Battery housing and motor vehicle with such a battery housing

Abstract

The invention relates to battery housings (6) for a battery (32) of an electrically powered motor vehicle (2), comprising a trough-shaped receptacle (8) with a housing base (10) and with a housing frame (12), wherein the receptacle (8) forms a housing interior (14), wherein the housing frame (12) is formed by means of two housing longitudinal sides (16) and by means of two housing transverse sides (18) extending transversely to these, wherein a deformation element (20) is arranged in the housing interior (14), which extends from one of the housing transverse sides (18) to the other housing transverse side (18) of the housing frame (12), wherein on those sides of the deformation element (20) which face the housing longitudinal sides (16) a rigid support structure (22) for a number of battery modules (30) of the battery (32) is arranged,wherein the support structures (22) within the housing interior (Gl) each have longitudinal structural walls (24) assigned to and abutting one of the housing longitudinal sides (16), and transverse structural walls (26) spaced apart from one another, forming receiving spaces (28) for the battery modules (30), which extend from the deformation element (20) to the respective longitudinal structural wall (24), and wherein the support structures (22) are stiffer than the deformation element (20). The invention further relates to an electrically powered motor vehicle (2) with such a battery housing (6).

Description

[0001] The invention relates to a battery housing for an electrically powered motor vehicle, wherein the battery housing has a trough-shaped recess with a housing base and a housing frame. The invention further relates to such a motor vehicle.

[0002] An electrically powered motor vehicle typically has a battery (traction battery) that supplies energy to an electric motor to propel the vehicle. The term "electrically powered motor vehicle" specifically refers to an electric vehicle that stores the energy required for propulsion solely in its battery (BEV, battery electric vehicle), an electric vehicle with a range extender (REEV, range extended electric vehicle), a hybrid vehicle (HEV, hybrid electric vehicle), and / or a plug-in hybrid vehicle (PHEV, plug-in hybrid electric vehicle).

[0003] A force impact, particularly from an accident such as a crash or collision, can damage the battery. Such damage can, for example, cause the energy stored in the battery to be released explosively. Furthermore, this can create a fire hazard and / or a risk to vehicle passengers (occupants) due to electrical discharge from the battery.

[0004] From DE 10 2017 101 110 A1, an assembly for an electrified vehicle is known. This assembly comprises a lower wall and an upper wall of a battery housing. The upper wall and the lower wall each include a centrally arranged upper wall deformation area and a centrally arranged lower wall deformation area, respectively. These deformation areas deform under lateral loads in front of areas of the upper wall and the lower wall that are located near battery arrays.

[0005] Alternatively, to prevent damage to the battery, (stiffening) elements are arranged, for example, in an interior compartment of the battery housing. These elements increase the housing's rigidity and prevent deformation of the battery housing into the interior compartment. DE 10 2016 110 330 A1 discloses a housing for a vehicle battery. The housing has a cover plate and a base plate, with a frame connected to the cover plate and base plate arranged between them. At least one cross member is arranged in the space enclosed by the frame.

[0006] Typically, the battery consists of several battery modules housed within a battery casing and frame. The frame has longitudinal sides running lengthwise along the vehicle. Each of these longitudinal sides has an internal deformation zone, allowing the corresponding side to compress in the event of impact and subsequent deformation. This prevents damage to the battery even with relatively minor deformations. However, these two deformation zones reduce the available space for the battery and, consequently, the vehicle's range.

[0007] German patent application DE 10 2016 008 170 A1 further describes a battery comprising a battery housing and at least one cell block arranged within the battery housing. The cell block has at least two end plates designed to fix the battery cells of the cell block. The battery also features a stiffening structure, which is at least partially formed by the end plates.

[0008] German patent application DE 10 2013 204 765 A1 discloses a storage cell assembly. Its housing has an energy absorption area which is designed to be deformable for energy absorption in the event of a collision.

[0009] The invention is based on the objective of providing a suitable battery housing that protects a battery contained therein from external forces and thus from potential damage. Furthermore, a motor vehicle equipped with such a battery housing is to be provided.

[0010] This problem is solved according to the invention by a battery housing having the features of claim 1. Furthermore, the problem is solved according to the invention by an electrically powered motor vehicle having the features of claim 7. Advantageous further developments and embodiments are the subject of the dependent claims.

[0011] For this purpose, the battery housing, which is designed and configured for a battery of an electrically powered motor vehicle, has a preferably trough-shaped recess with a housing base and a housing frame. The housing frame is formed by means of two longitudinal housing sides (frame sides), which are expediently arranged parallel and spaced apart from each other, and by means of two transverse housing sides (frame sides) extending transversely to the longitudinal housing sides.

[0012] The housing forms an interior space. The housing base and frame define this interior space. Furthermore, a deformation element is arranged within the housing interior, extending from one transverse side to the other. Ideally, this deformation element runs parallel to the longitudinal sides of the housing.

[0013] On those sides of the deformation element facing the longitudinal sides of the housing, a rigid (deformation-stable) support structure for a number of battery modules or, alternatively, for battery cell packs is arranged. In other words, a support structure for battery modules is arranged on both sides of the deformation element inside the housing. The support structure is more rigid than the deformation element itself. Here and in the following, only battery modules are referenced; however, unless otherwise stated, the explanations also apply analogously to so-called cell packs.

[0014] Within the interior of the housing, each support structure has a longitudinal structural wall, which is associated with one of the housing's longitudinal walls and preferably extends parallel to it. The longitudinal structural wall rests against the housing's longitudinal wall in a space-saving manner. Furthermore, each support structure has transverse structural walls that extend from the longitudinal structural wall to the deformation element and, in particular, run perpendicular to the longitudinal structural wall. These transverse structural walls are spaced apart from each other, forming spaces for the battery modules.

[0015] In the assembled state with battery modules installed in the receiving spaces, the structural cross walls are arranged both between two battery modules and between the battery modules and the corresponding housing cross side.

[0016] When one of the housing's longitudinal sides deforms due to a corresponding force, the supporting structure adjacent to that housing side is pressed into the deformation element, in other words, pushed against it. Such a force is caused, in particular, by a side-impact collision with a vehicle containing the battery housing. Due to the greater rigidity of the supporting structures compared to the deformation element, only the deformation element is deformed. Consequently, battery modules housed within the supporting structure are protected from damage caused by an intrusion of the housing's longitudinal side. The deformation element and the housing frame thus absorb energy introduced into the battery housing, and this energy is used for deformation. The deformation element encompasses a deformation space specifically designed and configured for its deformation.

[0017] Advantageously, in the inventive battery housing, compared to the battery housing mentioned at the beginning, which has a deformation space on each of its longitudinal sides, only one deformation element or deformation space is provided. This advantageously provides more installation space for battery modules within the battery housing, thus increasing the range of an electric vehicle equipped with such a battery housing. Alternatively, it is possible to design the battery housing to be correspondingly smaller while maintaining the same design and number of battery modules, and to use it, for example, in smaller vehicle models.

[0018] According to an advantageous embodiment, the deformation element is arranged centrally, or in other words, centrally, between the longitudinal sides of the housing within the housing interior. Thus, the housing interior is divided into two compartments, with a support structure arranged in each compartment. Advantageously, due to such a symmetrical arrangement, the battery is equally protected against forces directed either in or against a (transverse housing) direction perpendicular to the deformation element, i.e., parallel to the transverse housing side.

[0019] According to an advantageous further development, the structural cross walls and longitudinal walls of the respective load-bearing structure are rigidly connected to each other, i.e., immovable relative to one another. "Connected" here means that the longitudinal wall and the corresponding transverse wall are held or fastened to each other. Alternatively, the load-bearing structure can also be monolithic. Advantageously, in this way, a force acting on the load-bearing structure is transferred relatively uniformly to the deformation element via all the structural cross walls of the load-bearing structure or at least via structural cross walls of different receiving spaces. Consequently, it is possible to convert a comparatively large amount of energy into deformation energy of the deformation element.

[0020] According to an alternative embodiment, two structural transverse walls are arranged between each of the battery module receiving spaces. The structural longitudinal wall is divided into wall sections, preferably movable relative to each other. These sections are rigidly connected to two of the structural transverse walls, which form the respective receiving space. Thus, the structural longitudinal wall is not continuous but has interruptions. The structural transverse walls forming the respective receiving space, together with the corresponding wall section of the structural longitudinal wall, are also referred to as a cage. In the assembled state with battery modules placed in the receiving space, each battery module is therefore enclosed by its own cage, and the cages are movable relative to each other, in particular, sliding.In the event of a force being applied to one of the cages, only that cage is pressed against the deformation element, thus preventing damage to the battery modules housed in adjacent cages or at least reducing the risk of such damage.

[0021] If cell packs are placed in the corresponding receiving spaces, the respective cage forms, for example, a housing for the battery cell packs, or the cage is integrated into this housing.

[0022] In a suitable embodiment, the deformation element is an extruded profile, for example made of aluminum. Advantageously, its profile is designed such that, when a force is applied by one of the structural crossbeams, the deformation element does not deform in the direction of the battery modules located on the side of the deformation element facing away from that crossbeam. For this purpose, the profile has, in particular, corresponding predetermined bending points. For example, the profile has cross walls that connect the outer profile walls adjacent to the cross walls, with the cross walls being zigzag or meandering in shape so that, under appropriate load, they buckle towards or away from the bottom of the housing.

[0023] Alternatively, the extruded profile can be designed as a so-called semicircular profile, which advantageously has a circular ring segment in cross-section. For example, the circular ring segment is integrally connected to walls extending in the longitudinal direction of the housing, which form a support for the structural transverse walls. When a force is applied, the circular ring segment deforms (bends) accordingly in its radial direction, i.e., particularly towards or away from the housing base. Another alternative is the extruded profile designed as a so-called nested profile, which has a truss-like structure in cross-section.

[0024] In an alternative embodiment, the deformation element is formed by two walls running parallel to the longitudinal sides of the housing. These walls are spaced apart from each other in the transverse direction of the housing, forming a deformation space. The deformation space is designed so that the walls can penetrate into it when a corresponding force is applied and deformation occurs.

[0025] In a further alternative embodiment, the deformation element is formed by means of an aluminum foam. Here, the pores of the foam form the deformation space. Preferably, the aluminum foam is enclosed laterally, i.e., on its sides facing the structural transverse walls, by a wall on each side. In other words, the deformation element preferably has walls extending in the longitudinal direction of the housing, between which aluminum foam is arranged.

[0026] According to an advantageous embodiment, an electrically powered motor vehicle, hereinafter also referred to as the motor vehicle, has a battery housing in one of the variants described above. In particular, a single deformation element is provided in the interior of the housing, on each of the longitudinal sides of which a support structure for the battery modules of the battery is arranged.

[0027] Furthermore, the deformation element of the battery housing extends in a longitudinal direction of the vehicle, also known as the X-direction, i.e., from the rear to the front of the vehicle. Consequently, in a side-impact collision, a force acting on the longitudinal sides of the housing is transferred in the transverse direction of the vehicle via the supporting structure to the deformation element. If the longitudinal side of the housing deforms, then—as explained above—only the deformation element and the longitudinal side of the housing are deformed, thus protecting the battery modules housed in the supporting structure from damage.

[0028] According to a suitable design, the vehicle has two so-called sills extending longitudinally. The sills are located primarily on the underside of the vehicle and are an integral part of the vehicle's body. The battery housing is positioned between the sills. The longitudinal sides of the housing frame are thus parallel to the sills. The sills protect the battery from damage due to their rigid design. However, if the applied force is sufficiently large to deform a sill towards the battery housing, the force is transmitted via the sill(s) to the battery housing frame and from there, as described above, via the supporting structure into the deformation element.

[0029] Exemplary embodiments of the invention are explained in more detail below with reference to a drawing. The drawing shows: Fig. 1 in schematic top view an electrically powered motor vehicle with two sills, between which a battery housing is arranged, wherein a deformation element extending in the longitudinal direction of the vehicle is arranged in an interior of the housing, and wherein a support structure for battery modules of a battery is arranged on both sides of the deformation element, which support structure has a longitudinal structural wall and transverse structural walls, Fig. 2 in a top view the battery housing with an alternative design of the deformation element, which has two parallel and spaced-apart walls, and Fig. 3 in a top view the battery housing with an alternative design of the supporting structure, wherein the structural cross wall of the supporting structure is divided into wall parts, each of which wall parts is assigned to a battery module.

[0030] Corresponding parts and sizes are always marked with the same reference symbols in all figures.

[0031] Fig. Figure 1 shows a schematic top view of an electrically powered motor vehicle 2, hereinafter also referred to as a motor vehicle. Its longitudinal direction (X-direction) and its transverse direction (Y-direction) are labeled X and Y, respectively, in an adjacent directional diagram. The motor vehicle 2 has sills 4, which are part of the body of the motor vehicle 2 (not shown). The sills 4 are arranged parallel to and spaced apart from each other and are located on the underside (ground side) of the motor vehicle 2. Furthermore, the sills 4 extend in the longitudinal direction X of the vehicle.

[0032] A battery housing 6 is arranged between the sills 4, which has a trough-shaped recess 8 with a housing base 10 and a housing frame 12. The recess 8 forms a housing interior 14. In other words, the recess 8 defines the housing interior 14. The housing frame 12, in turn, has two longitudinal housing sides 16 extending parallel to the sills 4, i.e., in the vehicle's longitudinal direction X, and two transverse housing sides 18 extending perpendicular to these, i.e., in the vehicle's transverse direction Y.

[0033] A force acting on the vehicle 2 in the transverse direction Y, and correspondingly on the respective sill 4 and via this on the battery housing 6, in particular on the housing frame 12, is designated by the reference numeral F and represented by a corresponding arrow. The force F is caused, for example, by an accident involving an impact (side crash, side impact) of a collision body on the vehicle 2 in the transverse direction Y.

[0034] Inside the housing 14, a deformation element 20 is arranged, extending from one of the housing transverse sides 18 to the other housing transverse side 18 and running perpendicular to these, i.e., in the longitudinal direction X of the vehicle. The deformation element 20 is positioned centrally between the housing transverse sides 16. The deformation element 20 is in the embodiment of Fig. 1 designed as an extruded profile, the longitudinal direction of which extends in the longitudinal direction of the vehicle X, i.e. parallel to the longitudinal sides of the housing 16.

[0035] The interior of the housing 14 is divided into two compartments by means of the deformation element 20. A support structure 22 is arranged in each compartment. In other words, one of the support structures 22 is arranged on each side of the interior of the housing 14, i.e., on those sides of the deformation element 20 that face the longitudinal sides 16 of the housing. Each of the support structures 22 has a longitudinal structural wall 24, which extends parallel to the longitudinal sides 16 of the housing within the interior of the housing 14 and is associated with and abuts one of the longitudinal sides 16 of the housing. Transverse structural walls 26 extend from the longitudinal structural wall 24 towards the deformation element 20. The transverse structural walls 26 are spaced apart from each other and form receiving spaces 28 for battery modules 30 of a battery 32. Fig. In Figure 1, the battery modules 30 are shown with dashed lines.

[0036] Furthermore, the structural cross walls 26 and the structural longitudinal wall 24 of the respective support structure 22 are rigidly connected to each other. When the force F acts and the housing longitudinal sides 16 deform towards the deformation element 20, the entire respective support structure 22 is pressed against the deformation element 20. Only the deformation element 20 is deformed due to the greater rigidity of the support structure 22 compared to the deformation element 20, so that the energy introduced by the impact causing the force is used as deformation energy to deform the deformation element 20. Consequently, the battery 32 is protected from damage.

[0037] In Fig. Figure 2 shows the battery housing 6 with an alternative configuration of the deformation element 20. With the exception of what is described below, the battery housing 6 corresponds to the design of the Fig. 1. For the sake of clarity, only the battery housing 6 is shown here; however, this is analogous to the Fig. 1 is arranged in the motor vehicle 2. The deformation element 20 has two walls 34 which extend parallel to each other from one of the housing transverse sides 18 to the other housing transverse side 18, i.e., in the longitudinal direction X of the vehicle. Furthermore, the two walls 34 are spaced apart from each other, so that a deformation space 36 is formed between them, into which the walls 34 can penetrate when they deform.

[0038] In Fig. Figure 3 shows the battery housing 6 with an alternative design of the support structure 22. With the exception of what is described below, the battery housing 6 corresponds to the design of the Fig. 1. For the sake of clarity, only the battery housing 6 is shown here; however, this is analogous to the Fig. 1 in the motor vehicle 2. The longitudinal structural wall 24 of the respective support structure 22 is divided into a number of wall sections 38 that are movable relative to each other, the number of wall sections 38 corresponding to the number of battery modules 30 accommodated in the respective support structure 22. Two transverse structural walls 26 are rigidly connected to each of the wall sections 38, forming the corresponding receiving space 28. Each battery module 30 is thus enclosed by a so-called cage, which is formed by the corresponding wall sections 38 of the longitudinal structural wall 24 and the corresponding transverse structural walls 26. Thus, two transverse structural walls 26 are arranged between each pair of adjacent receiving spaces 28. The cages are also movable relative to each other.In this way, when a force is applied to one of the cages, only that cage is pressed against the deformation element 20, so that force transmission to adjacent cages and thus damage to the battery modules 30 contained in the adjacent cages is avoided.

[0039] In a variant of the battery housing 6 not shown further, the supporting structure 22 is designed according to the Fig. 3 and the deformation element 20 according to the Fig. 2 trained.

[0040] The invention is not limited to the embodiments described above. Rather, other variants of the invention can also be derived by those skilled in the art without departing from the subject matter of the invention. In particular, all individual features described in connection with the embodiments can also be combined with one another in other ways without departing from the subject matter of the invention. Reference symbol list 2 motor vehicles 4 sills 6 battery cases 8th recording 10 Case bottom 12 housing frames 14 Interior of the housing 16 Case side 18 Case side 20 Deformation element 22 Supporting structure 24 structural longitudinal wall 26 Structural cross wall 28 Recording room 30 battery modules 32 battery 34 Wall 36 Deformation space 38 wall section F force X Vehicle longitudinal direction Y Vehicle transverse direction

Claims

[1] Battery housing (6) for a battery (32) of an electrically powered motor vehicle (2), comprising a, in particular trough-shaped, receptacle (8) with a housing base (10) and with a housing frame (12), wherein the receptacle (8) forms a housing interior (14), - wherein the housing frame (12) is formed by means of two housing longitudinal sides (16) and by means of two housing transverse sides (18) extending transversely to these, - wherein a deformation element (20) is arranged in the interior of the housing (14), which extends from one of the transverse sides (18) of the housing to the other transverse side (18) of the housing frame (12), - wherein on those sides of the deformation element (20) which face the longitudinal sides (16) of the housing, a rigid support structure (22) for a number of battery modules (30) of the battery (32) is arranged, - wherein the supporting structures (22) within the housing interior (14) each have a longitudinal structural wall (24) assigned to and adjacent to one of the housing longitudinal sides (16), and structural transverse walls (26) spaced apart from each other to form receiving spaces (28) for the battery modules (30), which extend from the deformation element (20) to the respective longitudinal structural wall (24), and - wherein the supporting structures (22) are stiffer than the deformation element (20). [2] Battery housing (6) according to claim 1, characterized by , that the deformation element (20) is arranged centrally between the longitudinal sides (16) of the housing inside the housing (14). [3] Battery housing (6) according to claim 1 or 2, characterized by , that the structural cross walls (26) and the structural longitudinal wall (24) are rigidly connected to each other and to each other. [4] Battery housing (6) according to claim 1 or 2, characterized by , - that two structural cross walls (26) are arranged between the receiving spaces (28) for the battery modules (30), and - that the structural longitudinal wall (24) is divided into wall sections (38), each of which is rigidly connected to two of the structural transverse walls (26), which structural transverse walls (26) form the corresponding receiving space (28). [5] Battery housing (6) according to any one of claims 1 to 4, characterized by , that the deformation element (20) is an extruded profile. [6] Battery housing (6) according to any one of claims 1 to 4, characterized by , that the deformation element (20) is formed by means of two walls (34) running parallel to the longitudinal sides (16) of the housing, wherein the walls (34) are spaced apart from each other to form a deformation space (36). [7] Electrically powered motor vehicle (2) with a battery housing (6) according to one of claims 1 to 6, wherein the deformation element (20) of the battery housing (6) extends in the longitudinal direction (X) of the vehicle. [8] Electrically powered motor vehicle (2) according to claim 7 characterized by two sills (4) extending in the longitudinal direction (X) of the vehicle, wherein the battery housing (6) is arranged between the sills (4).

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