An electric vehicle battery integrated floor assembly

Abstract

The application discloses a kind of electric vehicle battery integrated integrated floor assembly, including door sill beam, multiple floor cross beams and battery pack, battery pack frame is connected below door sill beam, battery pack upper cover is used as car body floor, without again specially configuring car body floor, it is conducive to reducing the vertical dimension of structure and reducing structural weight.Energy-absorbing aluminum box is configured in door sill beam, energy-absorbing aluminum box is separated by reinforcing plate structure Multiple cavities, box top plate and box bottom plate of box body are respectively wave-shaped and segmented thinning from outside to inside, the transverse partition of reinforcing plate structure also is segmented thinning from outside to inside, wave-shaped structure is used to guide compression energy absorption, the structure of gradually thinning section is used to ensure step-by-step compression energy absorption, annular structure of door sill beam, aluminum energy-absorbing box, floor cross beam can ensure the stiffness requirement of body in white, can also meet the energy-absorbing requirement in collision, protect the structure of electric core from invasion in collision.

Description

Technical Field

[0001] This invention relates to the field of vehicle structure technology, and more particularly to a floor assembly for an integrated electric vehicle battery. Background Technology

[0002] The vehicle floor assembly is a structure connecting the front floor assembly and the rear floor assembly. Existing vehicle floor assemblies generally include two sill beams and a middle floor connecting the two sill beams. In new energy vehicles, the battery pack is installed below the sill beams and the middle floor, with the battery pack top cover connected to the middle floor. This overlapping arrangement of the battery pack top cover and the middle floor is not conducive to reducing the vertical dimensions and weight of the structure. Existing sill beams consist of an outer sill beam plate and an inner sill beam plate, with a crash barrier placed between the outer and inner plates to improve the sill beam's stiffness and side-impact resistance. However, due to the use of crash barriers, their energy absorption effect is poor in the event of a side impact, resulting in a large impact on the inner sill beam plate and failing to protect the inner battery pack. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of existing technologies and provide an integrated floor assembly for electric vehicle batteries. This assembly uses the battery pack cover as the floor of the vehicle body, eliminating the need for a separate floor and reducing the vertical dimensions and weight of the structure. An energy-absorbing aluminum box is disposed between the outer and inner panels of the sill beam. This box is divided into multiple cavities by a reinforcing plate structure. The top and bottom plates of the box are wavy and gradually thin from the outside in. The transverse partitions of the reinforcing plate structure also gradually thin from the outside in. The wavy structure guides compression energy absorption, and the gradually thinning structure ensures step-by-step compression energy absorption. The ring structure composed of the sill beam, the aluminum energy-absorbing box, and the floor beam ensures both the overall rigidity of the body-in-white and the energy absorption requirements during a collision, protecting the battery cell structure from intrusion.

[0004] The present invention provides a floor assembly for an integrated electric vehicle battery, comprising a sill beam, multiple floor crossbeams connected to the sill beam, and a sill beam connected to the sill beam.

[0005] The battery pack frame of the battery pack is connected to the sill beam, the end of the floor beam is connected to the sill beam, the middle part of the floor beam is connected to the battery pack and is located above the battery pack cover, and the battery pack cover is used as the floor of the vehicle body;

[0006] The threshold beam includes an outer threshold beam plate and an inner threshold beam plate that are connected to each other, and a longitudinally extending energy-absorbing aluminum box is connected between the outer threshold beam plate and the inner threshold beam plate.

[0007] The energy-absorbing aluminum box includes a box body and a reinforcing plate structure disposed in the box body and divided into multiple cavities. The reinforcing plate structure includes at least two vertical partitions and at least two horizontal partitions that are cross-connected.

[0008] The outer panel of the box body is connected to the outer panel of the threshold beam, and the inner panel of the box body is connected to the inner panel of the threshold beam.

[0009] Along the direction from the outside to the inside, the top plate and bottom plate of the box are respectively wavy, and the top plate, bottom plate and transverse partition are respectively thinned in sequence according to the cavity segment.

[0010] In one of the alternative technical solutions, the top plate and the bottom plate of the box are arranged symmetrically in the upper and lower parts;

[0011] The upper end of each vertical partition is connected to a trough of the top plate of the box, and the lower end of each vertical partition is connected to a crest of the bottom plate of the box.

[0012] In one of the alternative technical solutions, the upper end of the outer panel of the box is connected to the outermost trough of the top panel of the box, and the lower end of the outer panel of the box is connected to the outermost crest of the bottom panel of the box.

[0013] The upper end of the inner plate of the box is connected to the innermost trough of the top plate of the box, and the lower end of the inner plate of the box is connected to the innermost crest of the bottom plate of the box.

[0014] In one of the alternative technical solutions, the outer panel of the box and the inner panel of the box have the same thickness, and the thickness of the vertical partition is less than the thickness of the outer panel of the box.

[0015] In one of the alternative technical solutions, a preset gap is left between the bottom plate of the box and the bottom plate of the threshold beam.

[0016] In one of the alternative technical solutions, the floor beam includes a beam body and beam joints located at both ends of the beam body;

[0017] The two ends of any two adjacent crossbeams are connected by a support plate, which is located below the crossbeam joint.

[0018] The crossbeam joint and the support plate are respectively connected to the inner plate of the threshold beam.

[0019] In one of the alternative technical solutions, the main body of the beam includes an interconnected bottom plate and a top plate in the shape of a "Z" shaped beam, wherein the length of the top plate is greater than the length of the bottom plate.

[0020] The support plate is connected to the bottom surface of the end of the top plate of the crossbeam, the bottom plate of the crossbeam is connected between the two support plates, and the crossbeam joint is connected to the top plate of the crossbeam and is located above the support plate.

[0021] In one of the alternative technical solutions, the thickness of the beam joint and the support plate is less than the thickness of the top plate of the beam.

[0022] In one of the alternative technical solutions, the support plate includes a support plate main board and a support plate under-flanged edge connected to one end of the support plate main board;

[0023] The end of the main body of the crossbeam is connected to the main plate of the support plate, and the lower flange of the support plate is connected to the inner plate of the sill beam.

[0024] A deformation guide is provided between the lower flange of the support plate and the main plate of the support plate to guide the deformation of the support plate.

[0025] In one of the alternative technical solutions, the deformable guide portion includes a concave guide portion and a convex guide portion;

[0026] The recessed guide portion is located on the top surface of the main board of the bracket plate and the outer side of the lower flange of the bracket plate;

[0027] The downward protruding guide portion is located on the bottom surface of the main board of the bracket plate and the inner side of the lower flange of the bracket plate;

[0028] The convex guide portion corresponds to the concave guide portion and is integrally stamped.

[0029] In one of the alternative technical solutions, the beam connector includes a Z-shaped connector main board, a connector upper flange on the top surface of the connector main board, and connector side flanges on the front and rear sides of the connector main board.

[0030] The upper flange of the joint is welded to the inner plate of the sill beam, and the side flange of the joint is connected to the inner plate of the sill beam through a connector.

[0031] In one of the alternative technical solutions, the floor assembly in the integrated electric vehicle battery includes three of the aforementioned floor crossbeams;

[0032] The middle floor beam is located in the middle of the front-to-back movable trajectory of the seat slide rail, the midpoint of the energy-absorbing aluminum box coincides with the centerline of the floor beam, and the length of the energy-absorbing aluminum box is equal to or greater than the length of the front-to-back movable trajectory of the seat slide rail.

[0033] In one of the alternative technical solutions, the battery pack frame is provided with a battery pack longitudinal beam, and the battery pack longitudinal beam has a plurality of upwardly extending longitudinal beam connecting parts, the longitudinal beam connecting parts extending out of the battery pack cover;

[0034] Each of the floor beams has a recessed section at the bottom of its middle position, and the longitudinal beam connector is at least partially connected to the recessed section.

[0035] In one of the alternative technical solutions, the longitudinal beam connection includes a main connection and a secondary connection located on one side of the main connection, wherein the main connection is higher than the secondary connection;

[0036] Along the front-to-back direction, the floor beam includes a middle section of the beam and beam edge sections located on the front and back sides of the middle section of the beam;

[0037] The receiving recess is located at the bottom of the middle part of the crossbeam, the main connecting part is correspondingly matched with the receiving recess, and the secondary connecting part is located below the edge of the crossbeam;

[0038] The middle part and the edge part of the crossbeam are respectively connected to the main connecting part and the secondary connecting part by fasteners.

[0039] In one of the alternative technical solutions, the bottom surface of the battery pack cover is provided with a mesh reinforcing patch.

[0040] In one of the alternative technical solutions, a fire-resistant buffer material layer is filled between the battery pack cover and the underlying battery cell.

[0041] The above technical solution has the following beneficial effects:

[0042] The present invention provides an integrated floor assembly for electric vehicle batteries, including a sill beam, multiple floor crossbeams and a battery pack. The battery pack frame is connected below the sill beam, and the battery pack cover is used as the floor of the vehicle body. There is no need to configure a separate floor for the vehicle body, which helps to reduce the vertical dimensions and weight of the structure.

[0043] The sill beam consists of an outer sill beam plate and an inner sill beam plate that are connected to each other. An energy-absorbing aluminum box is disposed between the outer sill beam plate and the inner sill beam plate. The energy-absorbing aluminum box is divided into multiple cavities by a reinforcing plate structure. The top plate and bottom plate of the box are wavy and gradually thin from the outside to the inside. The transverse partitions of the reinforcing plate structure are also gradually thin from the outside to the inside. The wavy structure is used to guide compression energy absorption, and the gradually thinning structure is used to ensure step-by-step compression energy absorption. The ring structure composed of the sill beam, the aluminum energy-absorbing box, and the floor beam can not only ensure the overall rigidity of the body-in-white, but also meet the energy absorption requirements in a collision, protecting the battery cell structure from intrusion during a collision. Attached Figure Description

[0044] The disclosure of this invention will become more readily understood by referring to the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings:

[0045] Figure 1 This is a perspective view of a floor assembly in an integrated electric vehicle battery according to an embodiment of the present invention, wherein... Figure 1 The outer panel of the threshold beam is omitted in the text.

[0046] Figure 2 for Figure 1 The image shown is a perspective view of the floor assembly in the integrated battery pack of an electric vehicle from another angle.

[0047] Figure 3 for Figure 1 The image shows a side view of the floor assembly in the integrated battery pack for an electric vehicle.

[0048] Figure 4 for Figure 1 The diagram shows a top view of the floor assembly in the integrated battery system of an electric vehicle.

[0049] Figure 5 for Figure 1 The image shown is a bottom view of the floor assembly in the integrated battery system of an electric vehicle.

[0050] Figure 6 A three-dimensional view of the assembled floor beams, sill beams, A-pillar inner panels, and central passage cover.

[0051] Figure 7 for Figure 6 Exploded view;

[0052] Figure 8 A magnified view of the connection between the floor beam and the inner panel of the threshold beam;

[0053] Figure 9 A three-dimensional view of the three floor beams assembled together;

[0054] Figure 10 for Figure 9 A stereoscopic image viewed from below;

[0055] Figure 11 for Figure 9 Exploded view;

[0056] Figure 12 A 3D view of the floor beams;

[0057] Figure 13 for Figure 12 The image shown is a three-dimensional view of the floor beam from a downward perspective.

[0058] Figure 14 This is a partial exploded view of the floor beam;

[0059] Figure 15 This is a cross-sectional view of the floor beam;

[0060] Figure 16 This is a schematic diagram showing the crossbeam joint before it collapses and deforms prior to a side impact.

[0061] Figure 17 This is a schematic diagram showing the collapse and deformation of the crossbeam joint during a side impact.

[0062] Figure 18 This is a 3D view of the door sill beam viewed from the outside in.

[0063] Figure 19 This is a 3D view of the door sill beam viewed from the inside out.

[0064] Figure 20 This is an exploded view of the threshold beam;

[0065] Figure 21 A three-dimensional view of the energy-absorbing aluminum box installed on the inner plate of the door sill beam;

[0066] Figure 22 for Figure 21 Side view;

[0067] Figure 23 A three-dimensional view of the energy-absorbing aluminum box from one perspective;

[0068] Figure 24 This is a three-dimensional view of the energy-absorbing aluminum box from another perspective.

[0069] Figure 25 This is a schematic diagram of the end face of the energy-absorbing aluminum box;

[0070] Figure 26 A 3D view of the battery pack;

[0071] Figure 27 A perspective view of the battery pack frame with the battery pack longitudinal beams installed.

[0072] Figure 28 A 3D view showing the connection between the floor beams and the battery pack longitudinal beams;

[0073] Figure 29 This is a cross-sectional view of the connection between the floor beams and the longitudinal beams.

[0074] Figure 30 This is a cross-sectional view of the floor assembly along the width direction in the integrated battery system of an electric vehicle.

[0075] Figure 31 This is a schematic diagram of the energy-absorbing aluminum box beginning to collapse during the initial stage of a side impact.

[0076] Figure 32 This is a schematic diagram of the energy-absorbing aluminum box collapsing during a side impact, either in the middle or at the end.

[0077] Figure 33 A cross-sectional view showing cooling water channels within the battery pack frame;

[0078] Figure 34 A schematic diagram showing a mesh reinforcement patch on the bottom surface of the battery pack cover. Detailed Implementation

[0079] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. Identical components are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0080] like Figure 1-7 and Figure 18-32 As shown, an embodiment of the present invention provides a floor assembly for an integrated electric vehicle battery, including a sill beam 1, multiple floor crossbeams 2 connected to the sill beam 1, and a battery pack 3 connected to the sill beam 1.

[0081] The battery pack frame 31 of the battery pack 3 is connected to the sill beam 1, the end of the floor beam 2 is connected to the sill beam 1, the middle part of the floor beam 2 is connected to the battery pack 3 and is located above the battery pack cover 32, which serves as the floor of the vehicle body.

[0082] The threshold beam 1 includes an outer threshold beam 11 and an inner threshold beam 12 that are connected to each other. A longitudinally extending energy-absorbing aluminum box 4 is connected between the outer threshold beam 11 and the inner threshold beam 12.

[0083] The energy-absorbing aluminum box 4 includes a box body 41 and a reinforcing plate structure 42 disposed in the box body 41 and divided into multiple cavities 43. The reinforcing plate structure 42 includes at least two vertical partitions 421 and at least two horizontal partitions 422 that are cross-connected.

[0084] The outer panel 413 of the box body 41 is connected to the outer panel 11 of the threshold beam, and the inner panel 414 of the box body 41 is connected to the inner panel 12 of the threshold beam.

[0085] Along the direction from the outside to the inside, the top plate 412 and the bottom plate 411 of the box body 41 are respectively wavy, and the top plate 412, the bottom plate 411 and the transverse partition 422 are respectively thinned in segments according to the cavity 43.

[0086] In this invention, the direction along the front and rear of the vehicle is referred to as longitudinal, the direction along the left and right of the vehicle is referred to as transverse, and the direction along the up and down of the vehicle is referred to as vertical.

[0087] The electric vehicle battery integrated floor assembly provided by this invention is a vehicle floor assembly integrating a battery pack, which includes a sill beam 1, a floor crossbeam 2, a battery pack 3, and an energy-absorbing aluminum box 4. Specifically, it includes two longitudinally extending sill beams 1, multiple laterally extending floor crossbeams 2, a battery pack 3, and two energy-absorbing aluminum boxes 4, with one energy-absorbing aluminum box 4 in each sill beam 1.

[0088] The front end of the threshold beam 1 is connected to the inner plate of the A-pillar 5, and the central passage cover plate 6 is connected to multiple floor beams 2 and extends forward.

[0089] The sill beam 1 includes an outer sill beam plate 11 and an inner sill beam plate 12, which are connected to each other, specifically by welding and / or riveting and / or pin connection. The outer sill beam plate 11 and the inner sill beam plate 12 each have a U-shaped portion, thereby forming a cavity for installing the energy-absorbing aluminum box 4.

[0090] The two ends of the floor beam 2 are connected to the threshold beam 1 respectively. The front and rear positions can be set as needed, and the number can also be set as needed.

[0091] The battery pack 3 includes a battery pack frame 31 and a battery pack cover 32 connected to the top of the battery pack frame 31. The battery cells are located below the battery pack cover 32. The battery pack cover 32 serves as the floor of the vehicle body, eliminating the need for a separate floor. The left and right edges of the battery pack frame 31 are connected to the sill beams 1, respectively, thus mounting the battery pack 3 between the two sill beams 1. The battery pack bottom plate may slightly protrude below the sill beams 1. Preferably, the thickness of the battery pack 3 is less than the height of the sill beams 1, and the battery pack bottom plate will not protrude downwards from the sill beams 1.

[0092] The floor beam 2 is connected to the battery pack 3 at its middle position, achieving three-point fixation at both ends and the middle position. The floor beam 2 is located above the battery pack cover 32, which serves as the floor of the vehicle body, eliminating the need for a separate floor in the vehicle body, thus reducing the vertical dimensions and weight of the structure.

[0093] An energy-absorbing aluminum box 4 is disposed between the outer panel 11 and the inner panel 12 of the sill beam. The box body 41 of the energy-absorbing aluminum box 4 includes a bottom panel 411, a top panel 412, an outer panel 413, and an inner panel 414 connected in a frame structure. The outer panel 413 is welded to the outer panel 11 of the sill beam or connected by fasteners (e.g., bolts, rivets, etc.), and the inner panel 414 is welded to the inner panel 12 of the sill beam or connected by fasteners (e.g., bolts, rivets, etc.). Preferably, the length of the inner panel 414 is greater than the lengths of the bottom panel 411, the top panel 412, and the outer panel 413. Ear plates extend from both the front and rear ends of the inner panel 414, and ear plates are provided with through holes for connection to the inner panel 12 of the sill beam via fasteners. One ear plate through hole is circular, and the other is oblong, for position adjustment. The outer panel 413 of the box has two spaced-apart connecting holes for connecting to the outer panel 11 of the sill beam via fasteners. One connecting hole is circular, and the other is oblong to allow for position adjustment.

[0094] The box body 41 is integrally equipped with a reinforcing plate structure 42, which divides the space of the box body 41 into multiple cavities 43. The cross-section of the energy-absorbing aluminum box 4 can be a nine-square grid structure, or it can be configured with more cavities 43. The energy-absorbing aluminum box 4 is a casting, which is integrally cast.

[0095] The reinforcing plate structure 42 includes at least two vertical partitions 421 and at least two horizontal partitions 422 that are cross-connected / vertically. The lower end of the vertical partition 421 is connected to the bottom plate 411 of the box, and its upper end is connected to the top plate 412 of the box. The outer end of the horizontal partition 422 is connected to the outer plate 413 of the box, and its inner end is connected to the inner plate 414 of the box. The box 41 is divided into multiple rows and columns of cavities 43 by the vertical partitions 421 and the horizontal partitions 422.

[0096] The bottom plate 411 and top plate 412 of the box are respectively wavy, with the waves extending laterally. The wavy structure is designed to guide the bottom plate 411 and top plate 412 of the box to crush during a side impact, so as to guide the energy-absorbing aluminum box 4 to compress and absorb energy.

[0097] Along the direction from the outside to the inside, the bottom plate 411, top plate 412, and transverse partition 422 are progressively thinner in segments, specifically according to the segments of the cavities 43. That is, each segment of the bottom plate 411, top plate 412, and transverse partition 422 has a thickness less than the previous segment. This progressively thinning design of the bottom plate 411, top plate 412, and transverse partition 422 ensures that the energy-absorbing aluminum box 4 is compressed and absorbs energy in stages during a side impact. This ensures the rigidity requirements of the initial impact stage and meets the energy absorption requirements of the later stages of the impact, thus better protecting the inner battery pack 3.

[0098] The ring structure composed of door sill beam 1, aluminum energy absorption box 4, and floor crossbeam 2 can ensure the overall rigidity of the body-in-white, meet the energy absorption requirements in a collision, and protect the internal cell structure of the battery pack 3 from intrusion during a collision.

[0099] In one embodiment, the box bottom plate 411, box top plate 412, and transverse partition 422 are divided into three segments from the outside in along the cavity 43, and are named sequentially from the outside in as the first segment, second segment, and third segment, for example, bottom plate first segment, bottom plate second segment, and bottom plate third segment. The box top plate 412 and transverse partition 422 adopt a similar naming method. The thickness difference between the first segment and the second segment is smaller than the thickness difference between the third segment and the second segment. With this arrangement, the thickness difference between the first two segments is small, and the thickness difference between the last two segments is large. In the front or middle section of a side impact, the stiffness of the energy-absorbing aluminum box 4 is relatively large, and the deformation is relatively small, thereby improving the impact resistance. In the rear or end section of a side impact, the stiffness of the energy-absorbing aluminum box 4 is relatively small, and the deformation is relatively large, thereby improving the energy absorption capacity.

[0100] In one embodiment, the cross-section of the energy-absorbing aluminum box 4 is a nine-square grid structure. The box bottom plate 411, the box top plate 412, and the horizontal partition 422 are divided into three sections from the outside to the inside. The thickness of the box bottom plate 411, the box top plate 412, and the horizontal partition 422 is equal in each section, and the thicknesses from the outside to the inside are 4mm, 3.8mm, and 3.2mm, respectively.

[0101] In one embodiment, such as Figure 24-25 As shown, the top plate 412 and the bottom plate 411 of the box are arranged symmetrically. The upper end of each vertical partition 421 is connected to a trough 4121 of the top plate 412, and the lower end of each vertical partition 421 is connected to a crest 4111 of the bottom plate 411.

[0102] In this embodiment, the top plate 412 and the bottom plate 411 of the box are arranged symmetrically vertically. The troughs 4121 of the top plate 412 and the crests 4111 of the bottom plate 411 are arranged opposite each other. A vertical partition 421 connects the troughs 4121 and the crests 4111. The height of the vertical partition 421 is relatively short and will not affect the upward bending deformation of the crests of the top plate 412 or the downward bending deformation of the troughs of the bottom plate 411.

[0103] In one embodiment, such as Figure 24-25 As shown, the upper end of the outer panel 413 of the box is connected to the outermost trough 4121 on the top panel 412 of the box, and the lower end of the outer panel 413 of the box is connected to the outermost crest 4111 on the bottom panel 411 of the box.

[0104] The upper end of the inner plate 414 is connected to the innermost trough 4121 on the top plate 412 of the box, and the lower end of the inner plate 414 is connected to the innermost crest 4111 on the bottom plate 411 of the box.

[0105] In this embodiment, the outer panel 413, the inner panel 414, and the vertical partition 421 are arranged in the same way. When there is a side impact, the outer panel 413 crushes the top panel 412 and the bottom panel 411 of the box from the outer end of the waveform, which is conducive to the top panel 412 and the bottom panel 411 of the box collapsing and deforming along the waveform.

[0106] In one embodiment, such as Figure 24-25 As shown, the outer panel 413 and the inner panel 414 of the box have the same thickness, and the thickness of the vertical partition 421 is less than the thickness of the outer panel 413.

[0107] In this embodiment, the outer panel 413 and the inner panel 414 of the box are relatively thick and of equal thickness, which can meet the installation stability requirements of the outer panel 413 and the inner panel 414, as well as the side impact requirements of the outer panel 413. The thickness of the vertical partition 421 is less than the thickness of the outer panel 413. Under the premise of meeting the vertical support requirements, its lateral bending resistance is weakened as much as possible to reduce the deformation impact on the energy-absorbing aluminum box 4.

[0108] In one embodiment, the outer panel 413 and the inner panel 414 of the box are both 4mm thick, and the vertical partition 421 is 3mm thick.

[0109] In one embodiment, such as Figure 21 As shown, a preset gap is left between the bottom plate 411 of the box and the bottom plate of the threshold beam 1 to allow the electrophoretic paint to flow into the space and meet the electrophoresis requirements.

[0110] In one embodiment, the wave-shaped structure of the box bottom plate 411 and the box top plate 412 respectively includes multiple semi-circular arcs. The two ends of the semi-circular arcs are arranged roughly vertically so as to connect with the vertical partition 421. The lateral support force at the two ends of the semi-circular arcs is relatively small, so as to facilitate the compression and collapse of the wave-shaped structure of the box bottom plate 411 and the box top plate 412.

[0111] In one embodiment, the distance between the outer panel 413 and the inner panel 414 of the box is approximately 90 mm, the lateral dimension of each cavity 43 is approximately 30 mm, the distance between the crest 4111 and the trough 4121 is approximately 45 mm, and the radius of the semicircular arc is approximately 15 mm.

[0112] In one embodiment, such as Figure 8-17 As shown, the floor beam 2 includes a beam body 21 and beam joints 22 located at both ends of the beam body 21.

[0113] The two ends of any two adjacent crossbeam bodies 21 are connected by a support plate 23, which is located below the crossbeam joint 22.

[0114] The crossbeam joint 22 and the support plate 23 are respectively connected to the inner plate 12 of the threshold beam.

[0115] In this embodiment, the bottom ends of multiple floor beams 2 are connected together by a support plate 23. Each floor beam 2 includes a beam body 21 with a cavity, and beam connectors 22 are connected to both ends of the beam body 21.

[0116] Both ends of each crossbeam body 21 are connected to the support plate 23. Specifically, the support plate 23 is connected to the bottom of the crossbeam body 21, and the crossbeam joint 22 is located above the support plate 23.

[0117] The crossbeam joint 22 and the support plate 23 are respectively connected to the inner plate 12 of the threshold beam.

[0118] The beam joint 22 and the support plate 23 are separate structures. Compared with the integrated structure, the separate beam joint 22 and the support plate 23 are more easily deformed and less likely to break. In the event of a side impact, the beam joint 22 and the support plate 23 collapse and deform to absorb energy, while maintaining their connection with the inner plate 12 of the sill beam.

[0119] The joint strength and flexibility (toughness) of the beam joint 22 can be calculated using existing formulas.

[0120] In one embodiment, the structural strength (stiffness) of the crossbeam joint 22 is greater than that of the support plate 23, so that in the event of a side impact, the support plate 23 deforms first or deforms more severely than the crossbeam joint 22, guiding the inner plate 12 of the sill beam to bend downwards (e.g., Figure 17(As shown), to avoid intrusion into the vehicle cabin.

[0121] The structural strength (rigidity) of the beam joint 22 and the bracket plate 23 can be set by selecting materials, sheet metal thickness, structural layout, connection and fixing aspects.

[0122] In one embodiment, such as Figure 12-14 As shown, the main body 21 of the crossbeam includes a bottom plate 212 and a top plate 211 of the crossbeam that are connected to each other. The length of the top plate 211 is greater than the length of the bottom plate 212.

[0123] The support plate 23 is connected to the bottom surface of the end of the top plate 211 of the crossbeam, the bottom plate 212 of the crossbeam is connected between the two support plates 23, and the crossbeam joint 22 is connected to the top plate 211 of the crossbeam and is located above the support plate 23.

[0124] In this embodiment, the top plate 211 of the beam is shaped like a "Z" and the bottom plate 212 of the beam is roughly flat, thus forming a cavity between the top plate 211 and the bottom plate 212 of the beam. This reduces the structural weight while still meeting structural strength requirements. The two ends of the top plate 211 extend beyond the two ends of the bottom plate 212 of the beam.

[0125] The beam joint 22 is connected to the end of the beam top plate 211. Specifically, the beam joint 22 wraps around the beam top plate 211 and extends partially out of the beam top plate 211 so as to connect with the inner plate 12 of the sill beam.

[0126] The support plate 23 is connected to the bottom surface of the top plate 211 of the crossbeam. The support plate 23 is located outside the bottom plate 212 of the crossbeam, and part of the support plate 23 extends out of the top plate 211 of the crossbeam so as to connect with the inner plate 12 of the sill beam.

[0127] The bottom surface of the support plate 23 is flush with the bottom plate 212 of the crossbeam, which helps to maintain the flatness of the bottom surface of the floor crossbeam 2.

[0128] The beam joint 22 and the support plate 23 can be connected by riveting, pressing, welding or pins, respectively.

[0129] In one embodiment, the thickness of the beam joint 22 and the support plate 23 is less than the thickness of the beam top plate 211. During a side impact and collapse, the beam joint 22 and the support plate 23 bend relative to the beam top plate 211, minimizing the collapse of the beam top plate 211. During maintenance, the beam joint 22 and the support plate 23 are replaced, and the beam top plate 211 is repaired.

[0130] In one embodiment, such as Figure 8-11 As shown, the support plate 23 includes a support plate main board 231 and a support plate under-flanged edge 232 connected to one end of the support plate main board 231.

[0131] The end of the main body 21 of the crossbeam is connected to the main body 231 of the support plate, and the lower flange 232 of the support plate is connected to the inner plate 12 of the sill beam.

[0132] A deformation guide is provided between the lower flange 232 of the support plate and the main plate 231 of the support plate to guide the deformation of the support plate 23.

[0133] In this embodiment, the support plate 23 includes a support plate main board 231 and a support plate lower flange 232, which is integrally connected to the end of the support plate main board 231 facing the sill beam 1.

[0134] The main board 231 of the support plate is connected to the bottom of one end of the main body 21 of the crossbeam. Specifically, the main board 231 of the support plate is connected to the bottom surface of one end of the top plate 211 of the crossbeam.

[0135] The inner plate 12 of the threshold beam is provided with a step section, which includes a step section elevation 121 and a step section plane 122. The underside flange 232 of the support plate is attached to and connected to the step section elevation 121, which can be done by welding, riveting or pin connection.

[0136] A deformation guide is provided at the connection between the lower flange 232 of the support plate and the main plate 231 of the support plate, which is used to guide the support plate 23 to deform and bend downward. The deformation guide can be a groove, a notch, a fold line, etc.

[0137] In one embodiment, such as Figure 8-11 As shown, the deformable guide portion includes a concave guide portion 233 and a convex guide portion 234.

[0138] The recessed guide portion 233 is located on the top surface of the main board 231 of the bracket plate and the outer side of the lower flange 232 of the bracket plate.

[0139] The downward protruding guide portion 234 is located on the bottom surface of the main board 231 of the bracket plate and the inner side of the lower flange 232 of the bracket plate.

[0140] The convex guide portion 234 corresponds to the concave guide portion 233 and is integrally stamped.

[0141] In this embodiment, the deformable guide portion includes a recessed guide portion 233 and a convex guide portion 234 corresponding to the recessed guide portion 233. The convex guide portion 234 is naturally formed during the molding of the recessed guide portion 233.

[0142] The recessed guide portion 233 has a groove, pit or other structure, part of which is located on the top surface of the main board 231 of the support plate, and the other part is located on the outer side of the lower flange 232 of the support plate.

[0143] The convex guide portion 234 is a convex rib or convex portion formed when the concave guide portion 233 is formed. Part of it is located on the bottom surface of the main board 231 of the support plate, and the other part is located on the inner side of the lower flange 232 of the support plate.

[0144] When the threshold beam 1 collapses, the lower flange 232 of the support plate is first subjected to force and is guided downward bending and deformation by the concave guide part 233 and the convex guide part 234.

[0145] In one embodiment, such as Figure 8 and Figure 14 As shown, the crossbeam connector 22 includes a U-shaped connector main board 221, a connector upper flange 222 on the top surface of the connector main board 221, and connector side flanges 223 on the front and rear sides of the connector main board 221.

[0146] The upper flange 222 of the joint is welded to the inner plate 12 of the sill beam, and the side flange 223 of the joint is connected to the inner plate 12 of the sill beam through a connector.

[0147] In this embodiment, the crossbeam connector 22 includes a connector main board 221, a connector upper flange 222, and a connector side flange 223.

[0148] The connector main plate 221 is shaped like a "Z" so that it can be wrapped around the end of the "Z" shaped top plate 211 of the crossbeam. The flange 222 of the connector is integrally connected to the top of the end of the connector main plate 221 facing the sill beam 1 and extends outward, and is welded to the stepped plane 122 of the inner plate 12 of the sill beam.

[0149] The main connector 221 has integrally formed connector side flanges 223 on both the front and rear sides of the end facing the sill beam 1. These flanges are connected to the stepped surface 121 of the inner plate 12 of the sill beam via connectors, such as bolts or pins. The connector side flanges 223 and the connector upper flanges 222 use different connection methods. In the event of a collision, if one connection method fails, the other connection method may remain effective, effectively preventing both flanges from failing simultaneously.

[0150] The triangular configuration of the two side flanges 223 and one top flange 222 of the connector also improves the connection stability between the crossbeam connector 22 and the inner plate 12 of the sill beam.

[0151] In one embodiment, such as Figure 9 and Figure 11 As shown, the main body 21 of the crossbeam is provided with several fixing covers 24, and the fixing covers 24 are provided with welding nuts to provide connection points for the bolts above. For example, the fixing bolts of the seat guide rail can be connected to the fixing covers 24.

[0152] In one embodiment, the floor assembly in the integrated electric vehicle battery includes three floor crossbeams 2.

[0153] The middle floor beam 2 is located in the middle of the front and rear movable trajectory of the seat slide rail. The midpoint of the energy-absorbing aluminum box 4 coincides with the center line of the floor beam 2, and the length of the energy-absorbing aluminum box 4 is equal to or greater than the length of the front and rear movable trajectory of the seat slide rail, so as to ensure that the energy-absorbing aluminum box 4 can cover the driver's front and rear movement range and provide better protection.

[0154] Assuming the length of the forward and backward movable trajectory of the seat slide rail is d, the length of the energy-absorbing aluminum box 4 is preferably d+200mm, so as to provide maximum protection without adding extra weight.

[0155] In one embodiment, such as Figure 26-29 As shown, the battery pack frame 31 is provided with a battery pack longitudinal beam 33, and the battery pack longitudinal beam 33 has a plurality of longitudinal beam connecting parts 34 extending upward, the longitudinal beam connecting parts 34 extending out of the battery pack cover 32.

[0156] Each floor beam 2 has a receiving recess 213 at the bottom of its middle position, and the longitudinal beam connection 34 is at least partially connected in the receiving recess 213.

[0157] In this embodiment, the middle position of the floor beam 2 is fixed to the battery pack longitudinal beam 33, making the connection more stable.

[0158] Specifically, the battery pack longitudinal beam 33 is located in the middle of the width direction in the battery pack frame 31, and its top is provided with several longitudinal beam connecting parts 34, such as bosses, connecting posts, etc. The battery pack cover 32 has a cover through hole corresponding to the position of the longitudinal beam connecting parts 34, for the longitudinal beam connecting parts 34 to pass through upward.

[0159] A receiving recess 213 is provided at the bottom of the middle position of the floor beam 2. Specifically, the receiving recess 213 is located at the middle position of the bottom plate 212 of the beam. The receiving recess 213 is used to receive at least a portion of the longitudinal beam connecting part 34.

[0160] The longitudinal beam connecting part 34 is connected to the floor beam 2 by fasteners 343. The longitudinal beam connecting part 34 may be provided with nuts or internal threaded holes, and the fasteners 343 are bolts, which are connected to the nuts or internal threaded holes for fixing.

[0161] In one embodiment, such as Figure 26-29 As shown, the longitudinal beam connection portion 34 includes a main connection portion 341 and a secondary connection portion 342 located on one side of the main connection portion 341, with the main connection portion 341 being higher than the secondary connection portion 342.

[0162] Along the front-to-back direction, the floor beam 2 includes a beam middle portion 214 and beam edge portions 215 located on the front and back sides of the beam middle portion 214.

[0163] The receiving recess 213 is provided at the bottom of the middle part 214 of the crossbeam, the main connecting part 341 is correspondingly matched with the receiving recess 213, and the secondary connecting part 342 is located below the edge part 215 of the crossbeam.

[0164] The middle part 214 and the edge part 215 of the crossbeam are respectively connected to the main connecting part 341 and the secondary connecting part 342 by fasteners 343.

[0165] In this embodiment, the floor beam 2 is divided into a middle section 214 and two side edge sections 215 along the front-to-back or longitudinal direction. The middle section 214 is approximately flush with the middle portion of the U-shaped top plate 211, and the side edge sections 215 are approximately flush with the edge portions of the U-shaped top plate 211. A receiving recess 213 is provided at the bottom of the middle section 214.

[0166] The longitudinal beam connection 34 is divided into a main connection 341 and a secondary connection 342. The secondary connection 342 is located on one side of the main connection 341 and is lower than the main connection 341. Nuts or internal threaded holes are respectively provided on the main connection 341 and the secondary connection 342.

[0167] The main connecting portion 341 corresponds to and mates with the receiving recess 213, and is at least partially located within the receiving recess 213. The secondary connecting portion 342 is located below the edge portion 215 of the crossbeam.

[0168] The middle part 214 of the crossbeam is connected to the main connecting part 341 by fasteners 343 (bolts), and the edge part 215 of the crossbeam on one side is connected to the secondary connecting part 342 by fasteners 343 (bolts). The floor crossbeam 2 and the longitudinal beam connecting part 34 are fixed at two points, making the connection structure more stable.

[0169] In one embodiment, such as Figure 34 As shown, a mesh reinforcing patch 35 is provided on the bottom surface of the battery pack cover 32 to improve structural rigidity. The mesh reinforcing patch 35 is adhered to the bottom surface of the battery pack cover 32. The mesh reinforcing patch 35 can be made of epoxy resin and fiberglass.

[0170] In one embodiment, a fire-retardant buffer material layer is filled between the battery pack cover 32 and the underlying battery cell. This layer serves both fire-retardant and buffering purposes, absorbing the energy from the deformation of the battery pack cover 32 during a collision and protecting the battery cell. The fire-retardant buffer material layer can be made of materials such as melamine foam.

[0171] As needed, the above technical solutions can be combined to achieve the best technical effect.

[0172] The above are merely the principles and preferred embodiments of the present invention. It should be noted that, for those skilled in the art, several other modifications can be made based on the principles of the present invention, and these modifications should also be considered within the scope of protection of the present invention.

Claims

1. A floor assembly for integrated electric vehicle battery, characterized in that, It includes a sill beam (1), multiple floor beams (2) connected to the sill beam (1), and a battery pack (3) connected to the sill beam (1). The battery pack frame (31) of the battery pack (3) is connected to the sill beam (1), the end of the floor beam (2) is connected to the sill beam (1), the middle part of the floor beam (2) is connected to the battery pack (3) and is located above the battery pack cover (32), and the battery pack cover (32) is used as the floor in the vehicle body; The threshold beam (1) includes an outer threshold beam plate (11) and an inner threshold beam plate (12) that are connected to each other. A longitudinally extending energy-absorbing aluminum box (4) is connected between the outer threshold beam plate (11) and the inner threshold beam plate (12). The energy-absorbing aluminum box (4) includes a box body (41) and a reinforcing plate structure (42) disposed in the box body (41) and divided into multiple cavities (43). The reinforcing plate structure (42) includes at least two vertical partitions (421) and at least two horizontal partitions (422) that are cross-connected. The outer panel (413) of the box body (41) is connected to the outer panel (11) of the threshold beam, and the inner panel (414) of the box body (41) is connected to the inner panel (12) of the threshold beam. Along the direction from the outside to the inside, the top plate (412) and bottom plate (411) of the box body (41) are respectively wavy, and the top plate (412), the bottom plate (411) and the transverse partition (422) are respectively thinned in segments according to the cavity (43); The battery pack frame (31) is provided with battery pack longitudinal beams (33), and the battery pack longitudinal beams (33) have multiple longitudinal beam connecting parts (34) extending upward, the longitudinal beam connecting parts (34) extending out of the battery pack cover (32); each floor beam (2) has a receiving recess (213) at the bottom of the middle position, and the longitudinal beam connecting parts (34) are at least partially connected in the receiving recess (213); The longitudinal beam connecting part (34) includes a main connecting part (341) and a secondary connecting part (342) located on one side of the main connecting part (341), wherein the main connecting part (341) is higher than the secondary connecting part (342); along the front-rear direction, the floor beam (2) includes a beam middle part (214) and beam edge parts (215) located on the front and rear sides of the beam middle part (214); the receiving recess (213) is provided at the bottom of the beam middle part (214), the main connecting part (341) and the receiving recess (213) are correspondingly engaged, and the secondary connecting part (342) is located below the beam edge part (215); the beam middle part (214) and the beam edge part (215) are respectively connected to the main connecting part (341) and the secondary connecting part (342) by fasteners (343).

2. The floor assembly in the integrated battery system for electric vehicles according to claim 1, characterized in that, The top plate (412) and the bottom plate (411) of the box are arranged symmetrically in the upper and lower parts; The upper end of each of the vertical partitions (421) is connected to a trough (4121) of the top plate (412) of the box body, and the lower end of each of the vertical partitions (421) is connected to a crest (4111) of the bottom plate (411) of the box body.

3. The floor assembly in the integrated electric vehicle battery system according to claim 2, characterized in that, The upper end of the outer panel (413) of the box is connected to the outermost trough (4121) on the top plate (412) of the box, and the lower end of the outer panel (413) of the box is connected to the outermost crest (4111) on the bottom plate (411) of the box. The upper end of the inner plate (414) of the box is connected to the innermost trough (4121) on the top plate (412) of the box, and the lower end of the inner plate (414) of the box is connected to the innermost crest (4111) on the bottom plate (411) of the box.

4. The floor assembly in the integrated battery system for electric vehicles according to claim 1, characterized in that, The outer panel (413) of the box is equal in thickness to the inner panel (414) of the box, and the thickness of the vertical partition (421) is less than the thickness of the outer panel (413) of the box.

5. The floor assembly in the integrated battery system for electric vehicles according to claim 1, characterized in that, A preset gap is left between the bottom plate of the box body (411) and the bottom plate of the threshold beam (1).

6. The floor assembly in the integrated battery system for electric vehicles according to claim 1, characterized in that, The floor beam (2) includes a beam body (21) and beam joints (22) located at both ends of the beam body (21). The two ends of any two adjacent main beams (21) are connected by a support plate (23), which is located below the beam joint (22); The crossbeam joint (22) and the bracket plate (23) are respectively connected to the inner plate (12) of the threshold beam.

7. The floor assembly in the integrated battery system for electric vehicles according to claim 6, characterized in that, The main body of the crossbeam (21) includes a bottom plate (212) and a top plate (211) of the crossbeam connected to each other. The length of the top plate (211) is greater than the length of the bottom plate (212). The support plate (23) is connected to the bottom surface of the end of the top plate (211) of the crossbeam, the bottom plate (212) of the crossbeam is connected between the two support plates (23), and the crossbeam joint (22) is connected to the top plate (211) of the crossbeam and is located above the support plate (23).

8. The floor assembly in the integrated battery system for electric vehicles according to claim 7, characterized in that, The thickness of the plate of the beam joint (22) and the support plate (23) is less than the thickness of the plate of the beam top plate (211).

9. The floor assembly in the integrated battery system for electric vehicles according to claim 6, characterized in that, The support plate (23) includes a support plate main board (231) and a support plate under-flanged edge (232) connected to one end of the support plate main board (231). The end of the main body (21) of the crossbeam is connected to the main body (231) of the bracket plate, and the lower flange (232) of the bracket plate is connected to the inner plate (12) of the threshold beam. A deformation guide is provided between the lower flange (232) of the support plate and the main plate (231) of the support plate for guiding the deformation of the support plate (23).

10. The floor assembly in the integrated battery system for electric vehicles according to claim 9, characterized in that, The deformable guide portion includes a concave guide portion (233) and a convex guide portion (234). The recessed guide portion (233) is located on the top surface of the main board of the support plate (231) and the outer side of the lower flange (232) of the support plate; The convex guide portion (234) is located on the bottom surface of the main board of the support plate (231) and the inner side surface of the lower flange (232) of the support plate; The convex guide portion (234) corresponds to the concave guide portion (233) and is integrally stamped.

11. The floor assembly in the integrated battery system for electric vehicles according to claim 6, characterized in that, The crossbeam connector (22) includes a zig-shaped connector main board (221), a connector upper flange (222) on the top surface of the connector main board (221), and connector side flanges (223) on the front and rear sides of the connector main board (221). The upper flange (222) of the joint is welded to the inner plate (12) of the sill beam, and the side flange (223) of the joint is connected to the inner plate (12) of the sill beam through a connector.

12. The floor assembly in the integrated battery system for electric vehicles according to claim 1, characterized in that, Includes the three floor beams (2); The floor beam (2) in the middle is located in the middle of the front and rear movable trajectory of the seat slide rail. The midpoint of the energy-absorbing aluminum box (4) coincides with the center line of the floor beam (2), and the length of the energy-absorbing aluminum box (4) is equal to or greater than the length of the front and rear movable trajectory of the seat slide rail.

13. The floor assembly in the integrated battery system for electric vehicles according to claim 1, characterized in that, The bottom surface of the battery pack cover (32) is provided with a mesh reinforcing patch (35).

14. The floor assembly in the integrated battery system for electric vehicles according to claim 1, characterized in that, A fire-resistant buffer material layer is filled between the battery pack cover (32) and the battery cell below.

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