Method for installing battery pack in vehicle

Abstract

A method of mounting a battery pack to a vehicle body of a passenger vehicle is provided. The method includes providing a vehicle frame defining at least a floor portion of a vehicle body. A battery pack is provided and disposed in a floor portion of a vehicle body. The battery pack is then bonded to the frame using at least one adhesive link located at an interface between the battery pack and the frame.

Description

Technical Field

[0001] This invention relates to a method for mounting a battery pack to the body of a passenger vehicle. Specifically, this invention relates to a method for mounting a traction battery for powering an electric motor to the body of an electric or hybrid passenger vehicle. Background Technology

[0002] In electric and hybrid passenger vehicles, a fairly large battery pack must be integrated into the vehicle body. The way the battery pack is integrated affects the vehicle's structure, safety, comfort, and handling performance. The battery pack is typically manufactured separately from the vehicle frame and then mounted to it. Existing methods for attaching the battery pack to the vehicle body rely on mechanical fasteners to provide maintainability. That is, the battery pack is typically attached to the frame using mechanical fasteners such as bolts, which are quick and easy to engage and disengage to install the battery during manufacturing and subsequently remove it, for example, for maintenance.

[0003] One of the most significant differences between electric or hybrid passenger vehicles and internal combustion engine vehicles is the need to keep both occupants and the battery safe by preventing battery pack intrusion in a collision. This is typically achieved in part by transferring collision loads around the battery pack for both frontal and rear-end collisions. One of the biggest design challenges is ensuring the battery pack is protected in a side impact collision or crash event. This is particularly challenging because there is a limited space in the side skirts or sills required to absorb side impact collision loads without damaging the battery pack, creating the necessary crumple zone.

[0004] Mechanical fasteners used to mount battery packs to the vehicle body are typically oriented with a generally vertical axis for easy access during manufacturing and maintenance. This connection orientation also allows the mating surfaces between the battery pack and the vehicle body to be positioned on generally horizontal and flat (planar) mating surfaces to avoid the risk of manufacturing tolerance stacking, creating undesirable gaps between adjacent components (in this case, the battery pack and the vehicle body). This connection orientation is also compatible with the substantially vertical orientation used for installing and removing heavy battery packs. However, mechanical fasteners that allow for a vertical mounting orientation are generally inefficient at transmitting or resisting loads applied perpendicular to their principal axis (i.e., shear loads). Therefore, to hold the battery pack in place during impacts, the number and size of fasteners must be increased to prevent all possible failure modes, including bolt shear failure, connector slippage failure, and failure at the edges of bolt holes. Shear loads originating from side impacts, particularly side pole impacts, that affect passenger vehicles are of particular importance. Strengthening mechanical fasteners in an attempt to prevent all possible failure modes can result in a significant increase in vehicle body weight. This is particularly disadvantageous in the context of electric vehicles, where lightweight is an important consideration, especially since achieving the target range is a necessary design consideration and the solution often involves adding more batteries and thus more weight.

[0005] Therefore, it is desirable to provide alternative methods for mounting battery packs within the vehicle body that overcome the pointed disadvantages through mechanical fasteners. Summary of the Invention

[0006] According to a first aspect of the invention, a method for mounting a battery pack to the body of a passenger vehicle is provided, the method comprising: providing a vehicle frame defining at least a floor portion of the body; providing a battery pack; arranging the battery pack in the floor portion of the body; and bonding the battery pack to the frame using at least one adhesive connector located at a mating surface between the battery pack and the frame.

[0007] According to the invention, the battery pack is mounted to a vehicle frame and secured, at least in part, using one or more adhesive fasteners at the mating surfaces between the battery pack and the frame. If the adhesive fasteners are used as a replacement for or in combination with mechanical fasteners, they enable substantially lighter designs. This is because adhesive fasteners typically have a superior ability to transfer or react to shear loads compared to mechanical fasteners.

[0008] It will be understood that this technology is intended for use in mounting a main vehicle battery pack (sometimes referred to as a traction battery) that powers the vehicle's electric motors. Therefore, the method may also include connecting the battery pack to one or more electric motors of the passenger vehicle.

[0009] A vehicle frame typically corresponds to a so-called body-in-white (BIW), where the vehicle frame at least defines the passenger compartment of a passenger vehicle. However, the frame can also be a component that will subsequently be assembled into the body or BIW. For example, the frame may include a floor frame that may define side skirts and / or sill portions of the body, which substantially define the plane of the vehicle's floor. Thus, the battery pack can be installed within the floor frame before it is connected to one or more other frame portions defining the body or BIW.

[0010] This method can be applied to mounting any type of battery pack to a vehicle body. This includes batteries based on different battery chemistry and different battery cell and module architectures. Typically, a battery pack will consist of one or more battery modules located within a housing, wherein the battery pack is mounted to the vehicle body by attaching the battery pack housing to a frame.

[0011] Preferably, the battery pack includes a housing formed of a fiber-reinforced composite material, which preferably includes a resin matrix, reinforcing fibers, and metal inserts. However, other battery pack housings can be used, such as a metal housing made of aluminum alloy. The vehicle frame can be made of metal, such as aluminum alloy components. Alternatively, the frame can be formed of a fiber-reinforced composite material, which can also include a resin matrix, reinforcing fibers, and metal inserts.

[0012] Preferably, the adhesive connector is formed by a paste-like adhesive applied to the battery pack or vehicle frame, or both, before the battery pack and vehicle frame are joined together. In some cases, it may be advantageous to use a liquid adhesive, in which case the adhesive can be injected into the gap between the battery and the vehicle frame after they have been joined or otherwise positioned. Preferably, the adhesive, when cured, is capable of withstanding all major external loads that the connector will experience throughout the lifespan of the vehicle and battery pack. Therefore, the adhesive is preferably a structural adhesive capable of producing sufficiently high strength in the connector (e.g., greater than 5 MPa, preferably greater than 10 MPa, more preferably greater than 25 MPa). Preferably, the adhesive is tough and therefore well-suited to maintaining the integrity of the connector when subjected to impact loads. For example, the structural adhesive fracture toughness can be greater than 0.1 N / mm, preferably greater than 1 N / mm, more preferably greater than 10 N / mm.

[0013] Preferably, the adhesive exhibits thixotropic behavior to facilitate application to the battery or vehicle frame by hand or via an automated delivery system.

[0014] Preferably, the adhesive viscosity is moderate in order to limit the load required to attach the battery pack to the vehicle frame, due to the hydraulic locks derived from the adhesive flow.

[0015] The adhesive is preferably applied to the battery pack when it is decoupled from the vehicle frame and the adhesive application surface is predominantly horizontal and facing upwards. The adhesive is preferably capable of filling gaps and thus compensating for any minor geometric variations between the vehicle frame and the battery pack due to manufacturing and assembly tolerances.

[0016] The adhesive chemical composition is preferably selected from widely available commercial grades of structural adhesives (preferably polyurethane or epoxy resin or acrylic or other structural adhesives).

[0017] The adhesive preferably has a different color than that of the vehicle frame and battery pack, such as a bright color, to provide visual confirmation of its presence for inspection purposes.

[0018] Preferably, the adhesive exhibits fire resistance that meets international requirements (e.g., ECE R100) for battery systems in passenger vehicles.

[0019] In some embodiments, the adhesive may be conductive. For example, the adhesive may include conductive additives, such as graphene. Conductive adhesives can be used to electrically connect the battery pack to a frame for a grounding circuit.

[0020] Typically, before the battery pack is placed on the vehicle's floor, an adhesive used to form adhesive joints is pre-applied to the battery pack or frame. Specifically, the adhesive can be applied to multiple sections of the frame or battery pack, which will subsequently form part of the mating surface. Once the battery pack is in place, the frame and battery pack can be pressed together, with the adhesive bonding them together.

[0021] Another advantage of adhesive connectors is that they improve manufacturing tolerances due to the adhesive's ability to fill gaps in the bonded surfaces. Manufacturing tolerances may necessitate adjustments to the adhesive layer thickness to suit these surface variations. It has been found that the thickness of each adhesive connector should be at least 0.5 mm, preferably at least 1 mm, more preferably at least 2 mm, and most preferably at least 3 mm. Thicker adhesive connectors will also allow for easier removal of the battery pack during maintenance, as described below. The adhesive can therefore be applied to the battery pack or frame with a thickness of at least 0.5 mm, preferably at least 1 mm, more preferably at least 2 mm, and most preferably at least 3 mm. The adhesive will typically be pressed during the bonding process, and therefore the adhesive coating thickness may need to be thicker than the desired final adhesive connector thickness. The coating thickness required to achieve a specific connector thickness will depend on the specific adhesive used, its applied parameters, the pressure applied during the bonding process, and other factors.

[0022] While adhesive can be provided anywhere the battery pack joins to the frame, preferably, one or more adhesive connectors are positioned along a peripheral edge portion of the battery pack. This peripheral edge portion can be considered as an area closer to the edge of the battery pack in a direction generally defined by the plane of the base plate portion, rather than an area closer to the central axis of the battery pack in a direction perpendicular to that plane. Typically, the frame defining the base plate portion of the vehicle body will have a generally rectangular coverage area defining longitudinal edges opposite the base plate (corresponding to opposite sides of the vehicle body) and possibly front and rear edges corresponding to the front and rear of the vehicle, respectively. The plane generally defined by the base plate portion may correspond to the plane between these opposing longitudinal edges and the front and rear edges of the frame (if provided). Typically, the battery pack also typically defines a plane with a height less than its length and width and generally aligned with the plane of the base plate portion, and may also have a generally rectangular coverage area. The battery pack will typically extend across the base plate portion between the opposing longitudinal edges defined by the frame. The battery pack may have opposing longitudinal edges extending alongside the opposing longitudinal edges of the base plate portion defined by the frame. It is preferred to provide adhesive fasteners along the peripheral edge portion of the battery pack, as this is typically where the battery will be joined to the frame defining the base plate, and because this is generally more accessible during manufacturing and maintenance. The adhesive fasteners will typically be elongated, thus defining a path extending along the peripheral edge portion.

[0023] While adhesive connectors can be positioned along any one or more peripheral edge portions of the battery pack, preferably one or more adhesive connectors are positioned along at least two opposing peripheral edge portions of the battery pack. This improves the bonding strength of the battery pack. For example, adhesive connectors can be provided along the peripheral edge portions adjacent to the opposing longitudinal edges of the base plate portion defined by the frame. In a particularly preferred embodiment, one or more adhesive connectors generally surround the central region of the battery pack. For example, one or more adhesive connectors can extend along opposing longitudinal edge portions of the battery pack and along the front and rear edge portions of the battery pack. In this case, there can be a single long, continuous adhesive connector extending along all four edge portions, or multiple separate adhesive connectors along these edge portions. Providing adhesive along a larger proportion of the battery pack edges improves the bonding strength with the frame.

[0024] The design of the mating surface between the battery pack and the frame can take many forms. In a simple case, the battery pack may have a flat upper or lower surface and may rest against a flat base surface provided by the frame. However, the mating surface can be designed to provide additional advantages for the mounting method. In particular, in some embodiments, the battery pack includes one or more peripheral flanges configured to form at least a portion of the mating surface with the frame, and one or more adhesive connectors are positioned along one or more of said peripheral flanges. It should be understood that additional adhesive connectors may also be provided in areas away from the peripheral flanges. The frame may also be provided with one or more complementary edge portions configured to engage with the peripheral flange portions of the battery pack. Providing peripheral flanges of the battery pack (on which the adhesive connectors will be provided) can provide many advantages, including ensuring that the adhesive connectors are spaced apart from the battery cells of the battery pack, which is advantageous during maintenance. Furthermore, using peripheral flanges with complementary edges can facilitate the placement of the battery pack within the frame.

[0025] Another advantageous way to configure the mating surface is to include one or more portions defining a generally stepped mating surface between the battery pack and the frame. Preferably, at least one adhesive connector is located on at least two different surfaces of one or more of the portions defining the generally stepped mating surface. Again, this can be provided by an adhesive connector extending across the two surfaces or separate adhesive connectors. The stepped mating surface can define surface portions at two different height levels (in a direction perpendicular to the plane generally defined by the base plate), along which adhesive connectors can be arranged. Alternatively, the stepped mating surface can allow adhesive connectors to be provided along surfaces at different angles to each other (e.g., generally perpendicular to each other), such that the connectors are subjected to impact forces in different relative directions. Furthermore, the stepped mating surface can again facilitate the placement of the battery pack in the frame before bonding using adhesive connectors.

[0026] As described above, the vehicle's floor portion generally defines a plane, and the battery pack will also generally define a plane that is substantially aligned with or at least parallel to the plane of the floor. However, it may be preferable that the mating surface between the battery pack and the frame includes one or more portions arranged at an angle (preferably oblique) to the plane defined by the floor portion, and at least one adhesive connector is located at said one or more portions of the mating surface, arranged at an angle to the plane defined by the floor portion. Specifically, preferably, the mating surface between the battery pack and the frame includes one or more portions defining an angle of less than 45° relative to the plane defined by the floor portion; more preferably, one or more portions defining an angle of less than 30° relative to the plane defined by the floor portion; and most preferably, one or more portions defining an angle of less than 20° relative to the plane defined by the floor portion. This may, for example, involve a peripheral flange portion of the battery pack defining an angle of inclination relative to the generally plane of the battery pack, and a portion of the frame providing a complementary angle to engage the peripheral flange portion. Providing portions of the mating surface that are neither parallel nor perpendicular to the plane generally defined by the base plate portion of the frame can help the adhesive joint handle impact forces. In particular, impact forces in directions within the base plate plane can thus partially place the adhesive joint in compression rather than pure shear. To most advantageously handle impact forces, one or more inclined portions of the mating surface between the battery pack and the frame should be arranged at an angle generally inclined toward or away from the center of the battery pack. For example, inclined portions positioned along the longitudinal edge of the battery pack should be inclined about the longitudinal axis in the base plate plane, while inclined portions positioned along the front or rear edge of the battery pack should be inclined about the transverse axis in the base plate plane, such that the longitudinal edge advantageously handles lateral impact forces and the front and rear edges advantageously handle front and rear impact forces.

[0027] In some embodiments of this method, the frame defines an opening therethrough at the bottom plate portion, and the battery pack closes the opening, thereby defining at least a region of the vehicle's bottom plate. In other words, the battery pack itself constitutes a large portion of the vehicle body's bottom plate surface.

[0028] In other embodiments, the frame may define a generally continuous floor surface at the floor portion of the vehicle body, wherein the battery pack is arranged generally adjacent to said floor surface, for example, wherein the plane of the battery pack is parallel to the plane of said floor surface. In this embodiment, the floor surface of the vehicle body is provided by the frame, which can simplify the removal and replacement of the battery pack during maintenance.

[0029] The frame defining the floor portion may include, for example, longitudinal structural members, such as side skirts or sill portions of the frame, or a center channel structure, wherein one or more transverse structural members substantially correspond to the front and rear edges of the floor portion. If provided, an opening through the frame may extend substantially between the longitudinal and transverse structural members. Thus, the battery pack may substantially fill this opening through the frame and be bonded to the longitudinal and / or transverse structural members via adhesive fasteners. Such an arrangement can make the vehicle body lighter. In other embodiments, a substantially continuous floor may extend between the longitudinal and transverse structural members, and the battery pack may be bonded to the longitudinal and / or transverse structural members and / or the floor surface of the frame via adhesive fasteners.

[0030] While this method uses adhesive fasteners to overcome several disadvantages of mechanical fasteners, in many embodiments, two mounting devices can preferably be used to benefit from the advantages they each offer. Therefore, in some embodiments, the method further includes securing the battery pack to the frame using one or more mechanical fasteners. The mechanical fasteners may be located at the mating surfaces between the battery pack and the frame. In particularly preferred embodiments, the mechanical fasteners can be used to position and hold the battery pack relative to the frame for subsequent bonding using adhesive fasteners. Therefore, preferably, arranging the battery pack in the floor portion of the vehicle body includes engaging one or more mechanical fasteners located at the mating surfaces between the battery pack and the frame to guide and / or hold the battery pack in place on the frame. Alternatively, the guiding effect can be achieved by guide members (such as locating pins and corresponding openings) provided on the battery pack and the frame. Mechanical fasteners are preferred because they help hold the battery pack in place in the event of adhesive failure and during the curing of the adhesive. In particular, preferably, bonding the battery pack to the frame includes clamping the battery pack to the frame using one or more mechanical fasteners while the adhesive hardens. While mechanical fasteners are preferred for pushing the frame and battery pack together, it may be desirable to ensure a specific spacing between the battery pack and the frame, for example, to prevent excessive adhesive from being squeezed out of the connectors or to ensure that the battery pack is horizontal within the frame. Therefore, preferably, one or more mechanical fasteners include one or more spacer elements configured to prevent direct contact between the battery pack and the frame and preferably configured to ensure a predetermined minimum spacing between the battery pack and the frame.

[0031] The frame, as described above, may include longitudinal and transverse structural members to which the battery pack is attached. More generally, the frame may include opposing structural members, and the method includes arranging the battery pack between opposing structural members and connecting the battery pack to each of the opposing structural members, wherein preferably, connecting the battery pack to one or more of the opposing structural members includes attaching the battery pack to the structural members using adhesive connectors located at the mating surfaces between the battery pack and the structural members. In this way, the battery pack can form a load path between the opposing structural members, allowing impact forces to be transmitted between the opposing structural members through the battery pack. Preferably, the battery pack can be connected in this manner to each of two sets of opposing structural members (preferably two sets of vertically opposing structural members, such as a pair of longitudinal structural members (e.g., a sill portion) and a pair of transverse structural members (e.g., a front structural member and a rear structural member)). In several particularly preferred embodiments, the mating surface between the battery pack and the frame includes one or more portions arranged at an angle to the plane defined by the base plate portion, and at least one adhesive connector is located at said one or more portions of the mating surface arranged at an angle to the plane defined by the base plate portion. Opposing structural members define one or more portions arranged at an angle to the plane defined by the base plate portion, wherein, preferably, each opposing structural member defines a corresponding portion arranged at an angle to the plane defined by the base plate portion, and at least one adhesive connector is preferably located at each of said corresponding portions, said corresponding portions being arranged at an angle to the plane defined by the base plate portion. In other embodiments, the mating surface and opposing structural members may define a generally stepped mating surface, wherein at least one adhesive connector is located on at least two different surfaces of said portions defining one or more of the generally stepped mating surface.

[0032] Alternatively or additionally, the frame may define at least a portion (e.g., partially or continuously) of the floor surface at the floor portion of the vehicle body and at structural members extending away from the floor surface, and the method may include connecting the battery pack to the structural members and connecting the battery pack to the floor surface of the frame, wherein, preferably, connecting the battery pack to the structural member includes bonding the battery pack to the structural member using adhesive fasteners located at the mating surfaces between the battery pack and the structural member, and / or wherein, preferably, bonding the battery pack to the floor surface includes bonding the battery pack to the floor surface using adhesive fasteners located at the mating surfaces between the battery pack and the floor surface. In this way, the battery pack may define a portion of a load path for transmitting impact forces from the structural members to the floor surface of the frame.

[0033] In some embodiments, the frame may include opposing structural members and at least a portion of the floor surface at the vehicle body floor portion, and the method may include arranging the battery pack between the opposing structural members and connecting the battery pack to each of the opposing structural members, and preferably connecting the battery pack to the floor portion at a plurality of corresponding locations adjacent to each of the opposing structural members, wherein preferably one or more, preferably each connection step is performed by using adhesive connectors located at the joint surfaces between the respective portions. In this way, loads can be transferred between the opposing structural members and between the structural members and the floor surface, thereby more effectively protecting the contents of the battery pack from damage.

[0034] As mentioned above, the frame may include opposing longitudinal structural members positioned along opposing longitudinal edges of the vehicle body's floor portion. These structural members are particularly useful for protecting the battery pack from impact forces, and therefore, arranging the battery pack in the vehicle body's floor portion preferably includes arranging the battery pack generally between these opposing longitudinal structural members. That is, the battery pack may be generally arranged in a plane defined between the opposing longitudinal structural members.

[0035] In some embodiments, the steps of arranging the battery pack in the floor portion of the vehicle body and attaching the battery pack to the frame include arranging the battery pack within the frame such that the weight of the frame acts to press the battery pack against it during attachment. This method is particularly useful when combined with guide elements that ensure proper in-plane relative positioning of the battery pack and the frame. As mentioned above, guide elements can be provided by mechanical fasteners or separate elements such as locating pins. This technique is particularly preferred compared to techniques using clamping systems because it allows the method to be performed using readily available lifting equipment and eliminates the need for expensive, model-specific clamps.

[0036] The adhesive connector should be located at a relatively rigid portion of the battery pack, such that it helps hold the battery pack in place within the frame and allows impact loads to be transferred across the connector and then guided by the battery pack in a manner that protects the contents of the battery pack from damage. Preferably, the battery pack material at the location of the adhesive connector has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, more preferably at least 20 GPa, and most preferably at least 50 GPa. Preferably, the adhesive connector is located on the surface of the fiber-reinforced composite material of the battery pack. Preferably, the frame material at the location of the adhesive connector is also rigid, having a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, more preferably at least 20 GPa, and most preferably at least 50 GPa. The frame will typically be aluminum or an aluminum alloy, which may have a Young's modulus of 70 or higher.

[0037] One way a battery pack can protect its contents from impact forces is by transferring the impact load across the battery pack and back to another segment of the frame. Therefore, preferably, the battery pack includes a housing in which the material of the housing extending between the adhesive connector and another connector between the battery pack and the frame, or between another segment of the same adhesive connector, has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, more preferably at least 20 GPa, and most preferably at least 50 GPa. In these embodiments, by providing a rigid material between two separate connectors of the frame or between two different (e.g., opposite) segments of the same connector, the rigid material of the battery pack housing can form part of the load path between the two connectors. A particularly preferred embodiment is one in which the battery pack is connected to two opposing structural members of a frame, and the housing extending between the opposing structural members has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, more preferably at least 20 GPa, and most preferably at least 50 GPa. Preferably, the battery pack comprises a housing surrounding one or more internal battery modules, and substantially the entire housing has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, more preferably at least 20 GPa, and most preferably at least 50 GPa. While preferred, in alternative embodiments, only a portion of the battery pack housing may be rigid while achieving the same effect. For example, the base and optional sidewalls of the battery pack may be rigid, with a less rigid cover, in which case impact forces can be transmitted across the battery pack through the rigid base.

[0038] One disadvantage of using adhesive connectors and mechanical fasteners, or alternatives to mechanical fasteners, is that adhesive connectors are typically permanent, while mechanical fasteners selectively engage and disengage to install and remove the battery pack from the vehicle body. Therefore, when using adhesive connectors, ease of battery pack removal is desirable. Preferably, bonding the battery pack to the frame using at least one adhesive connector includes providing a conduit across at least one of the adhesive connectors, through which a wire can be inserted for cutting at least one adhesive connector. The conduit may be a tube inserted between the battery pack and the frame before the adhesive is applied to form the adhesive connector. The conduit may remain open at both ends or may be closed to prevent material access. The conduit retains a hollow center after the adhesive connector is formed and allows a convenient path along which a wire can be threaded for cutting the adhesive connector. As will be described in more detail below, once the wire has been laid through the conduit, it can be pulled through the adhesive connector (e.g., by a technician holding the wire at one end on either side of the conduit) to cut the connector. To allow for the insertion of a suitable wire to cut the connector, the pipe preferably has a width of at least 0.5 mm, more preferably at least 1 mm, and most preferably at least 2 mm.

[0039] To allow for proper wiring and maneuvering during battery pack removal, the conduit is preferably arranged such that a first end of the conduit is accessible from a first side of the adhesive connector, and a second end of the conduit is accessible from a second side of the adhesive connector. For example, one end of the conduit should be inaccessibly positioned and closed between the frame and the battery pack. Accessibility at both ends of the conduit can be conveniently provided when the frame has an opening through it in the base plate portion. In this case, one side of the conduit may be accessible from the outside of the frame, and the other side may be accessible through the opening in the frame in the base plate portion. Other foreseeable ways of providing access to both ends of the conduit include providing a conduit that extends across the entire width of the battery pack and optionally across multiple adhesive connectors.

[0040] In some embodiments, providing a conduit accessible from both sides across the adhesive connector to allow a technician to insert and manipulate a wire for cutting the connector may be impractical. Therefore, some embodiments also include providing at least one wire for the frame or battery pack to cut at least one adhesive connector, wherein the cutting wire is arranged and secured in place such that a portion of the wire is accessible for pulling the wire through at least one adhesive connector to cut it. For example, at least one end of the wire may extend across the adhesive connector so that a technician can access it for pulling through the adhesive connector. Some such embodiments include providing at least one wire for the frame or battery pack to cut at least one adhesive connector, wherein a first end of the wire is anchored to the frame or battery pack, and wherein the battery pack is arranged and coupled to the frame such that a portion of the wire is accessible for pulling the wire through at least one adhesive connector to cut it.

[0041] There are many ways in which the integral wire can be arranged for cutting adhesive connectors. For example, the wire can be placed along a path (e.g., along the joint surface between the battery pack and the frame, generally following the path of at least one adhesive connector), optionally, the wire is weakly bonded or otherwise detachably attached to the frame or battery pack along its length, wherein a portion of the wire (e.g., a second end in the case of a first end anchored to the battery pack or frame) is positioned accessible to a technician. Thus, a technician can arrange the wire through the accessible end such that it extends across the adhesive connector, through a conduit, or at the end of the adhesive connector, and then pull the wire through the adhesive connector via one accessible end. The anchored first end will ensure that the wire only needs to be pulled by the technician from one side of the adhesive connector (where the anchor point is typically located on the opposite side of the adhesive connector) to cut the connector.

[0042] Some embodiments include providing a conduit across at least one of the adhesive connectors, wherein a first end of a wire is anchored to a frame or battery pack at a first side of the conduit, and wherein the wire is arranged through the conduit such that a portion of the wire is accessible from a second side of the conduit, or wherein the wire is arranged such that the portion of the wire is accessible through the conduit from a second side of the conduit. In these embodiments, the conduit across the adhesive connector is used to arrange a bulk cut wire or to make the bulk cut wire accessible to facilitate cutting of the adhesive connector. In this case, the conduit can be simply provided by arranging the cut wire at a location across the adhesive connector before the adhesive is applied, such that the cut wire is embedded across the adhesive and itself defines a conduit through the adhesive connector. Alternatively, a separate conduit of the type described above can be provided through which the wire extends across the adhesive connector.

[0043] As an alternative to anchoring one end of the wire to the battery pack or frame, a cut wire can be provided such that the opposite ends of the cut wire pass through the same or corresponding conduit in at least one of the adhesive connectors. Thus, a technician can pull both ends of the wire to cut the adhesive connector.

[0044] In the above embodiments, which include a monolithic cutting line for cutting adhesive bonds, it will be understood that one or more monolithic cutting lines can be provided. A single cutting line can be used to cut multiple adhesive bonds. Alternatively, separate bonds can be provided with corresponding cutting lines. Multiple cutting lines can also be provided for cutting different portions of individual adhesive bonds.

[0045] Preferably, the method further includes electrically and / or hydraulically connecting the battery pack and the frame to each other. For example, the battery pack can be connected to the frame via an electrical conductor to provide a grounding circuit. The grounding circuit can be provided, for example, by one or more mechanical fasteners. Therefore, the mechanical fasteners should be formed of a conductive material.

[0046] According to a second aspect of the invention, a method for removing a battery pack mounted to the body of a passenger vehicle is provided, wherein the passenger vehicle includes a vehicle frame defining at least a floor portion of the body and a battery pack in the floor portion of the body, the battery pack being attached to the frame by at least one adhesive connector located at a mating surface between the battery pack and the frame, the method comprising pulling along a pull line along at least one adhesive connector to cut at least one adhesive connector.

[0047] This aspect of the invention corresponds to a method for removing an installed battery using the method according to the first aspect of the invention. Therefore, a vehicle performing this method may include any of the features described above with respect to the first aspect of the invention.

[0048] As noted above, this method utilizes the technique for wire cutting adhesive connectors described with respect to the first aspect of the invention. This overcomes a key drawback of adhesive connectors compared to mechanical fasteners, which make bonded battery packs difficult to remove. This method can be used to cut any type of adhesive connector described above with respect to the first aspect of the invention.

[0049] It should be noted that pulling the line through the adhesive connector can be a manual action or can be assisted by tools or machinery.

[0050] In some embodiments, the passenger vehicle further includes a conduit spanning at least one of the adhesive connectors, wherein the method includes routing a wire through the conduit and using the end of the wire on either side of the conduit to pull the wire along at least one adhesive connector to cut at least one adhesive connector. This method is typically performed where a technician has access to both sides of the conduit.

[0051] In other embodiments, the passenger vehicle includes a line, wherein a first end of the line is anchored to a frame or battery pack, and includes a portion of the line (typically a second end) for retracting the line and pulling the line through at least one adhesive connector to cut at least one adhesive connector.

[0052] In any of the above embodiments, the method may further include heating the adhesive and / or the wire before pulling the wire through at least one adhesive connector, wherein preferably, heating the wire involves passing an electric current through the wire. This can facilitate cutting the adhesive connector. In embodiments where a first end of the wire is anchored to a frame or battery pack, if an electric current is to be used to heat the wire, the anchor point preferably connects the wire to a circuit for heating the wire. In use, a technician can retract a second end of the wire and complete the circuit to achieve heating of the wire.

[0053] According to a third aspect of the invention, a passenger vehicle is provided, the passenger vehicle comprising: a vehicle frame defining at least a floor portion of a vehicle body; and a battery pack located in the floor portion of the vehicle body, the battery pack being joined to the frame by at least one adhesive connector located at a mating surface between the battery pack and the frame.

[0054] The vehicle according to this aspect corresponds to a vehicle manufactured using the method according to the first aspect of the invention. Therefore, the vehicle may include any of the features described above with respect to the first aspect of the invention.

[0055] Preferably, one or more adhesive connectors are positioned along the peripheral edge portions of the battery pack. More preferably, one or more adhesive connectors are positioned along at least two opposing peripheral edge portions of the battery pack. Most preferably, one or more adhesive connectors are positioned substantially around the central region of the battery pack.

[0056] In many embodiments, the battery pack includes one or more peripheral flanges that form at least a portion of a mating surface with the frame, wherein one or more adhesive fasteners are positioned along one or more of the peripheral flanges.

[0057] Preferably, the mating surface between the battery pack and the frame includes one or more portions defining a generally stepped mating surface, and wherein preferably, at least one adhesive connector is located on at least two different surfaces of one or more of the portions defining the generally stepped mating surface.

[0058] In some embodiments, the vehicle's floor portion generally defines a plane, and the mating surface between the battery pack and the frame includes one or more portions arranged at an angle to the plane defined by the floor portion, and at least one adhesive connector is located at said one or more portions of the mating surface arranged at an angle to the plane defined by the floor portion. Preferably, the mating surface between the battery pack and the frame includes a plurality of portions arranged at different angles relative to the plane defined by the floor portion, and at least one adhesive connector is located at said plurality of portions of the mating surface arranged at different angles relative to the plane defined by the floor portion. For most advantageous handling of impact forces, preferably, one or more portions of the mating surface between the battery pack and the frame are arranged at an angle generally inclined toward or away from the center of the battery pack.

[0059] Preferably, the thickness of each adhesive connector is at least 0.5 mm, more preferably at least 1 mm, more preferably at least 2 mm, and most preferably at least 3 mm. Preferably, each adhesive connector is also elongated.

[0060] In some embodiments, the frame defines an opening through it at a floor portion, and the battery pack closes the opening, thereby defining at least a region of the vehicle's floor. In other embodiments, the frame defines a generally continuous floor surface at a floor portion of the vehicle body, and the battery pack is positioned generally adjacent to said floor surface.

[0061] Many embodiments utilize both adhesive connectors and mechanical fasteners. In this case, the vehicle also includes one or more mechanical fasteners located at the mating surface between the battery pack and the frame, which, together with the adhesive connectors, hold the battery pack in place on the frame.

[0062] Preferably, the frame includes a plurality of opposing longitudinal structural members positioned along opposing longitudinal edges of the floor portion of the vehicle body, and the battery pack is positioned in the floor portion of the vehicle body generally between the opposing longitudinal structural members.

[0063] The vehicle may also be provided with any of the features described for facilitating the cutting of the adhesive connectors. Preferably, the vehicle includes a conduit across at least one of the adhesive connectors through which a wire can be inserted for cutting at least one adhesive connector. Preferably, the conduit is arranged such that a first end of the conduit is accessible from a first side of the adhesive connector, and a second end of the conduit is accessible from a second side of the adhesive connector. In other embodiments, the frame or battery pack includes at least one wire for cutting at least one adhesive connector, wherein a first end of the wire is anchored to the frame or battery pack, and wherein the battery pack is mounted to the frame such that a portion of the wire is accessible for pulling the wire through at least one adhesive connector to cut at least one adhesive connector. The vehicle may also include a conduit across at least one of the adhesive connectors, wherein a first end of the wire is anchored to the frame or battery pack at a first side of the conduit, and wherein the wire passes through the conduit such that a portion of the wire is accessible from a second side of the conduit, or wherein the wire is positioned such that a portion of the wire is accessible from a second side of the conduit. The line can be arranged to roughly follow the path of at least one adhesive connector along the joint surface between the battery pack and the frame. Attached Figure Description

[0064] The invention will now be described with reference to the accompanying drawings, in which:

[0065] Figure 1 A top view of a portion of the vehicle body, including the installed battery pack, is shown;

[0066] Figure 2 It shows crossing Figure 1 A schematic cross-section of the vehicle body and battery pack;

[0067] Figure 3 It shows Figure 1 The schematic top view of the battery pack on the vehicle body is omitted.

[0068] Figures 4A to 4E Five alternative schematic cross-sections are shown through the vehicle body with the installed battery pack;

[0069] Figure 5 Enlarged details of a schematic cross-section through a vehicle body with a mounted battery pack are shown;

[0070] Figure 6 A schematic top view of the battery pack, with the vehicle body installation omitted, is shown.

[0071] Figure 7 A schematic top view of the battery pack, with the vehicle body installation omitted, is shown.

[0072] Figure 8 This is a flowchart illustrating a method for installing a battery pack in a vehicle body; and

[0073] Figure 9 This is a flowchart illustrating a method for removing a battery pack installed in a vehicle body. Detailed Implementation

[0074] Now see Figures 1 to 3 Detailed description of the embodiments.

[0075] Figure 1 A portion of the body 1 is shown. The body includes a frame 10. This frame can be what is known as a body-in-white (BIW). Figure 1 The diagram shows a floor frame segment comprising opposing longitudinal structural members 11a and 11b, corresponding to side skirts or sill areas of the vehicle body. This floor frame may be part of the BIW (Body-In-Wall) or a separate frame portion to be later assembled into the BIW. The longitudinal structural members 11a and 11b extend along the longitudinal length of the vehicle body between the front and rear wheels and typically include collision-absorbing structures designed to absorb side impacts. The frame 10 also includes a front transverse structural member 12 extending between the longitudinal structural members 11a and 11b, just behind the front wheel area of ​​the vehicle body, and a rear transverse structural member 13 extending between the longitudinal structural members 11a and 11b, just before the rear wheel area of ​​the vehicle body. The transverse and longitudinal structural members thus define the floor portion of the vehicle body. The floor portion of the vehicle body generally defines a plane of the floor that is substantially parallel to the ground. The lateral and longitudinal structural members also define generally rectangular openings having multiple truncated corners 14 extending vertically through the base plate portion, in which the battery pack 20 is positioned. The front lateral structural member 12 is connected to the front impact structure 2 and is designed to transmit forward impact forces along the longitudinal structural members 11a, 11b and around the battery pack 20. Similarly, the rear lateral structural member 13 is connected to the rear impact structure 3 and is designed to transmit rear impact forces along the longitudinal structural members 11a, 11b and around the battery pack 20.

[0076] As mentioned above, the battery pack 20 is located in the opening 14 through the frame 10. The battery pack includes a main housing 21 in which multiple battery modules, along with other battery components, are located. The battery pack 20 is generally shaped to correspond to the shape of the opening 14 through the frame 10. The battery pack is generally planar, having a width in the lateral direction similar in size to the width of the frame and a length in the longitudinal direction similar in size to the length of the frame, but relatively small in the vertical direction, thus intended to be located approximately within the vehicle's floor. A peripheral flange 22 is located at the peripheral edge of the battery pack 20 surrounding the main housing 21. In this embodiment, the battery pack is inserted into the frame from below, and therefore the flange 22 extends from the lower surface of the battery pack away from its central axis, which is perpendicular to the overall plane of the battery pack. The flange has a smaller thickness in the vertical direction than the main housing 21 of the battery pack. Therefore, when inserted from below the frame 10, the peripheral flange 22 can engage the transverse structural members 12, 13 and the longitudinal structural members 11a, 11b along the respective sides of the battery pack 20, while most of the main housing 21 is located inside the opening 14, generally between the transverse structural members 12, 13 and the longitudinal structural members 11a, 11b. Figure 2 A cross-section through the frame is shown in a plane extending along the vertical and horizontal directions, and the main housing of the battery located between the longitudinal structural members 11a, 11b is shown, wherein the upper surface of the flange 22 and the vertical sidewall of the housing 21 form a mating surface with the frame 10.

[0077] In this embodiment, the battery pack 20 is used in Figure 2 and Figure 3 The adhesive connector 30 shown is installed within the frame 10. (As shown in...) Figure 2 As can be seen, the adhesive connector is positioned on the upper surface of the peripheral flange 22 of the battery pack and engages the peripheral flange to the lower surface of the lateral structural members 11a, 11b. The lower surfaces of the lateral structural members 12, 13 and the longitudinal structural members 11a, 11b are defined as complementary edges surrounding the opening 14, which engage with the peripheral flange. Although the engagement surface between the upper surface of flange 22 and the lower surfaces of the lateral structural members 12, 13 and the longitudinal structural members 11a, 11b is shown as a flat surface, it should be understood that any complementary engagement surface can be used.

[0078] Figure 3 A top view of the battery pack 20, with frame 10 omitted, is shown, allowing the path followed by the adhesive connectors 30 to be seen. Figure 3As shown, the main housing of the battery pack has a generally rectangular coverage area with truncated corners to match the shape of the opening 14 through the frame. A peripheral flange 22 extends from the lower surface of the battery pack around the entire periphery of this main housing 21, creating a step that descends from the upper surface of the battery pack to the upper surface of the peripheral flange 22. An adhesive connector 30 is disposed in a continuous path extending around the entire peripheral flange 22 of the battery pack 20 to surround the main housing 21. This allows the battery pack to be bonded to the frame 10 around its entire periphery.

[0079] The adhesive used for the adhesive connector 30 can be a stretchable structural adhesive with polyurethane chemistry. The materials for the battery housing 21 and flange 22 can be composite materials comprising a resin matrix, reinforcing fibers, and metal inserts. For example, the battery housing 21 can be made of carbon fiber reinforced polypropylene, which can have a Young's modulus >20 GPa. In an alternative embodiment, the housing can be formed of aluminum, which can have a Young's modulus of about 70 GPa. The frame 10 can be made of aluminum alloy components. While these materials are typical, in principle, any combination of materials used for the battery pack and frame can be used with adhesives suitable for bonding those materials.

[0080] Figures 1 to 3 The illustration shows one possible mating surface and mounting arrangement of the battery pack 20 and the frame 10, but other mounting arrangements are possible. See now for further details. Figures 4A to 4E Several alternative configurations are described, each of which is an alternative cross-section passing through frame 10 in a plane extending along both the vertical and horizontal directions. These alternative embodiments will now be described in conjunction with... Figures 1 to 3 Differences between the embodiments.

[0081] Figure 4A An embodiment is shown in which the frame 10 is further provided with a flange 16 that partially projects from the sidewalls of the transverse structural members 12, 13 and the longitudinal structural members 11a, 11b into the opening 14 for engaging the upper surface of the main housing 21 of the battery pack 20. This defines a generally stepped engagement surface between the battery pack 20 and the frame 10. The battery pack is additionally bonded to the frame 20 by a second adhesive connector 31 positioned between the lower surface of the flange 16 of the frame 10 and the upper surface of the main housing 21 of the battery pack. The second adhesive connector may be configured to extend around the entire periphery of the upper surface of the main housing 21 or may extend only partially around the periphery. The second adhesive connector increases the bonding strength between the battery pack 20 and the frame 10.

[0082] Figure 4B The joint surface between the frame 10 and the battery pack 20 is shown. Figures 1 to 3The same embodiment has the same mating surfaces. However, in this embodiment, a second adhesive connector 31 is provided between the vertical sidewall of the main housing 21 of the battery pack 20 and the inner sidewalls of the transverse structural members 12, 13 and the longitudinal structural members 11a, 11b facing the opening 14. This second adhesive connector not only increases the bonding strength between the battery pack 20 and the frame 10, but also ensures that the adhesive connectors experience the same forces in different relative directions by arranging the two adhesive connectors on surfaces that define an angle between them. For example, a lateral impact force can generate a shear force on the first adhesive connector 30, but a compressive force on the second adhesive connector 31. This reduces the risk that both adhesive connectors will fail due to the same impact.

[0083] Figure 4C The joint surface between the battery pack 20 and the frame 10 is shown in the figure. Figure 4A In the embodiment described, the flange 16 partially protrudes from the sidewalls of the transverse structural members 12, 13 and the longitudinal structural members 11a, 11b into the opening 14. However, in this embodiment, there is no adhesive fastener provided along the mating surface between the flange 16 and the upper surface of the main housing 21 of the battery pack. Instead, a plurality of mechanical fasteners 40a, 40b are provided at the mating surface between the flange 16 and the upper surface of the main housing 21. Figure 4C Only two mechanical fasteners are shown in the cross-section, but it should be understood that mechanical fasteners can be provided at multiple locations around the mating surface between the battery pack 20 and the frame 10. In this embodiment, the mechanical fasteners include bolts. Threaded bolt shafts are provided that project from the upper surface of the main housing 21 of the battery pack. These bolt shafts are received in corresponding holes passing through the flange 16 and secured by nuts, such that the battery pack is bolted to the frame. Although bolts are described as mechanical fasteners in this embodiment, it should be understood that any type of mechanical fastener can be used, including clips, pins, or rivets. In this embodiment, the use of mechanical fasteners 40a and 40b, in addition to the adhesive connection 30 between the flange 22 of the battery pack 20 and the frame, ensures that the battery mounting section is more resilient to different failure modes that individually affect each connection type. Mechanical fasteners can also be used to position the battery pack and hold it in place when the adhesive dries.

[0084] Figure 4DAn embodiment is shown in which a generally continuous base plate surface 15 extends between transverse structural members 12, 13 and longitudinal structural members 11a, 11b such that there are no openings through the frame in the vertical direction. In this embodiment, the battery pack is mounted to the frame by adhesive connectors 30, which are again positioned in a continuous path extending around the entire peripheral flange 22 of the battery pack 20 to surround the main housing 21. Furthermore, mechanical fasteners 40a, 40b are again provided in the form of bolts, with threaded bolt shafts configured to protrude from the upper surface of the main housing 21 of the battery pack; however, in this embodiment, they are received in corresponding holes by the generally continuous base plate surface 15.

[0085] Figure 4E It shows the relationship with Figure 4D Different embodiments exist, in which the mating surface between the battery pack and the frame includes multiple portions arranged at an angle relative to the horizontal plane, and adhesive fasteners are provided along the mating surface. Specifically, instead of a peripheral flange 22 extending in the horizontal plane, in this embodiment, the flange 22a is arranged at an angle inclined downwards in a direction away from the main housing 21 of the battery pack. Figure 4E As shown, this means that the angle between the flange and the horizontal plane (i.e., the plane of the base plate and the battery pack) is... Figure 4E The left side is an angle of approximately 10° counterclockwise rotation, and... Figure 4E The right side represents an angle of approximately 10° clockwise rotation. Although not shown in the figure, the flanges along the front and rear edges of the battery pack 20 similarly slope downwards from and away from the main housing 21 of the battery pack. The lower surfaces of the transverse structural members 12, 13 and the longitudinal structural members 11a, 11b slope in a complementary manner, i.e., downwards in a direction away from the center of the frame. The adhesive connector 30 is disposed between the sloped upper surface of the flange 22a and the sloped lower surfaces of the transverse structural members 12, 13 and the longitudinal structural members 11a, 11b. This joint surface shape means that lateral impact forces will partially place the adhesive connector in compression rather than pure shear, meaning it is less likely to fail.

[0086] It should be understood that the different features described above regarding alternative cross sections can be combined as desired. For example, Figure 4E The inclined flange 22a can be set at Figure 2 or Figures 4A to 4D In any embodiment. Similarly, Figure 4B The second adhesive connector 31 on the vertical sidewall can be provided in any other embodiment.

[0087] Figure 5 It is shown in comparison with the reference Figures 1 to 3An enlarged portion of the frame and battery pack is constructed in a substantially similar manner to that described. However, in this embodiment, a conduit 50 is provided across the adhesive connector 30. This conduit can be a channel through the adhesive connector, which is created by including a wire within the adhesive before the adhesive hardens. Alternatively, the conduit can be a small tube (approximately 2 mm in diameter) made of a soft and thin rubber or polymer material (e.g., EPDM or ABS) extending through the adhesive connector 30. In this embodiment, the conduit follows a path beginning at a first end 51 located at exactly the outer edge of the peripheral flange, in an opening into the gap between the flange and the lower surface of the longitudinal structural member, so that it is accessible from the outside of the frame. The conduit extends from this first end 51 toward the center of the battery pack across the adhesive connector. The conduit runs along the mating surface between the frame 10 and the battery pack 20 until it reaches the opening through the frame. The second end 52 of the conduit is thus accessible near the upper surface of the main housing 21 of the battery pack 20 through the opening 14 through the frame 10. As will be described in more detail below, this conduit can be used to remove the battery pack from the frame. Specifically, a technician can insert a cutting wire along the conduit 50 through the first end 51 or the second end 52 and retract the wire at the opposite end. By arranging the wire in this way, a technician can pull the wire along the path around the adhesive connectors of the battery pack 20 through the adhesive connectors to cut the adhesive connectors to allow removal of the battery pack.

[0088] Figure 6 Alternative embodiments that allow the removal of battery pack 20 are shown in the figure. Figure 6 A top view of the battery pack is shown. The battery pack has a generally square outline and again includes a main housing 21 that holds battery modules, etc., and a peripheral flange 22 extending therefrom. Again, an adhesive connector 30 is provided that extends along the peripheral flange 22, thereby surrounding the main housing 21 of the battery pack 20. In this embodiment, an integral cut line 60 is provided on the battery pack. For example, the line can be made of stainless steel and can have a diameter of 1 mm. The line can have a circular cross-section or a square or rectangular cross-section to define a sharper cut edge. Alternatively, the line can be a braided cut line. The majority of the line's length extends along the peripheral flange 22, thereby being positioned between the main housing 21 and the adhesive connector 30. The line can be weakly bonded to the flange 22 using small dot adhesive. A first end 61 of the cut line 60 is securely anchored to the battery pack. In this embodiment, the first end is anchored near the upper left corner of the main housing 21, such as... Figure 6 As shown. The cutting line follows... Figure 6The wire follows a counter-clockwise path that extends completely around the main housing 21. After completing the full path around the main housing 21, the shorter section of the wire overlaps itself, and then the second end of the wire passes through the conduit 50 provided across the adhesive connector 30. This free second end is thus provided at the outer edge of the battery pack 20, where it can be reached by a technician. To cut the adhesive, the technician only needs to retract the second end of the wire 62 and pull the wire through the adhesive connector along the path around the battery pack 20.

[0089] exist Figure 7 Alternative embodiments are shown. This embodiment is related to... Figure 6 The difference lies in that four spaced-apart adhesive connectors are provided along the respective edges of the battery pack, corresponding to the edges of the transverse structural members 12, 13 and the longitudinal structural members 11a, 11b, respectively. In this embodiment, the second end of the wire 62 can simply be provided through the gap between two adjacent adhesive connectors to allow the second end of the wire to be accessible along the outer edge of the battery pack 20.

[0090] What will be understood is that, as mentioned above... Figures 1 to 4E Any of the described embodiments provides information about Figure 6 and Figure 7 The type of cutting wire described.

[0091] Now will be further referenced Figure 8 This describes a process for mounting a battery pack within a vehicle frame. In a first step S101, a vehicle frame defining the floor portion of the vehicle body is provided, and in step S102, a battery pack to be mounted to the frame is provided. The frame 10 may be as specifically described above. Figures 1 to 4E Any frame described and battery pack 20 can be the corresponding battery pack described above.

[0092] In step S103, a cutting wire 60 is provided. A first end 61 of the cutting wire is anchored to the battery pack 20 at a point where an adhesive connector, to which the wire will be applied in a subsequent step, will be positioned. For this purpose, any suitable anchoring member, such as an eyelet bolt to which the wire is bound, can be used. The wire is arranged to extend around the perimeter of the battery pack along a path slightly inside the path of the adhesive connector applied in a subsequent step, until the wire extends approximately around the entire perimeter of the battery pack 20. As described above, to hold the wire in proper position on the battery pack 20, small dots of adhesive can be applied along the path of the wire at regular intervals.

[0093] In step S104, conduit 50 is provided and arranged near the second end 62 of the wire, and arranged such that it will extend across the adhesive connector applied in a subsequent step. The second end of the wire 62 then passes through conduit 50. It should be understood that steps S103 and S104 can be omitted if an integral cutting wire is not provided for the battery pack, or if the separate cutting wire is intended to remove the battery pack, the conduit can be arranged such that it will extend across the adhesive connector without any wire.

[0094] In step S105, an adhesive is applied to coat the peripheral flange 22 of the battery pack 20. As described above, the adhesive is preferably a paste-like, extensible structural adhesive with polyurethane chemistry, and is applied by coating the peripheral flange 22 of the battery pack 20 with the peripheral flange horizontal and facing upward. The adhesive is applied in a thickness of at least 3 mm, which will compensate for any roughness on the surface of the battery pack or frame. The adhesive is applied to define one or more adhesive connectors 30, which generally extend around the entire periphery of the battery pack to surround the main housing 21 of the battery pack. The adhesive is applied such that it extends over the conduit provided in step S104, such that the second end of the wire remains accessible and free to move within the conduit 50.

[0095] In step S106, the battery pack 20 is positioned within the base plate portion defined by the frame 10. The battery pack is arranged such that the adhesive on the battery pack is located at a suitable mating surface with the frame 10, as described above. In this step, any mechanical fasteners 40a, 40b can be used to properly position the battery pack 20 and can therefore include means for guiding and positioning the battery pack to its precise position within the vehicle frame during the arrangement step. For example, if the mechanical fasteners include bolts, the bolt shaft and complementary bolt holes can aid in positioning the frame and battery pack. A similar effect can be achieved without using mechanical fasteners such as locating pins.

[0096] Finally, in step S107, the battery pack is bonded to the frame using adhesive connectors. This process may include pressing the battery pack against the frame as the adhesive solidifies. This can simply involve lowering the frame onto the battery pack or pressing the battery pack upwards into the frame, allowing the weight of the frame to act, pressing the battery pack against the frame and counteracting the hydraulic pressure generated by adhesive extrusion. However, preferably, mechanical fasteners 40a, 40b are used to clamp the battery pack against the frame while the adhesive solidifies to bond the battery pack to the frame. These mechanical fasteners between the battery pack and the vehicle frame can hold them together during bonding to counteract the hydraulic pressure generated by adhesive extrusion. Such mechanical fasteners can be driven to a hard stop by a compression limiter to control the adhesive gap to a precise size and avoid hard contact between the vehicle frame and the battery case. For example, in the case where the mechanical fasteners include bolts, 3 mm spacer elements can be placed on one or more bolt shafts between the battery pack and the frame to ensure a 3 mm adhesive connector thickness. Mechanical fasteners can also exclusively provide a means of holding the battery pack in place as the adhesive hardens, thus enabling subsequent vehicle handling operations while the adhesive reaches its full strength.

[0097] Now refer to Figure 9 The process of removing the battery pack installed in the manner described above is further described. In the first step (S201), cutting lines are laid across the adhesive connectors. Figure 5 In similar embodiments as shown, this could involve threading the cutting wire along a conduit 50 provided across the adhesive connector from the first end 51 to the second end 52, where the wire is retrieved. Regarding Figure 6 and Figure 7 In the case of embodiments of the types shown and described, the cutting lines can be pre-arranged to cross the adhesive connector.

[0098] In step S202, the adhesive and / or the wire may be heated. Heating the adhesive can soften it, and heating the wire causes it to soften the adhesive when it comes into contact with it. The adhesive can be heated by placing a heat source in contact with the opposing surface of the peripheral flange. The wire can be heated by a resistance process. If the wire is anchored to the battery pack or frame at one end, the anchoring point may include an electrical connection to the vehicle floor or to a vehicle-specific circuit that is accessible in the vehicle when the battery is being serviced.

[0099] In step S203, the cutting wire is pulled through the adhesive connector. The cutting wire can be pulled to follow the path of the adhesive connector around the battery pack. Pulling can be done manually or with tool assistance. If an integral cutting wire is used, only one end of the wire needs to be pulled while the other end remains anchored in place. If a separate cutting wire is used, both ends may need to be manipulated to pull the wire through the adhesive connector. Once the wire has been pulled through the entire path of the adhesive connector, the adhesive is cut.

[0100] In step S204, any mechanical fasteners 40a, 40b can be disengaged. For example, if the battery pack 20 is also bolted to the frame, the bolts can be removed to allow the battery pack to be removed.

[0101] Finally, in step S205, the battery pack is separated from the vehicle frame by cutting the adhesive connectors and disengaging any mechanical fasteners.

Claims

1. A method for mounting a battery pack to the body of a passenger vehicle, the method comprising: Provides a vehicle frame that defines at least the floor portion of the vehicle body; Battery packs are provided; The battery pack is arranged in the floor portion of the vehicle body; as well as The battery pack is attached to the frame using at least one adhesive connector located at the joint surface between the battery pack and the frame.

2. The method according to claim 1, wherein, One or more adhesive connectors are positioned along the peripheral edge portion of the battery pack.

3. The method according to claim 2, wherein, The one or more adhesive connectors are positioned along at least two opposite peripheral edge portions of the battery pack.

4. The method according to any one of the preceding claims, wherein, The one or more adhesive connectors generally surround the central region of the battery pack.

5. The method according to any one of the preceding claims, wherein, The battery pack includes one or more peripheral flanges configured to form at least a portion of the mating surface with the frame, wherein the one or more adhesive fasteners are positioned along one or more of the peripheral flanges.

6. The method according to any one of the preceding claims, wherein, The mating surface between the battery pack and the frame includes one or more portions defining a generally stepped mating surface, and wherein, preferably, the at least one adhesive connector is located on at least two different surfaces defining the one or more portions of the generally stepped mating surface.

7. The method according to any one of the preceding claims, wherein, The vehicle's floor portion generally defines a plane, wherein the mating surface between the battery pack and the frame includes one or more portions arranged at an angle to the plane defined by the floor portion, and wherein the at least one adhesive connector is located at the one or more portions of the mating surface arranged at an angle to the plane defined by the floor portion.

8. The method according to claim 7, wherein, The mating surface between the battery pack and the frame includes a portion arranged at a different angle relative to the plane defined by the base plate portion, and wherein the at least one adhesive connector is located at the portion of the mating surface arranged at a different angle relative to the plane defined by the base plate portion.

9. The method according to claim 7 or 8, wherein, One or more portions of the joint surface between the battery pack and the frame are arranged at an angle generally inclined toward or away from the center of the battery pack.

10. The method according to any one of the preceding claims, wherein, The thickness of each adhesive connector is at least 0.5 mm, preferably at least 1 mm, more preferably at least 2 mm, and most preferably at least 3 mm.

11. The method according to any one of the preceding claims, wherein, The adhesive connector, or each adhesive connector, is elongated.

12. The method according to any one of the preceding claims, wherein, The frame defines an opening through the frame at the bottom plate portion, and wherein the battery pack closes the opening, thereby defining at least one area of ​​the vehicle's bottom plate.

13. The method according to any one of claims 1 to 11, wherein, The frame defines a generally continuous floor surface at the floor portion of the vehicle body, and wherein the battery pack is arranged generally adjacent to the floor surface.

14. The method according to any one of the preceding claims, wherein, Arranging the battery pack in the floor portion of the vehicle body includes engaging one or more mechanical fasteners to guide the battery pack into place on the frame.

15. The method according to any one of the preceding claims, wherein, Attaching the battery pack to the frame includes clamping the battery pack to the frame using one or more mechanical fasteners while the adhesive is curing.

16. The method according to claim 14 or claim 15, wherein, The one or more mechanical fasteners include one or more spacer elements configured to prevent direct contact between the battery pack and the frame.

17. The method according to any one of the preceding claims, wherein, The frame includes opposing structural members, wherein the method includes arranging the battery pack between the opposing structural members and connecting the battery pack to each of the opposing structural members, wherein, preferably, connecting the battery pack to one or more of the opposing structural members includes: bonding the battery pack to the structural members using an adhesive connector located at the mating surface between the battery pack and the structural member.

18. The method of claim 17 when dependent on any one of claims 7 to 9, wherein, The opposing structural members define one or more portions arranged at an angle to the plane defined by the base plate portion, wherein, preferably, each opposing structural member defines a corresponding portion arranged at an angle to the plane defined by the base plate portion, and the at least one adhesive connector is preferably arranged at each corresponding portion of the corresponding portions arranged at an angle to the plane defined by the base plate portion.

19. The method according to any one of the preceding claims, wherein, The frame defines at least a portion of the floor surface at the floor portion of the vehicle body and structural members extending away from the floor surface, and the method further includes connecting the battery pack to the structural member and connecting the battery pack to the floor surface of the frame, wherein preferably, connecting the battery pack to the structural member includes: bonding the battery pack to the structural member using an adhesive connector located at the joint surface between the battery pack and the structural member, and / or wherein, preferably, connecting the battery pack to the floor surface includes: bonding the battery pack to the floor surface using an adhesive connector located at the joint surface between the battery pack and the floor surface.

20. The method according to any one of the preceding claims, wherein, The frame includes opposing longitudinal structural members positioned along opposing longitudinal edges of the floor portion of the vehicle body, wherein arranging the battery pack in the floor portion of the vehicle body includes: generally arranging the battery pack between the opposing longitudinal structural members.

21. The method according to any one of the preceding claims, wherein, The material of the battery pack at the location of the adhesive connector has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, and most preferably at least 20 GPa.

22. The method according to any one of the preceding claims, wherein, The battery pack includes a housing, wherein the material of the housing extending between the adhesive connector and another connector between the battery pack and the frame or another segment of the same adhesive connector has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, and most preferably at least 20 GPa.

23. The method according to claim 22 when subordinate to at least claim 17, wherein, The material of the shell extending between the opposing structural members has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, and most preferably at least 20 GPa.

24. The method according to any one of the preceding claims, wherein, Attaching the battery pack to the frame using at least one adhesive connector includes providing a conduit across at least one of the adhesive connectors, with a wire capable of being inserted through the conduit for cutting the at least one adhesive connector.

25. The method according to claim 24, wherein, The conduit is arranged such that a first end of the conduit is accessible from a first side of the adhesive connector, and a second end of the conduit is accessible from a second side of the adhesive connector.

26. The method according to any one of the preceding claims, further comprising providing the frame or the battery pack with at least one wire for cutting the at least one adhesive connector, wherein, The first end of the wire is anchored to the frame or the battery pack, and wherein the battery pack is arranged and coupled to the frame such that a portion of the wire is accessible to pull the wire through the at least one adhesive connector to cut the at least one adhesive connector.

27. The method of claim 26, further comprising providing a conduit across at least one of the adhesive connectors, wherein, The first end of the wire is anchored to the frame or the battery pack at a first side of the conduit, and wherein the wire is arranged to pass through the conduit such that a portion of the wire is accessible from a second side of the conduit, or wherein the wire is arranged such that a portion of the wire is accessible from a second side of the conduit through the conduit.

28. The method according to claim 26 or 27, wherein, The line is arranged to generally follow the path of the at least one adhesive connector along the joint surface between the battery pack and the frame.

29. A body for a passenger vehicle, the body comprising: A vehicle frame that defines at least a floor portion of the vehicle body; as well as A battery pack, located in the floor portion of the vehicle body, is attached to the frame by at least one adhesive connector at the joint surface between the battery pack and the frame.

30. The vehicle body according to claim 29, wherein, One or more adhesive connectors are positioned along the peripheral edge portion of the battery pack.

31. The vehicle body according to claim 30, wherein, The one or more adhesive connectors are positioned along at least two opposite peripheral edge portions of the battery pack.

32. The vehicle body according to any one of claims 29 to 31, wherein, The one or more adhesive connectors generally surround the central region of the battery pack.

33. The vehicle body according to any one of claims 29 to 32, wherein, The battery pack includes one or more peripheral flanges configured to form at least a portion of the mating surface with the frame, wherein the one or more adhesive fasteners are positioned along one or more of the peripheral flanges.

34. The vehicle body according to any one of claims 29 to 33, wherein, The vehicle's floor portion generally defines a plane, wherein the mating surface between the battery pack and the frame includes one or more portions arranged at an angle to the plane defined by the floor portion, and wherein the at least one adhesive connector is located at the one or more portions of the mating surface arranged at an angle to the plane defined by the floor portion.

35. The vehicle body according to claim 34, wherein, The mating surface between the battery pack and the frame includes a plurality of portions arranged at different angles relative to the plane defined by the base plate portion, and wherein the at least one adhesive connector is located at the plurality of portions of the mating surface arranged at different angles relative to the plane defined by the base plate portion.

36. The vehicle body according to claim 34 or 35, wherein, One or more portions of the joint surface between the battery pack and the frame are arranged at an angle generally inclined toward or away from the center of the battery pack.

37. The vehicle body according to any one of claims 29 to 36, wherein, The thickness of each adhesive connector is at least 0.5 mm, preferably at least 1 mm, more preferably at least 2 mm, and most preferably at least 3 mm.

38. The vehicle body according to any one of claims 29 to 37, wherein, The adhesive connector, or each adhesive connector, is elongated.

39. The vehicle body according to any one of claims 29 to 38, wherein, The frame defines an opening through the frame at the bottom plate portion, and wherein the battery pack closes the opening, thereby defining at least a region of the vehicle's bottom plate.

40. The vehicle body according to any one of claims 29 to 38, wherein, The frame defines a generally continuous floor surface at the floor portion of the vehicle body, and wherein the battery pack is arranged generally adjacent to the floor surface.

41. The vehicle body according to any one of claims 29 to 40, wherein, The battery pack is further connected to the frame by one or more mechanical fasteners.

42. The vehicle body according to claim 41, wherein, The one or more mechanical fasteners include one or more spacer elements configured to prevent direct contact between the battery pack and the frame.

43. The vehicle body according to any one of claims 29 to 42, wherein, The frame includes opposing structural members, wherein the battery pack is arranged between the opposing structural members, and wherein the battery pack is connected to each of the opposing structural members, wherein, preferably, the battery pack is connected to one or more of the opposing structural members by adhesive fasteners located at the joint surfaces between the battery pack and the structural members.

44. The vehicle body according to claim 43 when it is dependent on any one of claims 34 to 36, wherein, The opposing structural members are defined as one or more portions arranged at an angle to the plane defined by the base plate portion, wherein, preferably, each opposing structural member is defined as a corresponding portion arranged at an angle to the plane defined by the base plate portion, and the at least one adhesive connector is preferably arranged at each corresponding portion of the corresponding portions arranged at an angle to the plane defined by the base plate portion.

45. The vehicle body according to any one of claims 29 to 44, wherein, The frame defines at least a portion of the floor surface at the floor portion of the vehicle body and structural members extending away from the floor surface, and wherein the battery pack is connected to the structural member and the battery pack is connected to the floor surface of the frame, wherein, preferably, the battery pack is connected to the structural member using an adhesive connector located at the joint surface between the battery pack and the structural member, and / or wherein the battery pack is connected to the floor surface using an adhesive connector located at the joint surface between the battery pack and the floor surface.

46. ​​The vehicle body according to any one of claims 29 to 45, wherein, The frame includes opposing longitudinal structural members positioned along opposing longitudinal edges of the floor portion of the vehicle body, wherein the battery pack is generally arranged between the opposing longitudinal structural members.

47. The vehicle body according to any one of claims 29 to 46, wherein, The material of the battery pack at the location of the adhesive connector has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, and most preferably at least 20 GPa.

48. The vehicle body according to any one of claims 29 to 47, wherein, The battery pack includes a housing, wherein the material of the housing extending between the adhesive connector and another connector between the battery pack and the frame, or another segment of the same adhesive connector, has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, and most preferably at least 20 GPa.

49. The vehicle body according to claim 48 when it is subordinate to at least claim 43, wherein, The material of the shell extending between the opposing structural members has a Young's modulus of at least 1 GPa, preferably at least 2 GPa, more preferably at least 3 GPa, more preferably at least 5 GPa, more preferably at least 10 GPa, and most preferably at least 20 GPa.

50. The vehicle body according to any one of claims 29 to 49, wherein, A conduit is provided across at least one of the adhesive connectors, through which a wire can be inserted for cutting the at least one adhesive connector.

51. The vehicle body according to claim 50, wherein, The conduit is arranged such that a first end of the conduit is accessible from a first side of the adhesive connector, and a second end of the conduit is accessible from a second side of the adhesive connector.

52. The vehicle body according to any one of claims 29 to 51, wherein, The frame or the battery pack is provided with at least one wire for cutting the at least one adhesive connector, wherein a first end of the wire is anchored to the frame or the battery pack, and wherein the battery pack is arranged and coupled to the frame such that a portion of the wire is accessible to pull the wire through the at least one adhesive connector to cut the at least one adhesive connector.

53. The vehicle body according to claim 52, further comprising a conduit extending across at least one of the adhesive connectors, wherein, The first end of the wire is anchored to the frame or the battery pack at a first side of the conduit, and wherein the wire is arranged to pass through the conduit such that a portion of the wire is accessible from a second side of the conduit, or wherein the wire is arranged such that a portion of the wire is accessible from a second side of the conduit through the conduit.

54. The vehicle body according to claim 52 or 53, wherein, The line is arranged to generally follow the path of the at least one adhesive connector along the joint surface between the battery pack and the frame.

55. A method for removing a battery pack mounted to the body of a passenger vehicle, wherein, The passenger vehicle includes a frame defining at least a floor portion of the vehicle body and a battery pack in the floor portion of the vehicle body, the battery pack being attached to the frame via at least one adhesive connector located at a mating surface between the battery pack and the frame, the method including pulling a wire through the at least one adhesive connector to cut the at least one adhesive connector.

56. The method according to claim 55, wherein, The passenger vehicle also includes a conduit passing through at least one adhesive connector of the adhesive connector, and wherein the method includes arranging the line through the conduit and using the end of the line on either side of the conduit to pull the line along the at least one adhesive connector to cut the at least one adhesive connector.

57. The method of claim 55, wherein, The passenger vehicle includes the line, wherein a first end of the line is anchored to the frame or the battery pack, and the method includes retracting a portion of the line and pulling the line through the portion through the at least one adhesive connector to cut the at least one adhesive connector.

58. The method according to any one of claims 55 to 57, further comprising heating the adhesive and / or the wire before pulling the wire through the at least one adhesive connector, wherein, Preferably, heating the wire includes: passing an electric current through the wire.

59. The method according to any one of claims 55 to 58, wherein the method is performed on a vehicle body according to any one of claims 29 to 54.

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