GB2561363A

GB2561363A - Battery unit for mounting into chassis for providing increased torsional strength

Info

Publication number: GB2561363A
Application number: GB1705779.5A
Authority: GB
Inventors: lam Albert
Original assignee: Detroit Electric EV Technologies Zhejiang Ltd
Current assignee: Detroit Electric EV Technologies Zhejiang Ltd
Priority date: 2017-04-10
Filing date: 2017-04-10
Publication date: 2018-10-17
Anticipated expiration: 2037-04-10
Also published as: GB201705779D0; WO2018189675A3; GB2561363B; WO2018189675A2

Abstract

A battery unit 800 for mounting into an electrical vehicle chassis. The battery unit has an outer casing, a battery mounting frame that is arranged to be accommodated within the outer casing, and a plurality of battery modules that are arranged to be supported upon the battery mounting frame. The battery unit is mountable onto a bulkhead 202 of the chassis of the electrical vehicle to provide increased torsional strength with respect to an elongate axis of the electrical vehicle. The battery mounting frame may have a bottom support panel, a plurality of partitioning plates coupled to the bottom panel, and at least one transverse load-bearing plate orthogonal to the partitioning plates. The mounting frame may also have mounting rods supporting the battery modules. The battery unit may also have a cooling arrangement. The battery unit may be mounted in a cavity in the bulkhead, and the outer casing may be made from one of the following materials: aluminium, stainless steel, magnesium, ceramic, carbon fibre, or glass fibre. Also disclosed is a method of providing an increased torsional strength to a chassis by providing the abovementioned battery unit and mounting it in a cavity formed with the bulkhead.

Description

(54) Title of the Invention: Battery unit for mounting into chassis for providing increased torsional strength Abstract Title: A battery unit which provides torsional strength for an electrical vehicle chassis (57) A battery unit 800 for mounting into an electrical vehicle chassis. The battery unit has an outer casing, a battery mounting frame that is arranged to be accommodated within the outer casing, and a plurality of battery modules that are arranged to be supported upon the battery mounting frame. The battery unit is mountable onto a bulkhead 202 of the chassis of the electrical vehicle to provide increased torsional strength with respect to an elongate axis of the electrical vehicle. The battery mounting frame may have a bottom support panel, a plurality of partitioning plates coupled to the bottom panel, and at least one transverse load-bearing plate orthogonal to the partitioning plates.

The mounting frame may also have mounting rods supporting the battery modules. The battery unit may also have a cooling arrangement. The battery unit may be mounted in a cavity in the bulkhead, and the outer casing may be made from one of the following materials: aluminium, stainless steel, magnesium, ceramic, carbon fibre, or glass fibre. Also disclosed is a method of providing an increased torsional strength to a chassis by providing the abovementioned battery unit and mounting it in a cavity formed with the bulkhead.

800

FIG. 8

1/5

P/G. ₁

2/5

300

306

FIG. 3

350

360

FIG. 4

3/5

400

FIG. 6

4/5

350

FIG. 7

FIG. 8

5/5

900 /

FIG. 9

BATTERY UNIT FOR MOUNTING INTO CHASSIS FOR PROVIDING INCREASED TORSIONAL STRENGTH

TECHNICAL FIELD

The present disclosure relates generally to battery units, and more specifically, to increasing torsional strength of a chassis of a vehicle by mounting a battery unit onto the chassis of the vehicle. Moreover, the present disclosure concerns methods of strengthening chassis of vehicles by mounting battery units therein.

BACKGROUND

Generally, high performance vehicles such as sports cars, supercars and hypercars are required to be lightweight to increase their top speed, their acceleration performance, their fuel efficiency and so forth. Conventionally, a reduction in weight of a given vehicle is achieved by using lightweight materials such as carbon fiber and aluminum for production of the given vehicle, and by making modifications to design of the given vehicle (such as modifications to a chassis of the given vehicle) by removal of extra material and/or omission of inessential components therefrom, and so forth. However, modifications to the design of the given vehicle may have adverse effects. For example, a modification to a chassis of a vehicle may result in the vehicle exhibiting a reduced rigidity or stiffness (such as torsional strength) of the chassis of the vehicle, and may further result in the vehicle having a weakened structure.

Usually, chasses of high performance vehicles such as sports cars are required to meet minimum torsional strength requirements to ensure safety of passengers of the vehicle, as well as for providing an acceptably comfortable driving experience when the high performance vehicles are driven in operation. However, failure to meet such requirements may cause various problems, for example, the vehicle may be deemed unfit for driving by regulatory authorities. Furthermore, a chassis with reduced torsional strength may induce flex that may lead to reduction in effectiveness of the vehicle's suspension. Such reduction in effectiveness of the vehicle's suspension may adversely affect factors related to control of the vehicle, such as steering response and/or cornering ability. It may be evident that an adverse affect to control of the vehicle may lead to an unfavorable driving experience, as aforementioned. Additionally, weakness of the chassis of the vehicle may lead to fatigue therein and ultimately, breakdown of the vehicle through crack formation as a result of work-hardening of metallic components.

Therefore, there exists a need to maintain required torsional strength of the chassis of the vehicle subsequent to modification of the chassis.

SUMMARY

The present disclosure seeks to provide a battery unit for mounting into a chassis of an electrical vehicle, wherein the battery unit is operable to increase a torsional strength of the electrical vehicle.

The present disclosure also seeks to provide a method for providing increased torsional strength to a chassis of an electrical vehicle.

According to a first aspect, there is provided a battery unit for mounting into a chassis of an electrical vehicle, characterized in that the battery unit comprises:

(i) an outer casing;

(ii) a battery mounting frame that is arranged to be accommodated within the outer casing; and (iii) a plurality of battery modules that are arranged to be supported upon the battery mounting frame;

wherein the battery unit is mountable onto a bulkhead of the chassis of the electrical vehicle to provide an increased torsional strength with respect to an elongated axis of the electrical vehicle.

The present disclosure seeks to counteract a reduction in torsional strength of a chassis of a vehicle due to modification of the chassis.

According to a second aspect, there is provided a method of providing increased torsional strength to a chassis of an electrical vehicle, the method comprising:

(a) providing a battery unit (800), the battery unit comprising:

an outer casing;

a battery mounting frame that is arranged to be accommodated within the outer casing; and a plurality of battery modules that are arranged to be supported upon the battery mounting frame;

(b) forming a cavity in the bulkhead of the chassis; and (c) mounting at least a portion of the battery unit into the cavity in the bulkhead of the chassis.

It will be appreciated that features of the invention are susceptible to being combined in various combinations without departing from the scope of the invention as defined by the appended claims.

The present invention is included in the general business context, which aims to substitute vehicles powered by traditional fuels, for example gasoline or diesel, by electric vehicles. In particular, the present invention is intended for use in electric vehicles used within cities, which can be highly beneficial to the local environment due to significant reduction of gaseous emissions as well as significant reduction of noise. Overall environmental benefits can also be significant when electric vehicles are charged from renewable energy sources.

DESCRIPTION OF THE DIAGRAMS

Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

FIG. 1 is a perspective view of an internal combustion engine vehicle chassis of conventional design;

FIG. 2 is a perspective view of a modified internal combustion engine vehicle chassis, in accordance with an embodiment of the present disclosure;

FIG. 3 is a perspective view of an outer casing, in accordance with an embodiment of the present disclosure;

FIG. 4 is a perspective view of a battery mounting frame, in accordance with an embodiment of the present disclosure;

FIG. 5 is a perspective view of a battery module, in accordance with an embodiment of the present disclosure;

FIG. 6 is a perspective view of an arrangement of the plurality of battery modules to be supported upon the battery mounting frame, in accordance with an embodiment of the present disclosure;

FIG. 7 is a perspective view of a battery mounting frame (such as the battery mounting frame of FIG. 4) with the left and right partitioning plates removed, in accordance with an embodiment of the present disclosure;

FIG. 8 is a perspective view of a battery unit mounted onto the bulkhead of the chassis of the vehicle, in accordance with an embodiment of the present disclosure; and

FIG. 9 is an illustration of steps of a method for providing increased torsional strength to a chassis of an electrical vehicle, in accordance with an embodiment of the present disclosure.

In the accompanying diagrams, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.

DESCRIPTION OF EMBODIMENTS

In overview, embodiments of the present disclosure are concerned with an arrangement for mounting a battery unit onto a chassis of a vehicle without compromising a torsional strength of the chassis.

Referring to FIG. 1, there is shown a perspective view of an internal combustion engine vehicle chassis 100 of conventional design. As shown, the chassis 100 includes a transverse member 102 that provides upper protection for a combustion fuel tank (not shown) of the internal combustion engine vehicle chassis 100; moreover, the transverse member 102 forms a component of the chassis 100, and also imparts torsional stiffness to the chassis 100.

Referring next to FIG. 2, there is shown a perspective view of a modified internal combustion engine vehicle chassis 200 (such as the chassis obtained after modification of internal combustion engine vehicle chassis 100 of FIG. 1), in accordance with an embodiment of the present disclosure. As shown, the modified vehicle chassis 200 is obtained by removing an upper portion of the traverse member 102 of the internal combustion engine vehicle chassis 100, for example, by grinding; alternatively, the chassis 200 is achieved by changing a design of the transverse member 102 during manufacture. The modified transverse member forms a bulkhead 202 and comprises a cavity 204. It will be appreciated that removing the upper portion of the traverse member 102 of the internal combustion engine vehicle chassis 100 may reduce torsional strength of the vehicle chassis. The bulkhead further comprises weight-bearing flanges 206A and 206B on a front portion and a rear portion of the bulkhead 202 that are added subsequent to removal of the upper portion of the transverse member 102, for example, by welding the weight bearing flanges 206A and 206B to the bulkhead 202.

Referring now to FIGs. 3 to 6, there are shown perspective views of a battery unit for mounting into a chassis of an electrical vehicle, and various components thereof, in accordance with an embodiment of the present disclosure. The battery unit comprises an outer casing 300. As shown, the outer casing 300 further comprises a substantially L-shaped main member 302 that forms a substantial part of the casing 300, a left member 304 and a right member 306; optionally, the left member 304 and the right member 306 are integral to the casing 300. It may be appreciated that the main member 302 is hollow and the left and right members 304, 306 are attached to the main member 302 to obtain the outer casing 300, for example, using fasteners (such as nuts and bolts or screws). In an embodiment, the top plate 308 of the outer casing 300 may be made of a heat-insulating material. In another embodiment, the outer casing is made of at least one of aluminum, stainless steel, magnesium, ceramic, carbon fiber, and/or glass fiber.

The battery unit further comprises a battery mounting frame 350 that is arranged to be accommodated within the outer casing 300. The battery mounting frame 350 further comprises a bottom support panel 352, a plurality of partitioning plates 354, 356, 358 coupled to the bottom support panel 352 and at least one transverse load-bearing plate 360 disposed substantially orthogonally to the plurality of partitioning plates 354, 356, 358. As shown, the plurality of partitioning plates comprise a left partitioning plate 354, a central partitioning plate 356 and a right partitioning plate 358. In an embodiment, the partitioning plates 354, 356, 358 are made of aluminum. Furthermore, the plurality of partitioning plates 354, 356, 358 are disposed so that their major planes are mutually substantially parallel, and the bottom support panel is adapted to be attached to, or rest onto, the bulkhead 202. In an embodiment, the plurality of partitioning plates 354, 356, 358 may have an angle in a range of -5° to +5° therebetween. In another embodiment, the transverse load-bearing plate 360 may be disposed within an angular range of 85° to 95° with respect to the plurality of partitioning plates 354, 356, 358. Furthermore, as shown the plurality of partitioning plates 354, 356, 358 each have substantially an L-shape. It may be evident that the shape of the plurality of partitioning plates 354, 356, 358 correspond to the shape of the outer casing 300 such that the frame 350 formed by the plurality of partitioning plates and the transverse loadbearing plate 360 may be accommodated into the outer casing 300. It may be appreciated that the plurality of partitioning plates 354, 356, 358 may have slightly smaller dimensions as compared to the outer casing 300 to be accommodated into the hollow cavity of the casing. Consequently, the battery unit formed by the outer casing 300 and the battery mounting frame 350 has substantially an L-shape and correspondingly, has a long arm and a short arm (corresponding to long and short arms of the letter L). In an embodiment, a vertex of the Lshape has an angle of more than 90° (namely, is an obtuse angle). Additionally, the left and right partitioning plates 354, 358 comprise a plurality of holes for receiving components of a cooling arrangement, described in greater detail below.

The battery unit further comprises a plurality of battery modules 400 that are arranged to be supported upon the battery mounting frame 350 (illustrated in FIG. 6). As shown, the plurality of battery modules 400 comprise holes 402 at a front region of the battery modules passing therethrough to the rear of the battery modules 400; the holes 402 are provided in corners of each battery cell of the battery modules 400. Further, each of the plurality of battery 400 modules comprises an elongate plate 404 for arrangement of the battery modules 400 onto the battery mounting frame 350. As shown, the elongate plate 404 comprises a C-notch therein for receiving a fastener (such as a nut and bolt) subsequent to arrangement of the battery module 400 on the battery mounting frame 350.

Referring to FIG. 6, there is shown a perspective view of the arrangement of the plurality of battery modules 400 to be supported upon the battery mounting frame 350, in accordance with an embodiment of the present disclosure. As shown, ten (10) battery modules 400 are supported onto the battery mounting frame 350, in two (2) sets of five (5) battery modules on each side of the central partitioning plate 356. Furthermore, eight (8) battery modules 400 are arranged in the long arm of the substantially L-shaped battery unit (in two (2) sets of four (4) battery modules on each side of the central partitioning plate 356) and two (2) battery modules are arranged in the short arm of the substantially Lshaped battery unit.

Referring to FIG. 7, there is shown a perspective view of a battery mounting frame (such as the battery mounting frame 350 of FIG. 4) with the left and right partitioning plates removed, in accordance with an embodiment of the present disclosure. As shown, the battery mounting frame 350 comprises a plurality of transverse mounting rods 370 that are mounted through the central partitioning plate 356 for supporting each of the plurality of battery modules 400. As shown by section under the transverse load-bearing plate 360, each battery module 400 is supported by a set of four mounting rods that are configured to align with the holes 402 of the battery module 400. During arrangement of the battery modules 400 upon the battery frame 350, the mounting rods 370 pass through the holes 402 and clamp to the left and right partitioning plates 354, 358. In an embodiment, the mounting rods 370 may comprise a threaded portion at the ends thereof and may be operable to receive a fastener (such as a nut) after passing through the battery module 400, and the left partitioning plate 354 or the right partitioning plate 358.

In operation, the plurality of battery modules 400 are held in place using the plurality of mounting rods 370 and are supported by the bottom support panel 352. Furthermore, the load-bearing plate 360 is operable to support a substantial load of the plurality of battery modules 400. Furthermore, grooves or recess regions 310 on the outer casing 300 (shown in FIG. 3) are operable to prevent movement of the plurality of battery modules from their location.

Referring to FIG. 8, there is shown a perspective view of a battery unit 800 mounted onto the bulkhead 202 of the chassis 200 of the electrical vehicle, in accordance with an embodiment of the present disclosure. The battery unit 800 is mountable onto the bulkhead 202 of the chassis 200 of the vehicle to provide an increased torsional strength with respect to an elongate axis 802 of the vehicle. For example, the elongate axis of the electrical vehicle may be an axis passing from a front region to a rear region of the electrical vehicle. As shown, the long arm of the substantially L-shaped battery unit is mounted into the cavity in the bulkhead 202 of the chassis 200 of the electrical vehicle. Furthermore, the short arm of the battery unit 800 may be attached to the chassis 200 of the electrical vehicle, for example, by bolting the outer casing 302 to the chassis 200. Additionally, the reduction in torsional strength with respect to the elongate axis of the electrical vehicle due to removal of the upper portion of the traverse member 102 is counteracted primarily by arrangement of the at least one transverse load-bearing plate 360 and the plurality of partitioning plates 354, 356, 358 in place of the removed upper portion the of the traverse member 102. Furthermore, an addition of the weight bearing flanges 206A, 206B, and an arrangement of the bottom support panel 352 along the bulkhead 202 enable further increase in the torsional strength of the chassis 200. Moreover, an arrangement of the battery modules 400 (on the mounting rods 370) and the outer casing 300 along the bulkhead 202 of the chassis 200 enables a further increase in the torsional strength of the chassis 200.

In an embodiment, the battery unit 800 further comprises a cooling arrangement for removing heat generated by the plurality of battery modules 400 when storing or providing electrical power in operation. The cooling arrangement comprises at least one cooling plate that is operable to be in contact with the plurality of battery modules 400, wherein the at least one cooling plate is arranged peripherally along a length of the battery modules 400. Furthermore, the at least one cooling plate comprises a hollow structure having an inlet and outlet for flow of coolant therethrough and the plurality of holes in the left and right partitioning plates 354, 358 are operable to accommodate inlet and outlet nozzles of the of cooling plates. In an embodiment, the cooling arrangement for each battery module 400 is implemented using at least one cooling plate that is strapped using a strapping arrangement to at least one peripheral side face of each battery module 400, and wherein the at least one cooling plate is maintained in position on the battery module 400 by using the strapping arrangement that encircles an elongate axis of the battery module 400.

Referring next to FIG. 9, there are shown steps of a method 900 of providing increased torsional strength to a chassis of an electrical vehicle, in accordance with an embodiment of the present disclosure. At a step 902 of the method, a battery unit is provided, the battery unit comprising an outer casing, a battery mounting frame that is arranged to be accommodated within the outer casing, and plurality of battery modules that are arranged to be supported upon the battery mounting frame. At a step 904 of the method, a cavity is formed in the bulkhead of the chassis. At a step 906 of the method, at least a portion of the battery unit is mounted into the cavity in the bulkhead of the chassis.

The steps 902 to 906 are only illustrative and other alternatives can also be provided wherein one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein. For example, the battery mounting frame comprises a bottom support panel, a plurality of partitioning plates coupled to the bottom support panel and at least one transverse load-bearing plate disposed substantially orthogonally to the plurality of partitioning plates, wherein the plurality of partitioning plates are disposed so that their major planes are mutually substantially parallel, and the bottom support panel is adapted to be attached to, or rest onto, the bulkhead. In another example, at least one of the plurality of partitioning plates has substantially an L-shape. In yet another example, a long arm of the substantially L-shaped plurality of partitioning plates is mounted into the cavity in the bulkhead of the chassis.

During assembly of the battery unit, the plurality of battery modules may be arranged on the plurality of mounting rods. Subsequently, the left and right partitioning plates may be clamped to the plurality of mounting rods to be arranged on the battery mounting frame. Furthermore, the battery mounting frame is arranged into the main member of outer casing and subsequently, the left member and a right member are attached to the main member to complete the battery unit.

It will be appreciated that mounting the battery unit onto the bulkhead of the chassis of the electrical vehicle enables counteracting the reduction in torsional strength of the vehicle chassis due to removal of the upper portion of the traverse member. Furthermore, the L-shaped battery unit enables arrangement of the plurality of battery modules in a compact manner, without raising a center of gravity of the electrical vehicle. Furthermore, arrangement of the battery unit between seats and a rear portion of the electrical vehicle allows replacement of a fuel tank in an internal combustion engine vehicle chassis of conventional design (such as the internal combustion engine vehicle chassis of FIG. 1) with the battery unit without requirement of additional modifications to the vehicle chassis.

Electrical vehicles of the present disclosure are capable of providing transport for users with a reduced amount of Carbon Dioxide being generated. Moreover, components parts of the electrical vehicles are susceptible to being recycled.

Modifications to embodiments of the invention described in the foregoing are possible without departing from the scope of the invention as defined by the accompanying claims. Expressions such as including, comprising, incorporating, consisting of, have, is used to describe and claim the present invention are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. Numerals included within parentheses in the accompanying claims are intended to assist understanding of the claims and should not be construed in any way to limit subject matter claimed by these claims.

Claims

1. A battery unit (800) for mounting into a chassis (200) of an electrical vehicle, characterized in that the battery unit (800) comprises:

(i) an outer casing (300);

(ii) a battery mounting frame (350) that is arranged to be accommodated within the outer casing (300); and (iii) a plurality of battery modules (400) that are arranged to be supported upon the battery mounting frame (350);

wherein the battery unit (800) is mountable onto a bulkhead (202) of the chassis (200) of the electrical vehicle to provide an increased torsional strength with respect to an elongate axis of the electrical vehicle.

2. A battery unit (800) of claim 1, characterized in that the battery unit (800) is adapted to be mountable onto the bulkhead (202), wherein the bulkhead (202) is provided in a modified design of an internal combustion engine vehicle chassis (200).

3. A battery unit (800) of claim 2, characterized in that the bulkhead (202) is generated by removing an upper portion of a transverse beam member (102) of the internal combustion engine vehicle chassis (100) that provides upper protection for a combustion fuel tank of the internal combustion engine vehicle chassis (100).

4. A battery unit (800) of claim 1, 2 or 3, characterized in that the battery mounting frame (350) comprises a bottom support panel (352), a plurality of partitioning plates (354, 356, 358) coupled to the bottom support panel (352) and at least one transverse load-bearing plate (360) disposed substantially orthogonally to the plurality of partitioning plates (354, 356, 358), wherein the plurality of partitioning plates (354, 356, 358) are disposed so that their major planes are mutually substantially parallel, and the bottom support panel (352) is adapted to be attached to, or rest onto, the bulkhead (202).

5. A battery unit (800) of claim 4, characterized in that substantially orthogonal is within an angular range of 85° to 95°, and substantially parallel is within an angular range of -5° to +5°.

6. A battery unit (800) of claim 1, characterized in that the battery unit (800) further comprises a cooling arrangement for removing heat generated by the plurality of battery modules (400) when storing or providing electrical power in operation.

7. A battery unit (800) of claim 1, characterized in that a lower portion of the battery unit (800) is configured to be mounted into a cavity (204) in the bulkhead (202) of the chassis (200).

8. A battery unit (800) of claim 1, characterized in that the outer casing (300) is made of at least one of: aluminum, stainless steel, magnesium, ceramic, carbon fiber, glass fiber.

9. A battery unit (800) of claim 4, characterized in that the plurality of partitioning plates (354, 356, 358) comprise a left partitioning plate (354), a central partitioning plate (356) and a right partitioning plate (358).

10. A battery unit (800) of claim 1, characterized in that the battery mounting frame (350) further comprises a plurality of mounting rods (370) that are mounted through the central partitioning plate (356) for supporting each of the plurality of battery modules (400).

11. A battery unit (800) of claim 10, characterized in that the plurality of partitioning plates (354, 356, 358) each have substantially an L-shape.

12. A battery unit (800) of claim 11, characterized in that a vertex of the L-shape has an angle of more than 90°.

13. A method of providing an increased torsional strength to a chassis (200) of an electrical vehicle, characterized in that the method comprises:

(a) providing a battery unit (800), the battery unit (800) comprising:

- an outer casing (300);

- a battery mounting frame (350) that is arranged to be accommodated within the outer casing (300); and

- a plurality of battery modules (400) that are arranged to be supported upon the battery mounting frame (350);

(b) forming a cavity (204) in the bulkhead (202) of the chassis (200); and (c) mounting at least a portion of the battery unit (800) into the cavity (204) in the bulkhead (202) of the chassis (200).

14. A battery unit (800) of claim 13, characterized in that a vertex of the L-shape has an angle of more than 90°.

LO o

LO

Intellectual

Property

Office

Application No:

14. A method of claim 13, characterized in that the battery mounting frame (350) comprises a bottom support panel (352), a plurality of partitioning plates (354, 356, 358) coupled to the bottom support panel (352) and at least one transverse load-bearing plate (360) disposed substantially orthogonally to the plurality of partitioning plates (354, 356, 358), wherein the plurality of partitioning plates (354, 356, 358) are disposed so that their major planes are mutually substantially parallel, and the bottom support panel (352) is adapted to be attached to, or rest onto, the bulkhead (202).

15. A method according to claim 13, characterized in that at least one of the plurality of partitioning plates (354, 356, 358) has substantially an L-shape.

16. A method according to claim 15, characterized in that a long arm of the substantially L-shaped plurality of partitioning plates (354, 356, 358) is mounted into the cavity (204) in the bulkhead (202) of the chassis (200).

1505 18

Amendment to the claims have been filed as follows

1. A method of providing a torsional strength to a chassis (200) of an electrical vehicle, characterized in that the method comprises:

(a) providing a battery unit (800), the battery unit (800) comprising:

- an outer casing (300);

- a battery mounting frame (350) comprising a plurality of transverse mounting rods (370) and a bottom support panel (352), such that the battery mounting frame (350) is arranged to be accommodated within the outer casing (300); and

- a plurality of battery modules (400) that are arranged to be supported upon the battery mounting frame (350) with the help of plurality of transverse mounting rods (370);

(b) forming a bulkhead (202) wherein the bulkhead (202) comprises a cavity (204) and weight-bearing flanges (206A, 206B) on a front portion and a rear portion of the bulkhead (202); and (c) mounting at least a portion of the battery unit (800) into the cavity (204) in the bulkhead (202) of the chassis (200).

2. A method of claim 1, characterized in that the battery mounting frame (350) comprises a plurality of partitioning plates (354, 356, 358) coupled to the bottom support panel (352) and at least one transverse loadbearing plate (360) disposed substantially orthogonally to the plurality of partitioning plates (354, 356, 358), wherein the plurality of partitioning plates (354, 356, 358) are disposed so that their major planes are mutually substantially parallel, and the bottom support panel (352) is adapted to be attached to, or rest onto, the bulkhead (202).

3. A method according to claim 1, characterized in that at least one of the plurality of partitioning plates (354, 356, 358) has substantially an Lshape.

1505 18

4. A method according to claim 3, characterized in that a long arm of the substantially L-shaped plurality of partitioning plates (354, 356, 358) is mounted into the cavity (204) in the bulkhead (202) ofthe chassis (200).

5. An electrical vehicle chassis (200) comprising:

a battery unit (800) for mounting into the chassis (200) of an electrical vehicle, characterized in that the battery unit (800) comprises:

(i) an outer casing (300);

(ii) a battery mounting frame (350) comprising a plurality of transverse mounting rods (370) and a bottom support panel (352) such that the battery mounting frame (350) is arranged to be accommodated within the outer casing (300); and (iii) a plurality of battery modules (400) that are arranged to be supported upon the battery mounting frame (350) with the help of plurality of transverse mounting rods (370);

wherein the battery unit (800) is mountable onto a bulkhead (202) of the chassis (200) of the electrical vehicle to provide a torsional strength with respect to an elongate axis of the electrical vehicle, wherein the bulkhead (202) comprises a cavity (204) and weight-bearing flanges (206A, 206B) on a front portion and a rear portion of the bulkhead (202).

6. A battery unit (800) of claim 5, characterized in that the battery mounting frame (350) comprises a plurality of partitioning plates (354, 356, 358) coupled to the bottom support panel (352) and at least one transverse load-bearing plate (360) disposed substantially orthogonally to the plurality of partitioning plates (354, 356, 358), wherein the plurality of partitioning plates (354, 356, 358) are disposed so that their major planes

1505 18 are mutually substantially parallel, and the bottom support panel (352) is adapted to be attached to, or rest onto, the bulkhead (202).

7. A battery unit (800) of claim 6, characterized in that substantially orthogonal is within an angular range of 85° to 95°, and substantially parallel is within an angular range of -5° to +5°.

8. A battery unit (800) of claim 5, characterized in that the battery unit (800) further comprises a cooling arrangement for removing heat generated by the plurality of battery modules (400) when storing or providing electrical power in operation.

9. A battery unit (800) of claim 5, characterized in that a lower portion of the battery unit (800) is configured to be mounted into a cavity (204) in the bulkhead (202) of the chassis (200).

10. A battery unit (800) of claim 5, characterized in that the outer casing (300) is made of at least one of: aluminum, stainless steel, magnesium, ceramic, carbon fiber, glass fiber.

11. A battery unit (800) of claim 6, characterized in that the plurality of partitioning plates (354, 356, 358) comprise a left partitioning plate (354), a central partitioning plate (356) and a right partitioning plate (358).

12. A battery unit (800) of claim 5, characterized in that the plurality of mounting rods (370) that are mounted through a central partitioning plate (356) for supporting each of the plurality of battery modules (400).

13. A battery unit (800) of claim 12, characterized in that the plurality of partitioning plates (354, 356, 358) each have substantially an L-shape.