 2021-03-30 straddle vehicle where the seat is straddled by a rider, such as a snowmobile, personal watercraft or ATV, among others.

[0042] Fig. 1 is a block diagram of components of an electric vehicle according to one example of the present disclosure. The electric vehicle 100 includes a chassis 110 (or frame), a suspension system 112 and a battery pack 114, among other components that are not shown. The battery pack 114 is configured as a structural element that receives loads from at least the suspension system 112, indicated at 115a, and transfers loads, at least partially, from the suspension system 112, through the battery pack 114 to the vehicle's center of mass and/or other elements of the chassis 110, indicated at 115b. As will be described in more detail below, the battery pack 114 is further configured to receive loads from all or some of the suspension system 112, the seating of the electric vehicle 100 and steering column 152 among other components or mechanisms of the electric vehicle 100, and transfer those loads, at least partially, to the vehicle's center of mass and/or the chassis 110.

[0043] In one example, the battery pack 114 comprises a battery enclosure 116 housing one or more battery modules 119. In one example, it is the battery enclosure 116 that is coupled to the suspension system 112 for receiving and transferring loads between the other vehicle components. A brace structure 118 that forms part of the chassis 110 may be present to transfer loads between the battery enclosure 116 and the suspension system 112.

[0044] Fig. 2 is a front perspective view of an electric vehicle 110 embodied as an electric snowmobile 120, according to one example of the present disclosure.
The snowmobile 120 is illustrated with one or more elements removed to aid in describing the remaining elements of the snowmobile 120. For example, in one or more figures the snowmobile hood is removed and/or the snowmobile seat is removed.

[0045] The snowmobile 120 includes a chassis 122 (or frame), a battery pack 124 and a suspension system 126. As described above with respect to Fig. 1, the Date Recue/Date Received 2021-03-30 battery pack 124 comprises a battery enclosure 128 that houses one or more battery modules therein.

[0046] In one example, the battery pack 124, and more specifically the battery enclosure 128, forms a structural element of the snowmobile 120 and is configured to receive, partially absorb and transfer loads from other snowmobile components, including the suspension system 126, the seating (seat 510 and/or backrest 512), and the steering system 150, to the vehicle's center of mass and/or to the chassis 110.

[0047] Battery enclosure 128 is made of a material that provides sufficient structural support to the snowmobile 120, or other electric vehicle 110, such that it acts as a structural element of the vehicle. The material of the battery enclosure 128 has a stiffness sufficient for receiving and absorbing loads, as well as transmitting loads between the vehicle components (e.g. the suspension system 126, seating and steering system) and the vehicle's center of mass and/or the chassis 122.
The battery enclosure 128 provides sufficient structural support to replace traditional support members such as braces, tubes and linkages, thus facilitating a more ergonomic design for the snowmobile 120.

[0048] In one example, the battery enclosure 128 is made of a carbon fiber composite material, having a thickness of 2 - 3 millimeters with an elastic modulus (i.e. stiffness) rating of at least 60 GPa. In other examples, the material has a stiffness rating between 10 GPa and 60 GPa. The battery enclosure 128 may be formed in a single piece, or multiple pieces that are secured together. For example, the battery enclosure 128 may be made of a floor (not shown) that may be a relatively flat plate that is secured to the chassis 122 and a lid that connects to the floor in order to create a cavity for housing the electric battery module(s). In another example, the battery enclosure 128 may be made of two halves that connect at a central seam. In other examples, the battery enclosure 128 could be made of a bucket and a top cover; or there could be a floor, a ring-like central portion and a cover or lid.
Date Recue/Date Received 2021-03-30

[0049] In another example, the battery enclosure 128 is made of a material such as a polymer or a loaded polymer. In one example, the battery enclosure is made of a glass fiber reinforced polymer (plastic) using an injection molded process. In one example, the polymer incudes glass fiber reinforcement that provides stiffness to the battery enclosure 128. For example, the polymer may include between 20-40% glass fiber content, and in another non-limiting example, 30% glass fiber content. In another example, the material of the battery enclosure 128 has a stiffness rating of at least 10 times the stiffness of a suspension spring element (i.e., the shock). In another example, the material of the battery enclosure 128 has a stiffness that can range from 3GPa without any fiber reinforcement to approximately 13GPa with a 40% fiber reinforcement. It is recognized that other combinations of material and fiber reinforcement may be used based on the type of material and fiber used, and design requirements for a given application.

[0050] It is also recognized that in areas where additional support is needed, the thickness of the material can be increased to provide additional stiffness. For example, reinforcement ribs can be injection molded into the material shape and thickness using the same material. In this manner, additional support and stiffness can be selectively provided to desired areas of the battery enclosure while still injection molding the same material throughout the process.

[0051] In one example, in addition to being a structural element that is able to receive, absorb and/or transfer loads received from the suspension system 126, the steering system 150 and seating (seat 510 and/or backrest 512), the battery enclosure 128 is also designed to withstand impact and damage that may be experienced during use of the electric vehicle 110, 120. In a further example, the battery enclosure 128 is designed to protect the electric battery from the elements, and when sealed, may provide a water-tight enclosure that is closed to water and foreign debris ingress. In this manner, the battery enclosure 128 may provide sufficient protection such that the electric battery module(s) can be housed directly within the battery enclosure 128. In an alternative example, the battery enclosure 128 may not be completely sealed to the elements and the electric battery module(s) Date Recue/Date Received 2021-03-30 may be provided within a non-structural watertight enclosure that is then, in-turn, housed within the structural battery enclosure 128.

[0052] In one example shown in Fig. 3, the chassis 122 of the snowmobile 120 includes rear tunnel 130 and a front brace structure 132. The front brace structure 132 is configured to receive loads from the suspension system 126.
The front brace structure 132 includes a first top brace 134 and a second top brace 136.

[0053] Referring back to Fig. 2, the suspension system 126 may be coupled to the battery enclosure 128, either directly or indirectly through the chassis 122, and more specifically through at least the front brace structure 132. In one example, the suspension system 126 may comprise a front suspension system that includes a first suspension leg 138 and a second suspension leg 140. The first suspension leg includes a first shock 142 and is coupled to a first ski assembly 144. The second suspension leg 140 includes a second shock 146 and is coupled to a second ski assembly 148. The first top brace 134 is coupled between the battery enclosure and the first suspension leg 138. The second top brace 136 is coupled between the battery enclosure 128 and the second suspension leg 140.

[0054] The shocks 142, 146 may each comprise a coil over spring and damper assembly, a hydraulic or pneumatic piston assembly, or any other type of shock assembly known to those skilled in the art. The shocks 142, 146 are connected either directly or indirectly between their respective ski assemblies 144, 148 and the front brace structure 132 of the chassis 122.

[0055] Also illustrated in Fig. 2 is a steering system 150 having handlebar attachment 154 coupled to steering column 152. The steering system 150 also includes steering assembly 156 coupled to first and second ski assemblies 144, 146.
The steering column 152 is securely and rotatably coupled to battery enclosure at location 160 via a steering mount. The steering column 152 may extend at least partially through the battery enclosure 128. In one example, the steering column 152 freely rotates within a tunnel or slot 162 defined by the battery enclosure 128 during steering of snowmobile 120. One or more examples of steering system 150 are described in detail later in this specification.
Date Recue/Date Received 2021-03-30

[0056] Reference is now made to Fig. 3 and Fig. 4. As indicated above, chassis 122 comprises a rear tunnel 130 and a front brace structure 132.
Battery pack 124 is illustrated positioned, at least partially, over rear tunnel 130.
Battery enclosure 128 of battery pack 124 defines a tunnel portion 200 (or rear portion) and a front portion 202. In one example, the tunnel portion 200 (or rear portion) is connected to the rear tunnel 130 of the chassis 122, and the front portion 202 is connected to the front brace structure 132. In one example, the tunnel portion may be generally rectangular shaped, although other shapes are also possible, including an elongated dome shape, or a truncated prismatic shape, among other possibilities. Tunnel portion 200 is connected to the rear tunnel 130 of the chassis 122 at connection points or blocks 204. Tunnel portion 200 may be connected to the rear tunnel 130 via mechanical fasteners such as nuts and bolts, rivets, staples, etc.
In some embodiments, a bottom portion or floor of the battery enclosure 128 may be connected to the rear tunnel 130 more permanently via welding, soldering or adhesion among other possibilities. In such a case, an upper portion or lid of the battery enclosure 128 may then be fastened to the floor via mechanical fasteners, friction fit, snap fit or any other suitable removable fastening mechanism.

[0057] As shown in Fig. 2, the front portion 202 of the battery enclosure 128 may be generally rectangular shaped and is located towards the front of snowmobile 120. In one example, front portion 202 of the battery enclosure 128 has different width and height dimensions from tunnel portion 200 of the battery enclosure 128, such that there is a clear visual demarcation between the tunnel portion 200 and the front portion 202 of the battery enclosure 128. However, in other embodiments, the front portion 202 may have only a different height or a different width from the tunnel portion 200, and not both. In still further embodiments, the front portion 202 may have the same height and width as the tunnel portion 200 along an entire length of the battery enclosure 128, such that there is no distinct visual demarcation between the tunnel portion 200 and the front portion 202. In still further embodiments, the battery enclosure 128 may gradually increase in height and/or width from the rear of the tunnel portion 200 to the front of the front portion 202. The battery enclosure 128 Date Recue/Date Received 2021-03-30 may have any shape or configuration that is suitable for housing one or more battery modules and attaching to the tunnel 130 and front brace structure 132 of the electric vehicle.

[0058] With reference to Fig. 5A, in one example, front portion 202 of battery enclosure 128 defines a first height 206 and the tunnel portion 202 of battery enclosure 128 defines a second height 208. In one example, the first height 206 is greater than the second height 208. In other examples, the first height 206 is less than the second height 208. In one example, the front portion 202 of battery enclosure 128 defines a first width 210 and the tunnel portion 202 of battery enclosure 128 defines a second width 212. In one example, the first width 210 is greater than the second width 212. In other examples, the first width 210 is less than the second width 212.

[0059] In one example, battery pack 124 has an approximate overall length of 1563mm, width of 596mm, and height of 437mm. It is recognized that the overall length, width and height of battery pack 124 may vary based on the design of snowmobile 120. In another example, the approximate overall length of battery pack 124 is in a range of 750 ¨ 2000mm, the width is in a range of 450mm ¨ 600mm, and the height is in a range of 350 ¨550mm.

[0060] Fig. 6 is a top front perspective view of battery pack 124 including battery enclosure 128. The battery enclosure 128 includes tunnel portion 200 positioned over rear tunnel 130, and front portion 202 positioned at or in proximity to the front of rear tunnel 130.

[0061] In one or more examples, it is recognized that the battery enclosure 128 may provide one single internal cavity for the battery module(s) of the electric battery, or multiple segmented internal cavities that can separate the different battery module(s) of the electric battery. There may be cutouts in the segmenting walls for enabling electrical interconnection of the battery modules.

[0062] In one example, the battery enclosure 128 may be one overall component made up of a floor and a cover or lid. In another example, the battery enclosure 128 may comprise multiple separate battery enclosure components that Date Recue/Date Received 2021-03-30 each have a floor and cover or lid. The separate enclosure components may comprise two separate enclosure components (for example. the tunnel portion and the front portion may each form a separate distinct battery enclosure component).
Alternatively, the battery enclosure 128 could be divided up differently, and into even more than two separate battery enclosure components. The separate battery enclosure components can be positioned on the chassis in the same configuration as described for a single battery enclosure (i.e. in the same position as the embodiment shown in the Figures), or the different individual battery enclosure components could be positioned differently in relation to the rear tunnel 130 and front brace structure 132 of the chassis 122. In one example, the front portion 202 may be positioned in a mid-bay region in horizontal alignment with the rear tunnel and the motor is positioned above the front portion of the battery enclosure.
The separate battery enclosure components may be unconnected when installed on an electric vehicle, or the separate battery enclosure components could be connected together with brackets, etc. The electric battery module(s) housed within the separate battery enclosure components would be electrically interconnected.

[0063] As described above, multiple battery enclosures may be used and operably connected together. The multiple battery enclosures may allow for a more optimal weight distribution. In one example, as batteries get smaller and more powerful it may be beneficial to locate the batteries in a number of enclosures to improve ergonomic design and performance of the electric vehicle.

[0064] In one example, the battery enclosure 128 may house only the electric battery modules (and possibly wiring/electronics and supporting structures for the battery modules) of the electric battery. In another example, the battery enclosure may house the electric battery as well as other components of the electric vehicle, such as battery management controllers, thermal management systems, motor assembly, etc.

[0065] Fig. 7 is a close-up view of section A of Fig. 6 showing the battery enclosure 128 front portion 202. The front portion 202 includes a top surface 300, a front surface 302, a first side surface 304, a second side surface 306, and a floor Date Recue/Date Received 2021-03-30 bottom surface 308. In one example, the front brace structure 132 is coupled to battery enclosure 128 at the top surface 300. In another example, the front brace structure 132 is coupled to the battery enclosure 128 at the front surface 302. In another example, the front brace structure 132 is coupled to the battery enclosure 128 at an edge 330 between the top surface 300 and the front surface 302. The front brace structure 132 may also be coupled to the battery enclosure 128 at the bottom surface 308.

[0066] In one example, front brace structure 132 is coupled to battery enclosure 128 at four connection points for transferring load to battery enclosure 128. Front brace structure 132 includes the first top brace 134 and the second top brace 136. First top brace 134 includes a first end 320 and a second end 322.
Second top brace 136 includes a first end 324 and a second end 326. First top brace 134 is connected to battery enclosure 128 at first end 320. In one example, the first end 320 of first top brace 134 is connected to both top surface 300 and front surface 302 at front edge 330 (at first connection location 332). Second top brace 136 is connected to battery enclosure 128 at first end 324. In one example, the first end 324 of second top brace 136 is connected to both top surface 300 and front side surface 302 at front edge 330 (at second connection location 334). In one example, first connection location 332 is spaced apart from second connection location along front edge 330, identified as top space 336.

[0067] Fig. 7A is an enlarged partial view of connection location 344, indicated at 321. Referring to Fig. 7A, second top brace 136 is connected to battery enclosure 128 at second end 322 through joint member 354 and mechanical linkage 325. In one example not shown, the second end 326 of top brace 132 is connected to bottom surface 308 at front bottom edge 340 (at connection location 344). Second top brace 136 is connected to battery enclosure 128 at second end 326 through joint member 354 and mechanical linkage 325. In one example, the second end 326 of second top brace 136 is connected to bottom surface 308 at front bottom edge 340 (at fourth connection location 344).
Date Recue/Date Received 2021-03-30

[0068] Referring back to Fig. 7, in one example, third connection location 342 is spaced apart from fourth connection location 346 along front bottom edge 344, identified as bottom space 346. In one example, bottom space 346 is wider than top space 336. In another example, top space 336 is wider than bottom space 346.

[0069] In one example, the front brace structure 132 includes cross brace structure 350. Cross brace 350 extends between first top brace 134 and second top brace 136. Cross brace 350 provides bracing between the first top brace 134 and the second top brace 136 at second end 322 and second end 326. In one example, cross brace 350 is connected to second end 322 at joint member 352. Cross brace 350 is connected to second end 326 at joint member 354.

[0070] As explained above, the front portion 202 of the battery enclosure 128 is coupled to the front brace structure 132. In the example shown in Fig. 7, the first top brace 134 and the second top brace 136 of the front brace structure 132 are connected to front portion 202 of the battery enclosure 128. More specifically, in the example shown, the four connection points 332,334,342,344 provide a secure and rigid connection between the front brace structure 132 and battery enclosure 128.
This provides for the transferring of loads between suspension system 126 and the battery pack 124. It is recognized that other design configurations and connections may exist between the front brace structure 132 and battery enclosure 128, in order for the battery enclosure 128 to be connected to and receive loads from suspension system 126. In one example, there are fewer than four connection points between front brace structure 132 and battery enclosure 128. In one example, there are more than four connection points between the front brace structure 132 and battery enclosure 128. The connection points may be fixed or removable. The structure of the front brace structure 132 may take on many different forms and remain within the scope of the present disclosure.

[0071] In one example, loads or forces imparted by the steering system 150, and more specifically by the steering column 152 of the electric vehicle are received by the battery enclosure 128 of the battery pack 124. These loads are partially Date Recue/Date Received 2021-03-30 absorbed by the battery enclosure 128 and/or transferred to the vehicle's center of mass and/or chassis 122 through the battery pack 124.

[0072] In one example shown in Fig. 11 steering system 150 comprises a steering mount 430 that includes a first side mount 452 and a second side mount 454 attached to the front portion 202 of the battery enclosure 128. Member 424 extends between first side mount 452 and second side mount 454, and operates to hold the steering column 152 to the battery enclosure 128. Member 424 also allows steering column 152 to rotate 162 during operation of the steering system 150.

[0073] In one example, member 424 includes a pipe member having an axis aligned with an axis of the steering column 152. In operation, the steering column 152 passes through the pipe member and is supported by the pipe member.

[0074] As the operator of the snowmobile 120 steers and maneuvers the vehicle, loads are transferred from the steering column 152 to steering mount 430, which in turn transfers loads from the steering column 152 to the battery pack 124, and specifically the battery enclosure 128. The battery enclosure 128 may absorb some of those loads and/or transfer the loads from the steering column 152 to the vehicle's center of mass and/or the chassis 130.

[0075] Fig. 12 is a partial side view of a snowmobile 500, according to one example of the present disclosure. Snowmobile 500 is similar to the snowmobile 120 previously detailed herein. Snowmobile 500 includes battery pack 124 having battery enclosure 128. Battery pack 124 provides structural support for the snowmobile 500 seating, which may comprise one or both of a snowmobile seat and backrest 512. In one example, the snowmobile seat 510 and backrest 512 are mounted directly to the battery pack enclosure 128. The snowmobile seat 510 is a straddle seat that is straddled by the rider.

[0076] The battery enclosure 128 includes tunnel portion 200 and front portion 202. Tunnel portion 200 includes a tunnel portion front end 506 and a tunnel portion back end 508. The tunnel portion 200 is located over and secured to the chassis rear tunnel 130. The front portion 202 is located near the front of the snowmobile 500, at the tunnel portion front end 506.
Date Recue/Date Received 2021-03-30

[0077] Snowmobile 500 includes a seat 510 and a backrest 512. The seat 510 is connected to the tunnel portion 200 of the battery enclosure 128, and extends from the front portion 202 at the tunnel portion front end 506 to the tunnel portion back end 508. Battery enclosure 128 is a structural element of the snowmobile that supports seat 510 and optionally backrest 512. Further, the battery enclosure tunnel portion 200 receives loads transmitted from the seat 510 and partially absorbs and/or transfers those loads to the vehicle's center of mass and/or chassis 130 due to one or more riders positioned on the seat 510 or the result of operation of the snowmobile over various snow terrain.

[0078] Snowmobile 500 further includes the seat backrest 512. The seat backrest 512 is supported by battery enclosure 128 tunnel portion 200. In one example, the seat backrest 512 is mounted directly to battery enclosure 128 at the tunnel portion back end 508. Seat back rest 512 includes a cushion 522 and bracket 524. Bracket 524 is generally L shaped, including a generally vertical first leg 526 and a generally horizontal second leg 528. Cushion 522 is attached to the first leg 526. Second leg 528 is attached to tunnel portion 200. Seat 510 may extend rearward beyond a top surface of the battery enclosure tunnel portion 200 and be supported by second leg 528. Seat loads (e.g., by a rider during operation of the snowmobile) are received by the battery pack 124, and specifically the battery enclosure 128, via connection points between the seat 510 and the battery pack 124.
Additionally, seat loads are transferred during use from seat backrest 512 to battery pack 124 at locations where the seat backrest 512 is connected to battery pack 124.

[0079] In one example, seat 510 is fastened at four places onto battery pack 124. There may be two plastic hooks (not shown) on the top surface of the rear tunnel portion of the battery enclosure 128 that mate with corresponding slots located on the bottom of the seat (i.e., the seat pan). Additionally, there may be two aluminum tabs on a fore portion of the seat pan (one on each side) that fasten the seat to the battery enclosure 128. In one example, the seat 510 is fastened to the battery pack 124 via the seat pan using screw holes with threaded inserts on the lid of the battery enclosure 128.
Date Recue/Date Received 2021-03-30

[0080] In one example, seat backrest 512 is fully supported by battery enclosure 128. Typical backrests are mounted directly to a snowmobile chassis.

With battery enclosure 128 being used to fully support seat backrest 512, additional storage area is available on the rear tunnel 130 for cargo or other utility use. In one example, backrest 512 is a separate component independently and directly attached to the battery pack 124. In another example, seat backrest 512 is at least partially part of or an extension of seat 510.

[0081] Loads imparted on the snowmobile seating (i.e. one or both of seat 510 and backrest 512), are received directly by the battery pack 124, and specifically the battery enclosure 128. The battery enclosure 128 may absorb some of those loads and/or transfer the loads from the seating to the vehicle's center of mass and/or the chassis 130.

[0082] Referring back to Fig. 5B, in operation, as the snowmobile 120, 500 is driven across a varied terrain, loads are transferred from the suspension system 126 (e.g. the first suspension leg 138 and the second suspension leg 140) through the front brace structure 132 (e.g. through the corresponding first top brace 134 and second top brace 136) to the battery enclosure 128. Likewise, loads are transferred from the seating (seat 510, backrest 512) and the steering system 150 to the battery enclosure 128. The battery enclosure 128 acts as a structural element, and after receiving the loads then transfers the loads through the body of the battery enclosure 128 to the vehicle's center of mass and /or the rear tunnel 130. In one or more examples described herein, loads are transferred to rear tunnel 130 since the center of mass of the vehicle is located at the rear tunnel 130. As such, it is recognized that the loads are transferred to the center of mass located within the rear tunnel 130.

[0083] Fig. 5B illustrates one example of a load path of suspension system 126 of snowmobile 120 having a battery enclosure 128 that acts as a structural element. The load path is illustrated using arrows 220, 222, 224, 226 and 228.
In one example, as the snowmobile 120 moves over a given terrain or snow profile, load is transferred from suspension system 126 (via first suspension leg 138 and second suspension leg 140) to front brace structure 132 (via first top brace 134 and Date Recue/Date Received 2021-03-30 second top brace 136); load is then transferred from front brace structure 132 (via first top brace structure 134 and second top brace structure 136) to battery enclosure 128 (e.g. to the front surface 302 of the battery enclosure 128); and the load is then transferred, at least partially, from battery enclosure 128 (via front portion 202 and tunnel portion 200) to chassis 122 including rear tunnel 130.

[0084] Reference is now made to Fig. 8. Fig 8 is a front view of the battery enclosure 128 and chassis 122 of snowmobile 120. In one example, the battery enclosure 128 front portion 202 may define a slot 162. Slot 162 extends downward from top surface 300 of the battery enclosure for receiving the steering column 152 of the snowmobile 120. Battery enclosures 128 that do not include a slot 162 are also included within the scope of the present application.

[0085] Traditional electric powersport vehicles, such as combustion engine snowmobiles, often have curved steering columns and/or complex linkages connecting the steering column to their steering assembly. This is a result of the steering column having to avoid interference with the combustion engine, which is typically housed in the front portion of the snowmobile. The slot 162 defined within the battery enclosure 128 enables the electric vehicle to use a linear, substantially straight, steering column 152 and a relatively uncomplex connection between the steering column 152 and the steering assembly 156.

[0086] In one example, slot 162 extends from the top surface 300 of battery enclosure 128 to a front surface 302 of the battery enclosure 128. In another example, the slot 162 extends downwards from the top surface 300 of the battery enclosure 128 to a bottom surface 308 of the battery enclosure 128.

[0087] In one example, slot 162 is generally geometrically shaped. For example, the slot 162 can be partially circular, oval or square shaped in cross-section. In other examples, the slot 162 is not geometrically shaped. Slot 162 has an open side along its length. In other embodiments, slot 162 can be defined as a wholly or partially enclosed slot extending through the battery enclosure 128.
In one or more examples, the slot 162 may take on the form of a tunnel, pipe, or tubular member.
Date Recue/Date Received 2021-03-30

[0088] Reference is also made to Fig. 9. Fig. 9 is a partial cross-sectional view of slot 162. In one example, the slot is generally U-shaped in cross-section.
The slot 162 is defined by a first side wall 400, a second side wall 402, and a bottom surface 404. In one example, the bottom surface has an angle along its length that generally matches an angle of the steering column. In reference to Fig. 10, in another example the bottom surface 404 of the slot 162 extends at an angle of between 30 degrees and 60 degrees with respect to a substantially horizontal longitudinal axis of the electric snowmobile, indicated at 410. In one example, the substantially horizontal longitudinal axis of the electric snowmobile is defined by a top surface of rear tunnel 130.

[0089] A width 412 of slot 162 is defined by the distance between the first sidewall 400 and the second sidewall 402. In one example, the width of slot 162 is between 30 millimeters and 60 millimeters. The width of slot 162 may vary along its length. In one example, the width of slot 162 is wider at a top end of the slot 162 than at a bottom end of slot 162. In another example, the width of slot 162 is substantially constant along its length with first sidewall 400 being substantially parallel to second sidewall 402.

[0090] Referring back to Fig. 8, in one example, slot 162 divides front portion 202 of battery enclosure 128 into two sides, defined as a front portion first side 420 and a front portion second side 422. In one example, the slot 162 is positioned substantially centrally with respect to first side surface 304 and second side surface 306, such that the slot 162 divides the front portion 202 of the battery enclosure into two halves. Alternatively, the slot 162 may not be positioned centrally such that the front portion first side 420 and front portion second side 422 are of different sizes. In operation, the front portion first side 420 and the front portion second side 422 each house one or more electric battery modules. In one example, the front portion first side 420 and the front portion second side 422 each house a stack of battery modules. In other examples, at least one of the front portion first side 420 and the front portion second side 422 contain or house something other than a battery module.
Date Recue/Date Received 2021-03-30

[0091] As described above, slot 162 is configured such that a substantially straight steering column 152 passes through the slot 162. Steering system 150 includes the steering mount 430 that operably couples the steering column 152 to the battery enclosure 128. The first side mount 452 is attached on the front portion first side 420 at a top end of slot 162 and the second side mount 4545 is attached on the front portion second side 422 on an opposite side of the slot 162 from the first side mount 452. Steering mount 430 allows steering column 152 to operate within slot 162 while providing structural support to the steering column within steering system 150. For example, steering mount 430 may provide support and structural stiffness to the steering column 162. Steering mount 430 is coupled to battery enclosure 128 at a position that enables the steering column 152 to be received within slot 162. The steering mount 430 provides a structural stiffness to the snowmobile handlebars, and in turn, an improved experience to a snowmobile operator.

[0092] Fig. 13 is a partial side view of battery pack 124 positioned on snowmobile chassis 122, according to one example of the present disclosure. An electric battery is housed within the battery enclosure 128 of the battery pack 124.
The electric battery comprises multiple electric battery modules. Both tunnel portion 200 and front portion 202 of battery enclosure 128 contain battery modules to power snowmobile 120.

[0093] Fig. 13 is a partial side view of a snowmobile 600, according to one example of the present disclosure. Snowmobile 600 is similar to the snowmobile 120 and snowmobile 500 previously detailed herein. Snowmobile 600 illustrates one example of the relative locations of battery pack 124 and an electric motor assembly 610 on the snowmobile chassis 122. By optimizing the locations of battery pack and electric motor assembly 610, the location of center of gravity 612 can be optimized. This provides for a better snowmobile ride experience and better snowmobile performance. Too much weight forward can result in poor snowmobile traction and acceleration. Too much weight backward and there can be a loss of Date Recue/Date Received 2021-03-30 snowmobile steering and control. As such, it is desirable to locate the center of gravity and weight distribution to optimize both snowmobile control and performance.

[0094] Snowmobile 600 includes rear chassis 122 having rear tunnel 130.
The battery enclosure 128 is mounted to the rear tunnel 130. The electric motor assembly 610 is mounted below the battery enclosure 128 and adjacent a front side 620 of the rear tunnel 130. The chassis 122 further defines a mid-bay 630. The mid-bay 630 is located between the rear tunnel 130 and front brace structure 132.
In some embodiments, the mid-bay 630 may form part of the front brace structure 132.
In one example, the electric motor assembly 610 is positioned within the mid-bay 630. Electric motor assembly 610 includes a drive shaft operably aligned with the snowmobile drive transmission 640. In one example the system is a belt drive system. As such, it is efficient to have the motor assembly 610 located within the mid-bay 630 in the lower front area of chassis 122. In this configuration, the motor assembly 610 and drive transmission 640 are efficiently mounted right next to each other on the snowmobile chassis 122.

[0095] One example of the position of electric motor assembly 610 within mid-bay 630 is described in further detail later in this specification.

[0096] Battery pack 124 includes a tunnel battery pack 710 and a mid-bay battery pack 712. Each battery pack 710 and 712 includes a plurality of battery modules 714. Battery modules 714 are one of the heaviest design elements of snowmobile 600. The location of battery pack 710 and 712 and therefore distribution of the battery modules 714 over the chassis 122 aids in desired weight distribution across snowmobile 600. Tunnel battery pack 710 is located above rear tunnel (and below the snowmobile seat). Mid-bay battery pack 712 is located above the front end of rear tunnel 130 within mid-bay 630 and above electric motor assembly 610. This may provide a shifted and improved center of gravity 612, resulting in a snowmobile with improved weight distribution and balance, and overall snowmobile performance.

[0097] Battery pack 124 includes battery enclosure 128 having a lid or cover and floor. The battery cover operates primarily to protect the battery modules and Date Recue/Date Received 2021-03-30 as a structural element to transfer loads from the suspension system 126 to the snowmobile chassis 122. The battery pack floor primarily operates to support the battery modules 714 within the battery pack 124.

[0098] Figs. 14-17 illustrate one example of battery pack 124, including battery modules 714. For ease of illustration, the battery pack 124 is shown with the battery enclosure lid removed for a view of the internal structure of the battery pack 124.

[0099] Fig. 14 is a front perspective view of battery modules that make up an electric battery within battery pack 124, according to one example of this disclosure.
Battery pack 124 includes battery enclosure 128 that houses battery modules 714.
The battery enclosure 128 includes a battery pack cover or lid 716 (shown removed) and a battery pack support floor 718. The battery pack support floor holds and supports battery modules 714. Further, battery modules 714 are securely retained within battery pack 124 by battery support structure 720.

[00100] Battery pack 124 comprises a plurality of battery stacks 740, where each stack is retained within a cartridge assembly. Each battery stack 740 is made up of two or more battery modules and retained within a cartridge assembly 742. In one example, tunnel battery pack 710 is made up of four battery stacks 744.
Each battery stack 744 includes two battery modules 714 stacked together within a cartridge assembly. As such, tunnel battery stack 710 includes eight total battery modules. The battery stacks 744 are positioned on battery pack support floor 718.
Battery support structure 720 aids in maintaining each battery stack 744 in a desired location on support floor 718. Battery support structure operates to maintain a desired spacing between individual battery stacks 740, and also maintain spacing between the battery stacks 740 and the battery enclosure.

[00101] In one example, mid-bay battery pack 712 is made up of two battery stacks 748. Each battery stack 748 includes three battery modules 714 stacked together within a cartridge assembly. As such, mid-bay battery stack 712 includes six total battery modules. The battery stacks 748 are positioned on battery pack support floor 718. Battery support structure 720 aids in maintaining each battery stack 748 in a desired location on support floor 718. Battery support structure 720 Date Recue/Date Received 2021-03-30 operates to maintain a desired spacing between individual battery stacks 748, and also maintain spacing between the battery stacks 748 and the battery enclosure 128.
In one example, the battery support structure is part of the battery enclosure 128. In one example, the spacing between battery stacks 748 located within mid-bay battery pack 712 is also dependent on the space requirements for slot 162 to accommodate the snowmobile steering column.

[00102] In one example, the battery support structure 720 is made of a rigid material, such as a rigid polymeric material. In one example, individual members of battery support structure 720 are generally tubular shaped members.

[00103] In one example, each battery module is generally rectangular shaped.
The battery modules 714 within battery stacks 744 are orientated in a direction different than the battery modules 714 positioned within battery stacks 744.
In one example, the battery modules 714 within battery stack 744 are orientated perpendicular to an orientation of the battery modules 714 contained within battery stacks 748. In other embodiments, all of the battery modules 714 are oriented in the same direction.

[00104] Fig. 15 is a top view of the battery modules within battery pack 124 of Fig. 14, further illustrating the battery support structure 720, and battery stacks 740.
Fig. 16 is a side view of the battery pack 124 further illustrating tunnel battery pack 710 and mid-bay battery pack 712. Fig. 17 is a front end view of the battery pack 124, further illustrating the mid-bay battery stack 748.

[00105] Each battery module contained within battery pack 124 is made of one or more battery cells. In one example the battery modules are lightweight 'pouch"
battery modules. Each battery module includes two or more battery cells. The battery cells are prismatic battery cells. In one example, the prismatic battery cells are lithium-ion prismatic battery cells. One or more examples of a battery stack, a battery cartridge, battery module and battery cooling panel assembly, including pouch battery modules and pouch battery cells, suitable for use in the present electric vehicle are disclosed in U.S. Patent Application No. 17/091,777 titled Battery Cooling Date Recue/Date Received 2021-03-30 Panel for Electric Vehicles filed November 6, 2020, the entire contents of which are incorporated herein by reference.

[00106] Figs. 18 ¨ 22 illustrate one example of an electric motor assembly 610.
The electric motor assembly 610 is mounted below the battery enclosure 128 and adjacent to a front side 620 of rear tunnel 130. The snowmobile chassis 122 includes the rear tunnel 130. The chassis 122 includes a mid-bay and the front brace structure, the mid-bay being located between the rear tunnel 130 and the front brace structure 132. The electric motor assembly 610 is positioned within the mid-bay.

[00107] Fig. 18 is a partial perspective view of electric motor assembly 610 positioned within a snowmobile. Electric motor assembly 610 is shown coupled to drive transmission 800. In one example, electric motor assembly 610 is coupled to drive transmission 800 via belt drive system 810. The electric motor assembly is positioned in front of rear tunnel 130. The motor assembly is oriented generally horizontally relative to the longitudinally extending rear tunnel 130. Fig. 19 further illustrates the position of electric motor assembly 610. A transmission plate 812 is positioned between the belt drive system 810 and motor assembly 610. In one example, transmission plate 812 is positioned substantially parallel to a first side edge 814 of rear tunnel 130. The transmission plate 812 includes a first end and a second end 822. The transmission plate 812 is attached at first end 820 to the first side edge 814 of rear tunnel 130, and at second end 822 to a component of the front brace structure 132. Additionally, the transmission plate 812 is attached to a front plate 824 of motor assembly 610.

[00108] In one example, the transmission plate 812 is supported at one end by attachment to the rear tunnel 130 of the chassis 122 and at the other end is connected (e.g., via the three bolt holes shown in Figure 19) at connection points 813 to the front brace structure 132. This provides a rigid support for the motor and improved handling of transmission loads from the belt. It also allows for a lighter transmission plate since the transmission plate 812 is supported at both ends.
An additional plate (not shown) covers the U-shaped opening or slot once the motor Date Recue/Date Received 2021-03-30 assembly 610 is positioned within the snowmobile 120 that aids in managing torque loads from the motor.

[00109] Reference is additionally made to Fig. 20. In one example, the electric motor assembly 610 is mounted proximate to the drive transmission 800 by the transmission plate 812. The electric motor assembly 610 includes a motor drive shaft 830. The drive transmission includes a transmission drive shaft 832. The motor drive shaft 830 and the transmission drive shaft 832 extend parallel to each other. The motor drive shaft 830 is operably coupled to the transmission drive shaft 832 via the belt drive system 810.

[00110] Transmission plate 812 includes a U-shaped opening that extends downwards from a top side of the transmission plate 812. The electric motor assembly 610 drive shaft 830 extends through the U-shaped opening. In one example, the electric motor assembly 610 is attached to both sides of the U-shaped opening at an interior of the transmission plate such that the motor drive shaft 830 extends through the U-shaped opening from an interior to an exterior of the U-shaped opening.

[00111] In one example, the electric motor includes an electric motor drive gear and the transmission includes a transmission gear, and wherein a drive belt 810 is connected between the electric motor drive gear and the transmission gear such that an angle of a top portion of the drive belt between the electric motor drive gear and the transmission gear with respect to a substantially horizontal longitudinal axis of the snowmobile is equal to or less that 20% and equal to or greater than -20%.
A
drive belt idler pulley contacts a bottom surface of the bottom portion of the drive belt, and the top portion of the drive belt is connected directly between the electric motor drive gear and the transmission gear.

[00112] Fig. 21 and Fig. 22 further illustrate electric motor assembly 610.
Electric motor assembly 610 is shown positioned immediately adjacent the front side 620 of rear tunnel 130. In the embodiment shown, the electric motor assembly does not extend the entire width of the rear tunnel 130. As such, the electric motor 850 remains substantially unsupported, or supported by sheet metal with minimal Date Recue/Date Received 2021-03-30 structural support, at the end opposite from the motor drive shaft 830. The electric motor assembly 610 incudes a motor 850 coupled to an inverter 852. The inverter 852 is directly coupled to the motor 850, and contained within a common housing 854. The electric motor assembly 610 having the inverter 852 integrated into the same housing provides for efficient locating of the motor assembly 610 in the chassis mid-bay in front of the rear tunnel 130. One motor assembly including a motor coupled to an inverter, suitable for use in the present electric vehicle, is disclosed in U.S. Patent Application No. 63/135,466 (Attorney Docket No.
T1670.109.101/TPA013), titled DRIVE UNIT FOR ELECTRIC VEHICLE, filed January 8, 2021, the entire contents of which are incorporated herein by reference.

[00113]
Although specific examples have been illustrated and described herein, a variety of alternate and/or equivalent implementations may be substituted for the specific examples shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific examples discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.
Date Recue/Date Received 2021-03-30

Claims (42)

29

1. An electric vehicle comprising, an electric motor, a battery pack comprising:
one or more battery modules for providing power to the electric motor; and a battery enclosure housing the one or more battery modules, the battery enclosure being a structural element of the electric vehicle for receiving loads from at least two of a suspension system, a seat and a steering system of the electric vehicle.

2. The electric vehicle of claim 1, the battery enclosure transferring the loads received, at least partially, to a center of mass of the electric vehicle.

3. The electric vehicle of any one of claims 1 or 2, the battery enclosure transferring the loads received, at least partially, to a chassis of the electric vehicle.

4. The electric vehicle of any one of claims 1 to 3, wherein the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from a front suspension of the electric vehicle.

5. The electric vehicle of any one of claims 1 to 3, wherein the battery enclosure defines a front portion and a rear portion, the front portion receiving loads from the steering system and the rear portion receiving loads from the seat.

6. The electric vehicle of any one of claims 4 or 5, wherein the electric vehicle comprises a chassis defining a tunnel portion and a front brace structure, the tunnel portion connected to the rear portion of the battery enclosure and the front brace structure connected to the front portion of the battery enclosure.
Date Recue/Date Received 2021-03-30

7. The electric vehicle of any one of claims 1 to 6, wherein the electric vehicle is a snowmobile.

8. A battery enclosure for an electric vehicle, the battery enclosure being a structural element of the electric vehicle and comprising:
a rear portion adapted for connection to a rear portion of a chassis of the electric vehicle, the rear portion of the battery enclosure configured to receive loads from a seat of the electric vehicle; and a front portion adapted for connection to a front portion of the chassis of the electric vehicle, the front portion of the battery enclosure configured to receive loads from a front suspension of the electric vehicle.

9. The battery enclosure of claim 8, wherein the battery enclosure is configured to transfer loads received from the seat and the front suspension, at least partially, to a center of mass of the electric vehicle.

10. The battery enclosure of one of claims 8 or 9, wherein the battery enclosure is configured to transfer loads received from the seat and the front suspension, at least partially, to a chassis of the electric vehicle.

11. The battery enclosure of claim 9, the front portion further adapted for receiving loads from a steering system of the electric vehicle and transferring those loads, at least partially, to a center of mass of the electric vehicle.

12. The battery enclosure of any one of claims 8 toll , wherein the electric vehicle is a snowmobile.

13. The battery enclosure of claim 12, wherein the rear portion of the battery enclosure is adapted for connection to a tunnel of the snowmobile, and the front portion of the battery enclosure is adapted for connection to a front brace structure of the snowmobile.
Date Recue/Date Received 2021-03-30

14. A snowmobile comprising:
a chassis that comprises:
a rear tunnel; and a front brace structure adapted to receive loads from a front suspension system of the snowmobile;
a battery enclosure defining a tunnel portion and a front portion, the tunnel portion being connected to the rear tunnel of the chassis and the front portion being connected to the front brace structure of the chassis;
wherein the battery enclosure receives loads from the front suspension system of the snowmobile through the front brace structure and transfers the loads from the front suspension system to at least one of the rear tunnel and a center of mass of the electric vehicle through a body of the battery enclosure.

15. The snowmobile of claim 14, wherein the battery enclosure is further connected to the front brace structure at a bottom surface.

16. The snowmobile of one of claims 14 or 15, wherein a steering mount is connected to the front portion of the battery enclosure for connection to a steering column, the steering mount transferring loads from the steering column into the body of the battery enclosure.

17. The snowmobile of any one of claims 14 to 16, further comprising a seat connected to the tunnel portion of the battery enclosure, wherein loads from the seat are received by and transferred into the body of the battery enclosure.

18. The snowmobile of any one of claims 14 to 17, wherein the front portion of the battery enclosure defines a first height and the tunnel portion of the battery enclosure defines a second height, the first height being greater than the second height.
Date Recue/Date Received 2021-03-30

19. The snowmobile of any one of claims 14 to 18, wherein the front portion of the battery enclosure defines a first width and the tunnel portion of the battery enclosure defines a second width, the first width being greater than the second width.

20. The snowmobile of any one of claims 14 to 19, wherein the front suspension system comprises at least one coil over spring and damper assembly.

21. The snowmobile of claim 20, wherein the at least one coil over spring and damper assembly is connected between a pair of skis and the front brace structu re.

22. The snowmobile of any one of claims 14 to 21,wherein the battery enclosure comprises a carbon fiber composite material.

23. The snowmobile of any one of claims 14 to 21, wherein the battery enclosure comprises an injection molded glass fiber reinforced plastic material.

24. The snowmobile of any one of claims 14 to 23, wherein the tunnel portion of the battery enclosure is connected to the rear tunnel of the chassis via two or more right side blocks and two or more left side blocks.

25. The snowmobile of any one of claims 14 to 24, wherein the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa.

26. The snowmobile of any one of claims 14 to 25, wherein the battery enclosure comprises a cover and a floor.
Date Recue/Date Received 2021-03-30

27. The snowmobile of any one of claims 14 to 26, further comprising an electric motor, wherein the battery enclosure houses at least two electric battery modules for supplying electricity to the electric motor.

28. The snowmobile of claim 27, wherein the at least two electric battery modules comprise one or more pouch battery cells.

29. A battery enclosure for an electric snowmobile, the battery enclosure comprising:
a tunnel portion adapted for connection to a rear tunnel of a snowmobile chassis;
a front portion adapted for connection to a front brace structure of the snowmobile chassis, wherein the battery enclosure is configured to receive loads from a front suspension system of the snowmobile through the front brace structure and transfers the loads from the front suspension system to at least one of the rear tunnel and a center of mass of the electric vehicle through a body of the battery enclosure.

30. The battery enclosure of claim 29, configured for connection to a steering column via a steering mount for receiving loads from the steering column into the body of the battery enclosure.

31. The battery enclosure of claim 29, configured for connection to a seat of the electric vehicle for receiving loads from the seat into the body of the battery enclosure.

32. The battery enclosure of any one of claims 29 to 31, wherein the front portion of the battery enclosure defines a first height and the tunnel portion of the battery enclosure defines a second height, the first height being greater than the second height.
Date Recue/Date Received 2021-03-30

33. The battery enclosure of any one of claims 29 to 32, wherein the front portion of the battery enclosure defines a first width and the tunnel portion of the battery enclosure defines a second width, the first width being greater than the second width.

34. The battery enclosure of any one of claims 29 to 33, wherein the battery enclosure comprises a carbon fiber composite material.

35. The battery enclosure of any one of claims 29 to 34, wherein the battery enclosure comprises an injection molded glass fiber reinforced plastic material.

36. The battery enclosure of any one of claims 29 to 35, wherein the battery enclosure has a stiffness that is within a range that is equal to or greater than 10 gigapascal (Gpa) and equal to or less than 70 Gpa.

37. The battery enclosure of any one of claims 29 to 36, wherein the battery enclosure comprises a cover and a floor.

38. A straddle-seat electric vehicle, comprising;
a chassis including a suspension system; and a battery pack configured as a structural element that receives loads from the suspension system.

39. The straddle-seat electric vehicle of claim 38, the battery pack comprising a battery enclosure coupled to the suspension system for transferring, at least partially, loads from the suspension system through a body of the battery enclosure to the chassis.

40. The straddle-seat electric vehicle of claim 38, comprising a brace structure that transfers loads between the suspension system and the battery enclosure.
Date Recue/Date Received 2021-03-30

41. The straddle-seat electric vehicle of claim 38, further comprising a straddle seat, the straddle seat being mounted directly to the battery pack.

42. The straddle-seat electric vehicle of claim 39, wherein the straddle-seat vehicle is a snowmobile.
Date Recue/Date Received 2021-03-30