Field

The invention relates to battery pack supporting apparatus and a method of mounting a battery pack on such apparatus, and especially, but not solely, for supporting a battery pack during recycling operations or processes, such as discharging and/or dismantling of the battery pack.

Background

Typically, a battery pack comprises a number of individual battery cells that are electrically coupled together in series or parallel and then encapsulated, typically in an aluminium and plastics enclosure, to form the battery pack. In some cases the cells are connected and packaged together in modules and a number of modules are then connected and packaged together to form the battery pack. The battery pack may also include the battery management system. Rechargeable battery packs that are used in many applications, such as the power source for electrical vehicles, have a finite lifetime. The ability of a rechargeable battery pack to hold charge governs its useful life and this is typically related to the number and frequency of charging cycles, the type of charging cycles, as well as factors such as the environmental conditions in which the battery pack is used.

When the charge holding capacity of a rechargeable battery reduces to a point where it no longer useful, the battery pack needs to be replaced. However, one of the problems with used rechargeable battery packs that have reached end of life is how to recycle them.

Rechargeable battery packs for electric vehicles are typically large and heavy, some weighing up to 800 kg or more. Therefore, handling such battery packs during the initial discharge and dismantling processes of recycling can be challenging due to the weight of such battery packs. There is also the added complication that such battery packs are not of a standard size or weight as they are generally designed specifically to fit and be compatible with a particular model of vehicle. Different electric vehicle models from the same manufacturer will usually have different battery packs and is not uncommon for different variants of the same model to also have different battery packs.

The wide range of sizes, shapes and weights of different electric vehicle battery packs complicates the material handling of the various battery packs when they need to be recycled. Conventionally, used rechargeable battery packs from electric vehicles are recycled by mounting them on a jig that is custom made to fit a specific battery pack. The jig is then used to transport the battery pack during the various recycling and dismantling processes, such as the discharge and dismantling operations.

However, this conventional solution has the problem that it requires a different jig for each different battery pack. In addition, as the number of electric vehicle models increases, all with different battery packs, the number of jigs required also increases.

Summary

In accordance with a first aspect of the present invention, there is provided battery pack supporting apparatus, the apparatus comprising a base; two mounting members mounted on the base, at least one of the mounting members being movably mounted on the base to enable the setting of a separation distance between the mounting members, in use; and a first mounting member securing device to releasably secure the at least one movable mounting member to the base.

In accordance with a second aspect of the present invention, there is provided a method of mounting a battery pack on battery pack supporting apparatus, the method comprising:

(i) providing a base and two mounting members mounted on the base, at least one of the mounting members being movable relative to the base to enable the separation distance of the movable members to be adjusted,

(ii) moving the at least one movable mounting member relative the base to set a separation distance from the other mounting member corresponding to the battery pack; (iii) releasably securing the at least one movable mounting member to the base to prevent movement of the at least one mounting member relative to the base;

(iv) placing the battery pack on the mounting members; and

(v) securing the battery pack to the apparatus.

The term “battery pack” as used herein refers to battery packs comprising a plurality of battery cells (and optionally modules) and having an energy content of at least 1 kWh or a weight of at least 10 kg. For example, the battery packs may be for use with electric vehicles or hybrid electric vehicles, or battery packs for use with other applications, such as fixed energy storage systems where the battery pack is stationary and located in a fixed position during use.

Preferably, the base comprises a first formation adapted to receive the first mounting member securing device to releasably secure the first mounting member to the base, and wherein the first formation is adapted to permit the first mounting member to be releasably secured to the base in a continuous number of positions.

Preferably, the mounting members each comprise a second formation adapted to receive a battery pack securing device to secure the battery pack to the mounting members, in use; and wherein the second formation is adapted to permit the battery pack securing device to be received by the second formation in a continuous number of positions.

Typically, at least one of the first formation and the second formation comprises a channel formation.

Preferably, the at least one movable member is slidably mounted on the base.

In one example of the invention, the base comprises at least two longitudinal members and at least two transverse members orientated transverse to the longitudinal members, the transverse members being fixedly attached to the longitudinal members. Typically, the two mounting members are both mounted on either the longitudinal members or the transverse members.

Preferably, the transverse members are shorter than the longitudinal members and located on the opposite side of the longitudinal members from the mounting members.

Typically, the at least one movable mounting member is movable in a direction substantially parallel to the transverse members.

Preferably, the other mounting member is also movably mounted on the base and the apparatus comprises a second mounting member securing device to releasably secure the other mounting member to the base.

Typically, the apparatus further comprises a number of battery pack securing devices adapted to be engaged with the mounting members to secure a battery pack to the apparatus. The battery pack securing devices may be adapted to be inserted though formations in the battery pack to engage with the mounting members after the battery pack has been placed on the mounting members, in use. The battery pack securing devices may be adapted to be inserted through apertures in the battery pack.

At least one of the mounting member securing devices and the battery pack securing devices comprise a fastener. Typically, the fastener is a threaded fastener and the fastener may comprise a male member and a female member, the female member being adapted to engage with the male member.

The respective mounting member securing device or battery pack securing device may comprise a channel engaging formation.

The fastener may comprise a T-shaped head and where the fastener is a threaded fastener, the fastener may comprise a T bolt.

Preferably, both the mounting members are movable relative to the base and relative to each other, both the mounting members are moved relative to the base to set the separation distance, and both the mounting members are releasably secured to the base. Typically, securing the battery to the apparatus comprises inserting a number of battery pack securing devices through formations in the battery pack to engage the battery pack securing devices with the mounting members.

Preferably, the battery pack securing devices comprise a number of fasteners, each fastener comprising a male member and female member adapted to engage the male member, and the male members are inserted through the formations in the battery pack to engage with the mounting members. Typically, washers may be used in conjunction with the fasteners to reduce the effective width of the formations in the battery pack to enable securing of the battery pack to the mounting members.

Preferably, the mounting members are located on the same side of the base as each other.

Typically, the longitudinal axes of the transverse members extend in a direction that is substantially perpendicular to the direction in which the longitudinal axes of the longitudinal members extend.

Preferably, the battery pack is positioned on top of the mounting members, typically, such that opposite edges of the each locate on a respective mounting member.

Typically, the base and the mounting members are formed from one or more metal materials. Typically the releasable securing devices are formed from one or more metal materials. Suitable metal materials include steel and aluminium.

Brief Description of the Drawings

An example of battery supporting apparatus in accordance with the invention will now be described with reference to the accompanying drawings, in which:

Fig. 1 is a perspective end view of a battery supporting apparatus in the form of a frame;

Fig. 2 is an enlarged end view of section C in Fig. 1 ;

Fig. 3 is an enlarged side view of section C in Fig. 1 ; Fig. 4 is a perspective side view of the battery supporting apparatus with a battery pack positioned on the apparatus;

Fig. 5 is an enlarged view of section A in Fig. 4 showing a fastener used to secure the battery pack to the apparatus;

Fig. 6 shows the fastener being inserted through a mounting hole in the battery pack;

Fig. 7 is a side view of the battery supporting apparatus with the battery pack positioned on the apparatus; and

Fig. 8 is an enlarged view of section B in Fig. 7.

Detailed Description

Fig. 1 shows apparatus 1 for supporting a battery pack 2 (see Fig. 4) comprising a base and two mounting members 12 movably mounted on the base. The base is in the form of a frame structure and comprises four longitudinal members 3, four transverse members 4 and eight T-shaped channel sections 8 each mounted on sections 5 attached to the transverse members 4. The longitudinal and transverse members are typically formed from U-shaped beams, which are preferably formed from a metal material such as steel. The longitudinal and transverse members are fixedly attached to each other, such as by bolting the members 3, 4 together using bolts 11. Alternatively, or in addition, they could be welded together or fixed together by any other suitable means.

Mounted on upper surfaces 9 of the transverse members 4 and located between the longitudinal members 3 are the eight sections 5 which are U-shaped. The U-shaped sections 5 preferably have the same height as the longitudinal members 3 so that upper surfaces 6 of the longitudinal members 3 are at the same height (or flush) with upper surfaces 7 of the sections 5. Mounted on each of the sections 5 on the upper surfaces 7 is a T-shaped channel section 8. Typically, the sections 5 are fixedly attached to the transverse members 4 by bolts 10 and the sections 8 are fixedly attached to the upper surfaces of the sections 5 by bolts (not shown).

Slidably mounted on the base, on the sections 8, are two mounting members 12. Each mounting member 8 is formed from a U-shaped beam 13 with a T-shaped channel 14 fixedly attached to an upper surface 15 of the U-shaped beam 13. Each mounting member 12 is slidably attached to four adjacent sections 8, as shown in Fig. 1.

Enlarged views of section C of Fig. 1 are shown in Figs. 2 and 3. These show how the mounting members 12 are slidably attached to the sections 8. In particular, each T-shaped channel section 8 has a T-shaped head 16 of a T-bolt 17 located within the channel of each section 8. Corresponding holes are formed in one of the sides of the U-shaped channels 13. The bolts 17 can be inserted through the holes and nuts 18 engaged with threads on the bolts 17. Tightening of the nuts 18 on the bolts 17 releasably secures the mounting members 12 to the sections 8 and releasing the nuts 18 permits the mounting members 12 to slidably move relative to the sections 8 as the T-shaped heads 16 are permitted to slide within the T-shaped channel sections 8. This enables the mounting members 12 to be moved relative to each other to adjust or set a separation distance, d, between the mounting members 12. In addition, it permits a relative angle between the mounting members 12 to be adjusted by moving one end of a mounting member 12 may be position closer to the other mounting member 12 than the other end. This permits the mounting members to be substantially parallel to each other or to be non-parallel to each other.

In use, the separation of the mounting members 12 is adjusted by slidably moving the mounting members 12 relative to each other and relative to the longitudinal and transverse members 3, 4 until a desired separation distance, d, of the mounting members 12 is obtained. This separation distance corresponds to the dimensions of battery pack 2, and especially the separation of holes 20 formed in the battery pack 2. The members 12 are slidably movable in a direction substantially perpendicular to the longitudinal axis of the members 12. Typically the members 12 are mounted on the base so that they are substantially parallel to each other. However, it is possible that they could be mounted at an angle relative to each other by changing the relative positioning of the holes in the U-shaped members 13 in which the bolts 17 are located. In this case, the separation distance, d, would change along the length of the movable members 12.

When the desired separation distance, d, is obtained the nuts 18 are tightened to releasably secure the mounting members relative to the longitudinal and transverse members 3, 4 and to fix the separation distance, d, between the mounting members 12. The battery pack is then lowered onto the mounting members 12 so that it sits on and is supported by the mounting members, as shown in Figs. 4, 7 and 8.

After the battery pack 2 is placed on the mounting members 12, T-shaped heads 22 of T-bolts 21 are then inserted through the holes 20 and orientated (that is, rotated) until the T-shaped heads 22 are aligned to enter the T-shaped channel of the respective mounting member 12. The T-bolts are then rotated through 90 degrees to engage the T-shaped head 22 with the T-shaped channel 14 and prevent withdrawal of the bolts 21 from the T-shaped channel and the hole 20 before placing washers 23 and nuts 22 onto the bolts 21 and tightening the nuts 24 onto the bolts 21 to secure the battery pack 2 to the apparatus 1 .

Typically, the separation of the transverse members 4 is such that it permits the apparatus 1 (and the battery pack 2, if present) to be lifted using a fork lift. In addition the apparatus 1 has eyes 25 located on the longitudinal members 3 to permit the apparatus 1 (and the battery pack 2, if present) to be suspended from and lifted using a crane or winch (not shown).

Typically, all the components used in the apparatus are formed from a metal, such as steel or aluminium. For example, the longitudinal members 3, the transverse members 4, members 13, the sections 5 and the bolts may be formed from steel and the T-shaped channels 8, 14 may be formed from aluminium. However, the components could be formed from any suitable metal or alloy.

An advantage of the invention is that by providing battery pack supporting apparatus 1 in which the mounting members 12 are movable relative to each other, or at least one of the mounting members 12 is movable relative to the longitudinal and transverse members 3, 4, it is possible to accommodate different sizes of battery packs on the same apparatus 1 .

Another advantage of the invention is that it permits a continuous adjustment of the movable members 12 relative to the base and also a continuous positioning of the bolts 21 in the mounting members 12 so that a battery pack 2 can be secured in any position to the mounting members 12 and different sized battery packs 2 can be accommodated with different positioning of holes 20 relative to the battery pack 2 and relative to other holes 20.

The present disclosure is further explained through the following numbered clauses.

1 . Battery pack supporting apparatus, the apparatus comprising a base; two mounting members mounted on the base, at least one of the mounting members being movably mounted on the base to enable the setting of a separation distance between the mounting members, in use; and a first mounting member securing device to releasably secure the at least one movable mounting member to the base.

2. Apparatus according to clause 1 , wherein the base comprises a first formation adapted to receive the first mounting member securing device to releasably secure the first mounting member to the base, and wherein the first formation is adapted to permit the first mounting member to be releasably secured to the base in a continuous number of positions.

3. Apparatus according to any of the preceding clauses, wherein the mounting members each comprise a second formation adapted to receive a battery pack securing device to secure the battery pack to the mounting members, in use; and wherein the second formation is adapted to permit the battery pack securing device to be received by the second formation in a continuous number of positions.

4. Apparatus according to clause 2 or clause 3, wherein at least one of the first formation and the second formation comprises a channel formation.

5. Apparatus according to any of the preceding clauses, wherein the at least one movable member is slidably mounted on the base.

6. Apparatus according to any of the preceding clauses, wherein the base comprises at least two longitudinal members and at least two transverse members orientated transverse to the longitudinal members, the transverse members being fixedly attached to the longitudinal members. Apparatus according to clause 6, wherein the two mounting members are both mounted on either the longitudinal members or the transverse members. Apparatus according to clause 6 or clause 7, wherein the transverse members are shorter than the longitudinal members and located on the opposite side of the longitudinal members from the mounting members. Apparatus according to any of clauses 6 to 8, wherein the at least one movable mounting member is movable in a direction substantially parallel to the transverse members. Apparatus according to any of the preceding clauses, wherein the other mounting member is also movably mounted on the base and the apparatus comprises a second mounting member securing device to releasably secure the other mounting member to the base. Apparatus according to any of the preceding clauses, further comprising a number of battery pack securing devices adapted to be engaged with the mounting members to secure a battery pack to the apparatus. Apparatus according to clause 11 , wherein the battery pack securing devices are adapted to be inserted though formations in the battery pack to engage with the mounting members after the battery pack has been placed on the mounting members, in use. Apparatus according to clause 12, wherein the battery pack securing devices are adapted to be inserted through apertures in the battery pack. Apparatus according to any of the preceding clauses wherein at least one of the mounting member securing devices and the battery pack securing devices comprise a fastener. Apparatus according to clause 14, wherein the fastener is a threaded fastener. 6. Apparatus according to clause 14 or clause 15, wherein the fastener comprises a male member and a female member, the female being adapted to engage with the male member. /.Apparatus according to any of clauses 14 to 16, wherein the respective mounting member securing device or battery pack securing device comprises a channel engaging formation. 8. Apparatus according to clause 17 when dependent on clause 15 or 16, wherein the threaded fastener comprises a T bolt. 9. A method of mounting a battery pack on battery pack supporting apparatus, the method comprising:

(i) providing a base and two mounting members mounted on the base, at least one of the mounting members being movable relative to the base to enable the separation distance of the movable members to be adjusted,

(ii) moving the at least one movable mounting member relative the base to set a separation distance from the other mounting member corresponding to the battery pack;

(iii) releasably securing the at least one movable mounting member to the base to prevent movement of the at least one mounting member relative to the base;

(iv) placing the battery pack on the mounting members; and

(v) securing the battery pack to the apparatus. 0. A method according to clause 19, wherein both the mounting members are movable relative to the base and relative to each other, both the mounting members are moved relative to the base to set the separation distance, and both the mounting members are releasably secured to the base. 1 .A method according to clause 19 or clause 20, wherein securing the battery to the apparatus comprises inserting a number of battery pack securing devices through formations in the battery pack to engage the battery pack securing devices with the mounting members. A method according to clause 21 , wherein the battery pack securing devices comprise a number of fasteners, each fastener comprising a male member and female member adapted to engage the male member, and the male members are inserted through the formations in the battery pack to engage with the mounting members.