Vehicle

Abstract

A vehicle capable of suppressing vibration of an upper case of a battery pack is provided. The vehicle of the present application includes: a pair of rear floor side members (132) disposed on the left and right of the rear portion of the vehicle; a rear floor under cross member (130) fixed between the pair of rear floor side members (132); a battery pack (200) disposed in the lower portion of the vehicle and including a lower case (300) on which battery stacks (900) are disposed in one layer on the front side and in two layers on the rear side; and a case fixing member (460) extending upward from the rear end portion of the lower case (300) and fixing the lower case (300) to the rear floor under cross member (130).

Description

[0001] This application is a divisional application of the invention patent application entitled "Battery Pack and Vehicle Equipped with the Battery Pack", filed on January 7, 2020, with application number 202010025954.3. Technical Field

[0002] This disclosure pertains to vehicles. Background Technology

[0003] U.S. Patent No. 8,833,499 discloses prior art related to battery packs for electric vehicles and vehicles equipped with such battery packs. However, this prior art has issues that need to be addressed.

[0004] Prior art literature

[0005] Patent documents

[0006] Patent Document 1: US Patent No. 8,833,499

[0007] One of the challenges that needs to be addressed is suppressing the vibration of the upper casing of the battery pack. In the aforementioned prior art, a partition layer for sound insulation, heat insulation, and vibration suppression is provided between the lower surface of the vehicle floor and the upper casing of the battery pack. However, it is difficult to say that simply providing a partition layer is sufficient to suppress the vibration of the upper casing of the battery pack. Summary of the Invention

[0008] This disclosure is made in view of the above-mentioned issues, and its purpose is to provide a battery pack capable of suppressing vibration of the upper casing of the battery pack and a vehicle equipped with the battery pack.

[0009] The battery pack disclosed herein is a battery pack disposed under the floor of a vehicle, comprising: a lower housing on which a battery stack is mounted and fixed under the floor; an upper housing mounted on the lower housing; and a support member extending upward from a rigid body disposed inside the lower housing and supporting the upper housing from the rear. According to this structure, since the upper housing can be supported from below, vibration of the upper housing can be suppressed.

[0010] In the battery pack disclosed herein, the support member may also support the upper housing from the back at its central portion in the width direction of the battery pack. By utilizing the support member to support the easily flexible central portion of the upper housing from below, vibration of the upper housing can be suppressed.

[0011] In the battery pack disclosed herein, the battery pack may also include an elastic member disposed on the surface of the upper housing and sandwiched between the upper housing and the lower surface of the floor. In such a structure, by using the elastic member and the support member to clamp the upper housing from above and below, vibration of the upper housing can be suppressed. In particular, since the upper housing is not sandwiched between rigid bodies, but rather one of them is an elastic member, the elastic member can absorb vibrations generated in the upper housing.

[0012] In the battery pack disclosed herein, multiple support members may be arranged along the front-rear direction of the battery pack. Alternatively, the elastic members may be configured such that, when the battery pack is viewed from the side, the position of the elastic members in the front-rear direction of the battery pack is located between two adjacent support members. In such a structure, by arranging the support members in front of and behind the elastic members, the upper housing can be stably supported between the support members and the elastic members.

[0013] In the battery pack disclosed herein, multiple support members may be arranged along the width direction of the battery pack. Alternatively, the elastic members may be configured such that, when the battery pack is viewed from the front, the position of the elastic members in the width direction of the battery pack is located between two adjacent support members. In such a structure, by arranging the support members on both sides of the elastic members, the upper housing can be stably supported between the support members and the elastic members.

[0014] In the battery pack disclosed herein, either a downwardly protruding rib is provided on the back of the upper housing, or the upper housing is supported by a support member. In such a structure, the upper housing can be stably supported by the rib with higher rigidity abutting against the support member.

[0015] In the battery pack disclosed herein, either the multiple ribs can be arranged separately from each other, or the cables can pass between the ribs. In such a structure, the cables can be arranged without being obstructed by the ribs.

[0016] In the battery pack disclosed herein, either multiple downwardly protruding ribs are provided on the back of the upper housing along the front-rear direction of the battery pack, or the upper housing is supported by a support member. Alternatively, the elastic member may be configured such that, when the battery pack is viewed from the side, the position of the elastic member in the front-rear direction of the battery pack is between two adjacent ribs. In such a structure, by positioning the ribs that abut against the support member in front of and behind the elastic member, the upper housing can be stably supported between the support member and the elastic member.

[0017] In the battery pack disclosed herein, either multiple downwardly protruding ribs can be provided on the back of the upper housing along the width direction of the battery pack, or the upper housing can be supported by a support member. Alternatively, the elastic member can be configured such that, when the battery pack is viewed from the front, the position of the elastic member in the width direction of the battery pack is located between two adjacent ribs. In such a structure, by arranging the ribs that abut against the support member on both sides of the elastic member, the upper housing can be stably supported between the support member and the elastic member.

[0018] In the battery pack disclosed herein, either multiple support members are arranged in two rows along the front-rear direction of the battery pack at the center in the width direction, or a central plate extending along the front-rear direction of the battery pack is mounted on the upper end of the multiple support members arranged in two rows, with ribs abutting against the central plate. In such a structure, by joining the multiple support members arranged in two rows via the central plate, the rigidity of the support structure as a whole supporting the upper housing can be improved, thereby stably supporting the upper housing.

[0019] In the battery pack disclosed herein, either flat surfaces that engage with ribs are formed at both ends of the battery pack in the width direction of the central plate, or a recess for cable passage is formed in the center portion of the battery pack in the width direction of the central plate. In such a structure, by having the rigid ribs abut against the flat surfaces of the central plate, the upper housing can be stably supported, and by allowing the cable to pass through the recess of the central plate, the cable can be arranged without being obstructed by the ribs.

[0020] In the battery pack disclosed herein, the upper housing may also be formed in a stepped shape, with a lower front portion and a higher rear portion in the longitudinal direction of the battery pack, and a support member may be used to support at least the longer side of the front and rear portions in the longitudinal direction of the battery pack. In such a structure, at least the side with lower rigidity of the front and rear portions of the upper housing can be stably supported.

[0021] In the battery pack disclosed herein, the support member may also be a plate with a cross-section machined into a cap shape perpendicular to the vertical direction of the battery pack. In such a structure, by ensuring high rigidity of the support member, the upper casing can be stably supported.

[0022] Alternatively, the battery pack of this disclosure may include an inner transverse reinforcing member disposed on the inner side of the lower housing and extending along the width direction of the battery pack; or the support member may be fixed to the inner transverse reinforcing member. In such a structure, since the support member is fixed to the inner transverse reinforcing member, which is a rigid body, and the rigidity of the lower housing can be improved by utilizing the inner transverse reinforcing member, the upper housing can be stably supported.

[0023] Alternatively, the battery pack of this disclosure may have a bracket extending along the width of the battery pack and engaging with an inner transverse reinforcing member via fasteners; or the support member may be engaged with the bracket. In such a structure, since the support member is securely fixed to the inner transverse reinforcing member via the bracket, and the rigidity of the lower housing can be further improved by utilizing the bracket, the upper housing can be stably supported.

[0024] In the battery pack disclosed herein, either multiple inner transverse reinforcing members can be arranged along the front-rear direction of the battery pack, or multiple battery stacks can be arranged with their long sides facing the width direction of the battery pack and positioned between two inner transverse reinforcing members arranged along the front-rear direction of the battery pack. Alternatively, each of the multiple battery stacks can have multiple claws on both sides of the short side of the battery stack, and these claws are fixed to the inner transverse reinforcing members by clamping the multiple claws with the inner transverse reinforcing members and brackets. In such a structure, since adjacent inner transverse reinforcing members are joined by battery stacks, the rigidity of the support structure as a whole supporting the upper shell can be further improved, and the upper shell can be stably supported.

[0025] Alternatively, the battery pack of this disclosure may include an outer transverse reinforcing member disposed on the outside of the lower housing and extending along the width direction of the battery pack. Alternatively, multiple inner transverse reinforcing members and multiple outer transverse reinforcing members may be alternately arranged in the front-rear direction of the battery pack. Alternatively, each of the outer transverse reinforcing members may be joined together with the lower housing to two adjacent inner transverse reinforcing members. In such a structure, since the two adjacent inner transverse reinforcing members are joined by the outer transverse reinforcing members while sandwiching the lower housing, the rigidity of the support structure as a whole supporting the upper housing can be further improved, and the upper housing can be stably supported. Furthermore, when each of the outer transverse reinforcing members is joined together with the lower housing to two adjacent inner transverse reinforcing members by welding, the liquid tightness of the lower housing can be ensured.

[0026] Alternatively, the battery pack of this disclosure may include an outer longitudinal reinforcing member disposed on the outside of the lower housing and extending along the long side of the battery pack. Alternatively, the outer longitudinal reinforcing member may sandwich multiple outer transverse reinforcing members between itself and the lower housing, and be joined to the lower housing together with the multiple outer transverse reinforcing members. In such a structure, since the multiple outer transverse reinforcing members arranged along the width direction of the battery pack are joined by the outer longitudinal reinforcing member, the rigidity of the support structure as a whole supporting the upper housing can be further improved, and the upper housing can be stably supported. Furthermore, when the outer longitudinal reinforcing member is joined to the lower housing together with the multiple outer transverse reinforcing members by welding, the liquid tightness of the lower housing can be ensured.

[0027] In the battery pack disclosed herein, either multiple support members are arranged along the front-to-back direction of the battery pack at its center in the width direction, or an outer longitudinal reinforcing member is disposed below the multiple arranged support members. In such a structure, the rigidity of the lower housing at the location where the support members are disposed can be increased, thus stably supporting the upper housing.

[0028] In the battery pack disclosed herein, the upper housing and the support member may also be joined using fasteners. In such a structure, the upper housing can be easily fixed to the support member. Alternatively, the fastening portions of the fasteners may be sealed using a sealing material.

[0029] The vehicle disclosed herein includes: a battery pack disposed below the floor of the vehicle; and an elastic member sandwiched between the lower surface of the floor and the battery pack. The battery pack includes: a lower housing on which the battery stack is mounted and fixed below the floor; an upper housing mounted on the lower housing and on which the elastic member is mounted; and a support member extending upward from a rigid body formed by the battery stack and the lower housing, and supporting the upper housing from its rear. Any structure of the battery pack of the vehicle disclosed herein can be applied. According to this structure, by using the elastic member and the support member to sandwich the upper housing from above and below, vibration of the upper housing can be suppressed. In particular, since the upper housing is not sandwiched between rigid bodies, but rather one of them is an elastic member, the elastic member can absorb vibrations generated in the upper housing.

[0030] As described above, the battery pack and vehicle equipped with the battery pack according to this disclosure can suppress vibration of the upper casing of the battery pack. Furthermore, all the above-described features and advantages of this disclosure, as well as other features and advantages, become more apparent from the illustrative and non-limiting description with reference to the accompanying drawings. In addition, in the drawings, common reference numerals are used between different figures for the same elements. Attached Figure Description

[0031] Figure 1 This is a side view showing the structure of the vehicle according to the embodiment.

[0032] Figure 2 This is a perspective view showing the appearance of the battery pack according to the embodiment, viewed from the upper left front.

[0033] Figure 3 This is a diagram showing the structure of the battery pack according to the embodiment, and a perspective view of the battery pack after the upper casing, heating / cooling device and cables have been removed, viewed from the upper left front.

[0034] Figure 4This is a perspective view showing the appearance of the battery stack built into the battery pack of the embodiment.

[0035] Figure 5 This is a perspective view of the lower housing from the upper left front, with the reinforcing members and the arms for fixing the housing installed.

[0036] Figure 6 This is a top view of the lower housing with the reinforcing members and the arms used to fix the housing installed.

[0037] Figure 7 This is a bottom view of the lower housing with the reinforcing members and the arms for fixing the housing installed.

[0038] Figure 8 This is a perspective view taken from the upper left front, showing the structure of the side arm for fixing the housing and its surroundings.

[0039] Figure 9 It is a perspective view showing the middle frame and its supporting structure from the upper left front.

[0040] Figure 10 This is a perspective view of the lower housing with the middle frame installed on it, cut along the centerline of the battery pack in the front-rear direction, and viewed from the upper left front.

[0041] Figure 11 This is a perspective view of the lower housing, magnified from the upper left front, with the middle frame installed on top of the lower housing.

[0042] Figure 12 This is a perspective view of the front of the lower housing, with the middle frame installed on the lower housing. The lower housing is cut along the centerline of the battery pack in the front-rear direction and viewed magnified from the upper left front.

[0043] Figure 13 This is a perspective view of the front of the lower housing, with the intermediate frame and battery stack installed in the lower housing. The lower housing is cut along the centerline of the front-rear direction of the battery pack and viewed magnified from the upper left front.

[0044] Figure 14 This is a perspective view of the front of the lower housing, with the middle frame installed on the lower housing. The lower housing is cut along the centerline of the front-rear direction of the battery pack and viewed magnified from the lower left.

[0045] Figure 15 It is an enlarged and schematic cross-sectional view showing the joint between the bottom panel of the lower housing and the internal and external lateral reinforcements.

[0046] Figure 16It is an enlarged and schematic cross-sectional view showing the joint between the bottom panel of the lower housing and the external transverse reinforcement and the external central longitudinal reinforcement.

[0047] Figure 17 It is a top view schematically showing the engagement relationship between the center plate and the frame of the second floor.

[0048] Figure 18 It is a longitudinal sectional view schematically showing the engagement relationship between the center plate and the supporting legs and the second floor frame.

[0049] Figure 19 This is a schematic cross-sectional view showing the construction of the second floor.

[0050] Figure 20 This is a perspective view of the rear of the lower housing, with the middle frame installed on the lower housing. The lower housing is cut along the centerline of the battery pack in the front-rear direction and viewed magnified from the upper left rear.

[0051] Figure 21 This is a side view of the rear of the lower housing, taken with the middle frame installed on the lower housing, cut along the centerline of the battery pack in the front-rear direction and viewed magnified from the left side.

[0052] Figure 22 This is a perspective view of the rear of the lower housing, with the middle frame installed on the lower housing. The lower housing is cut along the centerline of the battery pack in the front-rear direction and viewed magnified from the lower left.

[0053] Figure 23 This is a perspective view showing the structure of the rear end portion of the outer side of the lower housing, on which the housing mounting arm is installed.

[0054] Figure 24 This is a three-dimensional view of the bottom right rear of the lower shell, viewed from a magnified angle from the lower left.

[0055] Figure 25 This is a three-dimensional view of the bottom surface of the lower shell from the left rear, viewed magnified from a lower left angle.

[0056] Figure 26 This is a perspective view of the lower casing viewed from the upper left front, with the middle frame and heating / cooling device installed.

[0057] Figure 27 This is a perspective view of the front of the lower housing, with the middle frame and heating / cooling device installed in the lower housing. The lower housing is cut along the centerline of the front-rear direction of the battery pack and viewed magnified from the upper left rear.

[0058] Figure 28This is a perspective view of the front of the lower housing, with the middle frame and heating / cooling device installed in the lower housing. The lower housing is cut along the centerline of the front-rear direction of the battery pack and viewed from a large, enlarged perspective from the upper left.

[0059] Figure 29 This is a side view of the front of the lower housing, with the middle frame and heating / cooling device installed in the lower housing. The lower housing is cut along the centerline in the front-rear direction of the battery pack and viewed from the left side with a larger magnification.

[0060] Figure 30 This is a perspective view of the front of the lower housing, viewed from the upper left, with the battery stack, intermediate frame, cables, and heating / cooling devices installed in the lower housing.

[0061] Figure 31 This is a three-dimensional view of the periphery of the center plate when the battery pack is cut along its width and viewed magnified from a frontal, obliquely upward perspective.

[0062] Figure 32 This is a side view of the front of the lower housing, which is cut along the centerline of the battery pack in the front-rear direction with the intermediate frame, heating / cooling device and battery stack installed in the lower housing. It is a magnified view of the front of the lower housing from the left side.

[0063] Figure 33 This is a side view of the perimeter of the partition bracket, taken with the intermediate frame, battery stack, and heating / cooling device installed in the lower housing. The lower housing is cut along the centerline in the front-rear direction of the battery pack and viewed magnified from the left side.

[0064] Figure 34 This is a perspective view taken from the lower left rear, showing the battery pack of the embodiment mounted in a vehicle.

[0065] Figure 35 This is a perspective view showing in detail the skeletal structure beneath the floor of the vehicle according to the embodiment.

[0066] Figure 36 It is a perspective view showing in detail the skeletal structure of the rear region of the vehicle according to the embodiment.

[0067] Figure 37 This is a perspective view showing in detail the structure of the rear suspension of the vehicle according to the embodiment.

[0068] Figure 38 This is a diagram showing the floor structure of a vehicle according to an embodiment, and a perspective view of the front portion of the floor when the battery pack without battery stack and heating / cooling device is mounted under the floor, cut along the centerline in the longitudinal direction of the vehicle.

[0069] Figure 39 This is a perspective view showing the engagement state of the battery pack with the frame structure under the floor when the battery pack is mounted under the floor of the vehicle in the embodiment.

[0070] Figure 40 This is a bottom view showing the battery pack mounted under the floor of the vehicle in this embodiment.

[0071] Figure 41 This is a bottom view showing the positional relationship between the battery pack and the floor when the battery pack is mounted under the floor of the vehicle in this embodiment.

[0072] Figure 42 This is a bottom view showing the reinforcement structure beneath the floor of the vehicle according to the embodiment.

[0073] Figure 43 This is a bottom view showing the state in which the bottom cover is installed under the floor of the vehicle in the embodiment.

[0074] Figure 44 This is a left-side view of the rear of the floor of the vehicle in the embodiment, showing the battery pack mounted under the floor.

[0075] Figure 45 This is a front view showing a cross-section of the floor and battery pack in the width direction, viewed from the front, of the vehicle in the embodiment where the battery pack is mounted under the floor.

[0076] Figure 46 This is a perspective view of the rear end of the lower housing, magnified from a lower left rearward angle, showing the battery pack housing mounted on the lower crossbeam of the rear floor using a rear arm.

[0077] Figure 47 This is a side view of the rear of the floor and battery pack, taken with the battery pack mounted under the floor, cut along the centerline of the vehicle in the longitudinal direction, and magnified from the left side.

[0078] Figure 48 It is an enlarged and schematic cross-sectional view showing the joint between the rear floor underbeam and the rear floor upper beam and floor panel.

[0079] Figure 49 This is a schematic diagram showing the details of the construction for securing the housing to the crossbeam under the rear floor.

[0080] Figure 50 This is a diagram showing the support structure of the upper housing, and a perspective view of the floor and battery pack with the battery pack (without the battery stack and heating / cooling device) mounted under the floor. The view is taken by cutting along the centerline of the vehicle in the longitudinal direction and magnifying from the left lower front.

[0081] Figure 51 This is a diagram showing the support structure of the upper housing, and a schematic front view of the periphery of the center plate when the floor and battery pack are cut along their width and viewed from the front.

[0082] Figure 52 This is a diagram showing the support structure of the upper housing, and a side view of the floor and battery pack with the battery pack mounted under the floor, cut along the centerline of the vehicle in the longitudinal direction and viewed magnified from the left side.

[0083] Figure 53 It is a schematic longitudinal sectional view showing the engagement state of the first elastic member with the first base formed on the floor panel.

[0084] Figure 54 It is a diagram showing the engagement state of the first elastic member with the first base formed on the floor panel, and a perspective view of the periphery of the first base of the floor panel viewed from a slightly lower angle.

[0085] Figure 55 It is a diagram showing the engagement state of the second elastic member with the second base formed on the floor panel, and a perspective view of the periphery of the second base of the floor panel viewed from a slightly lower angle.

[0086] Figure 56 This is a schematic longitudinal sectional view showing a modified example of the support structure of the upper shell.

[0087] Figure 57 This diagram illustrates the function and effect of the reinforcing structure beneath the floor of the vehicle and the battery pack in the embodiment.

[0088] Figure 58 yes Figure 36 The supplementary diagram is a schematic cross-sectional view of the ring-shaped skeleton.

[0089] Figure 59 yes Figure 21 The supplementary diagram shows a detailed perspective view of the area around the weld points at the rear end of the lower housing.

[0090] Figure 60 This is a schematic longitudinal sectional view showing a modified example of the structure of the rear end of the lower housing to which the housing fixing rear arm is fixed.

[0091] Figure 61 This diagram illustrates the function and effect of the reinforcing structure beneath the floor of the vehicle and the battery pack in the embodiment.

[0092] Figure 62 yes Figure 28The supplementary diagram is a schematic top view showing the air guide plate cut parallel to the bottom surface of the lower housing of the battery pack and viewed from above.

[0093] Explanation of reference numerals in the attached figures

[0094] 2 Roads; 4 Obstacles; 100 Vehicles; 101 Vehicle Body; 102 Floor Panels;

[0095] 102a Rear part of floor panel; 102b Front part of floor panel; 103 Front wheel;

[0096] 104 Rear wheel; 105 Front seat; 106 Rear seat;

[0097] 110 Floor passage; 112 First base; 113 Second base;

[0098] 120 floor underside reinforcement; 120a rear section;

[0099] 120b front bumper; 122 bumper reinforcement;

[0100] 123 Collision box; 130 Rear floor underbeam; 131 Bottom;

[0101] 132 Rear floor side member; 132a Opening for fixing longitudinal arm;

[0102] 134 Bracket; 136 Front floor under-floor reinforcement;

[0103] 140. Rear floor beam; 141. Internal reinforcement of side beams and columns;

[0104] 142 External reinforcement for side beams and columns; 143 Roof reinforcement;

[0105] 144 Wheel cover exterior panel; 145 Wheel cover interior panel;

[0106] 146 Rear pillar internal panel; 148 Upper side frame; 149 Lower side frame;

[0107] 150 Channel cover reinforcement; 151 Front bulkhead;

[0108] 152 Upper floor reinforcement; 153 Front component;

[0109] 154 Side beam; 155 First seat crossbeam;

[0110] 156 Second seat crossbeam; 160 Front suspension frame components;

[0111] 170 rear suspension; 171 trailing arm;

[0112] 172 Trailing arm mounting; 173 Rear suspension arm;

[0113] 174 shock absorber; 175 coil spring;

[0114] 176 Stabilizer bar; 179 Shock absorber mounting bracket;

[0115] 195 bottom cover; 200 battery pack; 201 rear end;

[0116] 210 Upper shell; 211 Lower top plate; 212 Higher top plate; 213 Central ridge;

[0117] 214 Front bulge; 215 Sealing component; 216 Reinforcing groove; 218 Rib;

[0118] 220 Flange; 221 Fastener; 231 First elastic member; 232 Second elastic member;

[0119] 250 Fasteners; 252 Sealing material; 300 Lower housing; 301 Bottom panel;

[0120] 302a-302g Reinforcing recess; 305 Rear surface of housing; 310 Flange;

[0121] 320 Internal transverse reinforcement; 321 Welding allowance; 330 Internal transverse reinforcement;

[0122] 340. Divider bracket; 341. Base; 342. Divider wall;

[0123] 343 Battery casing fixing part; 344 Fastener; 350 Fixing base;

[0124] 351 Alignment pin; 358 Inner top longitudinal reinforcement; 360 Second floor; 361 Second floor panel; 362 Second floor longitudinal frame;

[0125] 362a flange; 363 second floor transverse frame; 363a flange

[0126] 364 Second floor central frame; 364a Flange;

[0127] 366 divider bracket; 370 center plate; 371 flange;

[0128] 372 Recess; 374 Fastener; 375 Pad; 380 Center Beam;

[0129] 381 Side beams; 385 Intermediate frame; 390 Support legs;

[0130] 391 Support leg; 392 Support wall; 394 Support leg;

[0131] 395 support leg; 400 suspension bolt; 402 collar;

[0132] 404 suspension bolts; 406 collars; 410 side arms for housing fixing;

[0133] 411 Cover plate; 412 Extension plate; 420 Side arm for housing fixing;

[0134] 421 Cover plate; 422 Extension plate; 430 Side arm for housing fixing;

[0135] 431 Cover plate; 432 Extension plate; 440 Side arm for housing fixing;

[0136] 441 Cover plate; 460 Rear arm for housing fixing; 461 Folding part;

[0137] 462 ribs; 470 fasteners; 471 fasteners; 480 partitions;

[0138] 510 External transverse reinforcement; 511 Ridge; 520 External transverse reinforcement;

[0139] 521 ridge line; 530 external transverse reinforcement; 531 ridge line;

[0140] 540 External transverse reinforcement; 550 External transverse reinforcement;

[0141] 560 External transverse reinforcement; 561a Inner valley line; 561b Inner ridge line;

[0142] 561c Outer valley line; 561d Outer ridge line; 562 Rear surface; 570 Outer rear bracket;

[0143] 571 Rear surface of bracket; 572 Side of bracket; 573 Support surface;

[0144] 580 Rear end inner bracket; 590 Closed section component;

[0145] 601-603 External longitudinal reinforcement; 610 External central longitudinal reinforcement;

[0146] 611 Support part; 613 Ridge line; 614 Pressing part; 615 Welding allowance;

[0147] 620 External central longitudinal reinforcement; 630 External longitudinal reinforcement;

[0148] 631 Support part; 633 Ridge line; 634 Pressing part; 635 Welding allowance;

[0149] 640 outer longitudinal reinforcement; 650 outer longitudinal reinforcement;

[0150] 655 extension plate; 660 outer corner reinforcement;

[0151] The upper sides of the inner corners of 661a and 661b; the lower sides of the inner corners of 662a and 662b;

[0152] The upper outer corners of 663a and 663b; the lower outer corners of 664a and 664b;

[0153] 665a Inner valley line; 665b Inner ridge line; 665c Outer valley line; 665d Outer ridge line;

[0154] 700 Blower; 702 Right air supply duct; 704 Left air supply duct;

[0155] 705 Second floor left air supply duct; 706 Second floor right air supply duct;

[0156] 711 Air distribution unit; 712 Air guide plate; 713 Bracket; 714 Gasket;

[0157] 715 Rear wall; 721 Air distribution unit; 722 Air guide plate; 723 Bracket;

[0158] 724 gasket; 725 rear wall; 750 maintenance connector; 751 cable;

[0159] 760 junction box; 801 solder joint; 802 solder joint;

[0160] 803 weld point; 811 bolt; 812 nut; 900 battery stack;

[0161] 901 Battery cell; 905 Power distribution equipment; 910 Terminal board;

[0162] 912 Stack support bracket; 920 Battery casing; 922 Claw section;

[0163] 930 heater; 950 battery ECU; 951 battery ECU Detailed Implementation

[0164] The following is a table of contents showing the contents described in the embodiments of this disclosure and the order of description.

[0165]

[0166] 1. Vehicle Overview

[0167] 2. Battery pack

[0168] 2-1. Appearance and Overview of the Battery Pack

[0169] 2-2. Details of the reinforcement structure of the lower shell

[0170] 2-3. Construction of the intermediate frame

[0171] 2-4. Details of the supporting structure of the intermediate frame

[0172] 2-5. Details of the joint structure between reinforcing components

[0173] 2-6. Details of the frame construction of the second floor

[0174] 2-7. Detailed description of the rear end of the lower housing

[0175] 2-8. Heating / cooling device

[0176] 2-9. Cable Installation Structure

[0177] 2-10. Fixed Structure of Battery Stack

[0178] 3. Vehicle Body Structure

[0179] 3-1. Overview of Vehicle Body Structure

[0180] 3-2. The skeletal structure of the car body

[0181] 3-3. Structure mounted beneath the floor of the battery pack

[0182] 3-4. Installation structure of the rear end of the battery pack

[0183] 3-5. Support structure of the upper shell

[0184] 4. Features and Advantages

[0185] 4-1. Support from below the upper housing by support legs

[0186] 4-2. Connection structure based on external transverse stiffeners and internal transverse stiffeners

[0187] 4-3. Connection structure based on external longitudinal stiffener and external transverse stiffener

[0188] 4-4. Three-dimensional reinforcement of the battery pack by the intermediate frame

[0189] 4-5. Setting of the gap between the elastic member, the floor panel, and the upper shell.

[0190] 4-6. Reinforcement of the vehicle frame by the reinforcement structure of the battery pack

[0191] 4-7. Battery pack support provided by crossbeams forming a ring-shaped frame

[0192] 4-8. Suspension support for the rear end of the battery pack via the crossbeam under the rear floor

[0193] 4-9. Closed cross-section structure of the rear end of the lower shell

[0194] 4-10. Connection between the outer longitudinal stiffener (made by the outer corner stiffener) and the outer transverse stiffener at the rear end.

[0195] 4-11. Battery stack support with multiple reinforcing members

[0196] 4-12. Battery pack protection provided by external transverse and longitudinal reinforcement members

[0197] 4-13. Configuration of the air guide plate on the internal transverse reinforcement

[0198] 4-14. Protection of the battery stack via air supply ducts

[0199] 4-15. Alternating configuration of the left and right air distribution sections

[0200] 4-16. Inclined configuration of air guide vanes from the side of the air distribution section to the opposite side

[0201] 5. Other

[0202] The following will be explained in the order listed above.

[0203] 1. Vehicle Overview

[0204] use Figure 1 An overview of the vehicle described in this disclosure.

[0205] Figure 1 This is a side view showing the structure of the vehicle 100 according to an embodiment. The vehicle 100 is an electric vehicle that uses an electric motor as its power source. The electric motor operates by means of an electrical supply. The vehicle 100 includes a battery pack 200 that stores the electrical power supplied to the electric motor. The battery pack 200 houses multiple rechargeable batteries (battery stacks).

[0206] The battery pack 200 is mounted below the floor panel 102 of the body 101 constituting the vehicle 100. The battery pack 200 is positioned between the front wheel 103 and the rear wheel 104 in the longitudinal direction of the vehicle 100. Furthermore, the battery pack 200 is mounted such that its front side is directly below the front seat 105, and its rear side, which is one level higher than the front side, is directly below the rear seat 106. The battery pack 200 is mounted on the floor panel 102 in a form that allows it to be replaced as needed.

[0207] 2. Battery pack

[0208] The battery pack 200 of the embodiment will be described.

[0209] 2-1. Appearance and Overview of the Battery Pack

[0210] First, use Figures 2-4 Description of the appearance and overview of battery pack 200.

[0211] Figure 2This is a perspective view of the battery pack 200 from a slightly upper left front angle, showing its appearance. First, here, the front-rear direction of the vehicle is defined as the front-rear direction of the battery pack 200, the width direction of the vehicle is defined as the width direction of the battery pack 200, and the vertical direction of the vehicle is defined as the vertical direction of the battery pack 200. Furthermore, in the figures described below, arrows FR and UP indicate the front of the battery pack 200 in the front-rear direction and the top of the battery pack 200 in the vertical direction, respectively, and arrow RH indicates the right side from the perspective of an occupant in the vehicle. Additionally, the opposite directions of arrows FR, UP, and RH indicate the rear, bottom, and left (LH) of the battery pack 200. Hereinafter, only the front-rear, left-right, and vertical directions will be used in the description; unless otherwise specified, these refer to the front-rear direction of the battery pack 200, the left-right direction in the width direction, and the vertical direction in the vertical direction. Furthermore, when viewed from above, the centerline of the battery pack 200 in the longitudinal direction coincides with the centerline of the vehicle in the longitudinal direction. Here, the centerline in the longitudinal direction refers to an imaginary line passing through the center of the vehicle's width direction along the longitudinal direction (illustration omitted). The battery pack 200 is approximately symmetrical about the left and right sides with respect to the centerline.

[0212] Figure 2 The diagram shows the casing of the battery pack 200. The casing of the battery pack 200 consists of an upper casing 210 located on the upper side and a lower casing 300 located on the lower side. The upper casing 210 is made of, for example, a light metal or resin (or a portion thereof may be made of resin) or steel. The lower casing 300 is made of, for example, steel. Furthermore, except where specifically stated or clearly defined in principle, the components constituting the battery pack 200 are made of metals such as steel or aluminum.

[0213] The upper housing 210 has a shape resembling an inverted bathtub. Furthermore, the upper housing 210 is formed in a stepped shape, with the front portion lower and the rear portion higher in the longitudinal direction of the battery pack 200. Hereinafter, the front portion of the upper housing 210 with the relatively lower top plate will be referred to as the low top plate portion 211, and the rear portion of the upper housing 210 with the relatively higher top plate will be referred to as the high top plate portion 212. The low top plate portion 211 is longer in the longitudinal direction than the high top plate portion 212.

[0214] A central ridge 213 extending in the front-rear direction is formed at the center of the lower top plate portion 211 of the upper housing 210 in the width direction. A service plug 750 protrudes upward from the interior of the battery pack 200 from the central ridge 213. Cables connected to the service plug 750 are housed below the central ridge 213. When the battery pack 200 is mounted in a vehicle, the service plug 750 connects to a connector on the vehicle side. The opening in the central ridge 213 through which the service plug 750 passes is sealed, for example, by a resin sealing member 215.

[0215] The upper housing 210 is longer in the longitudinal direction than in the width direction, and has a constant width except for the top portion. The top portion of the upper housing 210 gradually tapers towards the top. A front ridge 214, which is further raised than the central ridge 213, is formed at the top portion of the upper housing 210. A junction box and a blower, described later, are disposed below the front ridge 214. The front ridge 214 and the central ridge 213 also serve to improve the rigidity of the lower top plate portion 211. Separately from the front ridge 214 and the central ridge 213, a plurality of reinforcing grooves 216 extending from the central ridge 213 in the left-right width direction are formed in the lower top plate portion 211.

[0216] Two elastic members 231 and 232 are arranged along the front-to-back direction on the central raised portion 213 of the upper housing 210. These elastic members 231 and 232 are, for example, rubber, sponge, or springs. The details of the position of the elastic members 231 and 232 and their function will be described below.

[0217] A flange 220 is formed around the upper housing 210. Similarly, a flange 310 is formed around the lower housing 300. The flange 220 of the upper housing 210 and the flange 310 of the lower housing 300 are matched and fastened together with fasteners, thereby fixing the upper housing 210 to the lower housing 300.

[0218] The lower housing 300 is provided with multiple housing fixing side arms 410, 420, 430, and 440 extending from its left and right sides along the width direction. The housing fixing side arms 410, 420, 430, and 440 are mounted to the bottom surface of the floor using suspension bolts 400 and 404. Additionally, although in Figure 2 The lower housing 300 is concealed behind other components, but it also has a housing mounting arm 460. The housing mounting arm 460 is mounted to the bottom of the floor by fasteners (bolts and nuts) 470.

[0219] Figure 3This is a perspective view of the battery pack 200 after the upper housing 210, the heating / cooling device (described later), and cables have been removed, viewed from the upper left front. Inside the battery pack 200 are multiple battery stacks 900 with a cuboid shape. The battery stacks 900 are arranged and mounted with their long sides facing the width direction of the lower housing 300 (the same meaning as the width direction of the battery pack 200), along the front-back direction of the lower housing 300 (the same meaning as the front-back direction of the battery pack 200).

[0220] A middle frame consisting of a second floor 360 and a center plate 370 is provided in the lower housing 300. The second floor 360 is a second mounting surface for the battery stacks 900, located at a position higher than the bottom surface of the lower housing 300. The three battery stacks 900 are arranged and mounted along the long side of the lower housing 300. Above the foremost battery stack 900 mounted on the second floor 360, battery ECUs 950 and 951 are arranged to control the charging and discharging of the battery stacks 900 and the heating / cooling devices described later. In addition, although not shown, three battery stacks 900 are also mounted below the second floor 360.

[0221] The center plate 370 is positioned at the center of the lower housing 300, higher than the bottom surface of the lower housing 300. The center plate 370 extends from the second floor 360 toward the top of the lower housing 300 in the front-rear direction. The top of the center plate 370 extends beyond the area where the battery stacks 900 are mounted and reaches the top of the lower housing 300 where the junction box 760, etc., is located. Five battery stacks 900 are mounted below the center plate 370. Therefore, the total number of battery stacks 900 mounted on the lower housing 300 is 11, consisting of 8 on the first layer and 3 on the second layer.

[0222] The details of the center plate 370 are then described, but one of its functions is as a conduit for cables (not shown). A maintenance connector 750 is mounted on top of the center plate 370. Cables connected to the junction box 760 located at the top of the lower housing 300, cables connected to the battery ECUs 950 and 951, and cables connected to the maintenance connector 750 pass through the center plate 370.

[0223] Figure 4 This is a perspective view showing the appearance of the battery stack 900. The battery stack 900 is constructed by stacking multiple battery cells 901 along the long side direction (also referred to as the length direction of the battery stack 900). The battery cells 901 are, for example, lithium-ion batteries, nickel-metal hydride batteries, all-solid-state batteries, lead-acid batteries, etc. The stacked battery cells 901 are housed in a battery casing 920 with end plates 910 pressing down on both ends of the battery stack 900 along its long side direction. A power distribution device 905 is mounted on the upper surface of the battery stack 900.

[0224] Stack support brackets 912 are joined to both sides of the battery stack 900 along its long side to restrict movement of the battery stack 900 along its long side. The stack support brackets 912 have a generally L-shaped shape and are fixed to the bottom surface of the lower housing 300 by other components.

[0225] A partition bracket 340 is provided along the short side direction of the battery stack 900 (also referred to as the width direction of the battery stack 900) to separate it from other adjacent battery stacks 900. The partition bracket 340 has a base 341 and a partition wall 342, the base 341 being fixed to the bottom surface of the lower housing 300 via other components, and the partition wall 342 being vertically erected relative to the base 341.

[0226] Additionally, the partition bracket 340 has a battery housing fixing portion 343. The battery housing fixing portion 343 is perpendicular to the partition wall 342, just like the base 341, but a gap is formed between it and the bottom surface of the lower housing 300. A claw portion (hidden in the figure) is formed on the battery housing 920. By engaging this claw portion with the battery housing fixing portion 343, the battery stack 900 is fixed to the lower housing 300.

[0227] 2-2. Details of the reinforcement structure of the lower shell

[0228] use Figures 5-8 The details of the reinforcement structure of the shell 300 are explained below.

[0229] Figure 5 This is a perspective view of the lower housing 300, viewed from the upper left front, with various reinforcing members and housing fixing arms installed. The lower housing 300 is a bathtub shape, with the bottom panel 301, which forms its bottom, lower than the rim, and a flange 310 is formed at its rim. Furthermore, although in Figure 2 and Figure 3 It is hidden behind other components, but the housing fixing rear arm 460 extends upward from the rear end of the lower housing 300.

[0230] A plurality of internal transverse reinforcement members 320, serving as internal transverse reinforcement members, are provided on the bottom panel 301 of the lower housing 300. The internal transverse reinforcement members 320 are arranged with their long sides facing the width direction of the lower housing 300 and along the front-rear direction of the lower housing 300. An internal transverse reinforcement member 330 with a different shape from the other internal transverse reinforcement members is provided at the rear end of the bottom panel 301 of the lower housing 300.

[0231] The internal lateral reinforcements 320 and 330 have a length extending from the right end to the left end of the bottom panel 301 in the width direction of the lower housing 300. Details will follow, but the internal lateral reinforcement 320 has a cap-shaped cross-section that opens downwards, and the internal lateral reinforcement 330 has a Z-shaped cross-section. The internal lateral reinforcements 320 and 330 are joined to the bottom panel 301 of the lower housing 300 by welding. Furthermore, a partition bracket 340 is fastened to each of the internal lateral reinforcements 320 and 330.

[0232] The top of the bottom panel 301 of the lower housing 300 is shallower than other parts. An inner top longitudinal reinforcement 358 extending in the front-rear direction of the lower housing 300 is provided at the top of the bottom panel 301 of the lower housing 300.

[0233] Fixing bases 350 extending in the front-rear direction of the lower housing 300 are provided on both sides of the bottom panel 301 of the lower housing 300 in the width direction. The fixing bases 350 are joined to the bottom panel 301 of the lower housing 300, for example, by welding. The fixing bases 350 are components for fixing the battery stack 900, and stack support brackets 912 are joined on the fixing bases 350 at intervals where the battery stacks 900 are arranged. The two ends of the internal transverse reinforcements 320 and 330 overlap with the fixing bases 350.

[0234] Figure 6 This is a top view of the lower housing 300 with various reinforcing members and housing fixing arms installed. Multiple reinforcing recesses 302a-302g are formed on the inner surface of the bottom panel 301 of the lower housing 300. The reinforcing recess 302a is a recess extending from the end of the lower housing 300 in the width direction, and is formed between each of the first to fifth internal transverse reinforcing members 320 from the front, and between the seventh and eighth internal transverse reinforcing members 320 from the front.

[0235] Reinforcing recesses 302b and 302c are provided at the top of the bottom panel 301 of the lower housing 300. An inner top longitudinal reinforcing member 358 is mounted on the reinforcing recesses 302b and 302c.

[0236] Reinforcing recesses 302e and 302d are formed between each of the fifth to seventh internal transverse reinforcing members 320 from the front. Reinforcing recess 302e is formed at the center of the lower housing 300 in the width direction. Reinforcing recesses 302d are formed on both sides of the reinforcing recess 302e in the width direction of the lower housing 300.

[0237] Reinforcing recesses 302g and 302f are formed between the eighth internal transverse reinforcing member 320 and the last internal transverse reinforcing member 330 from the front. The reinforcing recess 302g is formed at the center of the lower housing 300 in the width direction. The reinforcing recesses 302f are formed on both sides of the reinforcing recess 302g in the width direction of the lower housing 300.

[0238] Figure 7 This is a bottom view of the lower housing 300 with various reinforcing members and housing fixing arms installed. Multiple external transverse reinforcing members 510, 520, 530, 540, 550, and 560, serving as outer transverse reinforcing members, are provided on the bottom surface of the lower housing 300. The external transverse reinforcing members 510, 520, 530, 540, 550, and 560 are arranged with their long sides facing the width direction of the lower housing 300, along the front-to-back direction of the lower housing 300.

[0239] The external lateral reinforcements 510, 520, 530, 540, 550, and 560 have a length extending from the right end to the left end of the bottom panel 301 in the width direction of the lower housing 300. Furthermore, the width (length in the short side direction) of the external lateral reinforcements 510, 520, 530, 540, 550, and 560 is greater than that of the internal lateral reinforcement 320 (see reference). Figure 6 The width is as follows. Further details will follow, but the external transverse reinforcements 510, 520, 530, 540, 550, and 560 have a cap-shaped cross-section that opens upwards. The external transverse reinforcements 510, 520, 530, 540, 550, and 560 are joined to the bottom panel 301 of the lower housing 300 by welding.

[0240] External lateral reinforcement members 510 and 520 are provided at the top end of the bottom surface of the lower housing 300. External lateral reinforcement member 510 is the shortest, and external lateral reinforcement member 520 is the second shortest. Reinforcing recesses 302b and 302c are formed on the inner side of the portion of the bottom panel 301 where the external lateral reinforcement members 510 and 520 are mounted. Extension plates 412 extending outward in the width direction of the lower housing 300 are joined to both ends of the external lateral reinforcement member 510. However, the extension plates 412 may also be integrally formed with the external lateral reinforcement member 510. Extension plates 422 extending outward in the width direction of the lower housing 300 are joined to both ends of the external lateral reinforcement member 520. The extension plates 422 may also be integrally formed with the external lateral reinforcement member 520.

[0241] Four external transverse reinforcement members 530 are arranged closely beside the external transverse reinforcement members 520. The four external transverse reinforcement members 530 are of equal length and identical shape. A reinforcing recess 302a is formed on the inner side of the portion of the bottom panel 301 where the external transverse reinforcement members 530 are mounted. That is, the five inner transverse reinforcement members 320 and the four outer transverse reinforcement members 530 are alternately arranged in the front-rear direction of the lower housing 300. In other words, each external transverse reinforcement member 530 is configured to connect two adjacent inner transverse reinforcement members 320. Furthermore, extension plates 432 extending outward in the width direction of the lower housing 300 are joined at both ends of the external transverse reinforcement members 530. However, the extension plates 432 may also be integrally formed with the external transverse reinforcement members 530.

[0242] The outer lateral reinforcement 540 sandwiches the bottom panel 301 and is positioned on the opposite side of the sixth inner lateral reinforcement 320 from the front. Since the width of the outer lateral reinforcement 540 is wider than that of the inner lateral reinforcement 320, the inner lateral reinforcement 320 is contained within the width of the outer lateral reinforcement 540 when viewed from above.

[0243] An external lateral reinforcement 550 is disposed on the opposite side of a reinforcing recess 302a formed between the seventh and eighth internal lateral reinforcements 320 from the front. In other words, the external lateral reinforcement 550 is configured to connect the seventh and eighth internal lateral reinforcements 320 from the front.

[0244] An external lateral reinforcement 560 is disposed at the rear end of the bottom panel 301 of the lower housing 300. Additionally, the external lateral reinforcement 560 sandwiches an internal lateral reinforcement 330 (see reference) disposed at the rear end of the bottom panel 301. Figure 6 On the opposite side of the outer transverse reinforcement 560. Since the width of the outer transverse reinforcement 560 is wider than that of the inner transverse reinforcement 330, the inner transverse reinforcement 330 is contained within the width of the outer transverse reinforcement 560 when viewed from above.

[0245] External central longitudinal stiffeners 610 and 620, serving as outer longitudinal stiffeners, are provided on the bottom surface of the lower housing 300. The external central longitudinal stiffeners 610 and 620 have a cap-shaped cross-section with at least a portion opening upwards. The long side of the external central longitudinal stiffeners 610 and 620 faces the front-rear direction of the lower housing 300 and is positioned at the center of the width direction of the lower housing 300.

[0246] The outer central longitudinal stiffener 610 has a length that connects the outer transverse stiffener 510 to four outer transverse stiffeners 530. The outer central longitudinal stiffener 610 sandwiches the outer transverse stiffeners 510, 520, and 530 between itself and the bottom panel 301 of the lower housing 300, and is joined to the bottom panel 301 of the lower housing 300 together with the outer transverse stiffeners 510, 520, and 530 by welding.

[0247] The outer central longitudinal stiffener 620 has a length extending from the outer transverse stiffener 540 to the outer transverse stiffener 560. The outer central longitudinal stiffener 620 sandwiches the outer transverse stiffeners 540, 550, and 560 between itself and the bottom panel 301 of the lower housing 300, and is joined to the bottom panel 301 of the lower housing 300 together with the outer transverse stiffeners 540, 550, and 560 by welding. The rear end of the outer central longitudinal stiffener 610 and the front end of the outer central longitudinal stiffener 620 are joined by welding.

[0248] The lower housing 300 has external central longitudinal stiffeners 610 and 620 sandwiched on the left and right sides of its bottom surface, and external longitudinal stiffeners 630, 640, 650 and external corner stiffeners 660. Each stiffener 630, 640, 650 and 660 has a cap-shaped cross-sectional shape with at least a portion of it opening upwards.

[0249] The outer longitudinal stiffener 630 is positioned such that its long side faces the front-rear direction of the lower housing 300. The outer longitudinal stiffener 630 has a length that connects the outer transverse stiffener 520 to four outer transverse stiffeners 530. The outer longitudinal stiffener 630 sandwiches the outer transverse stiffeners 520 and 530 between itself and the bottom panel 301 of the lower housing 300, and is joined to the bottom panel 301 of the lower housing 300 together with the outer transverse stiffeners 520 and 530 by welding.

[0250] The outer longitudinal stiffener 640 and the outer transverse stiffener 540 are arranged with their ends overlapping. The outer longitudinal stiffener 640 sandwiches the end of the outer transverse stiffener 540 between itself and the bottom panel 301 of the lower housing 300, and together with the outer transverse stiffener 540, is joined to the bottom panel 301 of the lower housing 300 by welding. The outer longitudinal stiffener 640 has a cross-shaped form in which the length in the width direction of the lower housing 300 is longer than its length in the front-rear direction when viewed from above. The front end of the outer longitudinal stiffener 640 in the short side direction is joined to the rear end of the outer longitudinal stiffener 630 by welding. In addition, one end of the outer longitudinal stiffener 640 in the long side direction protrudes to the outside of the lower housing 300 in the width direction.

[0251] The outer longitudinal stiffener 650 and the outer transverse stiffener 550 are arranged with their ends overlapping. The outer longitudinal stiffener 650 sandwiches the end of the outer transverse stiffener 550 between itself and the bottom panel 301 of the lower housing 300, and is joined to the bottom panel 301 of the lower housing 300 together with the outer transverse stiffener 550 by welding. The front end of the outer longitudinal stiffener 650 is joined to the rear end of the outer longitudinal stiffener 640 by welding. In addition, an extension plate 655 extending outward in the width direction of the lower housing 300 is joined to the outer longitudinal stiffener 650. However, the extension plate 655 may also be integrally formed with the outer longitudinal stiffener 650.

[0252] The outer corner reinforcement 660 is a curved reinforcing member that connects the outer longitudinal reinforcement 650 to the outer transverse reinforcement 560 in a curved manner. The outer corner reinforcement 660 is welded to the bottom panel 301 of the lower housing 300. The front end of the outer corner reinforcement 660 is welded to the rear end of the outer longitudinal reinforcement 650. The rear end of the outer corner reinforcement 660 is welded to one end of the outer transverse reinforcement 560.

[0253] An outer rear end bracket 570 is provided at the rear end of the bottom panel 301 of the lower housing 300. The outer rear end bracket 570 is a component for mounting the housing fixing rear arm 460 to the lower housing 300. An outer transverse reinforcement 560 is sandwiched between the outer rear end bracket 570 and the bottom panel 301 of the lower housing 300, and is joined to the bottom panel 301 of the lower housing 300 together with the outer transverse reinforcement 560, for example, by welding. In addition, a portion of the outer rear end bracket 570 overlaps with the rear end of the outer central longitudinal reinforcement 620 and is held by the outer central longitudinal reinforcement 620 and the outer transverse reinforcement 560. The overlapping portions of the outer rear end bracket 570, the outer central longitudinal reinforcement 620, and the outer transverse reinforcement 560 are joined together, for example, by welding.

[0254] Figure 8 This is a perspective view taken from the upper left front, showing the structure of the housing mounting side arms 410, 420, 430, 440 and their surroundings. The housing mounting side arms 410, 420, 430, 440 are components used to suspend the battery pack 200 below the floor of the vehicle body. Each of the housing mounting side arms 410, 420, 430, 440 consists of two components, one upper and one lower.

[0255] The housing fixing side arms 410 and 420 have substantially the same shape. The housing fixing side arms 410 and 420 are composed of extension plates 412 and 422 and flat cover plates 411 and 421. The extension plates 412 and 422 extend outward in the width direction of the lower housing 300 and have a W-shaped cross-sectional shape. The flat cover plates 411 and 421 are attached to the extension plates 412 and 422.

[0256] The central part of the extension plates 412 and 422 is flat and serves as a base for mounting the cylindrical collar 402. Holes for the collar 402 to pass through are provided in the cover plates 411 and 421. Bolt holes are provided in the base of the extension plates 412 and 422, and suspension bolts 400 are installed thereon. The suspension bolts 400 protrude upwards from below the base of the extension plates 412 and 422 through the collar 402.

[0257] The housing fixing side arm 430 is composed of an extension plate 432 and a flat cover plate 431. The extension plate 432 extends outward in the width direction of the lower housing 300 and has a W-shaped cross-sectional shape. The flat cover plate 431 is attached to the extension plate 432. The extension plate 432 is arranged on the extension line of the external transverse reinforcement 530. Since there are four external transverse reinforcements 530, there are four housing fixing side arms 430 on each side.

[0258] The cross-sectional shape of extension plate 432 is slightly different from that of extension plates 412 and 422. The central part of extension plate 432, which serves as the base of collar 402, is lower than the sides. Therefore, when collar 402 is placed on the base of extension plate 432, collar 402 is slightly recessed below cover plate 431.

[0259] The housing fixing side arm 440 consists of a portion of the outer longitudinal stiffener 640 protruding to the outer side of the lower housing 300 in the width direction and a cover plate 441 attached to the outer longitudinal stiffener 640 and having a cap-shaped cross-section that opens downwards. The portion of the outer longitudinal stiffener 640 used for housing fixing has a W-shaped cross-section that opens upwards.

[0260] The central part of the W-shaped outer longitudinal stiffener 640 is flat and serves as a base for mounting the cylindrical collar 406. A hole is provided in the cover plate 441 for the collar 406 to pass through. The collar 406 used here is longer than the collar 402 used in other applications. Therefore, the suspension bolt 404 used here is longer than the suspension bolt 400 used in other applications.

[0261] 2-3. Construction of the intermediate frame

[0262] Next, use Figure 9 and Figure 10 Explain the construction of the intermediate framework.

[0263] Figure 9This is a perspective view taken from the upper left front, showing the intermediate frame 385 and its supporting structure. The intermediate frame 385 includes a second floor 360 and a center plate 370. The second floor 360 is surrounded by four frames 362 and 363. The longitudinal frames 362 of the second floor are respectively disposed on the left and right sides of the battery pack 200 in the width direction. The transverse frames 363 of the second floor are respectively disposed on the front and rear sides of the battery pack 200 in the front-rear direction.

[0264] Two central frames 364 of the second floor are equally spaced between the front and rear horizontal frames 363. The two ends of each central frame 364 are connected to the left and right vertical frames 362 of the second floor. Thus, the second floor 360 is divided into three rectangular areas. A second floor panel 361 is installed in each rectangular area.

[0265] The center plate 370 is located at the center of the battery pack 200 in the width direction and extends from the second floor 360 toward the front of the battery pack 200. The center plate 370 and the second floor 360 are joined, for example, by fasteners. The center plate 370 has a cap-shaped cross-sectional shape.

[0266] The center plate 370 and the second floor 360 are supported by a plurality of support legs 390, 391 fixed to the partition brackets 340. The partition brackets 340 are components that separate the battery stacks 900 arranged on the bottom panel 301 of the lower housing 300, and are arranged at constant intervals in the front-rear direction of the battery pack 200. One or two support legs 390 are welded together near the central portion of each partition bracket 340. The support legs 390 are components with a Z-shaped shape when viewed from the side and have a cap-shaped cross-section that opens rearward. These support legs 390 are arranged in two rows in the front-rear direction of the battery pack 200. The center plate 370 is supported by the support legs 390 extending upward from each partition bracket 340.

[0267] In the front-rear direction of the battery pack 200, support legs 391 are welded to both ends of the sixth and ninth (last) partition brackets 340 from the front. Each support leg 391 is a Z-shaped component in side view and has a cap-shaped cross-section that opens rearward. However, the width of support leg 391 is wider than that of support leg 390. The support leg 391 extending from the sixth partition bracket 340 from the front engages with the front second floor cross frame 363. The support leg 391 extending from the ninth partition bracket 340 from the front engages with the rear second floor cross frame 363. Thus, the second floor 360 is indirectly supported by the support legs 390 of the supporting center plate 370, and its four corners are directly supported by a total of four support legs 391.

[0268] Furthermore, the second floor 360 is supported on both sides in its width direction by support walls 392. The support walls 392 are wall-shaped members that extend in the front-rear and vertical directions of the battery pack 200, and are engaged with the longitudinal frame 362 of the second floor by fasteners, for example. That is, the second floor 360 is supported by multiple columns and two walls.

[0269] The partition brackets 366 are fastened to each of the second floor transverse frames 363 and each of the second floor central frames 364 using fasteners. The partition brackets 366 have the same shape as the partition brackets 340 provided on the first layer, and also have the same function as the partition brackets 340 in separating the battery stacks 900.

[0270] In the front-rear direction of the battery pack 200, each of the first to third partition brackets 366 from the front is joined with a support leg 394, for example by welding. The support leg 394 is a component with a Z-shaped form when viewed from the side and has a cap-shaped cross-section that opens rearward. The support leg 394 is located near the center of each partition bracket 366. A total of three support legs 394 support a central beam 380 extending in the front-rear direction of the battery pack 200.

[0271] In the front-rear direction of the battery pack 200, each of the first and second partition brackets 366, starting from the front, is joined with support legs 395, for example, by welding. The support legs 395 are Z-shaped members in side view and have a cap-shaped cross-section that opens rearward. However, the width of the support legs 395 is wider than that of the support legs 394. The support legs 395 are located at both ends of each partition bracket 366. The pair of support legs 395 on the left and the pair of support legs 395 on the right respectively support side beams 381 extending in the front-rear direction of the battery pack 200.

[0272] The center beam 380 and side beam 381 support the battery ECUs 950 and 951 (see reference). Figure 3 The battery ECU 950 is supported by a central beam 380 and a right-side side beam 381, while the battery ECU 951 is supported by a central beam 380 and a left-side side beam 381. Furthermore, the structure and function of the battery ECUs 950 and 951 are not limited.

[0273] Figure 10 This is a perspective view of the lower housing 300 with the intermediate frame 385 installed on it, cut along the centerline of the battery pack 200 in the front-rear direction, and viewed from the upper left front. Support legs 390 and 391 supporting the second floor 360 and the center plate 370 are fixed to internal transverse reinforcements 320 and 330 via partition brackets 340. Furthermore, the support wall 392 supporting the second floor 360 is fixed to the fixing base 350.

[0274] The internal transverse reinforcements 320 and 330 and the fixing base 350 are joined to the bottom panel 301 of the lower housing 300 by welding. Therefore, by fixing the support legs 390 and 391 to the internal transverse reinforcements 320 and 330 and fixing the support wall 392 to the fixing base 350, the second floor 360 and the center plate 370 are fixed to the bottom panel 301 of the lower housing 300.

[0275] 2-4. Details of the supporting structure of the intermediate frame

[0276] use Figures 11-13 The details of the support structure of the intermediate frame 385 are explained. However, here, taking the intermediate frame 385 as an example, the support structure of the center plate 370 is explained in detail (more specifically, the support structure based on the support leg 390).

[0277] Figure 11 This is a perspective view of the lower housing 300, magnified from the upper left front, with the intermediate frame 385 installed on the lower housing 300. The center plate 370 is a member with a cap-shaped cross-section and has a flange 371 and a recess 372. The flange 371 has a flat surface, and the recess 372 is one level lower than the flange 371. A support leg 390 is fastened to the flange 371 of the center plate 370 by fasteners 374. The support leg 390 is joined to the partition bracket 340 by welding. The partition bracket 340 is fastened to the internal transverse reinforcement 320 by fasteners 344.

[0278] Figure 12 This is a perspective view of the front of the lower housing 300, taken with the intermediate frame 385 installed on the lower housing 300, cut along the centerline of the battery pack 200 in the front-rear direction, and viewed magnified from the upper left front. Figure 12 The partition bracket 340 of the fixed support leg 390 is depicted in a magnified view.

[0279] The divider bracket 340 has a base 341, a divider wall 342, and a battery housing fixing part 343. The base 341 is a part that is fastened to the internal transverse reinforcement 320 by fasteners 344. The base 341 is provided in multiple locations (seven locations) on the divider bracket 340.

[0280] The partition wall 342 is erected vertically relative to the base 341 and separates the battery stacks 900. The partition wall 342 is located on the rear side of the battery pack 200 in the front-rear direction relative to the base 341. The partition wall 342 also serves to support the back of the support legs 390. Furthermore, the height of the partition wall 342 is not consistent in the width direction of the battery stack 900.

[0281] The battery housing fixing part 343 is a hill formed between the bases 341 and 341. While the battery housing fixing part 343 will be described later, it serves to fix the claw portion formed on the battery housing 920 of the battery stack 900. The support leg 390 is joined to a portion of the battery housing fixing part 343 by welding.

[0282] In addition, Figure 12 The X marks depicted indicate weld points 801 and 802. Multiple weld allowances 321 are formed at approximately constant intervals on both sides of the short side of the inner transverse reinforcement 320. Hollow X marks on the weld allowances 321 indicate weld points 801 used for welding the inner transverse reinforcement 320. Although described in detail later, at weld points 801 indicated by the hollow X marks, the weld allowances 321 of the inner transverse reinforcement 320 are welded together with the bottom panel 301 of the lower housing 300 and the outer transverse reinforcement 530.

[0283] The weld point 802, marked with a black X, is located at the intersection of the outer transverse stiffener 530 and the outer central longitudinal stiffener 610 when viewed from above. The area near the weld point 802 of the inner transverse stiffener 320 is removed to avoid interference with the weld point 802. Although described in detail later, at the weld point 802 marked with a black X, the bottom panel 301 of the lower housing 300 is welded together with the outer transverse stiffener 530 and the outer central longitudinal stiffener 610.

[0284] Figure 13 This is a perspective view of the front of the lower housing 300, with the intermediate frame 385 and battery stack 900 installed on the lower housing 300. The lower housing 300 is cut along the centerline of the battery pack 200 in the front-rear direction and viewed magnified from the upper left front. Two adjacent battery stacks 900 are separated by a partition bracket 340. Support legs 390, fixed to the partition bracket 340, pass between the battery stacks 900 and extend upwards.

[0285] With the intermediate frame 385 and battery stack 900 mounted on the lower housing 300, the center plate 370 passes above the battery stack 900. In other words, multiple battery stacks 900 are arranged directly below the center plate 370 in an orthogonal manner. The center plate 370 is supported by support legs 390 protruding from between the battery stacks 900. Furthermore, in Figure 13 In this section, a heater 930 is located between the battery stack 900 and the bottom panel 301. This will be described later.

[0286] 2-5. Details of the joint structure between reinforcing components

[0287] Next, use Figures 14-16 Provide details of the joint structure between reinforcing components such as stiffeners and brackets.

[0288] Figure 14 This is a perspective view of the front of the lower housing 300, with the intermediate frame 385 installed on the lower housing 300. The lower housing 300 is cut along the centerline of the battery pack 200 in the front-rear direction and viewed magnified from a lower left angle. Figure 14 The text depicts the joint structure of the outer central longitudinal stiffener 610 with the outer transverse stiffeners 510, 520, and 530, as well as the joint structure of the outer longitudinal stiffener 630 with the outer transverse stiffeners 520 and 530.

[0289] The outer central longitudinal stiffener 610 can be divided into a support portion 611 and a pressing portion 614 according to its function. Similarly, the outer longitudinal stiffener 630 can also be divided into a support portion 631 and a pressing portion 634 according to its function. Although the description is omitted, the outer central longitudinal stiffener 620, outer longitudinal stiffeners 640, and 650 can also be divided into support portions and pressing portions according to their functions.

[0290] The pressing parts 614 and 634 have the function of pushing the external transverse reinforcement member against the bottom panel 301 of the lower housing 300. Figure 14 In the example shown, the outer central longitudinal stiffener 610 presses against the outer transverse stiffeners 510, 520, and 530 using the pressing part 614. The outer longitudinal stiffener 630 presses against the outer transverse stiffeners 520 and 530 using the pressing part 634. The pressing parts 614 and 634 are formed to be in close contact with the surfaces of the outer transverse stiffeners. In addition, the pressing parts 614 and 634 are joined to the surfaces of the outer transverse stiffeners by welding, adhesive, or the like.

[0291] Support portions 611 and 631 function as pillars between adjacent external transverse reinforcement members. Figure 14 In the example shown, the support portion 611 of the outer central longitudinal stiffener 610 functions as a support column between the outer transverse stiffeners 510 and 520, between the outer transverse stiffeners 520 and 530, and between the outer transverse stiffeners 530. The support portion 631 of the outer longitudinal stiffener 630 functions as a support column between the outer transverse stiffeners 520 and 530, and between the outer transverse stiffeners 530.

[0292] The support portions 611 and 631 have a cap-shaped cross-section that opens upwards. The two ends of the support portions 611 and 631 in the front-rear direction widen as they approach the outer transverse reinforcement, and the ridges 613 and 633 of the support portions 611 and 631 are formed to be continuously connected to the ridges of the outer transverse reinforcement.

[0293] For example, focusing on the support portion 611 of the outer central longitudinal stiffener 610, the ridge line 613 of the support portion 611 is continuously connected to the ridge line 511 of the outer transverse stiffener 510 at the location where it abuts against the outer transverse stiffener 510. Similarly, at the location where it abuts against the outer transverse stiffener 530, the ridge line 613 of the support portion 611 is continuously connected to the ridge line 531 of the outer transverse stiffener 530. Focusing on the support portion 631 of the outer longitudinal stiffener 630, the ridge line 633 of the support portion 631 is continuously connected to the ridge line 531 of the outer transverse stiffener 530 at the location where it abuts against the outer transverse stiffener 530. Although the description is omitted, the locations where the support portions 611 and 631 abut against other outer transverse stiffeners are similarly formed.

[0294] Welding allowances 615 and 635 are formed at both ends of the support portions 611 and 631. For example, at the welding allowance 615 where it connects with the outer transverse reinforcement 530 (specifically, its flange portion), the bottom panel 301 is welded together with the outer transverse reinforcement 530 and the outer central longitudinal reinforcement 610. Similarly, at the welding allowance 635 where it connects with the outer transverse reinforcement 520 (specifically, its flange portion), the bottom panel 301 is welded together with the outer transverse reinforcement 520 and the outer longitudinal reinforcement 630. Although the description is omitted, at the welding allowances 615 and 635 where it abuts against other outer transverse reinforcements, the outer transverse reinforcement is also sandwiched between the bottom panel 301 and the welding allowance.

[0295] Figure 15 This is an enlarged and schematic cross-sectional view showing the joint between the bottom panel 301 of the lower housing 300 and the internal transverse reinforcement 320 and the external transverse reinforcement 530. To reiterate, the support leg 390 is joined to the partition bracket 340 by welding. The partition bracket 340 is secured to the internal transverse reinforcement 320 using fasteners 344.

[0296] The inner transverse stiffener 320 sandwiches the bottom panel 301 between itself and the outer transverse stiffener 530. The inner transverse stiffener 320 is welded at its welding allowance 321. The welding point 801 includes the welding allowance 321 of the inner transverse stiffener 320, the bottom panel 301, and the outer transverse stiffener 530. These three panel components are joined by welding. Furthermore, the outer transverse stiffener 530 is machined to overlap with the reinforcing recess 302a formed in the bottom panel 301, more specifically, so that their valley lines (when viewed from the outside) substantially overlap vertically.

[0297] The same welding method is also used when welding other internal transverse stiffeners to other external transverse stiffeners. For example, the internal transverse stiffener 320 and the external transverse stiffener 520 are welded together with the bottom panel 301.

[0298] Figure 16 This is an enlarged and schematic cross-sectional view showing the joint between the bottom panel 301 of the lower housing 300 and the outer transverse stiffener 530 and the outer central longitudinal stiffener 610. The outer central longitudinal stiffener 610 sandwiches the outer transverse stiffener 530 between itself and the bottom panel 301. The outer central longitudinal stiffener 610 is welded at its weld allowance 615. The weld point 802 includes the weld allowance 615 of the outer central longitudinal stiffener 610, the outer transverse stiffener 530, and the bottom panel 301. These three plate components are joined by welding. Furthermore, the weld allowance 615 of the outer central longitudinal stiffener 610 is machined so that its valley line (when viewed from the outside) substantially overlaps with the valley line of the outer transverse stiffener 530 in the vertical direction.

[0299] The same welding method is also used when welding other external longitudinal stiffeners to other external transverse stiffeners. For example, the external central longitudinal stiffener 620 and the external transverse stiffener 540 are welded together with the bottom panel 301.

[0300] 2-6. Details of the frame construction of the second floor

[0301] use Figures 17-19 This section describes the detailed structure of the second floor 360.

[0302] Figure 17 This is a top view schematically illustrating the engagement relationship between the central plate 370 and the frame of the second floor 360. The outer frame of the second floor 360 is formed by a pair of second floor longitudinal frames 362 and a pair of second floor transverse frames 363. Two second floor central frames 364 are arranged parallel to the second floor transverse frames 363 within the outer frame. These frames 362, 363, and 364 are all made of hollow aluminum square material and are joined together, for example, by fasteners.

[0303] The second floor 360 is mounted on the center plate 370. Specifically, the second floor transverse frame 363 and the second floor central frame 364 are orthogonal to the center plate 370 and are mounted on the center plate 370. The center plate 370 passes through the center of the second floor 360 and extends to the inner side of the second floor transverse frame 363.

[0304] Figure 18 This is a longitudinal sectional view schematically showing the engagement relationship between the center plate 370, the support legs 390, and the frame of the second floor 360. The area of ​​the center plate 370 on which the second floor 360 is placed is supported by the support legs 390, which have a Z-shaped form when viewed from the side. The second floor transverse frame 363 and the second floor central frame 364 are arranged at the part of the center plate 370 supported by the support legs 390.

[0305] Second floor panels 361 are provided in three areas divided by the second floor transverse frame 363 and the second floor central frame 364. A flange 363a for supporting the second floor panels 361 is formed on one side of the second floor transverse frame 363. Flanges 364a for supporting the second floor panels 361 are also formed on both sides of the second floor central frame 364.

[0306] Figure 19 This is a schematic cross-sectional view illustrating the construction of the second floor 360. (See image.) Figure 19 As shown, a flange 362a is formed on one side of the second floor longitudinal frame 362 where the second floor panel 361 is disposed. This flange 362a is located above the second floor panel 361. The second floor panel 361 is sandwiched between and fixed between the flange 362a of the second floor longitudinal frame 362 and the flanges 363a and 364a of the second floor transverse frame 363 and the second floor central frame 364.

[0307] 2-7. Detailed description of the rear end of the lower housing

[0308] use Figures 20-25 The details of the end of the housing 300 are described below.

[0309] Figure 20 This is a perspective view of the rear of the lower housing 300, with the intermediate frame 385 installed on the lower housing 300. The lower housing 300 is cut along the centerline in the front-rear direction of the battery pack 200 and viewed magnified from the upper left rear. On the rear outer side of the bottom panel 301 of the lower housing 300, the external central longitudinal reinforcement 620 extends along the centerline.

[0310] The outer central longitudinal stiffener 620 overlaps with the outer transverse stiffener 560, which is located at the rear end of the bottom panel 301 and extends in the width direction. An outer rear end bracket 570 is positioned further rearward and outward than the outer transverse stiffener 560, and the outer rear end bracket 570 is fitted with a housing fixing rear arm 460. The outer central longitudinal stiffener 620 also overlaps with the outer rear end bracket 570.

[0311] The outer rear end bracket 570 protrudes rearward compared to the rear end of the lower housing 300. The rear surface 305 of the rear end of the lower housing 300 is generally vertically erected, and the rear surface 571 of the bracket for the mounting arm 460 of the outer rear end bracket 570 is also generally vertically erected. A rear inner bracket 580 with a Z-shaped cross-section when viewed from the side is disposed between the rear end of the lower housing 300 and the outer rear end bracket 570. The rear inner bracket 580 engages with the rear surface 305 of the housing and the rear surface 571 of the bracket in a manner that connects the lower housing 300 and the outer rear end bracket 570.

[0312] Figure 21 This is a side view of the rear portion of the lower housing 300, taken with the intermediate frame 385 installed on the lower housing 300, cut along the centerline of the battery pack 200 in the front-rear direction, and viewed magnified from the left side. The housing fixing rear arm 460 is engaged with the outer rear end bracket 570 together with the inner rear end bracket 580 using fasteners (bolts and nuts) 471 that pass through the outer rear end bracket 570 and the inner rear end bracket 580.

[0313] The outer rear end bracket 570, which is fitted with the housing fixing rear arm 460, together with the outer lateral reinforcement 560, the rear inner bracket 580, and the lower housing 300, forms a closed section. The outer rear end bracket 570 and the rear inner bracket 580 are joined by fasteners 471 as described above. Furthermore, when the rear inner bracket 580 is cut with a plane perpendicular to the centerline, its cross-sectional shape near the center becomes a cap shape that opens downwards.

[0314] The lower housing 300 and the outer rear end bracket 570 are joined by welding at welding points 803 on the rear surface 305 of the housing. Multiple welding points 803 are provided. The outer lateral reinforcement 560 (specifically, its flange portion) and the lower housing 300 (specifically, its bottom panel 301) are joined by welding at welding points 804, which also overlap with the inner lateral reinforcement 330 (specifically, its flange portion). Multiple welding points 804 are provided.

[0315] The outer rear end bracket 570 and the outer transverse reinforcement 560 are joined together with the outer central longitudinal reinforcement 620 by welding. The overlapping part of these three plate components is designated as the welding point 805. There are one or more welding points 805. In addition, the outer central longitudinal reinforcement 620 and the outer transverse reinforcement 560 are joined together by welding at the welding point 802, which also overlaps with the bottom panel 301.

[0316] In addition, Figure 21 The image depicts a pin 351 located between two adjacent support legs 390 in the longitudinal direction of the battery pack 200 and protruding from the fixed base 350. This pin 351 is used for positioning the battery stack 900. More specifically, a stack support bracket 912 (see reference) restricts the movement of the battery stack 900 along its longitudinal direction. Figure 4 Installed at pin 351.

[0317] Figure 22 This is a perspective view of the rear of the lower housing 300, with the intermediate frame 385 installed on the lower housing 300. The lower housing 300 is cut along the centerline in the front-rear direction of the battery pack 200 and viewed magnified from the lower left. An outer corner reinforcement 660 is attached to the end of the outer lateral reinforcement 560 to which the outer rear end bracket 570 is attached.

[0318] The outer corner reinforcement 660 connects the outer lateral reinforcement 560, which extends along the width direction of the battery pack 200, to the outer longitudinal reinforcement 650, which extends along the front-rear direction of the battery pack 200. At the portion where the outer corner reinforcement 660 overlaps with the outer lateral reinforcement 560, it is joined to the bottom panel 301 by welding together with the outer lateral reinforcement 560. Furthermore, at the portion where the outer corner reinforcement 660 overlaps with the outer longitudinal reinforcement 650, it is joined to the bottom panel 301 by welding together with the outer longitudinal reinforcement 650.

[0319] Figure 23 This is a perspective view showing the structure of the rear end portion of the outer side of the lower housing 300, to which the housing fixing rear arm 460 is mounted. The outer rear end bracket 570 has a bracket rear surface 571 and a support surface 573. The housing fixing rear arm 460 is fixed to the bracket rear surface 571, and the support surface 573 engages with the surface of the outer lateral reinforcement 560 and is substantially perpendicular to the bracket rear surface 571. The support surface 573 has a trapezoidal shape that gradually expands from the bracket rear surface 571 side toward the side that engages with the outer lateral reinforcement 560.

[0320] In addition to the rear surface 571 of the bracket and the support surface 573, the rear arm 460 for fixing the housing also has a side surface 572 of the bracket. The side surface 572 of the bracket is erected approximately perpendicular to the support surface 573 and intersects approximately perpendicularly with the rear surface 571 of the bracket. Furthermore, it is continuously connected to the rear surface 562 of the external transverse reinforcement 560.

[0321] Figure 24 This is a perspective view of the bottom surface of the lower casing 300 from the rear right, viewed magnified from the lower left. Figure 24 The connection between the outer corner reinforcement 660 on the inner side of the corner and the outer transverse reinforcement 560, as well as the connection between the outer corner reinforcement 660 and the outer longitudinal reinforcement 650, are described in detail.

[0322] The inner valley line 665a of the outer corner reinforcement 660 is substantially continuous with the inner valley line 561a of the outer transverse reinforcement 560 on the upper side 661a of the inner corner, and substantially continuous with the inner valley line 651a of the outer longitudinal reinforcement 650 on the upper side 661b of the inner corner. Furthermore, the inner ridge line 665b of the outer corner reinforcement 660 is substantially continuous with the inner ridge line 561b of the outer transverse reinforcement 560 on the lower side 662a of the inner corner, and substantially continuous with the inner ridge line 651b of the outer longitudinal reinforcement 650 on the lower side 662b of the inner corner.

[0323] Figure 25 This is a perspective view of the bottom surface of the lower casing 300 from the left rear, viewed magnified from a lower left angle. Figure 25 The text details the connection between the outer corner reinforcement 660 and the outer transverse reinforcement 560, as well as the connection between the outer corner reinforcement 660 and the outer longitudinal reinforcement 650.

[0324] The outer valley line 665c of the outer corner reinforcement 660 is substantially continuous with the outer valley line 561c of the outer transverse reinforcement 560 on the upper side 663a of the outer corner, and substantially continuous with the outer valley line 651c of the outer longitudinal reinforcement 650 on the upper side 663b of the outer corner. Furthermore, the outer ridge line 665d of the outer corner reinforcement 660 is substantially continuous with the outer ridge line 561d of the outer transverse reinforcement 560 on the lower side 664a of the outer corner, and substantially continuous with the outer ridge line 651d of the outer longitudinal reinforcement 650 on the lower side 664b of the outer corner.

[0325] 2-8. Heating / cooling device

[0326] Next, use Figures 26-29 This describes the heating / cooling device included in battery pack 200.

[0327] Figure 26 This is a perspective view of the lower housing 300 viewed from the upper left front, with the intermediate frame 385 and heating / cooling device installed. The battery pack 200 incorporates a heating / cooling device for maintaining the battery stack 900 within a suitable operating temperature range. However, heating and cooling are performed by separate devices. Here, [the following is used] Figure 26 Provide an overall image of the cooling system.

[0328] A blower 700 is arranged side-by-side with a junction box 760 at the top of the lower housing 300. A pair of blowers 700 are arranged on the left and right sides of the junction box 760, and are positioned at the front of the battery pack 200 (on the lower housing 300). Air blown from the blowers 700 is cooled by heat exchange with externally supplied refrigerant via a pair of heat exchangers (not shown), and then delivered into the battery pack 200 through air ducts 702, 704, 705, and 706 installed in the lower housing 300. There is no air inflow or outflow between the heat exchangers and the outside; the blowers 700 draw in and deliver air from inside the battery pack 200. In other words, the cooling device is configured as an internal air circulation device that circulates air inside the battery pack 200.

[0329] The air supply ducts are installed along the left and right side edges of the lower housing 300. Specifically, along the left side edge of the lower housing 300, a left air supply duct 704 is installed, extending from the blower 700 toward the rear of the lower housing 300 in a front-to-back direction. The left air supply duct 704 branches midway and faces the second floor 360, becoming a second floor left air supply duct 705 that supplies air to the second floor 360. Additionally, along the right side edge of the lower housing 300, a right air supply duct 702 is installed, extending from the blower 700 toward the rear of the lower housing 300 in a front-to-back direction. The right air supply duct 702 also branches midway and faces the second floor 360, becoming a second floor right air supply duct 706 that supplies air to the second floor 360 (in...). Figure 26 In the image, only a portion of the right air supply duct 706 of the second floor is depicted. That is, air supply ducts 702, 704, 705, and 706 are arranged along the front-rear direction of the battery pack 200 on the outer side of the width direction of the plurality of battery stacks 900.

[0330] Although described in detail later, air guides 712 and 722 are provided at constant intervals along the front-to-back direction within the lower housing 300. This refers to the air guides 712 and 722 being provided in the gaps between battery stacks 900. Additionally, although not shown in the figures, air guides 712 and 722 are also provided on the second floor 360. Air delivered from the blower 700 is conveyed to the battery stack 900 via the air guides 712 and 722.

[0331] There are two types of air guide plates 712 and 722. The first air guide plate 712 is located behind the odd-numbered battery stack 900 from the front and is connected to the air distribution section 711 located in the right air supply duct 702. The air distribution section 711 is provided for each air guide plate 712. The second air guide plate 722 is located behind the even-numbered battery stack 900 from the front and is connected to the air distribution section 721 located in the left air supply duct 704. The air distribution section 721 is provided for each air guide plate 722. Furthermore, the air distribution sections 711 and 721 are also provided together with the air guide plates 712 and 722 on the second floor 360 (in... Figure 26 The air distribution section 722 on the second floor 360 is not shown in the diagram. The air distribution section 711 is mainly provided for directing airflow to the odd-numbered battery stacks 900 from the front, while the air distribution section 721 is mainly provided for directing airflow to the even-numbered battery stacks 900 from the front. Furthermore, the positions of the air distribution sections, i.e., the battery stacks 900 that are the air supply targets of the left and right air supply ducts 702 and 704, can also be reversed.

[0332] Figures 27-29 The diagram shows the lower housing 300 being cut along the centerline of the front-rear direction of the battery pack 200 with the intermediate frame 385 and the heating / cooling device installed on the lower housing 300. The observation is performed by changing the viewing direction. Figure 27 This is a three-dimensional view of the front of the lower casing 300, magnified from the upper left rear. Figure 28 This is a perspective view of the front of the lower casing 300, magnified significantly from a slightly upper left angle. Furthermore, Figure 29 This is a side view that is magnified from the left side and shows the front of the lower housing 300.

[0333] As shown in these figures, the air guides 712 and 722 are mounted together with the support leg 390 on the partition bracket 340. Specifically, as... Figure 29 As shown, brackets 713 and 723 are erected on the partition bracket 340, and these brackets 713 and 723 support the air guide plates 712 and 722. The brackets 713 and 723 are joined to the partition bracket 340, for example, by welding. The height of the air guide plates 712 and 722 is below the height of the support legs 390, so that they do not interfere with the center plate 370 disposed above the air guide plates 712 and 722.

[0334] The air guides 712 and 722 have a cap-shaped cross-sectional shape that is open on the side of the battery stack 900 that is the object of air supply. Figure 62 yes Figure 28 The supplementary diagram is a schematic top view showing the air guides 712 and 722 cut parallel to the bottom surface of the lower housing 300 and viewed from above. Figure 62As shown, the rear walls 715 and 725 of the air guides 712 and 722 are inclined such that they become closer to the back of the battery stack 900 from the sides of the respective air distribution sections 711 and 721 toward the opposite sides. In other words, the air guides 712 and 722 have a triangular shape when viewed from above: their width is widest at the outlets of the air distribution sections 711 and 721, and gradually narrows towards the top. Gaskets 714 and 724 are provided between the edges of the air guides 712 and 722 and the battery stack 900 to prevent air leakage.

[0335] With the above-described structure, the cross-sectional area of ​​the air guide plate 712 gradually decreases as it moves away from the air distribution section 711. Furthermore, the cross-sectional area of ​​the air guide plate 722 also decreases as it moves away from the air distribution section 721 (see reference 721). Figure 26 They gradually shrink as they move away. Furthermore, in Figures 27-29 The figure shows the structure of air distribution from the air distribution section 711 provided in the right air supply duct 702 to the air guide plate 712, but the structure of air distribution from the air distribution section 721 provided in the left air supply duct 704 to the air guide plate 722 is the same.

[0336] The battery stack 900 is heated using an electric heater 930. The heater 930 is mounted on the bottom panel 301 between partition brackets 340. That is, the heater 930 is provided for each battery stack 900. When the battery stack 900 is mounted inside the lower housing 300, for example... Figure 13 As depicted, heater 930 is sandwiched between battery stack 900 and bottom panel 301. Heater 930 has a length approximately the same as that of battery stack 900. However, heater 930 may also be an assembly of multiple heaters arranged along the long side of battery stack 900.

[0337] 2-9. Cable Installation Structure

[0338] Next, use Figure 30 and Figure 31 This describes the cable installation structure. Multiple cables 751, including power lines and signal lines, are introduced into the battery pack 200.

[0339] Figure 30 This is a perspective view of the front of the lower housing 300, viewed from the upper left, with the battery stack 900, intermediate frame 385, cables, and heating / cooling devices installed on the lower housing 300. A center plate 370 extending in the front-rear direction of the lower housing 300 is provided on the battery stack 900 arranged on the lower housing 300.

[0340] The cables 751 introduced into the battery pack 200 include cables connected to each battery stack 900, cables connected to the junction box 760 located at the top of the lower housing 300, the blower 700, and cables connected to the battery ECUs 950 and 951. These cables 751 are aggregated and pass through the center plate 370. That is, the center plate 370 is used as a passage for the cables 751 to pass through.

[0341] At least a portion of the cable 751 is connected to a maintenance connector 750 disposed on the center plate 370. When the upper housing 210 is mounted on the lower housing 300, the maintenance connector 750 protrudes from the upper housing 210. Furthermore, when the battery pack 200 is mounted in the vehicle, the maintenance connector 750 is connected to a connector on the vehicle side.

[0342] Figure 31 This is a perspective view of the periphery of the center plate 370 when the battery pack 200 is cut along its width and viewed magnified from a frontal, obliquely upward perspective. The center plate 370 has flanges 371 on the left and right sides. Support legs 390 are secured to the flanges 371 by fasteners 374 and via pads 375. A closed section is formed between the flanges 371 and the pads 375 around the fasteners 374.

[0343] A recess 372, which is one level lower than the flanges 371, is provided between the left and right flanges 371. When the upper housing 210 is installed on the lower housing 300, a space is formed between the upper housing 210 and the recess 372. The cable 751 passes through this space.

[0344] 2-10. Fixed Structure of Battery Stack

[0345] use Figure 32 and Figure 33 Explain the fixed structure of battery stack 900.

[0346] Figure 32 This is a side view of the front portion of the lower housing 300, magnified and viewed from the left side, with the intermediate frame 385, heating / cooling device, and battery stack 900 installed on the lower housing 300. The lower housing 300 is cut along the centerline in the front-rear direction of the battery pack 200. The battery stack 900 has a battery housing 920 that houses the batteries 901. A claw 922 extending toward the partition bracket 340 is formed at the bottom of the battery housing 920.

[0347] The claws 922 enter the space sandwiched between the partition bracket 340 and the internal lateral reinforcement 320. By positioning the left and right claws 922 below the partition bracket 340, upward movement of the battery casing 920 is restricted. Figure 33 The detailed map shows the engagement state of the claw 922 and the partition bracket 340.

[0348] Figure 33 This is a side view of the periphery of the partition bracket 340, taken with the intermediate frame 385, battery stack 900, and heating / cooling device installed in the lower housing 300, cut along the centerline of the battery pack 200 in the front-rear direction and viewed magnified from the left side. The partition bracket 340 is engaged with the internal lateral reinforcement 320 by fasteners 344.

[0349] The partition bracket 340 has a battery housing fixing part 343. A bracket 723 supporting the support leg 390 and the air guide plate 722 is engaged with the battery housing fixing part 343. The battery housing fixing part 343 is formed on both the left and right sides of the partition bracket 340, that is, on the front and rear sides in the front-rear direction of the battery pack 200. A gap is formed between the battery housing fixing part 343 and the internal transverse reinforcement member 320.

[0350] Separator brackets 340 are provided on both sides of the short side of each battery stack 900. Claws 922 are also formed on the left and right sides of the battery housing 920, that is, on the front and rear sides in the front-rear direction of the battery pack 200. By inserting the claws 922 into the gap formed between the battery housing fixing part 343 and the internal transverse reinforcement 320, the up-down and left-right movement of the battery housing 920 is restricted, and the battery stack 900 is fixed to the lower housing 300. Furthermore, in Figure 31 The text also depicts the engagement of the claw 922 with the battery housing fixing part 343.

[0351] 3. Vehicle Body Structure

[0352] Next, the vehicle body structure of the embodiment will be described.

[0353] 3-1. Overview of Vehicle Body Structure

[0354] First, use Figure 34 Provide an overview of the vehicle body structure.

[0355] Figure 34 This is a perspective view taken from the lower left rear, showing the battery pack 200 of the embodiment mounted on the vehicle 100. The battery pack 200 is mounted under the floor of the vehicle 100. Furthermore, the term "floor" in this disclosure refers to the entirety of the floor panel 102, the frame members supporting the floor panel 102, and the reinforcing members that reinforce the floor panel 102, and is not limited to the floor panel 102.

[0356] A pair of floor underside reinforcements 120, a pair of rear floor side members 132, a rear floor underside crossbeam 130, and a front floor underside reinforcement 136 are provided under the floor of the vehicle 100. They are joined to the floor panel 102, for example, by welding.

[0357] Floor underbody reinforcement members 120 are respectively disposed on the right and left sides of the vehicle 100 in the width direction, and extend from the center of the vehicle 100 in the front-rear direction to the front. Rear floor side members 132 are respectively disposed on the right and left sides of the vehicle 100 in the width direction, and extend in the front-rear direction at the rear of the vehicle 100. Rear floor underbody crossbeam 130 is a member extending in the width direction of the vehicle 100, and its two ends are joined near the center of the left and right rear floor underbody crossbeams 130. Front floor underbody reinforcement member 136 is a member extending in the width direction of the vehicle 100, and its two ends are joined near the front end of the left and right rear floor underbody crossbeams 130.

[0358] As described above, the battery pack 200 includes multiple suspension bolts 400, 404 and fasteners 470. These are used to secure the battery pack 200 to the floor of the vehicle 100. Specifically, the six suspension bolts 400 on the left side of the battery pack 200 are fastened to the left-side floor under-reinforcement 120, and the six suspension bolts 400 on the right side of the battery pack 200 are fastened to the right-side floor under-reinforcement 120.

[0359] The last suspension bolt 404 is longer than the other suspension bolts 400. The left suspension bolt 404 is fastened to the front end of the left rear floor side member 132 near the portion where the front floor under-reinforcement 136 is joined. The right suspension bolt 404 is fastened to the front end of the right rear floor side member 132 near the portion where the front floor under-reinforcement 136 is joined.

[0360] Two fasteners 470 are installed on the upper end of each pair of housing-fixing rear arms 460. A total of four fasteners 470 are fastened to the rear floor underbeam 130. The battery pack 200 is secured to the vehicle 100 and integrated with the vehicle 100 by fastening all the suspension bolts 400, 404 and fasteners 470 to the frame members or reinforcing members of the vehicle 100.

[0361] 3-2. The skeletal structure of the car body

[0362] use Figures 35-38 This describes the detailed structure of the vehicle's frame.

[0363] Figure 35 This is a perspective view showing in detail the frame structure beneath the floor of the vehicle 100 according to the embodiment. In addition to the aforementioned frame members and reinforcing members, a front suspension frame member 160 is also provided beneath the floor of the vehicle 100. The front suspension frame member 160 is connected to the front end of the floor-side reinforcing member 120.

[0364] The underfloor reinforcement 120 has a cap-shaped cross-section with a flange that opens upwards, and engages with the floor panel 102 at the flange. The underfloor reinforcement 120 consists of a rear portion 120a and a front portion 120b. The distance between the rear portion 120a and the opposite underfloor reinforcement 120 is approximately constant. The front portion 120b connects to the front side of the rear portion 120a, and its distance from the opposite underfloor reinforcement 120 decreases as it faces forward. That is, in the front portion 120b, the distance between a pair of underfloor reinforcements 120 widens from front to rear. The underfloor reinforcement 120 can be a single component or a component formed by combining multiple components. In this embodiment, at least the rear portion 120a is formed by combining multiple components. Figure 35 The diagram omits the components that form part of the rear section 120a.

[0365] The rear floor side member 132 has a cap-shaped cross-section that opens upwards. The front end of the rear floor side member 132 engages directly or via another member with the rear end of the floor underside reinforcement 120. The front side of the rear floor side member 132 bends upwards as it faces rearwards. An opening 132a for fixing the longitudinal arm is provided in the bent portion. The rear floor side member 132 can be a single member or a member composed of multiple members combined.

[0366] The rear floor underbeam 130 has a cap-shaped cross-section that opens upwards. The engagement position of the rear floor underbeam 130 with the rear floor side member 132 is located rearwards from the position of the longitudinal arm fixing opening 132a, and is the top rearward portion of the rear floor side member 132 extending straight rearwards. A pair of left-right separated partitions 480 are disposed within the rear floor underbeam 130. The partitions 480 are positioned within the rear floor underbeam 130 to secure the housing fixing rear arm 460 to the rear floor underbeam 130, and are fixed to the inner side of the rear floor underbeam 130 by welding or the like. Furthermore, the partitions 480, the rear floor underbeam 130, and the housing fixing rear arm 460 substantially overlap in the vertical direction and are secured by fasteners 470.

[0367] The front floor under-reinforcement 136 has an L-shaped cross-section with its long side vertically upright and its short side protruding forward. The engagement position of the front floor under-reinforcement 136 with the rear floor side member 132 is forward of the position of the longitudinal arm fixing opening 132a. The front floor under-reinforcement 136 is separated from the rear floor under-crossbeam 130 by a distance equal to the height of the top plate portion 212, which allows the upper housing 210 of the battery pack 200 to be housed between them.

[0368] Figure 36This is a perspective view showing the skeletal structure of the rear region of the vehicle 100 according to the embodiment. A ring-shaped skeletal structure composed of multiple skeletal members 140, 141, 142, and 143 is provided in the rear region of the vehicle 100.

[0369] The skeletal components constituting the ring-shaped frame include a rear floor crossbeam 140, internal side beam reinforcements 141, external side beam reinforcements 142, and a roof reinforcement 143. The roof reinforcement 143 is a component that reinforces the roof of the vehicle 100 and extends along the width direction of the vehicle 100. The roof reinforcement 143 has a hat-shaped cross-sectional shape that opens towards the inside of the vehicle body, i.e., downwards.

[0370] The internal side pillar reinforcement 141 and the external side pillar reinforcement 142 are components constituting the rear pillar of the vehicle. The internal side pillar reinforcement 141 has a cap-shaped cross-sectional shape that opens outwards toward the passenger compartment. On the other hand, the external side pillar reinforcement 142 has a cap-shaped cross-sectional shape that opens inwards toward the passenger compartment. Their respective upper ends engage with the end of the roof reinforcement 143. Furthermore, in Figure 1 The text also depicts the internal reinforcement component 141 of the side beam column.

[0371] The upper side of the internal reinforcement 141 of the side beam column engages with the upper side of the external reinforcement 142 of the side beam column. The lower side of the internal reinforcement 141 of the side beam column engages with the inner panel 145 of the wheel cover forming the inner side of the wheel cover. The lower side of the external reinforcement 142 of the side beam column engages with the outer panel 144 of the wheel cover forming the outer side of the wheel cover.

[0372] The rear floor crossbeam 140 has a cap-shaped cross-section that opens downwards. The rear floor crossbeam 140 engages at both ends with the lower ends of the internal reinforcements 141 of the left and right side beams. Additionally, although described later, the rear floor crossbeam 140 clamps the floor panel 102 and engages with the rear floor lower crossbeam 130.

[0373] Figure 37 This is a perspective view showing the structure of the rear suspension 170 of the vehicle 100 according to the embodiment. The rear of the battery pack 200 reaches the rear wheel 104 (see reference). Figure 1 The rear suspension is 170. Regarding the body 101 (refer to...). Figure 1 The rear suspension is positioned at 170, with reference to... Figure 1 The location of the shock absorber mounting part 179 is shown in the figure. Furthermore, the shock absorber mounting part 179 (see reference...) Figure 1 The body of 101 (refer to) Figure 1 The position of the front and rear direction of the crossbeam 140 on the rear floor (refer to) Figure 36 The positions of the vehicle body 101 in the front and rear directions at least partially overlap.

[0374] The rear suspension 170 is equipped with a trailing arm 171 that swings around a trailing arm fixing part 172. The trailing arm 171 is connected to the rear suspension arm 173. A shock absorber 174 is installed on the trailing arm 171, and a coil spring 175 is installed on the rear suspension arm 173. The left and right trailing arms 171 are connected by a stabilizer bar 176. Figure 1 The image also depicts the shock absorber 174 in the rear suspension 170.

[0375] The battery pack 200 is designed to fit within the width between the left and right trailing arms 171. Additionally, the shapes of the components of the rear suspension 170 are adjusted to avoid interference with the rear end of the battery pack 200.

[0376] Figure 38 This is a diagram showing the floor structure of the vehicle 100 according to an embodiment, and a perspective view of the front portion of the floor when the floor is cut along the centerline in the longitudinal direction of the vehicle 100 with the battery pack 200 (without the battery stack 900 and heating / cooling device) mounted under the floor. The diagram also shows the frame members and reinforcing members, particularly those provided in the upper part of the floor.

[0377] On the floor panel 102 of the vehicle 100, steps 102c are formed at the front and rear of the front floor under-reinforcement 136. The front floor panel 102 of the vehicle 100 is one level lower than the rear floor panel 102. This corresponds to the case in the upper housing 210 of the battery pack 200 where the front low top plate portion 211 is one level lower than the rear high top plate portion 212.

[0378] The floor panel 102 at the front of the vehicle 100 joins the front bulkhead 151 at its front end. Furthermore, a floor passage 110 is formed on the floor panel 102 along the centerline of the vehicle 100. The floor passage 110 is slightly higher than other parts, but this corresponds to the situation where the central bulge 213 in the upper housing 210 of the battery pack 200 is higher than other parts. Additionally, the front end of the floor passage 110 is higher, but this corresponds to the situation where the front bulge 214 at the front end of the upper housing 210 of the battery pack 200 is one level higher than other parts.

[0379] A passage cover reinforcement 150 extending to the floor panel 102 is provided along the centerline of the vehicle 100 on the floor passage 110. The passage cover reinforcement 150 has a cap-shaped cross-section that opens downwards. Side beams 154 are also provided in the longitudinal direction of the vehicle 100. The side beams 154 are located at both ends of the right and left sides of the vehicle 100 (only the right side beam 154 is shown in the figure).

[0380] Additionally, a pair of upper floor reinforcement members 152 are symmetrically arranged around the centerline of the vehicle 100 (only the right upper floor reinforcement member 152 is shown in the figure). The upper floor reinforcement members 152 extend along the longitudinal direction of the vehicle 100 and, when viewed from above, overlap with the lower floor reinforcement member 120 (not shown in the figure) disposed below the floor panel 102. More specifically, the upper floor reinforcement member 152 overlaps with each of the front portion 120b and the rear portion 120a of the lower floor reinforcement member 120 when viewed vertically. Furthermore, the upper floor reinforcement member 152 has a cap-shaped cross-section with a flange that opens downwards, and engages with the floor panel 102 at the flange. Additionally, the flange of the upper floor reinforcement member 152 is configured to overlap with the flanges of the floor panel 102 and the lower floor reinforcement member 120 when viewed vertically, and is welded in a three-piece overlapping manner.

[0381] A first seat crossbeam 155 and a second seat crossbeam 156 are provided in the width direction of the vehicle 100. They are located in the front seat 105 (see reference). Figure 1 Below the first seat crossbeam 155. The second seat crossbeam 156 is positioned behind the first seat crossbeam 155 in the longitudinal direction of the vehicle 100. Both the first seat crossbeam 155 and the second seat crossbeam 156 have a hat-shaped cross-section that opens downwards and engage with the floor panel 102. In addition, both the first seat crossbeam 155 and the second seat crossbeam 156 pass through the upper floor reinforcement 152 and through the passage cover reinforcement 150 to engage with the left and right side beams 154.

[0382] 3-3. Structure mounted beneath the floor of the battery pack

[0383] use Figures 39-45 This describes the structure of the battery pack 200 mounted under the floor.

[0384] Figure 39 This is a perspective view showing the engagement state of the battery pack 200 with the frame structure under the floor when the battery pack 200 is mounted under the floor of the vehicle 100 of the embodiment. However, the illustration of the component that constitutes part of the rear portion 120a of the floor underside reinforcement 120 is omitted in this figure.

[0385] When the battery pack 200 is mounted under the floor of the vehicle 100, it is housed in an area surrounded by the left and right floor underside reinforcements 120, the left and right rear floor side members 132, and the rear floor underside crossbeam 130. Furthermore, the rear portion of the battery pack 200, namely the high roof portion 212 of the upper housing 210, is housed in an area surrounded by the left and right rear floor side members 132, the rear floor underside crossbeam 130, and the front floor underside reinforcement 136. Although the distance between the front portions 120b of the left and right floor underside reinforcements 120 decreases as they face forward, this corresponds to the shape of the top portion of the battery pack 200.

[0386] Figure 40 This is a bottom view showing the battery pack 200 mounted under the floor of the vehicle 100 in this embodiment. The battery pack 200, housed between the left and right floor underside reinforcements 120, is engaged with the floor underside reinforcements 120 via housing fixing side arms 410, 420, 430, and 440. In other words, the battery pack 200 is held from below by the housing fixing side arms 410, 420, 430, and 440 suspended from the floor underside reinforcements 120.

[0387] The rear of the battery pack 200 is housed between the left and right longitudinal arms 171. A concern when installing or removing the longitudinal arms 171 is interference between the longitudinal arm fixing part 172 and the battery pack 200. However, even the extension plate 655, which is closest to the longitudinal arm fixing part 172, is housed in a position further inward than the longitudinal arm fixing part 172 when viewed from above.

[0388] Figure 41 This is a bottom view showing the positional relationship between the battery stack 900 and the floor when the battery pack 200 is mounted under the floor of the vehicle 100 in this embodiment. The battery stack 900 is arranged in eight rows in the longitudinal direction of the vehicle 100. However, the last three rows are arranged in two layers, vertically. The first five rows of battery stacks 900 are held in place laterally by floor underside reinforcement 120. Furthermore, although not shown, the last two layers of three rows of battery stacks 900 are held in place laterally by the rear suspension.

[0389] Figure 42 This is a bottom view showing the reinforcement structure beneath the floor of the vehicle 100 according to the embodiment. A pair of front side members 153 are provided on the front side of the vehicle 100. The front side members 153 are skeletal members respectively disposed on the right and left sides of the vehicle 100 in the width direction and extending along the front-rear direction of the vehicle 100. A collision box 123 is mounted at the front end of the front side members 153. A bumper reinforcement member 122 extending in the width direction is provided between the left and right collision boxes 123.

[0390] The front member 153 engages its rear end with the front end of the front portion 120b of the underfloor reinforcement 120. The front portion 120b of the underfloor reinforcement 120 faces outward in the width direction of the vehicle 100 as it moves rearward and connects to the rear portion 120a. The distance between the left and right underfloor reinforcements 120 increases in the front portion 120b as it moves rearward and becomes constant in the rear portion 120a. Furthermore, in Figure 42 In order to simplify the representation of the positional relationships of these components, they are indicated by solid lines.

[0391] With the battery pack 200 mounted on the vehicle 100, multiple external lateral reinforcements are fixed to the underfloor reinforcement 120 via suspension bolts. Thus, the left and right underfloor reinforcements 120 are connected by these multiple external lateral reinforcements. Specifically, the left and right front portions 120b, which extend rearward, are connected by external lateral reinforcements 510 and 520. The left and right rear portions 120a are connected by four external lateral reinforcements 530.

[0392] Figure 43 This is a bottom view showing the bottom cover 195 installed under the floor of the vehicle 100 according to the embodiment. The bottom cover 195 is provided from a position adjacent to the front suspension member 160 to the rear end of the vehicle 100, so as to cover the entire bottom surface of the battery pack 200. In addition, although not shown, the bottom cover 195 is configured to overlap with the underfloor reinforcement 120. Furthermore, the bottom cover 195 can be a single cover component or composed of multiple cover components.

[0393] Figure 44 This is a left-side view showing the rear portion of the floor with the battery pack 200 mounted under the floor of the vehicle 100 in this embodiment. A rear floor side member 132 is provided at the rear of the floor. The rear floor side member 132 is composed of a front portion and a rear portion, the front portion being curved upwards as it moves rearwards, and the rear portion extending straight towards its rear end. The floor panel 102 has a rear floor panel portion 102a made to match the height of the rear portion of the rear floor side member 132 and a front floor panel portion 102b made to match the height of the side beam 154. Therefore, the floor panel 102 has a step 102c between the rear floor panel portion 102a and the front floor panel portion 102b.

[0394] The rear end of the battery pack 200 extends beyond the rear end of the underfloor reinforcement 120 and reaches the rear floor side member 132. Since the underfloor reinforcement 120 is located at a relatively low position, the collar 402 used to secure the housing fixing arm 430 to the underfloor reinforcement 120 is relatively short. On the other hand, since the rear floor side member 132 bends upwards as it moves rearwards, a collar 406 longer than the collar 402 is required to secure the last housing fixing arm 440 to the rear floor side member 132. In other words, by using a longer collar 406, the rear floor side member 132 can be connected to the housing fixing arm 440.

[0395] Regarding the mounting of the rear end of the battery pack 200, instead of using the combination of the side arm and collar for mounting the housing, a rear arm 460 for mounting the housing is used. This will be explained in detail in the following sections.

[0396] Figure 45 This is a front view showing a cross-section of the floor and battery pack 200 in the width direction, viewed from the front, of the vehicle 100 in the embodiment with the battery pack 200 mounted under the floor. The battery pack 200 is held from the left and right by a pair of floor underside reinforcements 120. A floor top reinforcement 152 is provided on the opposite side of the floor underside reinforcement 120 that holds the floor panel 102. The floor underside reinforcement 120 has a deeper, cap-shaped cross-section that opens upwards, and the floor top reinforcement 152 has a shallower, cap-shaped cross-section that opens downwards; the two are joined together to hold the floor panel 102. A seat crossbeam extending in the width direction (in...) Figure 45 The image only shows the first seat crossbeam 155 pressing down on the upper floor reinforcement 152 from above.

[0397] The lower housing 300 of the battery pack 200 is reinforced and supported by multiple reinforcing members on its bottom surface. Figure 45 In this design, the bottom surface of the lower housing 300 is reinforced and supported by an external transverse stiffener 530 extending along the width direction and external central longitudinal stiffener 610 and outer longitudinal stiffener 630 extending along the front-rear direction. When viewed from the front, the support portions 611 and 631 of the external central longitudinal stiffener 610 and outer longitudinal stiffener 630 overlap with the long side of the external transverse stiffener 530. Although not shown in the figure, in other combinations of external longitudinal stiffeners and external transverse stiffeners, the support portion of the external longitudinal stiffener also overlaps with the long side of the external transverse stiffener when viewed from the front.

[0398] A gap is provided between the upper housing 210 of the battery pack 200 and the floor panel 102. The vertical position of the battery pack 200 is determined by left and right collars (in... Figure 45Only the length of the collar 402 is shown for adjustment. Although described in detail later, an elastic member is sandwiched between the central bulge 213 of the upper housing 210 and the floor channel 110 of the floor panel 102. Figure 45 Only the first elastic member 231 is shown in the figure.

[0399] 3-4. Installation structure of the rear end of the battery pack

[0400] use Figures 46-49 This section describes the detailed installation structure of the rear end of the battery pack 200.

[0401] Figure 46 This is a perspective view of the rear end of the lower housing 300, magnified from a lower left rearward angle, showing the battery pack 200 housing mounting arm 460 on the rear floor crossbeam 130. The housing mounting arm 460 has a cap-shaped cross-section that opens rearward. The housing mounting arm 460 has a folding portion 461 at its upper end, formed by folding the flange of the cap forward.

[0402] The vehicle-side component near the rear end of the battery pack 200 is a rear floor underbeam 130 extending along the width direction of the vehicle 100. The rear floor underbeam 130 engages with the rear floor side component 132 via a bracket 134. However, since there is a distance from the lower housing 300 of the battery pack 200 to the rear floor underbeam 130, it is difficult to use suspension bolts and collars as used in side fixings for securing. Therefore, a housing fixing rear arm 460 extending from the rear end of the lower housing 300 is used for fixing the rear end of the battery pack 200 to the vehicle 100.

[0403] The lower end of the housing-fixing rear arm 460 is fastened to the outer rear end bracket 570. The rear end of the battery pack 200 is fixed to the vehicle 100 by fastening the folding portion 461 located at the upper end to the rear floor crossbeam 130. Fasteners 471 are used in fastening the outer rear end bracket 570 to the housing-fixing rear arm 460, and also in fastening the rear floor crossbeam 130 to the housing-fixing rear arm 460. Furthermore, a reinforcing rib 462 is formed in the housing-fixing rear arm 460. The rib 462 passes between the two fasteners 471 and extends upward.

[0404] Figure 47This is a side view of the rear of the floor and battery pack 200, taken with the battery pack 200 mounted under the floor, cut along the centerline of the vehicle 100 in the longitudinal direction, and magnified from the left side. The housing mounting arm 460 leans forward towards the front of the vehicle 100. Specifically, the housing mounting arm 460 rises directly upward from its fastening point with the outer rear end bracket 570, and bends forward to extend to its fastening point with the rear floor under-beam 130. Thus, when the battery pack 200 is mounted on the vehicle 100, the rear end 201 of the battery pack 200 is positioned below or further rearward than the rear floor under-beam 130.

[0405] The housing fixing rear arm 460 is disposed within the rear floor lower crossbeam 130, and is fastened to the rear floor lower crossbeam 130 by means of welding or the like. The rear floor lower crossbeam 130 clamps the floor panel 102 and engages with the rear floor upper crossbeam 140.

[0406] Figure 48 This is an enlarged and schematic cross-sectional view showing the junction of the rear floor underbeam 130, the rear floor upper beam 140, and the floor panel 102. The rear floor underbeam 130 has a cap-shaped cross-section that opens upwards, and the rear floor upper beam 140 has a cap-shaped cross-section that opens downwards. The open sides of the rear floor underbeam 130 and the rear floor upper beam 140 each form a closed section with the floor panel 102, and the open sides of the rear floor underbeam 130 and the rear floor upper beam 140 sandwich the floor panel 102 and face each other generally vertically.

[0407] Figure 49 This diagram schematically illustrates the details of the construction for securing the housing mounting arm 460 to the rear floor underbeam 130. A reinforcing partition 480 is housed within the rear floor underbeam 130, which has a cap-shaped cross-section. The partition 480 has a box-shaped or dish-shaped form with an open top. Fasteners 470 are installed to clamp the bottom 131 of the rear floor underbeam 130 between the bottom 481 of the partition 480 and the folded portion 461 of the housing mounting arm 460.

[0408] 3-5. Support structure of the upper shell

[0409] Next, use Figures 50-55 Explain the support structure of the upper shell 210.

[0410] Figure 50This diagram shows the support structure of the upper housing 210, and is a perspective view of the floor and battery pack 200 with the battery pack 200 (without the battery stack 900 and heating / cooling device) mounted under the floor. The view is taken by cutting along the centerline of the vehicle 100 in the longitudinal direction and magnifying from a lower left front. Multiple support legs 390, serving as support members, extend upwards from the bottom of the lower housing 300. Furthermore, a center plate 370 is mounted on the upper end of the support legs 390 arranged along the centerline.

[0411] The central ridge 213 of the upper shell 210 is located directly above the center plate 370. Multiple, mutually separated ribs 218 are formed on the back side of the central ridge 213. Furthermore, the ribs 218 extend in the left-right direction, reinforcing the upper shell 210. The ribs 218 abut against the center plate 370, which supports the ribs 218 from below. That is, the support leg 390 serves as a support member supporting the center plate 370, and also functions as a support member supporting the upper shell 210 from below via the center plate 370 and the ribs 218. Moreover, the shape of the lower edge of the rib 218 is formed to be approximately consistent with the shape of the opposing center plate 370.

[0412] A gap is ensured between the upper housing 210 and the floor panel 102. Two elastic members 231 and 232 are disposed in this gap and are clamped between the surface of the upper housing 210 and the bottom surface of the floor panel 102. The first elastic member 231, located at the front, is positioned directly below the first seat crossbeam 155. The second elastic member 232, located at the rear, is positioned directly below the second seat crossbeam 156.

[0413] Figure 51 This diagram shows the support structure of the upper housing 210, and is a schematic front view of the periphery of the center plate 370 when the floor and battery pack 200 are cut along their width and viewed from the front. The support legs 390 supporting the center plate 370 engage with the partition bracket 340. The partition bracket 340 engages with the internal transverse reinforcement 320 that reinforces the bottom panel 301. Engaging the partition bracket 340 further increases the rigidity of the internal transverse reinforcement 320. Since the engagement between the partition bracket 340 and the internal transverse reinforcement 320 is a rigid body, it can be said that the support legs 390, as support members, extend upwards from the rigid body disposed inside the lower housing 300.

[0414] The center plate 370 has a recess 372 for the cable 751 to pass through and flanges 371 formed on both sides thereon. The flanges 371 have flat surfaces, and two rows of ribs 218 are provided on the back side of the upper housing 210 (specifically, the back side of the central bulge 213) when viewed from the front. The right row of ribs 218 abuts against the flat surface of the right flange 371, and the left row of ribs 218 abuts against the flat surface of the left flange 371. The cable 751 passes between the two rows of ribs 218.

[0415] Elastic members 231 and 232 are provided in the central raised portion 213 (however, in Figure 51 The second elastic member 232 is hidden behind and not visible from the first elastic member 231. The first elastic member 231 is configured such that, when viewed from the front, its position in the width direction is located between the two rows of support legs 390. Additionally, the first elastic member 231 is configured such that, when viewed from the front, its position in the width direction is located between the two rows of ribs 218. The second elastic member 232 (not shown) is also configured similarly to the first elastic member 231. Furthermore, the fact that the elastic members 231 and 232 are located between the two members does not mean that the elastic members 231 and 232 are housed between the two members. It is sufficient that at least a portion (preferably the center or center of gravity) of the elastic members 231 and 232 is located between the two members.

[0416] A first base 112 is formed on the floor panel 102 where it contacts the first elastic member 231. The first base 112 is recessed upward from the back of the floor panel 102 and restricts the first elastic member 231 from shifting forward, backward, left, or right. A similar base is also formed on the floor panel 102 where it contacts the second elastic member 232. Furthermore, the elastic members 231 and 232 are joined to the upper housing 210, for example, by an adhesive.

[0417] Figure 52 This diagram shows the support structure of the upper housing 210, and is a side view of the floor and battery pack 200, viewed magnified from the left side with the battery pack 200 mounted under the floor, cut along the centerline of the vehicle 100 in the longitudinal direction. At least two sets of ribs 218, which form two rows in side view, are provided on the back of the central bulge 213 of the upper housing 210. The two rows of ribs 218 at the front are located below the first elastic member 231 in side view, and the two rows of ribs 218 at the rear are located below the second elastic member 232 in side view.

[0418] The first elastic member 231 is configured such that, in a side view, its position in the front-rear direction is between two adjacent support legs 390. Furthermore, the first elastic member 231 is configured such that, in a side view, its position in the front-rear direction is between two rows of ribs 218. The second elastic member 232 is configured such that, in a side view, its position in the front-rear direction is between two adjacent support legs 390. Furthermore, the second elastic member 232 is configured such that, in a side view, its position in the front-rear direction is between two rows of ribs 218.

[0419] Figure 53 This is a schematic longitudinal sectional view showing the engagement state of the first elastic member 231 with the first base 112 formed on the floor panel 102. Additionally, Figure 54 This is a diagram showing the engagement state of the first elastic member 231 with the first base 112 formed on the floor panel 102, and a perspective view of the periphery of the first base 112 of the floor panel 102 viewed from a slightly downward angle. A first seat crossbeam 155, opening downwards, is engaged with the floor panel 102. The first base 112 is recessed upwards from the back of the floor panel 102 on the inner side of the first seat crossbeam 155. The top surface of the first base 112 is flat and formed parallel to the surface of the upper housing 210. When the battery pack 200 is mounted on the vehicle 100, the first elastic member 231 is restricted from shifting forward, backward, left, and right by the first base 112, and is compressed between the first base 112 and the surface of the upper housing 210.

[0420] Figure 55 This is a diagram showing the engagement state of the second elastic member 232 with the second base 113 formed on the floor panel 102, and a perspective view of the periphery of the second base 113 of the floor panel 102 viewed from a slightly downward angle. A second seat crossbeam 156, opening downwards, is engaged with the floor panel 102. The second base 113 is recessed upwards from the back of the floor panel 102 on the inner side of the second seat crossbeam 156. The top surface of the second base 113 is flat and formed parallel to the surface of the upper housing 210. When the battery pack 200 is mounted on the vehicle 100, the second elastic member 232 is restricted from shifting forward, backward, left, and right by the second base 113, and is compressed between the second base 113 and the surface of the upper housing 210.

[0421] 4. Features and Advantages

[0422] Features and advantages of the battery pack 200 and the vehicle body structure of the vehicle 100 according to the embodiments are listed below. However, these are only part of the features of this disclosure, and this disclosure is not limited to the features and advantages listed below.

[0423] 4-1. Support from below the upper housing by support legs

[0424] For example, Figures 50-52 As shown, in this embodiment, the battery pack 200 supports the upper housing 210 from below using support legs 390. Since the support legs 390 are engaged with a rigid body, their feet are stable. By using stable support legs 390 to support the upper housing 210 from below, vibration of the upper housing 210 can be suppressed.

[0425] For example, Figure 12 and Figure 51 As shown, in this embodiment, the battery pack 200 connects the support leg 390 to the internal lateral reinforcement 320 via a partition bracket 340. By connecting the partition bracket 340 to the internal lateral reinforcement 320, which is a rigid body, the rigidity of the lower housing 300 can be further improved, thus enabling stable support of the upper housing 210.

[0426] In addition, for example, Figure 50 and Figure 51 As shown, in this embodiment, the battery pack 200 supports the central portion of the upper housing 210 using support legs 390. Since the central portion of the upper housing 210 is particularly prone to bending, supporting this portion from below helps to suppress vibrations of the upper housing.

[0427] In addition, for example, Figures 9-11 As shown, a central plate 370 extending in the front-rear direction is mounted on the upper end of two rows of support legs 390 arranged in the front-rear direction. By joining multiple support legs 390 via the central plate 370, the overall rigidity of the support structure supporting the upper housing 210 can be improved, thus stably supporting the upper housing 210. Since the central plate 370 has a cap-shaped cross-sectional shape, and the support legs 390 also have a cap-shaped cross-sectional shape, they can also be used to ensure high rigidity.

[0428] Ribs 218 formed in the central part of the back surface of the upper housing 210 increase the rigidity of the upper housing 210. For example, Figures 50-52 As shown, in this embodiment, the battery pack 200 supports the ribs 218 via a center plate 370 and support legs 390. Furthermore, by abutting the center plate 370 against the ribs 218 formed on the back surface of the upper housing 210, the upper housing 210 can be stably supported regardless of its surface shape. Additionally, for example... Figure 51 As shown, by having the rib 218 abut against the flat surface of the flange 371 formed on the central plate 370 and allowing the cable 751 to pass through the recess between the flanges 371, the upper housing 210 can be stably supported and the cable 751 can be arranged without being obstructed by the rib 218.

[0429] In addition, for example, Figure 32 As shown, each of the battery stacks 900 has multiple claws 922 on both sides of the short side of the battery stack 900. The multiple claws 922 are clamped between the partition bracket 340 and the internal transverse reinforcement 320, thereby fixing them to the internal transverse reinforcement 320. In this structure, since the torsion between two adjacent internal transverse reinforcements 320 is limited by the battery stack 900, the rigidity of the support structure as a whole supporting the upper housing 210 can be further improved, and the upper housing 210 can be stably supported.

[0430] For example, Figure 12 As shown, the battery pack 200 of the embodiment has an external central longitudinal stiffener 610 extending in the front-rear direction of the battery pack 200 below the side-by-side support legs 390. With this structure, the rigidity of the bottom panel 301 at the location where the support legs 390 are arranged can be increased, thus stably supporting the upper housing 210.

[0431] In the battery pack 200 of this embodiment, the support leg 390 is erected from the partition bracket 340, but it can also be erected directly from the internal transverse reinforcement 320. In this case, the support leg 390 and the internal transverse reinforcement 320 can be fastened with fasteners or welded together. Furthermore, since the battery stack 900 is also a rigid body, the support leg 390 can also be erected from the battery stack 900. Additionally, since the bottom panel 301, which is fixed with the internal transverse reinforcement, external transverse reinforcement, or external longitudinal reinforcement, can be considered a rigid body that suppresses deformation, the support leg 390 can also be erected from the bottom panel 301. Furthermore, the back of the upper housing 210 can be supported directly using the support leg 390 without passing through the center plate 370.

[0432] In the battery pack of this embodiment, the lower top plate portion 211 of the upper housing 210 is supported from below, but the higher top plate portion 212 may also be supported from below. Alternatively, the less rigid side of the lower top plate portion 211 and the higher top plate portion 212 (e.g., the side with a longer length in the front-rear direction of the battery pack 200) may be supported from below. That is, if the higher top plate portion 212 is longer, only the higher top plate portion 212 may be supported from below.

[0433] The battery pack 200 of the embodiment can also be modified in the following way, for example. Figure 56 (a) and (b) show schematic longitudinal sectional views of modified examples of the support structure of the upper housing 210. In each modified example, the upper housing 210 and the support leg 390 are directly joined by fasteners 250. The fastening portions of the fasteners 250 are sealed with sealing material 252 for waterproofing. Figure 56In the modified example shown in (a), a dome-shaped sealing material 252 is used. The dome-shaped sealing material 252 is bonded in a manner that covers the nut, or its bottom is embedded between the nut and the upper housing 210. Figure 56 In the modified example shown in (b), a disc-shaped sealing material 252 is used. The disc-shaped sealing material 252 is sandwiched between the nut and the upper housing 210. With this structure, liquid tightness can be maintained, and the upper housing 210 can be fixed to the support leg 390 using a simple structure.

[0434] 4-2. Connection structure based on external transverse stiffeners and internal transverse stiffeners

[0435] For example, Figure 10 As shown, the battery pack 200 of this embodiment includes a plurality of internal lateral reinforcement members (inner lateral reinforcement members) 320, 330 and a plurality of external lateral reinforcement members (outer lateral reinforcement members) 510, 520, 530, 540, 550, 560 arranged alternately in the front-rear direction. Each of the external lateral reinforcement members 510, 520, 530, 540, 550, 560 is joined together with the bottom panel 301 to two adjacent internal lateral reinforcement members 320, 330. Figure 12 In the example shown, two adjacent internal transverse stiffeners 320 are welded together with the bottom panel 301 using an external transverse stiffener 530 disposed between them. This structure increases the rigidity of the lower housing 300. Furthermore, it further enhances the overall rigidity of the support structure supporting the upper housing 210, providing stable support for the upper housing 210.

[0436] 4-3. Connection structure based on external longitudinal stiffener and external transverse stiffener

[0437] For example, Figure 7 and Figure 14 As shown, in this embodiment, the battery pack 200 has external transverse reinforcement members (outer transverse reinforcement members) 510, 520, 530, 540, 550, and 560 sandwiched between the external longitudinal reinforcement members (outer longitudinal reinforcement members) 610, 620, 630, 640, and 650 extending in the front-rear direction of the battery pack 200 and the bottom panel 301, and these three members are joined by welding. By reinforcing the bottom panel 301 in this way, the rigidity of the lower housing 300 can be improved. In addition, the rigidity of the support structure as a whole supporting the upper housing 210 can be further improved, and the upper housing 210 can be stably supported.

[0438] In addition, such as Figure 14As shown, for example, the outer central longitudinal stiffener 610 has a support portion 611 between adjacent outer transverse stiffeners 530. Similarly, for example, the outer longitudinal stiffener 630 has a support portion 631 between adjacent outer transverse stiffeners 530. The ends of these support portions 611, 631 in the front-rear direction approach the outer transverse stiffeners (in... Figure 14 In the examples shown, the width is expanded for external lateral reinforcements 510, 520, and 530, and as... Figure 45 As shown, when viewed from the front, it is related to the external lateral reinforcement (in Figure 14 In the example shown, the sides of the external lateral reinforcement 530 overlap along its long side. With this configuration, the load applied along the front-rear direction of the battery pack 200 can be effectively distributed along its width.

[0439] In addition, such as Figure 14 As shown, the ridge line 633 of the outer central longitudinal stiffener 610 bends longitudinally from the front-rear direction in a manner that follows the shape of the ridge line 531 of the outer transverse stiffener 530. Furthermore, the ridge line 631 of the outer longitudinal stiffener 630 bends longitudinally from the front-rear direction in a manner that follows the shape of the ridge line 531 of the outer transverse stiffener 530. With this configuration, the load applied along the front-rear direction of the battery pack 200 can be effectively distributed along the width direction.

[0440] In addition, such as Figure 14 As shown, the valley line (starting point of the flange) of the outer central longitudinal stiffener 610 bends longitudinally from the front-rear direction in a manner that follows the shape of the valley line of the outer transverse stiffener 530. Similarly, the valley line of the outer longitudinal stiffener 630 bends longitudinally from the front-rear direction in a manner that follows the shape of the valley line of the outer transverse stiffener 530. With this configuration, the load applied in the front-rear direction of the battery pack 200 can be effectively distributed along the width direction.

[0441] 4-4. Three-dimensional reinforcement of the battery pack by the intermediate frame

[0442] For example, Figure 18 and Figure 19 As shown, the second floor 360 at the rear of the intermediate frame 385 is constructed by combining frames 362, 363, and 364 with hollow cross-sections. Additionally, for example... Figure 9 and Figure 10 As shown, the second floor 360 is supported at its four corners and at its center in the width direction by multiple support legs 390, 391, and on both sides in the width direction by support walls 392. By assembling such a three-dimensional reinforced structure, the rigidity of the rear part of the lower housing 300 can be improved, and it can correspond to the two-layer stack of the battery stack 900.

[0443] A center plate 370, on which cable 751 is mounted, extends forward of the battery pack 200 across the battery stack 900. This reduces interference between cable 751 and the battery stack 900 and increases the capacity of the battery stack 900. Additionally, for example... Figure 13 As shown, the support leg 390 of the support center plate 370 extends upward from the partition bracket 340 that separates the battery stack 900 from the battery stack 900. That is, the support leg 390 is positioned above the partition bracket 340. This allows for efficient use of the space within the battery pack 200. Furthermore, the support leg 390 is positioned above the internal lateral reinforcement 320. This also allows for efficient use of the space within the battery pack 200.

[0444] 4-5. Setting of the gap between the elastic member, the floor panel, and the upper shell.

[0445] For example, Figures 50-52 As shown, in this embodiment, the battery pack 200 has elastic members 231 and 232 sandwiched between the surface of the upper housing 210 and the lower surface of the floor panel 102. By using the elastic members 231 and 232 and the support leg 390 to clamp the upper housing 210 from both above and below, vibration of the upper housing 210 can be suppressed. In particular, since the upper housing 210 is not sandwiched between rigid bodies, but one of them is set as an elastic member 231 or 232, the elastic members 231 and 232 can absorb the vibration generated in the upper housing 210. In addition, since the gap between the upper housing 210 and the floor panel 102 can be kept small, the volume of the battery pack 200 can be increased or the minimum ground clearance can be raised.

[0446] For example, Figures 53-55 As shown, bases 112 and 113 are formed on the floor panel 102 at the locations where they connect with the elastic members 231 and 232, recessed upwards from the back of the floor panel 102. Furthermore, since the portions of the floor panel 102 where the elastic members 231 and 232 are located overlap with the seat crossbeams 155 and 156, rigidity is ensured. With this configuration, the elastic members 231 and 232 can be stably clamped between the floor panel 102 and the upper housing 210.

[0447] For example, Figure 52 As shown, the elastic members 231 and 232 are configured such that, when the battery pack 200 is viewed from the side, the positions of the elastic members 231 and 232 in the front-rear direction of the battery pack 200 are located between two adjacent support legs 390. Additionally, when the battery pack is viewed from the front, for example... Figure 51As shown, the elastic members 231 and 232 in the width direction of the battery pack 200 are also positioned between two adjacent support legs 390. By configuring the support legs 390 to surround the elastic members 231 and 232, the upper housing 210 can be stably supported between the elastic members 231 and 232.

[0448] For example, Figure 52 As shown, the elastic members 231 and 232 are configured such that when the battery pack 200 is viewed from the side, the positions of the elastic members 231 and 232 in the front-rear direction of the battery pack 200 are located between two adjacent ribs 218. Additionally, when the battery pack is viewed from the front, for example... Figure 51 As shown, the elastic members 231 and 232 in the width direction of the battery pack 200 are positioned between two adjacent ribs 218. By configuring the ribs 218 to surround the elastic members 231 and 232, the upper housing 210 can be stably supported between the ribs 231 and 232. In addition, since the rigidity of the upper housing can be increased by utilizing the ribs 218, the elastic members 231 and 232 can be stably clamped between the floor panel 102 and the upper housing 210.

[0449] 4-6. Reinforcement of the vehicle frame by the reinforcement structure of the battery pack

[0450] For example, Figure 7 As shown, the battery pack 200 of this embodiment includes external longitudinal reinforcement members (outer longitudinal reinforcement members) 610, 620, 630, 640, 650 extending in the front-rear direction of the battery pack 200, and external transverse reinforcement members (outer transverse reinforcement members) 510, 520, 530, 540, 550, 560 extending in the width direction of the battery pack 200. This mesh-like combination improves the rigidity of the bottom panel 301. Therefore, the strength of the battery pack 200 relative to external forces can be increased.

[0451] In addition, for example, Figure 42 As shown, in this embodiment, the battery pack 200 has frontal external lateral reinforcements 510, 520, and 530 mounted on the floor underside reinforcement 120, which serves as a reinforcing member of the vehicle 100. With this structure, the load applied to the floor underside reinforcement 120 can be distributed to the reinforcing structure of the battery pack 200. In particular, since the two frontal external lateral reinforcements 510 and 520 are mounted on the front portion 120b, which expands in distance towards the rear, deformation of the floor underside reinforcement 120 can be prevented when loads from the front side are transmitted to the floor underside reinforcement 120 via the front member 153, etc.

[0452] Figure 57This diagram illustrates the function and effect of the reinforcing structure beneath the floor of the vehicle 100 and the battery pack 200 in the embodiment. Furthermore, for simplicity, the central and left / right external longitudinal reinforcing members 601, 602, and 603 are shown as a single member. Of course, in practice, the external longitudinal reinforcing members 601, 602, and 603 could also be formed using such a single member. Additionally, for simplicity, in... Figure 57 Draw the floor underside reinforcement 120 from above.

[0453] When a load is applied from the front of the vehicle 100, as shown by arrows in the figure, a portion of the load is applied to the underfloor reinforcement 120 and the upper floor reinforcement 152. The load applied to the underfloor reinforcement 120 is distributed to the outer lateral reinforcements 510, 520, and 530, and also to the outer longitudinal reinforcements 601, 602, and 603. When a load is applied from the rear of the vehicle 100, a portion of the load is applied to the outer longitudinal reinforcements 601, 602, and 603 via the last outer lateral reinforcement 560, and is distributed to the outer lateral reinforcements 510, 520, 530, 540, and 550. It is also distributed to the underfloor reinforcement 120 and the upper floor reinforcement 152. When a load is applied from the side of the vehicle 100, a portion of the load is applied to the outer lateral reinforcements 510, 520, and 530 via the underfloor reinforcement 120, and is distributed to the outer longitudinal reinforcements 601, 602, and 603. That is, the reinforced structure of the battery pack 200, together with the floor underside reinforcement 120 which serves as a reinforcing member on the side of the vehicle 100, disperses the load applied to the vehicle 100.

[0454] 4-7. Battery pack support provided by crossbeams forming a ring-shaped frame

[0455] For example, Figure 36 As shown, the vehicle body structure of the embodiment 100 has an annular frame composed of multiple frame members 140, 141, 142, 143, etc. More specifically, the upper frame 148, which is arranged in a U-shape with its opening facing downward on the upper side of the vehicle, and the lower frame 149, which is arranged in a U-shape with its opening facing upward on the lower side of the vehicle, overlap in the portion extending in the vertical direction of the vehicle and form an annular shape.

[0456] In this embodiment, such as Figure 58As shown in the supplementary figure, the upper frame 148 is configured to cover the lower frame 149. The upper frame 148 is formed into a U-shape with an opening facing downwards when the vehicle is viewed from the front, by connecting the roof reinforcement 143 to the inner side of the left and right side pillar external reinforcements 142 located on the outer side of the vehicle body. The lower frame 149 is formed into a U-shape with an opening facing upwards when the vehicle is viewed from the front, by connecting the rear floor crossbeam 140 to the inner side of the left and right side pillar internal reinforcements 141 located on the inner side of the vehicle body. In this way, the upper frame 148 and the lower frame 149 overlap in at least a portion of their vertical direction. Furthermore, the upper frame 148 and the lower frame 149 can also be formed by joining more subdivided components, respectively.

[0457] The roof reinforcement 143 may also extend in the width direction and have a hat-shaped cross-section, overlapping with an inner panel (not shown) to form a closed cross-section. Additionally, the side pillar external reinforcement 142 may also extend in the vertical direction and have a hat-shaped cross-section, and be joined to the wheel arch external panel 144 and the rear pillar inner panel 146 by welding or the like, thereby forming a closed cross-section between them. The side pillar internal reinforcement 141 may also extend in the vertical direction and have a hat-shaped cross-section, and be joined to the wheel arch inner panel 145 and the rear pillar inner panel 146 by welding or the like, thereby forming a closed cross-section between them. The side pillar internal reinforcement 141 and the wheel arch external panel 144 are arranged facing each other in a portion of their length, and are either directly welded or overlapped and welded together with the rear pillar inner panel 146.

[0458] In addition, for example, Figure 47 and Figure 48 As shown, a rear floor lower crossbeam 130 is joined to the floor panel 102 via a rear floor crossbeam 140 forming a ring-shaped frame. More specifically, the flanges of the rear floor upper crossbeam 140, the floor panel 102, and the rear floor lower crossbeam 130 are welded together in an overlapping manner. Additionally, a housing fixing arm 460 for securing the battery pack 200 is fixed to the rear floor lower crossbeam 130. With this structure, the relatively rigid ring-shaped frame of the vehicle 100 can be used to support the rear portion of the heavier battery pack 200.

[0459] 4-8. Suspension support for the rear end of the battery pack via the crossbeam under the rear floor

[0460] In the vehicle body structure of the embodiment 100, for example, Figure 44As shown, the rear portion 102a of the floor panel is one layer higher than the front portion 102b of the floor panel. Therefore, the lower floor reinforcement 120 is interrupted at the front portion 102b of the floor panel. A rear floor side member 132 that bends upwards as it moves rearwards is disposed below the rear portion 102a of the floor panel.

[0461] For a curved rear floor side member 132 like this, the distance to the lower housing 300 increases, or the lower surface of the rear floor side member 132 is inclined. Additionally, there are cases where a longitudinal arm fixing part is provided. In these cases, it is difficult to directly fix it using suspension bolts similar to those used for the floor underside reinforcement 120. However, by extending the housing fixing rear arm 460 upwards from the rear end of the lower housing 300 and fixing it to the rear floor underbeam 130, and suspending the rear end of the battery pack 200 from the lower housing 300, the rear end of the battery pack 200 can be stably held.

[0462] 4-9. Closed cross-section structure of the rear end of the lower shell

[0463] For example, Figure 20 , Figure 21 and Figure 59 As shown, the battery pack 200 of the embodiment has a closed cross-section structure at the rear end of the lower housing 300, consisting of a bottom panel 301, an external lateral reinforcement 560, an external rear end bracket 570, and a rear inner bracket 580. Figure 59 yes Figure 21 The supplementary diagram shows a perspective view in detail around the welding points at the rear end of the lower housing 300. Since the housing is fixed to the outer rear end bracket 570, which has a relatively rigid closed cross-section structure, the rear end of the battery pack 200 can be stably held.

[0464] Figure 60 This is a schematic longitudinal sectional view showing a modified example of the structure of the rear end of the lower housing 300 to which the housing fixing rear arm 460 is fixed. Alternatively, instead of a closed section structure composed of multiple components, a single component (e.g., an aluminum extrusion) 590 with a closed section can be provided at the rear end of the lower housing 300 and used to fix the housing fixing rear arm 460.

[0465] 4-10. Connection between the outer longitudinal stiffener (made by the outer corner stiffener) and the outer transverse stiffener at the rear end.

[0466] For example, Figure 24 and Figure 25As shown, in this embodiment, the battery pack 200 connects the outer longitudinal reinforcement 650 to the rear-end outer transverse reinforcement 560 using a curved outer corner reinforcement 660. The shape of the ridge and valley lines of the outer corner reinforcement 660 is curved to form the shape of the ridge and valley lines along the outer longitudinal reinforcement 650 and the outer transverse reinforcement 560. Therefore, when a load acts on the outer transverse reinforcement 560 from the rear of the vehicle 100, stress concentration can be suppressed while efficiently transferring the acting load from the outer transverse reinforcement 560 extending in the left-right direction to the outer longitudinal reinforcement 650 extending in the front-rear direction.

[0467] 4-11. Battery stack support with multiple reinforcing members

[0468] For example, Figure 13 , Figure 15 and Figure 16 As shown, in this embodiment, the battery pack 200 has an inner lateral reinforcement 320 and an outer lateral reinforcement 530 overlapped and welded together on the bottom panel 301, and the outer lateral reinforcement 530 and the outer central longitudinal reinforcement 610 overlapped and welded together on the bottom panel 301. By joining multiple reinforcements to the bottom panel 301 in this way, the rigidity of the lower housing 300 can be improved, and the battery stack 900 can be stably supported.

[0469] In addition, for example, Figure 13 and Figure 32 As shown, in this embodiment, the battery pack 200 does not directly fix the battery stack 900 to the bottom panel 301, but instead fixes the battery stack 900 to the internal transverse reinforcement 320. This structure helps to prevent the load from being directly transmitted to the battery stack 900.

[0470] 4-12. Battery pack protection provided by external transverse and longitudinal reinforcement members

[0471] For example, Figure 40 and Figure 42 As shown, the vehicle body structure of the embodiment 100 reinforces the bottom surface of the battery pack 200 using multiple external lateral and longitudinal reinforcements. In... Figure 61 In the event that the underside of the vehicle 100 collides with an obstacle 4 on the road 2, as shown, these reinforcements function as protective members to protect the battery pack 200 from the impact caused by the obstacle 4. Additionally, multiple external lateral reinforcements and external longitudinal reinforcements configured in a frame shape are provided below... Figure 43 The bottom cover 195 shown further suppresses impacts on the battery pack 200.

[0472] In addition, such as Figure 61As shown, due to the positional relationship between the front wheel 103, the rear wheel 104, and the battery pack 200 disposed between the front wheel 103 and the rear wheel 104, during normal driving, the portion of the battery pack 200 from the center to the front is more likely to violently impact the bottom surface compared to the rear. Regarding this, for example... Figure 7 As shown, in the battery pack 200 of the embodiment, the arrangement density between the external lateral reinforcements 510, 520, and 530 that reinforce the front side is higher than the arrangement density between the external lateral reinforcements 540, 550, and 560 that reinforce the rear side of the bottom panel 301. Furthermore, for example, as... Figure 13 As shown, the external lateral reinforcement 530, which is fixed to the rear part 120a of the floor underside reinforcement 120, is positioned directly below the battery stack 900.

[0473] 4-13. Configuration of the air guide plate on the internal transverse reinforcement

[0474] For example, Figures 27-29 As shown, the battery pack 200 of this embodiment has air guides 712 and 722 arranged on the internal transverse reinforcement 320 to direct airflow from the air ducts 702 and 704 toward the battery stack 900. More specifically, support legs 390 and air guides 712 and 722 are arranged along the front-rear direction of the battery pack 200 and engage with the partition bracket 340. With this structure, the space within the battery pack 200 can be utilized effectively.

[0475] 4-14. Protection of the battery stack via air supply ducts

[0476] For example, Figure 26 As shown, in this embodiment, the battery pack 200 has air ducts 702, 704, 705, and 706 arranged along the front-rear direction of the battery pack 200 on the outer side of the plurality of battery stacks 900 in the width direction. When a lateral impact load acts on the battery pack 200 from the outer side in the width direction, at least one of these air ducts 702, 704, 705, and 706 can absorb the impact. This reduces the impact input to the battery cells 901.

[0477] 4-15. Alternating configuration of the left and right air distribution sections

[0478] For example, Figure 26As shown, in the battery pack 200 of this embodiment, when viewed from the center of the width direction along the front-to-back direction, air distribution sections 711 and 721 are alternately arranged in the left and right air supply ducts 702 and 704. Additionally, although not shown, air distribution sections 711 and 721 are also alternately arranged in the left and right second floor air supply ducts 705 and 706. This arrangement of air distribution sections 711 and 721 reduces the number of air distribution sections 711 and 721 in each of the left and right air supply ducts 702 and 704 and the left and right second floor air supply ducts 705 and 706, and reduces pressure loss. In other words, efficient air supply is achieved in the left and right air supply ducts 702 and 704 and the left and right second floor air supply ducts 705 and 706 up to the end opposite to the blower 700. Furthermore, by configuring the air distribution sections 711 and 721 as described above, the difference in pressure loss between the right air supply duct 702 and the left air supply duct 704 can be reduced. As a result, the difference in load applied to the left and right blowers 700 can be reduced.

[0479] 4-16. Inclined configuration of air guide vanes from the side of the air distribution section to the opposite side

[0480] For example, Figure 62 As shown, the battery pack 200 of the embodiment includes air guides 712 and 722, the rear walls 715 and 725 of which are inclined such that they approach the back of the battery stack 900 from the respective air distribution sections 711 and 721 toward opposite sides. Cooling air blown from the air distribution sections 711 and 721 toward the inside of the battery pack 200 is guided by the air guides 712 and 722 and transported to the back of the battery stack 900. However, the inclination of the rear walls 715 and 725 of the air guides 712 and 722 can suppress the deviation of the cooling air supply in the long side direction of the battery stack 900. As a result, the difference in cooling amount between the battery cells 901 near the air distribution sections 711 and 721 and the battery cells 901 away from the air distribution sections 711 and 721 can be reduced.

[0481] 5. Other

[0482] In the above embodiments, most of the frame members and reinforcing members use members with a cap-shaped cross-section. However, in the case of a vehicle 100 that is a carbon fiber or lightweight metal vehicle, members with a non-cap-shaped cross-section are not required. Furthermore, in the above embodiments, most of the joints between members use welding-based joints or fastener-based joints. However, depending on the joint location, welding can be replaced by fastening, or vice versa. Depending on the material of the members, adhesives can also be used for jointing, for example.

Claims

1. A vehicle, characterized in that, The vehicle has the following features: A pair of rear floor side members (132) are disposed on the left and right sides of the rear of the vehicle; A rear floor underbeam (130) is fixed between the pair of rear floor side members (132); A battery pack (200) is disposed in the lower part of the vehicle and has a lower housing (300). On the lower housing (300), a battery stack (900) is disposed in a front layer and a rear layer. The battery stack (900) includes a plurality of stacked battery cells (901) and a battery housing (920) housing the plurality of battery cells (901). A housing fixing member (460) extends upward from the rear end of the lower housing (300) and fixes the lower housing (300) to the rear floor underbeam (130).

2. The vehicle according to claim 1, characterized in that, The vehicle also has a rear floor crossbeam (140) configured to sandwich a floor panel (102) between the rear floor crossbeam (140) and the rear floor lower crossbeam (130). The rear floor upper crossbeam (140) and the rear floor lower crossbeam (130) each form a closed section between themselves and the floor panel (102). The rear floor upper crossbeam (140) and the rear floor lower crossbeam (130) clamp the floor panel (102) facing each other in such a way that their respective openings match.

3. The vehicle according to claim 2, characterized in that, The vehicle also has a pair of internal reinforcement members (141) on the side beams and pillars, which are arranged on the left and right sides inside the passenger compartment. The rear floor beam (140) connects its left and right ends to the inside of the pair of side beam internal reinforcements (141).

4. The vehicle according to any one of claims 1 to 3, characterized in that, The vehicle also features: A pair of front side members (153), the pair of front side members (153) being skeleton members disposed on the left and right sides of the front of the vehicle and extending along the length direction of the vehicle; as well as A pair of floor underside reinforcements (120) are disposed behind the pair of front side members (153) and have a cap-shaped cross-sectional shape that opens upwards. The rear ends of the pair of front members (153) engage with the front ends of the pair of floor underside reinforcements (120). The lower housing (300) is fixed to the pair of floor underside reinforcement members (120).

5. The vehicle according to claim 4, characterized in that, The pair of floor underside reinforcements (120) are arranged to face the rear of the vehicle and to be spaced further apart from each other. The battery pack (200) is disposed between the pair of floor underside reinforcements (120).

6. The vehicle according to claim 4, characterized in that, The rear ends of the pair of floor underside reinforcements (120) are directly or via other components joined to the pair of rear floor side members (132).

7. The vehicle according to claim 4, characterized in that, The lower housing (300) includes a bottom panel (301) for mounting the battery stack (900) and reinforcing members (510, 520, 530, 540, 550, 560, 610, 620, 630, 640, 650, 660) that reinforce the bottom panel (301) from the outside. A portion (510, 520, 530) of the reinforcing members (510, 520, 530, 540, 550, 560, 610, 620, 630, 640, 650, 660) is fixed to the pair of floor underside reinforcing members (120).

8. The vehicle according to claim 4, characterized in that, The lower housing (300) is fixed to the fixing portions (400, 404) of the pair of floor underside reinforcement members (120) to form a plane. The fixing part (470) for fixing the shell fixing member (460) to the lower crossbeam (130) of the rear floor is positioned above the plane.

9. The vehicle according to any one of claims 1 to 3, characterized in that, The lower housing (300) includes a bottom panel (301) for mounting the battery stack (900) and reinforcing members (510, 520, 530, 540, 550, 560, 610, 620, 630, 640, 650, 660) that reinforce the bottom panel (301) from the outside. The housing fixing member (460) is fixed to a portion (560) of the reinforcing member (510, 520, 530, 540, 550, 560, 610, 620, 630, 640, 650, 660).

10. The vehicle according to any one of claims 1 to 3, characterized in that, The vehicle also includes a front underfloor reinforcement (136) that is fixed between a pair of rear floor side members (132) in front of the rear underfloor crossbeam (130). The battery pack (200) has an upper housing (210) having a low top plate portion (211) corresponding to a battery stack (900) arranged on the first layer and a high top plate portion (212) corresponding to a battery stack (900) arranged on the second layer. The high roof section (212) is disposed between the front floor under-reinforcement member (136) and the rear floor under-beam (130).

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