BATTERY HOLDER ARRANGEMENT WITH RAMP PLATE

Description

[0001] The present invention relates to a battery carrier arrangement of an electric motor vehicle according to the features of claim 1.

[0002] For many decades, passenger cars have been known from the state of the art, which use an internal combustion engine to transport people and light loads from one place to another.

[0003] In recent years, drive systems have increasingly shifted from combustion engines to electric drive systems. An electric drive requires an energy storage source, also known as a drive battery. However, in order for a passenger car weighing up to 7.5 tons, including payload, to carry a sufficient energy reserve, such drive batteries must be large in area and weigh up to several hundred kilograms.

[0004] For this purpose, the batteries or storage cells are usually housed in a so-called battery tray. It is advisable to place such a battery tray under the floor, i.e., below the passenger compartment. This gives the electric vehicle a low center of gravity, which has a positive effect on handling, especially when cornering.

[0005] In the event of a vehicle crash, it is important to protect the battery tray as much as possible to prevent mechanical damage to the storage cells contained within. On the one hand, there is a risk of fire, and on the other hand, replacing the storage cells involves considerable financial expense.

[0006] From DE 10 2022 126585 B3 a front protective cap is known which is arranged between a battery carrier and a front axle above a parting plane.

[0007] From US 2022 / 379963 A1, a battery carrier arrangement is also known which is supported on a front axle via support struts.

[0008] The object of the present invention is therefore to show a possibility of avoiding damage to a battery carrier as far as possible in certain driving situations, in particular in the event of a vehicle crash.

[0009] The above-mentioned object is achieved according to the invention in a battery carrier arrangement of an electric vehicle having the features in claim 1.

[0010] Advantageous embodiments are described in the dependent claims.

[0011] The battery carrier assembly is intended for an electric vehicle. The electric vehicle has a battery carrier arranged in the underfloor area of ​​the electric vehicle. The battery carrier is a battery box that extends, in particular, in the transverse direction of the vehicle over more than 50%, in particular more than 60%, preferably more than 70% of the vehicle width. The battery carrier preferably has a front that runs essentially in the transverse direction of the vehicle. The battery carrier is arranged in the underfloor area of ​​the electric vehicle.

[0012] Furthermore, the battery carrier assembly includes a front axle carrier, which can also be referred to as a motor axle carrier. The front axle carrier is designed, in particular, as a frame component and accommodates components of the front axle, thus securing or positioning the front axle below the body of the electric vehicle.

[0013] According to the invention, the battery carrier assembly is characterized in that a single-shell ramp plate extending or running in the longitudinal direction of the vehicle is arranged in a transition region from the front axle carrier to the battery carrier. Furthermore, according to the invention, the ramp plate is designed as a hot-formed and press-hardened component with a tensile strength Rm greater than 1200 MPa.

[0014] The ramp plate according to the invention performs two functions. In the event of a frontal crash, it reinforces the area and is coupled, in particular, to the front axle carrier and the battery carrier. It thus prevents the front axle carrier from penetrating the battery carrier. The ramp plate serves a second purpose: in the event of an impact with or driving over a ground obstacle, the ramp plate prevents the ground obstacle from penetrating the battery carrier head-on and damaging it. The ramp plate allows the ground obstacle to slide or deflect below the battery carrier, thus preventing further damage.

[0015] The ramp plate is coupled, in particular, to the front axle carrier and / or the battery carrier, in particular by screwing. This enables easy assembly of the ramp plate. By using hot forming and press hardening technology, thus providing a component made of high-strength, particularly ultra-high-strength steel, the ramp plate can be designed as a single-shell sheet metal component. This saves weight and production costs compared to other components that would require significantly more material and / or increased production effort.

[0016] The ramp plate itself is preferably made from a single-piece, uniform sheet metal blank. Alternatively, the ramp plate can be made from a tailor-welded blank, i.e., a sheet metal blank welded together from several different sheets of different thicknesses and / or sheet material qualities.

[0017] The ramp plate has a ramp surface that runs diagonally relative to the longitudinal direction of the vehicle, which in turn preferably extends across a large part of the width of the battery carrier. In particular, the ramp surface covers the entire front area of ​​the battery carrier that extends in the transverse direction of the vehicle.

[0018] Preferably, the ramp surface is arranged at an angle of 3° to 20° to a horizontal or longitudinal direction of the vehicle. This allows ground obstacles to be deflected downwards below the battery tray using the ramp surface.

[0019] Furthermore, coupling areas are particularly preferably formed. This particularly applies to recesses in the ramp plate. These can particularly preferably have a lower strength than the rest of the ramp plate. This increases ductility. In the event of an accident, these areas cannot tear off. However, the remaining areas of the ramp plate with high tensile strength provide appropriate stiffening in the event of an accident.

[0020] A front coupling surface and / or a rear coupling surface are arranged so as to run essentially parallel to the longitudinal direction of the vehicle or a plane spanned by the longitudinal direction and the transverse direction of the vehicle. This makes it possible to fasten the ramp plate below the front axle support and below the battery carrier. The ramp surface running between them then slopes downwards. The front surface below the front axle support and / or the rear surface below the battery carrier is each designed as a rectangle in plan view. The extension in the longitudinal direction of the vehicle is significantly shorter than the extension in the transverse direction of the vehicle. The extension in the transverse direction of the vehicle preferably corresponds to the width of the battery carrier. This in turn corresponds to a large part of the width of the vehicle itself.

[0021] Reinforcing beads can also be formed in the longitudinal direction of the vehicle, at least in sections of its length. Within the reinforcing beads 11, or preferably in flat sheet metal areas between the beads, coupling surfaces for the front axle support attachment and / or the aforementioned spacers can be provided. These are then formed in particular in the ramp area or the ramp surface of the ramp sheet. The ramp surface is thus further stiffened and allows ground obstacles to slide downwards beneath the vehicle.

[0022] Alternatively or additionally, reinforcement patches can be arranged on the ramp sheet. These are then placed on the side facing away from the substrate, i.e., on the inside of the ramp sheet, and are preferably hot-formed and press-hardened together with the ramp sheet.

[0023] It has also proven particularly advantageous if the ramp plate extends at least halfway under the front axle support in the longitudinal direction of the vehicle.

[0024] For further reinforcement, additional spacers can be placed between the inner side of the ramp plate and the front axle carrier under the battery tray. This also provides additional stiffening for the ramp plate.

[0025] A further aspect of the invention provides that a buffer element is arranged in the ramp plate in front of the battery tray in the longitudinal direction of the vehicle. The buffer element functions according to the principle of a crash box or stop. In the event of an underfloor frontal crash, i.e. a frontal crash that would affect the front of the battery tray in the longitudinal direction of the vehicle, energy is dissipated according to the functional principle of a crash box. For this purpose, for example, a hollow profile can be additionally arranged in front of the battery tray on the inside of the ramp plate. The hollow profile can simultaneously serve as a spacer and stiffening element. However, if the crash energy is so great that the ramp plate itself is deformed, the hollow profile acts as a crash box and protects the front of the battery tray.

[0026] The buffer element can also be designed as a stop. This supports the bolting of the ramp plate to the battery tray in the event of a frontal impact or frontal crash. The force acting in the longitudinal direction of the vehicle would otherwise lead to high loads, possibly leading to the ramp plate tearing off. The buffer element thus provides a stop, preventing the ramp element from being forced beneath the battery tray.

[0027] A battery carrier arrangement according to the invention interacts synergistically, particularly in conjunction with a sufficiently impact-protected battery carrier with integrated or mounted underrun protection, whereby the obstacle can slide further along the ramp plate under the battery carrier or its underrun protection.

[0028] Further advantages, features, properties, and aspects of the present invention are the subject of the following description. Preferred embodiments are illustrated in schematic figures. These serve to facilitate understanding of the invention. They show: Figure 1 shows a schematically simplified battery carrier arrangement according to the invention; Figure 2 shows a view from below of the battery carrier arrangement according to the invention; Figure 3a and b show a side view and a view from below of a modified ramp plate; Figure 4a and b show an alternative design variant of the ramp plate; Figure 5a and b show an alternative with a reinforcement patch; Figure 6 shows an alternative design variant; Figure 7a, b and c show an alternative design variant according to Figure 1 ; Figure 8 shows a further design variant with buffer element; Figure 9a, b and c various buffer elements and Figure 10 shows an alternative arrangement to Figure 1 .

[0029] In the figures, the same reference symbols are used for identical or similar components, even if a repeated description is omitted for reasons of simplification.

[0030] Figure 1shows a battery carrier arrangement 1 according to the invention in a simplified schematic side view. A front axle carrier 2 is shown, comprising cross members 2-2 and two longitudinal members 2-1 as well as a battery carrier 3 arranged behind it in the motor vehicle longitudinal direction X. With reference to the motor vehicle vertical direction Z, a ramp plate 4 is arranged below the battery carrier 3 and below the front axle carrier according to the invention, and the ramp plate 4 also has an inclined ramp surface 5. The ramp surface 5 lies at an angle α to the motor vehicle longitudinal direction X. A bollard or object (not shown in detail) coming from the front is thus diverted by the inclined ramp surface 5 below the battery carrier 3 or the vehicle is accordingly lifted upwards by the ramp surface. Damage to the battery carrier 3 is thus effectively avoided.For example, screw connections may be present on the front axle carrier, but also on the battery carrier 3, but at least over an area occupied by the battery cells or battery packs.

[0031] Likewise, the coupling surfaces for the preferably force-fitting and detachable fastening of the ramp plate to the front axle support are indicated, here as an example on the longitudinal members of the front axle support running in the longitudinal direction of the vehicle.

[0032] Figure 2 shows a view from below of the battery carrier arrangement 1 according to the invention. In the motor vehicle longitudinal direction X, the ramp plate 4 extends at least over half of the front axle carrier 2. In relation to the motor vehicle transverse direction Y, the ramp plate 4 preferably extends over the entire width of the battery carrier 3.

[0033] Figures 3a and bshow a side view and a bottom view of a modified ramp plate 4. The ramp plate 4 has a front ramp surface 5 and a rear coupling surface 10. The coupling surface 10 lies at least partially beneath a battery carrier 3 (not shown in detail) and runs essentially parallel to a horizontal line or the longitudinal direction X of the motor vehicle. Individual reinforcing beads 11 are arranged at the transition from the coupling area to the ramp surface 5. Furthermore, larger reinforcing beads 11 are arranged in the front area and extend at least in lengthwise sections in the longitudinal direction X of the motor vehicle over the ramp surface 5.

[0034] Figures 4a and bshow an alternative design variant of the ramp plate 4. Here, a reinforcement patch 13 is arranged on an inner side 14 of the ramp plate 4, in particular in the ramp surface 5. Furthermore, reinforcement beads 11 are arranged in the transition area between the ramp surface 5 and the coupling surface 10.

[0035] Figures 5a and b A reinforcement patch 13 is also arranged. However, this reinforcement patch 13 is arranged at a distance 15 from the ramp surface 5 of the ramp plate 4, forming one or more stiffening cavities. The reinforcement patch 13 can thus also function according to the principle of a crash box, so that a reinforcement 7 is provided to deflect an object. However, if the impact is of such high intensity that intrusion is to be feared, the reinforcement patch 13 would reinforce the ramp plate 4.

[0036] Figure 6shows an alternative design variant. Four so-called soft zones 16 are arranged in the ramp area. The soft zones are areas with lower tensile strength Rm and serve to dissipate energy and / or prevent cracks in coupling surfaces.

[0037] Figures 7a, b and c show a design variant according to Figure 1 However, according to Figure 7b or Figure 7c In each case a spacer 17 is arranged. According to the spacer 17 in Figure 7b Two individual spacers 17 are arranged one behind the other in the longitudinal direction X of the vehicle. Not shown in detail, but referring to the transverse direction of the vehicle, such an arrangement with spacers is then provided in the area of ​​the left side of the vehicle and in the area of ​​the right side of the vehicle. According to Figure 7cA spacer block is provided. Referring again to the left and right sides of the vehicle in the transverse direction Y of the vehicle, a spacer block can be arranged on each of the left and right sides. Furthermore, in all variants, a front longitudinal edge 18 and a rear longitudinal edge 19 can be formed. The longitudinal edges 18, 19 each preferably extend across the entire width of the ramp plate 4.

[0038] Instead of the local arrangement of the spacers, it would also be possible to arrange them continuously in the vehicle transverse direction from a left coupling surface to a right coupling surface, thus between the two front axle longitudinal members 2-1 according to Figure 2 to train progressively.

[0039] Figure 8shows a further design variant. Here, a buffer element 20 is arranged. The buffer element 20 can, for example, be a hollow profile. If an object impacts, it acts in the direction of force f on the ramp plate 4 or the ramp surface 5 of the ramp plate 4. If the intensity is so high, this object 6 would impact a front side 21 of the battery tray 3 and potentially damage it. The buffer element 20 is arranged here and functions according to the principle of a crash box.

[0040] Various buffer elements 20 are in Figure 9a, b and cThese can therefore be separately formed hollow profiles arranged on an inner side 14 of the ramp plate 4. The buffer elements 20 then deform in the event of a high-intensity impact between the object and the front side 21 of the battery carrier 3, thus protecting the battery carrier 3 in the event of non-discharge. Furthermore, the buffer elements 20 hold the ramp plate 4 in position in front of the battery carrier 3.

[0041] Figure 10 shows an alternative embodiment of the invention. It can be seen that a front and a rear coupling surface 10 of the ramp plate 4 extend parallel to the front axle support 2 and the vehicle's longitudinal axis.

[0042] The ramp plate 4 is connected to the front axle support 2 via indicated sleeves, starting from the coupling surface 10. The front axle support 2 can also have a shaped coupling surface 2-3, which is adapted to the shape and position of the sleeves or reduces the distance to the ramp plate 4.

[0043] Furthermore, in this example, the ramp plate is designed with its rear longitudinal edge 19 flush with the battery tray 3 in the vehicle's vertical direction. It is flush with the lower part or the floor or undercarriage of the battery tray. Any higher areas of the battery tray in the vehicle's vertical direction, such as a side crash frame, can be engaged from underneath by the ramp plate, which is reflected in the very schematic rectangular shape of the Figure 10 is not shown. Reference symbol:

[0044] 1 -Battery carrier arrangement 2 -Front axle carrier 3 -Battery carrier 4 -Ramp plate 5 -Ramp surface 6 -Object 7 -Screw connection 8 -Half to 2 9 -Width to 3 10 -Coupling surface 11 -Reinforcement bead 12 -Larger reinforcement bead 13 -Reinforcement patch 14 -Inside to 4 15 -Spacing 16 -Soft zone 17 -Spacer 18 -Front longitudinal edge 19 -Rear longitudinal edge 20 -Buffer element 21 -Front to 3 X - vehicle longitudinal direction Y - vehicle transverse direction Z - vehicle vertical direction α angle

Claims

1. A battery holder assembly (1) of an electric motor vehicle, having a battery holder (3) which is arranged in the underfloor region of the electric motor vehicle and a front axle holder (2), characterised in that, in the transition from the front axle holder (2) to the battery holder (3), a single-shell ramp plate (4), running in the motor vehicle longitudinal direction (X), is arranged as a hot-forming and press-hardening component with a tensile strength Rm greater than 1200 MPa and in that the ramp plate (4) has a ramp surface (5) running obliquely to the motor vehicle longitudinal direction (X).

2. The battery holder assembly (1) according to claim 1, characterised in that the ramp plate (4) has coupling regions for connection to the front axle holder (2) and / or battery holder (3), wherein the coupling regions preferably have a lower strength.

3. The battery holder assembly (1) according to claim 1 or 2, characterised in that the ramp plate (4) has a front longitudinal edge in the motor vehicle longitudinal direction (X) for connection to the front axle holder (2) and / or in that the ramp plate (4) has a rear longitudinal edge in the motor vehicle longitudinal direction (X) for connection to the battery holder (3), in particular the ramp plate is coupled at least flush with the battery holder in the motor vehicle longitudinal direction, particularly preferably the ramp plate (4) engages underneath the battery holder (3).

4. The battery holder assembly (1) according to any one of the preceding claims, characterised in that the ramp plate (4) is made from a single-piece sheet metal blank of uniform material or in that the ramp plate (4) is made from a tailored blank.

5. The battery holder assembly (1) according to any one of the preceding claims, characterised in that the ramp plate (4) has a surface which runs obliquely to the motor vehicle longitudinal direction (X) over a large part of the width (9) of the battery holder (3), preferably at an angle of 3 to 20 degrees.

6. The battery holder assembly (1) according to any one of the preceding claims, characterised in that a front coupling surface (10) and / or a rear coupling surface (10) are oriented running substantially parallel to the motor vehicle longitudinal direction (X).

7. The battery holder assembly (1) according to any one of the preceding claims, characterised in that at least one reinforcement bead (11) is formed in lengthwise sections in the ramp plate (4) running in the motor vehicle longitudinal direction (X).

8. The battery holder assembly (1) according to any one of the preceding claims, characterised in that at least one reinforcement patch (13) is arranged, preferably arranged, in particular coupled, on the side facing away from the substrate.

9. The battery holder assembly (1) according to any one of the preceding claims, characterised in that the ramp plate (4) extends in the motor vehicle longitudinal direction (X) to at least halfway below the front axle holder (2).

10. The battery holder assembly (1) according to any one of the preceding claims, characterised in that spacers (17) are arranged between an inner side of the ramp plate (4) and the front axle holder (2) and / or battery holder (3).

11. The battery holder assembly (1) according to any one of the preceding claims, characterised in that a buffer element (20) is arranged in front of the battery holder (3) on the inner side (14) of the ramp plate (4) in the motor vehicle longitudinal direction (X).