Battery pack installation assembly

Abstract

An electric vehicle includes a vehicle frame, a battery pack mounted to the vehicle frame, a main bracket fixed to each of the vehicle frame and the battery pack, and a support bracket fixed to the battery pack and the main bracket. The support bracket improves the rigidity of the main bracket.

Description

Technical Field

[0001] The present disclosure relates to mounting a battery pack to an electric vehicle. An example mounting assembly for mounting a battery pack to a vehicle frame includes a frequency enhancing support bracket for improving vibration characteristics of the mounted battery pack. Background Art

[0002] The need to reduce automotive fuel consumption and emissions is well documented. Electric vehicles are being developed with the goal of reducing or completely eliminating reliance on internal combustion engines. Generally, electric vehicles differ from conventional motor vehicles in that they are selectively powered by one or more battery-powered electric motors. In contrast, conventional motor vehicles rely entirely on internal combustion engines to drive the vehicle.

[0003] High voltage battery packs typically power the electric motors of electric vehicles. The high voltage battery packs are typically attached to the vehicle frame using various attachments and supports. These attachments and supports must be designed to meet the noise, vibration and harshness requirements of electric vehicles. Summary of the invention

[0004] According to an exemplary aspect of the invention, an electric vehicle includes, among other aspects, a vehicle frame, a battery pack mounted to the vehicle frame, a main bracket secured to each of the vehicle frame and the battery pack, and a support bracket secured to the battery pack and the main bracket.

[0005] In a further non-limiting embodiment of the foregoing electric vehicle, the main bracket is secured to a tray of a housing of the battery pack.

[0006] In a further non-limiting embodiment of any of the foregoing electric vehicles, the main bracket includes a base and a bracket arm protruding from the base.

[0007] In a further non-limiting embodiment of any of the foregoing electric vehicles, the support bracket is secured to the bracket arms of the main bracket and to the tray of the housing of the battery pack.

[0008] In a further non-limiting embodiment of any of the foregoing electric vehicles, the bracket arm includes a first arm portion extending generally parallel to a side wall of the battery pack and a second arm portion projecting at a lateral angle from the first arm portion.

[0009] In a further non-limiting embodiment of any of the foregoing electric vehicles, the second arm portion includes an opening for receiving a fastener for mounting the battery pack to a vehicle frame.

[0010] In a further non-limiting embodiment of any of the foregoing electric vehicles, the support bracket includes a first mounting lug mounted to the battery pack, a second mounting lug mounted to the main bracket, and a wall extending between the first mounting lug and the second mounting lug.

[0011] In a further non-limiting embodiment of any of the foregoing electric vehicles, the predetermined breaking area is formed in the second mounting lug.

[0012] In a further non-limiting embodiment of any of the foregoing electric vehicles, the predetermined fracture area includes a groove.

[0013] In a further non-limiting embodiment of any of the foregoing electric vehicles, the first mounting tab includes a distal portion that is spaced from the wall and includes a contoured profile.

[0014] In a further non-limiting embodiment of any of the foregoing electric vehicles, a weld bead connects the first mounting tab to the battery pack along a wavy profile.

[0015] In a further non-limiting embodiment of any of the foregoing electric vehicles, the weld includes at least one curved portion.

[0016] In a further non-limiting embodiment of any of the foregoing electric vehicles, the support bracket includes at least one groove establishing a predetermined fracture area in the support bracket.

[0017] In a further non-limiting embodiment of any of the foregoing electric vehicles, the support bracket includes a Z-shaped structure.

[0018] In a further non-limiting embodiment of any of the foregoing electric vehicles, the support bracket includes a C-shaped structure.

[0019] According to another exemplary aspect of the invention, a method includes, among other aspects, securing a battery pack to a vehicle frame using a mounting assembly including a main bracket and a support bracket extending between the battery pack and the main bracket to increase the rigidity of the main bracket.

[0020] In a further non-limiting embodiment of the foregoing method, securing the battery pack includes welding the main bracket to a housing of the battery pack, and mechanically fastening the main bracket to a vehicle frame.

[0021] In a further non-limiting embodiment of any of the foregoing methods, securing the battery pack includes welding the support bracket to the housing of the battery pack using a first weld, and welding the support bracket to the main bracket using a second weld.

[0022] In a further non-limiting embodiment of any of the foregoing methods, the first weld extends along a non-linear path and the second weld extends along a linear path.

[0023] In a further non-limiting embodiment of any of the foregoing methods, the supporting stent includes a predetermined fracture region.

[0024] Embodiments, examples and alternative examples including any of the various aspects or individual features of the above paragraphs, claims or following description and drawings may be obtained independently or in any combination. Features described as being relevant to one embodiment are applicable to all embodiments unless these features are incompatible.

[0025] From the detailed description, the various features and advantages of the present disclosure will become apparent to those skilled in the art. The drawings accompanying the detailed description can be briefly described as follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 schematically illustrates a powertrain system for an electric vehicle;

[0027] Figure 2 Is equipped with Figure 1 A side view of an electric vehicle with a powertrain, a battery pack of the powertrain is shown mounted to the electric vehicle;

[0028] Figure 3 A mounting assembly for securing a battery pack to an electric vehicle is shown;

[0029] Figure 4A , 4B and 4C illustrate an exemplary support bracket for a battery pack mounting assembly;

[0030] Figure 5 Another exemplary support bracket for a battery pack mounting assembly is shown;

[0031] Fig. 6A , 6B 6C show yet another exemplary support bracket for a battery pack mounting assembly. DETAILED DESCRIPTION

[0032] The present disclosure details a mounting assembly for securing a battery pack to an electric vehicle. An exemplary battery pack mounting assembly for an electric vehicle includes a main bracket mounted to each of the battery pack and the vehicle frame, and a support bracket mounted to each of the battery pack and the main bracket. The support bracket increases the stiffness of the main bracket, thereby improving the vibration characteristics of the mounted battery pack. These and other features of the present disclosure will be described in more detail below.

[0033] Figure 1 A powertrain system 10 for an electric vehicle is schematically shown. Although described as a hybrid electric vehicle (HEV), it should be understood that the concepts described herein are not limited to HEVs and may be extended to any other type of electric vehicle, including but not limited to plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), fuel cell vehicles, etc.

[0034] The powertrain 10 includes a battery pack 14 having a plurality of battery arrays 18, an internal combustion engine 20, a motor 22, and a generator 24. The battery pack 14 may be a high voltage traction battery pack. The motor 22 and the generator 24 may be various types of electric machines. The motor 22 and the generator 24 may be separate or in the form of a combined motor-generator.

[0035] In one embodiment, the powertrain 10 is a power split powertrain that uses a first drive system and a second drive system. The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels 28. The first drive system includes a combination of an engine 20 and a generator 24. The second drive system includes at least a motor 22, a generator 24, and a battery pack 14. The motor 22 and the generator 24 can establish an electric drive system of the powertrain 10.

[0036] The engine 20 and the generator 24 can be connected through a first power transfer unit 30, such as a planetary gear set. Of course, other types of power transfer units, including other gear sets and transmissions, can be used to connect the engine 20 to the generator 24. In one embodiment, the first power transfer unit 30 is a planetary gear set including a ring gear 32, a sun gear 34, and a carrier assembly 36.

[0037] Generator 24 can be driven by engine 20 through first power transmission unit 30 to convert kinetic energy into electrical energy. Alternatively, generator 24 can function as a motor to convert electrical energy into kinetic energy, thereby outputting torque to shaft 38 connected to power transmission unit 30.

[0038] The ring gear 32 of the first power transfer unit 30 is connected to a shaft 40, which is connected to the vehicle drive wheels 28 via a second power transfer unit 44. The second power transfer unit 44 may include a gear set having a plurality of gears 46. In other examples, other power transfer units may be used.

[0039] Gear 46 transfers torque from engine 20 to differential 48 to ultimately provide traction to vehicle drive wheels 28. Although not shown in FIG. Figure 1 Although shown in a highly schematic depiction of FIG. 4 , the differential 48 may include multiple gears that enable torque to be transferred to the vehicle drive wheels 28 . In this example, the second power transfer unit 44 is mechanically connected to the axle 50 through the differential 48 to distribute torque to the vehicle drive wheels 28 .

[0040] The motor 22 can be selectively used to drive the vehicle drive wheels 28 by outputting torque to a shaft 54 ​​that is also connected to the second power transfer unit 44. In one embodiment, the motor 22 and the generator 24 cooperate as part of a regenerative braking system, in which both the motor 22 and the generator 24 can be used as motors to output torque. For example, the motor 22 and the generator 24 can each output electrical energy to recharge battery cells of the battery pack 14.

[0041] Figure 2 Shown with Figure 1 The battery pack 14 of the powertrain 10 may contain one or more battery arrays 18 (e.g., grouped battery cells) within a housing 54. The housing 54 may include a cover 55 and a tray 56. The cover 55 is secured to the tray 56 to enclose the battery array 18 and other electronic components of the battery pack 14. In one embodiment, the housing 54 is a metal structure. However, the housing 54 may be made of other materials including polymer materials.

[0042] The battery pack 14 may be secured to a frame 58 of the electric vehicle 12 by at least one mounting assembly 60. In one embodiment, the frame 58 is part of the chassis of the electric vehicle 12. When secured to the frame 58, the battery pack 14 is suspended from the floor of the electric vehicle 12 and is located outside of the passenger compartment of the electric vehicle 12.

[0043] In one embodiment, the battery pack 14 is secured to the vehicle frame 58 by at least two mounting assemblies 60. Each side wall 66 ( Figure 2 In one embodiment, the battery pack 14 is secured to the vehicle frame 58 using a mounting assembly 60 secured to each end wall 68 of the battery pack 14. In yet another embodiment, the battery pack 14 is secured to the vehicle frame 58 using four mounting assemblies 60, one mounting assembly 60 secured to each side wall 66 and each end wall 68 of the battery pack 14. The number of mounting assemblies 60 used to mount the battery pack 14 may vary depending on various factors, including, but not limited to, the size, shape, and weight of the battery pack 14.

[0044] Now refer to Figure 2 and Figure 3 , each mounting assembly 60 can include at least one main bracket 62 and at least one support bracket 64. In one embodiment, the main bracket 62 is fixed to the housing 54 (e.g., fixed to the tray 56) and fixed to the frame 58 to mount the battery pack 14 to the frame 58. For example, the main bracket 62 can include a base 70 welded to the housing 54 and at least one bracket arm 72 mechanically fixed to the frame 58 using one or more fasteners 74. The frame 58 may include hardware for receiving the fasteners 74.

[0045] In another embodiment, a plurality of bracket arms 72 protrude upward (i.e., in a direction toward the frame 58) from the base 70 of the main bracket 62. The total number of bracket arms 72 provided on the main bracket 62 is not intended to limit the present disclosure. Each bracket arm 72 may include a first arm portion 76 extending generally parallel to the side wall 66 of the battery pack 14 and a second arm portion 78 protruding from the first arm portion 76 at a lateral angle. Each second arm portion 78 is thus generally parallel to the frame 58. The second arm portion 78 may include an opening 80 to receive one of the fasteners 74 for securing the battery pack 14 to the frame 58.

[0046] The support bracket 64 can be fixed to the outer shell 54 (e.g., the tray 56) and the main bracket 62. The support bracket 64 can be welded (e.g., spot welded or inert gas shielded (MIG) welded) or mechanically attached to each of the outer shell 54 and the main bracket 62. In one embodiment, the support bracket 64 extends between the outer shell 54 and at least one bracket arm 72 of the main bracket 62. Although Figure 2 and Figure 3 Only a single bracket 64 is shown, but the mounting assembly 60 may include multiple support brackets 64 extending between the housing 54 and one or more bracket arms 72 of the main bracket 62. The support brackets 64 increase the rigidity of the main bracket 62 to meet the normal mode frequency requirements, safety requirements, and durability requirements associated with the battery pack 14.

[0047] In one embodiment, the main bracket 62 and the support bracket 64 are made of the same type of material or combination of materials. However, in another embodiment, the support bracket 64 is made of a thinner gauge material than the main bracket 62.

[0048] Continue to refer Figure 1-3 , Figures 4A-4C Additional details of the support bracket 64 of the exemplary mounting assembly 60 described above are shown. The support bracket 64 may include a first mounting lug 82, a second mounting lug 84, and a wall 86 extending between the first mounting lug 82 and the second mounting lug 84. The first mounting lug 82, the second mounting lug 84, and the wall 86 together establish a unitary structure without mechanical fasteners. The first mounting lug 82 and the second mounting lug 84 may protrude from the wall 86 in opposite directions. Thus, in this embodiment, the support bracket 64 is generally Z-shaped. Figure 4C The Z-shaped structure is best shown in FIG. However, other shapes are also contemplated within the scope of the present disclosure (see, e.g. Fig. 6A , 6B and 6C embodiments).

[0049] When installed, the first mounting lug 82 of the support bracket 64 is connected to the housing 54, the second mounting lug 84 is connected to the main bracket 62, and the wall 86 can extend at a nearly perpendicular angle relative to the housing 54 (see FIG. Figure 3 ). This increases the rigidity of the main bracket 62, thereby improving the vibration characteristics of the battery pack 14 once the battery pack 14 is mounted to the vehicle frame 58.

[0050] The first mounting lug 82 extends between a proximal portion 88 connected to the wall 86 and a distal portion 90 spaced apart from the wall 86. The distal portion 90 may include a wavy profile 91 to accommodate a weld 92 for securely securing the support bracket 64 to the housing 54. In one embodiment, the wavy profile 91 includes a first surface 93 extending in a direction toward the proximal portion 88, a second surface 94 extending parallel to the proximal portion 88, and a third surface 95 extending in a direction away from the proximal portion 88. When the support bracket 64 is mounted to the housing 54, the weld 92 can be formed by closely following the path of the wavy profile 91. Therefore, the weld 92 will include at least one curved portion 96 for avoiding stress concentration at the interface between the first mounting lug 82 and the housing 54 (e.g., the tray 56). Therefore, the weld 92 extends along a non-linear path.

[0051] The second mounting lug 84 may also extend between a proximal portion 98 connected to the wall 86 and a distal portion 99 spaced apart from the wall 86. In one embodiment, a groove 100 is formed at an edge 102 of the second mounting lug 84 at a location between the proximal portion 98 and the distal portion 99. The edge 102 may be a top edge or a bottom edge of the second mounting lug 82 when viewed in the installed position. In another embodiment, the second mounting lug 84 may include at least one groove 100 formed in both the top edge 102 and the bottom edge 102 of the second mounting lug 82 (see, e.g., Figure 5 ). The one or more grooves 100 form a predetermined fracture area in the second mounting lug 84 of the support bracket 64. Therefore, in the event of any collision event (e.g., front, side, rear, side pillar, etc.), the second mounting lug 84 can shear through the one or more grooves 100, thereby dissipating energy and minimizing intrusion into the housing 54.

[0052] The support bracket 64 can be provided by providing a weld 104 along the lateral edge of the distal portion 99 of the second mounting lug 84 (see Figure 3 and 4B ) to be fixed to the main bracket 62. The weld 104 extends along a linear path between the opposite weld ends 106. In one embodiment, the depth D of the groove 100 extending into the second mounting lug 84 is greater than that of the groove 100 (see Figure 4B) is located deeper at the end 106 of the weld 104 on the same side as the groove 100. In other words, the distance from the edge 102 to the bottom surface 101 of the groove 100 is farther than the distance to the end 106 of the weld 104. Therefore, during a collision event, the collision load is directed to the groove 100 and is not significantly shared by the weld 104.

[0053] Fig. 6A , 6B 6C shows another exemplary support bracket 264 for use within a battery pack mounting assembly. Support bracket 264 is similar to support bracket 64 described above, but is shown to demonstrate another packaging option provided by the mounting assembly of the present disclosure. Support bracket 264 may include a first mounting lug 282, a second mounting lug 284, and a wall 286 extending between the first mounting lug 282 and the second mounting lug 284. The first mounting lug 282, the second mounting lug 284, and the wall 286 together establish a monolithic structure. The first mounting lug 282 and the second mounting lug 284 may protrude in the same direction away from the wall 286. Therefore, in this embodiment, support bracket 264 is generally C-shaped. Figure 6C The C-shaped structure is best shown in .

[0054] The support bracket 264 may further include one or more grooves 200. In one embodiment, the grooves 200 are formed in the top edge 202 of the second mounting lug 284, in the bottom edge 203 of the second mounting lug 284, or both (when viewed from the mounting position of the support bracket 264). The one or more grooves 200 form a predetermined fracture area in the second mounting lug 284 of the support bracket 264. Thus, in the event of any collision, the second mounting lug 284 can shear through the one or more grooves 200, thereby dissipating energy and minimizing intrusion into the housing 54.

[0055] The disclosed battery pack mounting assembly includes one or more support brackets. The support brackets increase the stiffness of the main bracket of the mounting assembly, thereby improving the vibration performance of the battery pack once installed on the vehicle frame, while meeting safety and durability requirements. The main bracket and the support bracket together provide a relatively lightweight modular mounting assembly.

[0056] Although different non-limiting embodiments are described as having specific components or steps, the embodiments of the present disclosure are not limited to only those specific combinations. It is possible to use some components or features from any non-limiting embodiment in combination with components or features from any other non-limiting embodiment.

[0057] It should be understood that throughout the several drawings, like reference numerals indicate corresponding or similar elements.It should be understood that although specific component arrangements are disclosed and depicted in these exemplary embodiments, other arrangements may be obtained according to the teachings of the present disclosure.

[0058] The above description should be understood as illustrative rather than restrictive. Those skilled in the art will appreciate that certain modifications may be made within the scope of the present disclosure. For these reasons, the scope of legal protection for the present invention should be determined by studying the following claims.

Claims

1. An electric vehicle comprising: Vehicle frame; a battery pack mounted to the vehicle frame; a main bracket secured to each of the vehicle frame and the battery pack; a support bracket secured to the battery pack and the main bracket, wherein the support bracket includes a first mounting tab mounted to the battery pack, a second mounting tab mounted to the main bracket, and a wall extending between the first mounting tab and the second mounting tab, the first mounting tab including a distal portion spaced from the wall and including a wavy profile; and A weld connects the first mounting tab to the battery pack along the undulating profile. 2 . The electric vehicle according to claim 1 , wherein the main bracket is fixed to a tray of a housing of the battery pack.

3. An electric vehicle according to claim 1 or 2, wherein the main bracket includes a base and a bracket arm protruding from the base, and wherein the support bracket is fixed to the bracket arm of the main bracket and a tray of the housing of the battery pack.

4. The electric vehicle of claim 3, wherein the bracket arm includes a first arm portion extending generally parallel to a side wall of the battery pack and a second arm portion projecting at a lateral angle from the first arm portion, the support bracket being fixed to the first arm portion of the bracket arm but not to the second arm portion of the bracket arm, and wherein the second arm portion includes an opening for receiving a fastener for mounting the battery pack to the vehicle frame. 5 . The electric vehicle of claim 1 , wherein the support bracket includes a predetermined break region formed in the second mounting tab. The electric vehicle according to claim 5 , wherein the predetermined fracture area comprises a groove.

7. The electric vehicle of claim 1, wherein the first mounting lug and the second mounting lug are perpendicular to the wall.

8. The electric vehicle of claim 1, wherein the weld includes at least one curved portion.

9. The electric vehicle of claim 1, wherein the support bracket includes at least one groove that establishes a predetermined fracture area in the support bracket.

10. The electric vehicle of claim 1, wherein the supporting bracket comprises a Z-shaped structure or a C-shaped structure.

11. A method of securing a battery pack to an electric vehicle, comprising: A battery pack is secured to a vehicle frame using a mounting assembly including a main bracket and a support bracket, wherein the support bracket extends between the battery pack and the main bracket to increase the rigidity of the main bracket, wherein the support bracket includes a first mounting lug mounted to the battery pack, a second mounting lug mounted to the main bracket, and a wall extending between the first mounting lug and the second mounting lug, the first mounting lug including a distal portion that is spaced from the wall and includes a wavy profile, Wherein fixing the battery pack comprises: The first mounting lug of the support bracket is welded to the battery pack via a first weld along the undulating profile.

12. The method of claim 11, wherein securing the battery pack comprises: Welding the main bracket to the housing of the battery pack; as well as The main bracket is mechanically fastened to the vehicle frame.

13. The method according to claim 11 or 12, wherein fixing the battery pack comprises: welding the first mounting lug of the support bracket to the housing of the battery pack via the first weld; as well as The second mounting lug of the support bracket is welded to the main bracket by a second weld.

14. The method of claim 13, wherein the first weld extends along a non-linear path and the second weld extends along a linear path.

15. The method of any one of claims 11-12, wherein the supporting stent comprises a predetermined fracture region.

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