WO2024062501A1

WO2024062501A1 - Chassis frame for electric vehicles

Info

Publication number: WO2024062501A1
Application number: PCT/IN2023/050879
Authority: WO
Inventors: Bhavish Aggarwal; Samraj J Dhinagar; Channakeshava Murthy; Arun V; Santosh Mahajan
Original assignee: Ola Electric Mobility Limited
Priority date: 2022-09-23
Filing date: 2023-09-22
Publication date: 2024-03-28

Abstract

A chassis frame (100) for a two-wheel electric vehicle (EV) or a modification of a two-wheel EV. The chassis frame (100) includes a plurality of structural members (102). The plurality of structural members (102) includes a first structural member (102b). The first structural member (102b) is an enclosure for housing at least a battery (515a, 515b). Remaining structural members (102a, 102c) of the plurality of structural members (102) are mechanically coupled to the first structural member (102b).

Description

CHASSIS FRAME FOR ELECTRIC VEHICLES

FIELD

[0001] The present disclosure relates to the field of electric vehicles. More specifically, the present disclosure relates to a chassis frame for electric vehicles.

BACKGROUND

[0002] Recent times have witnessed a significant rise in development and sale of electric vehicles (EVs), such as electric bikes, electric cars, or the like. Batteries or battery packs for these EVs are typically stored in a casing (battery pack casing) that is attached to a chassis or chassis frame. Auxiliary electronics components such as battery management systems, motor control units, power converters, or the like, required for functioning of an EV are typically located outside the battery pack casing.

[0003] However, such an arrangement has several drawbacks. This arrangement leads to an increase in the space occupied by the battery pack casing and the auxiliary electronics components, thereby, reducing space that is available for other purposes (e.g., storage space for users) in the EVs. Further, in an EV, a battery pack casing adds weight to the EV but may not add structural rigidity to a chassis frame of the EV. Further, there exists a difficulty in achieving and maintaining a high level of accuracy for assembly of chassis frames for EVs since many components are welded onto the chassis frames, negatively affecting structural integrity of the chassis frames.

[0004] In light of the foregoing, there exists a need for a technical solution that overcomes the above-mentioned problems, and enables efficient packaging of battery packs and other components, such as the auxiliary electronics components, in EVs.

SUMMARY

[0005] A chassis frame for electric vehicles is provided substantially as shown in, and described in connection with, at least one of the figures.

[0006] These and other features and advantages of the present disclosure may be appreciated from a review of the following detailed description of the present disclosure, along with the accompanying figures in which like reference numerals refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The accompanying drawings illustrate the various exemplary embodiments of systems, methods, and other aspects of the disclosure. It will be apparent to a person skilled in the art that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. In some examples, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another, and vice versa.

[0008] Various exemplary embodiments of the present disclosure are illustrated by way of example, and not limited by the appended figures, in which like references indicate similar elements:

[0009] FIG. 1 is a diagram that illustrates a perspective view of a chassis frame for an electric vehicle (EV), in accordance with an exemplary embodiment of the present disclosure;

[0010] FIG. 2 is a diagram that illustrates an exploded perspective view of the chassis frame for the EV, in accordance with an exemplary embodiment of the present disclosure;

[0011] FIG. 3 is a diagram that illustrates a side view of a structural member of the chassis frame, in accordance with an exemplary embodiment of the present disclosure;

[0012] FIG. 4 is a diagram that illustrates a cross-sectional view of the structural member, in accordance with an exemplary embodiment of the present disclosure;

[0013] FIG. 5 is a diagram that illustrates an exploded perspective view of a first battery module and a second battery module, in accordance with an exemplary embodiments of the present disclosure; [0014] FIG. 6 is a diagram that illustrates a perspective view of the first and second battery modules, in accordance with an exemplary embodiment of the present disclosure;

[0015] FIG. 7 is a diagram that illustrates placement of the first and second battery modules within the structural member, in accordance with an exemplary embodiment of the present disclosure;

[0016] FIG. 8 is a diagram that illustrates a cross-sectional view of the structural member, in accordance with an exemplary embodiment of the present disclosure; and

[0017] FIG. 9 is a diagram that illustrates the EV, in accordance with an exemplary embodiment of the present disclosure.

[0018] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description of exemplary embodiments is intended for illustration purposes only and is, therefore, not intended to necessarily limit the scope of the disclosure.

DETAILED DESCRIPTION

[0019] The present disclosure is best understood with reference to the detailed figures and description set forth herein. Various exemplary embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described exemplary embodiments. In one example, the teachings presented and the needs of a particular application may yield multiple alternate and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments that are described and shown.

[0020] References to “an embodiment”, “another embodiment”, “yet another embodiment”, “one example”, “another example”, “yet another example”, “for example”, “an exemplary embodiment”, “ another exemplary embodiment” and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in an exemplary embodiment” does not necessarily refer to the same embodiment.

[0021] In various embodiments, disclosure is made for a chassis frame for a two-wheel electric vehicle (EV) or a modification of a two-wheel EV. The chassis frame includes a plurality of structural members. The plurality of structural members includes a first structural member. The first structural member is an enclosure for housing at least a battery. Remaining structural members of the plurality of structural members are mechanically coupled to the first structural member.

[0022] In various embodiments, disclosure is made for a two-wheel EV or a modification of a two-wheel EV. The two-wheel EV or the modification of the two wheel EV comprises a chassis frame that includes a plurality of structural members. The plurality of structural members includes a first structural member that is an enclosure for housing at least a battery. Remaining structural members of the plurality of structural members are mechanically coupled to the first structural member.

[0023] FIG. 1 is a diagram that illustrates a perspective view of a chassis frame 100 for an electric vehicle (EV), in accordance with an exemplary embodiment of the present disclosure. Examples of the EV include, but are not limited to, two-wheel EVs, three-wheel EVs, four-wheel EVs, or the like. In a non-limiting example, it is assumed in the current embodiment that the EV corresponds to a two-wheel EV (e.g., a moped, a scooter, or the like) or a modification/modified version of the two-wheel EV. The modified two-wheel EV may include addition of a wheel on each side of a rear wheel of the two-wheel EV for use by handicapped users.

[0024] The chassis frame 100 forms a base frame or a skeletal frame of the EV. Components to be included in a chassis of the EV may be coupled to or attached to the chassis frame 100. In other words, the chassis frame 100 provides a foundation for construction of the EV. The chassis frame 100 may include a plurality of structural members such as the first through third structural members 102a- 102c. For the sake of brevity, the plurality of structural members are hereinafter designated and referred to as the “plurality of structural members 102”. The first through third structural members 102a- 102c may correspond to a front structural member, an intermediate structural member, and a rear structural member, respectively, of the chassis frame 100. The first structural member 102a and the third structural member 102c are coupled to the second structural member 102b. In a non-limiting example, the first structural member 102a and the third structural member 102c may be mechanically coupled to the second structural member 102b by way of a plurality of brackets, bolts, fasteners, or the like. Coupling of structural members included in a chassis frame (e.g., the chassis frame 100) is well known to those of skill in the art. Detailed description of the coupling of the first structural member 102a and the third structural member 102c to the second structural member is skipped to avoid obscuring the disclosure.

[0025] The second structural member 102b is an enclosure/casing that houses, therein, various components (e.g., a battery, a battery pack, or battery cells) of the EV. Components that are housed or included in the second structural member 102b are explained in conjunction with FIGS. 5-8. Since the chassis frame 100 corresponds to a frame for the two-wheel EV, the second structural member 102b may form a floor board of the two-wheel EV. A user (e.g., a rider) of the two-wheel EV may rest his or her feet on the floor board while riding the two- wheel EV. Similarly, in other types of EVs (e.g., three-wheel EVs, four-wheel EVs, or the like), the second structural member 102b may form a floor (e.g., floor board) of a corresponding EV. Remaining structural members (e.g., the first and third structural members 102a and 102c) of the plurality of structural members 102 are mechanically coupled to the second structural member 102b.

[0026] FIG. 2 is a diagram 200 that illustrates an exploded perspective view of the chassis frame 100 for the EV, in accordance with an exemplary embodiment of the present disclosure. It is assumed that the second structural member 102b is monolithically formed. In other words, the second structural member 102b may be a monolithic structure (e.g., monolithic structure formed out of aluminium) that is formed by way of one or more known processes (e.g., extrusion, casting, or the like). In a non-limiting example, the monolithically formed second structural member 102b is an extruded casing (e.g., case or enclosure) that is formed (e.g., manufactured) using a process of extrusion. Extrusion is well known to those of skill in the art and is therefore not described in detail.

[0027] A set of end joints (e.g., end portions, end sections, peripheral sections, or the like) of the extruded casing may be open (e.g., uncovered or exposed), following a completion of the process of extrusion. For the sake of brevity, it is assumed that the set of end joints includes a first end joint 201a and a second end joint 201b. The first end joint 201a may be a first end, of the second structural member 102b, that is proximate to the first structural member 102a that is coupled to the second structural member 102b. The second end joint 201b may be a second end, of the second structural member 102b, that corresponds to a section (e.g., portion) of the second structural member 102b that is most distant with respect to the first structural member 102a, which is coupled to the second structural member 102b. The first end joint 201a and the second end joint 201b are opposite each other. The first structural member 102a may be coupled to the second structural member 102b at the first end joint 201a. Similarly, the third structural member 102c may be coupled to the second structural member 102b at the second end joint 201b. For the sake of brevity, the set of end joints are hereinafter designated and referred to as “the set of end joints 201”.

[0028] The set of end joints 201 may be sealed (e.g., covered) with a set of covers (e.g., first and second covers 202a and 202b). The first and second covers 202a and 202b may be constructed and installed on the first and second end joints 201a and 201b in a manner that hermetically seals the second structural member 102b (e.g., the extruded casing). For the sake of brevity, the first and second covers 202a and 202b are collectively designated and referred to as “the set of covers 202”. The set of covers 202 may be installed in a manner that provides a high degree of air resistance and/or a high degree of water resistance (e.g., an ingress protection or IP rating of “67”) to the second structural member 102b. The extruded casing may be sealed with the set of covers 202 using appropriate arrangements such as, but not limited to, adhesive seals, static O-ring seals, dynamic O-ring seals, or any other method known in the art to hermetically seal the second structural member 102b.

[0029] As described in the foregoing, the first and third structural members 102a and 102c are mechanically coupled to the second structural member 102b. In a non-limiting example, the first structural member 102a is coupled to the second structural member 102b by way of a first bolt-on structure, and the third structural member 102c is coupled to the second structural member 102b by way of a second bolt-on structure.

[0030] The first bolt-on structure (not labelled) includes a first set of brackets (e.g., a first bracket 204a and a second bracket 204b) mounted on the second structural member 102b (e.g., the first cover 202a). The first bolt-on structure further includes a first set of fasteners 206 (e.g., four fasteners; not labelled individually). For the sake of brevity, the first set of brackets are hereinafter designated and referred to as “the first set of brackets 204”. In a nonlimiting example, the first bolt-on structure is shown to include only two brackets (e.g., the first bracket 204a and the second bracket 204b) and four fasteners. However, in an actual implementation, any number of brackets and any number of fasteners may be included in the first bolt-on structure without deviating from the scope of the disclosure. Each of the first set of fasteners 206 may extend through one or more slots (not labelled) formed on the first structural member 102a and one of the first set of brackets 204 to couple the first structural member 102a to the second structural member 102b.

[0031] The abovementioned first bolt-on structure that is used to couple the first structural member 102a to the second structural member 102b is merely exemplary. In another embodiment, a different coupling mechanism or a variation of the first bolt-on structure may be used to couple the first and second structural members 102a and 102b without deviating from the scope of the disclosure.

[0032] The second bolt-on structure (not labelled) includes a second set of brackets 208 (e.g., a third bracket) mounted on the third structural member 102c. The second bolt-on structure further includes a second set of fasteners 210. To avoid obscuring the drawings, a single bracket of the second set of brackets 208 and two fasteners of the second set of fasteners 210 is shown. However, in an actual implementation, any number of brackets and any number of fasteners may be included in the second bolt-on structure without deviating from the scope of the disclosure. Each of the second set of fasteners 210 may extend through one or more slots (e.g., a slot 209) formed on the second structural member 102b and one of the second set of brackets 208 to mechanically couple the second structural member 102b to the third structural member 102c.

[0033] The second structural member 102b may include various slots, holes, and/or grooves, formed thereon, for mounting panels on the second structural member 102b. For example, the second structural member 102b may include a set of holes 211 for mounting panels on a top surface (not labelled) of the second structural member 102b. To avoid obscuring the drawings, only two of the set of holes 211 are labelled. However, in an actual implementation, the set of holes 211 may include any number of holes without deviating from the scope of the disclosure.

[0034] Similarly, a first set of slots (labelled in FIG. 4) may be formed on side surfaces (e.g., a set of outer side surfaces; labelled in FIG. 4) of the second structural member 102b to enable installation or mounting of a set of peripheral components (e.g., a set of side stands, a set of foot rests, or the like) on the second structural member 102b. For example, a first set of installation mounts 212 may be mounted on (e.g., installed on) the first set of slots formed on a first outer side surface of the second structural member 102b. A first foot rest 214 (e.g., the set of foot rests) may be mounted on the second structural member 102b by way of a third set of fasteners 216. The third set of fasteners 216 extends through the first foot rest 214 and the first set of installation mounts 212 to mechanically couple the first foot rest 214 to the second structural member 102b. In such a manner, the first foot rest 214 (e.g., the set of foot rests) may be mounted on the second structural member 102b. For the sake of brevity, a single foot rest of the set of foot rests is shown. It will be apparent to those of skill in the art that other foot rests may be mounted on (e.g., a second outer side surface opposite the first outer side surface) the second structural member 102b in a similar manner.

[0035] Similarly, a second set of installation mounts 218 may be mounted on (e.g., installed on) the first set of slots formed on the first outer side surface of the second structural member 102b. A center stand (not shown), for parking the two-wheel EV, may be mounted on the second structural member 102b by way of a fourth set of fasteners (not shown). Each of the fourth set of fasteners extends through the center stand (e.g., a hole in the center stand) and the second set of installation mounts 218 to mechanically couple the center stand to the second structural member 102b. In such a manner, the center stand may be mounted on the second structural member 102b.

[0036] Similarly, a third set of installation mounts 220 may be mounted on (e.g., installed on) the first set of slots formed on the first outer side surface of the second structural member 102b to mount a set of panels (e.g., side panels) on the first outer side surface of the second structural member 102b. It will be apparent to those of skill in the art that the mounting of the set of panels (e.g., the side panels) on the first outer side surface may be similar to the mounting of the center stand and/or the mounting of the set of foot rests.

[0037] A fourth set of installation mounts 222 may be mounted on (e.g., installed on) the first set of slots formed on the set of outer side surfaces of the second structural member 102b. A set of side stands 224 for parking the two-wheel EV may be mounted on the second structural member 102b by way of the fourth set of installation mounts 222. To avoid obscuring the disclosure, FIG. 2 is shown to include a single side stand of the set of side stands 224 and a single installation mount, of the fourth set of installation mounts 222, that is mounted on the first groove. No fastener for coupling the set of side stands 224 and the fourth set of installation mounts 222 is shown. However, each of the set of side stands 224 may be coupled to the fourth set of installation mounts 222 by way of one or more fasteners that extend through a correspond side stand and a corresponding installation mount (e.g., the fourth set of installation mounts 222).

[0038] It will be apparent to those of skill in the art that the set of peripheral components that may be mounted on the second structural member 102b is not limited to abovementioned peripheral components. It will be apparent to those of skill in the art that the set of peripheral components may include additional or different peripheral components without deviating from the scope of the disclosure. Further, different methods or mechanisms may be used to mount the set of peripheral components on the second structural member 102b without deviating from the scope of the disclosure.

[0039] The second structural member 102b of the chassis frame 100 is further explained in conjunction with FIG. 3.

[0040] FIG. 3 is a diagram 300 that illustrates a side view of the second structural member 102b of the chassis frame 100, in accordance with an exemplary embodiment of the present disclosure. The second structural member 102b is further shown to include the first and second covers 202a and 202b, the second bracket 204b, and the second set of installation mounts 218. In a non-limiting example, a shape of the second structural member 102b is curved and substantially same as a banana.

[0041] FIG. 4 is a diagram 400 that illustrates a cross-sectional view of the second structural member 102b, in accordance with an exemplary embodiment of the present disclosure. The cross-sectional view illustrates a cross-section of the second structural member 102b along an axis 4-4 shown in FIG. 2. The cross-sectional view of the second structural member 102b shows a first set of slots 401 (e.g., a first slot 401a and a second slot 401b) and a second set of slots (e.g., a third slot 402a and a fourth slot 402b). The third slot 402a and fourth slot 402b are collectively designated and referred to as “the second set of slots 402”. The first set of slots 401 (e.g., guide slots) is formed on the set of outer sides surfaces (e.g., a first outer side surface 404a and a second outer side surface 404b). Hereinafter, the first outer side surface 404a and the second outer side surface 404b of the second structural member 102b are designated and referred to as “the first outer side surface 404a” and “the second outer side surface 404b”.

[0042] As shown in the FIG. 4, the first outer side surface 404a and the second outer side surface 404b are parallel and opposite each other. The first outer side surface 404a and the second outer side surface 404b have the first set of slots 401 formed thereon. In a non-limiting example, each of the first set of slots 401 may be a T-shaped slot. However, in an actual implementation, each of the first set of slots 401 may be of any shape or size without deviating from the scope of the disclosure. The first and second outer side surfaces 404a and 404b are collectively designated and referred to as “the set of outer side surfaces 404”.

[0043] The second set of slots 402 (e.g., guide slots) is formed on a set of inner side surfaces (e.g., a first inner side surface 406a and a second inner side surface 406b) of the second structural member 102b. The first inner side surface 406a and the second inner side surface 406b are collectively designated and referred to as “the set of inner side surfaces 406”. In a non-limiting example, each of the second set of slots 402 may be a T-shaped slot. However, in an actual implementation, each of the second set of slots 402 may be of any shape or size without deviating from the scope of the disclosure.

[0044] In a non-limiting example, the cross-section of the second structural member 102b is shown to be shaped substantially as a rectangle. However, in another embodiment, the cross-section of the second structural member 102b may be shaped as a square, a trapezoid, a curved trapezoid or any other shape as known in the art, without deviating from the scope of the disclosure.

[0045] FIG. 5 is a diagram 500 that illustrates an exploded perspective view of a first battery module 502a and a second battery module 502b, in accordance with an exemplary embodiment of the present disclosure. The first and second battery modules 502a and 502b and the second battery module 520 are configured to include, therein, a plurality of batteries that are to be used to store and supply energy for the EV.

[0046] The first and second battery modules 502a and 502b are mechanically coupled to each other and placed within the second structural member 102b. In other words, the second structural member 102b houses the first and second battery modules 502a and 502b. A shape of the first and second battery modules 502a and 502b may be substantially same as a shape of the second structural member 102b. For example, if the second structural member 102b is curved (e.g., banana- shaped), the first and second battery modules 502a and 502b may also be curved (e.g., banana- shaped). Similarly, if the second structural member 102b is bricked- shaped (e.g., shaped as cuboid), the first and second battery modules 502a and 502b may also be brick-shaped. In other words, a shape of a cross-section of the first and second battery modules 502a and 502b may be same (e.g., substantially same) as the shape (e.g., rectangle, trapezoid, curved trapezoid, or the like) of the cross section of the second structural member 102b.

[0047] The first battery module 502a includes a first holder 504 (e.g., a battery cell holder) and a second holder 506 (e.g., a battery cell holder). The second holder 506 is mounted on the first holder 504 and is oriented parallel to the first holder 504 (as shown in FIG. 5). The first and second holders 504 and 506 may include, therein, a first plurality of slots (shown in FIG. 7) for holding battery cells (e.g., a first plurality battery cells; battery). The first plurality of battery cells may be placed in the first plurality of slots.

[0048] In a non-limiting example, the first and second holders 504 and 506 may be made of plastic (e.g., polypropylene). However, it will be apparent to those of skill in the art that the first and second holders 504 and 506 may be made of (e.g., constructed using) any suitable material without deviating from the scope of the disclosure.

[0049] The second structural member 102b is not limited to housing the first plurality of battery cells. In other words, the first battery module 502a is not limited to include only battery cells (e.g., the first plurality of battery cells). The first battery module 502a may further include one or more additional components that are required for functioning of the EV. For example, the first battery module 502a may further include a heat sink (e.g., a first heat sink 508) that enables dissipation of heat or removal of heat from the first plurality of battery cells and/or other components to be included in the first battery module 502a. The first heat sink 508 may be a heat exchange plate that is oriented parallel to the first holder 504 and the second holder 506.

[0050] The first battery module 502a may further include a set of insulators 510 (e.g., a set of spacers) that are coupled to the second holder 506 and the first heat sink 508, separating the first heat sink 508 from the second holder 506. Therefore, the set of insulators 510 provide thermal and electrical isolation between the second holder 506 and the first heat sink 508.

[0051] The first and second battery modules 502a and 502b may include a plurality of guide pins that are configured to engage with the second set of slots 402 for the placement of the first and second battery modules 502a and 502b within the second structural member 102b. The plurality of guide pins enables accurate and placement of the first and second battery modules 502a and 502b within the second structural member 102b. The plurality of guide pins may include a first set of guide pins 512a mounted on the first battery module 502a and a second set of guide pins 512b mounted on the second battery module 502b. For the sake of brevity, the plurality of guide pins are collectively designated and referred to as “the plurality of guide pins 512”.

[0052] As shown in FIG. 5, the first set of guide pins 512a is mounted on the first holder 504. In a non-limiting example, only three guide pins of the first set of guide pins 512a are labelled. However, it will be apparent to those of skill in the art that the first set of guide pins 512a may include any number (e.g., tens, hundreds, or the like) of guide pins without deviating from the scope of the disclosure.

[0053] Preferably, each guide pin of the first set of guide pins 512a and the second set of guide pins 512b is suitably shaped for placement of a corresponding guide within a slot of the second set of slots 402. For example, each guide pin of the first and second sets of guide pins 512a and 512b may be T-shaped, since each of the second set of slots 402 (e.g., guide slots) is a T-shaped slot. It will be apparent to those of skill in the art that a shape of the plurality of guide pins is not limited to T-shaped pins. In an actual implementation, the shape of the plurality of guide pins may vary without deviating from the scope of the disclosure.

[0054] Further, a set of electronics components required for the functioning of the EV may be included in the first battery module 502a. The set of electronic components may include, but are not limited to, a battery management system 514, for the first plurality of battery cells 515a and a second plurality of battery cells 515b included in the second battery module 502b, a motor control unit 516, or a power converter 518 (e.g., a direct current to direct current converter). It will be apparent to those of skill in the art that the set of electronic components is not restricted to abovementioned components. In an actual implementation, the set of electronic components may include different or additional components (e.g., bus bars, power supply modules, wires, or the like) without deviating from the scope of the disclosure. However, it is not necessary that all electronics components required for the function of the EV be included in the first battery module 502a and the second battery module 502b (e.g., the second structural member 102b). One or more electronics or modules may be located outside the second structural member 102b without deviating from the scope of the disclosure.

[0055] The second battery module 502b includes a third holder 520, a fourth holder 522, a second heat sink 524, and a second set of insulators 526. In a non-limiting example, it is assumed that the third holder 520, the fourth holder 522, the second heat sink 524, and the second set of insulators 526 are structurally and functionally similar to the first holder 504, the second holder 506, the first heat sink 508, and the first set of insulators 510, respectively. The fourth holder 522 is mounted on the third holder 520 oriented parallel to the third holder 520. The second heat sink 524 is oriented parallel to the third and fourth holders 520 and 522. The second set of insulators 526 is coupled to the fourth holder 522 and the second heat sink 524. Further, the second set of insulators 526 is oriented parallel to the fourth holder 522. A plurality of bushes 532 are mounted on the second heat sink 524 to enable coupling of the first and second battery modules 502a and 502b. The coupling of the first and second battery modules 502a and 502b is illustrated and described in conjunction with FIG. 6.

[0056] The second set of guide pins 512b, of the plurality of guide pins, is mounted externally on the third holder 520 and is configured to engage with the second set of slots 402. The third holder 520 and the fourth holder 522 include a second plurality of slots (shown in FIG. 6). The second plurality of battery cells 515b are placed in the second plurality of slots formed.

[0057] In the current embodiment, two battery modules (e.g., the first battery module 502a and the second battery module 502b) are placed within the second structural member 102b. However, in another embodiment, fewer battery modules (e.g., a single battery module) or additional battery modules may be placed within the second structural member 102b without deviating from the scope of the disclosure.

[0058] FIG. 6 is a diagram 600 that illustrates a perspective view of the first and second battery modules 502a and 502b, in accordance with an exemplary embodiment of the present disclosure. FIG. 6 further illustrates a mechanism for coupling the first and second battery modules 502a and 502b. For example, FIG. 6 illustrates a plurality of fasteners 602 and the plurality of bushes 528 that are used to mechanically couple the first and second battery modules 502a and 502b to each other. The plurality of fasteners 602 extend (e.g., are configured to extend) through the first holder 504, the second holder 506, the first heat sink 508, the plurality of bushes 528, the second heat sink 524, the fourth holder 522, and the third holder 520 to couple the first and second battery modules 502a and 502b. For the sake of brevity, a combination of the first battery module 502a and the second battery module 502b, post coupling, is interchangeably referred to as a “ battery assembly” (labelled in FIG. 7). FIG. 6 further illustrates the second plurality of slots. The second plurality of slots are hereinafter designated and referred to as “the second plurality of slots 604”. To avoid obscuring the drawings, only a few slots of the second plurality of slots 604 are labelled. [0059] The coupling of the first and second battery modules 502a and 502b is not limited to the abovementioned method (e.g., the plurality of bushes 528 and the plurality of fasteners 602). It will be apparent to those of skill in the art that in another embodiment, any other known method for coupling two structures may be used for coupling the first and second battery modules 502a and 502b. For example in another embodiment, alternate arrangements such as bolts, screws, rivets, pins, brackets, or the like may be used to couple the first and second battery modules 502a and 502b. In another embodiment, the first and second battery modules 502a and 502b may be welded to each other.

[0060] FIG. 7 is a diagram 700 that illustrates placement of the first and second battery modules 502a and 502b within the second structural member 102b, in accordance with an exemplary embodiment of the present disclosure. FIG. 7 illustrates insertion (e.g., the placement) of the battery assembly (hereinafter, designated and referred to as “the battery assembly 701”) into the second structural member 102b. FIG. 7 further illustrates the first plurality of slots (hereinafter, referred to as “the first plurality of slots 704”). To avoid obscuring the disclosure, only a few slots of the first plurality of slots 704 are labelled.

[0061] When the battery assembly 701 is inserted (in direction 702) into the second structural member 102b, the plurality of guide pins 512 (e.g., the first and second sets of guide pins 512a and 512b) engage with the second set of slots 402 formed on the set of inner side surfaces 406 of the second structural member 102b, facilitating placement of the first and second battery modules 502a and 502b with the second structural member 102b. When the plurality of guide pins 512 are engaged with the second set of slots 402, the first and second battery modules 502a and 502b (e.g., the battery assembly 701) may be securely locked in place within the second structural member 102b.

[0062] Based on the placement of the battery assembly 701 within the second structural member 102b, the enclosure is sealed with the set of covers 202 (e.g., the first and second covers 202a and 202b).

[0063] FIG. 8 is a diagram 800 that illustrates a cross-sectional view of the second structural member 102b, in accordance with an exemplary embodiment of the present disclosure. FIG. 8 is explained in conjunction with FIG. 7. FIG. 8 illustrates the cross-section of the second structural member 102b when the battery assembly 701 (e.g., the first and second battery modules 502a and 502b) is placed within the second structural member 102b and the set of end joints 201 is sealed with the set of covers 202. [0064] FIG. 9 is a diagram 900 that illustrates the EV, in accordance with an exemplary embodiment of the present disclosure. In a non-limiting example, the EV is shown to be a wheel EV 902. As described in the foregoing, the EV is not limited to two-wheel EVs (e.g., the two-wheel EV 902) or modified versions of two-wheel EVs. The EV may correspond to three- wheel EVs, four-wheel EVs, or the like, without deviating from the scope of the disclosure. The two-wheel EV 902 may include the chassis frame 100 (e.g., the first through third structural members 102a- 102c). The chassis frame 100 may further include other components (e.g., the first and second battery modules 502a and 502b, the set of side stands 224, or the like) described in the foregoing descriptions of FIGS. 1-8.

[0065] The disclosed chassis frame 100 includes various advantages. The inclusion of the first and second battery module 502a and 502b and the set of electrical components in the second structural member 102b increases usable space in EVs. Compact and efficient packaging enables liberation of space within these EVs. This usable space may be used for various purposes such as, but not limited to, creation of storage areas in the EVs for users, inclusion of additional components within the EVs, or the like.

[0066] Further, an efficiency of vehicle assembly during manufacturing of EVs is also improved. The battery assembly 701 is closely packaged within the chassis frame 100, resulting in a significant reduction in length of cables used and complexity of routing these cables. Further, the inclusion or integration of the second structural member 102b within the chassis frame 100 results in increased rigidity of chassis of EVs and reduces weight of the EVs. This ultimately leads improved performance (e.g., steering, handling, braking, or the like) of the EVs. Further, the chassis frame 100 includes mountings for peripheral components such as side stands, center stands, foot rests, or the like.

[0067] Techniques consistent with the disclosure provide, among other features, the chassis frame 100 for EVs. While various exemplary embodiments of the disclosed system and method have been described above it should be understood that they have been presented for purposes of example only, not limitations. It is not exhaustive and does not limit the disclosure to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practicing of the disclosure, without departing from the breadth or scope.

[0068] While various exemplary embodiments of the disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these exemplary embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure.

Claims

We claim:

1. A chassis frame (100) for a two-wheel electric vehicle (EV) or modification thereof, comprising: a plurality of structural members (102), comprising: a first structural member (102b) that is an enclosure for housing at least a battery, wherein remaining structural members, of the plurality of structural members, are mechanically coupled to the first structural member (102b).

2. The chassis frame (100) as claimed in claim 1, wherein the first structural member (102b) further houses therein, first (502a) and second (502b) battery modules that are mechanically coupled to each other.

3. The chassis frame (100) as claimed in claim 2, wherein the first (502a) and second (502b) battery modules are mechanically coupled to each other by way of a plurality of fasteners (602) and a plurality of bushes (528).

4. The chassis frame (100) as claimed in claim 3, wherein the first structural member (102b) includes a set of guide slots (402) formed on a set of inner surfaces of the first structural member (102b), and wherein a plurality of guide pins (512a, 512b) are mounted on the first (502a) and second (502b) battery modules and configured to engage with the set of guide slots (402) for placement of first (502a) and second (502b) battery modules within the first structural member (102b).

5. The chassis frame (100) as claimed in claim 4, wherein: the first battery module (502a) includes: a first holder (504), wherein a first set of guide pins (512a), of the plurality of guide pins (512), is mounted on the first holder (504); a second holder (506) mounted on the first holder (504) and oriented parallel to the first holder (504); a first heat sink (508) oriented parallel to the first (504) and the second holders (506); and a first set of insulators (510) coupled to the second holder (506) and the first heat sink (508), separating the first heat sink (508) from the second holder (506), wherein a set of electronics components are mounted on the first heat sink (508). The chassis frame (100) as claimed in claim 5, wherein: the second battery module (502b) includes: a third holder (520), wherein a second set of guide pins (512b), of the plurality of guide pins (512), is mounted on the third holder (520); a fourth holder (522) mounted on the third holder (520) and oriented parallel to the third holder (520); a second heat sink (524) oriented parallel to the third (520) and fourth holders (522); and a second set of insulators (526) coupled to the fourth holder (522) and the second heat sink (524), separating the second heat sink (524) from the fourth holder (522), wherein the plurality of bushes (528) are mounted on the second heat sink (524), and wherein the plurality of fasteners (602) extend through the first holder (504), the second holder (506), the first heat sink (508), the first set of insulators (510), the second heat sink (524), the second set of insulators (526), the fourth holder (522), and the third holder (520) to couple the first (502a) and second (502b) battery modules. The chassis frame (100) as claimed in claim 6, wherein: the first through fourth holders include a plurality of slots formed thereon, the battery includes a plurality of battery cells (515a, 515b), and the plurality of battery cells (515a, 515b) are placed in the plurality of slots (604,704). The chassis frame (100) as claimed in claim 4, wherein each of the set of guide slots (402) is a T-shaped slot. The chassis frame (100) as claimed in claim 5, wherein the set of electronics components includes at least one of a motor control unit (516), a battery management system (514), or a power converter (518). The chassis frame (100) as claimed in claim 1, wherein the first structural member (102b) is monolithically formed. The chassis frame (100) as claimed in claim 10, wherein the monolithically formed first structural member (102b) is an extruded casing. The chassis frame (100) as claimed in claim 11, wherein a set of end joints (201) of the extruded casing is sealed with a set of covers (202). The chassis frame (100) as claimed in claim 1, wherein a cross-section of the first structural member (102b) is shaped substantially as a rectangle, a trapezoid, and a curved trapezoid. The chassis frame (100) as claimed in claim 1, wherein the first structural member (102b) forms a floor board of the two-wheel EV or the modification thereof. The chassis frame (100) as claimed in claim 1, wherein the first structural member (102b) includes a set of slots (401), formed thereon, for mounting a set of peripheral components. The chassis frame (100) as claimed in claim 15, wherein the set of peripheral components includes a set of foot rests (214). The chassis frame (100) as claimed in claim 15, wherein the set of peripheral components includes a set of side stands (224). The chassis frame (100) as claimed in claim 15, wherein each of the set of slots (401) is a T-shaped slot formed on a set of outer surfaces (404) of the first structural member (102b). A two- wheel electric vehicle (EV) or modification thereof, comprising: a chassis frame (100) that includes a plurality of structural members comprising: a first structural member (102b) that is an enclosure for housing at least a battery, wherein remaining structural members, of the plurality of structural members, are mechanically coupled to the first structural member (102b).