Form fit of a housing of a traction battery of an electric vehicle with a chassis of the electric vehicle

Abstract

A chassis for an electric vehicle, comprising a support, and a housing for a traction battery of an electric vehicle, comprising a lateral flange portion protruding from the housing; a system for an electric vehicle, comprising a chassis of the electric vehicle and a housing for a traction battery of the electric vehicle, an electric vehicle, and a method for assembling a traction battery of an electric vehicle.

Description

[0001] The invention relates to a chassis for an electric vehicle, which comprises a support, and a housing for a traction battery of an electric vehicle, which housing comprises a lateral flange portion protruding from the housing. Furthermore, the invention relates to a system for an electric vehicle, which comprises a chassis of the electric vehicle and a housing for a traction battery of the electric vehicle, an electric vehicle, and a method for mounting a traction battery of an electric vehicle.

[0002] During any normal journey of a vehicle, i.e., a motor vehicle and in particular a passenger car (car), the vehicle and each of its components is subjected to a plurality of longitudinal accelerations (i.e., accelerations in a front-to-rear direction of the vehicle) and lateral accelerations (i.e., accelerations in a left-to-right direction of the vehicle). Accordingly, each time the vehicle accelerates, each component is subjected to a force proportional to its mass.

[0003] To maintain the integrity of the vehicle, the position of each assembly relative to the vehicle must be maintained under the influence of the force associated with acceleration. In other words, a vehicle mount must be provided for each assembly of the vehicle that absorbs the applied force and keeps the assembly constantly in a designated location relative to the vehicle.

[0004] One of the components of a vehicle powered by an internal combustion engine is a fuel tank.

[0005] For example, DE 10 2017 001 123 A1 discloses a system for a vehicle comprising a body part of the vehicle, a fuel tank of the vehicle, and a bracket for the fuel tank. The bracket comprises a projection that engages a corresponding recess in the fuel tank and fixes the fuel tank between the body part and a trim element of the bracket.

[0006] Accordingly, one of the components of an electric vehicle includes a traction battery, which typically comprises a housing and a plurality of battery cells arranged within the housing. The housing may have a lateral flange portion protruding from the housing. To attach the traction battery to a chassis of the vehicle, the flange portion is connected to a chassis support by means of a plurality of screws.

[0007] From DE 31 50 652 A1, it is known to arrange a traction battery in the storage compartment of an electric vehicle. The traction battery is held in place by a positive engagement of pins on the floor of the storage compartment into corresponding recesses in the traction battery. The pins and recesses are designed as electrical contacts.

[0008] US 2012 / 0 321 381 A1 discloses a chassis with bow-shaped projections and a housing of a traction battery with locking devices which are designed to engage behind the bow-shaped projections engaging in the locking devices in the locked state.

[0009] Due to the large mass of the traction battery, the connection between the traction battery and the chassis must be able to absorb considerable force, especially in the event of a rear-end impact, for example, as a result of a rear-end collision. However, the number of bolts may not be sufficient due to the inherently limited installation space. Furthermore, the stability of the bolts against shearing, especially in the event of a rear-end impact, cannot be guaranteed with sufficient safety.

[0010] It is therefore an object of the invention to provide a chassis for an electric vehicle and a housing for a traction battery of the electric vehicle, which ensure a secure connection between the chassis and the housing even in the event of a rear impact. Further objects of the invention are to provide a system for an electric vehicle comprising a chassis and a housing for a traction battery, and to propose a method for assembling a traction battery of an electric vehicle.

[0011] One subject of the invention is a chassis for an electric vehicle, comprising a support. The chassis support is designed to absorb a force occurring during a rear-end collision. Furthermore, the support is provided for attaching a traction battery of the electric vehicle.

[0012] According to the invention, the carrier comprises a projection protruding from the carrier, which is designed for a three-dimensional positive fit with a corresponding recess of a housing of a traction battery of the electric vehicle. The projection is integrally formed on the carrier and is intended to secure the housing of the traction battery to the carrier by a positive engagement. The three-dimensional positive fit secures the housing to the carrier in three spatial dimensions, i.e., in an x-direction (longitudinal direction of the vehicle), a y-direction (lateral transverse direction of the vehicle), and a z-direction (vertical transverse direction of the vehicle).

[0013] The connection provided by the engagement, i.e., the positive engagement connection, between the carrier and the housing can, on the one hand, absorb a rear impact, i.e., a short-term, strong acceleration in the longitudinal direction of the vehicle. On the other hand, the three-dimensional positive engagement facilitates positioning of the traction battery relative to the chassis when mounting it in the chassis.

[0014] Furthermore, according to the invention, the projection has an internal thread for a screw, and the projection is at least partially formed as a cone with a conical outer surface. The internal thread allows the housing to be screwed to the support. In the event of a rear impact, the screws do not have to absorb the entire force acting in the longitudinal direction of the vehicle, since the positive engagement connection also absorbs a portion of the force. Consequently, the positive engagement connection also counteracts shearing of the screws.

[0015] The conical shape of the outer surface of the projection allows the traction battery to be fixed in the vertical transverse direction of the vehicle and the traction battery to be fixed in the longitudinal direction and the horizontal transverse direction of the vehicle at the same time, thus facilitating the installation of the traction battery.

[0016] Advantageously, the support is designed as a longitudinal member of the chassis. The longitudinal member is intended to absorb forces acting in the longitudinal direction of the vehicle.

[0017] Another subject of the invention is a housing for a traction battery of an electric vehicle, which comprises a lateral flange portion protruding from the housing. The flange portion of the housing is designed to absorb a force occurring during a rear-end impact. Furthermore, the flange portion is provided for attaching the traction battery to the chassis.

[0018] According to the invention, the flange portion has an indentation formed on the flange portion, which is designed for a three-dimensional positive fit with a corresponding projection of the chassis of the electric vehicle. The indentation is formed integrally on the flange portion and is provided to secure the housing of the traction battery to the carrier by a positive engagement. The three-dimensional positive engagement secures the housing to the carrier in three spatial dimensions, i.e., in an x-direction (longitudinal direction of the vehicle), a y-direction (lateral transverse direction of the vehicle), and a z-direction (vertical transverse direction of the vehicle).

[0019] Furthermore, according to the invention, the recess has a passage for a screw, and the recess is at least partially formed as a hollow cone with a conical inner surface. The passage allows the housing to be screwed to the support. In the event of a rear impact, the screws do not have to absorb the entire force acting in the longitudinal direction of the vehicle, since the positive engagement connection also absorbs a portion of the force. Consequently, the positive engagement connection also counteracts shearing of the screws.

[0020] The conical shape of the inner surface of the recess allows the traction battery to be fixed in the vertical transverse direction of the vehicle and the traction battery to be fixed in the longitudinal direction and the horizontal transverse direction of the vehicle at the same time, which facilitates the installation of the traction battery.

[0021] In one embodiment, a hollow cylinder is integrally formed on the flange portion, and the indentation is formed at a free end of the hollow cylinder. A length of the hollow cylinder establishes a position of the traction battery relative to the chassis, i.e., a distance between the flange portion and the support, and allows flexible positioning of the traction battery in the vertical transverse direction.

[0022] Another subject of the invention is a system comprising a chassis and a housing for a traction battery. The system is designed to provide a connection between the chassis and the housing of the traction battery.

[0023] According to the invention, the chassis is designed as a chassis according to the invention, the housing is designed as a housing according to the invention, and the system has a plurality of corresponding projections and indentations. The plurality of corresponding projections and indentations distribute the force occurring during a rear impact and correspondingly reduce the force acting on each individual positive engagement of a projection and indentation. In this way, a secure connection between the traction battery and the chassis is ensured.

[0024] A fourth aspect of the invention is an electric vehicle comprising a chassis and a housing for a traction battery, which is mounted three-dimensionally on a support of the chassis. Electric vehicles with a chassis and a housing for a traction battery mounted three-dimensionally on the chassis are widespread. Accordingly, the invention has numerous and diverse applications.

[0025] According to the invention, the chassis is designed according to the invention, the housing is designed according to the invention, and a projection projecting from a support of the chassis and a recess formed on a lateral flange portion projecting from the housing are in positive engagement. The electric vehicle provides a firm connection between the traction battery and the chassis, thereby increasing the safety of the electric vehicle in the event of a rear impact.

[0026] A fifth aspect of the invention is a method for assembling a traction battery of an electric vehicle, in which a housing enclosing a traction battery of an electric vehicle is mounted on a support of a chassis of the electric vehicle. The assembly method is carried out during every production of an electric vehicle. Accordingly, the invention has numerous and diverse applications.

[0027] According to the invention, a projection protruding from the chassis support and a recess formed on a lateral flange portion protruding from the housing are brought into positive engagement. Thanks to this positive engagement, the housing is secured to the support in three spatial dimensions, i.e., in an x-direction (longitudinal direction of the vehicle), a y-direction (lateral transverse direction of the vehicle), and a z-direction (vertical transverse direction of the vehicle), thereby facilitating installation of the traction battery.

[0028] Furthermore, according to the invention, a screw is screwed through a passage in the recess into an internal thread of the projection. The screw connection further strengthens the connection between the traction battery and the chassis and counteracts movement of the traction battery relative to the chassis in the vertical transverse direction of the vehicle.

[0029] A significant advantage of the chassis and housing for a traction battery according to the invention is that, when combined, they ensure a secure connection between the chassis and the housing, even in the event of a rear impact. Another advantage is that mounting the traction battery is easier.

[0030] The invention is schematically illustrated in the drawings using an embodiment and will be further described with reference to the drawings. It shows: Fig. 1 is a partial side view of a system comprising a chassis and a housing of a traction battery according to an embodiment of the invention for an electric vehicle; Fig. 2 an enlarged detail of the Fig. 1 shown system; Fig. 3 another enlarged detail of the Fig. 2 shown system.

[0031] Fig. Figure 1 shows a partial side view of a system according to an embodiment of the invention for an electric vehicle (not shown). The system comprises a chassis 1 with a support 10 and a housing 2 for a traction battery, which has a flange portion 20. The chassis 1 and the housing 2 are suitable for the electric vehicle.

[0032] Fig. 2 shows an enlarged detail of the Fig. 1 with a connection according to the invention between the housing 2 and the carrier 10.

[0033] The chassis 1 comprises a support 10 with a projection 100 protruding from the support 10. The support 10 can be designed as a longitudinal member of the chassis 1. The projection 100 is designed for a three-dimensional positive fit with a corresponding recess 200 of the housing 2 of the traction battery of the electric vehicle. The projection 100 has an internal thread 1000 for a screw 3. The projection 100 is formed at least partially as a cone with a conical outer surface 101.

[0034] The housing 2 comprises a lateral flange section 20 protruding from the housing 2 and having a recess 200 formed on the flange section 20. A hollow cylinder 201 can be formed on the flange section 20, and the recess 200 can be formed at a free end of the hollow cylinder 201. The recess 200 is designed for three-dimensional positive engagement with the corresponding projection 100 of the chassis 1. The recess 200 has a passage 2000 for the screw 3. The recess 200 is formed at least partially as a hollow cone with a conical inner surface 202.

[0035] In advantageous embodiments, the system comprises a plurality of corresponding projections 100 and indentations 200.

[0036] The traction battery of the electric vehicle is assembled using a process as follows.

[0037] The housing 2 enclosing the traction battery of the electric vehicle is mounted on the support 10 of the chassis 1 of the electric vehicle. For this purpose, each projection 100 protruding from the support 10 of the chassis 1 and each recess 200 formed on a lateral flange portion 20 protruding from the housing 2 are brought into positive engagement in pairs.

[0038] Through each passage 2000 of the recess 200, a screw 3 is screwed into the internal thread 1000 of the corresponding projection 100.

[0039] The electric vehicle comprises the chassis 1 and the housing 2. After proper assembly, the housing 2 is held three-dimensionally on the support 10 of the chassis 1. The projection 100 protruding from the support 10 of the chassis 1 and the recess 200 formed on the lateral flange portion 20 protruding from the housing 2 are in positive engagement.

[0040] Fig. 3 shows a further enlarged detail of the Fig. 2 with a prior art connection between the housing 2 and the carrier 10.

[0041] The system according to the invention can - as in Fig. 1—include both connections known from the prior art and connections according to the invention. The connections according to the invention can be provided alternatively or additionally on a cross member of the chassis 1. LIST OF REFERENCE SYMBOLS: 1 chassis 10 carriers 100 lead 101 exterior area 1000 internal threads 2 housings 20 flange section 200 indentation 201 hollow cylinders 202 interior surface 2000 passage 3 screw 4 Rear impact force

Claims

[1] Chassis (1) for an electric vehicle, comprising a support (10) with a projection (100) projecting from the support (10), which is designed for a three-dimensional positive connection with a corresponding indentation (200) of a housing (2) of a traction battery of the electric vehicle, is designed at least partially as a cone with a conical outer surface (101) and has an internal thread (1000) for a screw (3). [2] Chassis (1) according to claim 1, wherein the support (10) is designed as a longitudinal support of the chassis (1). [3] Housing (2) for a traction battery of an electric vehicle, comprising a lateral flange section (20) projecting from the housing (2) with an indentation (200) formed on the flange section (20), which is designed for a three-dimensional positive connection with a corresponding projection (100) of a chassis (1) of the electric vehicle, is designed at least partially as a hollow cone with a conical inner surface (202) and has a passage (2000) for a screw (3). [4] Housing (2) according to claim 3, wherein a hollow cylinder (201) is formed on the flange portion (20) and the indentation (200) is formed at a free end of the hollow cylinder (201). [5] System for an electric vehicle, comprising a chassis (1) according to claim 1 or 2 and a housing (2) according to claim 3 or 4 for a traction battery and having a plurality of corresponding projections (100) and indentations (200). [6] Electric vehicle, comprising a chassis (1) according to claim 1 or 2 and a housing (2) according to claim 3 or 4 for a traction battery, which is held three-dimensionally on a support (10) of the chassis (1), wherein a projection (100) projecting from a support (10) of the chassis (1) and an indentation (200) formed on a lateral flange section (20) projecting from the housing (2) are in positive engagement. [7] Method for assembling a traction battery of an electric vehicle, in which - a housing (2) enclosing a traction battery of an electric vehicle is mounted on a support (10) of a chassis (1) of the electric vehicle; - a projection (100) projecting from the support (10) of the chassis (1) and a recess (200) formed on a lateral flange section (20) projecting from the housing (2) are brought into a three-dimensional positive engagement; and - a screw (3) is screwed through a passage (2000) of the recess (200) into an internal thread (1000) of the projection (100).

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