Power supply assembly for electric motor vehicle

Abstract

The invention relates to an electric power supply assembly for a motor vehicle, comprising a compartment mounted under the vehicle, and at least two battery modules (16, 16 ') connected to a cable and mounted within the compartment, each of these modules having an upper face and four faces perpendicular to the upper face, each of the modules includes an upper face having a boundary adjacent one of the four faces defining an edge (40, 40 '), each of the modules further including a cover having a rim disposed rearward from the edge. The two battery modules (16, 16 ') are arranged such that two faces from one of the four faces of each group face each other, while the two edges (40, 40') extend away from each other and the two edges extend facing each other. Moreover, the two covers have two projections (42, 42 ') which extend towards each other, overhang over respective adjacent boundaries, to locally catch the cable (58).

Description

Technical Field

[0001] The present invention relates to a power supply assembly for an electric motor vehicle. Background Art

[0002] The power supply assembly generally includes a compartment installed under the body shell of a motor vehicle, and a plurality of battery modules installed in the compartment.

[0003] Moreover, the battery conveys a high voltage of approximately 400V via a suitable cable.

[0004] In addition to accommodating the batteries and the cables connected to these batteries, the compartment must also house control devices for controlling the operation of the battery, connection elements, and also a junction box for connection to the vehicle.

[0005] The battery module has an overall shape of a rectangular parallelepiped, and includes a support surface that abuts against the bottom of the compartment and an upper surface opposite to the support surface. These battery modules have four faces perpendicular to the support surface and the upper surface, and these four faces are pairwise parallel. The upper surface has edges adjacent to the four faces.

[0006] Moreover, each module includes a cover member adapted to cover the upper surface. The cover member has a lip extending perpendicular to the adjacent edges.

[0007] As for the cables, these cables are inserted into split annular sheaths to protect and better insulate the cables. The outer diameters of these sheaths are relatively large. The outer diameter is, for example, between 10mm and 15mm.

[0008] In other words, these battery modules are intended to be juxtaposed in the compartment, and their dimensions are determined to occupy all available space. Therefore, there is a problem with the routing of the cables. Specifically, in the event of a vehicle collision, these cables must not be damaged or even broken due to the relative movement of the battery module and the compartment.

[0009] Therefore, a problem that arises and that the present invention attempts to solve is to provide a power supply assembly in which the cables are protected from the risk of damage. Summary of the Invention

[0010] For this purpose, a power supply assembly for an electric motor vehicle is proposed, the power supply assembly comprising a compartment adapted to be mounted under the body shell of the motor vehicle, and at least two battery modules, the at least two battery modules being connected to a cable and mounted in the compartment, each of the modules having a support surface opposite to an upper surface, and four surfaces perpendicular to the support surface and the upper surface, the upper surface having a boundary lip adjacent to one of the four surfaces so as to define an intersecting edge, each of the modules further comprising a cover for covering the upper surface, the cover having an edge adapted to extend substantially perpendicular to the boundary lip and be set back from the intersecting edge. The two battery modules are arranged in the compartment such that two of the four surfaces of one of the two face each other, while two intersecting edges extend parallel to each other and at a distance from each other, and two edges of the two covers extend facing each other. Further, the two covers have two protrusions respectively fixed to the two facing edges and extending towards each other such that the two protrusions respectively overhang above the adjacent boundary lips such that the cable can be locally clamped between the two intersecting edges and the two protrusions.

[0011] Accordingly, a feature of the present invention is that the space extending between the two edges of the covers of two adjacent battery modules is advantageously utilized for routing the cable, and also that two protrusions extending towards each other from the two covers are used to clamp the cable. In this way, and as will be explained in more detail later in the specification, the cable is thus protected from the relative movement of two adjacent modules, and the cable is kept away from the upper housing enclosing the compartment.

[0012] Such an embodiment makes it possible to dispense with the need for relatively bulky cable ties or collars.

[0013] Advantageously, the intersecting edges extend relative to each other at a first spacing, while the edges extend relative to each other at a second spacing greater than the first spacing. Accordingly, the intersecting edges extend relative to each other at a spacing less than the diameter of the cable such that the cable can be pressed against these intersecting edges. These edges extend relative to each other at a greater spacing so as to be able to define a space capable of accommodating the cable.

[0014] Further, according to a particularly advantageous embodiment of the present invention, the two protrusions extend towards each other until the spacing between them is substantially equal to the first spacing. As a result, as will be explained later, the cable is forced into the space between the two protrusions such that the cable can be clamped between the two protrusions and the two intersecting edges. Accordingly, the cable passes through between the two protrusions substantially due to the deformation of the cable, more specifically due to the deformation of its sheath, as will be explained in detail later in the specification.

[0015] In addition, each of the protrusions advantageously has a thickened free end. In this way, the cable can be more easily engaged and there is no risk of being damaged.

[0016] Preferably, each of the protrusions has a free end that is inclined to be able to receive the free end of the cable. In other words, the free ends of these protrusions are inclined towards the center of the passage defined by two intersecting edges and two edges. This then makes it easier to engage the cable within the passage.

[0017] According to a specific embodiment feature, each of the cover members and the protrusions are molded in one piece from a polymer material. In this way, the protrusions are carried on the edges of these cover members at a highly favorable marginal cost, which is similar to the cost of the additional material required to mold the protrusions.

[0018] Preferably, the two cover members have two other protrusions that are spaced apart from the two protrusions and are respectively fixed to the two mutually facing edges, and the two other protrusions extend towards each other and overhang above the adjacent boundary lips respectively. Thus, the two pairs of protrusions are spaced apart from each other, so as to better accommodate the cable in the passage extending between the two battery modules.

[0019] According to a particularly advantageous embodiment of the present invention, each of the two cover members has a reinforcing rib extending along the protrusion. In this way, the reinforcing rib can increase the second moment of area of the rib, especially when the cable is inserted between two mutually facing ribs.

[0020] Now, one of the two of the four faces is disposed facing each other, advantageously spaced between 9.5 mm and 10.5 mm. As a result, the two corresponding intersecting edges are spaced apart by substantially the same distance.

[0021] In addition, the two free ends of the two protrusions are spaced apart by a relatively small distance. For example, the two protrusions are spaced apart by a distance between 8 mm and 9 mm, and in the example shown, this distance is typically 8.63 mm.

[0022] In addition, the free end of each protrusion is advantageously spaced from the corresponding intersecting edge above which the free end overhangs by a distance between 6 mm and 7 mm, and in the example shown, this distance is typically 6.73 mm.

[0023] In addition, it can be noted that the cable extends in a split ring-shaped sheath made of, for example, polypropylene, and the sheath is relatively compressible. Description of the Drawings

[0024] Other features and advantages of the present invention will become apparent when reading the description of a specific embodiment of the present invention given below with reference to the accompanying drawings, which is provided by way of non-limiting illustration, in which:

[0025] Figure 1 is a schematic partial view of a longitudinal section of a power supply assembly according to the present invention;

[0026] Figure 2 is a schematic perspective view of an element of a power supply assembly according to the present invention;

[0027] Figure 3 is Figure 2 a schematic perspective detail view of the subject matter of;

[0028] Figure 4 is in Figure 2 a schematic detail view of a section on plane IV-IV identified in;

[0029] Figure 5 is a schematic view of the subject matter of Figure 4 including another element in a first assembly stage; and

[0030] Figure 6 is Figure 5 a schematic view of the subject matter in a second assembly stage. Detailed Description of the Invention

[0031] Figure 1 shows in part and in vertical section a power supply assembly according to the present invention. The power supply assembly is located in an orthogonal X, Y, Z reference system, in which the axis X extends in the longitudinal front-rear direction of a motor vehicle, pointing rearward; the axis Y extends in the transverse direction of the vehicle, from left to right; and the axis Z extends in the vertical direction, pointing away from the ground.

[0032] Thus, Figure 1 shows the floor 10 of a motor vehicle, below which the compartment 12 is mounted. The compartment 12 includes a bottom wall 14 on which the battery module 16 is rested. The compartment is enclosed by a housing 18.

[0033] The battery module 16 includes a plurality of lithium-ion type cells, which are connected to each other up to the two terminals of the module 16.

[0034] ​​​​​​​At present, the module 16 has a rectangular parallelepiped shape. Therefore, the module has a support surface 20 that abuts against the bottom wall 14 of the compartment 12, and an upper surface 22 opposite to the support surface. The module also has four surfaces that are opposite to each other in pairs and perpendicular to the support surface 20 and the upper surface 22: a front surface 24 opposite to the rear surface 28, and a right lateral surface 26 opposite to the left lateral surface 30.

[0035] In addition, the upper surface 22 of the module 16 is covered by a cover member 32, which has an end wall 34 and an edge 36 that cooperate with the upper surface 22.

[0036] Therefore, a plurality of modules 16 are installed in the compartment 12, and the terminals of these modules are respectively connected to each other and connected together by at least one cable not depicted herein.

[0037] Reference Figure 2 shows two identical modules (the first module 16 and the second module 16'), which are adjacent when assembled in the compartment 12. Other pairs of modules are advantageously inserted into the compartment 12 in the same configuration.

[0038] Two modules 16, 16' are assembled side by side, where the right lateral surface 26 of the first module 16 faces the left lateral surface 30' of the second module 16'.

[0039] Moreover, the upper surfaces 22, 22' of the two modules 16, 16' define two boundary lips 38, 38' that are adjacent to the right lateral surface 26 and the left lateral surface 30' respectively. Further, the two adjacent boundary lips 38, 38' respectively form two parallel intersecting edges 40, 40' with the right lateral surface 26 and the left lateral surface 30'.

[0040] Moreover, the two edges 36, 36' of the cover members 32, 32' are respectively assembled perpendicular to the adjacent boundary lips 38, 38' and are set back from their intersecting edges 40, 40'.

[0041] In addition, according to the present invention, the two cover members 32, 32' have two first protrusions 42, 42', which extend towards each other as they respectively protrude from the two edges 36, 36' and overhang above the adjacent boundary lips 38, 38'.

[0042] In addition, the two cover members 32, 32' have two second protrusions 44, 44', which are arranged at a certain distance from the two first protrusions 42, 42'.

[0043] Therefore, reference will be made to Figure 3 , which partially and detailedly shows in Figure 2The second module 16', more specifically the first protrusion 42' extending from the edge 36' of the cover member 32' covering the second module 16', as viewed in the direction of arrow V in the reference.

[0044] The adjacent boundary lip 38' and the intersection edge 40' formed by the boundary lip and the left lateral face 30' can also be seen.

[0045] It should be noted that the length by which the protrusion 42' extends from the edge 36' of the cover member 32' in the direction Y is, for example, between 6 mm and 7.5 mm, while the width by which the protrusion extends transversely in the direction X is, for example, between 20 mm and 30 mm.

[0046] Furthermore, the protrusion has a T-shaped free end 46', which is significantly deformed and defines an upper arm 48' opposite to the lower arm 50'. The two arms 48' and 50' define an inclined clamping surface 52', with the upper arm 48' close to the end wall 34' of the cover member 32', and the lower arm 50' being significantly separated from the edge 36'.

[0047] The cover member 32' also has two substantially parallel reinforcing ribs 54', 56', which extend into the protrusion 42' up to the upper arm 48'. These two reinforcing ribs 54', 56' increase the second moment of area of the protrusion 42'.

[0048] It should be noted that the cover members 32, 32' and the protrusions 42, 42' and the reinforcing ribs 54, 56, 54', 56' are molded as a single piece from the same polymeric material. In this way, the additional cost of implementing these protrusions 42, 42' is close to the additional cost of the polymeric material for manufacturing them. Therefore, this cost is essentially not high.

[0049] Reference will now be made to Figure 4 , which depicts in more detail two protrusions 42, 42' facing each other in the cross-sectional plane IV-IV shown in Figure 2 .

[0050] Thus, the two facing lateral faces 26, 30' of the two modules 16, 16', the two mutually parallel intersection edges 40, 40', the two facing edges 36, 36', and the two protrusions 42, 42' overhanging the two adjacent boundary lips 38, 38' can be seen. Therefore, the two lower arms 50, 50' and the two intersection edges 40, 40' define a trapezoid, the diagonals of which intersect at C, which is the center of the passage between the two modules 16, 16' and their respective cover members 32, 32'.

[0051] Thus, the distance D by which two mutually facing lateral faces 26, 30' of the two modules 16, 16' are spaced apart is, for example, 10 mm. As a result, the two intersecting edges 40, 40' are spaced apart from each other by substantially the same distance. Thus, the two lower arms 50, 50' are also spaced apart from each other by a distance similar to the distance D, while the distance by which the two edges 36, 36' are spaced apart is between 20 mm and 25 mm.

[0052] In addition, the lower arms 50, 50' of the free ends 46, 46' of the protrusions 42, 42' are spaced apart from the intersecting edges 40, 40' respectively, and the distances by which these lower arms respectively overhang are, for example, between 6 mm and 7 mm.

[0053] In addition, it should be noted that the two mutually facing lateral faces 26, 30' of the two modules 16, 16', the two mutually parallel intersecting edges 40, 40' and the two mutually facing edges 36, 36', as well as the two protrusions 42, 42' are symmetric with respect to each other about a mid-plane P extending between the two modules 16, 16'.

[0054] It should be noted that the two modules 16, 16' are held in fixed positions on the bottom wall 14 of the compartment 12.

[0055] Thus, then Figure 5 the cable 58 shown in four consecutive positions in

[0056] is inserted between the two modules 16, 16', as will be explained below.

[0057] First of all, the cable 58 includes a core 60 which includes copper conductors inserted into a first sheath made of, for example, polyvinyl chloride. Then, the core 60 is joined in a relatively thick split-ring-shaped second sheath 62 made of, for example, polypropylene.

[0058] The diameter of the core 60 is, for example, between 6 mm and 8 mm, while the outer diameter of the ring-shaped sheath 62 is, for example, between 13 mm and 14 mm.

[0059] Thus, in a first step, the cable 58 is brought into contact with the two clamping surfaces 52, 52' of the two T-shaped free ends 46, 46' of the two protrusions 42, 42' respectively.

[0060] Next, in a second step, the cable 58 is pushed forcefully between the clamping surfaces 52, 52' towards the two intersecting edges 40, 40'. The clamping surfaces 52, 52' which are inclined towards each other make it easier for the cable 58 to pass through.

[0061] Then, the cable 58 is further pushed forcefully between the two lower arms 50, 50' until the cable abuts against the intersecting edges 40, 40'.

[0062] In this position, as Figure 6 depicted, the annular sheath 62 of the cable 58 has returned to its original shape and also remains pressed against the two lower arms 50, 50'.

[0063] In other words, the cable 58 is locally stuck between the two intersecting edges 40, 40' and the two lower arms 50, 50' of the two protrusions 42, 42' that overhang above the two intersecting edges.

[0064] Therefore, the same procedure is used to insert the cable 58 between Figure 2 the two second protrusions 44, 44' shown at a certain distance from the two first protrusions 42, 42'.

[0065] In this way, the cable 58 is held in a fixed position so that it extends over the top of the adjacent modules 16, 16' and is locally stuck between the two intersecting edges 40, 40' and the two lower arms 50, 50'.

[0066] Therefore, this empty space inherent in the construction of the power supply assembly according to the present invention is beneficially used for cabling. In addition, it should be noted that if the two modules 16, 16' are forced to move closer to each other, for example due to a collision, the cable 58 will tend to be pushed vertically upward between the protrusions 42, 42' without being damaged.

Claims

1. An electric power supply assembly for an electric motor vehicle, the electric power supply assembly comprising a compartment (12) adapted to be mounted under a body shell of the motor vehicle, and at least two battery modules (16, 16'), the at least two battery modules being connected to a cable and mounted in the compartment, each of the modules having a support surface (20, 20') opposite to an upper surface (22, 22'), and four surfaces perpendicular to the support surface and the upper surface, the upper surface having a boundary lip (38, 38') adjacent to one of the four surfaces (26, 30') so as to define an intersecting edge (40, 40'), each of the modules further comprising a cover (32, 32') for covering the upper surface, the cover having an edge (36, 36') adapted to extend substantially perpendicular to the boundary lip (38, 38') and be set back from the intersecting edge; Characterized in that, the two battery modules (16, 16') are arranged in the compartment (12) such that two of the four surfaces (26, 30') of the two modules are arranged facing each other, and the two intersecting edges (40, 40') extend parallel to each other and at a distance, and the two edges (36, 36') of the two covers extend facing each other; and the two covers (32, 32') have two protrusions (42, 42'), the two protrusions being respectively fixed to the two facing edges (36, 36') and extending towards each other, such that the two protrusions respectively overhang above the adjacent boundary lips (38, 38'), so that the cable (58) can be locally clamped between the two intersecting edges (40, 40') and the two protrusions (42, 42').

2. The electric power supply assembly according to claim 1, Characterized in that, the intersecting edges (40, 40') extend relative to each other with a first spacing therebetween, and the edges (36, 36') extend relative to each other with a second spacing greater than the first spacing therebetween.

3. The electric power supply assembly according to claim 2, Characterized in that, the two protrusions (42, 42') extend towards each other until the spacing between the two protrusions is substantially equal to the first spacing.

4. The electric power supply assembly according to claim 2 or 3, Characterized in that, each of the protrusions (42, 42') has a thickened free end (46, 46').

5. The electric power supply assembly according to any one of claims 2 to 4, Characterized in that, each of the protrusions (42, 42') has a free end (46, 46') inclined to be able to accommodate the cable (58).

6. The electric power supply assembly according to any one of claims 1 to 5, Characterized in that, each of the covers (32, 32') and the protrusions (42, 42') are molded in one piece from a polymer material.

7. The electric power supply assembly according to any one of claims 1 to 6, Characterized in that, The two cover members (32, 32') have two other protrusions (44, 44') which are spaced apart from the two protrusions (42, 42') and are respectively fixed to the two mutually facing edges (36, 36'), and the two other protrusions respectively extend towards each other and overhang above these adjacent boundary lips (38, 38').

8. The power supply assembly according to any one of claims 1 to 7, characterized in that each of the two cover members (32, 32') has reinforcing ribs (54', 56') extending along the protrusion (42').

9. The power supply assembly according to any one of claims 1 to 8, characterized in that one of the two said four faces (26, 30') is arranged facing each other, with a spacing between 9.5 mm and 10.5 mm.

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