Battery carrier apparatus for electric vehicle

Abstract

The invention relates to a battery carrier device (1) for an electric vehicle, comprising a battery tray comprising a base (6) and a cover (7.1) mounted on the base (6), the cover having a cover base (7) and side walls (4, 5), the base (6) being made from a steel sheet blank as a hot-formed and press-hardened component, the cover base (7) being made from a steel sheet blank, and the side walls (4, 5) being made from a steel sheet blank. According to the invention, the base (6) has a frame side wall (8) which is integrally formed from the same material and which projects transversely beyond the side walls (4, 5) of the battery tray, said frame side wall extending partially obliquely upwards in the vertical direction (Z) of the motor vehicle.

Description

Technical Field

[0001] This invention relates to a battery holder device for electric vehicles. Background Technology

[0002] In existing technology, it is known that so-called battery racks are used in motor vehicles, especially electric vehicles. These battery racks are battery holders or battery trays. They have a battery tray for holding drive batteries or traction batteries. The battery tray is closed with a cover.

[0003] This type of battery tray is typically located under the floor of a motor vehicle. The battery tray usually extends across most of the under-floor area, especially in the passenger compartment. The long sides of the battery tray form along the sides of the sill area. Typically, the battery tray connects to the vehicle body from below via these long sides, particularly in the sill area. Lateral sides are also formed at the front and rear, essentially extending across the width of the vehicle.

[0004] A bottom plate is known from DE102023124896A1, which serves as a vehicle underbody protection plate and is arranged below such a battery tray. Summary of the Invention

[0005] The purpose of this invention is to provide a battery bracket device that has a simpler structure than battery bracket devices known in the prior art, while having at least the same or improved collision safety and lower manufacturing cost.

[0006] According to the present invention, the above objective is achieved by a battery holder device.

[0007] This battery holder device is suitable for electric vehicles. It has a battery box. The battery box itself consists of a cover and a base. The cover has a tray-like structure. However, when installed, the opening of the cover faces downwards along the vertical direction of the vehicle. Therefore, the cover is closed by the base. The base itself is also tray-like. However, the base is open at both ends, at the front and rear, that is, at both ends relative to the longitudinal direction of the vehicle, and there are no side walls on the tray.

[0008] The base and sidewalls thus form the battery tray. The base itself is a component made from steel sheet through thermoforming and pressure hardening. In particular, a hardenable steel alloy is used here. For example, this could be a boron-manganese steel alloy, such as 22MnB5.

[0009] Therefore, the battery box consists of a cover, which can also be called a lid. The cover has a cover base or a cover lid.

[0010] When installed, it is positioned upwards along the vertical direction of the vehicle. The cover still has sidewalls. The sidewalls are designed circumferentially. For this purpose, the cover is specifically manufactured as a deep-drawn member or a member formed or folded from a slab (especially a steel slab). However, the cover can also be made from a lightweight metal slab. The cover preferably has an outwardly projecting circumferential flange at the end of the sidewall. The flange is then preferably attached to the base. In particular, this attachment is achieved by screws. Preferably, a sealant is also applied between the flange and the base. During installation, the base is thus positioned below along the vertical direction of the vehicle, and the cover is positioned above it.

[0011] According to the present invention, the battery bracket device is characterized in that the base has a frame sidewall that integrally and laterally protrudes beyond the sidewall of the battery box and is made of the same material. Therefore, the frame sidewall protrudes laterally beyond the sidewall in the transverse direction of the vehicle. Thus, the frame sidewall can be designed as an extension of the base. The frame sidewall is integrally and identically made of steel sheet together with the base. The frame sidewall also stands upright in the vertical direction of the vehicle, extending at least partially obliquely upward.

[0012] According to the invention, the base or bottom plate is therefore at least partially tray-shaped. Specifically, this refers in part to the sidewalls or frame sidewalls. The sidewalls of the cover are then arranged on the base, i.e., within the bottom plate, thereby forming a battery box. In particular, they are end walls arranged at the front and rear along the longitudinal direction of the vehicle. They are also transverse sidewalls, arranged on one side respectively along the transverse direction of the vehicle. Thus, circumferential sidewalls are formed that rest on and connect with the base. This forms a battery tray together with the base. After installation, the battery tray is closed on top by the cover base. The cover base and sidewalls are preferably integrally formed from the same material as described above.

[0013] However, according to the present invention, the frame sidewalls protrude laterally relative to the transverse direction of the vehicle and extend upwards at an angle relative to the vertical direction of the vehicle. In particular, the base itself does not have front and rear walls relative to the longitudinal direction of the vehicle.

[0014] According to the present invention, the molding freedom of the base or bottom plate can be significantly simplified, thereby reducing production costs and material usage. Due to its high tensile strength (preferably exceeding 1200 MPa, particularly exceeding 1350 MPa), the bottom plate can also be used as a vehicle underbody protection device. Therefore, an additional bottom plate is no longer needed in the battery tray. Compared with the prior art described above, this reduces material usage, component weight, and manufacturing workload.

[0015] The sidewalls can be placed onto the base using flanges and then secured with screws, especially with the application of sealant. This allows for subsequent maintenance work, such as replacing or repairing the batteries located inside the battery compartment, or performing other maintenance tasks. To do this, the screws connecting the cover and the bottom plate can be loosened to access the inside of the battery compartment.

[0016] To enhance underbody protection, the base is formed with reinforcing ribs. These ribs can extend along the longitudinal direction of the vehicle. Preferably, the ribs are formed to protrude downwards beyond the base in the vertical direction of the vehicle. The ribs themselves have a U-shaped cross-section, with the cross-section along the transverse direction of the vehicle. The base itself is flat, with the ribs protruding beyond the flat base, particularly downwards relative to the vertical direction of the vehicle.

[0017] However, the reinforcing ribs can also extend along the transverse direction of the vehicle. Alternatively, reinforcing ribs extending in a combination of the longitudinal and transverse directions of the vehicle can be provided. In another alternative or supplementary design variation, the reinforcing ribs can be designed such that, during installation, they point upwards along the vertical direction of the vehicle and are thus arranged to protrude into the interior of the battery box. Objects such as battery modules can then be erected upright within the battery box onto the inwardly shaped reinforcing ribs, standing on the inwardly pointing reinforcing ribs or their supporting surfaces. Similarly, crossbeams in the battery box can also be placed on the reinforcing ribs.

[0018] Furthermore, the frame sidewalls are particularly preferably designed as reinforced frames. Therefore, additional reinforced frames as external members can be omitted. To this end, alternative or supplementary measures can be adopted, according to which, on the one hand, the lateral protrusions of the base are formed as transverse reinforcing ribs or stiffeners, embedded in the inclined upward surface of the frame sidewalls. Additionally or alternatively, reinforcing elements can be inserted between the frame sidewalls, particularly these reinforcing elements can function as ribs or fins. Specifically, these are spacers. Deformable elements can also be used, wherein the deformable elements themselves are designed, for example, a cap-shaped profile.

[0019] As a further reinforcement measure, it is preferable to place an upper frame plate on the sidewall of the frame. Particularly preferred is that a closed hollow profile is formed in cross-section between the upper frame plate, the frame sidewall, and the sidewall of the battery tray opposite to it. This forms a side frame. This side frame extends along the entire length of the battery tray or battery holder in the longitudinal direction of the vehicle. In this respect, the frame acts as a sill or reinforcing frame. However, for example, in the event of a side collision, the frame can be designed according to the working principle of the impact box and can initially deform and dissipate the impact energy, while first protecting the more inner battery tray from deformation.

[0020] Furthermore, it is particularly preferred that an outwardly projecting flange be formed on the sidewall of the frame. This outwardly projecting flange can be inclined upwards again along the vertical direction of the vehicle. Preferably, the outwardly projecting flange on the sidewall of the frame is used to connect the battery tray to the vehicle from below, particularly by means of screws. Preferably, a distance can also be provided between the flange and the upper frame plate. A spacer such as a sleeve is preferably used. The connecting element (e.g., in the form of bolts) then penetrates the flange, gasket, and upper frame plate, and is then connected to the vehicle from below. This distance, in turn, forms a hollow cross-sectional profile, thus creating an additional resistance member against bending in the form of a reinforcement.

[0021] Furthermore, the base is particularly preferably made of a custom-made plate. For example, the custom-made plate may be a welded plate or a welded rolled plate. Alternatively or additionally, the base may also have custom-designed characteristics. For example, reinforcing patches may be applied locally or higher strength characteristics may be locally applied, for example, through a custom tempering method.

[0022] Within the scope of this invention, it is conceivable to compress-harden the base or bottom plate only partially (i.e., locally). Therefore, in the compress-hardened region, it has the aforementioned strength values, particularly above 1000 MPa. This may be the case, for example, particularly in the reinforcing rib region or the central base region. In the frame sidewall region, lower strength can be formed, for example, a tensile strength Rm between 500 MPa and 850 MPa, so that targeted deformation behavior occurs here in the event of a side impact, according to the functional principle of the impact box. Therefore, the impact energy can be dissipated specifically in the form of deformation work. Attached Figure Description

[0023] Further advantages, features, and characteristics of the present invention are described in the following figures. These help to facilitate understanding of the invention.

[0024] Figure 1 A battery tray device according to the present invention is shown, which includes a battery tray;

[0025] Figure 2 A lower perspective view of the battery holder according to the present invention is shown;

[0026] Figure 3 A front view of the battery holder device according to the present invention is shown;

[0027] Figure 4 A perspective view from above the bottom panel is shown;

[0028] Figure 5 A perspective view from below the bottom panel is shown;

[0029] Figure 6 A front view of the bottom plate is shown;

[0030] Figure 7 The view shown is from above the bottom panel.

[0031] In the accompanying drawings, the same reference numerals are used for the same or similar parts, even if repeated descriptions or views are omitted for simplicity.

[0032] List of reference numerals in the attached diagram:

[0033] 1. Battery bracket assembly; 2. Battery bracket; 3. Bottom plate; 4. Lateral side wall; 5. Longitudinal side wall; 6. Base; 7. Protective cover base; 7.1 Protective cover; 8. Frame side wall; 9. Flange; 10. Screw connection; 11. Reinforcing rib; 12. Notch; 13. Mounting opening; 14. Upper frame plate; 15. Distance; 16. Pad; 17. Washer; 18. Vertical flange; X, longitudinal direction of motor vehicle; Y, lateral direction of motor vehicle; Z, vertical direction of motor vehicle. Detailed Implementation

[0034] Figure 1 A battery holder device 1 according to the present invention is shown, comprising a battery holder 2, also referred to as a battery box. The battery holder 2 has a bottom plate 3 disposed at the bottom in the vertical direction Z of the vehicle. Additionally, there are side walls 4 and 5. These are, on the one hand, transverse side walls 4 located at the front and rear of the vehicle in the longitudinal direction X, and a rear side wall (not shown in detail), and on the other hand, longitudinal side walls 5 extending along the longitudinal direction X relative to the vehicle's transverse direction Y and disposed transversely in the outer region relative to the vehicle's transverse direction Y. The transverse side walls 4 and longitudinal side walls 5 are also referred to as side walls, and they form outer circumferential side walls. The bottom plate 3 forms a base 6. Thus, the battery box is formed. The battery box then further includes a cover base 7 for inserting a cover 7.1 into the bottom plate 3. In the installed state, the opening (not shown in detail) of the cover 7.1 points downward in the vertical direction Z of the vehicle. Therefore, the cover base 7 points upward in the vertical direction Z of the vehicle. The cover 7.1 is also formed by the transverse side walls 4 and the longitudinal side walls 5.

[0035] The transverse sidewalls 4 and longitudinal sidewalls 5 are integrally formed from the same material as the cover base 7, for example, as molded components, particularly as foldable components, so that the sidewalls can be folded or bent relative to the cover base. Alternatively, the cover 7.1 may also be made as a deep-drawn component or composed of multiple components.

[0036] According to the present invention, a corresponding frame sidewall 8 is now formed that protrudes outward beyond the longitudinal sidewall 5 in the transverse direction Y of the motor vehicle. The frame sidewall 8 is part of the bottom plate 3. The frame sidewall 8 is integrally formed and is made of the same material as the base 6. The frame sidewall 8 first extends beyond the longitudinal sidewall 5 in the transverse direction Y of the motor vehicle, and thus the base 6 extends beyond the longitudinal sidewall 5 in the transverse direction Y of the motor vehicle. Then, a portion of the frame sidewall 8 is formed to slope upward in the vertical direction Z of the motor vehicle.

[0037] Preferably, an outwardly projecting flange 9 is also provided, which then protrudes along the transverse Y-direction of the vehicle from the front of the portion of the frame sidewall 8 that extends obliquely upward from the frame sidewall 8. The flange 9, the frame sidewall 8, and the base 6 are integrally formed from a slab of the same material.

[0038] The longitudinal sidewall 5 and the transverse sidewall 4 preferably have flanges, and the flanges are placed on the base 6, for example, by screw connection 10. Figure 2 As shown, it preferably includes a sealant.

[0039] Figure 2 A lower perspective view of the battery holder 2 according to the invention is also shown, showing that reinforcing ribs 11 or longitudinal ribs are formed in the longitudinal direction X of the vehicle. They extend along the longitudinal direction X of the vehicle. The reinforcing ribs 11 are designed to protrude downwards beyond the base 6 relative to the vertical direction Z of the vehicle. The reinforcing ribs 11 extend only a portion of the base 6 along the longitudinal direction of the vehicle, specifically less than 95%. This particularly ensures that the corresponding transverse sidewalls 4 can be joined by spot welding. At the same time, the resulting battery box is also designed to be correspondingly sealed.

[0040] Furthermore, a notch / screw 12, a recess, or a lateral flange is formed in the transition area of ​​the frame sidewall 8. Specifically, the notch 12 is formed between the horizontally extending portion and the obliquely upward extending portion of the frame sidewall 8. The notch 12 reinforces the protruding portion of the frame sidewall 8, particularly the protruding portion relative to the lateral direction Y and the vertical direction Z of the vehicle. Additionally, a mounting opening 13 is provided, allowing the battery bracket assembly 1 to be connected to the vehicle from below in the sill area via bolts passing through the flange 9. For example, a connection can be established here with the sill itself or other longitudinal supports.

[0041] An upper frame plate 14 is also provided. This upper frame plate 14, together with the side walls and frame side walls 8, forms a closed hollow profile in cross-section. This hollow profile is specifically L-shaped. Thus, a reinforcing frame is formed on the battery bracket 2. In the resulting distance 15 between the flange 9 and the frame plate 8, washers 17 or spacers (not shown in detail) can be arranged to provide sufficient stability when using corresponding screw connections.

[0042] Figure 3A front view of the battery bracket assembly 1 according to the invention is shown. It can be clearly seen that an L-shaped hollow profile is formed in cross-section between the upper frame plate 14 and the frame sidewall 8. Specifically, for example, a pad 16 can be used here to provide additional reinforcement between the frame sidewall 8 and the longitudinal sidewall 5 in the event of a side collision in the lateral direction Y of the vehicle. Furthermore, a washer 17 is shown so that a flange 9 can be passed through by a bolt (not shown in detail), and the battery bracket assembly 1 can then be screwed onto a vehicle (not shown in detail) from below along the vertical direction Z of the vehicle. A reinforcing rib 11 is also shown protruding downwards beyond the base 6 in the vertical direction Z of the vehicle.

[0043] Figure 4 , Figure 5 , Figure 6 and Figure 7 Different views of the bottom plate 3 according to the invention are shown. It is particularly evident here that the bottom plate 3 does not have front and rear walls, but only frame sidewalls 8 according to the invention. Therefore, the bottom plate 3 can be produced in a simplified manner by forming methods, particularly deep drawing or compression molding. The cross-section of the bottom plate 3 itself is U-shaped. A vertical flange 18 is formed above, opposite to a flange 9 projecting laterally in the transverse direction Y of the vehicle. This flange can then be attached to the upper frame plate 14 (not shown in detail).

Claims

1. A battery tray device (1) for an electric vehicle, comprising a battery tray including a base (6) and a cover (7.1) mounted on the base (6), the cover having a cover base (7) and sidewalls (4, 5), wherein, The base (6) is made of steel plate blank into a thermoformed and compressively hardened component, characterized in that the base (6) has a frame sidewall (8) integrally made of the same material and laterally protruding beyond the sidewalls (4, 5) of the battery tray, the frame sidewall extending partially upward along the vertical direction (Z) of the motor vehicle.

2. The battery holder device (1) according to claim 1, characterized in that, A reinforcing rib is formed in the base (6), and in particular, the reinforcing rib extends along the longitudinal direction (Y) of the vehicle, so that the base (6) is designed as a vehicle underbody protection plate.

3. The battery holder device (1) according to claim 1 or 2, characterized in that, Transverse reinforcing ribs are formed at the transition from the base (6) to the frame sidewall (8) and / or at the transition from the frame sidewall (8) to the flange (9).

4. The battery holder device (1) according to any one of the preceding claims, characterized in that, The sidewalls (4, 5) of the cover (7.1) are connected to the base (6).

5. The battery holder device (1) according to any one of the preceding claims, characterized in that, The upper frame plate (14) is placed on the frame sidewall (8), and the upper frame plate is specifically connected to the sidewall (5) such that a hollow profile closed in cross section is created between the sidewall (5), the frame sidewall (8) and the upper frame plate (14).

6. The battery holder device (1) according to any one of the preceding claims, characterized in that, Spacers or deformable elements are inserted between the frame sidewalls (8) and the longitudinal sidewalls (5).

7. The battery holder device (1) according to any one of the preceding claims, characterized in that, An outwardly protruding flange (9) is formed on the side wall (8) of the frame.

8. The battery holder device (1) according to any one of the preceding claims, characterized in that, A distance (15) is formed between the flange (9) of the frame plate (14) and the frame sidewall (8), wherein the washer (17) is inserted in such a way that the screw connection is arranged through the flange (9), the washer (16) and the frame plate (14) to connect the battery bracket (2).

9. The battery holder device (1) according to any one of the preceding claims, characterized in that, The base (6) is made of a custom board or the base (6) has custom features.

10. The battery holder device (1) according to any one of the preceding claims, characterized in that, The base (6) has at least a tensile strength Rm greater than 1200 MPa, particularly greater than 1350 MPa.

11. The battery holder device (1) according to any one of the preceding claims, characterized in that, The base (6) has high tensile strength, and the tensile strength is reduced relative to the base (6) in the region of the frame sidewall (8) and / or the flange (9). Preferably, the tensile strength in the frame sidewall (8) and / or the flange (9) is 500 MPa to 1000 MPa, particularly 550 MPa to 850 MPa.

12. The battery holder device (1) according to claim 2, characterized in that, The base (6) has inwardly protruding reinforcing ribs (6) and outwardly protruding reinforcing ribs (6).

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