Vehicle sill rail

Abstract

Vehicle sill rail (200), wherein the vehicle sill rail (200) comprises: an extruded element designed for mounting on a vehicle (10) equipped with the vehicle sill rail (200), the extruded element comprising a first side (202), a second side (204) opposite the first side (202), and a top (206) and a bottom (208) extending between the first side (202) and the second side (204), the first side (202) extending along a battery cell (102) of the vehicle (10) when the extruded element is mounted on the vehicle (10), and the extruded element defining a venting chamber (212); and a cell vent (214) which is formed through the first side (202), wherein the cell vent (214) is designed such that, when the extruded element is attached to the vehicle (10), it fluidly connects the battery cell (102) and the vent chamber (212); characterized by the fact that a package vent (218) is formed through the underside (208), wherein the package vent (218) is designed such that, when the extruded element is mounted on the vehicle (10), it fluidically connects the vent chamber (212) with an exterior of the vehicle (10) on the underside (208); and (i) wherein, in the case of an extruded element mounted on the vehicle (10), a venting chimney (116) extends from the battery cell (102) through the cell vent (214) and at least partially into the venting chamber (212) to fluidically connect the battery cell (102) and the venting chamber (212); and / or (ii) wherein, when mounted on the vehicle (10), the extruded element extends along a first side (202) of the battery cell (102) and is connected to a front support (108) extending along a front of the battery cell (102), a rear support (110) extending along a rear of the battery cell (102), a top plate (104) extending along a top of the battery cell (102), and a bottom plate (106) extending along a bottom of the battery cell (102); and wherein the lower plate (106) comprises a sliding rail (112) which, when the extruded element is mounted on the vehicle (10), extends along a longitudinal axis of the extruded element, wherein the pack vent (218) is designed such that it fluidly connects the vent chamber (212) with an exhaust chamber (124) of the sliding rail (112).

Description

INTRODUCTION

[0001] The present invention relates generally to structural battery arrangements for vehicles and in particular to structural battery arrangements with cell-to-pack (CTP) and cell-to-body (CTB).

[0002] In particular, the invention relates to a vehicle sill rail according to the preamble of claim 1, which provides a longitudinal structural support for the battery assembly and a sill rail structure for the vehicle. The side support structure comprises one or more first vents configured such that they fluidically couple a vent chamber of the side support structure to one or more battery cells of the battery assembly, and one or more second vents configured such that they fluidically couple the vent chamber on a lower surface of the side support structure to the exterior of the vehicle.

[0003] A generic vehicle rocker panel is essentially described in US 2011 / 0 174 556 A1. Comparable vehicle rocker panel designs are described in German patents DE 10 2020 106 780 A1 and CN 215 244 365 U.

[0004] Battery-powered vehicles, such as electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs), are typically equipped with structural battery packs integrated into the vehicle's chassis or frame. These battery packs usually comprise multiple battery cells. Thermal runaway of the battery pack can occur when a single cell within the pack fails, for example, due to impact during a collision with another vehicle or a short circuit. In thermal runaway, the failure of one battery cell can lead to the failure of other battery cells, for example, because the additional cells are exposed to hot gas, flames, and particles ejected from the failed cell.

[0005] To reduce the impact of a failed battery cell on other battery cells in the battery assembly, a side support structure of the battery assembly includes an extruded element that defines a venting chamber. A first vent formed by the extruded element is designed to fluidically connect one or more battery cells of the battery assembly to the venting chamber, and a second vent formed by the extruded element is designed to fluidically connect the venting chamber to the exterior of the vehicle.During thermal runaway of a battery cell, hot gas, flames and / or particles emitted by the failed battery cell are directed away from the battery assembly through the first vent and venting chamber and from the second vent, thereby reducing or eliminating the impact of the failed battery cell on other battery cells in the assembly. SUMMARY

[0006] According to the invention, a vehicle sill rail is presented which is characterized by the features of claim 1.

[0007] Implementations of the invention may include one or more of the following optional features. In some embodiments, the cell vent and the pack vent are spaced apart from each other along a longitudinal axis of the extruded element. In some examples, the extruded element includes one or more guide vanes within the venting chamber between the cell vent and the pack vent.

[0008] In some embodiments, the vehicle sill rail further comprises a flood opening extending through the second side. This flood opening is designed such that, when the extruded element is mounted on the vehicle, it fluidly connects the vent chamber to the exterior of the vehicle on the second side. In further embodiments, the vehicle sill rail further comprises a collecting opening extending through the first side. This collecting vent is designed such that, when the extruded element is mounted on the vehicle, it fluidly connects a collecting area on the battery cell to a flood chamber of the extruded element. The flood opening is further designed such that, when the extruded element is mounted on the vehicle, it fluidly connects the flood chamber to the exterior of the vehicle on the second side.

[0009] In other examples, when the extruded element is mounted to the vehicle, a central support extends along a second side of the battery cell, opposite the first side. The central support defines a central venting chamber and includes a central cell vent designed to fluidically connect the battery cell and the central venting chamber, as well as a central pack vent designed to fluidically connect the central venting chamber to the exterior of the vehicle on a lower surface of the central support. In some aspects, a body panel is mounted to the second side when the extruded element is mounted to the vehicle.

[0010] Furthermore, a vehicle battery assembly is described. The vehicle battery assembly comprises a battery cell configured such that, when the battery assembly is attached to a vehicle equipped with the vehicle battery assembly, it supplies energy to a propulsion system of the vehicle. A front support extends along a front face of the battery cell. A rear support extends along the rear face of the battery cell opposite the front face of the battery cell. A top plate extends along a top face of the battery cell. The top face of the battery cell extends between the front and rear faces of the battery cell. A bottom plate extends along a bottom face of the battery cell opposite the top face of the battery cell. A first sill rail extends along a first side face of the battery cell.The first side of the battery cell extends between the front and back of the battery cell. A second sill rail extends along a second side of the battery cell opposite the first side. The first and second sill rails each comprise an extruded element that includes a first side, a second side opposite the first side, and top and bottom sections extending between the first and second sides. The first side extends along the respective side of the battery cell. The extruded element defines a vent chamber. Both the first and second sill rails have a cell vent running through the first side. The cell vent fluidically connects the battery cell to the vent chamber.Both the first and second sill rails incorporate a vent on their underside. The vent connects the ventilation chamber on the underside of the extruded element to the exterior of the vehicle. This feature may include one or more of the following optional features.

[0011] In some aspects, the cell vent and the pack vent are spaced apart along a longitudinal axis of the extruded element. In some implementations, the extruded element includes one or more baffles in the venting chamber between the cell vent and the pack vent. In some examples, a venting chimney extends from the battery cell through the cell vent and at least partially into the venting chamber to fluidically connect the battery cell and the venting chamber.

[0012] In some cases, the first and second sill rails each include a flood opening formed by the second side of the extruded element. The flood opening fluidically connects the vent chamber to the exterior of the vehicle on the second side of the extruded element. In other versions, the first and second sill rails each include a vent extending through the first side of the extruded element. The collector vent connects a collector area at the battery cell to a flood chamber of the extruded element. The flood opening connects the flood chamber to the exterior of the vehicle on the second side of the extruded element. In some implementations, where the vehicle battery is mounted on the vehicle, a corresponding vehicle body element is mounted to the second sides of the extruded elements.

[0013] Furthermore, a vehicle is described. The vehicle includes a battery assembly. The battery assembly includes a battery cell that supplies energy to a propulsion system of the vehicle. A front support extends along a front face of the battery cell. A rear support extends along the rear face of the battery cell opposite the front face of the battery cell. A top plate extends along a top face of the battery cell. The top face of the battery cell extends between the front and rear faces of the battery. A bottom plate extends along a bottom face of the battery cell opposite the top face of the battery cell. A first sill rail extends along a first side face of the battery cell. The first side face of the battery cell extends between the front and rear faces of the battery cell.A second sill rail extends along a second side of the battery cell opposite the first side. Both the first and second sill rails comprise an extruded element that includes a first side, a second side opposite the first, and top and bottom sections extending between the first and second sides. The first side extends along the respective side of the battery cell. The extruded element defines a vent chamber. Both the first and second sill rails have a cell vent running through the first side. The cell vent connects the battery cell and the vent chamber fluidically. Both the first and second sill rails include a pack vent on their underside. The pack vent connects the vent chamber on the underside to the exterior of the vehicle.This aspect may include one or more of the following optional features.

[0014] In some aspects, the extruded element includes one or more guide vanes within the venting chamber between the cell vent and the pack vent. In some implementations, the lower plate includes corresponding guide rails extending along the respective longitudinal axes of the extruded elements. The respective pack vents connect the venting chamber to the respective exhaust chambers of the guide rails.

[0015] The details of one or more implementations of the invention are set forth in the accompanying drawings and in the description below. Further aspects, features, and advantages will become apparent from the description and the drawings, as well as from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings described here serve only to illustrate selected designs. Fig. Figure 1 is a perspective top view of a battery arrangement for supplying a vehicle's drive system. Fig. 2 is a cross-sectional view along line 2-2 of the Fig. 1. Fig. 2A is an expanded view of area 2A of the Fig. 2. Fig. 2B is an expanded view of area 2B of the Fig. 2. Fig. 3A is a cross-sectional view along line 3-3 of the Fig. 1. Fig. 3B is another cross-sectional view along line 3-3 of the Fig. 1. Fig. Figure 4 is a lower perspective view of the battery arrangement. Fig. 5 is a cross-sectional view along line 5-5 of the Fig. 1. Fig. Figure 6 is another top perspective view of the battery arrangement. Fig. 7A is a perspective cross-sectional view of area 7 of the Fig. 6. Fig. 7B is another cross-sectional view of area 7 of the Fig. 6. Fig. Figure 8 is another upper perspective view of the battery arrangement; Fig. 9A is an enlarged view of the battery arrangement in area 9 of the Fig. 8, with the rear support removed from the battery assembly. Fig. 9B is an extended view of the rear support of area 9 of the Fig. 8. Fig. Figure 10 is a rear perspective view of the battery arrangement. Fig. Figure 11 is a perspective view of a vent stack of a battery cell in the battery assembly. Fig. Figure 12 is a cross-sectional view of a battery assembly with a vehicle body element attached to an outside of the side support of the battery assembly.

[0017] The corresponding reference symbols designate the corresponding parts in the drawings. DETAILED DESCRIPTION

[0018] Referring to the figures and the embodiments shown therein, a structural battery arrangement or battery pack 100 for supplying a drive system of a battery-powered vehicle 10, such as an electric vehicle (EV) or a plug-in hybrid vehicle (PHEV), comprises several battery cells 102, 102a-b, which are accommodated between an upper plate 104 and a lower plate 106 ( Fig. 1 and Fig. 2) In the example shown, the battery assembly 100 comprises a first battery cell (or a first row of battery cells) 102a and a second battery cell (or a second row of battery cells) 102b, wherein it is understood that the battery assembly 100 can comprise any number of battery cells 102 for powering the propulsion system of the vehicle 10. A front end carrier 108 extends along a front face of the battery cells 102 and seals a front end of the battery assembly 100, and a rear end carrier 110 extends along a opposite rear face of the battery cells 102 and seals a rear end of the battery assembly 100.As explained further below, the battery cells 102, the front end carrier 108 and the rear end carrier 110 are arranged between a first side carrier or sill rail 200, 200a and a second side carrier or sill rail 200, 200b, wherein the respective sill rails 200 represent longitudinal support elements for the battery arrangement 100 and can provide body sill rails along the respective sides of the vehicle 10.

[0019] When the battery assembly 100 is mounted on the vehicle 10, the upper plate 104 is connected to the sill rails 200 and extends between them and along the top of one of the battery cells 102 to form a floor of the vehicle body. This means that components for the vehicle cabin, such as rails 12 for attaching seats to the vehicle 10 and a vehicle wiring harness 14, can be arranged along an upper or outer side of the upper plate 104 and / or attached to the structural elements of the battery assembly 100. Similarly, the lower plate 106 is connected to the sill rails 200 and extends between them and along the underside of one of the battery cells 102 to provide a lower outer surface of the vehicle 10.For example, the lower plate 106 can include one or more guide rails 112 extending from a lower or outer side of the lower plate 106 to reduce damage to the battery assembly 100 and the vehicle 10 during driving in low-clearance situations. One or more thermal elements 114, such as a cooling plate, thermal adhesive, and the like, can be arranged between the battery cells 102 and the lower plate 106 and / or the upper plate 104 to improve heat transfer away from the battery cells 102 and thus improve the cooling of the battery assembly 100.

[0020] The front end support 108 and the rear end support 110 provide cell stack compression plates and are clamped between the first sill rail 200a and the second sill rail 200b. Since the first sill rail 200a and the second sill rail 200b act as body sill rails of the vehicle 10, the sill rails 200 seal the side walls of the battery assembly 100 and provide an advanced vehicle-wide structure. The front end support 108 and the rear end support 110 seal the front and rear walls of the battery assembly 100 and provide vehicle-wide load transfer. A section of the sill rails 200 can extend beyond the front end support 108 to provide an installation space 16, for example, for contactors, cables, and other components associated with the battery assembly 100.Optionally, it extends between the front end carrier 108 and the rear end carrier 110 parallel to a longitudinal axis A. 200 The sill rails 200 include a central longitudinal member 300 that separates the first battery cell 102a and the second battery cell 102b. The central member 300 is not present if the battery assembly 100 has only a single battery cell 102 (or a single row of battery cells). Thus, the structural battery system 100 may comprise only six or seven structural components that form the frame or box of the battery assembly 100. Although described here as a cell-to-body (CTB) system, the structural battery assembly 100 can be implemented as part of a cell-to-pack (CTP) or CTB drive system for electric vehicles (EVs).

[0021] With reference to the Fig. 2 and Fig. 2A The first sill rail 200a extends along the first side of the battery cells 102 and along the first side of the vehicle 10, and the second sill rail 200b extends along the second side of the battery cells 102 and along the second side of the vehicle 10. Although only one sill rail 200 is described below, the sill rails 200 on both sides of the battery assembly 100 may have similar structures and features.

[0022] As in Fig. As shown in Figure 2A, the sill rail 200 comprises an extruded element, such as an extruded aluminum element, with a first side 202, a second side 204 opposite the first side 202, and a top 206 and a bottom 208, each extending between the first side 202 and the second side 204. One or more internal structural elements 210 extend between the first side 202, the second side 204, the top 206, and the bottom 208. The first side 202 extends along and is connected to the battery cell 102, while the second side 204 extends along an outer surface of the vehicle 10. As discussed below, the sill rail 200 defines an inner ventilation chamber 212, which is bounded by one or more of the first side 202, the second side 204, the top 206, the bottom 208 and one or more of the inner structural elements 210.

[0023] One or more first vents or cell vents 214 are formed through the first side 202 and connect the vent chamber 212 and the battery cell 102. For example, the sill rail 200 can comprise one or more cell openings 214, each connected to a single battery cell 102. Each cell vent 214 comprises a first cell opening or opening 216 formed by the first side 202 of the sill rail 200, and a vent chimney 116 extending from the battery cell 102 through the cell opening 216 and along the cell vent 214, and at least partially into the vent chamber 212, to fluidically connect the vent chamber 212 and the battery cell 102.The vent 116 and / or the battery cell 102 on and near the vent 116 can be sealed to the first side 204 of the sill rail 200, for example by means of a sealing element, gasket, or adhesive element 118 surrounding the vent 116 between the first side 202 and the battery cell 102. A blow-molded seal or cap 120, e.g., a mica cap, can extend over one or more openings of the vent 116 to seal the battery cell 102 during normal use. During thermal runaway, a failure of the battery cell 102 can cause the blow seal 120 to burst, allowing hot gas, flames and / or particles (collectively referred to as exhaust gas) to flow from the battery cell 102 through the vent stack 116 and the cell vent 214 into the vent chamber 212.

[0024] One or more secondary vent openings or pack vents 218 are formed through the underside 208 and establish a fluid connection between the vent chamber 212 and the environment outside the vehicle 10 at the underside 208 of the sill rail 200. For example, the sill rail 200 can include one or more pack vents 218 corresponding to each individual battery cell 102a. Each pack vent 218 comprises a secondary pack opening or an opening 220 formed through the underside 208 of the sill rail 200 and a vent plug or vent nozzle 222, which extends along the pack vent 218 at least partially within the vent chamber 212 and outwards from the underside 208 to connect the vent chamber 212 to the exterior of the vehicle 10.

[0025] The extruded sill rail 200 comprises one or more guide plates or screens 224 within the venting chamber 212 between the cell vent 214 and the pack vent 218 to dampen or distribute the exhaust gases emitted by the battery cell 102. For example, and as shown in Fig. As shown in Figure 2A, passages 226 are formed by the guide vanes 224, and the guide vanes 224 extend between the underside 208 and the internal structures 210 to separate, isolate, or define fluidically connected turbulence zones 228 of the venting chamber 212. That is, the guide vanes 224 and other structures of the sill rail 200 provide a turbulence-inducing geometry to improve exhaust gas cooling and promote particle accumulation in the turbulence zones 228 as the exhaust gas flows through the venting chamber 212 and out of the pack vent 218. Furthermore, the vent openings 214 and the vent openings 218 are located along the longitudinal axis A. 200 the sill rail 200 are axially offset from each other in order to further dampen or shield the exhaust gases within the ventilation chamber 212.

[0026] Sections of the extruded sill rail 200, such as the internal structures 210 and a section of the top 206 at or near the cell vent 214, may have a greater thickness to reduce or eliminate the risk of the sill rail 200 melting at these sections during a failure. For example, a section of the top 206 between the vent chamber 212 and the high-voltage busbars (HV busbars) or the electrical terminals 122 of the battery cell 102 is thicker or reinforced to insulate exhaust gases from the high-voltage busbars 122, thereby reducing or eliminating the risk of high-voltage flashovers and the propagation of thermal runaway to other battery cells 102.

[0027] Therefore, the sill rails 200 incorporate the vent chamber 212 to provide the passage of exhaust gases between the battery cells 102 and the environment outside the vehicle 10. The passage between the cell vent 214 and the pack vent 218 includes a series of vented walls that form a baffle or silencer to disperse the blast energy and separate particles. These baffle passages are integrated into the structural side members 200 to isolate gases from the HV busbar 122 and reduce the risk of HV rollovers. In addition, each longitudinal member 200 incorporates a crush structure or crush zone 230 on the second side 204, enabling the longitudinal member 200 to function as a sill rail. In other words, the sill rails 200 provide progressive wall stiffness in side impacts to form an effective inner trough.

[0028] With reference to the Fig. 2B, Fig. 3A and Fig. 3B The longitudinal central support 300 can provide a similar venting function to the side supports 200 for an opposite side or a central area of ​​the battery cells 102. In examples with two or more rows of battery cells 102, the central support 300 extends along the second sides of the battery cells 102 opposite the sill rails 200 between the front end support 108 and the rear end support 110, with a longitudinal axis A 300 of the central support 300 parallel to the longitudinal axis A 200the sill rails 200 run. The central support 300 comprises an extruded element, for example, an extruded aluminum element, with a first side 302, a second side 304 opposite the first side 302, and a top 306 and a bottom 308, each extending between the first side 302 and the second side 304. One or more internal structures 310 can extend between the first side 302, the second side 304, the top 306, and the bottom 308. The first side 302 extends along and is connected to the first battery cell 102a, and the second side 304 extends along and is connected to the second battery cell 102b.As explained further below, the central support 300 defines a central venting chamber 312, which is bounded by one or more of the first side 302, the second side 304, the top 306, the bottom 308 and one or more of the internal structural elements 310.

[0029] One or more cell vents 314 are formed through the first side 302 to fluidically connect the central vent chamber 312 and the first battery cell 102a, and one or more cell vents 314 are formed through the second side 304 to fluidically connect the central vent chamber 312 and the second battery cell 102b. Each cell vent 214 comprises a cell opening or an opening 316 formed by the respective side of the central support 300, and a vent chimney 116 extending from the battery cell 102 through the cell opening 316 and along the cell vent 314 and at least partially into the central vent chamber 312 to fluidly connect the vent chamber 312 and the battery cell 102.

[0030] One or more packing vents 318 are formed through the underside 308 and fluidically connect the central vent chamber 312 and the environment outside the vehicle 10 at the underside 308 of the central support 300. Each packing vent 318 comprises a packing opening or an opening 320 formed by the underside 308 of the central support 300, and a vent plug 322 extending along the packing vent 318 and at least partially within the vent chamber 312 and outwards from the underside 308 to connect the vent chamber 312 with the exterior of the vehicle 10.

[0031] The extruded central support 300 includes one or more guide vanes 324 within the central venting chamber 312 between each cell vent 314 and the pack vent 318 to dampen or distribute the exhaust gases emitted by the battery cell 102. The guide vanes 324 include passages 326, and the guide vanes 324 separate, isolate, or define fluidically connected turbulence zones 328 of the central venting chamber 312. Furthermore, the cell vents 314 and the pack vents 318 (and the passages 326 through the guide vanes 324) are arranged along the longitudinal axis A 300 of the central support 300 axially offset from each other to provide additional damping or shielding of the exhaust gases within the central ventilation chamber 312 (the Fig. 3A and Fig. 3B) to provide. Parts of the extruded central support 300 have a greater thickness to reduce or eliminate the risk of the central support 300 melting during thermal runaway. For example, a section of the internal structure 310 between the central venting chamber 312 and the high-voltage busbar 122 of the battery cells 102 is thicker or reinforced to insulate the exhaust gas from the high-voltage busbar 122.

[0032] The central support 300 and the sill rails 200 thus provide exhaust gas passages between the battery cells 102 and the environment, thereby reducing or eliminating the effects of thermal runaway at one battery cell 102 on other battery cells 102 within the battery assembly 100. Furthermore, the central support 300 and the sill rails 200 provide structural support for the battery cells 102 when mounted on the vehicle 10. For example, the sill rails 200 include a strip or lip 232 extending from the first side 202 to support a lower surface of the battery cell 102, and the central support 300 also includes strips or lips 332 extending from the first side 302 and the second side 304 to support the lower surfaces of both battery cells 102.

[0033] As in the Fig. As shown in Figures 2-4, the ventilation openings 218 of the sill rail 200 and the ventilation openings 318 of the center support 300 are fluidically connected to the respective exhaust chambers 124, which are formed along the guide rails 112 of the lower plate 106. This means that the respective guide rails 112 of the lower plate 106, which extend along the longitudinal axis A 200 the sill rails 200 and along the longitudinal axis A 300The exhaust chambers 124 extend from the central support 300 and are fluidically connected to the respective vent chamber 212 and the central vent chamber 312 via the packing vents 218 of the sill rails 200 and the packing vents 318 of the central support 300. Corresponding openings 126 are formed through the guide rails 112 to fluidically connect the exhaust chambers 124 to the environment, and the openings 126 are axially offset from the respective packing vents 218 and 318. The end pieces 128 of the guide rails 112 can be sealed or closed to ensure that the exhaust gases are directed outwards from the packing vents 218 and 318 and from the openings 126, thus directing the exhaust gases downwards.When the exhaust gases escape from the packing vents 218, 318, the exhaust gases are further dampened in the exhaust chamber 124 of the guide rails 112 to prevent heat and particles from the exhaust gases from entering the environment, and thus to reduce or eliminate the risk of heat and particles affecting grass, oil and / or the road surface under the vehicle 10.

[0034] Furthermore, the guide rails 112 can protect the battery assembly 100 and the lower surfaces of the vehicle 10 in areas with low ground clearance. The end pieces 128 of the guide rails 112 can be inclined, angled, curved, or contoured to reduce the risk of the guide rail 112 snagging on obstacles under the vehicle 10, which could otherwise lead to damage or removal of the guide rail 112.

[0035] Referring to Fig. 5 is a flood opening 234 formed through the second side 204 of the sill rail 200 and fluidically connects the ventilation chamber 212 to the exterior of the vehicle 10 at the second side 204. The flood opening 234 can, for example, be accessible outside the vehicle 10, e.g., in a wheel arch area of ​​the vehicle 10. The flood opening 234 comprises an opening or a through-hole 236 formed through the second side 204 of the sill rail 200, and a flood plug or a flood nozzle 238 extending along the flood opening 234 and at least partially within the ventilation chamber 212 to fluidically connect the ventilation chamber 212 outside the vehicle 10 at the second side 204. The flood opening 234 is designed such that it can be connected to a water source, such as a water source.a coupling end of a hose can be connected to the vent chamber 212 to supply water to battery cell 102 during a fault event. For example, an emergency responder, such as a firefighter, can insert or attach the coupling end of a hose to the flood opening 234 to extinguish and / or cool a battery cell 102 experiencing thermal runaway. Since the vent chamber 212 extends along the sill rail 200, water can be directed from the flood opening 234 along the vent chamber 212 (and through corresponding passages 226 in the guide plates 224) and through one or more cell vents 214 to extinguish and / or cool one or more of the battery cells 102.

[0036] In some examples, one or more third vents or collecting vents 240 extend through the first side 202 and fluidically connect a flood chamber 242 and / or the vent chamber 212 of the extruded sill rail 200 with the collecting area 122 of the battery cell 102. The flooding opening 234 connects the flood chamber 242 to the outside of the vehicle 10, so that water can be simultaneously discharged to the one or more collecting vents 240 and the one or more cell vents 214. Supplying water to the collecting areas 122 of the battery cells 102 provides improved cooling and reduces the propagation of thermal breakdowns between the battery cells 102.

[0037] With reference to the Fig. 1 and 6-10, the structural integrity of the battery assembly 100 contributes to the structural integrity and safety of the vehicle 10, as the side members 200 provide the sill rail function of the vehicle 10. Accordingly, the upper plate 104, which extends over and along the battery cells 102 and the central member 300, and the lower plate 106, which extends under and along the battery cells 102 and the central member 200, are connected to the front end member 108, the rear end member 110, and the side members 200 to seal the battery assembly 100. For example, several mechanical fasteners 602, such as bolts or other suitable threaded fasteners, are arranged around the respective circumferential areas of the upper plate 104 and the lower plate 106 (and optionally along the central member 300) to connect the upper plate 104 and the lower plate 106 to the frame structure.The mechanical fasteners 602, which connect the lower plate 106 to the frame structure, can be positioned as close as possible to the battery cell 102 to improve the sealing of the battery cell compartment from the environment. For example, the mechanical fasteners 602 can extend at least partially through the lower plate 106 and the underside 208 of the sill rails 200 into the ventilation chamber 212 to form a tight seal between the lower plate 106 and the sill rail 200 on the first side 204 or as close as possible to it. This encourages the exhaust gases to flow through the cell's vent openings 214 into the ventilation chamber 212.

[0038] Since at least one section of the first side 204 of the sill rail 200 can be spaced away from the battery cell 102 to accommodate the collection area 122, reinforcements 604, such as ribs or additional sheets like custom-welded blanks, can also be arranged or formed along the upper plate 104 in areas of the upper plate 104 that correspond to the collection area 122. In other words, the reinforcing ribs 604 extend along or within the upper plate 104 in the areas corresponding to the collection area 122 and between the sill rail 200 and the battery cell 102. This prevents the upper plate 104 from detaching from the sill rail 200 and the battery cell 102 in the event of a vehicle impact.The reinforcing ribs 604 can be omitted on sections of the upper plate 104 corresponding to the mounted components such as the seat rails 12, so that the seat rails 12 can be rigidly screwed through the upper plate 104 to the side supports 200 and / or the center support 300.

[0039] To clamp the front end carrier 108 and the rear end carrier 110 between the sill rails 200, one or more slots 244 are formed through the sill rails 200 at corresponding positions for the end carriers. The front end carrier 108 and the rear end carrier 110 can each comprise cast structures, such as cast aluminum structures, with threaded holes formed at their respective ends for receiving threaded fasteners 602 extending through the slots 244. The slots 244 accommodate component tolerances. That is, due to the assembly sequence and the adhesive thicknesses, the slots 244 can accommodate forward and backward length changes of the stack resulting from the connection of the end carriers 108, 110 to the side carriers 200 after the battery cells 102 are arranged between the end carriers 200 and / or the center carrier 300.Width variations and thus distances between the battery cells 102 and the first side 202 of the side beams can be compensated for by the cell chimneys 116.

[0040] When the front end carrier 108 and the rear end carrier 110 are connected to the sill rails 200, the respective ends 346 of the center carrier 300 are received in the respective pockets or recesses 146 formed on the inner surfaces of the front end carrier 108 and the rear end carrier 110. That is, the front end carrier 108 and the rear end carrier 110 each comprise a recess 146 with a shape or profile that corresponds to the shape or profile of the end 346 of the center carrier 300. For example, the center carrier end 346 and the end carrier pocket 146 can form a geometric impression or a ball-and-socket joint with minimal play (e.g., 1 millimeter or less).This ensures that in the event of a frontal or rear impact of the vehicle, the load can be transferred via the central support 300, even if the vehicle 10 impacts at an angle or offset to the central support 300, thereby reducing the transfer of the impact load to the battery cells 102. Furthermore, the rear end support 110 can have a rib or pocket structure on an outer surface to create a shock-absorbing or crumple zone 148.

[0041] In some examples, and as in Fig.As shown in Figure 12, a vehicle body element or a bumper 1200 can be attached to the sill rail 200 on the exterior of the vehicle 10. The bumper 1200 is attached to the second side 204 of the sill rail 200, e.g., at the crumple zone 230, by means of threaded fasteners 602 or other suitable fasteners (e.g., clamps, adhesive, and the like). Since the sill rail 200 provides a structural component for the battery assembly 100, damage to the sill rail 200 can lead to significant repairs. Accordingly, the bumper 1200 is designed to absorb or attenuate low-intensity impacts on the side of the vehicle 10 and to reduce or prevent the transfer of load to the sill rail 200. This allows the bumper 1200 to be repaired and / or replaced after a vehicle impact, and avoids the risk of damage to the sill rail 200.

Claims

[1] Vehicle sill rail (200), wherein the vehicle sill rail (200) comprises: an extruded element designed for mounting on a vehicle (10) equipped with the vehicle sill rail (200), the extruded element comprising a first side (202), a second side (204) opposite the first side (202), and a top (206) and a bottom (208) extending between the first side (202) and the second side (204), the first side (202) extending along a battery cell (102) of the vehicle (10) when the extruded element is mounted on the vehicle (10), and the extruded element defining a venting chamber (212); and a cell vent (214) which is formed through the first side (202), wherein the cell vent (214) is designed such that, when the extruded element is attached to the vehicle (10), it fluidly connects the battery cell (102) and the vent chamber (212); characterized by , that a package vent (218) is formed through the underside (208), wherein the package vent (218) is designed such that, when the extruded element is mounted on the vehicle (10), it fluidically connects the vent chamber (212) with an exterior of the vehicle (10) on the underside (208); and (i) wherein, in the case of an extruded element mounted on the vehicle (10), a venting chimney (116) extends from the battery cell (102) through the cell vent (214) and at least partially into the venting chamber (212) to fluidically connect the battery cell (102) and the venting chamber (212); and / or (ii) wherein, when mounted on the vehicle (10), the extruded element extends along a first side (202) of the battery cell (102) and is connected to a front support (108) extending along a front of the battery cell (102), a rear support (110) extending along a rear of the battery cell (102), a top plate (104) extending along a top of the battery cell (102), and a bottom plate (106) extending along a bottom of the battery cell (102); and wherein the lower plate (106) comprises a sliding rail (112) which, when the extruded element is mounted on the vehicle (10), extends along a longitudinal axis of the extruded element, wherein the pack vent (218) is designed such that it fluidly connects the vent chamber (212) with an exhaust chamber (124) of the sliding rail (112). [2] Vehicle sill rail (200) according to claim 1, wherein the cell vent (214) and the pack vent (218) are spaced apart from each other along a longitudinal axis of the extruded element. [3] Vehicle sill rail (200) according to claim 1, wherein the extruded element comprises one or more guide plates (224) within the venting chamber (212) between the cell vent (214) and the pack vent (218). [4] Vehicle sill rail (200) according to claim 1, which further comprises a flood opening (234) formed through the second side (204), wherein the flood opening (234) is designed such that, when the extruded element is mounted on the vehicle (10), it fluidly connects the vent chamber (212) with the exterior of the vehicle (10) on the second side (204). [5] Vehicle sill rail (200) according to claim 4, which further comprises a collecting vent (240) formed through the first side (202), wherein the collecting vent (240) is configured such that, when the extruded element is attached to the vehicle (10), it fluidically connects a collecting area on the battery cell (102) with a flood chamber (242) of the extruded element, wherein the flood opening is further configured such that, when the extruded element is attached to the vehicle (10), it fluidly connects the flood chamber (242) with the exterior of the vehicle (10) on the second side (204). [6] Vehicle sill rail (200) according to claim 1, wherein, in the case of an extruded element mounted on the vehicle (10), a central support (300) extends along a second side of the battery cell (102) opposite the first side of the battery cell (102), wherein the central support (300) defines a central venting chamber (212) and comprises a central cell vent (214) configured to fluidically connect the battery cell (102) and the central venting chamber (212), and a central pack vent (218) configured to fluidically connect the central venting chamber (212) to the exterior of the vehicle (10) on a bottom side (308) of the central support (300). [7] Vehicle sill rail (200) according to claim 1, wherein, in the case of an extruded element mounted on the vehicle (10), a vehicle body element (1200) is mounted on the second side (204).

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