Utility vehicle having a battery case

Abstract

The invention relates to a utility vehicle, in particular a trailer (20) for coupling to a semitrailer tractor, comprising a chassis (21), which is formed by crossmembers and longitudinal members for example and on the bottom side (22) of which at least one, in particular two or three, trailer axles (23) are arranged, wherein at least one trailer axle (23) is equipped with an electric drive unit (25) for driving and decelerating the utility vehicle (20), and comprising at least one battery case (10), which is arranged on the bottom side (22), for accommodating at least one electric battery module. According to the invention, provision is made for the battery case (10) to be connected to the chassis (21), wherein the battery case (10) is mounted on the chassis (21) in such a way that it is mechanically decoupled from the chassis (21) of the trailer (20).

Description

[0001] Commercial vehicle with battery box

[0002] The invention relates to a commercial vehicle, in particular a trailer with a battery box according to the preamble of claim 1.

[0003] Trailers (also known as semi-trailers, semi-trailers, or semi-trailers) are used for transport and work purposes, for example, in freight transport or agriculture. For a long time, they were considered non-motorized commercial vehicles and are usually mounted and towed via a kingpin on the fifth wheel coupling of a diesel-powered tractor unit. Trailers have a chassis constructed from cross members and longitudinal beams and are usually multi-axle (usually two to three).

[0004] As electromobility continues to develop, concepts have emerged that equip the trailer with an additional drive unit to support the tractor unit. For example, one of the one, two, or three trailer axles can be equipped with an electric motor / gearbox unit. This opens up the possibility of supporting the tractor unit during propulsion and deceleration phases as needed, thus improving the overall energy efficiency of the commercial vehicle.

[0005] Due to the nature of the system, large, high-voltage battery modules are required to supply power to such a trailer. The HV battery modules must be securely mounted on the trailer's chassis.

[0006] In this context, particular space-related problems arise. Furthermore, battery storage must meet increased safety requirements due to the high-voltage components. Furthermore, the structural integrity of the battery box is subject to stringent requirements. The battery modules housed in the battery box must be effectively protected against environmental influences such as moisture and dust. The protection of the electrical components and the electromagnetic shielding of the electrical components require a very rigid structure. However, the trailer chassis has significantly greater flexibility in terms of requirements than the battery box. Torsionally flexible chassis, in particular, pose significant challenges for the connection of the rigid battery box.

[0007] The prior art proposes various design variants for battery boxes and fastening structures for receiving and fixing a battery box to the underside of a trailer chassis.

[0008] Among these, for example, embodiments are proposed that provide for a direct, material-to-material fixation of the battery box to the trailer chassis. Further, for example, designs can be identified that provide telescopic fastening elements for receiving the battery box directly on the trailer chassis in the vertical direction of the vehicle, by means of which the battery box is fixed to the trailer chassis.

[0009] However, the solutions proposed in the prior art have various disadvantages, particularly for trailers with electric support drives. For example, dynamic driving loads cause movements and / or twisting and / or vibrations on the trailer chassis, which are directly transmitted to the battery box. This leads, among other things, to destabilization of the entire battery box structure. Furthermore, the solutions proposed in the prior art for battery boxes are not sufficiently protected from environmental influences. Conversely, this also means that the environment around the battery box is equally exposed to the high-voltage components of the HV battery modules, for example, electromagnetic fields.

[0010] Furthermore, the proposed solutions are not rigid enough and are often relatively heavy, with the proposed battery boxes only being able to accommodate a certain predefined battery dimension. Due to the angular outer structure and the relatively large external dimensions of the battery boxes, the aerodynamic drag forces on the underside of the chassis increase. Furthermore, the battery boxes do not provide sufficient side impact or underrun protection and can deform significantly in an impact. This, in turn, can lead to the battery box being torn off the chassis.

[0011] The object of the present invention is therefore to overcome the disadvantages of the prior art and to provide an improved battery box for commercial vehicles and in particular for powered trailers.

[0012] Main features of the invention are defined in the characterizing part of claim 1. Embodiments are the subject of claims 2 to 20.

[0013] In a commercial vehicle, in particular in a trailer for coupling to a semitrailer tractor, comprising a chassis formed, for example, by cross members and longitudinal members, on the underside of which at least one, in particular two or three trailer axles are arranged, wherein at least one trailer axle is equipped with an electric drive unit for driving and decelerating the commercial vehicle or trailer, and at least one battery box arranged on the underside for receiving at least one electric battery module, it is provided according to the invention that the battery box is connected to the chassis, in particular to its longitudinal members, wherein the battery box is mounted on the chassis in such a way that it is mechanically decoupled from the chassis of the trailer.

[0014] Due to the inventive mounting of the battery box on the chassis, the battery box is mechanically decoupled from the remaining elements of the commercial vehicle. For this purpose, so-called silent bearings can be arranged between the chassis and the battery box. This prevents the transfer of dynamic driving loads to the battery structure. This leads to a significant increase in mechanical strength and stability in the area of ​​the battery box. At the same time, this measure improves the overall driving dynamics of the commercial vehicle or the powered trailer.

[0015] According to a preferred embodiment of the invention, the trailer has support legs on the underside of the chassis for coupling and uncoupling, with the battery box arranged in a space between the support legs and the trailer axle(s). The space is formed in particular between the frontmost trailer axle and the support legs in the vehicle's longitudinal and transverse directions. This space is particularly suitable for the arrangement of the battery box and for the connection to the electric drive from a space-saving perspective. The frontmost trailer axle refers to the axle of the trailer that is closest to the support legs in the vehicle's longitudinal direction. The battery box preferably extends in a vehicle's longitudinal direction such that essentially the entire space between the support legs and the frontmost trailer axle in the vehicle's longitudinal and transverse directions is filled by the battery box.

[0016] In this context, it is particularly preferred that the geometric dimensions of the battery box be adapted to the geometric dimensions of the chassis, and in particular to the geometric dimensions of the chassis' outer edges. This essentially takes into account all legal requirements, and in particular the ECE R-73 regulation published by the Economic Commission for Europe (ECE) regarding the requirements to be met by a side impact protection system. Preferably, the side impact protection system can be integrated into the battery box. This saves additional installation space and additionally reinforces the battery box on its sides.

[0017] According to a preferred embodiment, the battery box has a cage structure for accommodating electrical battery modules, wherein the cage structure is of modular design. Modularity within the meaning of the invention means, among other things, the division of the entire cage structure into individual modules which, with a suitable shape and function, can be joined together or interact via corresponding interfaces. This creates a modular system suitable for different battery dimensions. Conversely, this also means that individual modules of the cage structure can be replaced by alternative modules depending on the application. Modules that determine the basic framework or the outer frame of the cage structure can be retained, so that, for example, the size of the interior of the battery box in a vehicle vertical direction can be adapted cost-effectively and with relatively little effort.

[0018] The modular cage structure preferably comprises an upper frame made of transverse and longitudinal elements, with the modular cage structure having a lower frame made of transverse and longitudinal elements arranged parallel to the upper frame. Further preferably, the upper and lower frames of the modular cage structure are releasably secured to one another at corner regions by four corner cross members, with the corner cross members being arranged between the upper and lower frames and extending in the vertical direction of the vehicle.

[0019] The corner cross members can be modularly interchanged depending on battery capacity and energy requirements, with the upper and lower frames being universally applicable to any possible corner cross member. This allows, for example, shorter corner cross members to be used when fewer battery modules need to be accommodated.

[0020] Preferably, the modular cage structure has two longitudinal walls running in the vehicle's longitudinal direction when the frames and corner cross members are in the fixed state, and two transverse walls running in the vehicle's transverse direction when the frame and corner cross members are in the fixed state. The universally applicable upper and lower frames, the interchangeable corner cross members, and the longitudinal and transverse walls of the modular cage structure formed in the fixed state create a solid base frame and an interior space for accommodating the battery modules. At the same time, the corner cross members stiffen the frame structure of the battery box.

[0021] According to a further preferred embodiment, the invention provides that the modular cage structure has a front attachment structure to improve the aerodynamics of the trailer, wherein the front attachment structure is formed via an extension of the longitudinal walls. It is preferred that the front attachment structure and thus the extension on the longitudinal walls extend in the longitudinal direction of the vehicle up to the support feet. This counteracts increased air resistance forces and pressure gradients on the underside in the region of the flow-loaded transverse wall of the modular cage structure because fewer air flows and turbulences reach the flow-loaded transverse wall of the battery box through the front attachment structure. The flows are thus advantageously guided along the front attachment structure and the longitudinal walls of the modular cage structure.

[0022] According to a further preferred embodiment, the front attachment structure of the modular cage structure is formed by an upper and a lower frame extension which are detachably fixed to the longitudinal elements of the upper and lower frames, wherein the upper and lower frame extensions are fixed with shortened side wall elements. The shortened side wall elements are preferably arranged parallel to the corner cross members of the upper and lower frame extensions. The shortened side wall elements are preferably shorter in relation to the height of the corner cross members. This creates an inclined profile on the underside of the battery box, which further optimizes the aerodynamics and flow guidance. Due to the shorter design of the side wall element, the lower frame extension in particular extends not only in the longitudinal direction of the vehicle like the upper frame extension, but also in the vertical direction of the vehicle.Alternatively, additional shapes and elements can be incorporated into the front attachment structure and / or the relevant areas of the battery box to reduce aerodynamic drag. The front attachment structure, formed by upper and lower extensions, together with the longitudinal walls, simultaneously forms a reliable side impact and underrun protection system that complies with legal requirements.

[0023] In a further preferred embodiment, the modular cage structure has a rear attachment structure for accommodating and connecting auxiliary battery components. These can include, among others, power converters, voltage converters, control elements, battery management devices, etc. The rear attachment structure is preferably formed by an upper and a lower frame extension, which are releasably fixed to the longitudinal elements of the upper and lower frames, wherein the upper and lower frame extensions are releasably fixed to a rear attachment frame consisting of transverse and vertical elements. This advantageously creates a rear receiving area on the battery box, where the auxiliary battery components can be accommodated and stored and are largely protected from unwanted influences. In addition, the rear attachment structure further reinforces and stiffens the modular cage structure.Due to the selected positioning, the auxiliary units are advantageously located between the electric drive unit and the electric battery modules. This significantly simplifies the connection of the corresponding connecting cables. The rear attachment structure, formed by upper and lower frame extensions, together with the longitudinal walls and the front attachment structure, simultaneously forms a safe side impact and underrun protection system that complies with legal requirements. This protection extends particularly in the longitudinal direction of the vehicle between the trailer's support legs and the trailer axles.

[0024] In a further embodiment of the invention, the longitudinal elements of the upper and lower frames are releasably secured to one another by at least two, preferably at least three, sidewall cross members arranged centrally in the region of the longitudinal walls. The sidewall cross members are arranged between the upper and lower frames and extend in the vertical direction of the vehicle. The sidewall cross members stiffen the modular cage structure and additionally protect the battery modules arranged in the interior of the battery box in the area of ​​the side impact protection. The central arrangement in the region of the longitudinal walls proves to be particularly advantageous in terms of mechanical strength because the greatest bending stresses are to be expected in this area.

[0025] Preferably, all corner cross members and side wall cross members each have two reinforcing elements arranged at the connection points to the upper and lower frames, wherein the reinforcing elements are in particular triangular in shape. It is further preferred that the triangular reinforcing elements rest with one leg against the corner cross members and side wall cross members, while another leg of the triangular reinforcing elements rests against the upper and lower frames of the cage structure. Due to the reinforcing elements, the force introduction and transmission in the area of ​​the corner cross members and side wall cross members is particularly improved. The dynamically occurring loads can thus be transferred via the upper frame of the modular cage structure into the respective cross members without generating mechanical stress peaks at the transition areas.

[0026] In order to be able to stow the connecting cables in a compact and suitable manner without compromising the interior space for accommodating the battery modules, the modular cage structure preferably has at least two guide elements on each of its longitudinal walls for guiding and storing connecting cables, wherein the guide elements are releasably fixed to the side wall cross members of the longitudinal walls and to the longitudinal elements of the upper frame. The connecting cables are preferably arranged along the longitudinal and transverse walls and surround the battery modules arranged in the interior of the battery box. The connecting cables are preferably hook-shaped and arranged around the battery modules in such a way that the shortest path along the transverse and longitudinal walls in the direction of the rear attachment structure is selected from the respective battery module.In the area of ​​the rear attachment structure, the connecting cables can then be connected to the respective battery auxiliary units.

[0027] In order to reinforce the base of the battery box and create a stable foundation for supporting the battery modules and further stiffening the cage structure, the modular cage structure preferably has a central longitudinal member arranged parallel to the longitudinal elements of the lower frame, wherein the central longitudinal member rests and is fixed on the transverse elements of the lower frame at its end. Further preferably, the central longitudinal member is designed to be shaped to match the transverse elements of the lower frame at its end. As a result, the central longitudinal member can limit or partially enclose the lower frame in the vehicle's vertical and longitudinal directions and rest on the lower frame. When the central longitudinal member is fixed, a tight fit is created via corresponding surface pressures.The central longitudinal member divides the interior of the battery box into two equal-sized areas for the modular accommodation of the battery modules between the provided cross members.

[0028] According to a preferred embodiment of the invention, at least one additional sidewall cross member is arranged centrally in the region of the transverse walls of the modular cage structure, wherein the sidewall cross members are releasably fixed to the transverse and longitudinal elements of the upper and lower frames perpendicular to and aligned in the vehicle's transverse direction with the central longitudinal member. The additional sidewall cross members particularly stiffen the transverse walls of the cage structure. A single sidewall cross member is sufficient because the transverse walls are already relatively short and therefore have greater rigidity. This saves material and manufacturing costs. At the same time, the overall weight of the cage structure is reduced as a result of this savings.

[0029] According to a further preferred embodiment of the invention, the modular cage structure has at least two lateral longitudinal members which are arranged parallel and adjacent to the longitudinal elements of the upper frame, wherein the lateral longitudinal members rest on the transverse elements of the upper frame at their ends and are fixed. Further preferably, the lateral longitudinal members are designed to be shaped to match the transverse elements of the upper frame at their ends. As a result, the lateral longitudinal members can delimit the upper frame in the vehicle's vertical and longitudinal direction and rest partially enclosing it on the upper frame. The lateral longitudinal members are advantageously suitable for fixing purposes on the underside of the chassis and support the majority of the battery box or the modular cage structure.The laterally offset arrangement of the side longitudinal members relative to the center longitudinal member creates a mechanical balance and further strengthens the modular cage structure in the area of ​​the longitudinal walls. Preferably, the center and side longitudinal members of the modular cage structure can be more solid than the corner and side wall cross members.

[0030] The modular cage structure preferably provides at least eight, preferably at least sixteen, cross members for modularly accommodating and securing the electric battery modules. These cross members extend in the transverse direction of the vehicle and are releasably fixed to the corner members and / or the side wall members. The cross members are preferably arranged at constant intervals in the vertical direction of the vehicle.

[0031] This allows the battery modules to be secured to the sides of the cross members and stacked on top of each other. Overall, the large number of cross members, sidewall cross members, and corner cross members creates a very rigid cage structure that forms a mechanical framework. The battery modules positioned in the interior are effectively protected by the mechanical framework structure in the event of an impact.

[0032] It is particularly preferred that the cross members extend in the transverse direction of the vehicle up to the central longitudinal member, with the central longitudinal member having at least two side wall cross members for securing the cross members. This preferred configuration makes the cross members shorter in the transverse direction of the vehicle, thereby further stiffening the entire modular cage structure. The two side wall cross members of the central longitudinal member are preferably arranged opposite two side wall cross members of the longitudinal walls. This distributes the forces more evenly, and the cross members are guided straight and cleanly parallel to the transverse elements of the upper and lower frames.

[0033] According to a preferred embodiment of the invention, the central longitudinal member and the lateral longitudinal members are identical to one another. Preferably, all four corner cross members of the modular cage structure are identical to one another. Further preferably, all side wall cross members of the modular cage structure are identical to one another. This primarily supports simple production and assembly of the battery box. Because the respective modules or elements are identical to one another, no special positioning or pre-adjustment is required during assembly. At the same time, manufacturing effort and costs are saved. This also opens up the possibility of equipping the modular cage structure with additional cross members as required or of deliberately omitting cross members.

[0034] Preferably, the modular cage structure is secured to a side of the lower frame and the central longitudinal member facing away from the underside of the chassis with a sheet metal plate. The sheet metal plate has openings on its side facing the underside for securing additional cage structure elements. The sheet metal plate is preferably arranged perpendicular to the transverse and longitudinal walls of the modular cage structure and forms a floor for the battery box. The openings are advantageous for securing purposes because the lowest cross members for accommodating the battery modules can also be secured to the sheet metal plate. At the same time, the sheet metal plate creates a secure foundation for the interior of the cage structure.

[0035] According to a further preferred embodiment, the modular cage structure has a cover side parallel to the sheet metal plate. In this context, it is particularly preferred that the cover side, the longitudinal and transverse walls, and the front and rear attachment structure of the modular cage structure are covered with a sheet metal cladding. This measure ensures all-round protection of the battery box or the modular cage structure. The sheet metal cladding forms a closed interior, which advantageously ensures optimal shielding of the battery box and protects the interior and the battery modules arranged therein from, among other things, dirt, moisture, dust, heat, UV radiation, vibrations, etc. The sheet metal cladding additionally protects the battery modules from side impacts. Furthermore, the sheet metal cladding creates a so-called Faraday cage.A Faraday cage is a completely enclosed enclosure made of an electrical conductor (in this case, a sheet metal casing) that acts as an electrical or electromagnetic shield. In the presence of external static or quasi-static electric fields, the interior remains free of the field due to the induction effect. In the case of time-varying processes such as electromagnetic waves, the shielding effect is based on the eddy currents that form in the conductive sheet metal casing, which counteract the external electromagnetic field. This also significantly protects the environment around the battery box from electromagnetic radiation and other influences. Otherwise, the environment around the battery box would be exposed to strong electromagnetic radiation due to the high-voltage components in the interior.In addition, the sheet metal cladding, particularly in the area of ​​the longitudinal walls of the modular cage structure, ensures that the legal requirements for side impact protection are met. Preferably, the sheet metal cladding can comprise at least one lightweight metal material. Further preferably, the modular cage structure and all of its individual modules can comprise at least one lightweight metal material. This not only improves the shielding effect but also optimizes the weight of the battery box.

[0036] To achieve optimal electromagnetic shielding and simultaneously protect the interior of the battery box from external influences, one embodiment of the invention preferably provides for the sheet metal cladding and the cage structure to be additionally sealed at all interfaces and contact points. The relevant areas are preferably sealed with a weather-resistant adhesive sealant, in particular Sikaflex. This ensures that the structure remains securely sealed despite elevated humidity and severe weather conditions. Alternatively, body sealing tape can also be used for sealing at the relevant locations.

[0037] According to a further important embodiment of the invention, the modular cage structure is designed so that it can be suspended from the longitudinal members of the chassis, wherein, when the cage structure is suspended, the distance between the lateral longitudinal members in the transverse direction of the vehicle is greater than the distance between the two longitudinal members of the chassis. This type of design is particularly suitable from a structural and mechanical point of view. Because the chassis of trailers have several cross members between their longitudinal members, the installation space is correspondingly limited. Due to the greater distance between the lateral longitudinal members, the battery box can be suspended and secured to the chassis via the lateral longitudinal members.

[0038] To securely suspend and secure the modular cage structure or the battery box, at least three, preferably at least four, fixing elements are preferably provided on the side longitudinal members of the chassis, wherein the fixing elements are distributed in the vehicle's longitudinal direction and arranged at equal intervals on the side longitudinal members. It is preferred that the fixing elements are arranged on the side longitudinal members opposite one another on an axis along the vehicle's transverse direction. It is preferred that each of the fixing elements has at least four claws, wherein the claws at least partially engage around the side longitudinal members. The partially engaging claws of the fixing elements ensure a particularly secure and firm fit of the fixing elements on the side longitudinal members.Because the individual fixing elements are fixed opposite each other and at equal distances on the side longitudinal members, a uniform mechanical suspension on the longitudinal members of the chassis is created.

[0039] In this context, it is further preferred that receiving profiles corresponding to the fixing elements are fixed to the longitudinal members of the chassis, wherein the receiving profiles are arranged parallel to the underside and extend from the longitudinal members of the chassis in the direction of the longitudinal walls. Preferably, support plates corresponding to the receiving profiles are fixed to the fixing elements, wherein the support plates are arranged parallel to the underside of the chassis and extend from the fixing elements in the direction of the longitudinal members of the chassis. Because the receiving profiles and the support plates protrude towards one another, secure storage and suspension via the support plates of the fixing elements is achieved. When hanging the cage structure, the support plates can be placed and fixed onto silent blocks easily and quickly, as well as in a form-fitting manner, thanks to their special arrangement.This ensures that the weight of the entire battery box is evenly distributed across the fixing elements and the side longitudinal members, minimizing the transmission of vibrations and oscillations.

[0040] According to a preferred embodiment, the support plates have stiffening struts on their upper sides, with the support plates being attached to the fixing elements via lateral grooves running in the transverse direction of the vehicle. Preferably, the fixing elements have slot-shaped recesses corresponding to the lateral grooves of the support plate. This effectively simplifies the assembly and adjustment of the support plates.

[0041] To ensure simple and secure mechanical decoupling of the battery box from the trailer chassis, a preferred embodiment of the invention provides for silent blocks for mechanical decoupling of the battery box to be fixed in the receiving profiles, with the support plates being positively placed on the silent blocks and releasably fixed to them. Silent blocks are relatively inexpensive connecting elements and are particularly well suited for the present mounting arrangement. They typically have an intermediate layer of rubber. This effectively dampens the movements and vibrations that occur between the battery box and the trailer chassis during driving. In contrast to a so-called silent bushing (also called rubber bearing), silent blocks do not contain pivot bearings and therefore do not allow any rotational movement between the connected parts.Preferably, the silent blocks have a base plate for insertion into the receiving profiles.

[0042] The receiving profiles preferably have a receiving plate and two side skirts, wherein the side skirts have slot-shaped recesses that are formed perpendicular to the longitudinal members of the chassis. Via the slot-shaped recesses, the receiving profiles can be positively inserted and fixed in the transverse direction of the vehicle onto a suitable section of the longitudinal members of the chassis. This creates a firm fit of the receiving profiles on the longitudinal members. The receiving profiles can preferably be a welded construction. Further preferably, the base plates of the silent blocks rest on the receiving plates of the receiving profiles and are detachably fixed to them, wherein the base plates extend in particular in the vertical direction of the vehicle and are more solid than the receiving plates of the receiving profiles.The base plates of the silent blocks stabilize the mounting and provide a solid foundation for the mounting of the support plates and fixing elements. They increase the mechanical strength values ​​in the area of ​​the battery box's mounting.

[0043] According to a further preferred embodiment, the electric battery modules are HV traction battery modules, whereby the HV traction battery modules can realize operating voltages of at least 600 V, preferably at least 800 V. Commercial vehicles have a very high system weight, which is why powerful high-voltage traction battery modules must be used to ensure sufficient energy supply to the electric traction drive. At the same time, the current intensity during charging and / or discharging of the battery modules can be reduced in phases due to the high voltage level. Avoiding current peaks has a particularly positive effect on the stress factor of the battery modules, thereby protecting the battery modules as much as possible. Overall, this measure can have a positive effect on the service life of the battery modules, depending on the route profile and trailer load.According to a preferred embodiment of the invention, the HV traction battery modules are fixed to the cross members in the vertical direction of the vehicle and arranged stacked one above the other, with each of the HV traction battery modules having an energy capacity of at least 30 kWh, preferably at least 33.33 kWh. Given the limited installation space on the underside of the chassis and the current state of development of battery technology, this provides sufficient electrical energy for the trailer drive.

[0044] According to another preferred embodiment, the modular cage structure can accommodate up to three levels stacked vertically in the vehicle's vertical direction, each with up to six HV traction battery modules. Preferably, each of the HV traction battery modules can have an energy capacity of at least 33.33 kWh.

[0045] According to a preferred specific embodiment, the invention provides that the modular cage structure has three levels stacked one above the other in the vertical direction of the vehicle, each with six HV traction battery modules per level. It is preferred that the total of eighteen HV traction battery modules have a total energy capacity of 600 kWh. Each individual HV traction battery module of the total of eighteen HV traction battery modules preferably has an energy capacity of 33.33 kWh. In this embodiment, a total of four corner cross members, ten side wall cross members (namely, six side wall cross members on the longitudinal walls and four side wall cross members at the level of the central longitudinal member), and sixteen cross members are provided. The cross members preferably extend between the longitudinal walls and the central longitudinal member. This configuration ensures full and optimal utilization of the available installation space.This provides sufficient energy capacity for fully loaded trailers. This configuration also achieves maximum rigidity because the maximum number of cross members is installed.

[0046] According to another preferred specific embodiment, the modular cage structure has two levels stacked one above the other in the vertical direction of the vehicle, each with five HV traction battery modules per level. It is preferred that the ten HV traction battery modules have a total energy capacity of 300 kWh. Each individual HV traction battery module of the total of ten HV traction battery modules preferably has an energy capacity of 30 kWh. This configuration highlights the advantageous modularity of the invention. According to this embodiment, the corner cross members and side wall cross members are preferably shorter in the vertical direction of the vehicle. This saves installation space and material costs.The upper and lower frames are preferably designed for universal use, meaning the elements of the upper and lower frames of the modular cage structure are adopted for any possible battery box height and are used regardless of the size of the cross members. Since the structure remains unchanged in the vehicle's longitudinal direction, the center and side longitudinal members can also be adopted. This configuration is suitable, for example, for use in smaller commercial vehicles or trailers. Furthermore, the configuration could be used for trailers that are regularly half-loaded.

[0047] Further features, details, and advantages of the invention will become apparent from the wording of the claims and from the following description of exemplary embodiments with reference to the drawings. They show:

[0048] Fig. 1. a schematic side view of a trailer according to the invention with a battery box;

[0049] Fig. 2a is a schematic oblique view of a modular cage structure of the battery box of Fig. 1;

[0050] Fig. 2b is a schematic oblique view of the modular cage structure of Fig. 2a with integrated battery modules;

[0051] Fig. 3a is a schematic oblique view of an alternative embodiment of a modular cage structure;

[0052] Fig. 3b is a schematic oblique view of the cage structure of Fig. 3a with integrated battery modules;

[0053] Fig. 4 is a schematic oblique view of the modular cage structure of Fig. 2b with sheet metal cladding applied;

[0054] Fig. 5a is a schematic representation of a receiving profile for suspending the battery box; Fig. 5b is a schematic representation of a silent block inserted into the receiving profile of Fig. 5a for suspending the battery box;

[0055] Fig. 5c is a schematic representation of a fixing element with a mounting plate for suspending the battery box.

[0056] Fig. 1 shows a trailer, generally designated 20, and a battery box, generally designated 10, positioned on a chassis 21 of the trailer 20.

[0057] The trailer 20 extends in a vehicle longitudinal direction L and comprises a chassis 21 formed by cross members and longitudinal members. The battery box 10 is mounted on the longitudinal members of the chassis 21 and is mechanically decoupled from the trailer 20 and the chassis 21. On an underside 22 of the chassis 21, next to the battery box 10, three trailer axles 23 are arranged. The middle of the three trailer axles 23 is equipped with an electric drive unit 25 for driving and decelerating the trailer 20. In addition, the trailer 20 has support feet 24 for coupling and uncoupling the trailer 20 on the side of the battery box 10 opposite the trailer axles 23, the battery box 10 being arranged in a space between the support feet 24 and the trailer axles 23.As can be seen, the battery box 10 is positioned between the frontmost of the three trailer axles 23 and the support feet 24 and essentially fills this space completely.

[0058] The battery box 10 has a longitudinal wall S3, which transitions into a front attachment structure 30 and a rear attachment structure 40. Furthermore, the battery box 10 comprises a modular cage structure 1 for accommodating electrical battery modules.

[0059] By adding Fig. 2a and Fig. 2b, the details of the modular cage structure 1 and the exact arrangement of the electric battery modules become apparent.

[0060] Fig. 2a illustrates the basic design of the cage structure 1 without inserted battery modules. The modular cage structure 1 has an upper frame 2 made of transverse and longitudinal elements, wherein the modular cage structure 1 has a lower frame 3 made of transverse and longitudinal elements arranged parallel to the upper frame 2. The upper and lower frames 2, 3 of the modular cage structure 1 are releasably fixed to one another at their corner regions by four corner cross members 7, wherein the corner cross members 7 are arranged between the upper and lower frames 2, 3 and extend in the vehicle's vertical direction H.

[0061] In the fixed state, the modular cage structure 1 has two longitudinal walls S3, S4 running in the vehicle's longitudinal direction L and two transverse walls S1, S2 running in the vehicle's transverse direction Q. The dimensions of the transverse and longitudinal walls S1, S2, S3, S4 are selected such that the geometric dimensions of the battery box 10 are adapted to the geometric dimensions of the chassis 21 and in particular to the geometric dimensions of the chassis outer edges.

[0062] The modular cage structure 1 has a front attachment structure 30 for improving the aerodynamics of the trailer 20, which is formed by an extension of the longitudinal walls S3, S4. The front attachment structure 30 of the modular cage structure 1 is formed by an upper and a lower frame extension 31, 33, which are detachably attached to the longitudinal elements of the upper and lower frames 2, 3. The upper and lower frame extensions 31, 33 are fixed with shortened side wall elements 32. As can be seen, the shortened side wall elements 32 are arranged parallel to the corner cross members 7 of the upper and lower frame extensions 31, 33. Due to the shorter design of the side wall element 32, the lower frame extensions 33 of the longitudinal walls S3, S4 also extend in the vehicle's longitudinal and vertical directions L, H.

[0063] The modular cage structure 1 further comprises a rear attachment structure 40 for accommodating and connecting auxiliary battery units. These can include, among others, power converters, voltage converters, control elements, battery management devices, etc. The rear attachment structure 40 is formed by an upper and a lower frame extension 41, 43, which are releasably fixed to the longitudinal elements of the upper and lower frames 2, 3. The rear attachment structure also comprises a rear attachment frame 44, which is arranged parallel to the transverse wall S2 and is releasably fixed to the upper and lower frame extensions 41, 43.

[0064] The longitudinal elements of the upper and lower frames 2, 3 are releasably secured to one another by three side wall cross members 8 arranged centrally in the region of the longitudinal walls S3, S4. The side wall cross members 8 are arranged vertically between the upper and lower frames 2, 3 and extend in the vehicle's vertical direction H. The side wall cross members 8 are arranged on the longitudinal walls S3, S4 on an axis opposite one another. Two reinforcing elements 14 are provided on the corner cross members 7 and side wall cross members 8 at the connection points to the upper and lower frames 2, 3, wherein the reinforcing elements 14 are triangular in shape. The triangular reinforcing elements 14 each rest with one leg against the corner cross members 7 and side wall cross members 8, whereas another leg of the triangular reinforcing elements 14 rests against the upper and lower frames 2, 3 of the modular cage structure 1.

[0065] For receiving and guiding connecting cables of the battery modules, the modular cage structure 1 preferably has at least two hook-shaped guide elements 9 on each of its longitudinal walls S3, S4, wherein the guide elements 9 are detachably fixed to the side wall cross members 8 of the longitudinal walls S3, S4 and to the longitudinal elements of the upper frame 2.

[0066] Furthermore, the modular cage structure 1 has a central longitudinal member 5, which is arranged parallel to the longitudinal elements of the lower frame 3 and divides the interior of the battery box into two equal areas. The central longitudinal member 5 rests on the transverse elements of the lower frame 3 at its end and is detachably fixed to them. The central longitudinal member 5 is shaped to match the transverse elements of the lower frame 3 at its end. A further side wall cross member 8 is arranged centrally in the area of ​​the transverse walls S1, S2 of the modular cage structure 1, wherein the side wall cross members 8 are detachably fixed to the transverse and longitudinal elements of the upper and lower frames 2, 3, perpendicular to the central longitudinal member 5 and aligned in the vehicle transverse direction Q.

[0067] The modular cage structure 1 further comprises two lateral longitudinal members 6, which are arranged parallel and adjacent to the longitudinal elements of the upper frame 2, wherein the lateral longitudinal members 6 rest on the transverse elements of the upper frame 2 at their ends and are releasably fixed. The lateral longitudinal members 6 are shaped to match the transverse elements of the upper frame 2 at their ends. As can be seen, the central longitudinal member 5 and the lateral longitudinal members 6 of the modular cage structure 1 are more solid than the corner and side wall cross members 7, 8 and than the frame elements of the upper and lower frames 2, 3. The central longitudinal member 5 and the lateral longitudinal members 6 are identical to one another. The modular cage structure 1 further comprises a sheet metal plate 4 on a side of the lower frame 3 and the central longitudinal member 5 facing away from the underside 22 of the chassis 21.The sheet metal plate 4 is provided with openings 13 on its side facing the underside 22 for securing additional cage structure elements. The sheet metal plate 4 is arranged perpendicular to the transverse and longitudinal walls S1, S2, S3, S4 of the modular cage structure 1 and forms a base for the battery box 10. Parallel and opposite the sheet metal plate 4, the modular cage structure 1 has a cover side S5.

[0068] Furthermore, the modular cage structure 1 is designed to be suspended from the longitudinal members of the chassis 21 and, for this purpose, has four fixing elements 60 on each of the lateral longitudinal members 6. The fixing elements 60 are distributed in the vehicle's longitudinal direction L and arranged at equal intervals on the lateral longitudinal members 6. The fixing elements 60 are arranged opposite one another on the lateral longitudinal members 6 along the vehicle's transverse direction Q on an axis.

[0069] A combined view of Fig. 2a and Fig. 2b reveals that the modular cage structure for accommodating and securing the electric battery modules comprises sixteen cross members 12, which extend in the vehicle transverse direction Q and are releasably secured to the corner members 7 and / or to the side wall members 8. The cross members 12 are arranged at constant intervals in the interior of the cage structure 1 in the vehicle vertical direction H.

[0070] The battery modules are high-voltage traction battery modules 50 (HV traction battery modules for short). The HV traction battery modules 50 are releasably fixed laterally with their transverse sides to the crossbeams 12 and arranged stacked one above the other. The crossbeams 12 each extend to the central longitudinal member 5. For this reason, two additional vertical sidewall crossbeams 8 are arranged on the longitudinal member 5 in order to fix the crossbeams 12. The two additional sidewall crossbeams 8 of the central longitudinal member 8 are arranged opposite two sidewall crossbeams 8 of the longitudinal walls S3, S4. The two additional sidewall crossbeams 8 are not visible in Fig. 2b due to the HV traction battery modules 50. They can be partially seen in Fig. 2a.

[0071] As can be seen in Fig. 2b, the modular cage structure 1 has three levels stacked one above the other in the vehicle's vertical direction H, each with six HV traction battery modules 50 per level. Each individual HV traction battery module 50 of the total of eighteen HV traction battery modules 50 has an energy capacity of 33.33 kWh in the illustrated embodiment. This results in a total energy capacity of 600 kWh. Furthermore, connecting cables 51 are arranged along the longitudinal and transverse walls of the modular cage structure 1, surrounding the HV traction battery modules 50 arranged in the interior of the battery box.

[0072] The modularity of the battery box 10 is illustrated in a joint view of Fig. 3a and Fig. 3b. The figures show a modular cage structure 1 that is shorter in the vehicle's vertical direction H. With the exception of the side wall cross members 8 and the corner cross members 7, each individual module element described above is adopted in a modular and identical manner from the embodiment of Fig. 2a and Fig. 2b. Only the corner cross members 7 and the side wall cross members 8 are shorter in the vehicle's vertical direction H according to this exemplary embodiment.

[0073] As particularly illustrated in Fig. 3b, the modular cage structure 1 has two levels stacked one above the other in the vehicle's vertical direction H, each with five HV traction battery modules 50 per level. In the exemplary embodiment shown, each individual HV traction battery module 50 of the total of ten HV traction battery modules 50 has an energy capacity of 30 kWh. This results in a total energy capacity of 300 kWh. Furthermore, connecting lines 51 are arranged along the longitudinal and transverse walls of the modular cage structure 1 and guided through the guide elements 9. The connecting lines 51 are guided through the guide elements 9 in such a way that they surround the HV traction battery modules 50 arranged in the interior of the cage structure 1.

[0074] Fig. 4 shows the embodiment shown in Fig. 2b with an additional sheet metal cladding. The HV traction battery modules 50 are placed inside the battery box 10 or the modular cage structure 1. As can be seen, the transverse walls S1, S2, the longitudinal walls S3, S4, the cover side S5, as well as the front and rear attachment structures 30, 40 of the modular cage structure 1 are all covered with a sheet metal cladding 15. All interfaces and contact points created by the cladding are additionally sealed with a weather-resistant adhesive sealant.

[0075] Fig. 5a to Fig. 5c illustrate the detailed designs of the fixing elements 60. Each fixing element 60 has four claws 64, wherein the claws 64 are placed in a form-fitting manner on the lateral longitudinal members 6 or at least partially encompass them. Receptacle profiles 62 corresponding to the fixing elements 60 are fixed to the longitudinal members of the chassis 21. The receiving profiles 62 are arranged parallel to the underside 22 and extend from the longitudinal members of the chassis 21 in the direction of the longitudinal walls S3, S4.

[0076] Mounting plates 61 corresponding to the receiving profiles 62 are fixed to the fixing elements 60, wherein the mounting plates 61 are arranged parallel to the underside 22 of the chassis 21 and extend from the fixing elements 60 in the direction of the longitudinal members of the chassis 21. The mounting plates 61 have stiffening struts 65 on their upper sides, wherein the stiffening struts 65 extend in the vehicle transverse direction Q.

[0077] Silent blocks 63 for mechanically decoupling the battery box 10 are fixed in the receiving profiles 62, with the support plates 61 being positively placed on the silent blocks 63 and releasably secured to them. The silent blocks 63 have a base plate 68 that rests on the receiving plates 69 of the receiving profiles 62 and is releasably secured to them. The base plates 68 extend further than the receiving plates 69 in the vehicle's vertical direction H and are more solid than the receiving plates 69 of the receiving profiles 68.

[0078] The receiving profiles 62 each have a receiving plate 69 and two side skirts 70, wherein the side skirts 70 have slot-shaped recesses 71 formed perpendicular to the longitudinal members of the chassis 21. Via the slot-shaped recesses 71, the receiving profiles 62 can be positively inserted and fixed in the vehicle transverse direction Q onto a suitable section of the longitudinal members of the chassis 21.

[0079] The invention is not limited to one of the embodiments described above, but can be modified in many ways.

[0080] All features and advantages arising from the claims, the description, and the drawings, including structural details, spatial arrangements, and method steps, may be essential to the invention both individually and in a wide variety of combinations. Reference symbols list

[0081] L Vehicle longitudinal direction 23 trailer axles

[0082] Q Vehicle transverse direction 24 support feet

[0083] H Vehicle vertical direction 25 electric drive unit

[0084] S1 Cross wall 30 Front attachment structure

[0085] S2 Transverse wall 31 Superior frame process

[0086] S3 Longitudinal wall 32 Shortened

[0087] S4 Longitudinal wall side wall element

[0088] S5 Cover side 33 Lower frame extension

[0089] (slanted)

[0090] 1 Modular cage structure 40 Rear attachment structure

[0091] 2 Upper frame 41 Upper frame extension

[0092] 3 Lower frame 43 Lower frame extension

[0093] 4 Sheet metal plate 44 Rear mounting frame

[0094] 5 Middle longitudinal member 50 HV traction battery module

[0095] 6 Side longitudinal members 51 Battery connection cables

[0096] 7 corner cross members 60 fixing elements

[0097] 8 side wall cross members 61 support plate

[0098] 9 guide elements 62 mounting profile

[0099] 10 battery boxes 63 silent blocks

[0100] 12 cross beams 64 claws

[0101] 13 openings sheet metal plate 65 stiffening strut

[0102] 14 reinforcement elements 68 base plate silent blocks

[0103] 15 Sheet metal cladding 69 Mounting plate

[0104] 20 trailers 70 side skirts

[0105] 21 Chassis 71 Recess side skirts

[0106] 22 Bottom

Claims

Patent claims Commercial vehicle, in particular trailer (20) for coupling to a tractor unit, comprising - a chassis (21), on the underside (22) of which at least one, in particular two or three trailer axles (23) are arranged, wherein at least one trailer axle (23) is equipped with an electric drive unit (25) for driving and decelerating the commercial vehicle (20), and - at least one battery box (10) arranged on the underside (22) for receiving at least one electric battery module, characterized in that the battery box (10) is connected to the chassis (21), wherein the battery box (10) is mounted on the chassis (21) in such a way that it is mechanically decoupled from the chassis (21) of the trailer (20). Commercial vehicle according to claim 1, characterized in that the trailer (20) has support feet (24) on the underside (22) of the chassis (21) for coupling and uncoupling, wherein the battery box (10) is arranged in a space between the support feet (24) and the trailer axle (23). Commercial vehicle according to claim 1 or 2, characterized in that the battery box (10) has a cage structure (1) for receiving electric battery modules, wherein the cage structure (1) is of modular design.Commercial vehicle according to claim 3, characterized in that the modular cage structure (1) has an upper frame (2) made of transverse and longitudinal elements, wherein the modular cage structure (1) has a lower frame (3) made of transverse and longitudinal elements and arranged parallel to the upper frame (2). Commercial vehicle according to claim 4, characterized in that the upper and lower frames (2, 3) of the modular cage structure (1) are each releasably fixed to one another at their corner regions by four corner cross members (7), wherein the corner cross members (7) are arranged between the upper and lower frames (2, 3) and extend in a vehicle vertical direction (H). Commercial vehicle according to claim 4 or 5, characterized in that the longitudinal elements of the upper and lower frames (2, 3) are connected by at least. two, preferably by at least three side wall cross members (8) arranged centrally in the region of the longitudinal walls (S3, S4), are releasably fixed to one another, wherein the side wall cross members (8) are arranged between the upper and lower frames (2, 3) and extend in the vehicle's vertical direction (H). Commercial vehicle according to claim 6, characterized in that the modular cage structure (1) provides at least eight, preferably at least sixteen cross members (12) for modularly accommodating the electric battery modules, wherein the cross members (12) extend in the vehicle's transverse direction (Q) and are releasably fixed to the corner cross members (7) and / or to the side wall cross members (8).Commercial vehicle according to one of claims 4 to 7, characterized in that the modular cage structure (1), in the fixed state of the frame and corner cross members, has two longitudinal walls (S3, S4) running in a vehicle longitudinal direction (L), wherein the modular cage structure (1), in the fixed state, has two transverse walls (S1, S2) running in a vehicle transverse direction (Q). Commercial vehicle according to one of claims 4 to 8, characterized in that the modular cage structure (1) has a central longitudinal member (5) which is arranged parallel to the longitudinal elements of the lower frame (3), wherein the central longitudinal member (5) rests on the transverse elements of the lower frame (3) at its end and is releasably fixed.Commercial vehicle according to one of claims 4 to 9, characterized in that at least one further side wall cross member (8) is arranged centrally in the region of the transverse walls (S1, S2), wherein the side wall cross members (8) are releasably fixed to the transverse elements of the upper and lower frames (2, 3) perpendicularly and in the vehicle transverse direction (Q) aligned with the central longitudinal member (5). Commercial vehicle according to one of claims 4 to 10, characterized in that the modular cage structure (1) has at least two lateral longitudinal members (6) which are arranged parallel to and adjacent to the longitudinal elements of the upper frame (2), wherein the lateral longitudinal members (6) rest on the end faces of the transverse elements of the upper frame (2) and are releasably fixed. Commercial vehicle according to claim 8, characterized in that the modular cage structure (1) has a front attachment structure (30) for improving the aerodynamics of the trailer (20), wherein the front attachment structure (30) is formed via an extension of the longitudinal walls (S3, S4) in the vehicle's longitudinal direction (L). Commercial vehicle according to claim 8, characterized in that the modular cage structure (1) has a rear attachment structure (40) for receiving and connecting battery auxiliary units, wherein the rear attachment structure (40) is formed via an extension of the longitudinal walls (S3, S4) in the vehicle's longitudinal direction (L). Commercial vehicle according to one of claims 4 to 13, characterized in that the modular cage structure (1) is fixed on the floor side with a sheet metal plate (4) on a side of the lower frame (3) facing away from the underside (22), wherein the sheet metal plate (4) has openings (13) on its side facing the underside (22) for fixing further cage structure elements.Commercial vehicle according to claim 14, characterized in that the modular cage structure has a cover side (S5) lying parallel and opposite the sheet metal plate (4), wherein the cover side (S5), the longitudinal and transverse walls (S1, S2, S3, S4), and the front and rear attachment structures (30, 40) of the modular cage structure (1) are covered with a sheet metal cladding (15). Commercial vehicle according to claim 11, characterized in that the modular cage structure (1) is designed to be suspendable from longitudinal members of the chassis (21), wherein, in the suspended state of the cage structure, the distance between the lateral longitudinal members (6) of the cage structure in the transverse direction (Q) of the vehicle is greater than the distance between the two longitudinal members of the chassis (21).Commercial vehicle according to claim 11, characterized in that at least three, preferably at least four fixing elements (60) are provided on the lateral longitudinal members (6) of the cage structure for suspending and fixing the cage structure (1) to the longitudinal members of the chassis (21), wherein the fixing elements (60) are distributed in the vehicle longitudinal direction (L) and in particular are arranged at equal intervals on the lateral longitudinal members (6). Commercial vehicle according to claim 17, characterized in that receiving profiles (62) corresponding to the fixing elements (60) are fixed to the longitudinal members of the chassis (21), wherein the receiving profiles (62) are arranged parallel to the underside (22) and extend from the longitudinal members of the chassis (21) in the direction of the longitudinal walls (S3, S4). Commercial vehicle according to claim 18, characterized in that support plates (61) corresponding to the receiving profiles (62) are fixed to the fixing elements (60), wherein the support plates (61) are arranged parallel to the underside (22) of the chassis (21) and extend from the fixing elements (60) in the direction of the longitudinal members of the chassis (21).Commercial vehicle according to claim 1, characterized in that silent blocks (63) for the mechanical decoupling of the battery box (10) are fixed in the receiving profiles (62), wherein the support plates (61) are placed positively on the silent blocks (63) and are detachably fixed to them.

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