Hybrid energy absorption for vehicle battery pack frame

Abstract

The invention relates to a vehicle battery pack frame for a vehicle, comprising: a base having a length and a width; side members on opposite sides of the base, extending along a length of the base, and attached to a perimeter of the base; a cross beam extending between the side members across the width of the base; wherein each side member comprises: a profiled body comprising a side wall having a first surface facing the cross beam and an opposing second surface; and a polymeric reinforcement attached to the profiled body and facing the second surface of the sidewall of the profiled body.

Description

[0001] This application is a divisional application of the Chinese patent application with international application number PCT / US2020 / 040551, national application number 202080045397.X, name "Hybrid Energy Absorption for Vehicle Battery Pack Frame", and application date July 1, 2020. Technical Field

[0002] The present invention relates to hybrid energy absorption for a vehicle battery pack frame. Background Art

[0003] Due to stringent global CO2 emission regulations, there is a growing interest in the development and use of electric vehicles, such as all-electric vehicles ("EV"), plug-in hybrid electric vehicles ("PHEV"), and hybrid electric vehicles ("HEV"; i.e., vehicles that use multiple propulsion sources, one of which is an electric drive system). Weight reduction is key to the viability of electric vehicles, as reducing the weight of an electric vehicle can extend its driving range.

[0004] One area of ​​focus for weight reduction is the vehicle battery pack assembly, which includes, for example, the battery modules and the vehicle battery pack frame. Most current vehicle battery pack frames use aluminum or high-strength steel designs. These designs provide structural integrity and protection during impacts, but they are heavy.

[0005] It is desirable to provide a lightweight vehicle battery pack frame for a battery module that is capable of protecting the battery module during a side impact collision. Summary of the invention

[0006] Provided herein are a vehicle battery pack frame for a vehicle, a vehicle battery pack assembly including the vehicle battery pack frame and a battery module, and an electric vehicle including the vehicle battery pack assembly.

[0007] In one embodiment, a vehicle battery pack frame may include: a base having a length and a width; side members located on opposite sides of the base, extending along the length of the base and attached to the perimeter of the base; a cross member extending between the side members across the width of the base; and a cover enclosing a plurality of battery modules in the vehicle battery pack frame. Each side member includes: a frame having a flange extending from a first side and a channel on a second side, wherein the base extends between the side members and extends over the flange of each side member; and a polymer reinforcement located in the channel. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following drawings are exemplary embodiments, wherein like elements are denoted by like numerals.

[0009] Figure 1 is a perspective view of a representative battery pack for an electric vehicle, which includes a battery module and Figure 5 The side members of the vehicle battery pack frame.

[0010] Figure 2 is a representative side view of a vehicle including a vehicle battery pack assembly.

[0011] Figure 3 is along Figure 2 A partial cross-sectional side view taken along line AA of FIG. 1 shows a vehicle battery pack assembly attached to a vehicle floor rocker.

[0012] Figure 4 is a side view showing a cross member attached to a side member of a vehicle battery pack assembly.

[0013] Figure 5 is a partial perspective view of an embodiment of a side member including a hybrid structure.

[0014] Figure 6 is a perspective enlarged front view of another embodiment of a side member including a frame and a polymer reinforcement.

[0015] Fig. 7A is a partial perspective view of another embodiment of a polymer reinforcement.

[0016] Figure 7B It was taken along route 7B-7B Fig. 7A Cross-sectional view of a polymer reinforcement.

[0017] Figure 7C Yes Fig. 7A and 7B A side view of a side member of another embodiment of a polymer reinforcement and frame.

[0018] Fig. 8A is a perspective view of another embodiment of a side member including another embodiment of a polymer reinforcement having a structural reinforcement element.

[0019] Figure 8B yes Fig. 8A A cross-sectional side view of an embodiment of the present invention.

[0020] Fig. 9 is an enlarged perspective view of another embodiment of a side member showing the assembly of the frame and polymer reinforcement.

[0021] Fig.10 is a partial perspective view of another embodiment of a side member.

[0022] Fig.11 is a schematic top view showing four battery packs of Comparative Example and Examples 1-3 before a collision test, each battery pack having a different side member.

[0023] Fig.12 It shows Fig.11 A top view of the four battery packs of the EV after a side impact test into a pole at 30 kilometers per hour (km / h).

[0024] Figures 13A-13C Shows the Fig. 8A and 8B Progressive details of the crash test of the side member embodiment shown in .

[0025] Fig.14 is a graph of force (kilonewtons (kN)) versus intrusion (millimeters (mm)) for the comparative example and examples 1-3, showing the results of the collision test.

[0026] Fig.15A is a graph of force (kilonewtons (kN)) versus intrusion (millimeters (mm)) for Example 4, showing the results of the low temperature crash test.

[0027] Fig. 15B is a graph of absorbed energy in Joules (J) versus temperature (ºC) for Example 4.

[0028] Fig.16A is a graph of force (kN) versus intrusion (mm) for Example 5, showing the results of the low temperature crash test.

[0029] Fig. 16B is a plot of absorbed energy (J) versus temperature (ºC) for Example 5. DETAILED DESCRIPTION

[0030] A vehicle battery pack frame for energy absorption and distribution is provided. The vehicle battery pack frame includes side members, a cross member, a base, an optional cover, an optional partition, an optional rear external support, and an optional secondary battery support area. The side members include a profiled body to which the vehicle cross member is attached. The side members extend in a direction parallel to the length direction ("L") of the vehicle (in the length direction), and the cross member extends between the side members, spanning the width ("W") of the vehicle (in the width direction). For example, the cross member can extend in a direction between the side members and perpendicular to the side members and parallel to the width direction of the vehicle. The side members are configured so that the vehicle battery pack frame maintains structural integrity during a rigid pole collision at 30 km / h in accordance with Federal Motor Vehicle Safety Standard 214. Maintaining structural integrity means that after the collision, the rigid pole does not invade the interior space of the vehicle battery pack assembly, and the battery modules within the vehicle battery pack assembly are not compressed.

[0031] The side members in a vehicle battery pack assembly can perform multiple functions. The side members can contribute to the structural integrity, such as stiffness, of the vehicle battery pack assembly by providing a structure that holds and supports the crossbars of the vehicle battery pack assembly, which can include one or more battery modules. It is desirable that the side members can be designed to also absorb and distribute energy in the event of a side impact and minimize or prevent intrusion and impact into the battery modules. The side members of the present application include polymer reinforcements.

[0032] In the present design, the side impactor will first contact the polymer reinforcement before contacting the rear wall and optional box structure, and therefore before contacting the crossbar. It is desirable that the intrusion of the impactor is less than the depth ("D") of the polymer reinforcement. The side members (polymer reinforcement, and the wall above the polymer reinforcement and the optional wall in front of the polymer reinforcement) can provide energy absorption before the side impactor contacts the surface of the wall to which the crossbar is attached. The profiled body can limit the deformation of the polymer reinforcement, but can provide a minimum amount of axial reinforcement. The side members can provide bending rigidity so that the vehicle battery pack assembly can be installed to the electric vehicle. Because of this design, the side members provide component integration and weight reduction compared to multi-piece metal members arranged to form a rigid protective support.

[0033] When installed in a vehicle, the vehicle battery pack frame may be positioned between front and rear vehicle suspension components and mounted between and mechanically coupled to vehicle structural members (e.g., rocker panels) located on either side of the vehicle. The vehicle battery pack frame may be mounted below and attached to the vehicle floor.

[0034] The vehicle battery pack assembly extends transversely to at least a portion of the width of the vehicle, i.e., from rocker panel to rocker panel, and also between the front and rear suspensions. The dimensions of the vehicle battery pack assembly are not particularly limited and depend on the size of the vehicle and on the desired battery capacity and the size of the battery modules. For example, the vehicle battery pack assembly may be up to 3 meters (m) long (e.g., approximately 2.7 m long) and up to 1.5 meters wide. Thus, the length of the side members may be up to 3 m, e.g., greater than 1 to 3 m, or 1.5 m to 2.0 m. The thickness of the vehicle battery pack assembly may vary between 0.1 m and 0.18 m, with the thicker dimensions applying to those portions of the vehicle battery pack assembly where the battery modules are positioned one on top of another.

[0035] A more complete understanding of the vehicle battery pack assembly disclosed herein may be obtained by reference to the accompanying drawings. These drawings (also referred to herein as "Figures") are merely schematic representations based on convenience and ease of display of the present disclosure and, therefore, are not intended to indicate the relative size and dimensions of the device or its components and / or to define or limit the scope of the exemplary embodiments. Although specific terms are used in the following description for clarity, these terms are intended to refer only to the specific structures of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the present disclosure. In the following drawings and the following description, it should be understood that the same reference numerals refer to components having the same functions.

[0036] Figure 1 1 is a representative illustration of a vehicle battery pack assembly 10 for an electric vehicle, which includes battery modules 12 and a vehicle battery pack frame 11, which includes side members 30, a partition member 18, and a cross member 16. A single battery module 12 can be positioned within a section of the vehicle battery pack assembly 10 defined by the side members 30, the cross member 16, and the base 14. The side members 30 extend along the length L of the vehicle battery pack assembly 10. The cross member 16 extends between the side members and has a width that can span from the base 14 to the cover 20 (see FIG. 1 ). Figure 3 ) in height, thereby forming a closed partition device. In the vehicle battery pack assembly 10, the partition device can be at least partially defined by the cross beams 16, the partition members 18 and the optional side members 30. Optionally, the partition members 18 can extend between adjacent cross beams 16 and can extend between adjacent battery modules 12. The battery modules 12 can be disposed on the base 14 of the vehicle battery pack assembly 10. Each section (between adjacent cross beams 16) can accommodate one or more battery modules 12, such as a pair of battery modules 12. Optionally, there can be a backup battery module (also called a secondary battery module).

[0037] Figure 3 is along Figure 2, a partial cross-sectional view taken along line AA of FIG. 1 , shows a vehicle battery pack assembly 10 in a vehicle 22 . The vehicle battery pack assembly 10 includes a side member 30 having a flange 52 extending from one side member 30 toward the opposite side member 30 . The base 14 is disposed on and attached to the flange 52 . The base 14 may be disposed on the flange 52 of the side member 30 , and the cross beam 16 may be disposed on the base 14 . The base 14 extends between the side members 30 and extends below the cross beam 16 . The front and rear ends of the vehicle battery pack assembly 10 may have additional cross beams 16 to improve the structural integrity of the vehicle battery pack assembly 10 . The base 14 may enable heat transfer, such as cooling, of the battery module 12 . For example, the base 14 may include a conduit 80 for a heat transfer fluid (e.g., a medium such as air or a liquid (e.g., water or other heat transfer fluid) that does not enter the interior of the vehicle battery pack assembly 10 ) to remove heat from the battery module. The base may have heat transfer fins 82 to allow heat transfer to the surrounding environment in addition to or in lieu of the conduits 80. When the vehicle battery pack assembly 10 is attached to the vehicle 22, the side of the base 14 facing away from the battery module 12 is exposed to the environment.

[0038] Ideally, a barrier between the battery module 12 and the surrounding environment is formed, for example, by the cover 20, the side member 30, and the base 14. In other words, the base 14, the side member 30, and the cover 20 form a housing for accommodating the battery module 12. In addition, two additional cross beams 16 may be formed on the front and rear sides of the vehicle battery pack assembly 10. The housing may be provided with one or more openings for airflow. The cover 20 may be attached to the side member 30 by mechanical fasteners and / or chemical attachments. Examples of mechanical fasteners include snaps, hooks, screws, bolts (e.g., threaded bolts), rivets, welds, crimps (e.g., crimped metal walls). Chemical attachments may include adhesives, such as glue, adhesives, and the like. Ideally, the cover 20 may be removably attached to the side member 30, for example, using a mechanical attachment that can be removed without damaging the side member 30. The removable attachment simplifies replacement of the battery module 12 and allows the battery module 12 interconnects, components of the vehicle battery pack assembly 10 , cooling system components, and other components of the vehicle battery pack assembly 10 to be repaired and / or replaced.

[0039] Based on the seals between the side members 30 , the base 14 , and the cover 20 , the vehicle battery pack assembly 10 may be configured as a substantially airtight enclosure.

[0040] like Figure 3As shown, the vehicle battery pack assembly 10 is coupled to the vehicle 22. The vehicle battery pack assembly 10 can be attached to the vehicle 22 using various mechanical fasteners, such as those described above. Illustrated is the side member 30 attached to the floor sill 26 of the vehicle 22 using mechanical fasteners 28. Thus, the vehicle battery pack assembly 10 can be located below the vehicle 22, below the vehicle floor 84, and attached to and extending between the floor sills 26.

[0041] The vehicle battery pack assembly 10 may include spacer members 18 that extend in a direction parallel to the side members and separate the battery modules 12. Each spacer member 18 may include a portion 24 opposite the base 14 that helps secure the battery module 12 within the vehicle battery pack assembly 10 by overlapping at least a portion of the battery module 12.

[0042] Figure 4 Schematically illustrates how the side members 30 and the cross beam 16 may be attached. For example, the side members 30 may include flanges 52, and the cross beam 16 may be attached to the flanges 52 adjacent to or via the base 14 or via other means. The base 14 may be supported on the flanges 52, such as between the flanges 52 and the cross beam 16.

[0043] Figure 5 A hybrid side member 30 is shown, i.e., including a profiled body 32 and a polymer reinforcement 60 positioned therein. The polymer reinforcement 60 may be optionally mechanically or chemically attached to the profiled body 32. For example, the polymer reinforcement 60 may be overmolded onto the profiled body 32. Alternatively or additionally, mechanical fasteners and / or chemical attachments, such as those described above, may be employed. A friction fit may also be used to retain the polymer reinforcement 60 in the profiled body 32. Since the polymer reinforcement 60 is opposite to the surface of the profiled body 32 to which the cross beam 16 is attached, the polymer reinforcement 60 is not directly attached to the cross beam 16.

[0044] The polymer reinforcement 60 can be locked to the profiled body 32 to create a mechanical bond between the profiled body 32 and the polymer reinforcement 60 without the use of adhesives. Optionally, the wall can include an opening 50 through the wall so that when the polymer reinforcement 60 is formed, molten polymer can pass from the interior of the cavity, through the opening and solidify to further secure the polymer reinforcement 60 within the profiled body 32.

[0045] Hybrid side members allow for complex geometries that would otherwise be difficult to achieve using only metal or composite materials. The polymer reinforcement may include a rib structure. For example, the rib may extend across a channel 35 defined between and by the top wall 34 and the bottom wall 36, and / or extend toward the side wall 42 or the rear wall 40 along the length of the channel 35 defined between and by the top wall 34 and the bottom wall 36. Various rib designs are possible, including triangles, rectangles, diagonals, crosses, and the like. The ribs may form a column array constituting a honeycomb structure (e.g., a honeycomb geometry), such as a shape having greater than or equal to 3 sides, such as a triangle, pentagon, hexagon, heptagon, and octagon, etc., preferably with a hexagonal geometry. Other geometries, such as those including channels, are also possible. The columns and / or channels of the geometry may have one or more open ends.

[0046] Optionally, the polymer reinforcement, and therefore the ribs of the polymer reinforcement, can extend from the end edge 37 of the top wall 34 to the rear wall 40, i.e., extend over a distance d defining the width of the top wall 34, or at least a portion of the distance d, and if the rear wall 40 is not present, to the side walls 42, i.e., extend beyond the distance d or beyond the width of the top wall 34. The distance D is not zero. The ribs can be extruded, formed separately and joined together to form the desired structure, injection molded, or otherwise formed. Optionally, the polymer reinforcement (e.g., such as a rib) can be formed by overmolding a plastic reinforcement into the profiled body 32 using an injection molding process. Figure 5 , 8A and 10). The polymer reinforcement 60 can be coextruded with the profile 32 to form a one-piece structure. The polymer reinforcement 60 can be coextruded with the metal using a die that can combine multiple materials. For example, the die can include a device that extrudes the metal at the periphery while the inner plastic material is extruded at the same rate as the metal. Alternatively, the polymer reinforcement 60 can be formed and then inserted into the profile 32 (see Figure 5 , 6 , 7A, 9 and 10). The preformed polymer reinforcement 60 allows the channels and / or columns 33 to be oriented in any desired direction, such as extending between the top wall 34 and the bottom wall 36 (see Figure 6 , 7A ), for example perpendicular to these walls. The channels and / or columns 33 of the structure may extend towards the side walls 42 (see Figure 5 , 8A , 9), for example, perpendicular to the side wall 42 and parallel to the top wall 34 and the bottom wall 36. The channel and / or column 33 of the structure can extend along the length of the side member 30 (for example, see Fig.10), for example parallel to the side wall 42. The orientation of the channels and / or columns 33 relative to the walls 34, 36, 42 can be selected to obtain the desired energy absorption characteristics. For example, the open ends can point toward the top wall 34 and / or the bottom wall 36.

[0047] The dimensions of the polymer reinforcement 60 can be designed to absorb energy during a side impact of the vehicle battery pack assembly. For example, the distance between non-adjacent ribs can vary from 20 mm to 40 mm, and the rib thickness can vary from 1.5 mm to 5.0 mm.

[0048] The polymer reinforcement 60 may include at least one of the following materials: acrylonitrile butadiene styrene (ABS); polycarbonate; acrylic styrene acrylonitrile (ASA); phenylene oxide; polyphenylene oxide; polycarbonate (PC); polyamide; polyethylene terephthalate (PET); polybutylene terephthalate (PBT); polyamide; phenylene sulfide; polyvinyl chloride (PVC); (high impact) polystyrene; polyolefins (e.g., polypropylene (PP) (e.g., expanded polypropylene (EPP)) or polyethylene); polysiloxane; polyurethane; or thermoplastic olefin (TPO).

[0049] The polymer reinforcement 60 may include fillers, such as fibers. Possible fiber materials may include at least one of glass, carbon, aramid or plastic, preferably glass. The fiber length may be chopped, long, short or continuous. Therefore, the polymer reinforcement 60 may include a fiber-filled thermoplastic material. For example, fiber-filled polyolefins may be used. Specifically, long glass fiber-filled polypropylene may be used. In the case of short glass fiber-filled polymers, the initial fiber length may vary from 1.5 mm to less than 3 mm, and the fiber length after molding may vary from 0.2 mm to 0.5 mm. Long fibers are defined as having an initial fiber length of at least 3 mm, such as 10 mm to 15 mm, before molding, and having a longer length after molding than the above-mentioned short glass fibers.

[0050] Optionally, there may be an aesthetically pleasing covering on the side members 30, particularly on the polymer reinforcements. The covering may prevent debris from entering the polymer reinforcements.

[0051] like Figure 6 As shown, the polymer reinforcement 60 can be disposed in the channel 35 formed by the profiled body 32. The channel 35 can be formed by the top wall 34, the bottom wall 36, and the rear wall 40 or the side wall 42. The rear wall 40 can extend between the top wall 34 and the bottom wall 36 at one end of the top wall 34. On the side of the rear wall 40 opposite to the channel 35, the profiled body can include a box structure 38 (e.g., a four-sided box structure; see, for example, Figure 7C). The first connecting wall 44 extends between the side wall 42 and the top wall 34, for example at the rear wall 40, and the second connecting wall 46 extends between the side wall 42 and the bottom wall 36, for example at the rear wall 40. The height of the side wall 42 is greater than the height of the channel 35, and / or greater than the height of the rear wall 40, thereby increasing the height of the channel 35 at the location of the box structure 38. Preferably, at least one longitudinal edge of the side wall 42 extends beyond the longitudinal edge of the rear wall. More preferably, the longitudinal edges of the side wall 42 extend beyond the longitudinal edges of the rear wall in a symmetrical manner, that is, the length of the extension is evenly distributed. The first connecting wall 44 and the second connecting wall 46 can extend from the side wall 42 toward the channel 35 at an angle θ of 90 degrees. Alternatively, the first connecting wall 44 and the second connecting wall 46 can extend from the side wall 42 toward the channel 35 at an angle θ of less than 90 degrees, for example, at an angle of 30 to 75 degrees, preferably at an angle of 40 to 50 degrees. The box structure 38 can have a rectangular or trapezoidal geometry. The connecting walls 44 , 46 may also have other geometric shapes, for example rounded or curved, or even stepped.

[0052] Extending from the side wall 42 in a direction opposite to the channel 35 may be a flange 52. The flange 52 may extend from the end of the side wall 42 or from a position that is a distance different from zero from the end of the side wall. Preferably, the flange 52 extends from the lower half of the side wall 42, the lower half being defined as the portion of the side wall 42 that is closer to the bottom wall 36 than the top wall 34 of the profiled body 32. The base 14 may be attached to the side member 30 via the flange 52 and / or the side wall 42, and the crossbar 16 may be mounted on top of the base 14 and the flange 52. The attachment may be various mechanical fasteners and / or chemical attachments as described above.

[0053] The profiled body 32 may provide structural integrity to the vehicle battery pack assembly 10. The structural integrity of the vehicle battery pack assembly 10 may be based on the bending and torsional stiffness of the vehicle battery pack assembly 10 during transportation and use. The exact thickness depends on the specific material of the wall and the desired structural integrity. For example, for a steel profiled body 32, the wall thickness may be 0.5 mm to 2 mm, while for aluminum, the wall thickness may be 1.0 mm to 8.0 mm. Thus, the thickness of each of the walls, top wall 34, bottom wall 36, rear wall 40, side wall 42, first connecting wall 44, and second connecting wall 46 may be selected based on the desired structural integrity. For example, since the polymer reinforcement 60 is intended to absorb side impact energy, the thickness of the top wall 34 and the bottom wall 36 may be less than the thickness of the rear wall 40, the side wall 42, the first connecting wall 44, and the second connecting wall 46. For example, the top wall 34 and the bottom wall 36 may have a thickness of 0.5 mm to 1.6 mm, specifically 1.0 mm to 1.5 mm, and more specifically 1.3 mm to 1.4 mm. The rear wall 40 may have a thickness of 0.5 mm to 4.0 mm, preferably 1 mm to 1.5 mm. The side wall 42 may have a thickness of 0.5 mm to 4.0 mm, preferably 1.00 mm to 1.5 mm. The first connecting wall 44 and / or the second connecting wall 46 may have a thickness of 0.5 mm to 3.00 mm, preferably 1.0 mm to 1.5 mm.

[0054] The profiled body 32, base 14, cover 20, and beam 16 may each individually be metal and / or composite. Composite materials may include polymers, such as fiber reinforced polymers (e.g., thermoplastic or thermosetting polymers), and the profiled body 32, base 14, cover 20, and beam 16 may each individually include metal and composite materials. For example, the profiled body 32 may be an extruded or stamped sheet metal. The profiled body 32 may be a composite material, such as a fiber reinforced laminate or sheet. For example, the profiled body 32, base 14, cover 20, and beam 16 may each individually include aluminum, steel, continuous glass fiber composite laminates or tapes, continuous carbon fiber laminates or tapes, fiber-filled thermoplastic resins, and / or highly oriented polymer material continuum.

[0055] Figure 6 and 7A -7C shows an embodiment in which the polymer reinforcement 60 is molded separately and inserted into the extruded profile 32. The stretching direction or processing movement of the polymer reinforcement 60 may be in the vertical direction. Figure 6 A polymer reinforcement 60 is shown inserted into the channel 35 of the profiled body 32 . Figures 7A-7C A polymer reinforcement 60 having a square wave rib design is shown (see Figure 7B , which shows that along Fig. 7A7B-7B). As shown, the polymer reinforcement 60 may include additional ribs 62 in the square wave valleys (see Fig. 7A ; for example, ribs parallel to each other in each valley of a square wave are shown). The ribs in the valley are perpendicular to the direction of collision, for example in the length direction (see Figure 1 ), extending from one side of the valley to the opposite side. Figure 7C Shown include Fig. 7A and 7B 1 is a side view of the profiled body 32 of the polymer reinforcement 60 .

[0056] Fig. 8A and 8BAnother design of the profiled body 32' is shown, which includes a top wall 34 extending to the first support wall 54, a bottom wall 36 extending to the second support wall 56, and a reinforcing support element 70 extending between the top wall 34 and the bottom wall 36 at the location of the first and second support walls 54, 56. The first support wall 54 can extend vertically from the top wall 34, away from the channel 35. The second support wall 56 can extend vertically from the bottom wall 36, away from the channel 35. The reinforcing support element 70 can optionally include a first support arm 72 and a second support arm 74, each extending from the end of the side wall 76 of the reinforcing support element 70 to form a connecting section between the support arms. The thickness of the reinforcing support element 70 can be greater than the total thickness of the first support wall 54, the second support wall 56, the top wall 34 and the bottom wall 36. Based on the stiffness requirements and the materials used, the thickness of the reinforcing support element 70 can vary, for example, from 0.5 mm to 2.00 mm. For example, if the reinforcing support element 70 includes steel, the thickness may be about 1.00 mm or less, and if the reinforcing support element 70 includes aluminum, the thickness may be about 2.00 mm. The second polymer reinforcement 64 may be attached (e.g., overmolded) to the first support wall 54 and / or the second support wall 56. The second polymer reinforcement 64 may be adjacent to the first and / or second support walls 54, 56. In addition, the second polymer reinforcement 64 may be adjacent to the top wall 34 and / or the bottom wall 36, respectively, i.e., the second polymer reinforcement 64 may be disposed in a corner formed between the top wall 34 and the first support wall 54, and / or disposed in a corner formed between the bottom wall 36 and the second support wall 56. The second polymer reinforcement 64 may provide additional compression resistance, which may help improve the energy absorption efficiency of the profiled body 32. The thickness of the second polymer reinforcement 64 may vary between 1.5 mm and 4.00 mm, and the second polymer reinforcement 64 may include a thermoplastic material. The second polymer reinforcement 64 may have a geometry as described above for the polymer reinforcement 60 and be inserted into the channel 35. The geometries of the polymer reinforcement 60 and the second polymer reinforcement 64 may be similar or different. When a square wave geometry is used for the second polymer reinforcement 64, the distance between alternating side walls of the second polymer reinforcement 64 may vary from 25 mm to 50 mm, and the second polymer reinforcement 64 may include alternating top and bottom surfaces, such as Fig. 7A Alternating top and bottom surfaces provides additional resistance to crush, which can help improve energy absorption efficiency.

[0057] Fig. 9An embodiment is shown in which an injection molded polymer reinforcement 60 can be slid into the extruded profile 32. The polymer reinforcement 60 can include ribs and / or a honeycomb structure, such as a honeycomb, which will extend in the channel 35, and further include shorter ribs that will extend between the side walls 42 and the rear wall 40'. In this embodiment, the rear wall 40' extends from the end of the channel 35, but does not extend across the channel 35. As with other designs, the flange 52 extends from the side walls 42, away from the channel 35.

[0058] Fig.10 An embodiment is shown in which the polymer reinforcement 60 has openings that extend the length of the side member 30 (as opposed to perpendicular to the length of the side member 30). In this design, the polymer reinforcement 60 can be coextruded with the profiled body 32 made of a metal or composite laminate or tape. Alternatively, the polymer reinforcement 60 can be formed separately and inserted into the profiled body 32. The polymer reinforcement 60 can include ribs that extend parallel and perpendicular to the walls 34, 36 of the profiled body 32.

[0059] exist Fig.10 In the design of , there is no rear wall 40. The first connecting wall 44 extends from the top wall 34 to the side wall 42, and the second connecting wall 46 extends from the bottom wall 36 to the side wall 42, that is, the connecting walls 44 and 46 extend from the side wall 42 to the channel 35, thereby forming a box structure (for example, a four-sided box structure) in the profiled body 32. The first connecting wall 44 and / or the second connecting wall 46 can extend from the side wall 42 to the top wall or the bottom wall at an angle θ of 90 degrees or less, for example, at an angle of 30 to 75 degrees, preferably at an angle of 40 to 50 degrees.

[0060] Example

[0061] According to Federal Motor Vehicle Safety Standard 214, vehicles under the speed limit of 30 kilometers per hour (km / h) Figure 5 (Example 1), Fig. 7A -C (Example 2) and Fig. 8A-B (Example 3) was subjected to a rigid pole collision of a vehicle battery pack frame including the side members shown in Example 1-B. The comparative example included an extruded aluminum side member without the polymer reinforcement 60. The comparative example included a rectangular channel with a 130 millimeter (mm) × 25 mm attachment portion and a 145 mm × 60 mm protruding rectangular cross section. The thickness varied from 1 mm to 8 mm, with the thickness of the attachment portion being 8 mm. The comparative example included multiple ribs that were a single extruded metal. The comparative example included an extruded aluminum wall. The overall design represented a T-shaped structure, with the legs of the T-shaped structure addressing the energy absorbing wall and the top horizontal wall providing bending stiffness. The overall dimensions of Examples 1-3 corresponded to those of the comparative example, with the thickness of the attachment portion in Examples 1-3 being 5 mm. The extruded aluminum side members of the comparative example all weighed approximately 15 kilograms (kg), while each of the side members in Examples 1-3 weighed approximately 12 kg, providing a weight reduction of approximately 20%. Therefore, for a 1.5 ton vehicle, it has been demonstrated that similar battery module protection can be obtained with a 20% weight reduction.

[0062] from Figure 11-14 As can be seen from the figure, the side members in Examples 1-3 exhibit an intrusion amount comparable to that of the comparative example. The intrusion amount is measured along the width of the vehicle perpendicular to the collision direction. Specifically, Fig.11 The comparative example (#90) and examples 1-3 (92, 94, 96 respectively) before the collision test are shown. Fig.12 The maximum intrusion amounts of the comparative example and examples 1-3 after a 30 kilometer / hour (km / h) pole collision are shown. Figures 13A-13C Shows the Fig. 8A and 8B Progressive details of the crash test of the illustrated embodiment. Specifically, Fig.13A shows the polymer reinforcement 60 at the beginning of the collision with the rigid rod 140, Fig. 13B shows the polymer reinforcement 60 during an impact with the rigid rod 140, and Fig. 13C The polymer reinforcement 60 is shown at the end of an impact with the rigid rod 140 .

[0063] Fig.14is a graph of force (kilonewtons (kN)) versus intrusion (millimeters (mm)) for the comparative example (line C) and examples 1-3 (lines 1, 2, and 3, respectively), showing the results of the impact tests. It can be seen from these tests that the results of example 1 are most comparable to the comparative example, with essentially the same area under the curve. As can be seen from the lower area under the curve, example 3 is not completely crushed, particularly at 100 mm intrusion, and at intrusions greater than 100 mm and high forces. Example 3 has a design of a polymer reinforcement 60 with a top wall, a bottom wall, and ribs extending therebetween to form a (four-sided) opening with ribs and an opening extending in the direction of the impact (e.g., away from the side wall 76 of the reinforcing support element 70).

[0064] Further testing was performed on side members having polymer reinforcement 60 made of XENOY™ (a PC / PBT blend sold by SABIC) (Example 4) or STAMAX™ (a long glass fiber filled polypropylene sold by SABIC) (Example 5) with 30 wt.% glass fibers at various low temperatures (i.e., below zero degrees Celsius). Fig.15A ) and Example 5 ( Fig.16A ) is a graph of force (kilonewtons (kN)) versus penetration (millimeters (mm)) showing the results of the low temperature impact test.

[0065] Fig.15A It is shown that for the XENOY™ stiffener, the area under the curve is almost similar at temperatures of minus 10 degrees Celsius (Test 12), minus 20 degrees Celsius (Test 13), and minus 30 degrees Celsius (Test 14). Fig. 15B Similar characteristics can be seen in the columns of , where at minus 10 degrees Celsius, minus 20 degrees Celsius, and minus 30 degrees Celsius, the columns similar to the amount of absorbed energy are almost equal, or at least do not change significantly. Fig. 15B The curve and column of the test at minus 40 degrees Celsius (test 15) show that XENOY TM The reinforcement is not able to absorb a similar amount of energy as at higher temperatures. This is due to the embrittlement of the XENOY™ material below -30 degrees Celsius, resulting in complete failure of the XENOY™ reinforcement at -40 degrees Celsius.

[0066] Fig.16A It is shown that for the STAMAX™ stiffener, the area under the curve is almost similar at temperatures of minus 10 degrees Celsius, minus 20 degrees Celsius, minus 30 degrees Celsius, and minus 40 degrees Celsius. Fig. 16BSimilar characteristics can be seen in the columns where the columns with similar amounts of absorbed energy are nearly equal, or at least do not change significantly, at -10 degrees Celsius (Test 37), -20 degrees Celsius (Test 40), -30 degrees Celsius (Test 41), and -40 degrees Celsius (Test 27). Thus, STAMAX™ stiffener 60 has stable performance at the low temperatures in each test and does not become brittle at -40 degrees Celsius. Furthermore, when comparing the maximum load and intrusion of XENOY™ and STAMAX™ as well as the total amount of absorbed energy, the STAMAX™ stiffener demonstrates the ability to withstand higher loads and absorb more energy at the same temperature.

[0067] The present disclosure further encompasses the following aspects.

[0068] Aspect 1: A vehicle battery pack frame for a vehicle, comprising: a base having a length and a width; side members located on opposite sides of the base, extending along the length of the base and attached to the periphery of the base; and a cross member extending between the side members across the width of the base; wherein each side member comprises: a profiled body, comprising a side wall having a first surface facing the cross beam and an opposite second surface; a polymer reinforcement attached to the profiled body and facing the second surface of the side wall of the profiled body.

[0069] Aspect 2: A vehicle battery pack frame for a vehicle, comprising: a base having a length and a width; side members located on opposite sides of the base, extending along the length of the base and attached to the periphery of the base; a cross beam extending between the side members across the width of the base; and a cover extending between the side members, wherein the cross beam is disposed between the cover and the base, and preferably, wherein the cover is configured to enclose a plurality of battery modules in the vehicle battery pack frame; wherein the side members include: a shaped body having an attachment surface for attaching the cross beam; and a polymer reinforcement located opposite to the attachment surface of the shaped body.

[0070] Aspect 3: A vehicle battery pack frame for a vehicle, comprising: a base having a length along a length direction and a width along a width direction; side members located on opposite sides of the base, extending along the length of the base and attached to the periphery of the base; a cross beam extending between the side members across the width of the base; and a cover extending between the side members, wherein the cross beam is arranged between the cover and the base, and preferably, wherein the cover is configured to enclose a plurality of battery modules in the vehicle battery pack frame; wherein each side member comprises: a frame to which the cross beam is attached; and a polymer reinforcement located opposite to a surface of the frame to which the cross beam is attached.

[0071] Aspect 4: A vehicle battery pack frame for a vehicle, comprising: a base having a length and a width; side members located on opposite sides of the base, extending along the length of the base and attached to the periphery of the base; a cross member extending between the side members across the width of the base; and a cover extending between the side members, wherein the cross member is disposed between the cover and the base, and preferably, wherein the cover is configured to enclose a plurality of battery modules in the vehicle battery pack frame; wherein each side member comprises: a shaped body having a flange extending from a first side and a channel on a second side, wherein the base extends between the side members and over the flange; and a polymer reinforcement located in the channel.

[0072] Aspect 5: A vehicle battery pack frame according to any of the preceding aspects, further comprising a cover extending between the side members, wherein a cross beam is disposed between the cover and the base, and preferably wherein the base, the side members and the cover enclose a plurality of battery modules in the vehicle battery pack frame.

[0073] Aspect 6: The vehicle battery pack frame according to any preceding aspect, wherein the polymer reinforcement is adjacent to the second surface of the side wall.

[0074] Aspect 7: The vehicle battery pack frame according to any preceding aspect, wherein the polymer reinforcement contacts a surface of the profiled body to which the cross member is attached.

[0075] Aspect 8: The vehicle battery pack frame according to any of the preceding aspects, wherein the profiled body comprises metal, preferably aluminum or steel, more preferably aluminum.

[0076] Aspect 9: The vehicle battery pack frame according to any preceding aspect, wherein each side member comprises a polymer reinforcement overmolded to the profiled body.

[0077] Aspect 10: The vehicle battery pack frame according to any preceding aspect, wherein the polymer reinforcement includes a rib extending in a direction away from the cross member.

[0078] Aspect 11: The vehicle battery pack frame according to any preceding aspect, wherein the stiffness of the polymer reinforcement is less than the stiffness of the profiled body.

[0079] Aspect 12: The vehicle battery pack frame according to any preceding aspect, wherein the polymer reinforcement comprises a foam, a cellular structure (eg, a honeycomb), a rib, or a combination comprising at least one of the foregoing.

[0080] Aspect 13: The vehicle battery pack frame according to any of the preceding aspects, wherein the columns of the honeycomb structure have different diameters of 20 to 40 mm and a wall thickness of 1.5 to 5.0 mm.

[0081] Aspect 14: A vehicle battery pack frame according to any of the preceding aspects, wherein the side members are configured such that each polymer reinforcement absorbs collision energy during a rigid pole collision at a speed of 30 kilometers per hour in accordance with Federal Motor Vehicle Safety Standard 214, so that each profile body and the vehicle battery pack frame maintain structural integrity after the rigid pole collision.

[0082] Aspect 15: The vehicle battery pack frame according to any preceding aspect, wherein the profiled body includes a channel extending away from the cross member; and wherein the polymer reinforcement is disposed in the channel.

[0083] Aspect 16: A vehicle battery pack frame according to any of the preceding aspects, wherein: the profiled body includes a channel opposite to a surface of the profiled body to which the cross beam is attached; and the polymer reinforcement is located in the channel.

[0084] Aspect 17: A vehicle battery pack frame according to any of the preceding aspects, wherein the profiled body includes a box structure adjacent to the channel, wherein the box structure includes a side wall spaced apart from the channel, and wherein the box structure is formed by a first connecting wall extending between the side wall and the top wall of the channel and a second connecting wall extending between the side wall and the bottom wall of the channel.

[0085] Aspect 18: The vehicle battery pack frame according to Aspect 17, wherein the box structure is formed by the side walls, connecting walls and rear wall of the channel, or wherein the box structure opens to the channel.

[0086] Aspect 19: A vehicle battery pack frame according to Aspect 17 or 18, wherein the height of the side wall is greater than the height of the channel and / or greater than the height of the rear wall, so that the height of the box structure is greater than the height of the channel.

[0087] Aspect 20: A vehicle battery pack frame according to any one of Aspects 17-19, wherein the first connecting wall and the second connecting wall extend from the side wall toward the channel at an angle θ of 90 degrees or less, preferably at an angle of 30 to 75 degrees, preferably at an angle of 40 to 50 degrees.

[0088] Aspect 21: A vehicle battery pack frame according to any one of Aspects 1-16, wherein the special-shaped body includes a top wall, a bottom wall, and a reinforcing support element extending between the top wall and the bottom wall, a channel is formed between the top wall and the bottom wall, wherein a first support wall extends away from the channel from the top wall, and a second support wall extends away from the channel from the bottom wall, wherein the reinforcing support element is arranged at the position of the first support wall and the second support wall.

[0089] Aspect 22: The vehicle battery pack frame according to Aspect 21, wherein the second polymer reinforcement is attached to the first and / or second support wall, preferably adjacent to the first and / or second support wall and / or adjacent to the top wall and / or bottom wall, respectively.

[0090] Aspect 23: The vehicle battery pack frame of any of the preceding aspects, wherein the polymer reinforcement comprises a honeycomb structure having columns oriented perpendicular to the longitudinal axis of the channel.

[0091] Aspect 24: The vehicle battery pack frame of any preceding aspect, wherein the reinforcement structure comprises honeycombs oriented perpendicular to the major axis of the channel, and wherein the major axis of the channel is the length direction.

[0092] Aspect 25: The vehicle battery pack frame according to any of the preceding aspects, wherein the length of the side member is greater than 1 to 3 meters, preferably between 1.5 and 2.0 meters.

[0093] Aspect 26: A vehicle battery pack frame according to any of the preceding aspects, wherein: each shaped body further comprises a flange; the flange of one side member extends from the side wall toward the flange of the other side member; and the base extends between the side members and is disposed on the flange of each side member.

[0094] Aspect 27: A vehicle battery pack assembly comprising: a vehicle battery pack frame according to any one of aspects 1-26; and a plurality of battery modules in the vehicle battery pack frame.

[0095] Aspect 28: A vehicle comprising the vehicle battery pack assembly according to Aspect 27.

[0096] Aspect 29: A method of forming a vehicle battery pack frame according to any one of aspects 1-26, the method comprising: combining a polymer reinforcement and a profiled body to form a side member; and attaching a cross member and the profiled body to each other.

[0097] Aspect 30: The method of aspect 29, comprising injection molding a polymer reinforcement 60 in the channel opposite the surface of the profiled body to which the cross beam is attached.

[0098] Aspect 31: The method according to any of Aspects 29-30, comprising coextruding the polymer reinforcement 60 and the profiled body.

[0099] Aspect 32: The method according to any of aspects 29-31, comprising: molding the polymer reinforcement 60; forming the profiled body by extruding or stamping a metal sheet; and inserting the polymer reinforcement 60 into the profiled body.

[0100] As used herein, the term "battery module" may refer to any of a variety of different battery types, chemistries, and configurations, including but not limited to lithium ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium ion polymer, nickel metal hydride, nickel cadmium, nickel metal hydride, nickel zinc, silver zinc, or other battery types / configurations. As used herein, the term "battery pack" refers to a plurality of individual battery modules contained within a single-piece or multi-piece housing, the individual battery modules being electrically interconnected to achieve the desired voltage and capacity for a particular application.

[0101] The compositions, methods and articles may alternatively comprise, consist of or consist essentially of any suitable component or step disclosed herein. The compositions, methods and articles may additionally or alternatively be formulated to be free of or essentially free of any step, component, material, ingredient, adjuvant or species that is not necessary to achieve the function or purpose of the compositions, methods and articles.

[0102] All ranges disclosed herein include endpoints, and the endpoints can be independently combined with each other (e.g., a range of "up to 25 wt.%, or more specifically, 5 wt.% to 20 wt.%" includes the endpoints and all intermediate values ​​within the range of "5 wt.% to 25 wt.%, etc.). "Compositions" include blends, mixtures, alloys, reaction products, and the like. Unless otherwise specified herein or clearly contradicted by the context, the terms "one" and "an" and "the" do not represent quantitative limitations and should be interpreted as covering the singular and plural. "Or" means "and / or" unless otherwise explicitly stated. References to "one embodiment" throughout the specification mean that the specific elements described in conjunction with the embodiment are included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it should be understood that in various embodiments, the described elements may be combined in any suitable manner.

[0103] Unless otherwise specified herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, as of the filing date of the earliest priority application in which the test standards appear.

[0104] Unless otherwise defined, the technical and scientific terms used herein have the same meanings as those generally understood by those skilled in the art to which the application belongs. All cited patents, patent applications and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term incorporated in a reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0105] Although specific embodiments have been described, substitutions, modifications, variations, improvements, and substantial equivalents that are not currently foreseeable or may not be foreseeable may occur to the applicant or other persons skilled in the art. Therefore, the appended claims as filed and as they may be amended are intended to include all such substitutions, modifications, variations, improvements, and substantial equivalents.

Claims

1. A vehicle battery pack frame (11) for a vehicle, comprising: a base (14) having a length and a width; side members (30) located on opposite sides of the base, extending along the length of the base, and attached to the periphery of the base; as well as a plurality of cross members (16) extending across the width of the base between the side members; Each side member comprises A profiled body (32) comprising a side wall (42) having a first surface facing the crossbeam and an opposite second surface; and A polymer reinforcement (60) is attached to the profiled body and faces the second surface of the side wall of the profiled body.

2. The vehicle battery pack frame of claim 1 further comprising a cover (20) extending between the side members, wherein the cross beam is disposed between the cover and the base, and preferably wherein the base, the side members and the cover enclose a plurality of battery modules in the vehicle battery pack frame. 3 . The vehicle battery pack frame of claim 1 , wherein the polymer reinforcement is adjacent to the second surface of the side wall.

4. A vehicle battery pack frame according to any one of the preceding claims, wherein the profiled body comprises a channel (35) extending away from the cross beam, the channel comprising a top wall (34) and a bottom wall (36), the channel being located between the top wall and the bottom wall; and wherein the polymer reinforcement is disposed in the channel.

5. A vehicle battery pack frame according to any one of the preceding claims, wherein the profiled body comprises a box structure (38) adjacent to the channel, wherein the box structure is formed by a side wall (42) spaced apart from the channel, a first connecting wall (44) extending between the side wall (42) and a top wall of the channel, and a second connecting wall (46) extending between the side wall and a bottom wall of the channel.

6. The vehicle battery pack frame according to claim 4, wherein the box structure is formed by side walls, connecting walls and a rear wall (40) of the channel, wherein the rear wall extends between the top wall and the bottom wall; or wherein the box structure opens into the channel.

7. The vehicle battery pack frame according to claim 4 or 5, wherein the height of the side wall is greater than the height of the channel and / or greater than the height of the rear wall, so that the height of the box structure is greater than the height of the channel.

8. The vehicle battery pack frame according to any one of claims 4-7, wherein the first connecting wall and the second connecting wall extend from the side wall toward the channel at an angle θ of 90 degrees or less, preferably at an angle of 30 to 75 degrees, preferably at an angle of 40 to 50 degrees.

9. A vehicle battery pack frame according to any one of the preceding claims, wherein: Each shaped body also includes a flange (52); The flange of one of the side members extends from the side wall toward the flange of the other side member; and The base extends between the side members and is disposed on a flange of each side member.

10. A vehicle battery pack frame according to any one of the preceding claims, wherein the polymer reinforcement comprises a honeycomb structure having columns (33) oriented perpendicularly to the longitudinal axis of the channel.

11. A vehicle battery pack assembly (10), comprising: The vehicle battery pack frame (11) according to any one of claims 1 to 10; and A plurality of battery modules (12) are disposed in a vehicle battery pack frame.

12. A vehicle comprising the vehicle battery pack assembly according to claim 11.

13. A method for forming a vehicle battery pack frame (11) according to any one of claims 1 to 10, the method comprising: combining a polymer reinforcement (60) and a profiled body (32) to form a side member (30); and The crossbeam (16) and the profiled body are attached to each other.

Images