Tubular shielding for the protection of electric vehicle batteries.

Description

1 / 6 Tubular shielding for the protection of electric vehicle batteries.

[001] The present invention relates to a tubular shield for protecting the batteries of an electric vehicle. More particularly, the invention relates to a metallic tubular shield for protecting the batteries of an electric vehicle in the event of a rear-end collision.

[002] This invention relates to the field of automotive safety, with a specific focus on protective structures for electric or hybrid vehicle batteries during a rear-end collision (as per FMVSS-301 rear-end test at 80 km / h). State of the Art

[003] In current electric or hybrid vehicles, a commonly used solution is to place the electric batteries, or battery packs, supported by the vehicle floor. To achieve this, the individual cell casing is presented as a parallelepiped-shaped structure with a low height, thus allowing the battery pack to be properly housed in the vehicle floor area without compromising the interior space of the passenger compartment. As an added advantage, the arrangement of the batteries adjacent to the floor of the vehicle's monocoque body helps lower the vehicle's center of mass, thus improving its handling.

[004] Although this solution is technically very appropriate, it is not without drawbacks. Due to the thinness of the battery casing, its other dimensions (width and length) must be increased in order to maintain the same internal storage volume, which depends exclusively on the number of individual cells to be stored. The greater extent of the battery casing in the plane of the vehicle floor brings its edges closer to the dimensional limits of the floor, thus leaving the battery pack more exposed in the event of vehicle collisions.

[005] One way to increase the safety of the battery pack is by providing safety devices or structures capable of protecting the battery pack in the event of collisions. Petition 870240111143, dated 12 / 30 / 2024, page 13 / 22 2 / 6

[006] Current solutions for protecting electric vehicle batteries during rear-end collisions also include reinforced battery housings, strategic positioning of the battery pack, and various forms of impact-absorbing materials. These solutions aim to prevent damage to the battery, which can lead to dangerous situations such as fires or loss of vehicle power.

[007] US11161401 document describes a body structure for an electric vehicle, including a floor panel and a battery anti-collision structure. The battery and a motor are arranged below the floor panel, and the motor is located behind the battery. The battery anti-collision structure is arranged between the battery and the motor, and is configured to prevent the motor from striking the battery in the event of a rear-end collision involving the electric vehicle.

[008] Document CN114261269 describes a rear collision protection structure for automobiles, which relates to the technical field of automobiles and solves the problem of a battery being extruded from the top of the battery compartment when a rear panel of the automobile is flipped over. The rear collision protection structure for automobiles comprises a lower support structure and a rear locking structure; the lower support structure is arranged in a spare tire well of an automobile, fixed to a floor beam of the automobile and used to support a battery; the rear locking structure is fixed in the position, facing the rear of the automobile, of the lower support structure, and the height of the rear locking structure in the vertical direction is not less than that of the battery. The rear collision protection structure for automobiles is used to protect the battery.

[009] Despite these measures, art solutions generally fail to address the specific scenario where a spare tire, displaced during a collision, impacts the battery. This can result in direct damage to the battery, compromising vehicle safety and performance. In addition, some solutions may add significant weight or complexity to the vehicle design, affecting efficiency and cost.

[0010] Thus, the need for a protective structure for the battery pack of an electric or hybrid vehicle remains in the art, capable of guaranteeing its integrity in Petition 870240111143, dated 12 / 30 / 2024, page 14 / 22 3 / 6 case of collisions.

[0011] Another objective of the invention is a shielding device for batteries, in particular for protection against rear-end collisions of the electric vehicle. Summary of the Invention

[0012] These and other objectives are satisfied by a tubular shield for the protection of the batteries of an electric vehicle, comprising a U-shaped tubular main body with a straight base, from each end of which project transversely and are defined first and second mounting supports, the first and second supports having respective first and second holes for fixing the shield to the vehicle floor, and from the median portion of the main body projecting at an angle a tubular arm, the opposite end of the arm projecting transversely and being defined a third mounting support having a third hole for fixing the shield to the vehicle floor.

[0013] In one embodiment, the mounting brackets are formed by crushing and bending the respective tubular metal ends, without any break in the continuity of the respective metal tubes.

[0014] In another embodiment, the armor is dimensioned so that the mounting brackets are fixed to respective crossbars in the vehicle floor.

[0015] In another embodiment, the shielding is installed between the rear axle and the vehicle's battery. Brief Description of the Figures

[0016] The object of the present invention may be better understood from the detailed description that follows, in a preferred and non-limiting embodiment of the invention, which is made with the support of the attached figures, provided by way of illustration and not limitation, in which: Figure 1 is a bottom perspective view of the rear portion of an electric vehicle; Figure 2 is a top elevation view of the tubular shielding of the invention; and Figure 3 is a side elevation view of the tubular armor. Preferred Embodiment of the Invention Petition 870240111143, dated 12 / 30 / 2024, page 15 / 22 4 / 6

[0017] For the purposes of this description, the reference used to describe any and all component parts of the invention is the same as that of the vehicle, considering the installed position of the component part in the vehicle.

[0018] Although the present invention is described below based on a preferred embodiment for an electric pickup truck, those skilled in the art will readily understand that the present tubular shielding can equally be applied to passenger vehicles, as well as to hybrid vehicles, provided that the fundamental characteristics that define the present invention are maintained.

[0019] In accordance with figure 1 attached, 1 refers, in its entirety, to an electric vehicle, in particular a pickup truck type vehicle, which comprises an engine compartment in a front position, a passenger compartment in an intermediate position and a cargo compartment 2, in the form of a truck bed, in a rear position.

[0020] In this type of vehicle, as in several others such as SUVs and compacts, it is usual to have the spare tire 3, or spare tire, fixed below the floor, and in particular in the rear portion of the vehicle floor 4, and specifically in a position behind the rear axle 5 of the vehicle. In this way, the loss of cargo space of the vehicle 1 is avoided.

[0021] In one embodiment, axle 5 of the vehicle is fixed to a rigid suspension 9.

[0022] Conversely, in the event of a rear-end collision with vehicle 1, the spare tire 3 may extend beyond the rear axle 5, thus colliding with the battery casing 6, damaging it and potentially causing significant electrical damage to the vehicle and possibly to the external environment. This situation has been verified in practice from rear-end collision tests of vehicles, the FMVSS-301 test, in which the vehicle collides with a rigid structure at 80 km / h.

[0023] In order to protect the battery casing 6, a shield 10, according to the invention, comprises a U-shaped tubular main body 11 with a straight base, from each end of which project transversely and are defined first and second mounting supports 12, 13. Each of said first and second Petition 870240111143, dated 12 / 30 / 2024, page 16 / 22 5 / 6 supports 12, 13 featuring respective first and second holes 14, 15 for fixing the armor to the floor 4 of the vehicle chassis 1.

[0024] Furthermore, from the median portion of the main body 11, a tubular arm 16 projects at an angle (relative to the plane defined by the main body 11). At the opposite end of the arm 16, a third mounting support 17 projects transversely and is defined, similarly having a third hole 18 for fixing the armor 10 to the floor 4 of the vehicle chassis 1.

[0025] Preferably, mounting brackets 12, 13 and 17 are formed by crushing and bending the respective tubular metal ends, without any break in the continuity of the respective metal tubes.

[0026] Regarding the assembly, shield 10 is installed between the rear suspension, in particular the rear axle 5, and the battery 8, in order to absorb an impact and prevent the dislodged spare tire 3 from hitting the battery 8.

[0027] In another preferred embodiment, the shielding 10 is dimensioned so that said mounting brackets 12, 13 and 17 are fixed to respective crossbars 6, 7 of the floor 4 of the vehicle 1.

[0028] In summary, the present solution makes it possible to increase the safety of the vehicle 1 and guarantee the integrity of the battery 8 in accordance with the homologation requirements, especially for pickup trucks with rigid rear axle suspension 4.

[0029] In particular, the tubular structure is made from high-strength steel tubing, which provides durability and impact resistance. Mounting brackets attach the armor 10 to the vehicle structure 1, ensuring stability and effectiveness. And with regard to the energy absorption design, the tubular structure is designed to deform under impact, absorbing energy and reducing the force transmitted to the battery.

[0030] As a result of the above, shielding 10 results in the following advantages: Enhanced safety: provides an additional layer of protection for the battery, reducing the risk of damage during collisions; - Lightweight design: the armor is designed to be lightweight, minimizing any impact on the vehicle's efficiency and range; and Petition 870240111143, dated 12 / 30 / 2024, page 17 / 22 6 / 6 Cost-effective: the solution is relatively simple to manufacture and install, offering an economical way to increase vehicle safety.

[0031] In order to ensure that the theoretical principles of the present solution were confirmed in practice, a failure analysis was carried out, based on the aforementioned FMVSS-301 rear-end collision test at 80 km / h, which resulted in no failures, thus guaranteeing the integrity of the system. In particular, it should be noted that: - Structural Stability: The shielding maintained its structural integrity during the test; - Battery: The battery remained intact and fully functional; - Vehicle Pulses: The vehicle's pulses were within acceptable limits, indicating effective energy absorption; and - High Voltage System: The high voltage system was protected and remained operational. Petition 870240111143, dated 12 / 30 / 2024, pages 18 / 22

Claims

1 / 1 Claims 1. TUBULAR SHIELD (10) FOR THE PROTECTION OF THE BATTERIES OF AN ELECTRIC VEHICLE, characterized by comprising a U-shaped tubular main body (11) with a straight base, from each end of which project transversely and are defined first and second mounting supports (12, 13), and wherein the first and second supports (12, 13) have respective first and second holes (14, 15) for fixing the shield to the floor (4) of the vehicle (1), and wherein from the median portion of the main body (11) projects, at an angle, a tubular arm (16), wherein at the opposite end of the arm (16) projects transversely and is defined a third mounting support (17) having a third hole (18) for fixing the shield (10) to the floor (4) of the vehicle (1).

2. SHIELDING, according to claim 1, characterized in that the mounting supports (12,13,17) are formed from crushing and bending the respective tubular metal ends, without any break in the continuity of the respective metal tubes.

3. SHIELDING, according to claim 1, characterized in that the shielding (10) is dimensioned so that the mounting brackets (12, 13, 17) are fixed to respective crossbars (6, 7) of the floor (4) of the vehicle (1).

4. SHIELDING, according to any of claims 1 or 3, characterized in that the shielding (10) is installed between the rear axle (5) and the vehicle battery (8). Petition 870240111143, dated 12 / 30 / 2024, p. 19 / 22

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