ELECTRIC VEHICLE WITH A REINFORCED FLOOR

Abstract

The invention relates to an electric vehicle whose floor comprises two parallel side members (3) connected to each other by at least one cross member, each cross member being welded by its ends (80) at least to one edge (4) of the floor, the space defined between a part of the edge (4) and at least two neighboring parallel cross members forming at least one housing for receiving at least one module of at least one battery, a side member reinforcement (6) being fixed to each side member (3), characterized in that at least one stamped zone (11) is provided in each side member reinforcement (6) and forms a connection zone on the edge (4) of the floor of each end (80) of at least one cross member, said stamped zone (11) delimiting a triple-thickness welding zone (12) between the end (80) of the cross member, the edge (4) of the floor and the side member (3). Figure to be published with the abstract: Fig.4

Description

Title of the invention: ELECTRIC VEHICLE PROVIDED WITH A REINFORCED FLOOR

[0001] The invention relates to an electric vehicle provided with a reinforced floor.

[0002] Here the term vehicle designates a car, a van, a truck, a public transport vehicle, a public works or agricultural machine, the vehicle being motorized, partially or solely, by at least one electric motor.

[0003] On an electric vehicle, the batteries are generally grouped into modules which are placed in the lower part, under the floor of the vehicle, in order to free up as much space as possible inside the vehicle and to have a lower center of gravity. The battery modules are frequently located in housings delimited by parallel crossmembers connecting the lower edges of the floor. The crossmembers have the function of transversely stiffening the floor and protecting the batteries. Since the latter are particularly exposed in the event of a side impact on the vehicle, side member reinforcements are also fixed on the outside of the edges of the floor, along the side members. These side member reinforcements also contribute to the protection of the batteries. In the event of a violent side impact, it is necessary to optimize the impact resistance of the floor and the protection of the batteries.CN-A-110481647 proposes welding the cross members on the one hand to the side members and on the other hand to a central substructure itself reinforced by plates welded to a central tunnel. This solution does not allow dissipation of the energy of a lateral impact in all the constituent parts of the floor, particularly during a violent impact.

[0004] The object of the invention is to propose a solution making it possible to improve the resistance of the floor to a lateral impact, to preserve the battery modules, whatever the violence of the impact, over the entire length of the floor and to dissipate the energy of the impact as best as possible, while respecting the manufacturing constraints and without significantly increasing the mass of the vehicle.

[0005] To this end, the invention relates to an electric vehicle whose floor comprises two parallel side members laterally reinforcing the floor and connected to each other by at least one cross member fixed to the so-called lower face of the floor which is opposite the vehicle's travel path, each cross member being welded by its ends at least to one edge of the floor, the space defined between a part of the edge of the floor and at least two neighboring parallel cross members forming at least one housing for receiving at least one module of at least one battery, a side member reinforcement being fixed to each side member and extending over the entire length of the latter, characterized in that at least one stamped zone is provided in each side member reinforcement and forms a connecting zone of each end of at least one crossmember on the edge of the floor, said stamped zone delimiting a triple-thickness welding zone between the end of the crossmember, the edge of the floor and the side member.

[0006] Thanks to the invention, welding zones are produced allowing welding on three thicknesses, which makes it possible to have connections between different elements by welding on triple thickness, which is the maximum possible. All the connections are optimized and reinforced, which makes it possible to dissipate the energy of a violent lateral impact on all the cross members and therefore to better protect the batteries. In addition, such a solution does not increase the initial mass and size of the floor.

[0007] According to advantageous, but not mandatory, aspects of the invention, such a vehicle may comprise one or more of the following characteristics:

[0008] Each end of each crossmember is provided with at least one tab extending outwardly and coplanar with the end edge of the crossmember.

[0009] The end of each crosspiece is welded to the edge of the floor by at least one tab.

[0010] Each crossmember end is provided with two outwardly extending legs coplanar with the end edge of the crossmember, each leg being welded to the edge of the floor.

[0011] The dimensions of each stamped area correspond to the added dimensions of the two legs and the end edge of a crosspiece.

[0012] Between two neighboring stamped areas, another connection area, not stamped, is delimited by triple-thickness welding between the edge of the floor, the side member and the side member reinforcement.

[0013] The stamped and non-stamped areas of triple-thickness weld connection are regularly alternated along the entire length of the floor.

[0014] In the alternating areas of welded connection, stamped and non-stamped, a welded connection is always made in each area between at least the edge of the floor and the side member.

[0015] The number of weld points in each weld bonding area, stamped and unstamped, is at least two.

[0016] The invention will be better understood and other advantages thereof will appear more clearly on reading the description which follows, given solely by way of non-limiting example and with reference to the appended drawings in which:

[0017] [Fig. 1] is a simplified perspective view, from the face facing the interior of the vehicle, of a vehicle floor according to an embodiment of the invention,

[0018] [Fig.2] is a perspective view similar to [Fig.l] and from the outward-facing face of the vehicle of the vehicle floor of [Fig.l],

[0019] [Fig.3] is a view on a larger scale of a part of [Fig.2], according to arrow III, with a part of the spar and a part of the floor, illustrating the fixing zones between the spar reinforcement, three ends of cross members, the spar and the floor, the spar reinforcement being illustrated in dotted lines,

[0020] [Fig.4] is a top view, on a larger scale, of detail IV in [Fig.3] and

[0021] [Fig.5] is a simplified schematic view of the underside of the vehicle floor, at a another scale, the battery modules being represented, illustrating the dissipation of energy during a side impact in a vehicle floor according to the invention.

[0022] [Fig.l] illustrates the floor 1 of a vehicle, simplified and seen from the upper face of the floor, namely the one facing the interior of the vehicle. The floor 1, made of metal, comprises a main body 2 that is generally rectangular and whose dimensions correspond to the wheelbase between the front and rear wheels of the vehicle. Two identical and parallel side members 3 are fixed to the long sides of the floor 1 and stiffen it. As noted in [Fig.l], the side members 3 extend upwards, looking at [Fig.l], the lateral edges 4 of the floor 1. The edges 4 of the floor, visible in particular in [Fig.2], are folded downwards so as to form a substantially vertical wall and to provide a volume V under the floor 1 intended to receive at least one module 5 of at least one battery of the electric vehicle. The modules 5 are illustrated only in [Fig.5] for greater readability.Subsequently, when reference is made to an internal or inward-facing face of floor 1, this will be in reference to the volume V defined under floor 1. The same will apply to an external or outward-facing face of floor 1.

[0023] Here, each side member 3 receives a side member reinforcement 6. The pairs formed by a side member 3 and a side member reinforcement 6 are identical on each side of the floor 1. A side member reinforcement 6 has the function of reinforcing the side member 3 and reducing the risk of lateral deflection and twisting of the floor 1 in the event of an impact. It also makes it possible to improve the protection of the elements present at the level of the floor 1 in the event of a side impact, in particular when it is a vehicle equipped with electric batteries placed under the floor. Alternatively, the side member reinforcements 6 are also mounted on vehicles without electric batteries.

[0024] Each spar reinforcement 6, according to the illustrated embodiment, is a hollow elongated structure divided into hollow, cubic and joined modules. Alternatively, the geometric configuration of the modules is different, for example in honeycomb, prism or other, it being understood that a hollow and deformable structure is to be favored due to its capacity to absorb the energy of an impact greater than that of a solid and rigid structure. Each spar reinforcement 6 is welded on a face of a spar 3 oriented towards the outside of the floor. In other words, the spar reinforcements 6 extend the spars 3 and de facto the floor in an outward direction.

[0025] [Fig. 2] is a view from the lower face 7 of the floor 1 of [Fig. 1], the lower face 7 being the one oriented towards the volume V and therefore also towards the traffic lane of the vehicle. In addition to the elements illustrated in [Fig. 1], at least one, here four, metal and parallel crosspieces 8 are regularly distributed along the width of the floor 1. They are configured as beams with a rectangular cross-section and, in the example, are all identical. Alternatively, the crosspieces are not all identical and / or have another geometric configuration. In addition, they can be solid or hollow. The crosspieces 8 are connected by their ends 80 to a face 9 of the edges 4 of the floor 1 which is oriented towards the volume V under the floor. The crosspieces 8 are also connected by a longitudinal face 81 defining their length, to the lower face 7 of the body of the floor.The crosspieces 8 have the function of stiffening the floor 1 by limiting any phenomenon of buckling or twisting of the floor. They also make it possible, in combination with portions of the edges 4 of the floor 1 located between two neighboring crosspieces 8, to divide the volume V defined under the floor and to delimit receiving housings 10 of at least one battery module 5 and to reinforce the protection of the modules 5 located in the volume V under the floor of the vehicle.

[0026] [Fig. 3] illustrates, on a larger scale and from volume V according to arrow III, the connection zone between the ends 80 of the crosspieces 8 and one of the folded edges 4 of the floor 1. The side member reinforcement 6 is illustrated in dotted lines. The ends 80 of each crosspiece 8 each comprise at least one, here two tabs 82 extending outwards on either side of the edge of the end 80 of the crosspiece 8. These tabs 82 are coplanar with the edge of the end 80 and bear on the internal face 9 of the edge 4 of the floor 1. The tabs 82 are welded to the edge 4 by at least two welding points. Generally speaking, the connections between the different elements described are definitive and made by welding in order to optimize the impact resistance of the assembly formed by the elements connected together by ensuring the best possible dissipation of the energy of an impact in all the elements.It turns out that if we want to optimize the impact resistance by dissipating the impact energy as much as possible between the various elements concerned, namely primarily the cross members 8 and the side member reinforcements 6, it is necessary to create connection zones between these elements, therefore welding zones. However, it turns out that it is not possible to weld four thicknesses of elements together, the maximum that can be achieved effectively being a weld on three thicknesses, which represents a connection by welding between at most three separate elements.

[0027] Considering the configuration of a state-of-the-art floor, a weld would have to be made between the following four elements: the legs 82, the edge 4 of the floor, the side member 3 and the side member reinforcement 6 to obtain an effective connection. between all these elements, which is not achievable according to the current state of the art. The invention makes it possible to create a lasting and effective connection between these four elements by welding and this over the entire length of the floor 1.

[0028] For this, as is particularly visible in [Fig.4] illustrating detail IV of [Fig.3], stamped zones 11 are provided on each side member reinforcement 6 and define connecting zones. These zones 11 are regularly distributed along the reinforcement 6 and have dimensions corresponding substantially to the added dimensions of the lugs 82 and the end edge 80 of each cross member 8. Opposite these stamped zones 11, only the lugs 82, the edge 4 of the floor 1 and the side member 3 are in contact, the side member reinforcement 6 is set back and has no contact with these three elements in this zone 11 due to the empty space defined by the stamping. This configuration makes it possible to weld together the three elements, namely the lugs 82, the edge 4 of the floor 1 and the side member 3 since there are only three thicknesses to be welded. This defines a first welding zone in triple thicknesses referenced 12.

[0029] On either side of the stamped zones 11, the edge 4 of the floor 1, the side member 3 and the side member reinforcement 6 are in contact. In this other connection zone, referenced 13, a weld is made between these three elements, namely the edge 4 of the floor 1, the side member 3 and the side member reinforcement 6 over a triple thickness. Subsequently, for greater readability, the reference 13 will designate both this non-stamped zone and this welding zone. This results in a regular alternation of connection zones, therefore welding zones 12 and 13 with each time three elements welded together. In all cases, the welding zones 12 and 13 concern a connection between the edge 4 of the floor and the side member 3, which ensures an optimal connection between these two elements out of the three welded together in each zone 12 or 13, this over the entire length of the floor 1.The presence in welding zones 12 and 13 of two common elements out of the three welded together optimizes the connection between all the elements.

[0030] [Fig. 5] illustrates, schematically, the dissipation of the energy of a lateral impact, illustrated by the arrows F, on the floor 1 of the vehicle. As noted, thanks to the welding zones 12 and 13 produced at and on either side of the stamped zones 11, the energy of the impact is dissipated not only in the side member reinforcements 6, the side members 3 and the edge 4 of the floor 1 but also in the cross members 8. This improves the protection of the battery modules 5 while limiting the deformation of the floor. The energy dissipated near the modules 5 is less than that dissipated in the case of a floor of the state of the art, because it is all of the elements that dissipate the energy. In addition to greater resistance to violent impacts, the protection of vehicle occupants is improved, as the battery modules 5 are preserved and do not deform and / or move, or at least only slightly, under impact.This is achieved by the invention, without additional parts, without modifications. fixing the nominal size and mass of the vehicle floor 1 and at a low cost.

Claims

Claims

1. Electric vehicle whose floor (1) comprises two parallel side members (3) laterally reinforcing the floor (1) and connected to each other by at least one cross member (8) fixed on the so-called lower face (7) of the floor (1) which is opposite the vehicle's travel path, each cross member (8) being welded by its ends (80) at least to one edge (4) of the floor (1), the space defined between a part of the edge (4) of the floor (1) and at least two neighboring parallel cross members (8) forming at least one housing for receiving at least one module (5) of at least one battery, a side member reinforcement (6) being fixed to each side member (3) and extending over the entire length of the latter, characterized in that at least one stamped zone (11) is provided in each side member reinforcement (6) and forms a connection zone of each end (80) of at least one cross member (8) on the edge (4) of the floor (1),said stamped zone (11) delimiting a welding zone (12) in triple thicknesses between the end (80) of the cross member (8), the edge (4) of the floor (1) and the side member (3).,

2. Vehicle according to claim 1, characterized in that each end (80) of each cross member (8) is provided with at least one tab (82) extending outwards and coplanar with the end edge (80) of the cross member (8).

3. Vehicle according to claim 2, characterized in that the end (80) of each cross member (8) is welded to the edge (4) of the floor (1) by at least one tab (82).

4. Vehicle according to claim 3, characterized in that each end (80) of the cross member (8) is provided with two tabs (82) extending outwards and coplanar with the end edge (80) of the cross member (8), each tab (82) being welded to the edge (4) of the floor (1).

5. Vehicle according to claim 4, characterized in that the dimensions of each stamped zone (11) correspond to the added dimensions of the two legs (82) and the end edge (80) of a cross member (8).

6. Vehicle according to claim 1, characterized in that between two neighboring stamped zones (11), another connection zone (13), not stamped, is delimited by triple-thickness welding between the edge (4) of the floor (1), the side member (3) and the side member reinforcement (6).

7. Vehicle according to claim 6, characterized in that the zones stamped (11) and non-stamped (13) welded connection in triple thicknesses of welds 12 and 13 are regularly alternated over the entire length of the floor (1)

8. Vehicle according to claim 7, characterized in that in the alternating areas of welded connection, stamped (12) and non-stamped (13), a welded connection is always made in each area (11, 13) between at least the edge (4) of the floor (1) and the side member (3).

9. Vehicle according to one of the preceding claims, characterized in that the number of welding points in each welding zone (12, 13) is at least equal to two.

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