WO2022018750A1

WO2022018750A1 - An integrated charge connector holder in a saddled electric vehicle

Info

Publication number: WO2022018750A1
Application number: PCT/IN2021/050693
Authority: WO
Inventors: Vishwanath Patil LOHIT; Ramakrishna Naraharisetti; Sridhar Balaguru
Original assignee: TVS Motor Co Ltd
Current assignee: TVS Motor Co Ltd
Priority date: 2020-07-18
Filing date: 2021-07-18
Publication date: 2022-01-27
Anticipated expiration: 2023-01-18
Also published as: EP4182209A1; CN115803252A

Abstract

The present subject matter relates generally to an integrated holder (107) for an electrical component (115) in a vehicle (100). The integrated holder (107) is an elongated structure having a first upstream portion (113) and a second downstream portion (114). The first upstream portion (113) and the second downstream portion (114) are formed integrally to be the integrated holder (107) to hold one or more electrical components (115) and connectors. This structure (107) provides a holder to accommodate electrical parts and guide electrical wires (112) without using extra brackets and at the same time providing reliable mounting structure.

Description

AN INTEGRATED CHARGE CONNECTOR HOLDER IN A SADDLED ELECTRIC VEHICLE

TECHNICAL FIELD

[0001] The present subject matter relates generally to an integrated holder in a vehicle. More particularly but not exclusively the present subject matter relates to an integrated holder for one or more electrical components in said vehicle.

BACKGROUND

[0002] Generally, in a vehicle electrical parts are packaged in an enclosed structure and electrical wires are routed through one or more metal brackets, or plastic holders to keep the electrical parts and the wires in defined positions. Typically, in electric and hybrid vehicles, a charger for charging a battery is placed in front or rear portion of the vehicle and is accessible either through rear of a front panel or side of a rear panel. Accessing these locations to charge the vehicle is not user friendly as the socket of the charger is not easily reachable and often requires bending of external charging wire provided at charging stations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The details are described with reference to an embodiment of a saddle type two wheeled vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference similar features and components. Figure 1 exemplarily illustrates a partial perspective view of a two-wheeled vehicle. [0004] Figure 2 (a) exemplarily illustrates a top view of the integrated holder disposed in the vehicle.

[0005] Figure 2 (b) exemplarily illustrates the side view of the integrated holder disposed in the vehicle.

[0006] Figure 3 exemplarily illustrates an exploded view of the integrated holder along with the associated elements.

[0007] Figure 4 exemplarily illustrates perspective bottom view of the integrated holder. [0008] Figure 5 (a) exemplarily illustrates a side perspective view of the integrated holder.

[0009] Figure 5 (b) exemplarily illustrates a top view of the integrated holder. [00010] Figure 6 (a) exemplarily illustrates a side view of the integrated holder along with a plurality of extensions portions.

[00011] Figure 6 (b) exemplarily illustrates a perspective view as per an additional embodiment of the integrated holder along with a plurality of extensions portions.

DETAILED DESCRIPTION

[0001] Multiple brackets are required to be welded on a sub frame of the vehicle to mount the charger and other related electrical components and to route electrical wires resulting in complex assembly layout. Also, with the advent of electric and hybrid electric vehicle, there is a significant increase in number of electrical parts, resulting in the problem to accommodate those increased number of parts.

[0002] Generally, the electrical components are disposed in an enclosed structure which is further mounted to the frame. In order to accommodate more number of parts, multiple enclosed structures are mounted to the frame through multiple brackets, resulting in increased weight of the frame and creation of stress concentration zones, which require increased strength of the frame. Apart from above-mentioned problems, inadequate provision of mounting brackets and guiding harness lead to poor vehicle quality, hose damage, harness damage and even short circuiting. This also occupies more packaging space.

[0003] There is a need to provide a holding structure to accommodate one or more electrical parts and guide electrical wires without using extra brackets and at the same time providing reliable mounting structure. Hence there exists a need for an improved layout design of a holding structure for a saddle type vehicle which overcomes all problems cited above and other problems of known art. An objective of the present subject matter is to provide an integrated holder which facilitates the ease of accessibility, mounting and packaging of electrical components and connectors. As per an aspect of the present invention, the integrated holder includes an elongated hollow structure having a first upstream portion and a second downstream portion. The first upstream portion and the second downstream portion being integrally attached to form a housing space for one or more electrical components.

[0004] As per an embodiment of the present subject matter, the first upstream portion of the integrated holder has plurality of surfaces to form an enclosed space. The outer portion of the plurality of surfaces of the enclosed space is provided with a plurality of ribs to maintain strength and rigidity of said integrated holder. As per an embodiment, the integrated holder is made up of a plastic material.

[0005] As per another embodiment of the present subject matter, the second downstream portion is a cylindrical hollow shape extending from one of the surfaces of the first upstream portion of the integrated holder. The second downstream portion of the integrated holder extends from the first upstream portion having an elevation with respect to the bottom plane of said first upstream portion. [0006] As per another embodiment of the present subject matter, the second downstream portion of the integrated holder is provided with an opening at a distal end of the hollow cylindrical shaped part at the rear end of the vehicle. The second downstream portion has a cap to cover the opening provided at the rear end of the vehicle.

[0007] As per another embodiment of the present subject matter, the second downstream portion of the integrated holder is provided with a cut-out section, when viewed from the bottom side of the second downstream portion. This cut-out section facilitates the passage of a cable or any other electrical wires for charging or other purposes.

[0008] As per another embodiment of the present subject matter, the first upstream portion is provided with a restricting member at the front side of the integrated holder to restrict the component within the enclosed space.

[0009] As per another embodiment of the present subject matter, the integrated holder is provided with a plurality of extension portions on both sides of the integrated holder to support the integrated holder on to a pair of side frame member of the vehicle. The integrated holder is placed below a rear cross bridge member located at the rear portion of the frame. The integrated holder hugs the rear cross bridge member from the bottom side of said rear cross bridge member. This is to ensure the secured mounting of the integrated holder.

[00010] As per another embodiment of the present subject matter, the front part of the integrated holder is mounted by a plurality of attaching means disposed at a front edge of the rear cross bridge member, the rear part of the integrated holder is fastened at a rear side of the rear cross bridge member by an attaching means which sits at the middle portion of the second downstream portion of said integrated holder. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[00011] Fig.l exemplarily illustrates a partial perspective view of a two wheeled vehicle 100 with many parts omitted for brevity. The two-wheeled vehicle 100 comprises a head tube (not shown), a down tube (not shown), a pair of frame member having a left frame member 102 and a right frame member 101, a utility box 103, a rear frame 104, a pair of rear shock absorber 105, a swingarm 106, a rear wheel 110, an integrated holder 107, a battery (not shown) and an external charging socket 108. The downtube (not shown) extending downward and moving rearward in horizontal direction. Said down tube (not shown) bifurcate in the pair of frame member, one left frame member 102 extends on a left side and the other frame member 101 extends on a right side of the vehicle 100 in rearward direction to form the rear frame 104 of the vehicle 100. The utility box 103 is mounted on the pair of left frame member 102 and the right frame member 101 forming the rear frame 104 of the vehicle 100. The pair of rear shock absorber 105 is connected to the rear frame 104 at one end and the other end of the rear shock absorber 105 is connected to an axle (not shown) of the rear wheel 110 through the swingarm 106. The swingarm 106 is connected to the rear frame 104 at one end in longitudinal direction of the vehicle 100 and the other end is connected to the axle (not shown) of the rear wheel 110. The integrated holder 107 is provided at a rear side of the vehicle 100 for accommodating one or more electrical parts such as charger, connectors, electrical wires and the like. The external charging socket 108 is connected with an exposed portion of the integrated holder 107 for charging the battery (not shown). [00012] Fig. 2(a) exemplarily illustrates a top view of the integrated holder 107 disposed in the vehicle 100 and Fig.2 (b) exemplarily illustrates the side view of the integrated holder 107 disposed in the vehicle 100. A rear cross bridge member

109 connects the left frame member 102 and the right frame member 101 of the rear frame 104. The integrated holder 107 is placed below the rear cross bridge member 109. Said integrated holder 107 is disposed with its length axis oriented parallel to a longitudinal axis X-X’ of the vehicle 100.

[00013] The integrated holder 107 is disposed between the rear cross bridge member 109 and the rear wheel 110, such that the integrated holder 107 is abutting a bottom surface of the rear cross bridge member 109 to leave a working clearance

110 (a) for the oscillation of the rear wheel 110. The rear wheel 110 is provided with a wheel hugger 111 to prevent mud, pebbles and other foreign materials from reaching to the integrated holder 107.

[00014] Fig. 3 illustrates an exploded view of the integrated holder 107 along with associated elements. The integrated holder 107 includes an elongated hollow structure having a first upstream portion 113 and a second downstream portion 114. The first upstream portion 113 and the second downstream portion 114 are integrally attached to form a housing space for one or more electrical components. [00015] In the present embodiment, the first upstream portion 113 has a plurality of surfaces to form an enclosed space. The first upstream portion is a substantially quadrilateral cross section shaped structure which accommodates a battery or a charging extension of the battery or any other related electrical components 115. An outer surface of the first upstream portion 113 is provided with a plurality of ribs 116 to enhance the strength for the integrated holder 107. An upper side of the first upstream portion includes one or more front mounting provisions (124 (a)), which are attached to the bottom surface of the rear cross bridge member 109 using any known mounting means (122, 123 (a)). A front end of the first upstream portion includes a restricting member 126 that securely locks the housed electrical components within the first upstream portion in assembled condition. The restricting member 126 ensures that the one or more electrical components 115 disposed inside the integrated holder 107 do not fall off, while the vehicle 100 is in operation and thus provides a secured location for the one or more electrical components 115.

[00016] The second downstream portion 114 of said integrated holder 107 is integrally formed with the first upstream portion 113. The second downstream portion 114 in the present embodiment is a hollow cylindrical structure extending substantially inclinedly or curvedly upwards from the first upstream portion 113 such that the second portion is positioned at an elevation with respect to a bottom plane (P) of said first upstream portion 113 of the integrated holder 107. An upper side of the second downstream portion 114 is provided with an opening 117 to accommodate a charger 118, preferably a type II charger. The opening 117 of the second downstream portion 114 is capable of accommodating one or more electrical or physical components in addition to the charger 118. An upper surface of the second downstream portion 114 is provided with a rear mounting provision 124 (b) which is attached to the bottom surface of the rear cross bridge member 109. [00017] In order to access the charger, a first cut-out 119 is provided on a centre portion of a tail cover 120 disposed above the charger 118. The external charging socket 108 or a charging gun is connected easily to the charger 118 through the first cut-out 119 to charge the battery. A cap 121 is placed on the charger 118 to cover and protect it from water or any other foreign material. The opening 117 at the upper end of the second downstream portion 114 facilitates ease of accessibility and ease of serviceability to the charger or other electrical components placed thereof. The one or more wire 112 (shown in figure 4), connecting electrical components disposed in the rear side of the vehicle 100 to the battery, are routed through the elongated hollow structure of the integrated holder 107. This mechanism eliminates the use of routing brackets to hold the electrical wires 112 (shown in figure 4), in place and thus eliminates the weight addition to the vehicle 100. [00018] In the present embodiment, the integrated holder 107 is made of plastic material, however in other embodiment the integrated holder can be made of any other suitable non conducting material, as conducting material or metal is not preferred because it may conduct current passing through electrical components and result in short circuit. This eliminates the need of separate brackets to hold individual electric components and thus reduces the weight of the vehicle 100. This also reduces the overall cost addition to the vehicle 100 as number of parts is reduced.

[00019] The front mounting provisions 124 (a) provided on the upper side of the first upstream portion 113 are attached to the bottom surface of the rear cross bridge member 109 at a two mounting points 122 provided at the front side of the rear cross bridge member 109 and are mounted using a plurality of attaching means 123 (a). The rear mounting provision 124 (b) provided on the upper surface of the second downstream portion 114 is attached to the rear side of the rear cross bridge member 109 using an attaching means 123 (b). These mountings are designed to interchange the mountings for other sub-systems like fuel tank (not shown) or any other part of the vehicle 100. This aids in part count reduction & layout commonization for vehicles 100.

[00020] Fig. 4 exemplarily illustrates the perspective bottom view of the integrated holder 107 disposed in the vehicle 100. The integrated holder 107 is connected with the external charging socket 108 to charge the battery (not shown). In an embodiment, a bottom surface of the second downstream portion 114 is provided with a cut-out 125. The cut-out 125 is provided to facilitate routing of the electrical wires 112 and other connections to be routed from the traction battery (not shown) or any other components to the electrical components disposed in rear side of the vehicle 100. This routing mechanism eliminates the need of extra brackets to hold the wiring harness as the integrated holder 107 itself will guide the wires or cables 112. Wire routing through the integrated holder 107 protects the wires and connections from environmental factors and reduces usage damage.

[00021] Fig.5 (a) exemplarily illustrates a side perspective view of the integrated holder 107. Fig.5 (b) exemplarily illustrates a top view of the integrated holder 107. The front side of the first upstream portion 113 of the integrated holder 107 is provided with the restricting member 126 to hold the electrical component (not shown in this figure) placed inside the integrated holder 107. This restricting member 126 is a band made to ensure that the electrical component (not shown in this figure) do not fall outside the first upstream portion 113 and thus secures the part inside while the vehicle 100 is in running condition as shown in fig. 5(a). In an embodiment, the restricting member 126 may be a C shape strip or of any other shape suitable to restrict the electrical components.

[00022] Figure 5(b) illustrates a top view of the integrated holder 107. In a preferred embodiment, the mounting point 124 (b) is provided substantially at the lateral centre 128 of upper surface of the second downstream portion 114. The mounting point 124 (b) extends out of the upper surface of the second downstream portion 114, in the vehicle 100 longitudinal direction to facilitate mounting of the integrated holder 107 with the bottom side of the rear cross bridge member (not shown in this figure). The front mounting point 124 (a) gets attached to the bottom surface of the rear cross bridge member (not shown in this figure) to hug the rear cross bridge member (not shown in this figure).

[00023] Fig. 6 (a) exemplarily illustrates a side view and Fig. 6 (b) illustrates a perspective view as per an additional embodiment of the integrated holder 107 along with a plurality of extensions portions 127. The integrated holder 107 is mounted to the left frame member (not shown in this figure) and the right frame member (not shown in this figure) of the rear frame (not shown in this figure) through the plurality of extensions portions 127. One extension of the plurality of extensions portions 127 is provided towards the left frame member (not shown in this figure) to attach the integrated holder 107 with the rear frame (not shown in this figure). Another second extension of the plurality of extensions portions 127 is provided towards the right-side frame member (not shown in this figure) to attach the integrated holder 107 with the rear frame (not shown in this figure). Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention. As per an embodiment, the invention can be used for holding any component and guiding the wiring harness present in the vehicle to provide a robust integrated holder and reduction in parts to enable ease of accessibility and service of the parts thereat.

List of Reference numerals

100: Two-wheeled vehicle

101: Right frame member of 104

102: Left frame member of 104

103: Utility box of 100

104: Rear frame of 100

105: Shock absorber of 100

106: Swingarm of 100

107: Integrated holder of 100

108: Charging socket connected to 107

109: Rear cross bridge member mounted on 104

110: Rear wheel of 100

110(a): Clearance for 110

111: Wheel hugger of 110

112: Electrical wire from 107

113: First Upstream portion of 107

114: Second Downstream portion of 107

115: Battery or other electrical components of 100

116: Plurality of ribs on 113

P: Bottom plane of first upstream portion of 107

117: Opening on 114

118: Type II charger

119: First cut out on 120

120: Tail cover of 104

121: Cap of 107

122: Two-point mounting on 109

123 (a): Plurality of attaching means on 109 for 113

123 (b): Plurality of attaching means on 109 for 114

124 (a): One or more front mounting provisions on 113 124 (b): One or more rear mounting provisions on 114 : Cut-out section at bottom portion of 114: Restricting member on 113 : Plurality of extensions portions on 107: Centre part of 114

Claims

We claim:

1. An integrated holder (107) in a vehicle (100) comprising: an elongated hollow structure including a first upstream portion (113) and a second downstream portion (114); the first upstream portion (113) and the second downstream portion (114) being integrally attached to form a housing space for one or more electrical components.

2. The integrated holder (107) as claimed in claim 1, wherein the first upstream portion (113) has plurality of surfaces to form an enclosed space, an outer surface of said plurality of surfaces of said first upstream portion (113) of the integrated holder (107) is provided with a plurality of ribs (116).

3. The integrated holder (107) as claimed in claim 1, wherein the second downstream portion (114) is a cylindrical hollow shape extending from one of the surfaces of the first upstream portion (113) of the integrated holder (107).

4. The integrated holder (107) as claimed in claim 3, wherein the second downstream portion (114) extends from the first upstream portion (113) and has an elevation with respect to the bottom plane (P) of said first portion

(113).

5. The integrated holder (107) as claimed in claim 4, wherein an opening (117) is provided at a distal end of said hollow shaped second downstream portion

(114) at the rear end ofthe vehicle (100), said opening (117) being provided to accommodate one or more electrical components.

6. The integrated holder (107) as claimed in claim 4, wherein the second downstream portion (114) of the integrated holder (107) being provided with a cut-out section (125) at a bottom side of the second downstream portion (114).

7. The integrated holder (107) as claimed in claim 1, wherein a restricting member (126) being provided at the front side of the first upstream portion (113) to restrict the component (115) within the enclosed space.

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8. The integrated holder (107) as claimed in claim 1, wherein the integrated holder (107) is mounted through a plurality of extensions portions (127) provided on both sides of the integrated holder to (107) to support the holder on to a pair of side frame members (101,102) of the frame of the vehicle

(100).

9. The integrated holder (107) as claimed in claim 1, wherein the integrated holder (107) is placed below a rear cross bridge member (109), the front portion of the integrated holder (107) is mounted by a plurality of attaching means (123 (a)) and a plurality of mounting means (122) disposed at a front edge of the rear cross bridge member (109), the rear portion of the integrated holder (107) is attached at a rear side of the rear cross bridge member (109) by the attaching means (123 (b)).

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