Power supply assembly for a motor vehicle

Abstract

An electrical power supply assembly (10'; 10") comprising: a housing (12'; 12") having a base (14'; 14") and at least two side walls (20', 22'; 20", 22"); a collection of battery pack modules (30', 32'; 30", 31, 32") each comprising a battery pack (34'; 34") having two opposite ends (36', 38'; 36", 38") and two opposite flanges (40', 42'; 40", 42") covering said ends, the modules being mounted on said base in the form of a plurality of rows (24', 26', 28'; 24", 26", 28") of (I) modules arranged substantially in line with each other. The rows are arranged such that the flanges (40', 42', 50'; 50", 40", 42") are aligned edge to edge; and the aligned flanges are connected to the base of the housing so as to form rigid cross members inside the housing.

Description

Technical Field

[0001] This invention relates to a power supply component for motor vehicles. Background Technology

[0002] Specifically, one envisioned application area is where its power supply components are onboard electric vehicles or even hybrid vehicles.

[0003] Therefore, the power supply assembly of a hybrid vehicle is typically installed under the trunk floor. This assembly includes a housing with a bottom and four walls that are paired opposite each other and project upright from the bottom: two side walls, a rear wall, and a front wall. The assembly also includes an assembly of battery pack modules housed within the housing. Each module in this assembly has a battery pack with two opposing ends and two opposing flanges covering those ends. For example, these batteries are prismatic lithium-ion batteries mounted in series between the two flanges.

[0004] The modules of this assembly are mounted inside the housing, on the bottom, in the form of multiple consecutive rows of n modules. These n modules are coaxially positioned within each other's extensions and substantially parallel to these sidewalls. Furthermore, these modules are electrically connected in series.

[0005] The housing containing the module assembly must provide resistance to deformation and must pass an impact test, or "crash test." Therefore, to achieve this, reinforcing cross members are installed across the housing between the modules and perpendicular to the sidewalls. These reinforcing cross members then extend from one sidewall to the other to mechanically connect these sidewalls and make the housing more rigid. However, the installation of these reinforcing cross members is detrimental to reserving space for the battery pack modules and therefore to the amount of electrical energy that can be stored.

[0006] Therefore, it is conceivable to mount the reinforcing element on the outside of the casing, but this is always disadvantageous in terms of reserving space for the battery pack. See document CN 101209659 A, which describes such a reinforcing element. Summary of the Invention

[0007] Therefore, one problem that has emerged and that this invention aims to solve is to provide a power supply assembly for motor vehicles that provides good resistance to deformation without affecting the energy that can be stored and the ease of integration into the vehicle, and without excessively increasing the weight and volume of the internal and external housing.

[0008] To address this problem, a power supply assembly for a motor vehicle is proposed, comprising: a housing having a bottom and at least two sidewalls opposite each other and projecting upright from the bottom; and an assembly of battery modules, each of the modules having a battery pack having two opposing ends and two opposing flanges respectively covering the ends, the modules being mounted inside the housing, on the bottom, in the form of a plurality of consecutive rows of n modules, the n modules being coaxially located in extensions of each other and substantially parallel to the sidewalls. The consecutive rows are arranged such that the flanges of the modules in the rows are aligned side-to-side in a direction substantially perpendicular to the opposing sidewalls; and the aligned flanges are secured to the bottom of the housing to form a rigid transverse member inside the housing.

[0009] Therefore, a feature of the present invention is that the specific arrangement of the rows of modules allows the flanges to be assembled side-to-side and aligned in a direction perpendicular to the sidewalls, and further secures the flanges to the bottom of the housing. In other words, the structure of the modules themselves is utilized to form transverse members with the flanges, thereby making the housing more rigid. In fact, since the flanges are assembled side-to-side in a direction perpendicular to the sidewalls and further secured to the bottom of the housing, these flanges constitute rigid elements capable of withstanding compression (as will be explained in more detail in the remainder of this specification).

[0010] In this way, there is no need to install auxiliary cross members, and therefore the housing is only reserved for installing the battery pack module, and the housing is still rigid so as to resist deformation and pass the impact test.

[0011] According to a particularly advantageous embodiment of the invention, the modules in each of the rows are connected together in pairs by a single flange. In this way, for each of these rows, two battery packs are connected by a single flange, and therefore, a greater number of batteries are accommodated relative to a given row length (where each module has two flanges).

[0012] Furthermore, the modules in the module set advantageously have only a single length. In this way, all the flanges of the module can be aligned side-to-side inside the housing, and thus can form reinforcing cross members after these flanges have been fixed in the bottom of the housing. In addition, it is easier to fill all the available space in the housing, the dimensions of which are provided according to the module.

[0013] Preferably, the housing has a front wall and an opposing rear wall that project upright from the bottom and respectively connect the side walls substantially vertically to enclose the housing. In this way, the rigidity of the housing is further improved.

[0014] Furthermore, each of the flanges advantageously has a given thickness, and at least one through-hole is formed in said thickness to allow a fastening screw to pass through. Preferably, the flange has two parallel holes formed in its thickness, thereby allowing two fastening screws to pass through to perfectly secure the flange and the bottom of the housing.

[0015] Therefore, according to a particularly advantageous embodiment of the invention, the bottom of the housing has a threaded portion for receiving screws used to fasten the flange. Thus, the threaded portion is formed in the bottom of the housing in a predetermined position to accommodate an assembly of battery pack modules. After the modules have been assembled in the housing, screws are then inserted into holes in the flange so that these screws can be screwed into the threaded portion, and the flange can therefore be removed from the bottom of the housing.

[0016] According to a variant embodiment, the bottom of the housing includes a threaded collar for receiving the fastening screw. In this way, when the thickness of the bottom of the housing is relatively small, these threaded collars help to anchor the screw in the bottom for better fixation.

[0017] Furthermore, according to this variant embodiment, the flange advantageously has a recess in the extension of the through-hole to accommodate the collar. In this way, there is no unused space in the housing, and the ratio between the power that can be stored due to the battery pack and the total space defined by the housing is optimal.

[0018] Preferably, each of the flanges has a substantially rectangular parallelepiped shape. In this way, the flanges, which are aligned side to side, can abut against each other, and thus provide perfect longitudinal compressive strength.

[0019] Furthermore, each of the flanges is preferably integrally formed from aluminum alloy. In this way, a reinforced cross member with an advantageous weight / strength ratio is formed. Attached Figure Description

[0020] Further specific features and advantages of the invention will become apparent when reading the following description of specific embodiments of the invention, given by way of non-limiting indication, with reference to the accompanying drawings:

[0021] [ Figure 1 [This is a schematic perspective view of a power supply component based on existing technology;]

[0022] [ Figure 2 [This is a schematic top view of a power supply assembly according to a first embodiment of the present invention;]

[0023] [ Figure 3 [This is a top view of a power supply assembly according to a second embodiment of the present invention;]

[0024] [ Figure 4 ] is in the attached figure [ Figure 3 A schematic detailed cross-sectional view of a variant embodiment, taken from plane IV-IV in the diagram; and,

[0025] [ Figure 5 ] is in the attached figure [ Figure 3 A schematic detailed cross-sectional view taken from plane IV-IV according to another variant embodiment. Detailed Implementation

[0026] Figure 1 A first power supply assembly 10 according to the prior art is shown. The first power supply assembly includes a first housing 12 having a first bottom 14, a first front wall 16, a first rear wall 18, and two opposing first side walls 20, 22 connected to the first front wall 16 and the first rear wall 18. Furthermore, the first housing 12 has a rectangular overall shape, and the lengths of the opposing first side walls 20, 22 are greater than the lengths of the first front wall 16 and the first rear wall 18.

[0027] The power supply assembly 10 has three consecutive first rows 24, 26, 28 consisting of two first battery pack modules (first first module 30 and second first module 32).

[0028] Each first battery pack module 30, 32 has a first battery pack 34 with two opposing first ends 36, 38 and two opposing first flanges (first first flange 40 and second first flange 42), which respectively cover the two opposing first ends 36, 38. The flanges 40, 42 have cutouts on their sides corresponding to the cross-sections of the opposing ends 36, 38 of the battery pack 34, so as to allow engagement in these opposing ends. Furthermore, the first battery packs 34 of each of the first modules 30, 32 in the first rows 24, 26, 28 are electrically connected to each other.

[0029] The first battery pack 34 has a rectangular cross-section and is made of a series of prismatic batteries that interact with each other and are electrically connected in series. Thus, these series of prismatic batteries are held together by first flanges 40, 42. The first flanges 40, 42 are identical and have a rectangular parallelepiped shape. The cross-section of these first flanges is substantially larger than the cross-section of the battery pack 34, and around the cuts of these first flanges, lips form shoulders 44 extending around opposing first ends 36, 38.

[0030] Moreover, despite the electrical connection, the first first module 30 and the second first module 32 of the three first rows 24, 26, 28 are separated from each other by a transverse member 46 that extends from one side wall 20 to the other side wall 22 and over the entire height of the housing 12.

[0031] The transverse member 46 allows for reinforcement of the outer shell 12 and thus provides better resistance to deformation when the two opposing sidewalls 20, 22 are compressed and forced toward each other (during an impact).

[0032] However, the horizontal member 46 necessitates the reservation of space, which is then wasted space for the battery pack, and therefore wasted space for the energy storage capacity of the power supply components.

[0033] Furthermore, please refer to the attached diagram [ Figure 2 The second housing 12' is described in accordance with a first variant embodiment of the main body according to the present invention. (See attached figures.) Figure 2 The subject and accompanying drawings of [] Figure 1 Elements that are identical or have the same function will use the same reference numerals followed by an apostrophe.

[0034] The second housing 12' comprises three consecutive rows 24', 26', and 28' consisting of two second battery pack modules (first second module 30' and second second module 32'). The second housing 12', having an overall rectangular shape, is identical to the first housing 12, and has a second bottom 14', a second front wall 16', a second rear wall 18', and two opposing second side walls 20' and 22' connected to the second front wall 16' and the second rear wall 18'.

[0035] First, it should be observed that the housing 12' has no transverse members, and since the first second module 30' and the second second module 32' each have a second battery pack 34' with two opposing second ends 36' and 38', these two adjacent second ends 38' and 36' are connected together only by a single intermediate flange 50. This intermediate flange 50 covers the two second ends 38' and 36' of the two second battery packs 34' on each side. Moreover, the intermediate flange 50 has cutouts on its two opposing sides corresponding to the cross-sections of the opposing second ends 36' and 38' of the battery packs 34', so as to receive these opposing second ends in these cutouts.

[0036] The other two second ends 36' and 38' of the two second battery packs 34' in the first second row 24' of the second module 30' and 32' respectively receive the second flanges 40' and 42'. These second flanges 40' and 42' are adjacent to the second front wall 16' and the second rear wall 18' respectively.

[0037] Furthermore, given that the length of the second housing 12' is equal to the length of the first housing 12, it should be understood that by replacing the two flanges with the intermediate flange 50 and by removing the transverse member 46, the length of the second module 30', which specifically contains more batteries, that can be inserted into its second battery pack 34' is greater.

[0038] It should be observed that the cross-sections of the two second flanges 40' and 42' and the intermediate flange 50 are consistent with those in the attached figure. Figure 1 The first flanges 40 and 42 shown have the same cross-section.

[0039] Furthermore, the other two second rows 26' and 28' are completely similar to the first second row 24'. Therefore, the middle flange 50 of the other two second rows 26' and 28' extends side-to-side along a single line L. Additionally, the two second flanges 40' and 42' of the other two second rows 26' and 28' are also aligned side-to-side.

[0040] Therefore, by fastening the three intermediate flanges 50, which are aligned side-to-side with the edges of the three second rows 24', 26', and 28', to the second bottom 14' of the second housing 12', a transverse element forming a rigid central transverse member is thus formed.

[0041] In this way, it should be understood that the stresses exerted on each other by the opposing sidewalls 20' and 22' along arrows F and G during impact will be countered and resisted by the rigid central transverse member.

[0042] Additionally, the two second flanges 40' and 42' of the three second rows 24', 26' and 28' can be fastened to the second bottom 14' so as to form two other auxiliary transverse members symmetrical to each other with respect to the rigid central transverse member along the second front wall 16' and the second rear wall 18', respectively.

[0043] Now refer to the attached diagram [ Figure 3 The image shows a power supply assembly 10'' according to a second embodiment. Methods for fastening the flanges according to two variant embodiments will also be described in detail.

[0044] This attached image [ Figure 3Therefore, a third housing 12'' is shown, which comprises three consecutive third rows 24'', 26'', 28'' consisting of three third battery pack modules; a first third module 30'' is at one end, a second third module 31 is at the center, and a third third module 32'' is at the other end. The third modules 30'', 31, 32'' of each of the three consecutive third rows 24'', 26'', 28'' are located in the extensions of each other.

[0045] The third outer casing 12'' has a third bottom 14'', a third front wall 16'', a third rear wall 18'', and two opposing third side walls 20'' and 22'' connected to the third front wall 16'' and the third rear wall 18''.

[0046] The third modules 30'', 31, and 32'' each have a third battery pack 34'', which has two opposing third ends 36'' and 38''.

[0047] Each of the three third rows 24'', 26'', 28'' has two adjacent second ends 38'', 36'' connected together only by two second intermediate flanges 50''. These second intermediate flanges 50'' respectively cover the two second ends 38'', 36'' of the three third battery packs 34''. Thus, the three third battery packs 34'' extend continuously to each other and are connected to each other by means of intermediate flanges 50'', thus forming three modules 30'', 31, 32'' as a single longitudinal block.

[0048] The two third end modules 32'' and 30'' have two opposing third end modules 36'' and 38'' receiving two third flanges 40'' and 42'' respectively.

[0049] Furthermore, the cross-sections of the two third flanges 40'' and 42'' and the two intermediate flanges 50'' are consistent with the attached drawing. Figure 1 The first flanges 40 and 42 shown have the same cross-section.

[0050] Furthermore, the other two third rows 26'' and 24'' are completely similar to the first third row 28''. Therefore, the three-by-two intermediate flanges 50'' of the other two third rows 26'' and 24'' extend side-to-side along the two parallel lines L1 and L2, respectively. In addition, the two third flanges 40'' and 42'' of the other two third rows 26'' and 24'' are also aligned side-to-side.

[0051] Therefore, by fastening the three-by-two intermediate flanges 50'' of the third row 24'', 26'' and 28'' side-to-side to the third bottom 14'' of the third housing 12'', two parallel rigid transverse elements are formed.

[0052] Now refer to the attached diagram [ Figure 4 ]and[ Figure 5 The method of fastening a flange to the bottom of a housing according to two variant embodiments is described.

[0053] Therefore, the attached figure [ Figure 4 The diagram shows a cross-section of a single intermediate flange 50''. This intermediate flange has an overall rectangular parallelepiped shape, consisting of two opposing large sides 52, 54 and two opposing small sides 56, 58. The intermediate flange also has the features shown in the attached figure. Figure 3 The thickness shown e And this thickness corresponds to the edge face. For example, the intermediate flange is integrally formed from aluminum alloy. Moreover, the intermediate flange 50'' has two parallel openings 60, 62, which are located at the thickness of the intermediate flange. e The two large, opposing sides 52 and 54, which are positioned at a certain distance from each other and are perpendicular to the two parallel openings, respectively, are connected to each other. In this way, the intermediate flange 50'' is vertically mounted against the third bottom 14'' of the third housing 12'' with one of its large sides 52, and is held there in a fixed position by two screws 64 and 66, which respectively engage in the two openings 60 and 62 and are screwed into two threaded portions 68 and 70 formed in the bottom wall 14''. The two screws 64 and 66 each have two heads 72 and 74 that act on the edge face of the other opposing large side 54, so as to hold the intermediate flange 50'' against the bottom wall 14'' in a fixed position.

[0054] In this way, the attached diagram [ Figure 3 The intermediate flanges 50'' shown (three intermediate flanges aligned along line L1 and three intermediate flanges aligned along line L2) are respectively held in fixed positions in their respective extensions by their small sides 56, 58 being adjacent to or in contact with each other (i.e., side to side).

[0055] According to the attached figure [ Figure 5 Another variant embodiment shown in the figure, wherein the figure is consistent with the original. Figure 2Elements that are identical or have the same function are referred to by the same reference numerals followed by “'''”. The bottom wall 14''' is equipped with two threaded collars 68''', 70''', which allows for the reception of screws 64''', 66'''. Meanwhile, the large side 52''' of the bottom wall 14''' has recesses 80, 82 in the extensions of the orifices 60''', 62''' to accommodate the threaded collars 68''', 70'''. This variant embodiment allows for a reduction in the thickness of the bottom wall, thereby reducing the volume and weight of the power supply assembly according to the invention.

Claims

1. A power supply assembly (10') for a motor vehicle; 10''), the power supply component includes: - A housing (12'; 12'') having a bottom (14'; 14'') and at least two sidewalls (20', 22'; 20'', 22'') opposite each other and projecting upright from the bottom (14'; 14''); - A collection of battery modules (30', 32'; 30'', 31, 32''), each of the modules in the collection having a battery pack (34'; 34'') having two opposing ends (36', 38'; 36'', 38'') and two opposing flanges (40', 42'; 40'', 42'') respectively covering the ends. The modules (30', 32'; 30'', 31, 32'') in the collection are mounted inside the housing (12'; 12'') and on the bottom (14'; 14'') in the form of multiple consecutive rows (24', 26', 28'; 24'', 26'', 28'') consisting of n modules. The n modules are coaxially located in each other's extensions and substantially parallel to the sidewalls (20', 22'; 20'', 22''). The characteristic feature is that the consecutive rows (24', 26', 28'; 24'', 26'', 28'') are arranged such that the flanges (40', 42', 50; 50'', 40'', 42'') of the modules in the rows are aligned side-to-side in a direction substantially perpendicular to the opposite sidewalls (20', 22'; 20'', 22''). Furthermore, the aligned flanges (40', 42', 50; 50'', 40'', 42'') are secured to the bottom (14'; 14'') of the housing (12'; 12'') to form a rigid transverse member inside the housing.

2. The power supply component as described in claim 1, characterized in that, Each of these modules (30', 32'; 30'', 31, 32'') in each of the rows (24', 26', 28'; 24'', 26'', 28'') is connected together in pairs by a single flange.

3. The power supply component as described in claim 1 or 2, characterized in that, The modules (30', 32'; 30'', 31, 32'') in the set have only a single length.

4. The power supply component as described in claim 1 or 2, characterized in that, The outer casing (12'; 12'') has a front wall (16'; 16'') and an opposing rear wall (18'; 18''), which project uprightly from the bottom (14'; 14'') and respectively support the side walls (20', 22'; (20'', 22'') are connected substantially vertically to close the outer shell (12'; 12''）。 5. The power supply component as described in claim 1, characterized in that, Each of the flanges has a given thickness, and at least one through hole (60, 62; 60''', 62''') is made in the thickness to allow a fastening screw (64, 66; 64''', 66''') to pass through.

6. The power supply component as described in claim 5, characterized in that, The bottom (14'') of the housing has a threaded portion (68, 70) for receiving screws (64, 66) for fastening the flange.

7. The power supply component as described in claim 5 or 6, characterized in that, The bottom (14''') of the housing includes threaded collars (68''', 70''') for receiving the fastening screws (64''', 66''').

8. The power supply component as described in claim 7, characterized in that, The flange has a recess (80, 82) in the continuation of the through hole (60''', 62''') so as to accommodate the collar (68''', 70''').

9. The power supply component as described in claim 1 or 2, characterized in that, Each of the flanges (40', 42', 50; 40'', 42'', 50''; 50''') has a substantially rectangular parallelepiped shape.

10. The power supply component as described in claim 1 or 2, characterized in that, Each of the flanges (40', 42', 50; 40'', 42'', 50''; 50''') is integrally formed from aluminum alloy.

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