MOTOR VEHICLE COMPRISING A BATTERY PROTECTION SCREEN EQUIPPED WITH A CONNECTOR PROTECTION CAGE, AND METHOD FOR MANUFACTURED SUCH A VEHICLE

Abstract

The invention relates to a motor vehicle comprising a body which includes: - a battery tray (B) forming a housing for battery modules; - a battery comprising battery modules housed at least partially in the housing, and at least one battery connector (C) connected to at least one module, disposed in front of the battery tray (B); - a protective screen (E) disposed under the battery tray (B), characterized in that said screen (E) comprises a protective cage (P) around said connector (C), with at least two side panels and one rear panel disposed on two lateral sides and behind said connector (C). The invention also relates to a method of manufacturing such a vehicle. Figure 3

Description

Title of the invention: MOTOR VEHICLE COMPRISING A BATTERY PROTECTION SCREEN EQUIPPED WITH A CONNECTOR PROTECTION CAGE, AND METHOD FOR MANUFACTURED BY SUCH A VEHICLE

[0001] The invention relates to the field of traction battery protection systems for motor vehicles, in particular with regard to frontal impacts.

[0002] In this field, electric motor vehicles have a battery tray structure known as "cell-to-body" (or "cell-to-body"). This structure allows for better synergy between the battery tray and the body.

[0003] The body components are illustrated in [Fig. 1] with reference to a coordinate system in space comprising a longitudinal axis X along a direction of travel of the motor vehicle; a lateral axis Y perpendicular to the longitudinal axis X; and a vertical axis Z perpendicular to the longitudinal axis X and to the lateral axis Y. The body comprises a battery tray B which includes a metal housing structure protecting the underside of the battery. The body further comprises an underbody screen E attached beneath the battery, made of composite material or polypropylene. The body further comprises an engine tray M formed by a steel frame arranged at the front of the battery tray B with reference to the longitudinal axis X.

[0004] Once installed, the battery has a connector C equipped with high-voltage electrical cables, located at the front of the battery tray B and at the rear of the engine tray M with reference to the longitudinal axis X.

[0005] In the event of a frontal impact to the front of the vehicle with reference to the longitudinal axis X, connector C may be displaced forward and impact the rear of the engine compartment. Such an impact poses a danger to the vehicle's occupants because it represents a risk of damage to a low-voltage electrical connection.

[0006] An objective of the present invention is to remedy the defects of the prior art, and in particular to offer a solution for protecting battery tray connectors against frontal impacts on the motor vehicle.

[0007] To achieve this objective, the invention proposes a motor vehicle having a reference frame in space comprising a longitudinal axis along a direction of movement of the motor vehicle; a lateral axis perpendicular to the longitudinal axis, and a vertical axis perpendicular to the longitudinal axis and to the lateral axis, the motor vehicle comprising a body which includes: - a battery tray forming a housing for battery modules; - a battery comprising battery modules housed at least partially in the housing, and at least one battery connector connected to at least one module, positioned in front of the battery tray with reference to the longitudinal axis; - a protective screen disposed under the battery tray with reference to the vertical axis, characterized in that the protective screen comprises a protective cage around said connector, comprising at least lateral sides disposed on two lateral sides of said connector with reference to the lateral axis, and a rear side disposed behind said connector with reference to the longitudinal axis.

[0008] Advantageously, the invention offers complete protection of battery connectors in the event of a severe frontal impact by means of a device that can be lightweight, easily manufactured or even added to the assembly.

[0009] In particular, the protective screen includes a front part disposed under said connector and carrying the protective cage.

[0010] Preferably, the protective screen includes a front section extending under said connector, and the front section includes ribs along the longitudinal axis.

[0011] The anterior section provides additional protection for said connector and support for the protective cage; and the ribs provide resistance of the anterior section to bending.

[0012] Preferably, the protective cage further comprises a lower side arranged below said connector with reference to the vertical axis.

[0013] This also helps to protect the underside of said connector.

[0014] Preferably, the protective cage comprises at least one layer of composite material or polypropylene.

[0015] This makes it possible to offer a material in one piece with the protective screen for rapid manufacturing of these two elements together.

[0016] Preferably, at least one of said flanks comprises a metal reinforcement.

[0017] This helps to reinforce the protection of said flanks.

[0018] Preferably, the metal frame has a flat structure at the lower side.

[0019] This further strengthens the protection of the lower flank.

[0020] Preferably, at least one of said flanks comprises the metal reinforcement between two layers of composite material or polypropylene.

[0021] This makes it possible to combine both the rigidity of the metal and the damping of the composite or polypropylene of the protective cage.

[0022] Another object of the invention relates to a method for manufacturing a motor vehicle according to the invention, characterized in that it comprises the following steps: - a step of installing the battery modules in the battery tray housing, and said connector in front of the battery tray with reference to the longitudinal axis; - a step of installing the protective screen under the battery tray with reference to the vertical axis, so that the protective cage is arranged around said connector, the side sides being arranged on two lateral sides of said connector with reference to the lateral axis, and the rear side being arranged behind said connector with reference to the longitudinal axis.

[0023] Preferably, the manufacturing process further includes a step of placing a metal frame in or on the protective cage with reference to the vertical axis.

[0024] The invention will be further detailed by describing non-limiting embodiments, and based on the accompanying figures in which: - [Fig.l] schematically illustrates a view in space from below of a battery tray and an engine tray of a motor vehicle according to the prior art; - [Fig.2] schematically illustrates a view in space of the underside of a protective screen of a motor vehicle according to a first preferred embodiment of the invention, as well as a close-up of its front section; - [Fig.3] schematically illustrates a top-space view of a front part of a battery tray and an engine tray of the motor vehicle according to the first preferred embodiment of the invention; - [Fig.4] schematically illustrates a view in space of a protective cage for the vehicle of [Fig.3]; - [Fig.5] schematically illustrates a view in space of a protective cage of a motor vehicle according to a second preferred embodiment of the invention.

[0025] The invention proposes a motor vehicle described with reference to a frame of reference in space comprising a longitudinal axis X along a direction of movement of the motor vehicle; a lateral axis Y perpendicular to the longitudinal axis X, and a vertical axis Z perpendicular to the longitudinal axis X and to the lateral axis Y.

[0026] The motor vehicle includes a body which is similar to that of the prior art vehicle, with the elements illustrated in [Fig.1].

[0027] The components of the vehicle body according to the invention are illustrated in Figures 2 to 5. The body comprises: - a battery tray B; - a battery comprising battery modules; - a protective screen E similar to that of the prior art, below the battery tray with reference to the vertical axis Z.

[0028] The battery tray B forms a housing for battery modules, partially housing the battery modules, namely at least the bottom and part of the height of the battery modules, as can be seen in [Fig.3].

[0029] The battery further comprises at least one battery connector C connected to at least one battery module. The connector C, illustrated in detail in [Fig. 3], is positioned in front of the battery tray B with reference to the longitudinal axis X.

[0030] According to the invention, the protective screen E comprises a front section SA extending under said connector C. The front section SA comprises ribs N along the longitudinal axis X. This is illustrated in [Fig.2].

[0031] Furthermore, according to the invention, the protective screen E comprises a protective cage P around said connector C. More specifically, in a first embodiment illustrated in [Fig.4], the protective cage P comprises; - two lateral flanks FDE, FGE arranged on two lateral sides of said connector C with reference to the lateral axis Y; - a rear FPE flank positioned behind said connector P with reference to the longitudinal axis X; and - a lower FIE flank arranged below said connector C with reference to the vertical axis Z.

[0032] In this embodiment, the protective cage P comprises a layer of composite material or polypropylene.

[0033] In a second embodiment illustrated in [Fig. 5], the protective cage P may comprise a layer of composite material or polypropylene, with a layer of metal reinforcement A on top, preferably comprising a flat metal lower side (flat structure FIM) and lateral tabs BD, BG. The protective cage P may comprise two layers of composite material or polypropylene, with an intermediate layer of said metal reinforcement A. In this case, the protective cage P is, for example, a metal cage that may be 0.5 mm thick, overmolded with two layers of composite or polypropylene.

[0034] The side tabs BD, BG can be tabs for fixing the cage P to the upper part of the battery housing illustrated in [Fig.3].

[0035] The invention further relates to a method for manufacturing a motor vehicle, comprising steps for setting up and assembling the elements described above.

[0036] The method includes a step of placing the battery modules in the housing of the battery tray B, and said connector C in front of the battery tray B with reference to the longitudinal axis X.

[0037] The method further includes a step of installing the protective screen E below the battery tray B with reference to the vertical axis Z. The screen E is positioned there so that the protective cage P is arranged around said connector C. More specifically, during this step, the side flanks FDE, FGE, FDI, FGI as appropriate, are arranged on two lateral sides of said connector C with reference to the lateral axis Y, and the rear flank FPE, FPI as appropriate, is arranged behind said connector C with reference to the longitudinal axis X.

[0038] Regarding the protective cage according to the second embodiment, the process may further include a preliminary step of placing a metal frame A in or on the protective cage P as appropriate.

[0039] The invention ensures optimal protection of the high-voltage traction battery connectors C in the event of severe frontal impacts. The impact on the mass and performance of the protective screen E is limited. The cage P can be attached during assembly, making it compatible with the continuation of the conventional design and easy to adapt to the prior art manufacturing process.

Claims

Demands

1. A motor vehicle having a frame of reference in space comprising a longitudinal axis (X) along a direction of movement of the motor vehicle; a lateral axis (Y) perpendicular to the longitudinal axis (X), and a vertical axis (Z) perpendicular to the longitudinal axis (X) and to the lateral axis (Y), the motor vehicle comprising a body which includes: - a battery tray (B) forming a housing for battery modules; - a battery comprising battery modules housed at least partially in the housing, and at least one battery connector (C) connected to at least one module, disposed in front of the battery tray (B) with reference to the longitudinal axis (X);- a protective screen (E) disposed under the battery tray (B) with reference to the vertical axis (Z), characterized in that the protective screen (E) comprises a protective cage (P) around said connector (C), comprising at least lateral flanks (FDE, FGE, FDI, FGI) disposed on two lateral sides of said connector (C) with reference to the lateral axis (Y), and a rear flank (FPE, FPI) disposed behind said connector (P) with reference to the longitudinal axis (X).

2. Motor vehicle according to claim 1, characterized in that the protective screen comprises a front section (SA) extending under said connector (C), and the front section (SA) comprises ribs (N) along the longitudinal axis (X).

3. Motor vehicle according to any one of claims 1 to 2, characterized in that the protective cage further comprises a lower side (FIE, FII) disposed below said connector (C) with reference to the vertical axis (Z).

4. Motor vehicle according to any one of claims 1 to 3, characterized in that the protective cage (P) comprises at least one layer of composite material or polypropylene.

5. Motor vehicle according to claim 4, characterized in that at least one of said sides (FDE, FGE, FDI, FGI, FPE, FPI, FIE, FII) comprises a metal reinforcement (A).

6. Motor vehicle according to claim 5, characterized in that the metal frame (A) has a flat structure (FIM) at the level of the lower side (FIE, FII).

7. Motor vehicle according to any one of claims 5 to 6, characterized in that at least one of said sidewalls (FDE, FGE, FDI, FGI, FPE, FPI, FIE, FII) comprises the metal reinforcement (A) between two layers of composite material or polypropylene.

8. A method for manufacturing a motor vehicle according to any one of claims 1 to 7, characterized in that it comprises the following steps: - a step of placing the battery modules in the housing of the battery tray (B), and of said connector (C) in front of the battery tray (B) with reference to the longitudinal axis (X); - a step of placing the protective screen (E) below the battery tray (B) with reference to the vertical axis (Z), so that the protective cage (P) is arranged around said connector (C), the lateral sides (FDE, FGE, FDI, FGI) being arranged on two lateral sides of said connector (C) with reference to the lateral axis (Y), and the rear side (FPE, FPI) being arranged behind said connector (C) with reference to the longitudinal axis (X).

9. A manufacturing method according to claim 8, characterized in that it further comprises a step of placing a metal frame (A) in or on the protective cage (P) with reference to the vertical axis (Z).

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