Upper floor for an electric or hybrid motor vehicle

Abstract

Upper floor for a hybrid or electric motor vehicle, comprising a central platform (10) and a rim (11) extending respectively in two distinct planes to form a hollow body that can receive battery modules (6), the upper floor (2) comprising an upper face (2a) and a lower face (2b) opposite the upper face (2a), the rim (11) comprising a first zone (11a) extending continuously on said upper face (2a) and a second zone (11b) extending continuously on said lower face (2b).

Description

[0001] TITLE: Upper floor for electric or hybrid motor vehicle

[0002] Technical field

[0003] The present invention relates, in general, to electric or hybrid vehicles and, in particular, to the sealing of an electrical energy storage zone intended to accommodate battery modules of such vehicles.

[0004] More specifically, the invention relates to an upper floor for an electric or hybrid vehicle, to a base comprising such an upper floor, as well as to an electric or hybrid vehicle incorporating such a base.

[0005] Previous techniques

[0006] In current electric vehicles, electrical energy is stored in battery cells packaged in an external casing housed under the floor of the vehicle.

[0007] This housing is waterproof and ensures the function of storing and maintaining the cells in the vehicle, generally by including intermediate packaging called modules. It also contributes to the protection of the cells in frontal and side impacts.

[0008] However, such a case limits the volume useful for storing electrical energy.

[0009] According to a new design, the external housing present under the floor is removed in order to maximize the available volume of the electrical energy storage area, intended to receive the battery cells. The underbody has been reconfigured and itself forms a structural enclosure for receiving the battery cells.

[0010] The battery modules are positioned under the upper floor.

[0011] In addition, the upper floor is attached to a central frame of the underbody comprising a front cross member, a rear cross member and two left and right side skirts.

[0012] Certain sealing requirements are imposed on the electrical energy storage area. It must be waterproof against water coming from outside and inside the vehicle, but also temperature and pressure resistant in order to resist potential thermal runaway of the battery cells and protect the passengers inside the vehicle.

[0013] In particular, the GTR-EVS (Global Technical Regulations - Electric Vehicle Safety) regulations require that fumes must not enter the passenger compartment for a minimum of five minutes, in order to allow passengers time to get out of the vehicle.

[0014] The removal of the casing results in the removal of the sealing of the electrical energy storage area intended to accommodate the battery modules.

[0015] In addition, the high number of parts making up the underbody leads to an increased risk of leaks between the vehicle's passenger compartment and the energy storage area located under the upper floor.

[0016] Statement of the invention

[0017] There is therefore a need to provide sealing of the electrical energy storage area suitable for a configuration in which the electrical energy storage area is directly formed by the underbody of an electric or hybrid vehicle.

[0018] There is therefore proposed an upper floor for a hybrid or electric motor vehicle, comprising a central platform and a perimeter extending respectively in two distinct planes to form a hollow body capable of receiving battery modules, the upper floor comprising an upper face and a lower face opposite the upper face, the perimeter comprising a first zone extending continuously on said upper face and a second zone extending continuously on said lower face.

[0019] Preferably, the central platform and the surround are one-piece.

[0020] Preferably, the upper floor comprises dimensions adapted to receive at least one battery module, preferably the height between the central platform and the perimeter is greater than or equal to the height of at least one battery module.

[0021] The invention also relates to a method of manufacturing an upper floor as described above, comprising a stamping step.

[0022] The invention also relates to a base for an electric or hybrid motor vehicle comprising an upper floor as described above. Advantageously, the base comprises an electrical energy storage area intended to receive battery modules, the electrical energy storage area being delimited by the upper floor and a lower closing plate.

[0023] Preferably, the base comprises at least one first sealing means arranged between the second zone of the perimeter of the upper floor and the lower closing plate, in particular the perimeter of the closing plate.

[0024] Advantageously, the base may comprise a central frame positioned around the upper floor, and at least one second sealing means arranged between the first area of ​​the perimeter of the upper floor and the central frame.

[0025] Preferably, the base includes fastening members configured to suspend battery modules are disposed on the underside of the upper floor.

[0026] Advantageously, the base comprises a plurality of central crosspieces arranged on the upper face of the upper floor.

[0027] Preferably, the central cross members are fixed to the upper face of the upper floor by welding.

[0028] Preferably, the fixing members are fixed to the underside of the upper floor by welding.

[0029] The invention also relates to an electric or hybrid motor vehicle comprising an upper floor as described above and / or an underbody as described above.

[0030] Advantageously, the motor vehicle may comprise a plurality of battery modules suspended by the fixing members on the lower face of the upper floor.

[0031] Brief description of the drawings

[0032] Other aims, advantages and characteristics will emerge from the description which follows, given purely for illustrative purposes and with reference to the attached drawings in which:

[0033] [Fig 1] illustrates a base for an electric or hybrid motor vehicle according to an embodiment of the invention shown in longitudinal section.

[0034] [Fig 2] is a cross-section of the base illustrated in Figure 1. [Fig 3] is a perspective view of an upper floor according to one embodiment of the invention.

[0035] Detailed description

[0036] In the remainder of the description, the terms “longitudinal”, “transverse”, “vertical”, “horizontal”, “front”, “rear”,

[0037] "left", "right", "lower", "upper", "under", "on", "above" and "below" are understood in relation to the usual orthogonal reference point for motor vehicles, shown in Figures 1 to 3, and including:

[0038] - a longitudinal axis X, horizontal and directed from the front to the rear of the vehicle;

[0039] - a transverse axis Y, horizontal, perpendicular to the X axis and directed from the left to the right of the vehicle moving forward;

[0040] - a Z axis, orthogonal to the X and Y axes and vertically directed from bottom to top.

[0041] Furthermore, the expression "at least one" used in this description is equivalent to the expression "one or more".

[0042] Figures 1 and 2 illustrate a base 1 for an electric or hybrid motor vehicle in section along, respectively, the longitudinal axis X and the transverse axis Y.

[0043] The base 1 comprises an upper floor 2 comprising an upper face 2a and a lower face 2b opposite the upper face 2a.

[0044] Advantageously, the base 1 may also comprise a central frame positioned on the periphery of the upper floor 2 and comprising a front cross member 7, a rear cross member 8 and left and right side flaps 3 connecting the front and rear cross members 7, 8.

[0045] By sill, we mean in the present invention a structural element which extends in the longitudinal direction of the vehicle on each side of the upper floor 2, in particular below the doors of the vehicle.

[0046] Only a lateral portion of the base 1 is shown in figure 2 so that only the left side flap 3 of the central frame is visible.

[0047] Preferably, a plurality of central crosspieces 4 are fixed to the upper face 2a of the upper floor 2. Preferably, the ends of the central crosspieces 4 are connected by embedding to the left and right side flaps 3. The central crosspieces 4 may be provided in sufficient number to cover the entire length of the upper floor 2 and thus to compensate for lateral impacts regardless of their position.

[0048] Advantageously, the central cross members 4 may include cross members for reinforcing the upper floor 2 in the event of a side impact and fixing cross members intended for fixing seats of the motor vehicle.

[0049] An electrical energy storage area ZE intended to receive battery modules is advantageously provided under the upper floor 2.

[0050] The upper floor 2 forms a sealing barrier between the electrical energy storage area ZE and the passenger compartment of the vehicle.

[0051] Preferably, the central crosspieces 4 are fixed to the upper face 2a of the upper floor 2 by welding, that is to say by means of welding points or beads. This makes it possible to avoid removing the seal formed by the upper floor 2 piercing the electrical energy storage zone ZE, for example by screwing.

[0052] According to a variant, it may be provided that the central crosspieces 4 and the upper floor 2 are in one piece so that the central crosspieces 4 are directly integrated into the upper floor 2.

[0053] Fastening members 5 configured to suspend at least one battery module 6 under the upper floor 2 are housed in the electrical energy storage zone ZE.

[0054] By "suspending at least one battery module from the vehicle" is meant that the battery module 6 is supported in its upper part positioned opposite the upper floor 2 by the fixing member 5 so that the battery module 6 is suspended from the fixing member 5 without it being necessary for the battery module 6 to rest on a base.

[0055] The fixing members 5 are, advantageously, fixed on the lower face 2b of the upper floor 2.

[0056] Preferably, the fixing members 5 are fixed to the lower face 2b of the upper floor 2 by welding, that is to say by means of welding points or beads. This makes it possible to avoid removing the seal formed by the upper floor 2 piercing the electrical energy storage zone ZE, for example by screwing. In the example illustrated, each fixing member 5 comprises a beam extending longitudinally along a longitudinal axis of the upper floor 2 in the electrical energy storage zone.

[0057] The beam of the fixing member 5 has, for example, a substantially omega-shaped cross-section whose free ends advantageously allow the fixing member 5 to be fixed to the lower face 2b of the upper floor 2.

[0058] The battery modules 6 comprise at least one fixing lug 6a configured to cooperate with one of the fixing members 5 for suspending the battery module 6 from the fixing member 5.

[0059] Preferably, the battery module 6 is fixed to the fixing member 5 by screwing.

[0060] In this regard, in the example illustrated, each fixing lug 6a advantageously comprises a hole configured to cooperate with a hole formed in a section of the beam for screwing the battery modules 6 onto the fixing members 5.

[0061] Advantageously, a lower closing plate 9 makes it possible to close the electrical energy storage zone ZE, ensuring protection of the battery modules 6, in particular against road debris.

[0062] The electrical energy storage area ZE is thus delimited by the upper floor 2 and the closing plate 9 when the latter two are assembled.

[0063] The base 1 advantageously comprises means F for fixing the lower closing plate 9 to the upper floor 2.

[0064] In the example illustrated, the fixing means F comprise a plurality of screw and nut assemblies distributed around the perimeter 11 of the upper floor 2 and the perimeter of the lower closing plate 9.

[0065] A plurality of orifices are provided on the periphery 11 of the upper floor 2, and each screw and nut assembly of the fixing means F cooperates with one of these orifices.

[0066] In addition, the base 1 advantageously comprises means for fixing the upper floor 2 to the central frame.

[0067] In the example illustrated, the fixing means F of the lower closing plate 9 on the upper floor 2 also make it possible to fix the upper floor 2 on the central frame. Advantageously, a vertical clearance J1 remains between each battery module 6 fixed to the upper floor 2 by means of a fixing member 5 and the lower closing plate 9.

[0068] The bottom plate 9 comprises, for example, aluminum and / or a fiber-reinforced plastic material.

[0069] Preferably, each fixing member 5 comprises an electrically insulating material in order to electrically insulate the battery modules 6 from the upper floor 2.

[0070] Advantageously, a vertical gap J2 remains between each battery module 6 housed in the electrical energy storage zone ZE and the upper floor 2 in order to electrically isolate the battery module 6 from the upper floor 2.

[0071] Optionally, the base 1 may comprise an insulating foam (not shown), in particular for thermal protection, surrounding the battery modules 6 in the electrical energy storage zone ZE.

[0072] The two right and left side flaps 3 extend longitudinally on either side of the upper floor 2.

[0073] Each of the side flaps 3 has a hollow body.

[0074] According to one example, the hollow body of the side flaps 3 can be delimited by a plurality of panels fixed to each other at their ends.

[0075] According to one example, the hollow body of the side flaps 3 may be delimited by a first panel 3a and a second panel of substantially U-shaped or omega-shaped section fixed to each other at their ends. The ends of the first panel 3a and the second panel are for example connected in a vertical plane of the vehicle.

[0076] In order to improve the lateral impact resistance of the upper floor 2 and of the electrical energy storage zone ZE comprising the battery modules 6, a reinforcement can be positioned in the hollow body of each of the side flaps 3.

[0077] Preferably, the reinforcement 7 of each side flap 3 extends in a plane passing through the central crosspieces 4.

[0078] Furthermore, the height of the reinforcement 7 is preferably similar to the height of the central crosspieces 4.

[0079] This allows an efficient and facilitated distribution of the forces due to a lateral impact towards the upper floor 2 and the central cross members 4. With reference to FIG. 3, the upper floor 2 comprises a central platform 10 and a perimeter 11, connected by a side 12, extending respectively in two distinct planes to form a hollow body capable of receiving the battery modules 6.

[0080] Advantageously, the central crosspieces 4 are fixed to the central platform 10.

[0081] The hollow body formed by the upper floor 2 takes the form of a bell or even a bowl.

[0082] Preferably, the dimensions of the upper floor 2 are adapted to receive, and in particular to surround, at least one battery module 6.

[0083] In the illustrated example, the height of the central platform 10 and the perimeter 11 is greater than the height of a battery module.

[0084] The longitudinal axis of each battery module 6 extends along the longitudinal axis X of the motor vehicle.

[0085] Preferably, the central platform 10 and the perimeter 11 are in one piece in order to form a first sealed protection for the electrical energy storage zone ZE.

[0086] The upper floor 2 preferably comprises a material having an elastic limit of a value greater than or equal to 400 mPa, preferably greater than or equal to 1000 mPa, such as steel, in order to give the upper floor 2 sufficient bending stiffness to withstand a lateral impact.

[0087] The perimeter 11 of the upper floor 2 comprises a first zone 11a, arranged on the upper face 2a, extending continuously.

[0088] The periphery 11 also comprises a second zone 11b, opposite the first zone 11a, arranged on the lower face 2b, and extending continuously.

[0089] By continuous zone is meant an area where the material of the upper floor 2 forms a continuity, without opening or orifice, extending all along the perimeter 1 1 so as to form a single closed track.

[0090] The second zone 11b is intended to receive a first sealing means 13, and the first zone 11a is intended to receive a second sealing means 14.

[0091] The first and second zones 11a and 11b are thus configured to each form a single sealing track, continuous along the entire perimeter 11 of the upper floor 2.

[0092] Preferably, the first and second sealing means 13 and 14 each comprise a seal. The seal of the first and second sealing means 13 and 14 may be made of mastic.

[0093] The first zone 11a forms, in addition to a sealing track for the second sealing means 14, an assembly and docking zone of the upper floor 2 on the central frame during the assembly of the various constituent parts of the base 1.

[0094] When the central frame and the upper floor 2 are assembled, the second sealing means 14 is held in a vice between the first zone 11a of the perimeter 11 of the upper floor 2 and the central frame.

[0095] Furthermore, when the upper floor 2 and the lower closing plate 9 are assembled, the first sealing means 13 is gripped between the second zone 11b of the perimeter 11 of the upper floor 2 and the perimeter of the lower closing plate 9.

[0096] The orifices provided on the periphery 11 of the upper floor 2 and the fixing means F, which allow the upper floor 2 to be fixed to the central frame and to the lower closing plate 9, are arranged between the first and second sealing zones 11a and 11b.

[0097] The first sealing means 13, positioned between the second zone 11b of the perimeter 11 of the upper floor 2 and the perimeter of the lower closing plate 9, is arranged opposite the electrical energy storage zone ZE, at a distance from the fixing means F so that the drilling of the orifices intended for the fixing means F does not degrade the sealing thus formed of the electrical energy storage zone ZE with respect to the passenger compartment of the vehicle.

[0098] The second sealing means 14, positioned between the first zone 11a of the perimeter 11 of the upper floor 2 and the central frame, is arranged facing the exterior of the vehicle, at a distance from the fixing means F so that the drilling of the orifices intended for the fixing means F does not degrade the sealing thus formed of the passenger compartment of the vehicle with respect to the exterior of the vehicle.

[0099] Advantageously, the central platform 10 and the perimeter 11 extend in two substantially parallel planes.

[0100] In the example illustrated, the perimeter 11 of the upper floor 2, the face of the central frame intended for docking with the perimeter 11 of the upper floor 2 and the perimeter of the lower closing plate 9 are substantially flat.

[0101] The various sealing means of the electrical energy storage zone allowing sealing of the electrical energy storage zone ZE with respect to the interior of the passenger compartment of the vehicle and vice versa are advantageously carried by a single part formed by the upper floor 2.

[0102] In addition, the perimeter 11 of the upper floor 2 forms a multifunctional zone making it possible to form sealing tracks as well as the docking of the upper floor 2 on the rest of the base 1.

[0103] In the example illustrated, a portion of the upper floor 2 includes a raised portion 15 allowing the integration of an anti-submarining system ASM intended to prevent a passenger's pelvis from passing under the seat belt in the event of a frontal impact on the vehicle.

[0104] Furthermore, the electrical energy storage area ZE may comprise a space 16, which may for example be delimited by a box, for the storage of electrotechnical elements such as electrical cables, or a device for cooling the battery modules 6.

[0105] Upper floor 2 can be manufactured by stamping.

[0106] The present invention encompasses any combinations of the different embodiments described above, which may be taken separately or in combination.

Claims

CLAIMS 1. Upper floor for a hybrid or electric motor vehicle, comprising a central platform (10) and a perimeter (11) extending respectively in two separate planes to form a hollow body capable of receiving battery modules (6), the upper floor (2) comprising an upper face (2a) and a lower face (2b) opposite the upper face (2a), the perimeter (11) comprising a first zone (11a) extending continuously on said upper face (2a) and a second zone (11b) extending continuously on said lower face (2b).

2. Upper floor according to claim 1, in which the central platform (10) and the perimeter (11) are in one piece.

3. Upper floor according to claim 1 or 2, comprising dimensions adapted to receive at least one battery module (6), preferably the height between the central platform (10) and the perimeter (11) is greater than or equal to the height of at least one battery module (6).

4. Underbody for an electric or hybrid motor vehicle comprising an upper floor (2) according to any one of claims 1 to 3.

5. Base according to claim 4, comprising an electrical energy storage area (ZE) intended to receive battery modules (6), the electrical energy storage area (ZE) being delimited by the upper floor (2) and a lower closing plate (9).

6. Base according to claim 4 or 5, comprising at least one first sealing means (13) arranged between the second zone (11b) of the periphery (11) of the upper floor (2) and the lower closing plate (9).

7. Base according to any one of claims 4 to 6, comprising a central frame positioned around the upper floor (2), and at least one second sealing means (14) arranged between the first zone (11a) of the periphery (11) of the upper floor (2) and the central frame.

8. Base according to any one of claims 4 to 7, comprises fixing members (5) configured to suspend battery modules (6) are arranged on the lower face (2b) of the upper floor (2).

9. Base according to any one of claims 4 to 8, in which a plurality of central crosspieces (4) are arranged on the upper face (2a) of the upper floor (2).

10. Electric or hybrid motor vehicle comprising an upper floor (2) according to any one of claims 1 to 3 and / or a base (1) according to any one of claims 4 to 9.

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