Chassis structure of an electric vehicle

Abstract

The invention relates to a chassis structure (1) of a vehicle at least partially powered by electrical energy, comprising a battery container (2) having a housing for a battery pack, the battery container (2) having an upper wall (4) forming a floor and a lower cover (5) closing the housing, the chassis structure (1) comprising a cavity in a front portion (22) of the chassis structure (1) delimited at least in part by a front portion (7) of the upper wall (4) of the battery container (2) and by a lower wall (8) of the chassis structure (1), the cavity opening towards the front of the chassis structure (1) through an opening (9). The chassis structure (1) includes a shutter (10) positioned in the opening (9), between the lower wall (8) of the chassis structure (1) and the upper wall (4) of the battery container (2), and configured to close the cavity. Abstract figure: Fig.2.

Description

Title of the invention: Chassis structure of an electric vehicle

[0001] The present invention relates to the field of hybrid or electric vehicles, and more particularly to a chassis structure for such vehicles.

[0002] Electric or hybrid motor vehicles, i.e. those powered at least partially by electrical energy, comprise one or more battery modules connected to a power network to supply an electric motor (traction or propulsion).

[0003] The battery modules are grouped in a casing and then form a battery block also often referred to by the English expression “battery pack”, this casing generally containing a mounting interface and connection terminals.

[0004] Each battery module comprises at least one electrochemical cell generating current by chemical reaction, for example of the lithium-ion (or Li-ion) type, of the Ni-Mh, or Ni-Cd or lead type.

[0005] The electric or hybrid vehicle comprises a chassis structure positioned at a lower portion of the vehicle. The chassis structure comprises a battery container or tray having a housing in which the battery pack is housed. The battery container has an upper wall forming a floor and a lower cover closing the housing.

[0006] The chassis structure comprises a front portion having two stretchers and a channel, conventionally called a "tunnel", formed in the chassis structure. The channel extends longitudinally in the middle of the chassis structure, from the front of the chassis structure to above the battery container.

[0007] A cavity opening at the front of the chassis structure through an opening is then formed between a front portion of the upper wall of the battery container and a lower wall of the chassis structure delimiting the channel.

[0008] However, this opening at the front of the chassis structure is conducive to the intrusion of foreign bodies from outside the vehicle, such as mud or gravel inside the cavity. Mud and gravel can thus accumulate indefinitely in the cavity and weigh down the vehicle.

[0009] The aim of the invention is therefore to overcome the drawbacks of the prior art, by proposing a chassis structure of an electric vehicle comprising a cavity in its front part, in which foreign bodies coming from the outside cannot accumulate.

[0010] To this end, the invention thus relates, in its broadest acceptance, to a chassis structure of a vehicle driven at least partially by electrical energy, comprising a battery container comprising a housing intended for housing a battery pack. The battery container has an upper wall intended to form a floor and a lower cover closing the housing. The chassis structure includes a cavity at a front portion of the chassis structure, delimited, at least in part, by a front portion of the upper wall of the battery container, and by a lower wall of the chassis structure. The cavity opens towards the front of the chassis structure through an opening.

[0011] According to the invention, the frame structure comprises a shutter positioned in the opening, between the lower wall of the frame structure and the upper wall of the battery container, and configured to close the cavity.

[0012] The invention thus provides a chassis structure of an electric vehicle comprising a cavity in its front part, in which foreign bodies coming from the outside cannot accumulate.

[0013] According to a variant, the shutter comprises a lower edge connected to a border of the front portion of the upper wall of the battery container.

[0014] This prevents foreign bodies from getting between the top wall and the shutter. The process of mounting the top wall on a frame of the chassis structure is made easier, since the shutter is already connected to the top wall.

[0015] According to one variant, the shutter comprises a lower tab extending from the lower edge of the shutter towards the rear of the frame structure. The lower tab is welded to the edge of the front portion of the upper wall of the battery container.

[0016] The lower tab allows the shutter to be securely fixed to the upper wall by welding.

[0017] According to a variant, the shutter comprises an upper edge, opposite the lower edge, and two side edges, each connected to the lower edge and to the upper edge. The upper edge and the side edges run along the lower wall of the frame structure.

[0018] This prevents foreign bodies from getting between the shutter and the lower wall of the chassis structure.

[0019] According to one variant, the shutter comprises an upper tab extending from the upper edge of the shutter, towards the front of the chassis structure. The upper tab is welded to the lower wall of the chassis structure.

[0020] The upper tab allows the shutter to be securely attached to the lower wall of the frame structure.

[0021] According to one variant, a sealing bead is formed by welding between the upper edge and the side edges of the shutter and the lower wall of the frame structure.

[0022] The sealing cord improves the seal between the edges of the shutter and the lower wall of the chassis structure.

[0023] According to a variant, the shutter comprises a central portion inserted into a channel formed in the lower wall of the chassis structure and two lateral extensions extending from a lower portion of the central portion, parallel to the central portion. Each lateral extension obstructs a gap formed between the upper wall of the battery container and a peripheral portion of the lower wall of the chassis structure, positioned at the periphery of the channel.

[0024] This configuration allows the shutter to match the shape of the cavity opening and to correctly seal all gaps.

[0025] According to a variant, the central part of the shutter comprises an orifice capable of being closed by a secondary shutter.

[0026] The hole makes it easier to grip the shutter during assembly.

[0027] The invention also relates to a vehicle powered at least partially by electrical energy, comprising a chassis structure as defined above.

[0028] The invention also relates to a method of manufacturing a vehicle powered at least by electrical energy, comprising a chassis structure as defined above. The manufacturing method comprises: - a step of fixing the shutter on the upper wall of the battery container, - a step of fixing the upper wall of the battery container to a frame of the chassis structure, - a step of fixing the shutter on the lower wall of the chassis structure, - a step of positioning the battery pack on the lower cover of the battery container, and - a step of fixing the lower cover to the upper wall of the battery container.

[0029] Embodiments of the present invention will be described below, by way of non-limiting examples, with reference to the appended figures in which:

[0030] [Fig-1] schematically illustrates a transparent view of a chassis structure of an electric vehicle of the prior art;

[0031] [Fig.2] schematically illustrates a detailed view of a chassis structure of a electric vehicle, according to one embodiment of the invention;

[0032] [Fig.3] schematically illustrates a detail view of a shutter mounted on an upper wall of a battery container of the frame structure of [Fig.2];

[0033] [Fig.4] schematically illustrates an exploded view of the chassis structure of the [Fig.2] ;

[0034] [Fig.5] schematically illustrates a longitudinal sectional view of the chassis structure of [Fig.2];

[0035] [Fig.6] schematically illustrates a front view of the mounted shutter closing a cavity of the frame structure of [Fig.2].

[0036] The term "lower" will be understood according to its usual definition, in which it indicates a greater proximity to the ground in the vertical direction than the term "upper".

[0037] The terms “longitudinal”, “front” and “rear” shall be understood in relation to the general orientation of the vehicle as taken in its normal direction of travel.

[0038] In the remainder of the description, elements having an identical structure and / or similar functions will be designated by the same reference.

[0039] Figures 2 to 6 illustrate a chassis structure 1 or a portion of the chassis structure 1 of an electric vehicle comprising a battery container 2 having a housing 3 intended to house a battery pack.

[0040] The invention applies generally to vehicles powered at least partially by electrical energy, such as electric or hybrid vehicles.

[0041] These vehicles include battery modules which are grouped in a casing and which then form a battery block also often referred to by the English expression “battery pack”, this casing generally containing a mounting interface and connection terminals.

[0042] The battery modules are connected to a power network to supply an electric motor (traction or propulsion).

[0043] Each battery module comprises at least one electrochemical cell generating current by chemical reaction, for example of the lithium-ion (or Li-ion) type, of the Ni-Mh, or Ni-Cd or lead type.

[0044] The chassis structure 1 is positioned at a lower part of the vehicle. The chassis structure 1 comprises a battery container 2 or tray having a housing 3 in which the battery pack is housed.

[0045] The battery container 2 comprises an upper wall 4 forming a floor and a lower cover 5 closing the housing 3. The lower cover 5 is positioned facing the ground.

[0046] The chassis structure 1 comprises a front portion 22 comprising two stretchers 23 and a channel 18, conventionally called a “tunnel”, formed in the front portion 22 of the chassis structure 1. The channel 18 extends longitudinally in the middle of the front portion 22 of the chassis structure 1, from a front end 24 of the front portion 22 to above the battery container 2. The channel 18 extends in a first direction X, corresponding to a direction of advance of the vehicle when it is moving forward. The channel 18 has a quadrilateral section.

[0047] A set of front bumpers is intended to be fixed to the stretchers 23.

[0048] A cavity 6 opening towards the front of the chassis structure 1 through an opening 9 is formed between a front portion 7 of the upper wall 4 of the battery container 2 and a lower wall 8 of the chassis structure 1 delimiting the channel 18. The front portion 7 of the upper wall 4 is curved.

[0049] [Fig.l] represents a frame structure 1a of the prior art making it possible to show the opening 9 of the cavity 6.

[0050] The cavity 6 is delimited at least in part by the front portion 7 of the upper wall 4 of the battery container 2 and by the lower wall 8 of the chassis structure 1. The cavity 6 comprises a closed rear end 25, as illustrated in [Fig.5].

[0051] The battery container 2 comprises a domed portion 26 at the location of the front portion 7 of the upper wall 4 and the lower wall 8 of the chassis structure 1, projecting towards the lower wall 8 of the chassis structure 1.

[0052] According to the invention, the cavity 6 comprises a shutter 10 positioned in the opening 9, between the lower wall 8 of the chassis structure 1 and the upper wall 4 of the battery container 2. The shutter 10 is configured to close the cavity 6, as illustrated in FIGS. 2 to 6.

[0053] The shutter 10 has a shape adapted to match the shape of the opening 9. The shutter 10 has a generally flat shape.

[0054] The shutter 10 comprises a central portion 15 inserted into the channel 18 formed in the lower wall 8 of the chassis structure 1 and two lateral extensions 19 extending from a lower portion 26 of the central portion 15, parallel to the central portion 15. Each lateral extension 19 obstructs a gap 20 formed between the upper wall 4 of the battery container 2 and a peripheral portion 30 of the lower wall 8 of the chassis structure 1, positioned at the periphery of the channel 18.

[0055] The central part 15 of the shutter 10 extends in a second direction Y, perpendicular to the first direction X and in a third direction Z, perpendicular to the first direction X and to the second direction Y.

[0056] The lateral extensions 19 extend along the second direction Y.

[0057] The shutter 10 comprises a lower edge 11 connected to a border 12 of the front portion 7 of the upper wall 4 of the battery container 2.

[0058] The upper wall 4 comprises an upper face 41 placed opposite a frame 40. The shutter 10 is fixed on the upper face 4L

[0059] The shutter 10 comprises an upper edge 13, opposite the lower edge 11, and two opposite lateral edges 14, each connected to the lower edge 11 and to the upper edge 13. The upper edge 13 and the lateral edges 14 run along the lower wall 8 of the frame structure 1.

[0060] The shutter 10 comprises a lower tab 16 extending from the lower edge 11 of the shutter 10, towards the inside of the battery container 2, i.e. towards the rear of the chassis structure 1 or in a direction opposite to the first direction X. The lower tab 16 projects relative to the central portion 15 of the shutter 10.

[0061] The lower tab 16 is welded to the edge 12 of the front portion 7 of the upper wall 4 of the battery container 2, by three weld points 39, for example.

[0062] As illustrated in [Fig. 3], the lower tab 16 comprises a substantially flat central body 27 and two lateral wings 28 extending from the central body 27 while being connected to the lower edge 11. The two lateral wings 28 are inclined relative to the central body 27 to match the curved shape of the edge 12 of the front portion 7 of the upper wall 4 of the battery container 2.

[0063] The two lateral wings 28 have a shorter length and width than those of the central body 27.

[0064] The shutter 10 comprises an upper tab 17 extending from the upper edge 13 of the shutter 10, towards a direction opposite to the lower tab 16, that is to say substantially along the first direction X. The upper tab 17 is welded to an internal wall 29 of the lower wall 8 of the frame structure 1 delimiting the bottom of the channel 18. The upper tab 17 is welded by several welding points, for example.

[0065] The upper tab 17 is inclined relative to the central part 15 of the shutter 10 and extends along the entire length, or almost, of the upper edge 13 of the shutter 10.

[0066] The central part 15 of the shutter 10 has a general quadrilateral shape and comprises two opposite upper rounded portions 31 connecting the upper edge 13 of the central part 15 to two opposite first lateral edges 32 of the central part 15.

[0067] Each first lateral edge 32 is connected to a first extension portion 35 of the lateral extension 19 by a lower rounded portion 36. The first extension portion 35 extends in the second direction Y.

[0068] The lower edge 11 and the upper edge 13 of the shutter 10 extend in the second direction Y.

[0069] The lower edge 11 has a substantially rectilinear part 33 at the location of the central part 15 which is connected to two curved parts 34 opposite at the location of the lateral extensions 19, as illustrated in [Fig.6].

[0070] Each lateral extension 19 comprises an inclined portion 37 which is inclined relative to the first extension portion 35. Each inclined portion 37 connects one of the curved portions 34 of the lower edge 11 to the first extension portion 35 of the lateral extension 19.

[0071] A projecting portion 38 is formed between each curved portion 34 of the lower edge 11 and each inclined portion 37 of the lateral extensions 19.

[0072] A sealing bead is formed by welding between the upper edge 13 of the shutter 10 and the lower wall 8 of the frame structure 1 and between the lateral edges 14 of the shutter 10 and the lower wall 8 of the frame structure 1.

[0073] Alternatively, the central portion 15 of the shutter 10 comprises an orifice 21 positioned substantially in its middle. A secondary shutter is provided to close the orifice 21.

[0074] The invention also relates to a method of manufacturing an electric vehicle comprising a chassis structure 1 as defined previously.

[0075] The manufacturing method comprises a step of fixing the lower edge 11 of the shutter 10 on the edge 12 of the front portion 7 of the upper wall 4 of the battery container 2.

[0076] Preferably, it is the lower tab 16 extending from the lower edge 11 of the shutter 10 which is welded to the edge 12, as illustrated in [Fig. 3]. The lower tab 16 is welded to the edge 12 by three weld points 39, for example.

[0077] The lower edge 11 of the shutter 10 perfectly matches the edge 12 of the front portion 7 of the upper wall 4 of the battery container 2. The shutter 10 projects from the front portion 7, that is to say from the upper face 41 of the upper wall 4, in the third direction Z.

[0078] The manufacturing method comprises a step of fixing the upper wall 4 of the battery container 2 to the frame 40 of the frame structure 1, as illustrated in [Fig.4] showing the upper wall 4 approaching the frame 40. The upper face 41 of the upper wall 4 is placed opposite the frame 40.

[0079] The upper wall 4 of the battery container 2 can be fixed to the frame 40 by screws, for example.

[0080] The shutter 10 is then welded to the lower wall 8 of the chassis structure 1 by three spot welds 39, for example. More precisely, it is the upper tab 17 extending from the upper edge 13 of the shutter 10 which is welded to the inner wall 29 delimiting the bottom of the channel 18. The upper tab 17 can be welded by spot welds, for example.

[0081] The manufacturing method then comprises a step of positioning the battery pack on an internal face 42 of the lower cover 5 of the battery container 2, and a step of fixing the lower cover 5 to the upper wall 4 of the battery container 2.

[0082] The lower cover 5 can be screwed to the upper wall 4, for example.

[0083] The frame structure 1 thus comprises a shutter 10 closing in such a way seal the opening 9, as shown in [Fig.2].

Claims

Claims

1. Chassis structure (1) of a vehicle powered at least partially by electrical energy comprising a battery container (2) having a housing (3) intended to house a battery pack, the battery container (2) having an upper wall (4) intended to form a floor and a lower cover (5) closing the housing (3), the chassis structure (1) comprising a cavity (6) at a front portion (22) of the chassis structure (1) delimited at least in part by a front portion (7) of the upper wall (4) of the battery container (2) and by a lower wall (8) of the chassis structure (1), the cavity (6) opening towards the front of the chassis structure (1) by an opening (9), characterized in that it comprises a shutter (10) positioned in the opening (9), between the lower wall (8) of the chassis structure (1) and the upper wall (4) of the battery container (2), and configured to close the cavity (6).

2. Frame structure (1) according to claim 1, characterized in that the shutter (10) comprises a lower edge (11) connected to a border (12) of the front portion (7) of the upper wall (4) of the battery container (2).

3. A frame structure (1) according to claim 2, characterized in that the shutter (10) comprises a lower tab (16) extending from the lower edge (11) of the shutter (10) towards the rear of the frame structure (1), the lower tab (16) being welded to the edge (12) of the front portion (7) of the upper wall (4) of the battery container (2).

4. Frame structure (1) according to any one of claims 2 or 3, characterized in that the shutter (10) comprises an upper edge (13), opposite the lower edge (11), and two lateral edges (14), each connected to the lower edge (11) and to the upper edge (13), the upper edge (13) and the lateral edges (14) running along the lower wall (8) of the frame structure (1).

5. A frame structure (1) according to claim 4, characterized in that the shutter (10) comprises an upper tab (17) extending from the upper edge (13) of the shutter (10), towards the front of the frame structure (1), the upper tab (17) being welded to the lower wall (8) of the frame structure (1).

6. A chassis structure (1) according to any one of claims 4 or 5, characterized in that a sealing bead is formed by welding between the upper edge (13) and the side edges (14) of the shutter (10) and the lower wall (8) of the frame structure (1).

7. A chassis structure (1) according to any one of claims 1 to 6, characterized in that the shutter (10) comprises a central portion (15) inserted into a channel (18) formed in the lower wall (8) of the chassis structure (1) and two lateral extensions (19) extending from a lower portion (26) of the central portion (15), parallel to the central portion (15), each lateral extension (19) obstructing a gap (20) formed between the upper wall (4) of the battery container (2) and a peripheral portion (30) of the lower wall (8) of the chassis structure (1), positioned at the periphery of the channel (18).

8. Frame structure (1) according to claim 7, characterized in that the central part (15) of the shutter (10) comprises an orifice (21) capable of being closed by a secondary shutter.

9. Vehicle powered at least partially by electrical energy, characterized in that it comprises a chassis structure (1) as defined according to any one of claims 1 to 8.

10. A method of manufacturing a vehicle powered at least by electrical energy comprising a chassis structure (1) as defined according to any one of claims 1 to 8, characterized in that it comprises: - a step of fixing the shutter (10) on the upper wall (4) of the battery container (2), - a step of fixing the upper wall (4) of the battery container (2) on a frame (40) of the chassis structure (1), - a step of fixing the shutter (10) on the lower wall (8) of the chassis structure (1), - a step of positioning the battery pack on the lower cover (5) of the battery container (2), and - a step of fixing the lower cover (5) to the upper wall (4) of the battery container (2).

Images