Reinforcement kit for an automotive battery assembly

Abstract

This reinforcement kit (6) for a motor vehicle battery assembly (2) comprises: - two primary reinforcement elements (8), generally elongated with a straight U-shaped cross-section, - two secondary reinforcement elements (10), generally elongated with a straight U-shaped cross-section. Each secondary reinforcement element (10) has two assembly notches, each configured to receive one end of one of the primary reinforcement elements (8), so as to form a generally rectangular frame in the assembled state, in which the primary reinforcement elements (8) extend into the assembly notches of the secondary reinforcement elements (10). See Figure 1 for abbreviations.

Description

Title of the invention: Reinforcement kit for a motor vehicle battery assembly

[0001] The invention relates to a battery assembly, in particular for a motor vehicle. More particularly, the invention relates to a reinforcement kit for a motor vehicle battery assembly, a battery assembly equipped with such a reinforcement kit as well as methods for reinforcing and disassembling a battery assembly.

[0002] There are regulations setting out tests that a battery pack must pass in order for it to be approved. Some of these tests are designed to verify that the battery pack has mechanical strength characteristics that enable it to withstand forces and stresses that could occur during an accident involving a vehicle equipped with such a battery pack.

[0003] One of these tests is the so-called "crush force" test, presented in the ECE R100 standard. According to this test, the battery pack is crushed by means of a crushing plate of a determined shape with a force between 100 and 105 kN for no more than 10 seconds. After this, the crushing plate is removed, and then the condition and operation of the battery pack are observed. For the battery pack to pass the test, it is necessary that it continues to operate normally, under conditions set out in the standard.

[0004] The battery assembly, as such, is generally manufactured with components and materials that do not allow it to pass the crushing force test. It is therefore necessary to equip it with reinforcement means allowing it to withstand the crushing test. To this end, it may be considered to equip the battery assembly with a shell or an external frame specifically dedicated to improving the mechanical resistance properties of the battery assembly.

[0005] While such elements can enable the crushing force test to be passed, they nevertheless have several drawbacks. Indeed, the battery assembly must be able to be easily dismantled to allow maintenance or replacement operations of the battery assembly. Reinforcing means surrounding the battery assembly and / or fixed in a non-removable manner to the battery assembly thus considerably complicate these operations, so it is preferable to avoid such means. Furthermore, the reinforcing means constitute an additional cost for the manufacture of the battery assembly, which is why it is preferable to make the reinforcing means as inexpensive as possible.

[0006] The invention aims in particular to provide reinforcement means for a battery pack that improves its crush resistance, is easily removable and is as inexpensive as possible.

[0007] To this end, the invention relates to a reinforcement kit for a motor vehicle battery assembly comprising:

[0008] - two primary reinforcing elements, of generally elongated shape with a section straight in the shape of a “U”,

[0009] - two secondary reinforcing elements, of generally elongated shape with a section straight in the shape of a “U”,

[0010] each secondary reinforcing element having two assembly notches each configured to receive one end of one of the primary reinforcing elements, so as to form a generally rectangular frame in an assembled state in which the primary reinforcing elements extend into the assembly notches of the secondary reinforcing elements.

[0011] Thus, the reinforcement kit consists of two primary reinforcement elements and two secondary reinforcement elements which can be manufactured separately. Their simple construction makes them simple to manufacture and inexpensive. The reinforcement elements are assembled around the battery assembly to form a frame around the battery assembly, the assembly notches making it possible to prevent the disassembly of the primary reinforcement elements as long as the secondary reinforcement elements are assembled on the battery assembly. This assembly by shape cooperation makes it easy to disassemble the reinforcement kit, which facilitates maintenance or replacement operations of the battery assembly.

[0012] Advantageously, the secondary reinforcing elements comprise, at the edge of each of their assembly notches, at least one secondary bearing face configured to bear against primary bearing faces provided on the primary reinforcing elements when the reinforcement kit is in the assembled state.

[0013] This increases the area of ​​the contact surfaces between the primary reinforcing elements and the secondary reinforcing elements, which contributes to improving the rigidity of the reinforcement kit in the assembled state.

[0014] According to one embodiment of the invention, said at least one secondary support face is oriented towards the inside of the frame when the reinforcement kit is in the assembled state.

[0015] An external force applied to a secondary reinforcement element thus transmits a force to at least one of the primary reinforcement elements which presses it towards the inside of the frame, in the direction of the battery assembly, which improves the cohesion of the frame formed by the reinforcement kit.

[0016] According to one embodiment of the invention, said at least one secondary support face is oriented towards the outside of the frame when the reinforcement kit is in the assembled.

[0017] An external force applied to a primary reinforcement element thus transmits a force to at least one of the secondary reinforcement elements which presses it towards the inside of the frame, in the direction of the battery assembly, which improves the cohesion of the frame formed by the reinforcement kit.

[0018] Preferably, the secondary reinforcing elements comprise, at the edge of each of their assembly notches, at least two secondary bearing faces configured to bear against primary bearing faces provided on the primary reinforcing elements when the reinforcing kit is in the assembled state, at least one secondary bearing face being oriented towards the inside of the frame when the reinforcing kit is in the assembled state and at least one secondary bearing face being oriented towards the outside of the frame when the reinforcing kit is in the assembled state.

[0019] Advantageously, the assembly notches are of the general shape of a disc sector with an angle strictly less than 90°, preferably less than 60°.

[0020] The assembly notches are thus simple to produce and allow the primary reinforcement elements to be effectively retained in the assembled state.

[0021] Advantageously, the primary and secondary reinforcement elements have mounting notches provided towards the inside of the frame when the reinforcement kit is in the assembled state.

[0022] The primary and secondary reinforcement elements can thus accommodate fastening means provided on the battery assembly, these fastening means extending through the mounting notches during assembly of the reinforcement kit on the battery assembly. In other words, the mounting notches allow the reinforcement kit not to be hindered by fastening components of the battery assembly during its assembly.

[0023] Advantageously, the secondary reinforcing elements each have at least one support opening provided with at least one fin extending from the support opening.

[0024] The secondary reinforcing elements can thus cooperate with the battery assembly to be fixed to the battery assembly or to produce an assembly stop by shape cooperation by means of the at least one fin.

[0025] Advantageously, the primary and secondary reinforcing elements are made of metal, for example aluminum or steel.

[0026] These materials allow the reinforcement kit to easily pass the crushing force test once assembled on the battery assembly.

[0027] Advantageously, the primary and secondary reinforcing elements are each produced by cutting, stamping, molding or folding from a metal sheet.

[0028] The reinforcing elements are thus manufactured by simple processes to implement. work and inexpensive. In particular, compared to a reinforcement kit which would be presented in the form of a single-piece frame, the material losses due to manufacturing are much less significant because to produce the single-piece frame, the material occupying the interior of the frame is generally machined, and therefore lost.

[0029] The invention also provides a battery assembly comprising a housing and a reinforcement kit as defined above, the primary and secondary reinforcement elements being coupled to the housing of the battery assembly, as well as a motor vehicle comprising such a battery assembly.

[0030] The invention also provides a method for reinforcing a battery assembly, in which the following successive steps are implemented:

[0031] - a battery pack and a reinforcement kit are provided as defined in this which precedes, then

[0032] - the primary reinforcement elements are inserted onto the battery assembly by translation primary reinforcement elements to the battery assembly, then

[0033] - the secondary reinforcement elements are inserted onto the battery assembly by translation secondary reinforcing elements to the battery assembly so as to house the primary reinforcing elements in the assembly notches of the secondary reinforcing elements.

[0034] The invention also provides a method for disassembling a battery assembly, in which the reinforcement method as defined above is implemented and then the following successive steps are implemented:

[0035] - the secondary reinforcement elements are removed from the battery assembly, then

[0036] - the primary reinforcement elements are removed from the battery assembly. Brief description of the figures

[0037] The invention will be better understood on reading the following description, given solely by way of example and with reference to the appended drawings in which:

[0038] [Fig. 1] is a perspective view of a battery assembly according to one embodiment of the invention,

[0039] [Fig.2] is a perspective view of a reinforcement kit, according to one embodiment of the invention, for the battery assembly of [Fig.l],

[0040] [Fig.3] is an enlarged view of a secondary reinforcement element of the reinforcement kit of [Fig.2],

[0041] [Fig.4] is an enlarged view of a primary reinforcement element of the reinforcement kit of [Fig.2], and

[0042] [Fig.5] is an enlarged view of the battery assembly of [Fig.l] illustrating the assembly of the reinforcement kit of [Fig.2]. Detailed description

[0043] [Fig. 1] shows a battery assembly 2 according to an embodiment of the invention intended to equip a motor vehicle. The battery assembly 2 comprises a housing 4 housing battery cells and components ensuring their proper functioning. Since the battery cells and these components are not essential to a good understanding of the invention, they have not been shown in the figures and will not be described further in the following. The battery assembly 2 comprises a reinforcement kit 6 which is assembled on the housing 4 of the battery assembly 2 in the configuration of [Fig. 1], so that the reinforcement kit 6 is in the assembled state in this figure. The reinforcement kit 6 is assembled around the housing 4, here at the base thereof.

[0044] The reinforcement kit 6 is shown in more detail in [Fig. 2], which shows it in a disassembled state. The reinforcement kit 6 comprises two primary reinforcement elements 8, each of which is generally elongated in shape with a “U”-shaped cross-section, and two secondary reinforcement elements 10, each of which is generally elongated in shape with a “U”-shaped cross-section. By bringing the reinforcement elements 8, 10 into contact with each other, it is possible to form a generally rectangular frame whose dimensions are compatible with the housing 4, in the sense that the frame can surround the housing 4 and be in contact with the housing 4 over the entire periphery of the housing 4. The open “U” shape of each of the primary 8 and secondary 10 reinforcement elements is oriented towards the inside of the frame so as to form a housing for receiving the housing 4.In the disassembled state, the reinforcement elements are far from each other.

[0045] The primary 8 and secondary 10 reinforcing elements are made of metal, here aluminum or steel. The primary 8 and secondary 10 reinforcing elements are each made by cutting, stamping, molding or folding from a metal sheet, which makes it possible to minimize losses due to falling material.

[0046] One of the secondary reinforcing elements 10 is shown on a larger scale in [Fig. 3], knowing that the other secondary reinforcing element 10 of the reinforcement kit 6 is functionally identical to it. The secondary reinforcing element 10 has two assembly notches 12 each configured to receive one of the primary reinforcing elements 8. Each assembly notch 12 has the general shape of a disc sector with an angle strictly less than 90°. Here, the angle of this disc sector is even less than 60° to be approximately equal to 45°.

[0047] The secondary reinforcement element 10 has, at the edge of each of its assembly notches 12, at least one secondary bearing face 14 configured to bear against the primary reinforcement elements 8 when the reinforcement kit 6 is in the assembled state. This will be presented in more detail below.

[0048] The secondary reinforcing element 10 has two support openings 16 each provided with at least one fin 18 extending from the support opening 16, towards the interior of the secondary reinforcing element 10. The fin 18 is configured to bear against a wall or an edge of the housing 4 of the battery assembly 2 in the assembled state to form either an assembly stop, facilitating the positioning of the secondary reinforcing element 10, or a mechanical retainer for maintaining the secondary reinforcing element 10 in the assembled state. This depends on the position of the fin 18 in the bearing opening 16. In the configuration of [Fig. 3], the fin 18 extends on one side of the bearing opening 16 close to the interior of the frame, so that it forms an assembly stop. In the case where it extends on a side of the bearing opening 16 opposite the interior of the frame, it would form a mechanical retainer. It can be provided that the secondary reinforcement element 10 comprises, for each support opening 16, several fins 18 so as to ensure the two functions presented.

[0049] The secondary reinforcement element 10 has mounting notches 20 arranged towards the inside of the frame when the reinforcement kit 6 is in the assembled state. These mounting notches 20 allow the secondary reinforcement element 10 not to abut against fixing means 26, such as screw-nut pairs, provided on the housing 4 for the assembly of the battery assembly 2 as such. In other words, the mounting notches 20 allow the reinforcement kit 6 to be assembled on the housing 4 of the battery assembly 2 in a particularly easy manner.

[0050] One of the primary reinforcing elements 8 is shown on a larger scale in [Fig. 4], knowing that the other primary reinforcing element 8 of the reinforcement kit 6 is functionally identical to it. The primary reinforcing element 8 has two ends 24 of a shape complementary to that of the assembly notches 12 provided on the secondary reinforcing elements 10. The primary reinforcing element 8 has, at the edge of each of its ends 24, at least one primary bearing face 22 configured to bear against the secondary bearing faces 14 provided on the secondary reinforcing elements 10 when the reinforcement kit 6 is in the assembled state. This will be presented in more detail below.

[0051] The primary reinforcement element 8 has mounting notches 20 arranged towards the inside of the frame when the reinforcement kit 6 is in the assembled state, similar to those present on the secondary reinforcement elements 10. These mounting notches 20 allow the primary reinforcement element 8 not to abut against fixing means 26, such as screw-nut pairs, provided on the housing 4 for the assembly of the battery assembly as such. In other words, the mounting notches 20 allow the reinforcement kit 6 to be assembled on the housing 4 of the battery assembly 2 in a particularly easy manner.

[0052] [Fig. 5] shows the primary reinforcing element 8 of [Fig. 4] and the secondary reinforcing element 10 of [Fig. 3] in the assembled state on the housing 4 of the battery assembly 2. [Fig. 5] illustrates the fin 18 which extends inside the bearing opening 16 and bears against an edge of the housing 4 to form an assembly stop. [Fig. 5] also illustrates the cooperation of the primary 22 and secondary 14 bearing faces. In the assembled state, each primary bearing face 22 of one of the primary reinforcing elements 8 is in contact with one of the secondary bearing faces 14 of one of the secondary reinforcing elements 10. The reinforcement kit 6 has two types of bearing. Some of the secondary bearing faces 14 are oriented towards the inside of the frame when the reinforcement kit 6 is in the assembled state. This is the case of the one at the bottom of [Fig. 5]. The other secondary bearing faces 14 are oriented towards the outside of the frame when the reinforcement kit is in the assembled state. This is the case of the one at the top of [Fig.5].

[0053] We will now present a method for reinforcing the battery assembly 2. We begin by making the battery assembly 2 and the reinforcement kit 6 available. The latter is initially in a disassembled state.

[0054] Next, the primary reinforcing elements 8 are inserted onto the battery assembly 2, more precisely onto the casing 4 thereof, by translation of the primary reinforcing elements 8 towards the battery assembly 2. Some of the fixing means 26 provided on the casing 4 are housed in the mounting notches 20 of the primary reinforcing elements 8.

[0055] Next, the secondary reinforcing elements 10 are inserted onto the battery assembly 2, more precisely onto the housing 4 thereof, by translating the secondary reinforcing elements 10 towards the battery assembly 2 so as to house the primary reinforcing elements 8 in the assembly notches 12 of the secondary reinforcing elements 10. The secondary bearing faces 14 come into contact with the primary bearing faces 22 or, at the very least, are positioned opposite them and close to them. This allows the secondary reinforcing elements 10 to prevent the primary reinforcing elements 8 from disassembling from the housing, thanks to the shape of the assembly notches 12 which can be compared to that of an undercut. Some of the fixing means 26 provided on the housing 4 are housed in the mounting notches 20 of the secondary reinforcing elements 10.Furthermore, the fins 18 of the secondary reinforcing elements 10 come into contact with the housing 4 to perform the assembly stop and / or mechanical retaining functions presented above. The fins 18 can deform elastically to adapt to the shape of the housing 4. Provision can be made for the reinforcement kit 6 to cooperate with an additional element intended to fix it in its assembled state.

[0056] After implementing the reinforcement method, the battery assembly 2 has the configuration illustrated in Figures 1 and 5. In this assembled state, the battery assembly 2 can be subjected to a crushing force test. A force is then applied to one of the primary 8 or secondary 10 reinforcement elements in a direction oriented towards the housing 4 of the battery assembly 2.

[0057] A force applied to a secondary reinforcing element 10 transmits a force to the primary reinforcing elements 8 which presses them in the direction of the housing 4 thanks to the secondary bearing faces 14 oriented towards the inside of the frame, which tends to tighten the frame formed by the reinforcement kit 6. Conversely, a force applied to a primary reinforcing element 8 transmits a force to the secondary reinforcing elements 10 which presses them in the direction of the housing 4 thanks to the secondary bearing faces oriented towards the outside of the frame, which also tends to tighten the frame formed by the reinforcement kit 6. It is thus understood that the different orientations of the primary 22 and secondary 14 bearing faces improve the cohesion of the frame formed by the reinforcement kit 6.The properties of the primary 8 and secondary 10 reinforcement elements, in particular their constituent materials, their dimensions and their shapes, can be adapted to allow the battery assembly 2 to successfully pass the crushing force test under the conditions imposed by the ECE R100 standard when the reinforcement kit 6 is assembled on the housing 4 of the battery assembly.

[0058] To disassemble the reinforcement kit 6 from the battery assembly 2, the secondary reinforcement elements 10 are first removed from the battery assembly 2, then the primary reinforcement elements 8 are removed from the battery assembly 2. The disassembly of the reinforcement kit 6 is thus very simple to carry out, so that the battery assembly 2 is thus easily accessible for maintenance or replacement operations.

[0059] The invention is not limited to the embodiments presented and other embodiments will become clear to those skilled in the art. List of references

[0060] 2: battery assembly 4: case 6: reinforcement kit 8: primary reinforcement element 10: secondary reinforcement element 12: assembly notch 14: secondary support face 16: support opening 18: fin 20: mounting notch 22: primary support face 24: end 26: means of fixing the housing

Claims

Claims

1. Reinforcement kit (6) for a motor vehicle battery assembly (2) characterized in that it comprises: - two primary reinforcement elements (8), of generally elongated shape with a "U" shaped cross section, - two secondary reinforcement elements (10), of generally elongated shape with a "U" shaped cross section, each secondary reinforcement element (10) having two assembly notches (12) each configured to receive one end (24) of one of the primary reinforcement elements (8), so as to form a generally rectangular frame in an assembled state in which the primary reinforcement elements (8) extend into the assembly notches (12) of the secondary reinforcement elements (10).

2. Reinforcement kit (6) according to the preceding claim, in which the secondary reinforcement elements (10) comprise, at the edge of each of their assembly notches (12), at least one secondary bearing face (14) configured to bear against primary bearing faces (22) provided on the primary reinforcement elements (8) when the reinforcement kit (6) is in the assembled state.

3. Reinforcement kit (6) according to claim 2, wherein said at least one secondary bearing face (14) is oriented towards the inside of the frame when the reinforcement kit (6) is in the assembled state.

4. Reinforcement kit (6) according to claim 2, wherein said at least one secondary bearing face (14) is oriented towards the outside of the frame when the reinforcement kit (6) is in the assembled state.

5. Reinforcement kit (6) according to any one of the preceding claims, in which the assembly notches (12) are of the general shape of a disc sector with an angle strictly less than 90°.

6. A reinforcement kit (6) according to any preceding claim, wherein the primary (8) and secondary (10) reinforcement members have mounting notches (20) provided towards the inside of the frame when the reinforcement kit (6) is in the assembled state.

7. Reinforcement kit (6) according to any one of the preceding claims, wherein the secondary reinforcement elements (10) each have at least one support opening (16) provided with at least one fin (18) extending from the support opening (16).

8. Reinforcement kit (6) according to any one of the preceding claims- preceding, in which the primary (8) and secondary (10) reinforcing elements are made of metal, for example aluminum or steel.

9. A reinforcement kit (6) according to any preceding claim, wherein the primary (8) and secondary (10) reinforcement elements are each made by cutting, stamping, molding or bending from sheet metal.

10. A battery assembly (2) comprising a housing (4) and a reinforcement kit (6) according to any one of the preceding claims, the primary (8) and secondary (10) reinforcement elements being coupled to the housing (4) of the battery assembly (2).

11. Motor vehicle comprising a battery assembly (2) according to the preceding claim.

12. Method for reinforcing a battery assembly (2), in which the following successive steps are implemented: - a battery assembly (2) and a reinforcement kit (6) according to any one of claims 1 to 9 are provided, then - the primary reinforcement elements (8) are inserted onto the battery assembly (2) by translation of the primary reinforcement elements (8) towards the battery assembly (2), then - the secondary reinforcement elements (10) are inserted onto the battery assembly (2) by translation of the secondary reinforcement elements (10) towards the battery assembly (2) so as to house the primary reinforcement elements (8) in the assembly notches (12) of the secondary reinforcement elements (10).

13. Method for disassembling a battery assembly (2), in which the reinforcement method according to the preceding claim is implemented and then the following successive steps are implemented: - the secondary reinforcement elements (10) are removed from the battery assembly (2), then - the primary reinforcement elements (8) are removed from the battery assembly (2).

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