Battery support structure of a high-voltage energy storage system with external longitudinal structure

Abstract

High-voltage energy storage device (1) for an electrically powered vehicle, wherein the high-voltage energy storage device (1) comprises several battery modules (2) and a battery support structure (3) for receiving the battery modules (2), wherein the battery support structure (3) comprises an outer, laterally arranged longitudinal structure (4) with a connection area (6) and an intermediate area (7), wherein the lateral distance between the outer walls (10, 10) of the battery module (2) and the lateral longitudinal structure (4) facing each other in the intermediate area (7) between connection points (5) of the battery module (2) on crossbeams (15) connected to the lateral longitudinal structure (4) is greater, at least in a partial area, than in the connection area (6) of the connection points (5) of this battery module (2) on crossbeams (15) connected to the lateral longitudinal structure (4), characterized in that further facing outer walls (9,9) of battery module (2) and lateral longitudinal structure (4) are provided, wherein the lateral distance of the facing outer walls (10, 10) of battery module (2) and lateral longitudinal structure (4) in the intermediate area (7) between the connection points (5) of the battery module (2) to crossbeams (15) connected to the longitudinal structure (4) defines a deformation clearance (16), wherein the further outer walls (9, 9) in the area of ​​the connection points (5, 5) have a significantly smaller distance from each other than the outer walls (10, 10).

Description

[0001] The invention relates to a high-voltage energy storage device for an electrically powered vehicle, wherein the high-voltage energy storage device comprises several battery modules and a battery support structure for receiving the battery modules, wherein the battery support structure has an outer, laterally arranged longitudinal structure with a connection area and an intermediate area, wherein the lateral distance between the outer walls of the battery module and the lateral longitudinal structure facing each other is greater in the intermediate area between the connection points of the battery module to cross members connected to the lateral longitudinal structure, at least in a partial area, than in the connection area of ​​the connection points of this battery module to cross members connected to the lateral longitudinal structure. Such a high-voltage energy storage device is also suitable for use in a partially electric vehicle.

[0002] High-voltage energy storage systems for electric vehicles must be protected in a crash to prevent the battery from catching fire. According to current technology, battery support structures for high-voltage energy storage systems typically consist of an outer frame, internal longitudinal profiles, and cross braces arranged between the battery modules. The cross braces are connected to the outer frame and the internal longitudinal profiles, thus forming the lateral load paths within the battery support structure. Such battery support structures are used, for example, in Tesla and BMW i3 vehicles.

[0003] To best protect the battery modules in a side pole impact, it is advantageous to provide sufficient deformation clearance between the inner edge of the outer frame's lateral longitudinal structure and the outer wall of each battery module. To achieve this deformation clearance between the lateral longitudinal structure and the battery modules, the battery module housings are typically connected directly and / or via additional brackets to the cross members. In particular, the high number of connection points—namely, the connections between the cross members and the outer frame / inner longitudinal profiles—results in a very complex manufacturing process and a high degree of geometric complexity in the battery support structure, consequently leading to high manufacturing costs.

[0004] EP 2 623 353 A1 describes a battery container designed to hold a vehicle battery, positioned between at least two frames located within the vehicle. The battery container is attached to a longitudinal member of the vehicle by means of clamps or similar devices.

[0005] Types of high-voltage energy storage devices are known, for example, from JP 2014-203755 A, JP 2008-277049 A, DE 10 2010 051 010 A1 and EP 2 482 365 A1. Although these high-voltage energy storage devices also feature deformation protection, this is implemented in a complex and therefore expensive manner.

[0006] The object of the present invention is to ensure optimal protection of the battery modules in a lateral pole impact in a high-voltage energy storage system of the type mentioned above, while maintaining a simple design and low weight of the high-voltage energy storage system.

[0007] The problem is solved by a high-voltage energy storage device designed according to the features of claim 1.

[0008] The high-voltage energy storage system is designed to include additional facing outer walls of the battery module and the lateral longitudinal structure in the connection area, whereby the lateral distance of the facing outer walls of the battery module and the lateral longitudinal structure in the area between the connection points of the battery module to crossbeams connected to the longitudinal structure determines a deformation clearance, whereby the additional outer walls in the area of ​​the connection points have a significantly smaller distance from each other than the outer walls.

[0009] The deformation clearance to the battery modules in areas where the battery modules are not protected by crossbeams can therefore be significantly increased, with the deformation clearance in the intermediate area being extended compared to the connection area. A particular advantage is that the required deformation clearance between the lateral longitudinal structure and the battery modules can still be achieved even when the connection points for the battery modules are integrated into the lateral longitudinal structure. This results in simplified manufacturing and cost savings due to functional integration. This is particularly advantageous or even necessary when integrating the crossbeams into the battery modules.Thus, the lateral distance between the outer walls of the battery module and the lateral longitudinal structure facing each other is, at least in one part, significantly greater in the area between the connection points of this battery module to the lateral longitudinal structure or to crossbeams connected to the lateral longitudinal structure than in the first area of ​​the connection points of this battery module to the lateral longitudinal structure or to crossbeams connected to the lateral longitudinal structure.

[0010] The high-voltage energy storage device according to the invention is thus characterized by a reduction in weight and cost compared to known high-voltage energy storage devices.

[0011] The significantly larger lateral distance is preferably two to eight times larger, and in particular four to six times larger, than in the area of ​​the connection points of the battery module.

[0012] The outer, laterally arranged longitudinal structure of the battery support structure can be designed in one piece or in multiple parts.

[0013] If the lateral longitudinal structure is formed in one piece, it is considered advantageous if it has bulges, at least partially, in the area between the crossbeams. These bulges make it easy to achieve the larger lateral spacing. If the longitudinal structure is formed in one piece, the bulges are preferably introduced into the outer longitudinal profile using mechanical machining processes.

[0014] The lateral longitudinal structure preferably consists of a light metal, in particular aluminium or magnesium, or consists of a fiber-reinforced plastic composite.

[0015] The lateral longitudinal structure is preferably produced using extrusion or pultrusion processes.

[0016] The lateral longitudinal structure may also feature local reinforcements in the form of metallic elements or plastic-based foams.

[0017] The battery modules are preferably connected to the battery support structure in a way that allows them to be removed.

[0018] The battery modules preferably have integrated load paths, in particular transverse load paths, in one or two lateral battery module housing walls, in particular extending from attachment points on the lateral longitudinal structure to attachment points on the inner longitudinal profile.

[0019] Further features of the invention will become apparent from the dependent claims, the accompanying drawing and the description of the preferred embodiments shown in the drawing, without being limited thereto.

[0020] It shows: Fig. 1 a first, non-inventive embodiment in a top view, Fig. 2 a cut according to line II-II in Fig. 1, Fig. 3. a cut along line III-III in Fig. 1, Fig. 4 a second, non-inventive embodiment in a top view, Fig. 5 a cut according to line VV in Fig. 4, Fig. 6. a cut along line VI-VI in Fig. 4, Fig. 7 a third, non-inventive embodiment in a top view, Fig. 8 a cut according to line VIII-VIII in Fig. 7, Fig. 9 a cut according to line IX-IX in Fig. 7, Fig. 10 a fourth, inventive embodiment in a top view, Fig. 11 a cut according to line XI-XI in Fig. 10, Fig. 12 a cut according to line XII-XII in Fig. 10, Fig. 13 a fifth, non-inventive embodiment with a one-piece lateral longitudinal structure, in a top view, Fig. 14 a sixth, non-inventive embodiment with a multi-part lateral longitudinal structure, in a top view, Fig. 15 a seventh, non-inventive embodiment in a top view, Fig. 16 a cut according to line XVI-XVI in Fig. 15, Fig. 17 a cut according to line XVII-XVII in Fig. 15.

[0021] The figures show only the components necessary for understanding the invention and the illustrated embodiments. These are depicted schematically. Additionally, the coordinates X for the vehicle's longitudinal direction, Y for the vehicle's transverse direction, and Z for the vehicle's vertical direction are shown. The vehicle in question is, in particular, a passenger car.

[0022] The Fig. Figures 1 to 3 show the area of ​​a high-voltage energy storage device 1 for a purely electric or partially electric vehicle that is relevant for understanding the invention. This device has several battery modules 2 and a battery support structure 3 for receiving the battery modules 2. The battery support structure 3 has an outer, laterally arranged longitudinal structure 4 on both sides for receiving the battery modules 2, with only a portion of this lateral longitudinal structure 4 being illustrated.

[0023] In the embodiment according to the Fig. Figures 1 to 3 show the connection of each battery module 2, three of which are illustrated, to the lateral longitudinal structure 4 without additional mounting elements. Each battery module 2 has four connection points 5, with two connection points located on each of the two narrow sides of the battery module 2 forming the connection to the lateral longitudinal structure 4. A connection area 6 of two adjacent and parallel battery modules 2 on the lateral longitudinal structure 4 is indicated by the reference numeral 6. An intermediate area located between the adjacent battery modules 2 is designated by the reference numeral 7. Fig. 1. The connection areas 6 are illustrated as examples. This intermediate area 7 represents a deformation clearance.

[0024] The sectional view according to the Fig. Figure 2 illustrates the formation in the area between the connection points 5 of a battery module 2. The sectional view according to Fig. Figure 3 illustrates the design in the connection area, specifically in the area of ​​connection point 5 of a battery module 2. The first facing outer walls of battery module 2 and the lateral longitudinal structure 4 are designated with reference numeral 8, the second with reference numeral 9, and the third with reference numeral 10. It can be seen that the outer walls 8, 8 and 9, 9 in the area of ​​connection points 5 are significantly closer together than the outer walls 10, 10 in the area between connection points 5, 5 on the respective end face of battery module 2.At least the lateral distance, the distance in the Y-direction, between the facing outer walls 10, 10 of battery module 2 and the lateral longitudinal structure 4 of the respective battery module 2 in the area between the connection points 5, 5 of this battery module 2 on the lateral longitudinal structure 4 in the sub-area 13 formed between the projections 11, 12 is significantly larger than in the area of ​​the connection points 5 of this battery module 2 on the lateral longitudinal structure 4. This lateral distance constitutes the deformation clearance. The significantly larger lateral distance is approximately two to eight times larger, and in particular four to six times larger.

[0025] The Fig. Figures 4 to 6 show an embodiment that differs from the one according to the Fig. 1 to 3 is modified in that the connection of the respective battery module 2 to the lateral longitudinal structure 4 is effected by means of mounting elements 14. These mounting elements 14 establish the connection between the battery modules 2 and the lateral longitudinal structure 4. Each mounting element 14 serves to connect two adjacent battery modules 2 in their adjacent corner regions. Even in this modified embodiment, the lateral distance between the outer walls of the battery module 2 and the lateral longitudinal structure 4 facing each other is significantly greater in the area between the connection points 5 of this battery module 2 on the lateral longitudinal structure 4, i.e., in the intermediate region 7, than in the area of ​​the connection points 5 of this battery module 2 on the lateral longitudinal structure 4.

[0026] Fig. Figure 5 illustrates the area between the connection points 5 of the battery module 2, Fig. Figure 6 illustrates the area of ​​connection of the battery module 2. The respective mounting element 14 is stored in the lateral longitudinal structure 4 and the battery module 2 is designed with an integrated load path.

[0027] The embodiment according to the Fig. 7 to 9 differs from the one according to the Fig. 4 to 6 by the fact that the respective mounting element 14 is larger and extends over a greater extent in the Z direction. Fig. Figure 8 shows the area between the connection points 5 of the battery module 2, Fig. 9 the area of ​​connection of battery module 2. Battery module 2 is designed with an integrated load path.

[0028] The Fig. Figures 10 to 12 illustrate an embodiment in which the battery modules 2 are not directly connected to the lateral longitudinal structure 4, but rather to crossbeams 15, which are connected to the lateral longitudinal structure 4. Thus, the crossbeams 15 form transverse load paths. Each battery module 2 is supported in two crossbeams 15 via its four connection points 5. Each crossbeam 15 is arranged between two battery modules 2 and serves to support these two battery modules. The connection areas 6 associated with each crossbeam 15 and the intermediate area 7 arranged between two connection areas 6 are illustrated. This results in an extended deformation clearance 16 in the intermediate area 7 between the battery module 2 and the lateral longitudinal structure 4. The crossbeams 15 therefore represent transverse load paths. Fig. Figure 11 illustrates the area between the connection points 5 of the battery module 2. Fig. Figure 12 illustrates the area of ​​the connection points 5 of the battery module 2. It shows that the outer walls 9, 9 facing each other of the battery module 2 and the lateral longitudinal structure have a significantly smaller lateral distance than the outer walls 10, 10 of the battery module 2 and the lateral longitudinal structure 4 in the area between the connection points 5 of the battery module 2, thus in the intermediate area 7, which results in the extended deformation clearance 16.

[0029] Thus, in this embodiment, the lateral distance between the outer walls 10, 10 facing each other of battery module 2 and lateral longitudinal structure 4 is significantly greater in the area between the connection points 5 of this battery module 2 to crossbeams 15 connected to the lateral longitudinal structure 4 than in the area of ​​the connection points 5 of this battery module 2 to crossbeams 15 connected to the lateral longitudinal structure 4.

[0030] Fig. Figure 13 illustrates an embodiment in which the lateral longitudinal structure 4 is formed in one piece. Here, the lateral longitudinal structure 4 has protrusions 17 created by mechanical post-processing. After mechanical processing, the lateral longitudinal structure 4 is thus in its functional state.

[0031] Fig. Figure 14 shows a multi-part lateral longitudinal structure 4, consisting of a lateral longitudinal profile 18 and brackets 19.

[0032] The Fig. Figures 15 to 17 illustrate an embodiment in which, compared to the embodiment according to the Fig. 4 to 6 the lateral longitudinal structure 4 is modified with mounting elements 14 that are positioned from below, thus in the positive Z-direction. This allows the battery modules 2 to be mounted on the lateral longitudinal structure 4 from below, in contrast to the mounting direction in the embodiment according to the Fig. 4 to 6 from the top. Reference symbol list 1 High-voltage energy storage 2 battery modules 3 Battery support structure 4 outer, lateral longitudinal structure 5 connection point 6 Connection area 7 Intermediate area 8 first outer wall 9 second outer wall 10 third outer wall 11 lead 12 lead 13 Sub-area 14 Mounting element 15 crossbeams 16 extended deformation clearance 17 bulge 18 Longitudinal profile 19 console

Claims

[1] High-voltage energy storage device (1) for an electrically powered vehicle, wherein the high-voltage energy storage device (1) comprises several battery modules (2) and a battery support structure (3) for receiving the battery modules (2), wherein the battery support structure (3) comprises an outer, laterally arranged longitudinal structure (4) with a connection area (6) and an intermediate area (7), wherein the lateral distance between the outer walls (10, 10) of the battery module (2) and the lateral longitudinal structure (4) facing each other in the intermediate area (7) between connection points (5) of the battery module (2) on cross members (15) connected to the lateral longitudinal structure (4) is greater, at least in a partial area, than in the connection area (6) of the connection points (5) of this battery module (2) on cross members (15) connected to the lateral longitudinal structure (4), characterized by, that in the connection area (6) further facing outer walls (9, 9) of battery module (2) and lateral longitudinal structure (4) are provided, wherein the lateral distance of the facing outer walls (10, 10) of battery module (2) and lateral longitudinal structure (4) in the intermediate area (7) between the connection points (5) of the battery module (2) on crossbeams (15) connected to the longitudinal structure (4) determines a deformation clearance (16), wherein the further outer walls (9, 9) in the area of ​​the connection points (5, 5) have a significantly smaller distance from each other than the outer walls (10, 10). [2] High-voltage energy storage device according to claim 1, characterized by , that the lateral distance of the mutually facing outer walls (10, 10) is significantly larger, preferably two to eight times larger, in particular four to six times larger, than the lateral distance in the area of ​​the connection points (5) of the battery module (2). [3] High-voltage energy storage device according to one of claims 1 or 2, characterized by , that the longitudinal structure (4) is formed in one part or in multiple parts. [4] High-voltage energy storage device according to claim 3, characterized by , that the single-piece longitudinal structure (4) has at least partial bulges (17) in the intermediate area (7) between the crossbeams (15). [5] High-voltage energy storage device according to claim 4, characterized by Bulges (17) introduced into a longitudinal profile of the longitudinal structure (4) by means of mechanical processing. [6] High-voltage energy storage device according to any one of claims 1 to 5, characterized by , that the longitudinal structure (4) consists of a light metal, in particular aluminium or magnesium, or a fiber-reinforced plastic composite. [7] High-voltage energy storage device according to any one of claims 1 to 6, characterized by a longitudinal structure produced by extrusion or pultrusion processes (4). [8] High-voltage energy storage device according to any one of claims 1 to 7, characterized by , that the longitudinal structure (4) has local reinforcements in the form of metallic elements or plastic-based foams. [9] High-voltage energy storage device according to any one of claims 1 to 8, characterized by that the battery modules (2) are detachably connected to the battery support structure (3). [10] High-voltage energy storage device according to any one of claims 1 to 9, characterized by , that the battery modules (2) have load paths, in particular transverse load paths, integrated into one or two lateral battery module housing walls.

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