Elastic coupling element for a motor vehicle and motor vehicle with at least one coupling element

Abstract

Elastic coupling element (100, 200, 300) for a motor vehicle for arrangement between an energy storage housing structure (102, 220) and a passenger cell floor structure (104, 218, 306), characterized in that the coupling element (100, 200, 300) is made of a spring sheet and is reversibly elastically deformable below a predetermined force application in order to reduce noise, and is irreversibly plastically deformable above a predetermined force application in order to allow for tolerance compensation, wherein the predetermined force application above which the coupling element is irreversibly plastically deformable is a maximum assembly force.

Description

[0001] The invention relates to an elastic coupling element for a motor vehicle for arrangement between an energy storage housing structure and a passenger cell floor structure. The invention also relates to a motor vehicle comprising an energy storage housing structure and a passenger cell floor structure.

[0002] Document WO 2019 / 121077 A1 relates to a motor vehicle with a body, wherein the body comprises a passenger compartment, the passenger compartment having a floor structure, wherein a housing structure for energy storage is attached to an underside of the floor structure, the housing structure being a closed container having a trough-shaped component and a lid spaced apart from the trough-shaped component, wherein at least one damping component is arranged in a space between the underside of the floor and an outer surface of the lid of the housing structure, which is installed under preload in the space between the lid of the housing structure and the floor, wherein the damping component is a compressible foam.To reduce vibrations of the floor assembly, document WO 2019 / 121077 A1 proposes using an elastomeric foam as the compressible foam of the damping component, the material properties of which exhibit dynamic hardening under dynamic loading, such that the stiffness under dynamic loading is greater than the stiffness under quasi-static loading, such as in the assembly case, by a dynamic hardening factor greater than 2 from a frequency greater than 0.1 Hz.

[0003] Document FR 2 964 623 A3 discloses a method for attaching an electric battery to a motor vehicle chassis, comprising the following steps: providing the electric battery and the chassis by inserting an elastically deformable means between them; applying an approach force to the electric battery and the chassis, wherein the approach force deforms the elastically deformable means and the elastically deformable means exerts a restoring force opposite to the approach force; and inserting a locking means which, in a relative position of the electric battery with respect to the chassis in which the elastically deformable means is deformed, blocks the relative movement of the electric battery with respect to the chassis under the action of the restoring force.

[0004] Document DE 10 2016 206 177 A1 discloses a motor vehicle with a body comprising a passenger compartment, wherein the passenger compartment has a floor structure, wherein a housing structure for an energy storage device is attached to an underside of the floor structure, wherein the housing structure is a closed container having circumferential side walls, a floor arranged thereon and a lid spaced from the floor, wherein at least one component is arranged in a space between the underside of the floor of the motor vehicle body and an outer surface of the lid of the housing structure, which is installed under preload in the space between the lid of the housing structure and the floor of the body, wherein the component has at least a spring-like property.

[0005] The invention is based on the objective of structurally and / or functionally improving a coupling element mentioned above. Furthermore, the invention is based on the objective of structurally and / or functionally improving a motor vehicle mentioned above.

[0006] The problem is solved with a coupling element having the features of claim 1. Furthermore, the problem is solved with a motor vehicle having the features of claim 7. Advantageous embodiments and / or further developments are the subject of the dependent claims.

[0007] The coupling element can be effective geometrically, mechanically, acoustically, and / or vibrationally. The coupling element can serve to reduce acoustically effective vibrations in a passenger compartment. The coupling element can serve to support a predetermined vibration behavior of the energy storage housing structure and / or the passenger compartment floor structure. The coupling element can serve to change a wavelength, in particular to shorten it, when the passenger compartment floor structure vibrates. The coupling element can serve to ensure that predetermined maximum mechanical stresses are not exceeded during an assembly process in the energy storage housing structure and / or in the passenger compartment floor structure, even when tolerances are taken into account. In this context, "structure" refers in particular to components and / or modules that have a structural design. These components and / or modules can be structurally and / or functionally effective.

[0008] The spring sheet can be made of a metal or metal alloy, in particular a steel such as stainless steel, or a copper alloy. The spring sheet can be made of a metal or metal alloy with increased strength compared to other metals or metal alloys. For example, the spring sheet can be made of one of the following materials: X10CrNi18-8, 38Si7, 61SiCr7, 52CrMoV4, 51CrV4, C67E / C67S. The spring sheet can be manufactured as a flat product, a long product, and / or a rolled product. The coupling element can be made of a strip-shaped, ribbon-shaped, and / or tubular spring sheet. The coupling element can be designed as a shaped spring, a flat spring, and / or a leaf spring.

[0009] The coupling element can have at least one first contact section associated with the energy storage housing structure, at least one second contact section associated with the passenger compartment floor structure, and / or at least one spring section. The at least one first contact section can serve for mechanical connection with the energy storage housing structure. The at least one second contact section can serve for mechanical connection with the passenger compartment floor structure. The at least one spring section can act between the at least one first contact section and the at least one second contact section.

[0010] The coupling element can exhibit a predetermined characteristic curve in a displacement-force diagram. The coupling element can exhibit linear-elastic or non-linear-elastic behavior. The characteristic curve of the coupling element can be progressive, linear, or degressive, at least in certain sections. The aim is to use the coupling element within a characteristic curve region with the smallest possible change in stiffness as a function of displacement. The coupling element can have a stiffness of approximately 2 kN / mm. 2 up to approximately 8 kN / mm 2 , in particular approx. 5kN / mm 2The coupling element can exhibit predetermined vibration behavior. Below a predetermined force, the coupling element is reversibly elastically deformable to reduce noise. This noise reduction can be achieved by reducing vibration, particularly by reducing amplitude and / or changing frequency. The coupling element can dampen low-frequency vibrations, especially vibrations in the range of approximately 10 Hz to approximately 70 Hz, and particularly approximately 35 Hz to approximately 40 Hz. Above a predetermined force, the coupling element is irreversibly plastically deformable to compensate for tolerances. The coupling element can increase body stiffness. The coupling element can compensate for tolerance-related dimensional deviations in a gap formed between the energy storage housing structure and the passenger cell floor structure.The predetermined force above which the coupling element becomes irreversibly plastically deformable is a maximum assembly force. This maximum assembly force can be, for example, approximately 2 kN to approximately 8 kN, and in particular approximately 5 kN. The coupling element can be designed geometrically and materially with regard to the predetermined force. Material selection can be made taking into account the material's elastic limit. For example, a material can be selected for an elastic limit of approximately 400 N / mm². 2 up to approximately 1,000 N / mm 2 , in particular of approximately 755 N / mm 2 , corresponding to a maximum force during operation. For example, a material can be selected for an elastic limit for plastic deformability of approximately 600 N / mm². 2 up to approximately 1,400 N / mm 2 , especially of approximately 1,000 N / mm 2 , corresponding to a maximum assembly force.

[0011] The coupling element can be arc-shaped with two end sections and a middle section. The two end sections can form the first contact sections of the coupling element. The middle section can form a second contact section of the coupling element. The two end sections can form second contact sections of the coupling element. The middle section can form a first contact section of the coupling element.

[0012] The coupling element can be designed in a ring shape with two contact sections and two spring sections. The coupling element can also be designed as a completely closed ring. The contact sections and spring sections can be arranged diametrically opposite each other.

[0013] The coupling element can be circular. The coupling element can be elliptical with two main vertices and two secondary vertices. The coupling element can be elliptical in its unloaded initial state. The contact sections can be assigned to the secondary vertices and the spring sections to the main vertices. The contact sections can be assigned to the main vertices and the spring sections to the secondary vertices. The contact sections can serve to represent a line contact and / or a surface contact.

[0014] The coupling element can be designed in a shape other than arc-shaped, ring-shaped or circular.

[0015] The coupling element can have at least one fastening section. This fastening section can be used to attach the coupling element to the energy storage housing structure and / or to the passenger compartment floor structure. The fastening section can have an opening for receiving a fastening element, such as a screw.

[0016] The motor vehicle can be a passenger car. The motor vehicle can be a hybrid electric vehicle or an electric vehicle. The motor vehicle can have a body. The body can be a unibody or a skeleton body. Body stiffness can be increased by means of at least one coupling element. The body can have a passenger cell. The passenger cell can have a passenger cell floor structure. The passenger cell floor structure can have an underside. In this context, "underside" refers in particular to a side facing the roadway. The motor vehicle can have an energy storage housing structure. The energy storage housing structure can serve to accommodate an energy storage device. The energy storage device can be an electrical energy storage device. The energy storage device can be a traction battery. The energy storage device can be a lithium-ion battery.The energy storage device can be a high-voltage storage device. The energy storage device can be a flat storage device. The energy storage device housing structure can be located on the underside of the passenger compartment floor structure. The energy storage device housing structure can have a top surface. In this context, "top surface" refers specifically to a side facing away from the roadway. The energy storage device housing structure can be enclosed.

[0017] A gap may be formed between the underside of the passenger compartment floor structure and the top of the energy storage housing structure. This gap may have a height in the vehicle's vertical direction. The at least one coupling element may serve to compensate for tolerance-related dimensional deviations in the gap height. The dimensional deviation to be compensated in the vehicle's vertical direction may, for example, be approximately 0 mm to approximately + / -20 mm, in particular approximately + / -5 mm. The gap may have a length in the vehicle's longitudinal direction. The gap may have a width in the vehicle's transverse direction. The at least one coupling element may serve to compensate for tolerance-related dimensional deviations in the vehicle's longitudinal and / or transverse direction. The dimensional deviation to be compensated in the vehicle's longitudinal and / or transverse direction may, for example, be approximately 0 mm to approximately + / -20 mm, in particular approximately + / -9 mm.

[0018] At least one coupling element can be arranged in the gap. A single coupling element or several coupling elements can be arranged between the energy storage housing structure and the passenger cell floor structure. A single coupling element can be arranged at least approximately centrally in the longitudinal direction and / or transverse direction of the gap. In this respect, the coupling element can serve as a central connection. Several coupling elements can be arranged in such a way as to optimize vibration behavior.

[0019] The at least one coupling element can be attached to the energy storage housing structure or to the passenger compartment floor structure. The at least one coupling element can be bolted to the energy storage housing structure or to the passenger compartment floor structure. The at least one coupling element can be attached to the energy storage housing structure or to the passenger compartment floor structure in such a way that a tightness, in particular a watertight seal, of the passenger compartment and / or a tightness, in particular a gas tightness, of the energy storage housing structure is ensured.

[0020] In summary, and in other words, the invention provides, among other things, a vibration-optimized central connection for high-voltage storage devices using a spring plate. According to the invention, the spring plate concept, through a closed "steel sheet ring," allows for reversible deformation in the elastic range to reduce vibration amplitudes and / or optimize wavelengths. A defined gap can be set by plastically deforming the "steel sheet ring" during the assembly of two components to be coupled, thus compensating for tolerances. Dynamic vibration behavior and quasi-static assembly forces can be adjusted by the geometry, wall thickness, and material grade of the "steel sheet ring."The spring sheet concept uses a closed "steel sheet ring" in an oval shape to elastically deform a body floor panel in electric vehicles with high-voltage flat batteries, thus optimizing vibrations and reducing noise, for example, by installing the element between the body and the high-voltage battery. Simultaneously, this allows for a defined limitation of the mounting force of the high-voltage battery when installed to the body, as well as enabling tolerance compensation in the vehicle's height direction.

[0021] The invention creates functional synergies. It reduces effort such as assembly, maintenance, locking, and / or costs. Customer-value properties are optimized, particularly with regard to interior acoustics. Noise levels in the passenger compartment are reduced. The overall system is acoustically tuned to an advantage. High rigidity is achieved during operation while simultaneously limiting assembly force. Furthermore, it enables tolerance compensation in the vehicle height direction between the body and the high-voltage storage system of, for example, up to + / -5 mm.

[0022] Exemplary embodiments of the invention are described in more detail below with reference to the figures, which show schematically and by way of example: Fig. 1 an arc-shaped coupling element in the maximum gap and in a minimum gap, Fig. 2 a ring-shaped coupling element in an initial position, in a maximum gap, in a construction position and in a minimum gap, and Fig. 3 a ring-shaped coupling element with fastening sections on a passenger cell floor structure.

[0023] Fig. Figure 1 shows coupling element 100, which is made of a sheet of spring steel and has an arc shape. The coupling element 100 is arranged in a space 106 formed between an energy storage housing structure 102 and the passenger cell floor structure 104 and has two end sections 108, 110 and a central section 112. The coupling element 100 is prestressed and supported at its end sections 102, 104 against the energy storage housing structure 102 and at its central section 106 against the passenger cell floor structure 104. The coupling element 100 has a comparatively high stiffness of approximately 5 kN / mm². 2below a predetermined force, it causes a reduction in low-frequency vibrations through reversible elastic deformation.

[0024] Furthermore, the coupling element 100 is irreversibly plastically deformable above a predetermined force, thus enabling compensation for tolerance-related dimensional deviations of the gap height 114. A gap height 114 at an upper tolerance limit is referred to as the maximum gap and is in Fig. 1 shown on the left. A gap height of 114 at a lower tolerance limit is called the minimum gap and is shown in Fig. 1 shown on the right-hand side.

[0025] Fig. Figure 2 shows a ring-shaped coupling element 200 in an unloaded initial position 202, in a maximum gap 204, in a design position 206 and in a minimum gap 208. The design position 206 corresponds to a target gap height, the maximum gap 204 results at the upper tolerance limit, and the minimum gap 208 results at the lower tolerance limit.

[0026] The coupling element 200 is elliptical in shape with two main vertices 210, 212 and two secondary vertices 214, 216 and is attached to the passenger compartment floor structure 218. In an installed or operating position, in which a maximum gap 204, a design position 206, a minimum gap 208, or an intermediate position may be present, the coupling element 200 is prestressed and supported at its secondary vertex 214 against the energy storage housing structure 220 and at its secondary vertex 216 against the passenger compartment floor structure 218. In the event of vibrations of the energy storage housing structure 220 and / or the passenger compartment floor structure 218, the main vertices 210, 212 can deflect laterally. To compensate for tolerance-related dimensional deviations in the gap height 222, the coupling element 200 is plastically deformable above a predetermined force. Furthermore, the following applies: Fig. 1 and the associated description are referenced.

[0027] Fig. Figure 3 shows an annular coupling element 300 with fastening sections 302, 304 on a passenger compartment floor structure 306. The coupling element 300 is made of a sheet of spring steel, is elliptical in shape, and has a width 308. The coupling element 300 acts between the passenger compartment floor structure 306 and an energy storage housing structure (not shown here). Further details are provided in the following sections. Fig. 1 and Fig. 2 and the associated description are referenced.

[0028] The term "may" refers in particular to optional features of the invention. Accordingly, there are also further developments and / or embodiments of the invention that additionally or alternatively include the respective feature(s).

[0029] From the combinations of features disclosed herein, isolated features can also be selected as needed and, by dissolving any structural and / or functional relationship that may exist between the features, used in combination with other features to define the subject matter of the claim. Reference sign 100 coupling elements 102 Energy storage housing structure 104 Passenger compartment floor structure 106 space 108 Final section 110 End section 112 Middle section 114 Spacing height 200 coupling elements 202 Initial situation 204 Maximum gap 206 Construction position 208 Minimum gap 210 Main vertex 212 Main vertex 214 secondary vertex 216 secondary vertices 218 Passenger compartment floor structure 220 Energy storage housing structure 222 Spacing height 300 coupling elements 302 Fastening section 304 Fastening section 306 Passenger compartment floor structure 308 Width of the coupling element

Claims

[1] Elastic coupling element (100, 200, 300) for a motor vehicle for arrangement between an energy storage housing structure (102, 220) and a passenger cell floor structure (104, 218, 306), characterized by , that the coupling element (100, 200, 300) is made of a spring sheet and is reversibly elastically deformable below a predetermined force to reduce noise, and irreversibly plastically deformable above a predetermined force to compensate for tolerances, wherein the predetermined force above which the coupling element is irreversibly plastically deformable is a maximum assembly force. [2] Coupling element (100) according to claim 1, characterized by , that the coupling element (100) is designed in an arc shape with two end sections (108, 110) and a middle section (112). [3] Coupling element (200, 300) Claim 1, characterized by, that the coupling element (200, 300) is designed in a ring shape with two contact sections and two spring sections. [4] Coupling element (200, 300) according to claim 3, characterized by , that the coupling element (200, 300) is elliptical with two main vertices (210, 212) and two secondary vertices (214, 216). [5] Coupling element (200, 300) according to claim 4, characterized by , that the contact sections are assigned to the secondary vertices (214, 216) and the spring sections to the main vertices (210, 212). [6] Coupling element (100, 200, 300) according to at least one of the preceding claims, characterized by , that the coupling element (100, 200, 300) has at least one fastening section (302, 304). [7] Motor vehicle with an energy storage housing structure (102, 220) and a passenger cell floor structure (104, 218, 306), characterized by, that at least one coupling element (100, 200, 300) according to at least one of claims 1 to 6 is effective between the energy storage housing structure (102, 220) and the passenger cell floor structure (104, 218, 306). [8] Motor vehicle according to claim 7, characterized by , that at least one coupling element (100, 200, 300) is attached to the energy storage housing structure (102, 220) or to the passenger cell floor structure (104, 218, 306).

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