Vehicle-mounted battery mounting structure

Abstract

A battery mounting structure for a vehicle is provided, capable of suppressing the thermal effects of a device disposed on top of an energy storage unit. The vehicle-mounted battery mounting structure includes: a top cover disposed above the energy storage unit; a device partially disposed above the energy storage unit and the top cover, and electrically connected to the energy storage unit; a device base on which the device is mounted; a plate-shaped resin component disposed between the energy storage unit and the top cover, having a thin-walled portion below the device, the upper surface of the thin-walled portion being lower than the upper surface of other portions; and a recess formed in the top cover, recessed downwards above the thin-walled portion.

Description

Technical Field

[0001] This disclosure relates to a battery mounting structure for use in vehicles. Background Technology

[0002] Japanese Patent Application Publication No. 2018-202946 discloses a structure in which a battery pack is covered by a floor chassis forming the floor surface of the vehicle compartment. It also discloses a structure in which a plate-shaped component is sandwiched between the battery pack and the floor chassis.

[0003] However, in the layout of the vehicle interior, sometimes devices electrically connected to the energy storage units that make up the battery pack are placed above them. In this case, for example, when the device generates heat, heat may be transferred from the device to the energy storage units via plate-like components. Summary of the Invention

[0004] This disclosure provides a battery mounting structure for a vehicle that can suppress the thermal effects of a device in an energy storage unit on which a device is disposed.

[0005] The first embodiment of the battery mounting structure for a vehicle includes: a top cover disposed above a storage unit; a device partially disposed above the storage unit and the top cover, and electrically connected to the storage unit; a device base on which the device is mounted; a plate-shaped resin component disposed between the storage unit and the top cover, having a thin-walled portion below the device, the upper surface of the thin-walled portion being lower than the upper surface of the other portions; and a recess formed in the top cover, recessed downward above the thin-walled portion.

[0006] In the first embodiment of the battery mounting structure mounted on a vehicle, when the device is driven, the heat generated during driving is dissipated to the device base. Furthermore, a downwardly recessed portion is formed in the upper cover of the energy storage unit disposed below the device base. This recess is formed above the thin-walled portion of the resin component. In other words, the space for forming the recess is formed in the upper cover through the thin-walled portion of the resin component.

[0007] These thin-walled sections and recesses ensure space between the device base and the top cover. This prevents heat transfer from the device base to the energy storage unit via the top cover, and prevents the energy storage unit from being locally heated.

[0008] Furthermore, the space ensured by the thin-walled portion and the recess can also suppress the transfer of heat generated during the operation of the energy storage unit to the device base via the top cover. Therefore, for example, when the device is not in operation, the energy storage unit is prevented from being partially cooled.

[0009] Thus, in the battery mounting structure for vehicles, heat transfer between the device and the energy storage unit is suppressed by the thin-walled portion of the resin component and the recess of the top cover, thereby suppressing the thermal impact from the device in the energy storage unit.

[0010] Furthermore, the load acting on the top cover is partially dispersed by the resin components. Therefore, it is possible to suppress localized loads acting on the energy storage unit.

[0011] In the second embodiment of the battery mounting structure for vehicle mounting, in the first embodiment of the battery mounting structure for vehicle mounting, an air layer provides thermal insulation between the device base and the top cover below the device, and the air layer communicates with the recess.

[0012] In the second type of battery mounting structure for vehicle mounting, the heat transfer suppression effect achieved by the thin-walled portion of the resin component and the recess of the top cover is enhanced by the air layer.

[0013] In the third type of vehicle-mounted battery mounting structure, a protrusion is formed on the lower surface of the device base in the second type of vehicle-mounted battery mounting structure, and the protrusion protrudes downward toward the air layer.

[0014] In third-party battery mounting structures for vehicles, the raised protrusion increases the surface area of ​​the lower surface of the device base, facilitating heat dissipation from the device base to the air layer. Therefore, heat dissipation from the device to the device base is easier compared to a structure without protrusions. On the other hand, since air has lower thermal conductivity than resin or metal, heat dissipated from the device base is less likely to transfer to the upper cover.

[0015] In the fourth type of vehicle-mounted battery mounting structure, the protrusions are formed as a grid along the width and longitudinal direction of the vehicle.

[0016] In the fourth type of battery mounting structure for vehicles, compared with the case where the protrusion is a rib along the width direction of the vehicle or a rib along the front-rear direction of the vehicle, it is easier to form a larger surface area of ​​the lower surface of the equipment base.

[0017] In the fifth type of battery mounting structure for vehicle mounting, the protrusion is formed above the recess in the third or fourth type of battery mounting structure for vehicle mounting.

[0018] In the fifth type of battery mounting structure for vehicle mounting, the protrusion can penetrate into the recess. This facilitates heat dissipation from the device base to the air layer and the air in the recess.

[0019] According to this disclosure, it is possible to suppress the thermal effects from the device in an energy storage unit on which the device is configured. Attached Figure Description

[0020] Figure 1 This is an exploded perspective view showing the main parts of a battery mounting structure for a vehicle according to an embodiment of the present disclosure.

[0021] Figure 2 This is a side cross-section illustrating an example of a battery mounting structure for a vehicle according to an embodiment of the present disclosure.

[0022] Figure 3A This is a partially enlarged side section showing an example of the protrusion of the device base and the resin component of an embodiment of the present disclosure.

[0023] Figure 3B This is a partially enlarged side section showing an example of the protrusion of the device base, the recess of the top cover, and the resin component of an embodiment of the present disclosure.

[0024] Figure 3C This is a partially enlarged side section showing a modified example of the resin component according to an embodiment of the present disclosure. Detailed Implementation

[0025] Hereinafter, a battery mounting structure for a vehicle according to an embodiment of the present disclosure will be described with reference to the accompanying drawings. Components indicated by the same reference numerals in the drawings refer to the same components. However, unless otherwise specified in the description, each component is not limited to one, and multiple components may exist.

[0026] Furthermore, descriptions of components and reference numerals that are repeated in the various figures are sometimes omitted. Moreover, this disclosure is not limited to the following embodiments, and can be implemented by appropriately applying changes such as omitting components, replacing them with different components, or combining one embodiment with various modifications within the scope of the purpose of this disclosure.

[0027] (Vehicle structure)

[0028] Figure 1 This is a perspective view showing the main parts of a vehicle V with a battery mounting structure implemented according to an embodiment of the present disclosure. Arrows FR, UP, and RH in the figure represent the forward, upward, and rightward directions of the vehicle V, respectively.

[0029] like Figure 1 As shown, a battery housing 12 is provided at the center of the vehicle V in the longitudinal direction. The battery housing 12 is located at the lower part of the vehicle. Furthermore, since the upper surface of the battery housing 12 forms the passenger compartment floor, no floor panel is provided on the vehicle V in this embodiment.

[0030] A pair of lower side beams 14 extending in the longitudinal direction of the vehicle are provided on both sides of the battery housing 12 in the vehicle width direction. The lower side beams 14 are skeleton components with a generally rectangular closed cross section. The battery housing 12 is mounted on the lower side beams 14 using fasteners (not shown).

[0031] The front end of the lower beam 14 is connected to the front module 20. On the other hand, the rear end of the lower beam 14 is connected to the rear module 30. The front module 20 and the rear module 30 are integrally formed, for example, by casting.

[0032] A first crossbeam 22 and a second crossbeam 24, serving as transverse components, are provided at the central portion of the lower side beam 14 in the vehicle's longitudinal direction. The first crossbeam 22 and the second crossbeam 24 extend above the battery casing 12 along the vehicle's width direction and are positioned between the left and right pairs of lower side beams 14. Furthermore, a vehicle seat (not shown) for the front seats is mounted on the first crossbeam 22 and the second crossbeam 24.

[0033] On the other hand, a third crossbeam 26, serving as a transverse component, is provided on the rear portion of the lower side beam 14 in the vehicle's longitudinal direction. The third crossbeam 26 also extends along the vehicle's width direction above the battery housing 12, and is mounted between the left and right pairs of lower side beams 14. The detailed structure of the third crossbeam 26 will be described later.

[0034] (Battery casing)

[0035] like Figure 2 As shown, the battery housing 12 includes an upper housing 12A and a lower housing 12B and is formed in a generally box-like shape. A battery 10 (energy storage unit) is housed inside the battery housing 12.

[0036] The upper housing 12A is a cover disposed above and covering the battery 10, and as described above, its upper surface forms the vehicle floor. An opening K2 is formed at the rear end of the upper housing 12A in the vehicle longitudinal direction. Through this opening K2, the internal space of the battery housing 12 communicates with the internal space of the equipment housing 40, which will be described later.

[0037] Alternatively, the battery housing 12 may consist solely of a top cover that covers the top of the battery 10. In this case, a component supporting the battery 10 from below may be provided instead of the lower housing 12B.

[0038] (Equipment casing)

[0039] An equipment housing 40 is disposed above the battery housing 12. The equipment housing 40 includes an equipment base 42 and a cover 44. The equipment base 42 is a box-shaped housing that is open at the top.

[0040] The material of the device base 42 is not particularly limited, but from the viewpoint of improving the heat dissipation performance of heat-generating devices such as the relay 110 described later, a material with high thermal conductivity, such as aluminum, is preferred. Furthermore, a die-cast part (casting) formed of cast aluminum or the like is even more preferred.

[0041] The cover 44 is a sealing component that closes the opening at the upper end of the equipment base 42 and is fixed to the equipment base 42 using fastening components not shown.

[0042] Furthermore, in this disclosure, the device base 42 does not necessarily have to be a casting; it can also be formed from a sheet of metal (e.g., aluminum, stainless steel), resin, or the like. Even if the device base 42 is formed from a sheet of metal, resin, or the like, heat is dissipated from the heat-generating device such as the relay 110 to the device base 42.

[0043] (Junction box)

[0044] Inside the device housing 40 is a junction box 50 that houses heat-generating devices such as a relay 110. The junction box 50 is mounted on the device base 42 and is fixed to the device base 42 using fastening components not shown.

[0045] In addition, inside the equipment housing 40, besides the junction box 50, there are auxiliary equipment 100. Auxiliary equipment 100 includes, for example, a PDU (Power Distribution Unit) or an ECU (Electronic Control Unit).

[0046] Relay 110 and auxiliary equipment 100 are connected to battery 10 via busbars or wiring harnesses (not shown) and are electrically connected to battery 10. Relay 110 and other heat-generating devices are sometimes driven by power supplied from battery 10, and generate heat during operation.

[0047] The relay 110 and junction box 50 are partially disposed above the battery 10 and the upper housing 12A. As an example, "partially disposed" means that the battery 10, which extends along the vehicle's longitudinal and width directions, is disposed in a portion of the vehicle's longitudinal direction (e.g., the rear side).

[0048] An opening is formed at the bottom of the junction box 50, and a heat sink 52 is disposed in this opening. The relay 110 is disposed above the heat sink 52. That is, the heat sink 52, serving as a heat-conducting component, is disposed between the relay 110 and the device base 42. Heat generated when the relay 110 is activated is transferred to the device base 42 via the heat sink 52. Furthermore, an insulating sheet 54 is disposed below the heat sink 52.

[0049] Furthermore, in this disclosure, the heat sink 52 is not necessarily required and can be omitted. In this case, the opening at the bottom of the junction box 50 may not be formed, and the insulating sheet 54 can also be omitted. Even without the heat sink 52, heat is transferred from the relay 110 to the device base 42.

[0050] (Auxiliary machine cover)

[0051] The auxiliary unit 100 is configured in multiple layers. Specifically, the auxiliary unit 100 is also disposed above the equipment housing 40, and is covered by an auxiliary unit cover 56. The auxiliary unit cover 56 is disposed above the equipment housing 40 and supports the seat cushion SC of the vehicle seat for the rear seat from the lower side of the vehicle. In addition, other components may be sandwiched between the auxiliary unit cover 56 and the seat cushion SC.

[0052] (Resin parts)

[0053] A plate-shaped resin component 16 is disposed between the battery 10 and the upper housing 12A. The resin component 16 extends in the vehicle longitudinal direction and the vehicle width direction, and covers the battery 10 from above.

[0054] like Figure 3A As shown, the battery 10 and the resin component 16 are bonded to each other by adhesive G. Additionally, the upper housing 12A is bonded to the resin component 16 by adhesive G.

[0055] The resin component 16, located below the junction box 50 and below the relay 110, has a thin-walled portion 16A whose upper surface is lower than the upper surface of other parts. Furthermore, the thin-walled portion 16A and the adhesive G... Figure 2 The illustration is omitted.

[0056] Here, as Figure 1 As shown, a plurality of downwardly recessed recesses 12H are formed in the upper housing 12A. The shape of the recesses 12H is not particularly limited. As an example, the recesses 12H are formed into a groove shape by a pair of wall portions extending downward from the upper surface of the upper housing 12A and a bottom portion connecting the lower ends of the pair of wall portions. Therefore, the recesses 12H are configured as grooves along the longitudinal direction of the vehicle, and a plurality of them are arranged in the width direction of the vehicle.

[0057] exist Figure 3B The figure shows a side cross-section of the upper housing 12A at the portion where the recess 12H is formed. As shown in the figure, the recess 12H is formed above the thin-walled portion 16A in the resin component 16. Furthermore, the recess 12H is formed along the shape of the thin-walled portion 16A.

[0058] Here, "along the shape of the thin-walled portion 16A" means that the curved portion B1 of the resin component 16 and the curved portion B2 of the upper housing 12A have the same or similar shape when viewed from the side and are arranged close to each other. The curved portion B1 is the boundary between the thin-walled portion 16A of the resin component 16 and other parts. In addition, the curved portion B2 is the boundary between the recess 12H of the upper housing 12A and other parts.

[0059] In this configuration, a recess 12H of the upper housing 12A and a thin-walled portion 16A of the resin component 16 are disposed below the relay 110.

[0060] Alternatively, the recess 12H may also be a shape that does not follow the shape of the thin-walled portion 16A. The curved portion B1 of the resin component 16 and the curved portion B2 of the upper housing 12A may have different shapes, or they may be configured separately from each other.

[0061] (Insulation structure)

[0062] like Figure 2 As shown, below the relay 110 and below the junction box 50, the equipment base 42 and the upper housing 12A are insulated by an air layer A1.

[0063] A fixing part 42C is formed on the equipment base 42, protruding downward from the bottom surface of the equipment base 42, and the fixing part 42C is fixed to the upper housing 12A. The thickness H2 of the air layer A1 is equal to the protrusion height of the fixing part 42C. In addition, an opening K1 is formed on the fixing part 42C, opening above the opening K2 of the upper housing 12A.

[0064] like Figure 3B As shown, the air layer A1 is connected to the recess 12H of the upper shell 12A. Therefore, in the portion where the recess 12H is formed, the thickness H3 of the connected air layer is greater than the thickness H2 of the other portions.

[0065] It should be noted that insulation performance can also be ensured by filling the air layer A1 with various insulation components such as fiber-based or foamed resin-based materials.

[0066] (Heat dissipation structure)

[0067] like Figure 3A As shown, a protrusion 42D protruding downward toward the air layer A1 is formed on the lower surface of the equipment base 42. The portion of the equipment base 42 with the protrusion 42D is thicker than the other portions. As a result, the heat capacity of the equipment base 42 is increased compared to the case without the protrusion 42D.

[0068] Furthermore, the protrusion 42D increases the surface area of ​​the lower surface of the device base 42 compared to the case without the protrusion 42D. This facilitates heat dissipation from the device base 42 to the air layer A1.

[0069] The protrusion height of protrusion 42D is lower than the thickness H2 of air layer A1 (the protrusion height of fixing part 42C). This avoids interference between protrusion 42D and upper shell 12A.

[0070] It should be noted that the shape of the protrusion 42D is not particularly limited; for example, it can be formed as a rib along the width direction of the vehicle. Additionally, the protrusion 42D can be formed as a rib along the longitudinal direction of the vehicle. Furthermore, the protrusion 42D can be formed as a grid along both the width and longitudinal directions of the vehicle. Moreover, the protrusion 42D can also be formed as a dot, such as a circle.

[0071] The size, length, height, placement, and number of these protrusions 42D are arbitrary. For example, a protrusion 42D formed as a rib along the longitudinal direction of the vehicle can be positioned above the recess 12H of the upper housing 12A. In this case, the protrusion 42D can penetrate into the recess 12H, and therefore the height of the protrusion 42D can be greater than the thickness H2 of the air layer A1.

[0072] It should be noted that the protrusion 42D is not necessarily required in this disclosure. For example, instead of the protrusion 42D, an upwardly recessed portion can be provided on the lower surface of the device base 42. Alternatively, the protrusion 42D and the recessed portion can be omitted, and the lower surface of the device base 42 can be formed flat.

[0073] <Functions and Effects>

[0074] (Insulation and heat dissipation functions)

[0075] In the battery mounting structure for a vehicle according to the embodiments of this disclosure, when Figure 2 When the relay 110 or other heat-generating devices are driven, the heat generated during the drive is dissipated to the device base 42. Furthermore, the device base 42 is insulated from the upper casing 12A of the battery 10 by air. Therefore, heat transfer from the device base 42 to the battery 10 via the upper casing 12A is suppressed, preventing the battery 10 from being locally heated.

[0076] Furthermore, by insulating the device base 42 from the upper housing 12A, the transfer of heat generated during the operation of the battery 10 to the device base 42 via the upper housing 12A is also suppressed. Therefore, for example, when heat-generating devices such as the relay 110 are not driven, partial cooling of the battery 10 is prevented.

[0077] In this way, in the battery mounting structure installed in the vehicle, heat transfer between heat-generating devices such as relay 110 and the battery 10 is suppressed by thermal insulation, thus suppressing the thermal effects from the devices in the battery 10.

[0078] Furthermore, in the battery mounting structure for a vehicle according to the embodiments of this disclosure, a heat sink 52, serving as a heat-conducting component, is provided between the relay 110 and the device base 42. Therefore, compared to the case without the heat sink 52, heat dissipation from the relay 110 to the device base 42 is easier, thus suppressing overheating of the relay 110.

[0079] Furthermore, in the battery mounting structure for a vehicle according to the embodiments of this disclosure, the device base 42 is a casting. Therefore, compared to cases where the device base 42 is formed from a metal sheet, resin, or the like, it has high thermal conductivity, facilitating heat dissipation from heat-generating devices such as the relay 110 to the device base 42. Consequently, overheating of heat-generating devices such as the relay 110 can be suppressed.

[0080] Furthermore, in the battery mounting structure for vehicle mounting according to the embodiments of this disclosure, the device base 42 and the upper housing 12A are insulated by an air layer A1. Air is a gas, and even if there are irregularities in the device base 42 and the upper housing 12A (e.g., protrusions 42D of the device base 42, see...), it will provide insulation. Figure 3A There will be no interference. Therefore, compared with the case of laying insulation components, the shape of the equipment base 42 and the upper shell 12A is less constrained.

[0081] Furthermore, since air has a lower thermal conductivity compared to resin or metal, it is difficult for heat dissipated from the device base 42 to be transferred to the upper housing 12A.

[0082] (The function of the concave part)

[0083] Furthermore, in the battery mounting structure for vehicles according to the embodiments of this disclosure, such as Figure 3B As shown, below the relay 110 and the junction box 50, the upper housing 12A has a downwardly recessed portion 12H. In this recess 12H, the gap between the device base 42 and the upper housing 12A is wider (air layer thickness H3) compared to other parts (air layer thickness H2). Therefore, the heat insulation effect is higher compared to the configuration without the recess 12H.

[0084] (The function of resin components)

[0085] Furthermore, in the battery mounting structure for a vehicle according to the embodiments of this disclosure, a plate-shaped resin component 16 is disposed between the battery 10 and the upper housing 12A. As a result, the load acting partially on the upper housing 12A constituting the vehicle floor is dispersed by the resin component 16. Therefore, localized loads acting on the battery 10 can be suppressed.

[0086] Furthermore, the resin component 16 has a thin-walled portion 16A below the relay 110 and the junction box 50, where the upper surface is lower than the upper surface of other parts. Also, the upper housing 12A has a recess 12H above the thin-walled portion 16A. In other words, the thin-walled portion 16A of the resin component 16 forms a space in the upper housing 12A for forming the recess 12H.

[0087] The recess 12H is formed above the thin-walled portion 16A, thus increasing the size of the recess compared to other portions. As a result, the resin component 16 can suppress localized loads on the battery 10, and the recess 12H in the upper housing 12A can improve the heat insulation effect.

[0088] (The function of the protrusion)

[0089] Furthermore, in the vehicle-mounted battery mounting structure of the embodiments of this disclosure, a protrusion 42D protruding downward toward the air layer A1 is formed on the lower surface of the device base 42. This protrusion 42D increases the surface area of ​​the lower surface of the device base 42, thus facilitating heat dissipation from the device base 42 to the air layer A1. Therefore, compared to the case without the protrusion 42D, heat dissipation from heat-generating devices such as the relay 110 to the device base 42 is easier.

[0090] On the other hand, since the thermal conductivity of air is lower than that of resin and metal, the heat dissipated from the equipment base 42 is difficult to transfer to the upper housing 12A through the air layer A1 between the equipment base 42 and the upper housing 12A. Therefore, heat transfer to the battery 10 can be suppressed.

[0091] It should be noted that, as mentioned above, the shape of the protrusion 42D is not particularly limited. Assuming that the protrusion 42D is formed in a lattice shape, it is easier to increase the surface area of ​​the lower surface of the device base 42 compared to forming it in a linear rib or dot shape.

[0092] Alternatively, assuming the protrusion 42D is formed as a rib along the longitudinal direction of the vehicle, the protrusion 42D can be positioned above the recess 12H. In this case, the protrusion 42D can penetrate into the recess 12H. As a result, heat dissipation from the equipment base 42 to the air layer A1 and the air in the recess 12H can be easily achieved.

[0093] It should be noted that in the above embodiment, the device base 42 and the upper housing 12A are thermally insulated by an air layer A1 communicating with the recess 12H, but the embodiments of this disclosure are not limited to this. For example, such an air layer A1 may not be formed. That is, the device base 42 and the upper housing 12A may be configured to contact each other.

[0094] Even under such circumstances, if a thin-walled portion 16A is provided in the resin component 16 and a recess 12H is formed in the upper housing 12A, space is ensured between the device base 42 and the upper housing 12A through these thin-walled portions 16A and recesses 12H. This suppresses the transfer of heat from the device base 42 to the battery 10 via the upper housing 12A, and prevents the battery 10 from being locally heated.

[0095] Similarly, the transfer of heat generated during the operation of the battery 10 to the device base 42 via the upper housing 12A is also suppressed. Therefore, for example, when the device is not in operation, the partial cooling of the battery 10 is prevented.

Claims

1. A battery mounting structure for use in a vehicle, comprising: The top cover is positioned above the energy storage unit; The device is partially disposed above the energy storage unit and the upper cover, and is electrically connected to the energy storage unit; Equipment base, on which the equipment is mounted; A plate-shaped resin component is disposed between the energy storage unit and the upper cover, and has a thin-walled portion below the device, the upper surface of which is lower than the upper surfaces of the other portions; and A recess is formed in the upper cover, which is recessed downward above the thin-walled portion.

2. The battery mounting structure for a vehicle according to claim 1, wherein, Below the device, the device base and the top cover are insulated by an air layer, which communicates with the recess.

3. The battery mounting structure for a vehicle according to claim 2, wherein, A protrusion is formed on the lower surface of the device base, and the protrusion protrudes downward toward the air layer.

4. The battery mounting structure for a vehicle according to claim 3, wherein, The protrusions are formed in a grid pattern along the width and longitudinal direction of the vehicle.

5. The battery mounting structure for a vehicle according to claim 3, wherein, The protrusion is formed above the recess.

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