Battery pack

Abstract

The battery pack includes a battery, electronic components connected to the battery, and a battery box housing the battery and the electronic components. The battery box includes a frame-shaped section, a battery box chassis supported by the frame section and open at the top, and a bracket for mounting the electronic components. The bracket is configured to engage with the battery box chassis via a first and a second engagement portion spaced apart along the vehicle's longitudinal and vertical directions. A portion between the first and second engagement portions is spaced apart from the battery box chassis, and the electronic components are mounted on this portion.

Description

Technical Field

[0001] This invention relates to battery packs. Background Technology

[0002] In vehicles such as hybrid electric vehicles and electric vehicles, a battery pack for supplying power to an electric motor that serves as a drive source is located in the lower part of the trunk behind the rear seats (for example, see Patent Document 1).

[0003] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2018-167640 Summary of the Invention

[0004] The problem that the invention aims to solve In the event of a rear-end collision, the aforementioned vehicles need to protect components such as the batteries and high-voltage units housed within the battery pack.

[0005] Therefore, the object of the present invention is to properly protect the components disposed inside the battery pack.

[0006] Technical solutions for solving technical problems A battery pack according to one embodiment of the present invention includes: a battery; electronic components connected to the battery; and a battery case housing the battery and the electronic components. The battery case includes: a frame portion formed in a frame shape; a battery case chassis supported by the frame portion and open at the top; and a bracket for mounting the electronic components. The bracket is configured to engage with the battery case chassis via a first engagement portion and a second engagement portion spaced apart along the vehicle's longitudinal and vertical directions. A portion between the first engagement portion and the second engagement portion is spaced apart from the battery case chassis, and the electronic components are mounted on this portion.

[0007] Invention Effects According to the present invention, components disposed inside the battery pack can be properly protected. Attached Figure Description

[0008] Figure 1 It is a diagram showing the general structure of a vehicle.

[0009] Figure 2 This is a diagram illustrating an example of a battery pack being installed.

[0010] Figure 3 This is a diagram showing the composition of a battery pack.

[0011] Figure 4 This is a top view of the lower box body.

[0012] Figure 5 This is a diagram showing the battery and high-voltage unit housed inside the lower casing.

[0013] Figure 6 This is a bottom view of the lower box body.

[0014] Figure 7 This is an exploded view of the battery cover.

[0015] Figure 8 yes Figure 3 Section VIII-VIII in the diagram.

[0016] Figure 9 yes Figure 3 IX-IX section view.

[0017] Figure 10 It is a diagram showing the structure of the vehicle body.

[0018] Figure 11 This is a diagram showing a vehicle body equipped with a battery pack.

[0019] Figure 12 This is a diagram showing a vehicle body equipped with a battery pack whose cover has been removed.

[0020] Figure 13 This is a diagram showing the structure and configuration of the left front bracket.

[0021] Figure 14 This diagram shows the situation around the left front bracket during a rear-end collision.

[0022] Figure 15 It is a diagram showing the shapes of the front ends of the central base frame, the left base frame, and the right base frame.

[0023] Figure 16 This is a diagram showing the shapes of the front ends of the central base, left base, and right base of the comparative example. Detailed Implementation

[0024] <1. Overview of Vehicle Structure> Figure 1 This is a diagram showing the general structure of vehicle 1. (For example...) Figure 1 As shown, vehicle 1 is an electric vehicle or hybrid vehicle that uses an electric generator 2 (denoted as "M / G" in the figure) as its power source. Vehicle 1 includes the electric generator 2, battery pack 3, inverter 4, and power transmission cables 5. Battery pack 3 includes batteries 11 and high-voltage units 12.

[0025] The electric generator 2 is the power source that drives the vehicle 1, such as a three-phase AC motor. The electric generator 2 uses electricity supplied from the battery 11 through the high-voltage unit 12, inverter 4, and power transmission cable 5 to generate driving force, and transmits this driving force to the drive wheels, thereby moving the vehicle 1. It should be noted that when the vehicle 1 is a hybrid vehicle, it may also have an engine as a power source.

[0026] The electric generator 2 can operate regeneratively to generate electricity. The electricity generated by the regenerative operation of the electric generator 2 is supplied to the battery 11 through the inverter 4, the transmission cable 5 and the high-voltage unit 12.

[0027] Inverter 4 converts the DC current supplied by battery 11 into three-phase AC current, which is then supplied to generator 2 via transmission cable 5. Additionally, when generator 2 is in regenerative operation, inverter 4 converts the AC current supplied by generator 2 into DC current, which is then supplied to battery 11 via transmission cable 5.

[0028] Battery 11 is a so-called high-voltage secondary battery that can store electricity for supplying to the electric generator 2. Battery 11 can be charged through the regenerative operation of the electric generator 2. Alternatively, battery 11 can also be charged by power from an external device (not shown).

[0029] The high-voltage unit 12 comprises a junction box and a monitoring unit. The junction box contains electronic components such as relays, fuses, and connectors. The monitoring unit contains electronic components such as sensors for monitoring the status of the battery 11.

[0030] It should be noted that in vehicle 1, the computer (BCU) used to control the operation of battery 11 is set separately from battery pack 3, but BCU may also be included in high voltage unit 12.

[0031] The high-voltage unit 12 is connected to the battery 11 via a cable (not shown). Therefore, a high voltage from the battery 11 is applied to the high-voltage unit 12.

[0032] Figure 2 This diagram illustrates an example of battery pack 3 being installed. (For example...) Figure 2 As shown, vehicle 1 has a trunk 7 located behind the rear seats 6. The trunk 7 can be opened and closed via the rear door 8.

[0033] Below the trunk 7, the battery pack 3 is installed. Above the battery pack 3, there is a trunk panel 9, on which luggage and other items can be placed.

[0034] <2. Battery Pack Composition> Figure 3 This is a diagram showing the composition of battery pack 3. Figure 4 This is a top view of the lower box 14. Figure 5 This is a diagram showing the lower housing 14 containing the battery 11 and the high-voltage unit 12. Figure 6 This is a bottom view of the lower box 14. Figure 7 This is an exploded view of the battery compartment cover 15. Figure 8 yes Figure 3 Section VIII-VIII in the diagram. Figure 9 yes Figure 3 IX-IX section view.

[0035] It should be noted that in the following description, the forward direction of vehicle 1 is referred to as the forward direction, the reverse direction of vehicle 1 is referred to as the rear direction, the direction to the right relative to the forward direction of vehicle 1 is referred to as the right direction, the direction to the left relative to the forward direction of vehicle 1 is referred to as the left direction, vertically upward is referred to as the upward direction, and vertically downward is referred to as the downward direction. In addition, the left and right directions are sometimes referred to as the width direction of vehicle 1 or simply as the width direction.

[0036] like Figure 3 As shown, the battery pack 3 includes a battery case 13. The battery case 13 houses the battery 11 and the high-voltage unit 12. The battery case 13 is composed of a lower housing 14 with an opening at the top forming a concave shape and a battery case cover 15 that blocks the opening of the lower housing 14.

[0037] like Figures 3 to 6 As shown, the lower housing 14 includes a front frame 21, a rear frame 22, a left frame 23, a right frame 24, a battery box chassis 25, a center frame 26, a support rod 27, a left front bracket 28, a right front bracket 29, a left side bracket 30, a right side bracket 31, a center base frame 32, a left side base frame 33, a right side base frame 34, a collision energy absorption box 35, a front base frame 36, and a rear base frame 37.

[0038] The front frame 21 extends in the left-right direction. For example... Figure 8 As shown, the front frame 21 is formed with a downward opening and a cross-section orthogonal to the length direction, which is approximately inverted U-shaped. In other words, the cross-section of the front frame 21 is formed in the shape of a hat.

[0039] The front frame 21 has connection holes 38a, 38b, 38c, and 38d for fixing the battery pack 3 to the vehicle body.

[0040] A front bracket 17 is attached to the front side plane of the front frame 21. The front bracket 17 is mounted to extend downward and forward from the front side wall of the front frame 21. Two through holes are formed on the front side of the front bracket 17, and the battery pack 3 is mounted on the vehicle body 100 (reference). Figure 10 When the time is right, it is connected to the front crossbeam 103 through the through hole using connecting parts (such as bolts and nuts).

[0041] The rear frame 22 is located behind the front frame 21 and is arranged side-by-side with the front frame 21 at intervals in the front-rear direction. It should be noted that "side-by-side" does not only mean completely side-by-side, but also includes roughly side-by-side, and the same applies below.

[0042] The rear frame 22 extends in the same left-right direction as the front frame 21, forming a roughly inverted U-shaped (hat-shaped) cross section orthogonal to the length direction.

[0043] The rear frame 22 has connection holes 38e, 38f, 38g, and 38h for fixing the battery pack 3 to the vehicle body.

[0044] The left frame 23 extends along the front-to-back direction. (Example) Figure 9 As shown, the left frame 23 is formed with a downward opening and a cross-section orthogonal to the length direction, which is approximately inverted U-shaped. In other words, the cross-section of the left frame 23 is formed in the shape of a hat.

[0045] A connecting hole 39a is formed on the rear side of the center of the left frame 23 in the front-rear direction. The connecting hole 39a is formed at a position opposite to the connecting hole 45a of the left bracket 45 described later, and the connecting hole 39a and the connecting hole 45a are connected by a connecting part 47a.

[0046] The right frame 24 is located to the right of the left frame 23, and is arranged side by side with the left frame 23 at intervals in the left-right direction. The right frame 24 and the left frame 23 also extend in the front-back direction, and the cross-section is roughly inverted U-shaped (cap-shaped).

[0047] A connecting hole 39b is formed on the rear side of the center of the right frame 24 in the front-rear direction. The connecting hole 39b is formed at a position opposite to the connecting hole 46a of the right bracket 46 described later, and the connecting hole 39b and the connecting hole 46a are connected by a connecting part 48a.

[0048] It should be noted that the connecting parts 47a and 48a are, for example, bolts and nuts.

[0049] The upper end of the left frame 23 is joined to the left end of the front frame 21. The upper end of the right frame 24 is joined to the right end of the front frame 21.

[0050] The lower end of the left frame 23 is joined to the left end of the rear frame 22. The lower end of the right frame 24 is joined to the right end of the rear frame 22.

[0051] Therefore, the front frame 21, rear frame 22, left frame 23, and right frame 24 are collectively formed into a roughly quadrilateral frame shape. In addition, the cross-sections of the front frame 21, rear frame 22, left frame 23, and right frame 24 are formed into a hat shape, thereby improving rigidity.

[0052] Battery box chassis 25 Figure 8 and Figure 9 As shown, a bottom surface 25a is continuously formed by bending a single sheet of material, along with a front sidewall 25b, a rear sidewall 25c, a left sidewall 25d, and a right sidewall 25e surrounding the bottom surface 25a. Furthermore, the battery box base 25 is formed into a concave shape with an opening at the top by means of the bottom surface 25a, the front sidewall 25b, the rear sidewall 25c, the left sidewall 25d, and the right sidewall 25e.

[0053] The bottom part 25a is formed as a roughly rectangular shape that extends horizontally (front-to-back and left-to-right).

[0054] A front sidewall 25b is continuously formed at the upper end of the bottom part 25a. The front sidewall 25b is formed to extend in the vertical and horizontal directions.

[0055] The lower end of the bottom part 25a is continuously formed with a rear sidewall 25c. The rear sidewall 25c is formed to extend in the vertical direction and the horizontal direction.

[0056] A left side wall 25d is continuously formed at the left end of the bottom part 25a. The left side wall 25d is formed to extend in the vertical and horizontal directions and the front-back direction.

[0057] A right side wall 25e is continuously formed at the right end of the bottom surface 25a. The right side wall 25e is formed to extend in the vertical and horizontal directions and the front-back direction.

[0058] It should be noted that the battery box chassis 25 can also be formed by combining the bottom part 25a, front side wall 25b, rear side wall 25c, left side wall 25d and right side wall 25e, which are composed of different plates, through welding or other means.

[0059] The upper ends of the front sidewall 25b, rear sidewall 25c, left sidewall 25d, and right sidewall 25e are continuously formed with flanges 25f in a manner that extends outwards. That is, the battery box base 25 has flanges 25f formed at its outer edge. The flanges 25f are formed to extend in the horizontal direction (front-back direction and left-right direction).

[0060] The front frame 21, rear frame 22, left frame 23 and right frame 24 are joined from above to flange 25f.

[0061] The center frame 26 is engaged with the upper surface of the bottom part 25a of the battery box base 25 in a manner that is centered in the left-right direction and along the front-back direction. The center frame 26 is as follows... Figure 8 As shown, the rear end abuts against the rear sidewall 25c, and the front end extends to the front side of the center of the bottom surface 25a in the front-rear direction.

[0062] Central frame 26 Figure 9 As shown, the cross-section orthogonal to the length direction is formed into an inverted U-shape (hat shape), thereby improving rigidity.

[0063] The strut 27 engages with the upper surface of the bottom part 25a in a manner that is centered in the left-right direction of the battery box chassis 25 and coincides with the front end of the center frame 26. The front end of the strut 27 abuts against the front sidewall 25b and extends obliquely upward from the rear to the front. The strut 27 is formed into a cap shape by means of an inverted U-shape (cap shape) orthogonal to the length direction, thereby improving rigidity.

[0064] The left front bracket 28 engages with the upper surface of the bottom portion 25a at its left front. The plate of the left front bracket 28 is curved such that its central portion is approximately horizontal above the upper surface of the bottom portion 25a. Furthermore, as... Figure 5 As shown, a high-voltage unit 12 is installed in the center of the left front bracket 28.

[0065] The right front bracket 29 engages with the upper surface of the bottom portion 25a at its right front. The plate of the right front bracket 29 is curved such that its central portion is approximately horizontal above the upper surface of the bottom portion 25a. Furthermore, as... Figure 5 As shown, a high-voltage unit 12 is installed in the center of the right front bracket 29.

[0066] Thus, the high-voltage unit 12 is installed on the left front bracket 28 and the right front bracket 29 respectively. However, the high-voltage unit 12 can also be installed on only one of the left front bracket 28 and the right front bracket 29.

[0067] The left bracket 30 engages with the upper surface of the bottom part 25a at the left rear. The left bracket 30 is configured to extend in the front-rear direction, and the plate is curved such that the central part is approximately horizontal at a position higher than the upper surface of the bottom part 25a.

[0068] The right bracket 31 engages with the rear right side of the upper surface of the bottom part 25a. The right bracket 31 is configured to extend in the front-rear direction, with the sheet metal curved so that the central part is approximately horizontal at a position higher than the upper surface of the battery box chassis 25.

[0069] Moreover, such as Figure 9 As shown, a battery 11 is mounted on the central part of the left bracket 30 and the right bracket 31.

[0070] It should be noted that battery 11 shown in the figure is an example of a stack consisting of two cells.

[0071] Center base frame 32 Figure 6 As shown, the battery box base 25 extends from the center in the left-right direction and along the front-back direction, engaging with the lower surface of the bottom part 25a. The left base frame 33 and the right base frame 34 are respectively arranged side by side on the left and right sides of the central base frame 32, extending along the front-back direction, and engaging with the lower surface of the bottom part 25a.

[0072] The center base frame 32, the left base frame 33, and the right base frame 34 are as follows: Figure 9 As shown, the rigidity is improved by forming a U-shape (inverted hat shape) by using a cross-section orthogonal to the length direction.

[0073] Thus, the lower housing 14 improves the rigidity of the upper part through the front frame 21, rear frame 22, left frame 23, and right frame 24. Thus, the lower housing 14 improves the rigidity of the lower part through the center frame 26, strut 27, center base frame 32, left base frame 33, and right base frame 34.

[0074] In addition, the lower housing 14 is protected from damage to the battery box chassis 25 by external forces from the left and right directions via the front frame 21 and the rear frame 22. Furthermore, the lower housing 14 is protected from damage to the battery box chassis 25 by external forces from the front and rear directions via the left frame 23, the right frame 24, the center frame 26, the support rod 27, the center base frame 32, the left base frame 33, and the right base frame 34.

[0075] The impact energy-absorbing box 35 is joined from below to the central rear end of the bottom surface 25a in the form of covering the rear ends of the central base frame 32, the left base frame 33 and the right base frame 34.

[0076] Collision energy absorption box 35 Figure 8 As shown, it is composed of two plates 35a and 35b and a partition member 35c. The front end of plate 35a is joined to the rear sidewall 25c near the center in the vertical direction, and extends downward and rearward from the front end to the rear end.

[0077] The front end of the plate 35b joins the rear end of the bottom surface 25a and the central base frame 32, extending upward and backward from the front end to the rear end.

[0078] The partition member 35c has a structure that connects two partitions that separate the plates 35a and 35b in the vertical direction.

[0079] Furthermore, the impact energy absorption box 35 is formed by plates 35a and 35b such that the cross section orthogonal to the left and right directions becomes a closed cross section (approximately quadrilateral), and its interior is reinforced by partition members 35c, thereby increasing its strength.

[0080] Front chassis 36 Figure 8 As shown, it engages with the front flange 25f of the battery box chassis 25 from below. Thus, the front flange 25f is sandwiched in the middle by the front frame 21 and the front base frame 36 in the battery box chassis 25, and the front rigidity of the lower housing 14 is further improved.

[0081] The rear base frame 37 engages with the rear flange 25f of the battery box chassis 25 from below. Thus, the rear flange 25f is sandwiched in the middle by the rear frame 22 and the rear base frame 37 in the battery box chassis 25, further improving the rear rigidity of the lower housing 14.

[0082] like Figure 3 and Figure 7As shown, the battery box cover 15 is composed of a main cover 41, a left front cover 42, a service plug cover 43, a right front cover 44, a left bracket 45, and a right bracket 46.

[0083] The main cover 41 is composed of a lower cover 51, a central top frame 52, a first cover beam 53, and a second cover beam 54.

[0084] The lower cover 51 is formed by cutting out approximately rectangular shapes from the left and right front sides of a generally rectangular plate. The front-to-back length of the lower cover 51 is formed to the same extent as the distance between the front frame 21 and the rear frame 22 of the lower housing 14, and the left-to-right length is formed to the same extent as the distance between the left frame 23 and the right frame 24 of the lower housing 14.

[0085] A through hole 51a is formed further below the second cover beam 54 of the lower cover 51. A cooling pipe (not shown) is connected to the through hole 51a. The cooling pipe is used to deliver air from the vehicle compartment to the battery box 13, and the air is delivered to the battery box 13 by a fan (not shown).

[0086] A through hole 51b is formed between the first cover beam 53 and the second cover beam 54 of the lower cover 51. An exhaust pipe 16 is connected to the through hole 51b. One end of the exhaust pipe 16 is connected to the through hole 51b, and the other end opens to the outside of the vehicle. The exhaust pipe 16 is configured to exhaust smoke to the outside of the vehicle when the battery 11 emits smoke.

[0087] The central top frame 52 is located at the center of the lower cover 51 in the left-right direction and extends in the front-back direction to engage with the upper surface of the lower cover 51.

[0088] The front-to-back length of the central top frame 52 is formed to the same extent as the lower cover 51.

[0089] Central top frame 52 Figure 8 As shown, it is mounted on the front frame 21 and the rear frame 22.

[0090] The first cover beam 53 engages with the upper surface of the lower cover 51 in a manner that is near the center in the front-rear direction and extends in the left-right direction. The length of the first cover beam 53 in the left-right direction is formed to the same extent as that of the lower cover 51.

[0091] The second cover beam 54 is joined to the upper surface of the lower cover 51 in a manner that is arranged side-by-side with the first cover beam 53 at a distance in the front-rear direction. The second cover beam 54 is located on the rear side of the first cover beam 53.

[0092] The second cover beam 54 is the same as the first cover beam 53, and its length in the left and right directions is formed to the same extent as the lower cover 51.

[0093] First cover beam 53 and second cover beam 54 as follows Figure 9 As shown, it is mounted on the left frame 23 and the right frame 24.

[0094] In addition, the first cover beam 53 and the second cover beam 54 are as follows Figure 8 As shown, it is positioned directly above battery 11.

[0095] The cross sections of the central top frame 52, the first cover beam 53, and the second cover beam 54, which are orthogonal to the length direction, are formed into an approximately inverted U-shape (hat shape), thereby improving rigidity.

[0096] The thickness of the first cover beam 53 and the second cover beam 54 in the vertical direction is greater than that of the central top frame 52. Therefore, the first cover beam 53 and the second cover beam 54 are engaged with the lower cover 51 in a manner that passes over the central top frame 52.

[0097] The left front cover 42 is formed into a roughly rectangular shape from sheet metal by inserting into the upper left notch of the lower cover 51.

[0098] The left front cover 42 has a through hole 42a located opposite the service plug of the high-voltage unit 12 located inside the battery compartment 13. A service plug cover 43 is installed in the through hole 42a in a manner that covers it from above.

[0099] The service plug cover 43 is formed of sheet metal and can be removed and installed relative to the left front cover 42.

[0100] The right front cover 44 is formed into a roughly rectangular shape from sheet metal by being embedded into the upper right notch of the lower cover 51.

[0101] The left front cover 42 and the right front cover 44 are connected to the lower cover 51 and the central top bracket 52 by means of connecting parts (e.g., bolts and nuts). Thus, the battery box cover 15 is generally rectangular.

[0102] Furthermore, the battery box cover 15 is connected to the front frame 21, rear frame 22, left frame 23, and right frame 24 of the lower housing 14 via a connecting part.

[0103] Viewed from above, the left bracket 45 and the right bracket 46 are formed into a roughly triangular shape from the sheet metal. The left bracket 45 has connecting holes 45a, 45b, and 45c at positions corresponding to the corners of the roughly triangular shape. The right bracket 46 has connecting holes 46a, 46b, and 46c at positions corresponding to the corners of the roughly triangular shape.

[0104] The main cover 41 has a connecting hole 41a at a position opposite to the connecting hole 45b, and a connecting hole 41b at a position opposite to the connecting hole 46b.

[0105] Furthermore, the connecting hole 45a of the left bracket 45 is connected to the connecting hole 39a of the left bracket 23 via the connecting part 47a, and the connecting hole 45b is connected to the connecting hole 41a of the main cover 41 via the connecting part 47b. Thus, the left bracket 45 is fixed to the left bracket 23 and the main cover 41.

[0106] The connecting hole 46a of the right bracket 46 is connected to the connecting hole 39b of the right bracket 24 via the connecting part 48a, and the connecting hole 46b is connected to the connecting hole 41b of the main cover 41 via the connecting part 48b. Thus, the right bracket 46 is fixed to the right bracket 24 and the main cover 41.

[0107] It should be noted that the left bracket 45 and the right bracket 46 are not mandatory configurations and can be omitted.

[0108] <3. Composition of the vehicle body> The following describes the configuration of the vehicle body equipped with battery pack 3. Battery pack 3 is envisioned to be housed in multiple different vehicle bodies. Therefore, an example of a vehicle body equipped with battery pack 3 will be described here.

[0109] Figure 10 This is a diagram showing the composition of the vehicle body 200. Figure 11 This is a diagram showing the vehicle body 200 equipped with battery pack 3. Figure 12 This is a diagram showing a vehicle body 200 equipped with a battery pack 3 with the battery box cover 15 removed.

[0110] like Figure 10 , Figure 11 and Figure 12 As shown, the vehicle body 200 includes a left main frame 201 and a right main frame 202. The left main frame 201 and the right main frame 202 are spaced apart in the left-right direction and extend in the front-back direction.

[0111] A front crossbeam 203 and a rear crossbeam 204 are mounted on the left main frame 201 and the right main frame 202. The front crossbeam 203 and the rear crossbeam 204 are connected to the left main frame 201 and the right main frame 202 in a manner that is spaced apart in the front-rear direction and extends in the left-right direction.

[0112] The front crossbeam 203 is positioned in the longitudinal direction near the boundary between the rear seat 6 and the trunk 7. The rear crossbeam 204 is positioned in the longitudinal direction approximately at the center of the trunk 7.

[0113] The front crossbeam 203 has a hollow, approximately quadrilateral closed section orthogonal to its length, thereby improving rigidity. The rear crossbeam 204 also has a hollow, approximately quadrilateral closed section orthogonal to its length, thereby improving rigidity.

[0114] Additionally, a floor base 205 is mounted on the left main frame 201 and the right main frame 202. The floor base 205 is made of bent material, forming a concave shape with an opening at the top. A flange is formed on the outer edge of the floor base 205, and the left main frame 201, the right main frame 202, and the front crossbeam 203 are joined to this flange. It should be noted that the rear crossbeam 204 is joined to the lower surface of the floor base 205.

[0115] A storage space 205a is formed on the rear side of the rear crossbeam 204 in the floor chassis 205. Therefore, compared with the case where no storage space is provided, the vehicle body 200 is longer behind the rear crossbeam 204.

[0116] A left corner brace 206 is joined at the joint between the left main frame 201 and the front crossbeam 203, thereby strengthening the joint between the left main frame 201 and the front crossbeam 203. Similarly, a right corner brace 207 is joined at the joint between the right main frame 202 and the front crossbeam 203, thereby strengthening the joint between the right main frame 202 and the front crossbeam 203.

[0117] A suspension support member 208, which abuts against the suspension, is joined to the left main frame 201 in the longitudinal direction, further forward than the rear crossbeam 204. The suspension support member 208 is configured to protrude to the left from the left main frame 201. In addition, the suspension support member 208 is configured to tilt upward as it moves toward the left.

[0118] A suspension support member 209, which abuts against the suspension, is joined to the right main frame 202 in the longitudinal direction, further forward than the rear crossbeam 204. The suspension support member 209 is configured to protrude to the right from the right main frame 202. In addition, the suspension support member 209 is configured to tilt upward as it moves toward the right.

[0119] A rear skirt 210 is attached to the rear end of the floor chassis 205. The rear skirt 210 is configured to extend upward from the floor chassis 205. A striker is installed at the center of the left and right sides of the rear skirt 210, which engages with the rear door 8 to close the trunk 7.

[0120] The rear ends of the left main frame 201 and the right main frame 202 are joined by a rear bumper 211. The rear bumper 211 is configured to extend in the left-right direction, with its two ends joining the left main frame 201 and the right main frame 202 respectively. Most of the rear bumper 211 is spaced apart from the left main frame 201, the right main frame 202, the floor chassis 205 and the rear skirt 210 on the rear side.

[0121] The rear bumper 211 is stronger than other components that make up the vehicle body 200, which can reduce the damage to the vehicle body 200 from rear-end collisions (including offset collisions).

[0122] In the vehicle body 200, the battery pack 3 is connected to the left main frame 201, the right main frame 202 and the front crossbeam 203.

[0123] The front crossbeam 203 (left corner brace 206, right corner brace 207) has connecting holes 212a and 212b spaced apart on the left side in the left-right direction, and connecting holes 212c and 212d spaced apart on the right side in the left-right direction.

[0124] The left main frame 201 has connecting holes 212e, 212f, and 212i spaced apart on its rear side in the front-to-back direction. Similarly, the right main frame 202 has connecting holes 212g, 212h, and 212j spaced apart on its rear side in the front-to-back direction.

[0125] Connection holes 212a to 212h are positioned at positions corresponding to connection holes 38a to 38h formed on the battery pack 3, respectively. Connection hole 212i is positioned corresponding to connection hole 45c on the left bracket 45. Connection hole 212j is positioned corresponding to connection hole 46c on the right bracket 46.

[0126] Furthermore, connecting holes 212a and 38a are connected by connecting portion 213a. Similarly, connecting holes 212b to 212h and connecting holes 38b to 38h are connected by connecting portions 213b to 213h respectively.

[0127] Furthermore, connecting holes 212i and 45c are connected via connecting part 213i. Connecting holes 212j and 46c are connected via connecting part 213j.

[0128] The connecting parts 213e and 213g are composed of screws and nuts welded in the form of extending upward from the upper surfaces of the left main frame 101 and the right main frame 102. The connecting parts 213a, 213b, 213c, 213d, 213f, 213h, 213i, and 213j are, for example, composed of bolts and nuts.

[0129] It should be noted that, in the following description without distinguishing between connecting parts 213a to 213j, they will be referred to as connecting parts 213.

[0130] <4. Battery Protection Structure> Figure 13 This is a diagram showing the structure and configuration of the left front bracket 28. Figure 14 This diagram shows the situation around the left front bumper 28 during a rear-end collision. It should be noted that... Figure 14 The upper section indicates the situation around the left front bracket 28 when vehicle 1 did not experience a rear-end collision. Figure 14 The middle section and Figure 14 The lower section describes the situation around the left front bracket 28 after the rear-end collision of vehicle 1.

[0131] In the event of a rear-end collision with vehicle 1, the rearward side of the battery pack 3 in the vehicle body 200 may be damaged, and the impact object may push the battery pack 3 forward. At this time, if the upper surface of the front crossbeam 203 is higher than the lower surface of the battery pack 3, the battery pack 3 will come into contact with the front crossbeam 203. Consequently, the high-voltage unit 12 housed in front of the battery pack 3 may collide with the front crossbeam 203 and be damaged.

[0132] Therefore, by studying the structure and configuration of the left front bracket 28 equipped with the high-voltage unit 12 in the battery pack 3, the risk of damage to the high-voltage unit 12 can be reduced even if the battery pack 3 comes into contact with the front crossbeam 203.

[0133] like Figure 13 and Figure 14 As shown in the upper section, the bent plate of the left front bracket 28 is joined to the battery box chassis 25 through five joint points 28a, 28b, 28c, 28d, and 28e.

[0134] The joints 28a and 28b are arranged side by side in the left-right direction on the front sidewall 25b of the battery box chassis 25. The joints 28a and 28b are located at a position higher than the upper surface 203a of the front crossbeam 203 (the upper position).

[0135] The joints 28c and 28d are arranged side by side in the left-right direction on the bottom surface 25a of the battery box chassis 25. The joints 28c and 28d are located at a position lower than the upper surface 203a of the front crossbeam 203 (the lower position).

[0136] Compared to joint 28b, joint 28e is located on the central side in the left-right direction and is at a lower position than joint 28b. However, joint 28e can also be set to the same height as joints 28a and 28b.

[0137] The left front bracket 28 extends upward from the joint points 28c and 28d, and bends forward at approximately 90 degrees at a specified height. After extending forward from the position where it bends at approximately 90 degrees, it extends upward and forward along the front side wall 25b of the battery box chassis 25 to the joint points 28a and 28b, thus drawing a large arc.

[0138] The left front bracket 28 extends in a generally horizontal direction from a position where it is bent at approximately 90 degrees to the point where it is about to form an arc, as the mounting surface 28f (the central part mentioned above), on which the high voltage unit 12 is mounted.

[0139] Therefore, the high-voltage unit 12 is mounted at a position higher than the bottom part 25a of the battery box chassis 25. This protects the high-voltage unit 12 from condensation even if it occurs inside the battery pack 3.

[0140] A high-voltage unit 12 is fixed on the mounting surface 28f. At this time, the battery 11 and the high-voltage unit 12 are arranged at a distance in the front-to-back direction. In other words, a space S is formed between the battery 11 and the high-voltage unit 12 where no object is placed.

[0141] Furthermore, when vehicle 1 experiences a rear-end collision, and when an obstacle pushes battery pack 3 forward, such as Figure 14 As shown in the middle section, the front sidewall 25b of the battery box chassis 25 of the battery pack 3 will contact the rear corner 203b of the front crossbeam 203.

[0142] Then, as battery pack 3 is pushed further forward, as... Figure 14 As shown in the lower section, the rear corner 203b will sink into the front sidewall 25b, causing the front sidewall 25b to be recessed (deformed).

[0143] At this time, the part of the front sidewall 25b that has deformed is the lower side of the joints 28a and 28b, so the joints 28a and 28b hardly move. On the other hand, the front side of the left front bracket 28, which is further forward than the mounting surface 28f, extends along the front sidewall 25b, and therefore deforms along with the deformation of the front sidewall 25b.

[0144] Therefore, the mounting surface 28f will tilt slightly backward, and the high-voltage unit 12 will also tilt slightly backward (displacement). At this time, the left front bracket 28 is engaged with the battery box chassis 25 through five engagement points 28a, 28b, 28c, 28d, and 28e, so the mounting surface 28f can move freely to a certain extent.

[0145] Furthermore, the battery pack 3 forms a space S between the battery 11 and the high-voltage unit 12, so even if the high-voltage unit 12 is displaced, it can avoid contact with the battery 11. Therefore, damage to the battery 11 and the high-voltage unit 12 can be reduced in the event of a subsequent collision.

[0146] Figure 15 This is a diagram showing the shape of the front ends of the central base frame 32, the left base frame 33, and the right base frame 34. Figure 16 This is a diagram showing the shape of the front ends of the central base frame 32A, the left base frame 33A, and the right base frame 34A of the comparative example. Figure 15 and Figure 16 This is a picture of battery pack 3 (3A) as seen from the lower left front.

[0147] Additionally, the front crossbeam 203 has a flange 203c extending rearward from its front end. Therefore, as... Figure 16As shown in the comparative example, since the front ends of the center base frame 32A, the left base frame 33A, and the right base frame 34A are short, the front ends of the center base frame 32A, the left base frame 33A, and the right base frame 34A may get stuck on the flange 203c when the front crossbeam 203 and the battery pack 3 come into contact.

[0148] Therefore, in battery pack 3, the front ends of the center base frame 32, left base frame 33, and right base frame 34 extend upwards and forwards compared to the comparative example. For example, the front ends of the center base frame 32, left base frame 33, and right base frame 34 extend further above the center of the front sidewall 25b in the vertical direction.

[0149] In addition, the front ends of the left base frame 33 and the right base frame 34 are roughly triangular in shape.

[0150] Therefore, when the crossbeam 203 and the battery pack 3 come into contact, the front ends of the central base frame 32, the left base frame 33, and the right base frame 34 are less likely to get stuck on the flange 203c.

[0151] <5. Variations> It should be noted that the above embodiments are one example of implementing the present invention, and the implementation of the present invention is not limited to the above examples; various modifications can be considered.

[0152] For example, the mounting surface 28f can also be positioned higher than the upper surface 203a of the front crossbeam 203. In this case, even if the battery pack 3 is pushed forward and the rear corner 203b of the front crossbeam 203 is embedded in the front sidewall 25b, the mounting surface 28f will hardly move, thus further protecting the battery 11 and the high-voltage unit 12 from damage.

[0153] <6. Summary> In summary, the battery pack 3 of this embodiment includes a battery 11, electronic components connected to the battery 11 (equivalent to a high-voltage unit 12), and a battery case 13 housing the battery 11 and the electronic components. The battery case 13 includes a frame portion formed in the shape of a frame (equivalent to a front frame 21, a rear frame 22, a left frame 23, and a right frame 24), a battery case chassis 25 supported by the frame portion and open at the top, and a bracket (equivalent to a left front bracket 28) for mounting the electronic components.

[0154] The bracket is configured to engage with the battery box chassis 25 via a first engagement portion (equivalent to engagement points 28a, 28b) and a second engagement portion (equivalent to engagement points 28c, 28d) spaced apart along the front-rear and vertical directions of the vehicle 1. The portion between the first engagement portion and the second engagement portion (equivalent to mounting surface 28f) is spaced apart from the battery box chassis 25, and electronic components are mounted on this portion.

[0155] Therefore, when vehicle 1 is rear-ended, battery pack 3 will move forward and the front sidewall 25b of battery box chassis 25 will deform, so that even if the left front bracket 28 is displaced, the mounting surface 28f can still move freely to a certain extent.

[0156] Therefore, the high-voltage unit 12 installed on the mounting surface 28f can also move freely to a certain extent, thus reducing the impact of the displacement of the battery box chassis 25.

[0157] In addition, even if the high-voltage unit 12 comes into contact with the battery 11, the high-voltage unit 12 can be moved before the battery 11 and the high-voltage unit 12 are damaged.

[0158] In this way, the battery pack 3 can properly protect the components located inside the battery pack 3.

[0159] In addition, the first joint is located above the upper surface 203a of the front crossbeam (front crossbeam 203) of the vehicle body.

[0160] Therefore, even if vehicle 1 is involved in a rear-end collision and the battery pack 3 comes into contact with the front crossbeam 203, the contact points 28a and 28b will hardly move because the contact occurs on the underside of the contact points. This reduces the displacement of the mounting surface 28f, thereby further reducing damage to the battery 11 and the high-voltage unit 12.

[0161] The second joint is located below the upper surface of the crossbeam on the front side of the vehicle body and behind the first joint.

[0162] Therefore, even if vehicle 1 is involved in a rear-end collision and battery pack 3 comes into contact with front crossbeam 203, the joint points 28c and 28d will be rarely affected, thereby reducing the displacement of mounting surface 28f.

[0163] A space S is formed between the electronic component and the battery 11 in the front-to-back direction.

[0164] Therefore, even if the vehicle 1 is rear-ended and the mounting surface 28f is displaced, causing the high-voltage unit 12 to be displaced, the risk of the high-voltage unit 12 coming into contact with the battery 11 can be reduced.

[0165] Symbol Explanation 1 vehicle 3 Battery Pack 11 batteries 12 High Voltage Units 13 Battery Box 28. Left front bracket.

Claims

1. A battery pack, comprising: Battery; Electronic components connected to the battery; as well as, The battery compartment houses the battery and the electronic components. The battery box includes: a frame portion formed in the shape of a frame, a battery box base supported by the frame portion and open at the top, and a bracket on which the electronic components are mounted. The bracket is configured to engage with the battery box chassis via a first engagement portion and a second engagement portion spaced apart along the vehicle's longitudinal and vertical directions, the portion between the first engagement portion and the second engagement portion being spaced apart from the battery box chassis, and the electronic components being mounted on the portion thereon.

2. The battery pack according to claim 1, wherein, The first joint is located above the upper surface of the crossbeam located on the front side of the vehicle body.

3. The battery pack according to claim 2, wherein, The second joint is located below the upper surface of the crossbeam on the front side of the vehicle body and behind the first joint.

4. The battery pack according to any one of claims 1 to 3, wherein, A space is formed between the electronic component and the battery in the front-to-back direction.

Images