Battery carrier device for electric vehicle

Abstract

The invention relates to a battery carrier arrangement (1) of an electric vehicle, comprising a battery carrier (3) and a front axle carrier (2), which are arranged in the underlying region of the electric vehicle, in the transition from the front axle carrier (2) to the battery carrier (3) a single-layer ramp plate (4) extending in the longitudinal direction (X) of the vehicle is arranged as a thermoformed press-hardened part, the tensile strength Rm being greater than 1200 MPa.

Description

Technical Field

[0001] The present invention relates to a battery carrier device for an electric vehicle. Background Art

[0002] In the prior art, passenger cars have long used internal combustion engines to drive people and light goods from one place to another.

[0003] In recent years, the drive has gradually shifted from internal combustion engine drive to electric drive. Electric drive requires an energy storage source, also known as a traction battery. However, for a passenger car weighing up to 7.5 tons including the load, if it is to carry the corresponding energy supply, this traction battery will inevitably be bulky and weigh hundreds of kilograms.

[0004] For this reason, the battery or accumulator is usually accommodated in a so-called battery tray. Reasonably, such a battery tray is arranged in the bottom area, that is, below the passenger compartment. This can reduce the center of gravity of the electric vehicle, especially when the vehicle is turning, which will have a positive impact on the driving behavior.

[0005] When a vehicle collision occurs, the battery carrier must be protected as much as possible to prevent the internal accumulator from suffering mechanical damage. On the one hand, there is a risk of fire in serious cases, and on the other hand, replacing the accumulator will also involve a considerable economic loss.

[0006] Patent document DE 10 2022 126585 B3 discloses a front shield located above the parting surface between the battery tray and the front axle.

[0007] Patent document US2022 / 379963 A1 also discloses a battery tray device supported on the front axle by struts. Summary of the Invention

[0008] In view of this, the object of the present invention is to propose a technical solution that can avoid damaging the battery tray as much as possible in certain driving situations, especially in the case of vehicle collision.

[0009] The battery tray device is provided for an electric vehicle. For this purpose, the electric vehicle has a battery tray arranged in the bottom area of the electric vehicle. The battery tray is a battery box, which especially extends more than 50%, especially more than 60%, preferably more than 70% of the vehicle width in the vehicle transverse direction. Preferably, the battery tray has a front part extending substantially in the vehicle transverse direction. The battery tray is arranged in the bottom area of the electric vehicle.

[0010] In addition, the battery tray device has a front axle carrier, also known as an axle carrier. In particular, the front axle carrier is designed as a frame member and houses the front axle components to fasten or arrange the front axle under the vehicle body of the electric vehicle.

[0011] According to the present invention, the battery carrier device is characterized in that a single-layer ramp plate extending or stretching along the longitudinal direction of the vehicle is arranged in the transition area from the front axle carrier to the battery carrier. According to the present invention, the ramp plate is also designed as a hot-formed press-hardened component with a tensile strength Rm greater than 1200 MPa.

[0012] The ramp plate according to the present invention has two functions. In the event of a head-on collision, the ramp plate will particularly reinforce the coupling area between the front axle carrier and the battery carrier, so as to prevent the front axle carrier from intruding into the battery carrier. The second function of the ramp plate is that in the case of touching or driving over a ground obstacle, the ramp plate can prevent the ground obstacle from hitting the battery carrier head-on and causing damage to it. The ramp plate allows the ground obstacle to slide under or avoid the battery carrier, thus avoiding further damage.

[0013] The ramp plate is coupled (especially bolted) to the front axle carrier and / or the battery carrier. This facilitates the assembly of the ramp plate. The use of hot-formed press-hardened technology provides a component made of high-strength steel, especially ultra-high-strength steel, so that the ramp plate can be designed as a single-layer sheet metal component. Compared with other components that require more materials and / or more input of materials and / or increased production costs, this can especially reduce weight and save production costs.

[0014] Preferably, the ramp plate itself is made of a sheet metal blank with a uniform material throughout. Alternatively, the ramp plate can be made of a welded blank, that is, a sheet metal blank formed by welding multiple sheets of different sheet thicknesses and / or different sheet qualities.

[0015] The ramp plate has a ramp surface inclined to the longitudinal direction of the vehicle. Preferably, it extends over most of the width of the battery carrier. In particular, the ramp surface covers the entire front area of the battery carrier extending in the transverse direction of the vehicle.

[0016] Preferably, the ramp surface is arranged at an angle of 3° to 20° with respect to the horizontal direction or the longitudinal direction of the vehicle. In this way, the ground obstacle can be deflected downward under the battery carrier by means of the ramp surface.

[0017] In addition, a coupling area is particularly preferably formed. This especially applies to the grooves in the ramp plate. Particularly preferably, the strength of these grooves can be lower than the rest of the ramp plate. This can enhance the ductility. These areas will not break off during an accident. The remaining high-tensile-strength areas of the ramp plate will provide corresponding reinforcement during an accident.

[0018] The front coupling surface and / or the rear coupling surface are arranged to extend substantially parallel to the vehicle longitudinal direction or the plane formed by the vehicle longitudinal direction and the vehicle transverse direction. In this way, the ramp plate can be fastened under the front axle bracket and under the battery bracket. The ramp surface between the two slopes downward. Viewed from the plan view, the front surface under the front axle bracket and / or the rear surface under the battery bracket are configured in a rectangular shape. The length in the vehicle longitudinal direction is significantly shorter than the length in the vehicle transverse direction. The extent of the vehicle in the transverse direction preferably corresponds to the width of the battery bracket. This in turn corresponds to most of the width of the vehicle itself.

[0019] Reinforcing ribs can also be molded at least longitudinally segmented in the vehicle longitudinal direction. In the reinforcing ribs 11 or preferably in the flat plate area between the reinforcing ribs, a front axle bracket fastening coupling surface and / or the above-mentioned spacer can be provided, and they are especially molded in the ramp area or the ramp surface of the ramp plate. Thereby, the ramp surface is harder and allows ground obstacles to slide under the vehicle.

[0020] Additionally, reinforcing patches can be arranged on the ramp plate, and they are arranged on the side facing away from the bottom layer, that is, on the inner side of the ramp plate, and are preferably hot-formed and compression-molded and hardened together with the ramp plate.

[0021] It has also been proven that it is particularly advantageous for the ramp plate to extend at least halfway under the front axle bracket in the vehicle longitudinal direction.

[0022] For further reinforcement, additional spacers can be arranged between the inner side of the ramp plate and the front axle bracket under the battery bracket. This in turn provides additional reinforcement for the ramp plate.

[0023] On the other hand, the present invention proposes that in the ramp plate, a buffer is arranged in front of the battery bracket along the vehicle longitudinal direction. The buffer functions according to the principle of a collision box or a stopper. If a frontal collision occurs on the bottom layer, that is, a frontal collision affecting the front part of the battery bracket in the vehicle longitudinal direction, according to the principle of the function of the collision box, the energy will be dissipated. For this purpose, for example, a hollow profile can be additionally arranged in front of the battery bracket on the inner side of the ramp plate. The hollow profile can be used as a spacer and a reinforcement at the same time. However, if the collision energy is too large so that the ramp plate itself is deformed, the hollow profile acts as a collision box to protect the front side of the battery bracket.

[0024] The buffer can also be designed as a stopper. In this way, when a frontal impact or a frontal collision occurs, the screwing of the ramp plate to the battery bracket can be supported. Otherwise, the force in the vehicle longitudinal direction will cause high loads and may even cause the ramp plate to crack. Therefore, the stopper provided by the buffer prevents the ramp element from being pressed under the battery bracket.

[0025] According to the present invention, the battery bracket device can work together, especially a battery bracket that is jointly integrated or installed with a vehicle bottom protection mechanism and is fully anti-collision, so that obstacles can further slide along the ramp plate under the battery bracket or its vehicle bottom protection mechanism. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The following describes further advantages, features, characteristics and aspects of the subject matter of the present invention. Preferred variants are shown in the schematic drawings. These drawings are used to clearly understand the present invention. In the drawings:

[0027] Figure 1 A simplified schematic view of a battery carrier device according to the present invention is shown;

[0028] Figure 2 A bottom view of the battery carrier device according to the present invention is shown;

[0029] Figure 3a and Figure 3b A side view and a bottom view of an improved ramp plate are shown;

[0030] Figure 4a and Figure 4b An alternative variant of the ramp plate is shown;

[0031] Figure 5a and Figure 5b An alternative with a reinforcement patch is shown;

[0032] Figure 6 An alternative variant is shown;

[0033] Figure 7a 、 Figure 7b and Figure 7c show Figure 1 the alternative variant shown;

[0034] Figure 8 Another variant with a buffer is shown;

[0035] Figure 9a 、 Figure 9b and Figure 9c show different buffers;

[0036] Figure 10 show Figure 1 an alternative arrangement of

[0037] LIST OF REFERENCE NUMERALS:

[0038] 1: Battery carrier device

[0039] 2: Front axle carrier

[0040] 3: Battery carrier

[0041] 4: Ramp plate

[0042] 5: Ramp surface

[0043] 6: Object

[0044] 7: Bolted part

[0045] 8: Half front axle bracket

[0046] 9: Battery bracket width

[0047] 10: Coupling surface

[0048] 11: Reinforcing rib

[0049] 12: Large reinforcing rib

[0050] 13: Reinforcing patch

[0051] 14: Inner side of ramp plate

[0052] 15: Distance

[0053] 16: Soft zone

[0054] 17: Spacer

[0055] 18: Longitudinal front edge

[0056] 19: Longitudinal rear edge

[0057] 20: Buffer

[0058] 21: Front side of battery bracket

[0059] X: Vehicle longitudinal direction

[0060] Y: Vehicle transverse direction

[0061] Z: Vehicle vertical direction

[0062] a: Angle

[0063] The same reference numerals in the drawings are used for the same or similar components, and for the sake of brevity, the repeated description is omitted. Detailed implementation mode

[0064] Figure 1 A simplified schematic side view of the battery bracket device 1 according to the present invention is shown. In the figure, a front axle bracket 2 having a cross frame 2-2 and two longitudinal frames 2-1 and a battery bracket 3 arranged behind it along the vehicle longitudinal direction X are shown. According to the present invention, based on the vehicle vertical Z, a ramp plate 4 is arranged below the battery bracket 3 and below the front axle bracket. For this purpose, the ramp plate 4 has an inclined ramp surface 5. The ramp surface 5 forms a certain angle a with the vehicle longitudinal direction X. In this way, the inclined ramp surface 5 deflects a column or object (not shown in detail) coming from the front under the battery bracket 3, or the ramp surface lifts the vehicle upward. This effectively avoids damage to the battery bracket 3. For example, a bolted part can be provided on the front axle bracket, and a bolted part can also be provided on the battery bracket 3, but at least in the occupied width occupied by the battery unit or battery pack.

[0065] Likewise, the figure also shows a coupling surface that releasably fastens the ramp plate to the front axle bracket in a force-fitting manner, for example, on a longitudinal frame of the front axle bracket that extends in the vehicle longitudinal direction.

[0066] Figure 2 A bottom view of the battery bracket device 1 according to the present invention is shown. In the vehicle longitudinal direction X, the ramp plate 4 extends at least half the length of the front axle bracket 2. In the vehicle transverse direction Y, the ramp plate 4 preferably extends across the entire width of the battery bracket 3.

[0067] Figure 3a and Figure 3b A side view and a bottom view of the improved ramp plate 4 are shown. The ramp plate 4 has a front ramp surface 5 and a rear coupling surface 10. The coupling surface 10 is at least partially located below the battery bracket 3 (not shown) and extends parallel to the horizontal direction or the vehicle longitudinal direction X. Individual reinforcing ribs 11 are arranged at the transition from the coupling area to the ramp surface 5. In addition, large reinforcing ribs 11 are arranged in the front area and extend at least longitudinally in segments along the vehicle longitudinal direction X on the ramp surface 5.

[0068] Figure 4a and Figure 4b An alternative variant of the ramp plate 4 is shown. Here, a reinforcing patch 13 is arranged on the inner side 14 of the ramp plate 4, particularly in the ramp surface 5. In addition, the reinforcing ribs 11 are located in the transition area between the ramp surface 5 and the coupling surface 10.

[0069] Figure 5a and Figure 5b The reinforcing patch 13 is also arranged therein. However, the reinforcing patch 13 is arranged at a distance 15 from the ramp surface 5 of the ramp plate 4, forming one or more reinforcing cavities. The reinforcing patch 13 can also function according to the principle of a crash box, thereby providing a reinforcement 7 to resist object impacts. However, if the impact intensity is high enough to pose a risk of intrusion, the ramp plate 4 is strengthened with the reinforcing patch 13.

[0070] Figure 6 An alternative variant is shown. Here, four so-called soft zones 16 are arranged in the ramp area. The soft zones are areas with a lower tensile strength Rm and are used to dissipate energy and / or prevent cracks from occurring in the coupling surface.

[0071] Figure 7a , Figure 7b and Figure 7c shows Figure 1 the variant shown. However, Figure 7b and Figure 7c spacers 17 are respectively arranged therein. According to Figure 7bIn the spacer 17, two separate spacers 17 are arranged successively in the longitudinal direction X of the vehicle. Although not shown in detail in the figure, in the transverse direction of the vehicle, there are such arranged spacers in both the left region and the right region of the vehicle. According to Figure 7c , spacer blocks are provided. Regarding the left and right sides of the vehicle in the transverse direction Y of the vehicle, spacer blocks can be respectively arranged on the left side and the right side. For all variants, a longitudinal front edge 18 or a longitudinal rear edge 19 can also be formed. Preferably, both the longitudinal edges 18 and 19 extend across the entire width of the ramp plate 4.

[0072] Instead of locally arranged spacers, the spacers can also be designed to continuously extend from the left coupling surface to the right coupling surface in the transverse direction of the vehicle, that is, Figure 2 continuously extend between the two front axle longitudinal frames 2-1 shown.

[0073] Figure 8 Another variant is shown. Here, a buffer 20 is arranged. The buffer 12 can be, for example, a hollow profile. If an object impacts this buffer, the ramp plate 4 or the ramp surface 5 of the ramp plate 4 will be acted upon in the direction of the force f. If the strength is high, the object 6 will collide with the front side 21 of the battery carrier 3, and in severe cases, the battery carrier 3 will be damaged. Therefore, a buffer 20 is arranged here and functions according to the principle of a collision box.

[0074] Figure 9a , Figure 9b and Figure 9c show various different buffers 20. As shown in the figure, these buffers can be hollow profiles separately designed on the inner side 14 of the ramp plate 4. In the case of a high-intensity impact between the object and the front side 21 of the battery carrier 3, the buffer 20 will deform, thereby protecting the battery carrier 3 without giving way. In addition, the buffer 20 can also keep the ramp plate 4 in an appropriate position in front of the battery carrier 3.

[0075] Figure 10 Another alternative embodiment of the present invention is shown. It can be seen that the front and rear coupling surfaces 10 of the ramp plate 4 extend parallel to the front axle carrier 2 and the longitudinal axis of the vehicle.

[0076] The ramp plate 4 is connected to the front axle carrier 2 via the shown sleeve starting from the coupling surface 10. The front axle carrier 2 can also have a formed coupling surface 2-3 to adapt to the shape and position of the sleeve or reduce the distance from the ramp plate 4.

[0077] In this example, the ramp plate is also designed such that its longitudinal rear edge 19 is flush with the battery carrier 3 in the vertical direction of the vehicle. This means flush with the lower part or bottom of the battery carrier or the vehicle floor. In the vehicle height direction, there may be any protruding areas in the battery carrier such as a lateral anti-collision frame ( Figure 10 not shown in the minimalist schematic rectangle), and the ramp plate can access the area below it.

Claims

1. A battery bracket device (1) for an electric vehicle, comprising a battery bracket (3) and a front axle bracket (2) arranged in a bottom area of ​​the electric vehicle, characterized in that: In the transition zone from the front axle bracket (2) to the battery bracket (3), a single-layer ramp plate (4) extending along the longitudinal direction (X) of the vehicle is arranged as a hot-formed die-hardened component, and the tensile strength Rm is greater than 1200 MPa; and the ramp plate (4) has a ramp surface (5) extending along the longitudinal direction (X) of the vehicle.

2. The battery bracket device (1) according to claim 1, characterized in that: The ramp plate (4) has a coupling area for connecting the front axle bracket (2) and / or the battery bracket (3), wherein the coupling area has a low strength.

3. The battery bracket device (1) according to claim 1 or 2, characterized in that: The ramp plate (4) has a longitudinal front edge in the longitudinal direction (X) of the vehicle for connecting to the front axle bracket (2); and / or the ramp plate (4) has a longitudinal rear edge (X) in the longitudinal direction of the vehicle for connecting to the battery bracket (3), the ramp plate is at least flushly coupled with the battery bracket in the longitudinal direction of the vehicle, and the ramp plate (4) is joined to the bottom of the battery bracket (3).

4. A battery bracket device (1) according to any one of the preceding claims, characterized in that The ramp plate (4) is made of a sheet metal blank with a uniform material; or the ramp plate (4) is made of a welded blank.

5. The battery bracket device (1) according to any one of the preceding claims, characterized in that The surface of the ramp plate (4) is inclined to the longitudinal direction (X) of the vehicle over most of the width (9) of the battery bracket (3), and the inclination angle is 3 to 20 degrees.

6. A battery carrier device (1) according to any one of the preceding claims, characterized in that The front coupling surface (10) and / or the rear coupling surface (10) are oriented substantially parallel to the longitudinal direction (X) of the vehicle.

7. A battery bracket device (1) according to any one of the preceding claims, characterized in that At least one reinforcing rib (11) is longitudinally sectionally molded in the ramp plate (4) along the longitudinal direction (X) of the vehicle.

8. A battery bracket device (1) according to any one of the preceding claims, characterized in that At least one reinforcing patch (13) is arranged, coupled to the side facing away from the bottom layer.

9. A battery carrier device (1) according to any one of the preceding claims, characterized in that The ramp plate (4) extends in the longitudinal direction (X) of the vehicle to a position at least halfway below the front axle bracket (2).

10. The battery carrier device (1) according to any one of the preceding claims, characterized in that A spacer (17) is arranged between the inner side of the ramp plate (4) and the front axle bracket (2) and / or the battery bracket (3).

11. A battery carrier device (1) according to any one of the preceding claims, characterized in that A buffer member (20) is arranged on the inner side (14) of the ramp plate (4) in the longitudinal direction (X) of the vehicle in front of the battery bracket (3).

Images