A flat front floor body structure and installation method for electric vehicles

Abstract

This invention discloses a flat front floor structure and installation method for an electric vehicle, including a front floor and a flat battery pack structure. The front floor is entirely flat, with sills on both sides. A front seat crossbeam and a rear seat crossbeam are positioned between the two sills, perpendicular to and penetrating the sills. A left and right cover plate are located at the front of the front seat crossbeam. Multiple nuts are welded onto the front floor to secure the flat battery pack structure. This invention extends the front and rear seat crossbeams to the left and right sills, and, in conjunction with the internal aluminum profile frame structure of the flat battery pack and the extruded aluminum profiles on both sides of the sills, the seat crossbeams can form an organic whole with the aluminum profiles of the sills and the crisscrossing frame inside the pack, perfectly solving the safety problems currently faced by electric vehicles, such as side collisions, pole collisions, front collisions, and roof crushes.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle component technology, specifically to a flat front floor body structure and installation method for an electric vehicle. Background Technology

[0002] Electric vehicles, as a type of new energy vehicle, have the advantages of energy conservation and environmental protection, and are increasingly becoming a research hotspot in the automotive field. Currently, a common challenge in the electric vehicle sector is the limited driving range of electric vehicle batteries, which restricts their widespread adoption.

[0003] Before gasoline-powered vehicles are completely phased out, major automakers will continue to use the gasoline-powered vehicle architecture as the underlying design framework, making minor modifications and adjustments. This reduces the development costs, time, and verification testing of entirely new platforms. In traditional front-floor structures, such as Figure 1 As shown, the central channel structure is still generally present, which facilitates the arrangement of the battery pack control system, such as BMS, BDU, charging base, water interface, etc.

[0004] The aforementioned front floor structure is prone to compression deformation in the central tunnel during whole-vehicle pole impact tests, affecting C-NCAP and E-NCAP crash scores. The solution is to add a Z-shaped beam inside the central tunnel for reinforcement, but this increases cost and weight, and the improvement effect is not significant, which can easily have a negative impact on automakers. On the other hand, the subframe mounting point of traditional fuel vehicle platforms is relatively far back, which inevitably affects the X-axis layout space of the battery pack, thereby affecting the X-axis dimensions of the battery pack and the amount of energy stored, which has a significant impact on the vehicle's range, causing range anxiety and significant user complaints. Summary of the Invention

[0005] To address the problems existing in the prior art, this invention provides a flat front floor body structure and mounting structure for electric vehicles, which can solve the safety problems currently faced by electric vehicles, such as side collisions, pole collisions, front collisions, and roof crushes. At the same time, by freeing up the space of the subframe mounting point, the X-axis space of the battery pack is maximized, thereby improving the utilization rate of the vehicle body space of the flat battery pack.

[0006] The technical solution of the present invention is as follows:

[0007] In a first aspect of the invention, a flat front floor body structure for an electric vehicle is provided, comprising a front floor and a flat battery pack structure; the front floor is entirely flat, with sills on the left and right sides, and a front seat crossbeam and a rear seat crossbeam between the two sills, the front seat crossbeam and the rear seat crossbeam being perpendicular to the sills and passing through the sills; wherein the front seat crossbeam is a stamped structure, the rear seat crossbeam is a high-strength steel profile, and a left cover body and a right cover body are provided at the front of the front seat crossbeam; multiple nuts are protruded and welded onto the front floor to fix the flat battery pack structure.

[0008] In some embodiments of the present invention, the plurality of nuts are distributed between the front and rear crossbeams of the seat, inside the side door sills, and at the front end of the vehicle body floor.

[0009] In some embodiments of the present invention, aluminum profiles are installed inside the sills on the left and right sides of the front floor of the vehicle body, and the aluminum profiles are fixed to the inner panel body of the sill.

[0010] In some embodiments of the present invention, the flat battery pack structure includes a battery pack frame and a battery pack body disposed on the battery pack frame. A front fixing structure is provided at the front of the battery pack frame, and the front fixing structure connects the front end of the flat battery pack structure to the front floor of the vehicle body.

[0011] In some embodiments of the present invention, side fixing brackets are respectively provided on the left and right sides of the battery pack frame, the side fixing brackets are fixedly connected to the door sills on the left and right sides of the front floor of the vehicle body, and the side fixing brackets and the battery pack frame are an integral structure.

[0012] In some embodiments of the present invention, a crossbeam is provided at the middle position of the battery pack frame, and the crossbeam is fixedly installed on the middle nut of the front floor of the vehicle body by a middle fixing bolt.

[0013] In some embodiments of the present invention, a U-shaped structure is provided at the front end of the front floor of the vehicle body, and the space formed by the U-shaped structure is used for installing a subframe.

[0014] In some embodiments of the present invention, a subframe rear mounting seat is provided inside the U-shaped structure, and the subframe rear mounting seat is separated from the battery pack front mounting point by a certain distance.

[0015] In some embodiments of the present invention, the bottom of the front floor of the vehicle body is provided with multiple local reinforcing rib structures.

[0016] In a second aspect of the present invention, a method for installing a flat front floor body structure of an electric vehicle is provided, comprising the following steps:

[0017] Step 1: Place the flat battery pack structure on the front floor of the vehicle and align the bolts on the crossbeam of the battery pack frame of the flat battery pack structure with the nuts in the middle position of the front floor of the vehicle. Tighten the nuts to fix the middle position of the flat battery pack structure to the front floor of the vehicle.

[0018] Step 2: Secure the front part of the battery pack frame of the flat battery structure to the nuts on the front floor of the vehicle body using bolts.

[0019] Step 3: Secure the battery pack frame brackets on both sides of the flat battery structure to the left and right door sills on the front floor of the vehicle using bolts to complete the installation of the flat battery pack structure to the front floor of the vehicle.

[0020] Step 4: Connect the subframe to the subframe rear mounting bracket on the front floor of the vehicle body using bolts to complete the installation of the flat front floor vehicle body structure.

[0021] One or more technical solutions of the present invention have the following beneficial effects:

[0022] (1) The electric vehicle body structure with a flat front floor provided by the present invention extends the front and rear seat beams through to the left and right door sills. Combined with the aluminum profile frame structure inside the flat battery pack and the extruded aluminum profiles added to both sides of the door sills, the seat beams can form an organic whole with the aluminum profiles of the door sills on both sides and the crisscrossing frame inside the pack. This perfectly solves the safety problems faced by electric vehicles such as side collisions, pole collisions, front collisions, and top pressure, and puts safety performance first in electric vehicles.

[0023] (2) In view of the fact that the subframe and front suspension structure of the traditional oil-to-electric platform are limited by the platform hard points, it is impossible to obtain the required large-capacity battery pack, resulting in insufficient driving range and user range anxiety. This invention adjusts the subframe rear mounting point by flattening the front floor, freeing up the space of the traditional vehicle subframe mounting point, maximizing the X-axis space of the battery pack, improving the vehicle space utilization rate of the flat battery pack, and solving the user range anxiety problem.

[0024] (3) The electric vehicle flat front floor body structure provided by the present invention eliminates the original central channel structure on the basis of the traditional front floor and replaces it with a flat front floor structure. Reinforcing ribs can be appropriately added locally on the flat floor to improve the modality and strength of the floor skin. Among them, by arranging two seat crossbeams in front and behind the front floor, it can contribute to the side pole impact of the whole vehicle and improve the body strength. By setting the left front cover body and the right front cover body on the front side of the seat crossbeam, the front cover body acts on the front impact and can play a role in strengthening the body's own strength and transmitting the front impact force.

[0025] (4) The electric vehicle flat front floor body structure installation method provided by the present invention fixes the battery pack structure to the front, middle and sides of the front floor of the vehicle body with multiple bolts. The battery pack frame structure and internal cells are firmly fixed to the vehicle body through the above installation method. At the same time, the side brackets and the entire pack frame form an integral whole, which has a positive effect on the rigidity of the flat battery pack itself and the torsional rigidity of the vehicle body; and improves the stability of the whole vehicle structure. Attached Figure Description

[0026] Figure 1 A schematic diagram of the existing front floor structure;

[0027] Figure 2 This is a top view of the front floor of the vehicle body according to the present invention;

[0028] Figure 3 This is a bottom view of the front floor of the vehicle body according to the present invention;

[0029] Figure 4 This is a schematic diagram of the flat battery pack structure of the present invention;

[0030] Figure 5 This is a schematic diagram of the subframe structure of the present invention;

[0031] Figure 6 This is a diagram of the electric vehicle flat front floor body structure assembly of the present invention;

[0032] Figure 7 For the present invention Figure 6 A schematic diagram of the threshold and aluminum profile at point AA.

[0033] In the diagram: 1. Front floor of the vehicle body; 2. Left front hood body; 3. Front crossbeam of the seat; 4. Middle fixing point of the battery pack; 5. Rear crossbeam of the seat; 6. Aluminum profile; 7. Rear mounting of the subframe; 8. Left sill body; 9. Flat front floor assembly; 10. Front fixing structure; 11. Side fixing bracket; 12. Longitudinal frame; 13. Middle fixing bolt; 14. Crossbeam; 15. Rear mounting point of the subframe; 16. Front mounting point of the battery pack; 17. Flat battery pack structure; 18. Sill cross section; 19. Aluminum profile cross section. Detailed Implementation

[0034] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0035] Example 1

[0036] Existing front floor structure of the vehicle body, such as Figure 1As shown, due to the limitations of the platform's hard points, the subframe and front suspension structure of traditional oil-to-electric conversion platforms cannot obtain the required large-capacity battery packs, resulting in insufficient driving range and user range anxiety. In addition, the existing front floor of the vehicle has a central tunnel structure and space, which poses a risk of squeezing and damaging the battery pack control devices in the event of a side pillar collision.

[0037] To address the problems existing in current vehicle front floor structures, a typical embodiment of this invention proposes a flat-front floor vehicle structure for electric vehicles, such as... Figure 2 and Figure 3 As shown, the vehicle includes a front floor 1 and a flat battery pack structure. The front floor 1 is a completely flat structure. Sills are provided on the left and right sides of the front floor 1, namely, a left sill body 8 and a right sill body (not marked in the figure). A front seat crossbeam 3 and a rear seat crossbeam 5 are provided between the two sills. The front seat crossbeam 3 and the rear seat crossbeam 5 are perpendicular to the sills and pass through the two sills. The front seat crossbeam 3 is a stamped structure, and the rear seat crossbeam 5 is a high-strength steel profile. A left cover body 2 and a right cover body (not marked in the figure) are provided at the front of the front seat crossbeam 3. Multiple nuts are welded onto the front floor 1 to fix the flat battery pack structure.

[0038] The electric vehicle flat front floor body structure provided in this embodiment eliminates the original central tunnel structure on the basis of the traditional front floor, replacing it with a flat front floor structure. Reinforcing ribs can be appropriately added to the flat floor to improve the modality and strength of the floor surface. Specifically, by arranging two seat crossbeams front and rear on the front floor, they contribute to the side pole impact resistance of the entire vehicle, improving body strength. Furthermore, by setting a left front cover body and a right front cover body on the front side of the seat crossbeams, the front cover body acts on the front impact, which can strengthen the body's own strength and transmit front impact force.

[0039] To facilitate the mounting of the flat battery pack on the front floor of the vehicle, nuts are installed at multiple locations on the front floor. Specifically, the nuts are distributed between the front seat crossbeam 3 and the rear seat crossbeam 5, inside the side sills, and at the front end of the front floor 1. Holes are drilled and nuts are welded onto the side sills of the front floor as needed to connect with the side brackets of the battery pack; holes are drilled and nuts are welded onto the front of the front floor to connect with the front mounting point of the battery pack; and four mounting holes are drilled at appropriate locations in the middle of the front floor, with nuts welded onto them, to securely connect with the central crossbeam of the battery pack. Through these three fixing points, the flat battery pack is securely mounted on the front floor of the vehicle.

[0040] In this embodiment, aluminum profiles 6 are installed inside the sills on both sides of the front floor 1 of the vehicle body. The aluminum profiles 6 are fixed to the inner panel of the sill. The cross-sectional view of the sill after the aluminum profiles are installed is shown in the figure. Figure 7As shown, by adding aluminum profiles inside the door sill, the body rigidity can be enhanced and the safety side pillar collision performance can be met.

[0041] like Figure 4 As shown, the flat battery pack structure includes a battery pack frame and a battery pack body mounted on the battery pack frame. The battery pack frame is a frame structure composed of a longitudinal frame 12 and a crossbeam 14, used to install the internal battery cells. A front fixing structure 10 is provided at the front of the battery pack frame, which connects the front end of the flat battery pack structure to the front floor 1 of the vehicle body. The front fixing structure 10 provides fixed support for the vehicle in a frontal collision, transmitting the force of the frontal collision rearward along the longitudinal frame 12 and both sides.

[0042] Furthermore, side fixing brackets 11 are respectively provided on the left and right sides of the battery pack frame. The side fixing brackets 11 are fixedly connected to the door sills on the left and right sides of the front floor of the vehicle body. The side fixing brackets 11 firmly fix the battery pack frame structure and internal cells to the vehicle body. At the same time, the side fixing brackets 11 and the battery pack frame are an integral structure, which can play a positive role in the rigidity of the flat battery pack itself and the torsional rigidity of the vehicle body.

[0043] Furthermore, a crossbeam 14 is provided in the middle of the battery pack frame. The crossbeam 14 is fixedly mounted on a nut in the middle of the front floor of the vehicle body by a central fixing bolt 13. The cooperation between the bolt and the nut makes a significant contribution to improving rigidity and impact resistance. In one specific embodiment of this example, four central fixing bolts are provided, and four nuts are correspondingly provided in the middle of the front floor of the vehicle body.

[0044] Furthermore, a U-shaped structure is provided at the front end of the vehicle's front floor, and the space formed by the U-shaped structure is used to install a subframe, the structure of which is as follows: Figure 5 As shown, the subframe is mounted on the front floor of the vehicle body as follows. Figure 6 As shown, a subframe rear mounting seat 7 is provided within the U-shaped structure, serving as the subframe rear mounting point 15. The subframe rear mounting point 15 is spaced a certain distance from the battery pack front mounting point 16. The main function of the subframe is to provide fixed support for important components such as steering and suspension of the vehicle. The forward positioning of its rear mounting point plays a crucial role in this invention. Compared with the space of traditional subframe mounting points, it can free up space for the subframe mounting points, maximizing the X-axis space of the battery pack, providing a strong guarantee for the X-axis space of the battery pack, improving the utilization rate of the vehicle body space of the flat battery pack, and solving the problems of large battery capacity and long range.

[0045] To improve the strength of the front floor of the vehicle, multiple local reinforcing ribs are provided at the bottom of the front floor to enhance the modality and strength of the floor skin.

[0046] Secure all mounting points in the middle, front, and sides of the battery pack, and check the reliability of each connection point. At the same time, rigidly connect the subframe to the vehicle body with bolts. This completes the construction of the vehicle body structure with a flat front floor. Currently, this architecture platform has been put into mass production, and all tests have met the predetermined goals. The structure is stable and reliable, and the platform has good scalability.

[0047] This embodiment utilizes a novel flat floor architecture to extend the front and rear seat crossbeams to the left and right door sills. Combined with the internal aluminum profile frame structure of the flat battery pack and the addition of extruded aluminum profiles on both sides of the door sills, the seat crossbeams can form an organic whole with the aluminum profiles of the door sills on both sides and the crisscrossing frame inside the pack. This perfectly solves the safety problems currently faced by electric vehicles, such as side collisions, pole collisions, front collisions, and roof crushes, placing safety performance as the top priority for electric vehicles.

[0048] Example 2

[0049] In a typical embodiment of the present invention, a method for installing a flat front floor body structure of an electric vehicle is provided, comprising the following steps:

[0050] Step 1: Place the flat battery pack structure on the front floor of the vehicle and align the bolts on the crossbeam of the battery pack frame of the flat battery pack structure with the nuts in the middle position of the front floor of the vehicle. Tighten the nuts to fix the middle position of the flat battery pack structure to the front floor of the vehicle.

[0051] Step 2: Secure the front part of the battery pack frame of the flat battery structure to the nuts on the front floor of the vehicle body using bolts.

[0052] Step 3: Secure the battery pack frame brackets on both sides of the flat battery structure to the left and right door sills on the front floor of the vehicle using bolts to complete the installation of the flat battery pack structure to the front floor of the vehicle.

[0053] Step 4: Connect the subframe to the subframe rear mounting bracket on the front floor of the vehicle body using bolts to complete the installation of the flat front floor vehicle body structure.

[0054] The above installation method firmly fixes the battery pack frame structure and internal cells to the vehicle body. At the same time, the side brackets and the entire pack frame form an integral whole, which has a positive effect on the rigidity of the flat battery pack itself and the torsional rigidity of the vehicle body; and improves the stability of the entire vehicle structure.

[0055] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A flat-front-floor body structure for an electric vehicle, characterized in that, The device includes a front vehicle floor and a flat battery pack structure. The front vehicle floor is entirely flat, with sills on both sides. A front seat crossbeam and a rear seat crossbeam are positioned between the two sills, perpendicular to and passing through the sills. The front seat crossbeam is a stamped structure, while the rear seat crossbeam is made of high-strength steel. A left and right cover plate are located at the front of the front seat crossbeam. Multiple nuts are welded onto the front vehicle floor to secure the flat battery pack structure. The flat battery pack structure includes a battery pack frame and a battery pack body disposed on the battery pack frame. A front fixing structure is provided at the front of the battery pack frame, and the front fixing structure connects the front end of the flat battery pack structure to the front floor of the vehicle. The battery pack frame is provided with side fixing brackets on the left and right sides respectively. The side fixing brackets are fixedly connected to the door sills on the left and right sides of the front floor of the vehicle. The side fixing brackets and the battery pack frame are an integral structure. The front end of the vehicle's front floor is provided with a U-shaped structure, and the space formed by the U-shaped structure is used to install a subframe; The U-shaped structure is equipped with a subframe rear mounting seat, which is spaced a set distance from the battery pack front mounting point.

2. The flat front floor body structure for electric vehicles as described in claim 1, characterized in that, The multiple nuts are distributed between the front and rear crossbeams of the seat, inside the side door sills, and at the front end of the vehicle's front floor.

3. The flat front floor body structure of the electric vehicle as described in claim 1, characterized in that, Aluminum profiles are installed inside the door sills on both sides of the front floor of the vehicle body, and the aluminum profiles are fixed to the inner door sill plate body.

4. The flat front floor body structure of the electric vehicle as described in claim 1, characterized in that, A crossbeam is provided in the middle of the battery pack frame, and the crossbeam is fixedly installed on the middle nut of the front floor of the vehicle body by a middle fixing bolt.

5. The flat front floor body structure of the electric vehicle as described in claim 1, characterized in that, The bottom of the front floor of the vehicle body is provided with multiple local reinforcing ribs.

6. A method for installing a flat front floor body structure for an electric vehicle as described in any one of claims 1-5, characterized in that, Includes the following steps: Step 1: Place the flat battery pack structure on the front floor of the vehicle and align the bolts on the crossbeam of the battery pack frame of the flat battery pack structure with the nuts in the middle position of the front floor of the vehicle. Tighten the nuts to fix the middle position of the flat battery pack structure to the front floor of the vehicle. Step 2: Secure the front part of the battery pack frame of the flat battery structure to the nuts on the front floor of the vehicle body using bolts. Step 3: Secure the battery pack frame brackets on both sides of the flat battery structure to the left and right door sills on the front floor of the vehicle using bolts to complete the installation of the flat battery pack structure to the front floor of the vehicle. Step 4: Connect the subframe to the subframe rear mounting bracket on the front floor of the vehicle body using bolts to complete the installation of the flat front floor vehicle body structure.

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