Electric vehicle substructure

Abstract

A lower structure of an electric vehicle (1) comprises: an automatic transmission (6) disposed below a floor panel (11) and in the middle thereof in the left-right direction; an inverter (50) disposed between the automatic transmission (6) and a floor side frame (13); and a mounting bracket (70) for mounting the inverter (50) on the floor panel (11). The mounting bracket (70) comprises a housing structure including an inner wall portion (71a) separating the inverter (50) from the automatic transmission (6), an outer wall portion (73a) separating the inverter (50) from the floor side frame (13), an upper wall portion (72), and a lower wall portion (75).

Description

Technical Field

[0001] The technology of the present invention relates to a lower structure of an electric vehicle such as a hybrid vehicle or an electric vehicle that can run on electric power. Background Art

[0002] Patent Document 1 discloses a hybrid vehicle. This hybrid vehicle includes high-voltage components for driving, such as an inverter 22 (denoted by the same reference numerals used in this document, and the same applies hereinafter), a converter 23, and a battery, located below the floor panel. Specifically, the 48V battery is located within the tunnel. Inverter 22 and converter 23 are arranged in series in the front-to-back direction in the area to the left of the tunnel.

[0003] A floor frame and a tunnel frame are installed in the left area of ​​the tunnel, extending in the front-to-rear direction at intervals. A plate-shaped bracket 26 is bolted between the floor frame and the tunnel frame. The inverter 22 is fixed above this bracket 26.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Laid-Open No. 2020-172879

[0007] Technical problem to be solved by the invention

[0008] In the event of a side collision with another vehicle (so-called side impact) involving the hybrid vehicle of Patent Document 1, there is a concern that the floor panel may deform and the bolts attaching the bracket may be severed. Consequently, in a side impact, the inverter may become trapped between the floor frame and the tunnel frame or fall and be damaged. Summary of the Invention

[0009] The technology of the present invention can effectively protect high-voltage components in an electric vehicle in which high-voltage components are arranged in areas lateral to the tunnel portion of a floor panel even when subjected to a strong impact from the side.

[0010] Technical means for solving technical problems

[0011] The technology of the present invention relates to a lower structure of an electric vehicle that is equipped with a high-voltage battery for driving and can travel using the electric power of the high-voltage battery.

[0012] The lower structure of the electric vehicle includes: a floor panel extending below the vehicle cabin; a predetermined vehicle structure provided below the floor panel and in the middle of the floor panel in the left-right direction; a pair of floor side frames extending in the front-to-rear direction along the left and right side portions of the lower surface of the floor panel; a predetermined high-voltage component connected to the high-voltage battery and arranged between the vehicle structure and one of the floor side frames; and a mounting bracket for mounting the high-voltage component to the floor panel.

[0013] Moreover, the mounting bracket has a shell structure, which includes: an inner wall portion, which separates at least a portion between the high-voltage component and the vehicle structure; an outer wall portion, which separates at least a portion between the high-voltage component and the floor side frame; an upper wall portion, which is mounted on the upper edge of the inner wall portion and the upper edge of the outer wall portion; and a lower wall portion, which is mounted on the lower edge of the inner wall portion and the lower edge of the outer wall portion.

[0014] Specifically, in this electric vehicle, a predetermined vehicle structure (e.g., a vehicle component, a frame, or other structure) is provided below a floor panel extending below the vehicle cabin and in the middle of the floor panel in the left-right direction. A pair of floor side frames extend in the front-to-rear direction along the left and right side portions of the floor panel on the lower surface of the floor panel.

[0015] Furthermore, these electric vehicles are equipped with a high-voltage battery for driving, which has a higher voltage than the battery (typically a 12V lead-acid battery) used as a power source for air conditioners, etc. The electric vehicle can run using this power. Examples of electric vehicles include hybrid vehicles and electric vehicles.

[0016] Electric vehicles include high-voltage components connected to a high-voltage battery, such as a motor, inverter, and converter. These high-voltage components are positioned between the vehicle structure and one floor frame and mounted to the floor panel using mounting brackets.

[0017] The mounting bracket has a housing structure including an inner wall portion that at least partially separates the high-voltage component from the vehicle structure, an outer wall portion that at least partially separates the high-voltage component from the floor side frame, an upper wall portion, and a lower wall portion.

[0018] Specifically, the lower structure of this electric vehicle ensures that, first, the high-voltage components are surrounded by mounting brackets, protecting them from impacts such as rocks during driving. Furthermore, the vehicle structure and floor side frames flank them, providing even more effective protection. While the vertical space beneath the vehicle body is relatively narrow, this configuration allows for efficient utilization of that space.

[0019] Second, the housing structure is formed by the mounting bracket, thereby effectively protecting high-voltage components even in the event of a collision.

[0020] That is, a collision with an electric vehicle from the side (so-called side collision) may cause the vehicle body to deform or be damaged. In this case, there is a concern that high-voltage components may fall or the deformed floor side frame may collide with the high-voltage components.

[0021] In particular, when high-voltage components are placed between the vehicle structure and the floor side frames, as in this electric vehicle, the high-voltage components may be trapped and crushed. To address this, in this electric vehicle, the high-voltage components are surrounded by a housing structure consisting of mounting brackets.

[0022] Therefore, when the floor frame deforms and intrudes, pressing the mounting bracket inward, it comes into contact with the vehicle structure, pressing it from both the left and right sides. At this point, the mounting bracket forms a shell structure that resists these pressing forces, thus preventing crushing. External forces are prevented from acting on the high-voltage components housed within the mounting bracket, protecting them even in a side collision.

[0023] Because it is firmly clamped between the vehicle structure and the floor side frame, the mounting bracket, including high-voltage components, is prevented from falling. Furthermore, the mounting bracket's support prevents significant changes in the spacing between the mounting bracket's mounting points, i.e., the points where the mounting bolts secure the mounting bracket. Consequently, shear forces acting on the mounting bolts are suppressed, preventing the mounting bolts from shearing.

[0024] The lower structure of the electric vehicle may also include: a channel portion, which is arranged to extend in the front-rear direction by being recessed upward in the middle of the left-right direction of the floor panel; and a channel side frame, which extends along the lower edge of the channel portion. The vehicle structure is a transmission arranged inside the channel portion, the outer wall portion is opposite to the side of the floor side frame, and is installed on the channel side frame through the mounting bracket, so that the inner wall portion is opposite to the side of the transmission.

[0025] That is, according to the lower structure of the electric vehicle, the vehicle structure is such that the transmission is disposed within the tunnel portion. Furthermore, the outer wall portion faces the side surface of the floor-side frame and is mounted to the tunnel-side frame via a mounting bracket, thereby causing the inner wall portion to face the side surface of the transmission.

[0026] Therefore, in a side collision, the mounting bracket is sandwiched between the floor-side frame and the transmission. Furthermore, by being pressed against them, it provides support. By attaching the mounting bracket to the tunnel-side frame, the side surface of the transmission, located within the tunnel, can be utilized. Since the mounting bracket does not need to be sandwiched between the floor-side frame and the tunnel-side frame, an increase in the cross-section of the tunnel-side frame can be avoided. Since the mounting bracket can be enlarged on the transmission side, the lateral width of the high-voltage components can be increased.

[0027] The lower structure of the electric vehicle may further include a second high-voltage component connected to the high-voltage battery and arranged between the vehicle structure and the floor side frame, wherein the second high-voltage component is arranged on the lower side of the lower wall portion so as to overlap with the high-voltage component.

[0028] This allows the mounting bracket to be used as a bracket for mounting the second high-voltage component to the floor panel, reducing the number of components and component costs. Furthermore, even in a side collision, the second high-voltage component will not be crushed because the mounting bracket supports it. Since the mounting bracket does not fall, the second high-voltage component also does not fall. Therefore, the second high-voltage component can be protected even in a side collision.

[0029] The lower structure of the electric vehicle may also be provided with: a front sub-frame, which is arranged in front of the floor panel, and one of the left and right rear end portions of the front sub-frame is located in front of the high-voltage component; and a guide bracket, which is arranged between the front sub-frame and the high-voltage component, and the guide bracket has: a guide surface portion, which is inclined upward toward the front; and a pair of flange portions, which are arranged on both sides of the guide surface portion, one of the flange portions is mounted on the floor side frame, and the other side of the flange portion is mounted on the channel side frame, and the guide surface portion guides the front sub-frame toward the bottom of the second high-voltage component when the front sub-frame moves backward.

[0030] Specifically, according to the lower structure of the electric vehicle, a front subframe is disposed in front of the floor panel, one of the left and right rear ends of the front subframe is located in front of the high-voltage components, and a guide bracket is disposed between the front subframe and the high-voltage components.

[0031] The guide bracket is mounted on both sides of the floor side frame and the channel side frame and has a guide surface portion inclined upward toward the front. The guide surface portion guides the front subframe downwardly toward the second high-voltage component when the front subframe is retracted.

[0032] Therefore, even if the front subframe moves backward during a head-on or oblique collision of the electric vehicle, the guide surface protects the high-voltage components and the second high-voltage components. Furthermore, the guide surface is attached to both the tunnel-side frame and the floor-side frame. This, in conjunction with the mounting bracket, prevents the floor panel from being crushed in the left-right direction during a side collision. This further protects the high-voltage components and the second high-voltage components during a side collision.

[0033] In the lower structure of the electric vehicle, the guide bracket may include a vertical wall portion that faces the vehicle structure in a left-right direction.

[0034] In this way, the vertical wall portion of the guide bracket is also pressed against the vehicle structure during a side collision. The guide bracket is supported in the left-right direction in the same manner as the mounting bracket. The guide bracket is also firmly supported, thus preventing it from falling.

[0035] The lower structure of the electric vehicle may further include at least one pipe extending in the front-rear direction along the floor panel for allowing fluid to flow, wherein the pipe is routed so as to pass above the upper wall portion.

[0036] In this way, the support function of the mounting bracket can protect the piping even in a side collision.

[0037] In particular, when the pipes are composed of a plurality of pipes, the plurality of pipes may be laid out in a state of being gathered at a central portion in the left-right direction of the upper wall portion.

[0038] In this manner, the pipes are located away from the left and right sides of the mounting bracket. Therefore, even if there are a plurality of pipes, they can be effectively protected in a side collision by the supporting effect of the mounting bracket.

[0039] Effects of the Invention

[0040] According to the electric vehicle to which the technology of the present invention is applied, high-voltage components can be effectively protected even when a strong impact is applied from the side. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 This is a schematic diagram of the lower structure of the front side portion of the electric vehicle as viewed from below.

[0042] Figure 2 yes Figure 1 An enlarged view of the main parts.

[0043] Figure 3 is equivalent to omitting the guide bracket Figure 2 Picture.

[0044] Figure 4 is Figure 2 A schematic cross-sectional view of the portion indicated by the arrow line AA in FIG.

[0045] Figure 5 This is a schematic perspective view of the main parts of the electric vehicle as seen from the upper left rear perspective.

[0046] Figure 6 This is a schematic diagram of the mounting bracket and guide bracket as viewed from the rear above.

[0047] Figure 7 This is a schematic diagram of the mounting bracket and guide bracket as viewed from the front above.

[0048] Figure 8 This is a schematic diagram showing the installation status of the mounting bracket and inverter.

[0049] Figure 9 is Figure 2 Schematic cross-sectional view of the portion indicated by arrow line BB in FIG.

[0050] Figure 10 is Figure 2 A schematic cross-sectional view of the portion indicated by arrow line CC in FIG.

[0051] Figure 11 This is a diagram for explaining the supporting function of the mounting bracket during a side collision.

[0052] Explanation of symbols

[0053] 1 Electric vehicles

[0054] 2 engines

[0055] 3 Motor

[0056] 5 Damper

[0057] 6 AT transmission

[0058] 8 transfer case

[0059] 9R rear drive shaft

[0060] 10 Lower side sill

[0061] 11 Floor panels

[0062] 11a Channel

[0063] 12 dash panel

[0064] 13 Floor side frame

[0065] 14 channel side frame

[0066] 15 Front longitudinal frame

[0067] 20 Front subframe

[0068] 30 Exhaust system

[0069] 31 Exhaust pipe

[0070] 32 Purification device

[0071] 40 DC / DC converters (high voltage components)

[0072] 42 CV wiring harness

[0073] 43 CV cooling water piping

[0074] 50 Inverter (second high voltage component)

[0075] 52 IV wiring harness

[0076] 53 IV cooling water piping

[0077] 60 high voltage battery

[0078] 60R right side high voltage battery

[0079] 60L left high voltage battery

[0080] 70 Mounting bracket

[0081] 70U upper bracket

[0082] 70D lower bracket

[0083] 71 Upper inner mounting portion

[0084] 71a Inner dividing surface (inner wall)

[0085] 72 Installation part (upper wall part)

[0086] 73a External dividing surface (outer side wall)

[0087] 75 bottom plate (lower wall)

[0088] 80 guide bracket

[0089] 90 piping

[0090] 91 Piping retainer DETAILED DESCRIPTION

[0091] The following describes one embodiment of the present invention. The front-back, left-right, and top-bottom directions shown in the description are relative to the vehicle. Arrows indicate these directions in the figures. The left-right direction corresponds to the vehicle width.

[0092] <Electric Vehicle Underbody Structure>

[0093] Figure 1 The lower structure of the electric vehicle 1 in the embodiment is shown. Figure 1 This is a schematic diagram of the lower structure of the front side portion of the electric vehicle 1 as viewed from below. Figure 1 In the figure, for the sake of convenience, a portion of the right side of the electric vehicle 1 is omitted from the illustration compared to the left side. In addition, in other figures, illustration may be omitted as appropriate.

[0094] Figure 2 yes Figure 1 An enlarged view of the main parts. Figure 3 is equivalent to omitting the guide bracket Figure 2 Picture. Figure 4 exist Figure 2 A schematic cross-sectional view of the portion indicated by the arrow line AA. Figure 5 It is a schematic perspective view of the main parts of the electric vehicle 1 as viewed from the upper rear side.

[0095] Electric vehicle 1 is a hybrid vehicle. That is, it is equipped with an engine 2 and a motor 3 as driving sources. Thus, electric vehicle 1 travels by being driven by either engine 2 alone, motor 3 alone, or both. Furthermore, the technology of the present invention is not limited to hybrid vehicles and can also be applied to electric vehicles equipped only with a motor.

[0096] The electric vehicle 1 is also a so-called FR vehicle. The electric vehicle 1 has an engine room on the front side of the vehicle cabin and travels by driving the rear wheels. The electric vehicle 1 drives the front wheels together with the rear wheels as needed (four-wheel drive). Figure 1 In the figure, a vehicle compartment is provided in a range indicated by CR, and an engine compartment is provided in a range indicated by ER.

[0097] like Figure 1 As shown, a pair of rocker sills 10, 10 extending parallel to each other in the front-to-rear direction are disposed on the left and right sides of the lower portion of the vehicle cabin. Furthermore, a substantially horizontal floor panel 11 extending below the vehicle cabin is disposed between these rocker sills 10, 10. A tunnel portion 11a is provided in the middle portion of the floor panel 11 in the left-to-right direction, extending in the front-to-rear direction and recessed toward the upper side (the vehicle cabin side).

[0098] The front edge of the floor panel 11 is connected to the lower edge of a dash panel 12, which extends in the left-right direction, while facing the front and rear directions. The boundary between the floor panel 11 and the dash panel 12 curves upward toward the front. The dash panel 12 divides the front portion of the vehicle cabin from the engine compartment. The tunnel portion 11a extends beyond the dash panel 12 into the engine compartment.

[0099] In the portion of the floor panel 11 between each rocker 10 and the tunnel portion 11a, a floor side frame 13 and a tunnel side frame 14 are provided extending in the front-rear direction. These floor side frames 13 and tunnel side frames 14 are formed into a closed cross-section structure by joining groove-shaped members to the lower surface of the floor panel 11. Compared with the tunnel side frames 14, the floor side frames 13 protrude downward from the floor panel 11 to a greater extent (see FIG. Figure 4 ).

[0100] Each tunnel side frame 14 is arranged to extend along the lower edge of the tunnel portion 11a. Each floor side frame 13 is arranged along the side of the lower surface of the floor panel 11. Specifically, it is arranged between each tunnel side frame 14 and the rocker 10 of the floor panel 11. The front end of each tunnel side frame 14 is connected to the adjacent floor side frames 13.

[0101] The engine 2 is vertically positioned substantially at the center of the engine compartment in the vehicle width direction.

[0102] A pair of front longitudinal frames 15, 15 extend in the front-to-rear direction on the left and right sides of the engine compartment (the right front longitudinal frame 15 is not shown). The rear end of each front longitudinal frame 15 is connected to the front end of each floor side frame 13 in a downwardly curved state. A cross beam 16 is spanned (installed in a spanned state) between the front ends of each front longitudinal frame 15.

[0103] A containment member 17 is disposed above and outwardly in the vehicle width direction of each front longitudinal frame 15. Meanwhile, a front subframe 20 is disposed below and inwardly in the vehicle width direction of the two front longitudinal frames 15. The front subframe 20 is disposed below the engine compartment and supports the engine 2, front suspension 21, and the like.

[0104] The front subframe 20 is composed of a pair of left and right side frame portions 20a, 20a, a front suspension member portion 20b, a rear suspension member portion 20c, a pair of left and right bracket portions 20d, 20d, etc. The front subframe 20 is configured in a bilaterally symmetrical shape.

[0105] Each side frame portion 20a extends in the front-rear direction along the lower side of each front longitudinal frame 15. Specifically, each side frame portion 20a is located in the lower part of the engine room in front of the dash panel 12 and is arranged at a position lower than the dash panel 12 and the floor panel 11 (see FIG. Figure 10 ).

[0106] The front end portion of each side frame portion 20a is bent upward and connected to the front end portion of each front longitudinal frame 15. The rear end portion of each side frame portion 20a is located just in front of and below the front panel 12 and is connected to the rear end portion of each front longitudinal frame 15. A rear suspension member portion 20c extending in the left-right direction is bridged between the rear end portions of each side frame portion 20a.

[0107] Each bracket portion 20d is further connected to the rear end portion of each side frame portion 20a. Each bracket portion 20d is configured to protrude outward in the vehicle width direction from the rear end portion of each side frame portion 20a. Each bracket portion 20d is tilted toward the rear, and its protruding end portion is connected to the lower surface of the front end portion of the floor panel 11.

[0108] The front suspension member 20b is spanned between the middle portions of the side frame portions 20a. The front suspension 21 is assembled to the front subframe 20. A portion of the front suspension 21 (lower arm, etc.) extends outward in the vehicle width direction of each side frame portion 20a.

[0109] like Figure 1 、 Figure 2 As shown, the motor 3 is connected to the rear of the engine 2 via a damper. The motor 3 is a permanent magnet synchronous motor and is driven by a three-phase AC controlled by an inverter.

[0110] An AT transmission 6 (automatic transmission) is connected to the rear of the motor 3. The AT transmission 6 changes the output of the driving force output from one or both of the engine 2 and the motor 3 according to the vehicle speed.

[0111] A transfer case 8 is provided at the rear of the AT transmission 6. A front propeller shaft 9F extends forward from the left side of the transfer case 8. A rear propeller shaft 9R extends rearward from the transfer case 8. The transfer case 8 transmits the driving force output from the AT transmission 6 to the front and rear wheels via the front propeller shaft 9F and the rear propeller shaft 9R.

[0112] The damper, motor 3, automatic transmission 6, transfer case 8, and rear propeller shaft 9R are connected in series to the rear of the engine 2 and extend linearly rearward through the interior of the tunnel portion 11a. The automatic transmission 6 is located within the front portion of the tunnel portion 11a. A bracket 22 is located below the transfer case 8, mounted on the left and right tunnel side frames 14. The transfer case 8 is supported by this bracket 22.

[0113] An exhaust system 30, such as an exhaust manifold, is mounted to the right side of the engine 2. An exhaust pipe 31 extends from the exhaust system 30 toward the rear end of the electric vehicle 1. The front portion of the exhaust pipe 31 is arranged along the lower surface of the floor panel 11, which extends to the right of the duct portion 11a. The rear portion of the exhaust pipe 31 is arranged in the duct portion 11a, aligned below the rear propeller shaft 9R. A purification device 32 is provided between the front and rear portions of the exhaust pipe 31.

[0114] <High voltage components>

[0115] The electric vehicle 1 is equipped with vehicle components such as electrical components and a control device similar to conventional vehicles driven by an engine. In addition to these vehicle components, the electric vehicle 1 is equipped with a high-voltage battery 60 and a plurality of high-voltage components to drive the motor 3 .

[0116] Specifically, an inverter 50 (corresponding to a “predetermined high-voltage component”), a DC / DC converter 40 (a second high-voltage component, also simply referred to as a converter 40 ), and the like are mounted.

[0117] (High voltage battery)

[0118] As a power source for vehicle components, a battery (typically a 12V lead-acid battery, hereinafter referred to as a low-voltage battery) is mounted in the engine compartment. Furthermore, the electric vehicle 1 is equipped with a higher-voltage battery (a high-voltage battery 60 ) as a power source for high-voltage components.

[0119] The electric vehicle 1 is equipped with a high voltage battery 60 with a voltage of 300V or more (so-called strong hybrid vehicle). The high voltage battery 60 is relatively large. Therefore, in the electric vehicle 1, as shown in FIG. Figure 1 As shown, the high-voltage battery 60 is composed of a pair of left and right batteries (a right high-voltage battery 60R and a left high-voltage battery 60L), and is arranged in wide areas on the left and right sides of the tunnel portion 11 a in the floor panel 11 .

[0120] Specifically, high-voltage batteries 60R and 60L are located on the right and left sides of the lower surface of the floor panel 11, extending along the floor-side frame 13 and the tunnel-side frame 14 (particularly, the left-side area will be referred to as the "left-side area"), and on both sides of the front portion of the transfer case 8 and the rear propeller shaft 9R. Each high-voltage battery 60R and 60L is housed in a large battery case mounted on the floor-side frame 13 and the tunnel-side frame 14.

[0121] like Figure 2 、 Figure 3As shown, the left end of the front end portion of the left high-voltage battery 60L protrudes forward, and the protruding end portion has a connection terminal 61. The connection terminal 61 is connected to the converter 40 via the CV harness 42. The connection terminal 61 is connected to the inverter 50 via the IV harness 52.

[0122] (Inverter, Converter)

[0123] like Figure 1 、 Figure 2 、 Figure 3 As shown, the inverter 50 and the converter 40 are arranged in front of the connection terminal 61 in the left area and to the left of the AT transmission 6.

[0124] The inverter 50 and the converter 40 are mounted on the floor panel 11 via the mounting bracket 70 in a state of being stacked up and down. Figure 1 、 Figure 2 As shown, a guide bracket 80 is arranged in front of the inverter 50 and the converter 40. The mounting bracket 70 and the guide bracket 80 will be described separately later.

[0125] The inverter 50 and the converter 40 are each a rectangular plate-shaped member whose outer shape is sufficiently larger in the horizontal and vertical directions than in the thickness (see Figure 4 The inverter 50 and converter 40 are each longer in the left-right (horizontal) direction than in the front-back (vertical) direction (i.e., have a larger horizontal width). The lateral width of the inverter 50 is approximately the same as that of the converter 40, and the longitudinal width of the inverter 50 is larger than that of the converter 40.

[0126] Although not shown, inverter 50 includes three built-in switching circuits arranged in a horizontal row. By evenly distributing these switching circuits across motor 3, motor 3 can be stably controlled. By switching these switching circuits, inverter 50 outputs three-phase AC power, which is controlled by motor 3. By controlling inverter 50, motor 3 is driven at a predetermined output.

[0127] like Figure 3 As shown, the inverter 50 has IV harness connectors 51 for connecting an IV harness 52 at both the front and rear ends of its right side. The front IV harness connector 51 is connected to the IV harness 52 connected to the motor 3. The rear IV harness connector 51 is connected to the IV harness 52 connected to the high-voltage battery 60.

[0128] Since the inverter 50 generates heat during operation, it is configured to be cooled by circulating cooling water (water cooling). IV cooling water pipes 53 for circulating cooling water are connected to both the front end and the rear end of the inverter 50.

[0129] The converter 40 steps down the voltage of the high-voltage battery 60 and outputs a 12V DC current. The converter 40 has CV harness connectors 41 on its left and right sides for connecting to a CV harness 42. The right CV harness connector 41 is connected to the CV harness 42 extending from the high-voltage battery 60. The left CV harness connector 41 is connected to the CV harness 42 that outputs a 12V current.

[0130] The converter 40 generates heat during operation and is therefore also configured to be cooled by circulating cooling water (water-cooled). CV cooling water pipes 43 for circulating cooling water are connected to both the front and rear sides of the left side of the converter 40 .

[0131] Mounting bracket, guide bracket

[0132] As described above, the inverter 50 and converter 40 are mounted on the floor panel 11 via the mounting bracket 70 in a vertically stacked configuration to the left of the AT transmission 6 in the left region. Specifically, the inverter 50 and converter 40 are positioned between the AT transmission 6 and the left floor side frame 13 at the front end of the left region (in this embodiment, the AT transmission 6 corresponds to the "predetermined vehicle structure").

[0133] like Figure 2 As shown in FIG. 1 , the left rear end of the front subframe 20 is located in front of the left region. Specifically, the rear end of the left vertical frame portion 20a and the left bracket portion 20d are located in front of the left region. The guide bracket 80 is positioned between the left rear end of the front subframe 20 and the inverter 50 and converter 40.

[0134] exist Figure 6 、 Figure 7 1 and 2 show the mounting bracket 70 and the guide bracket 80. The mounting bracket 70 and the guide bracket 80 are each formed of a stamped product of a metal plate formed into a predetermined structure. The mounting bracket 70 and the guide bracket 80 are in a connected state.

[0135] (Mounting bracket)

[0136] The mounting bracket 70 is formed integrally with an upper bracket 70U and a lower bracket 70D. The upper bracket 70U has a substantially L-shaped outer shape when viewed from the top and bottom (see FIG. Figure 8 The lower bracket 70D has a substantially rectangular outer shape that is long in the left-right direction when viewed from the top-down direction.

[0137] The upper bracket 70U and the lower bracket 70D are each formed with a predetermined bent structure and a predetermined concavo-convex structure, which structurally reinforce the rigidity of each of the upper bracket 70U and the lower bracket 70D.

[0138] The upper bracket 70U includes an upper inner mounting portion 71 extending in the front-to-back direction, and a bridging portion 72 connected to one end of the upper inner mounting portion 71 and extending in the left-to-right direction. The upper inner mounting portion 71 has an inner, longitudinally extending surface 71a extending in the left-to-right direction. An upper outer mounting portion 73 is provided at the protruding end of the bridging portion 72.

[0139] The upper outer mounting portion 73 has an outer dividing surface 73a facing the left-right direction. The outer dividing surface 73a is opposite to the inner dividing surface 71a in the left-right direction. A plurality of fastening seats 74 for fastening mounting bolts 101 are provided on each of the upper inner mounting portion 71 and the upper outer mounting portion 73.

[0140] The lower bracket 70D includes a bottom plate portion 75 having a substantially rectangular plate shape and a lower outer mounting portion 76 provided at an outer end portion in the longitudinal direction of the bottom plate portion 75. The lower outer mounting portion 76 is provided with a plurality of fastening seats 74 for fastening mounting bolts 101.

[0141] The upper bracket 70U and the lower bracket 70D are fastened together by the joint bolts 102 in a state of being butted against each other from the top and bottom. Figure 4 As shown, a bent portion 77 is provided at an inner end portion of the bottom plate portion 75 . The bent portion 77 is formed so as to be bent at a right angle to the bottom plate portion 75 .

[0142] In a state where the inner partition surface 71a of the upper inner mounting portion 71 overlaps the outer side of the bent portion 77, the joining bolts 102 are tightened from the inner side toward the outer side, thereby integrating the upper bracket 70U and the lower bracket 70D. Figure 6 、 Figure 7 As shown, with the upper outer mounting portion 73 and the upper side of the lower outer mounting portion 76 overlapping, the joining bolts 102 are tightened from the lower side toward the upper side, whereby the upper bracket 70U and the lower bracket 70D are integrated.

[0143] That is, the connecting bolts 102 are tightened from both the vertical and horizontal directions. Therefore, these connecting bolts 102 are not completely severed by loads from either the horizontal or vertical directions. The upper bracket 70U and the lower bracket 70D are firmly integrated through an effective three-dimensional structure. This creates a mounting bracket 70 with a highly rigid outer shell structure that is open in the front-to-back direction and partially open in the vertical and horizontal directions.

[0144] like Figure 8 As shown in the left figure, the upper inner mounting portion 71 is mounted to the tunnel side frame 14 via the fastening seat 74 using the mounting bolts 101. The upper outer mounting portion 73 is mounted to the floor side frame 13 via the fastening seat 74 using the mounting bolts 101.

[0145] Therefore, if Figure 4 As shown, the mounting bracket 70 is sandwiched between the AT transmission 6 and the floor side frame 13 with a gap therebetween. Specifically, the bottom plate 75 is located at substantially the same height as the lower ends of the AT transmission 6 and the floor side frame 13, and the mounting bracket 70 is located between the left side of the AT transmission 6 and the right side of the floor side frame 13.

[0146] As a result, an outer shell structure is formed by installing the bracket 70, which includes: an inner wall portion (an inner dividing surface 71a of the upper inner mounting portion 71), which is opposite to the left side of the AT transmission 6 and separates at least a portion between the inverter 50 and the AT transmission 6; an outer wall portion (an outer dividing surface 73a of the upper outer mounting portion 73), which is opposite to the right side of the floor side frame 13 and separates at least a portion between the inverter 50 and the floor side frame 13; an upper wall portion (a mounting portion 72), which is mounted on the upper edge portion of the inner wall portion and the upper edge portion of the outer wall portion; and a lower wall portion (a bottom plate portion 75), which is mounted on the lower edge portion of the inner wall portion and the lower edge portion of the outer wall portion.

[0147] In addition, the inverter 50 is housed inside the mounting bracket 70. Specifically, Figure 8 As shown in the right figure, the inverter 50 is housed between the upper bracket 70U and the lower bracket 70D. The inverter 50 is placed on the bottom plate 75 in the above-described predetermined arrangement and secured by bolts. Furthermore, since the mounting bracket 70 is open in the front-to-back direction, wiring and piping operations for the inverter 50 are facilitated.

[0148] The inverter 50 is surrounded by mounting brackets 70, protecting it from rocks and other objects while the vehicle is in motion. Furthermore, the AT transmission 6 and floor side frames 13 are positioned to its left and right, further effectively protecting it. While the vertical space beneath the vehicle body is relatively narrow, this configuration allows for effective utilization of that space.

[0149] (Inverter protection against side impact)

[0150] Furthermore, in the electric vehicle 1 , the mounting bracket 70 is used to form a housing structure, thereby effectively protecting the inverter 50 even in a collision.

[0151] Specifically, a collision from the left (a so-called side collision) against the electric vehicle 1 could cause the vehicle body to deform or be damaged. In this case, external forces are also likely to act on the inverter 50 located in the left area. For example, there is a concern that the inverter 50 could fall or collide with the floor frame 13 or other components.

[0152] In particular, when inverter 50 is positioned between AT transmission 6 and floor-side frame 13, as in electric vehicle 1, inverter 50 may become trapped and crushed. To address this, in electric vehicle 1, inverter 50 is surrounded by a housing structure formed by mounting bracket 70.

[0153] like Figure 11 As shown schematically in the figure above, in a side collision, the floor side frame 13 receives excessive external force from its outer side. As a result, the right side of the floor side frame 13 contacts the mounting bracket 70. The mounting bracket 70 is pressed inward. When the floor side frame 13 enters significantly, as shown in FIG. Figure 11 As schematically shown in the lower figure, the mounting bracket 70 contacts the left side of the AT transmission 6. The mounting bracket 70 is pressed from both the left and right sides.

[0154] At this time, the mounting bracket 70 forms a highly rigid housing structure, thus resisting these pressing forces. This prevents it from being crushed. External forces do not act on the inverter 50 housed within the mounting bracket 70, protecting the inverter 50 even in a side collision.

[0155] Because the mounting bracket 70 is firmly clamped between the AT transmission 6 and the floor-side frame 13, the inverter 50 and the entire mounting bracket 70 are prevented from falling. Furthermore, the support provided by the mounting bracket 70 prevents significant changes in the gap between the floor-side frame 13 and the tunnel-side frame 14. In other words, this gap is reduced only to the extent of the clearance between the two sides of the mounting bracket 70. Consequently, shear forces acting on the mounting bolts 101 are suppressed, preventing the mounting bolts 101 from shearing.

[0156] (DCDC converter protection)

[0157] Furthermore, in this electric vehicle 1 , the converter 40 is arranged on the lower side of the lower wall portion (bottom plate portion 75 ) so as to overlap with the inverter 50 . This design allows the converter 40 to be effectively protected even in a side collision.

[0158] Specifically, the converter 40 is fixed to the lower surface of the bottom plate 75 by bolting in the above-described arrangement. The mounting bracket 70 also serves as a bracket for mounting the converter 40 to the floor panel 11. This reduces the number of components and component costs.

[0159] As described above, the dimensions of the converter 40 are approximately the same as or smaller than those of the inverter 50. Therefore, the lateral width (left-right dimension) and length (front-back dimension) of the converter 40 are smaller than those of the mounting bracket 70. Therefore, when viewed from above, the converter 40 does not protrude from the mounting bracket 70 but is instead concealed beneath it.

[0160] Therefore, even in the event of a side collision, the converter 40 is not crushed from its left and right sides because the mounting bracket 70 is supported. Since the mounting bracket 70 does not fall, the converter 40 also does not fall. Furthermore, the converter 40 is located vertically at approximately the same height as, or below, the lower ends of the AT transmission 6 and the floor side frame 13. This prevents the converter 40 from being directly trapped between these elements.

[0161] Therefore, even in the event of a side collision, the converter 40 can be protected. Since the inverter 50 and the converter 40 are arranged in the same vertical orientation and stacked together, wiring and piping operations are also facilitated.

[0162] (Guide bracket)

[0163] like Figure 6 、 Figure 7 As shown, the guide bracket 80 has a generally V-shaped outer shape that narrows forward when viewed from above and below. The guide bracket 80 includes a guide surface 81 that extends in a generally horizontal direction while tilting upward and forward; a pair of flanges 82a, 82a provided on the outer side of the guide surface 81; and a vertical wall 83 that extends in a generally vertical direction, connected to the inner edge of the guide surface 81.

[0164] Each flange portion 82a is fastened to the floor side frame 13 by bolts. Figure 7 As shown, the inner rear end portion of the guide bracket 80 is fastened to the inner front end portion of the lower bracket 70D by a fastening bolt 103 , thereby fastening the guide bracket 80 to the mounting bracket 70 .

[0165] Thus, the vertical wall portion 83 is arranged to face one side of the tunnel portion 11a. Figure 9 As shown, the vertical wall portion 83 is located below the right edge of the tunnel portion 11a and is arranged to divide the lower space of both the tunnel portion 11a and the left area in a state of overlapping with the inner dividing surface 71a. Figure 9 As shown, the vertical wall portion 83 is configured to face the left side surface of the lower end portion of the AT transmission 6 .

[0166] Specifically, the guide bracket 80 is attached to both the tunnel-side frame 14 and the floor-side frame 13 while being coupled to the mounting bracket 70. This prevents the left side region of the floor panel 11 from being crushed in the left-right direction during a side collision by cooperating with the mounting bracket 70. This further protects the inverter 50 and converter 40 during a side collision.

[0167] Furthermore, during a side collision, the vertical wall portion 83 is pressed against the AT transmission 6. The guide bracket 80 is also supported in the left-right direction, similarly to the mounting bracket 70. The guide bracket 80 is also firmly supported, and thus can be prevented from falling.

[0168] The guide bracket 80 is arranged at the front end portion of the left region, that is, between the left rear end portion of the front sub-frame 20 and the mounting bracket 70. Figure 10 As shown, the front end of the guide surface portion 81 is configured to be located above the rear end portion of the front subframe 20 . The rear end of the guide surface portion 81 is configured to be directed downwardly toward the converter 40 .

[0169] The electric vehicle 1 may deform or be damaged by a frontal collision (so-called head-on collision), especially a left-side frontal collision (so-called oblique collision). In this case, the front subframe 20 may move backward and its left rear end may enter the left area.

[0170] In contrast, since the guide surface 81 of the above-described structure is arranged as described above, when the front subframe 20 moves backward, the rear end of the front subframe 20 is guided downwardly from the converter 40. Therefore, the inverter 50 and the converter 40 can be protected even in a head-on collision or an oblique collision.

[0171] (Pipe protection)

[0172] Furthermore, in the electric vehicle 1, the piping 90 is also designed to be protected in the event of a side collision. Specifically, in the lower portion of the electric vehicle 1, a plurality of piping 90 for fluids are routed along the lower surface of the floor panel 11 so as to extend in the front-to-rear direction in order to allow fluids such as fuel and cooling water to flow. Figure 4 、 Figure 5 As shown, these pipes 90 are routed so as to pass through the gap above the upper wall portion (mounting portion 72). The pipes 90, inverter 50, and converter 40 are arranged in a three-layered state at the top, middle, and bottom of the mounting bracket 70.

[0173] Specifically, battery refrigerant pipe 90a, which carries cooling water for cooling the batteries; fuel pipe 90b, which carries fuel for engine 2; and brake pipe 90c, which carries hydraulic oil for actuating the rear wheel brakes, are routed along the lower surface of floor panel 11 located above mounting bracket 70, concentrated in the left-right center. Therefore, the support provided by mounting bracket 70 protects these multiple pipes 90 even in a side collision.

[0174] Parts of the plurality of pipes 90 (fuel pipe 90b, brake pipe 90c) are routed along the inner side of the floor side frame 13, which serves as a strength member of the floor panel 11. Since these pipes 90 are routed so as to pass over the mounting bracket 70, they are located away from the floor side frame 13. Consequently, support for these pipes 90 becomes unstable.

[0175] In contrast, in the electric vehicle 1, a pipe holder 91 supporting a plurality of pipes 90 is disposed above the mounting bracket 70. The pipe holder 91 is a horizontally long, flat member mounted on the lower surface of the floor panel 11. The pipe holder 91 stably supports the plurality of pipes 90.

[0176] like Figure 5 、 Figure 6 As shown in FIG. 1 , a rectangular cutout 78 is provided on the rear side of the mounting portion 72 of the upper bracket 70U of the mounting bracket 70. One side of the rectangular cutout 78 is open to the floor side frame 13. A pipe holder 91 is disposed above the cutout 78. A plurality of pipes 90 supported by the pipe holder 91 extend rearward through the cutout 78.

[0177] The fuel pipe 90b and the brake pipe 90c further extending rearward are bent toward the floor side frame 13 using the notch 78 and the space in front of the notch 78. The pipes 90b and 90c can be easily routed.

[0178] As a result, the fuel pipe 90b and the brake pipe 90c are again routed along the inner side of the floor side frame 13. Thus, the plurality of pipes 90 routed along the lower surface of the floor panel 11 in the front-rear direction are also designed to be protected during a side collision by the support function of the mounting bracket 70.

[0179] Specifically, in this electric vehicle 1, the mounting bracket 70, which supports the inverter 50 and is located between the AT transmission 6 and the floor-side frame 13, is three-dimensionally structured to achieve high rigidity. This allows the inverter 50 to be housed within the mounting bracket 70. Even when the floor-side frame 13 is strongly pressed against one side of the AT transmission 6, the mounting bracket 70 provides left-right support.

[0180] As a result, even in a side collision, the inverter 50 housed within the mounting bracket 70 can be protected. Furthermore, the converter 40 is positioned below the mounting bracket 70. The plurality of pipes 90 are positioned above the mounting bracket 70. Therefore, the converter 40 and the plurality of pipes 90 can be protected even in a side collision.

[0181] Furthermore, a guide bracket 80 is attached to the front side of the mounting bracket 70. This enhances protection against side collisions and also protects these components in head-on and oblique collisions. Therefore, the electric vehicle 1 employing the technology of the present invention can effectively improve safety.

[0182] Furthermore, the technology of the present invention is not limited to the aforementioned embodiments and encompasses various other structures. For example, while the transmission is exemplified as a "predetermined vehicle structure" in the embodiments, the present invention is not limited to this. For example, other vehicle components such as a motor or a partial structure of a vehicle component such as a tunnel side frame may also be employed.

Claims

1. A lower structure of an electric vehicle equipped with a high-voltage battery for driving and capable of traveling using the power of the high-voltage battery, the lower structure of the electric vehicle being characterized by comprising: a floor panel extending on a lower side of the vehicle compartment; a predetermined vehicle structure provided below the floor panel and in the middle of the floor panel in the left-right direction; a pair of floor side frames extending in the front-rear direction along left and right side portions of the lower surface of the floor panel; a predetermined high-voltage component connected to the high-voltage battery and arranged between the vehicle structure and one of the floor side frames; a second high-voltage component connected to the high-voltage battery and disposed between the vehicle structure and the floor side frame; a mounting bracket for mounting the high voltage component to the floor panel; a front subframe disposed in front of the floor panel, with one of left and right rear end portions of the front subframe located in front of the high-voltage component; a guide bracket disposed between the front subframe and the high-voltage component; a tunnel portion that is recessed upward in the middle of the floor panel in the left-right direction and is provided to extend in the front-rear direction; as well as a channel side frame extending along the lower edge of the channel portion, The mounting bracket has a housing structure comprising: an inner wall portion separating at least a portion of the high-voltage component from the vehicle structure; an outer wall portion that separates at least a portion between the high-voltage component and the floor side frame; an upper wall portion, the upper wall portion being bridged between an upper edge portion of the inner wall portion and an upper edge portion of the outer wall portion; as well as a lower wall portion, the lower wall portion being connected to the lower edge portion of the inner wall portion and the lower edge portion of the outer wall portion; The second high-voltage component is arranged on the lower side of the lower wall portion so as to overlap with the high-voltage component. The guide bracket has: a guide face portion that is tilted upward toward the front; and a pair of flange portions, the pair of flange portions being provided on both sides of the guide surface portion, One side of the flange portion is attached to the floor side frame, and the other side of the flange portion is attached to the tunnel side frame. When the front subframe is retracted, the guide surface portion guides the front subframe downwardly from the second high-voltage component.

2. The lower structure of the electric vehicle according to claim 1, characterized in that: The vehicle structure is a transmission arranged inside the tunnel portion. The outer side wall portion faces a side surface of the floor side frame and is mounted to the tunnel side frame via the mounting bracket so that the inner side wall portion faces a side surface of the transmission.

3. The lower structure of the electric vehicle according to claim 1, characterized in that: The guide bracket includes a vertical wall portion that faces the vehicle structure in a left-right direction.

4. The lower structure of an electric vehicle according to any one of claims 1 to 3, characterized in that: The device further comprises at least one pipe extending in a front-to-rear direction along the floor panel for allowing fluid to flow. The pipe is routed so as to pass above the upper wall portion.

5. The lower structure of the electric vehicle according to claim 4, characterized in that: The plurality of pipes are arranged in a state of being gathered at a central portion in the left-right direction of the upper wall portion.

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