Battery structure of vehicle

Abstract

To secure sealing performance of a joining part of a vertical frame and a horizontal frame, while improving rigidity of a battery frame constituted of the vertical frame extending in the longitudinal direction and the horizontal frame extending in the vehicle width direction.SOLUTION: The battery frame (21) includes a pair of longitudinal frames (22) extending in a front-rear direction on both sides in a vehicle-width direction, and a pair of lateral frames (31) extending in the vehicle-width direction on both sides in the front-rear direction. The longitudinal frame (22) is fastened to a side 31t of an end portion of the lateral frame (31) in a longitudinal direction of the lateral frame (31) by fastening means (B). A seal shelf 40 forming a recessed shape with respect to a fastened surface 24 fastened to a lateral frame 31 in a vertical frame 22 is provided on a fastening surface 32 for fastening the vertical frame 22 in the lateral frame 31, and a seal material 60 is provided on the seal shelf 40.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a battery structure for a vehicle in which a battery is mounted under the floor of the vehicle. [Background technology]

[0002] In recent years, in electric vehicles such as electric vehicles (so-called EV vehicles) and hybrid vehicles (so-called HEV vehicles), there has been a trend toward larger and larger-capacity battery units that supply electricity to the motors that serve as drive sources in order to extend the driving range. Furthermore, installing such battery units in a vehicle increases the vehicle weight, so it is desirable to increase the rigidity of the vehicle body, such as its torsional rigidity.

[0003] The battery case for an electric vehicle disclosed in Patent Document 1 includes a battery frame that is formed into a frame shape in plan view by joining multiple skeletal members. The multiple skeletal members are all made of extruded aluminum material, and are joined by engaging their ends with each other.

[0004] In a structure in which skeletal members are joined by engagement, such as the battery frame of Patent Document 1, although joining with structural positional constraints is possible, it is expected that further increasing the joining strength between the skeletal members will enable the rigidity of one of the joined skeletal members to be increased by utilizing the rigidity of the other skeletal member. In other words, joining the skeletal members with a stronger joining strength is expected to increase the torsional rigidity of the entire battery frame, which is frame-shaped in plan view, so there is room for improvement.

[0005] Furthermore, because the battery unit is mounted under the floor of the vehicle, it must also have a high level of sealing ability to prevent water from entering from the road surface and causing malfunctions in the electronic components. Therefore, for example, when trying to ensure sealing (watertightness) at the joints between the skeletal members that make up the battery frame of Patent Document 1, it is conceivable to apply a sealant to the joints to remove the gap between the two members.

[0006] However, if the skeletal components are firmly fastened together using a fastening means with a sealing material interposed between them, the sealing material may fall off, making it difficult to interpose the components while maintaining the desired thickness. Therefore, ingenuity is required to increase the rigidity of the battery frame while ensuring sealing between the two components.

[0007] The battery case for an electric vehicle in Patent Document 1 is configured to place a bathtub-shaped tray in the space within the battery frame, which has a frame-like shape when viewed from above, to ensure sealing within the frame. However, providing a tray that is a separate component from the battery frame increases costs, so there is room for improvement. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Japanese Patent Application Publication No. 2023-131342 Summary of the Invention [Problem to be solved by the invention]

[0009] This invention was made in consideration of such problems, and aims to provide a vehicle battery structure that can improve the rigidity of a battery frame that has a frame shape when viewed from above, while ensuring sealing between the vertical frames and horizontal frames that are joined to each other to form the battery frame. [Means for solving the problem]

[0010] The vehicle battery structure of this invention is provided below the floor panel of the vehicle and has a first frame that faces each other across a first direction, either the fore-and-aft direction or the width direction of the vehicle, and a second frame that faces each other across a second direction different from the first direction, and is a rectangular battery frame in a plan view of the vehicle that can store a battery, and the second frame is fastened to the longitudinal end of the first frame in the longitudinal direction of the first frame by fastening means, and at least one of the fastening surface of the first frame that fastens the second frame and the fastened surface of the second frame that is fastened to the first frame has a sealing shelf that is concave with respect to the other surface, and the sealing shelf is equipped with a sealing material.

[0011] The fastening surfaces are surfaces that receive pressure from the fastened surfaces of the second frame when the second frame is fastened by the fastening means. That is, the fastening surfaces are surfaces that cooperate with the fastening means to sandwich the second frame having the fastened surfaces. The fastened surfaces are surfaces that are pressed against the fastening surfaces of the longitudinal ends of the first frame when the second frame is fastened to the longitudinal ends of the first frame.

[0012] According to the above configuration, by mechanically fastening the second frame to the first frame, the rigidity of the entire battery frame, such as torsional rigidity when the vehicle is running, is improved, and by providing the sealing material on the sealing shelf, watertightness can be ensured at the fastening point where the fastening surface and the fastened surface are fastened.

[0013] As an aspect of the present invention, the first frame may be a horizontal frame extending along the vehicle width direction as the second direction, and the second frame may be a vertical frame extending along the vehicle fore-and-aft direction as the first direction, the horizontal frame being a cast member and the vertical frame being an extruded member.

[0014] According to the above configuration, by using the vertical frame as the extruded member, a closed cross-sectional structure along the fore-and-aft direction of the vehicle can be easily constructed, thereby ensuring excellent rigidity of the vertical frame against side impact loads (collision loads input to the vehicle from the side).

[0015] Furthermore, by using the cast member as the horizontal frame, which has the property that the rigidity can be easily controlled depending on the mold and has a high degree of freedom in shape, the horizontal frame can have excellent torsional rigidity when the vehicle is running.

[0016] Furthermore, by mechanically fastening the vertical frame to the horizontal frame, which has high rigidity such as torsional rigidity, the rigidity of the vertical frame can be increased by utilizing the rigidity of the horizontal frame as described above, which not only increases the rigidity of the entire battery frame but also further improves the rigidity of the vertical frame against side impact loads.

[0017] In another aspect of the present invention, the one surface on which the seal shelf is provided may be the fastening surface of the horizontal frame. According to the above configuration, by utilizing the mold used when casting the horizontal frame, which is a cast member, the seal shelf can be easily provided without requiring additional processing on the fastening surface.

[0018] In another aspect of the present invention, the seal shelf may be provided continuously along approximately the entire vertical length of the inner edge portion located on the inner edge of the battery frame, which is rectangular in plan view of the vehicle, on one of the surfaces.

[0019] According to the above configuration, by providing the seal shelf on the inner edge portion of the one surface in a plan view of the vehicle, it is possible to prevent the seal material from unintentionally falling off the seal shelf due to physical external forces such as washing of the battery frame from the outside in a plan view of the vehicle, compared to when the seal shelf is provided on the outside of the one surface. Therefore, the seal material can be maintained in a state where it is provided on the seal shelf, and the water-stopping function can be maintained for a long period of time.

[0020] In another aspect of the present invention, the seal shelf may be provided with a seal shelf outer edge portion that is continuously provided along approximately the entire vertical length of the outer edge portion located on the outer edge of the rectangular frame-shaped battery frame on the one side when viewed from above the vehicle, a seal shelf upper edge portion that extends inward from the upper end of the outer edge portion along the upper edge portion of the one side, and a seal shelf lower edge portion that extends inward from the lower end of the outer edge portion along the lower edge portion of the one side.

[0021] According to the above configuration, by providing the sealing ledge outer edge along substantially the entire length of the outer edge on the one surface in the vertical direction, the sealing material provided on the sealing ledge outer edge can reliably prevent water from seeping in between the fastening surface and the fastened surface on the outer edge side of the one surface, thereby preventing the fastening means and the like from rusting due to water seeping in between the fastening surface and the fastened surface.

[0022] Furthermore, the sealing material provided on the upper edge portion of the sealing shelf can prevent water from entering from the upper edge portion on one side, and the sealing material provided on the lower edge portion of the sealing shelf can prevent water from entering from the lower edge portion.

[0023] In another aspect of the present invention, the upper edge portion of the seal shelf and the lower edge portion of the seal shelf may be configured to extend to just before the inner edge portion located on the inner edge of the rectangular frame-shaped battery frame when viewed from above the vehicle. According to this configuration, when a lid body that covers the inside of the battery frame from above when viewed from above is joined to the front part of the inner edge portion at the upper edge portion of one of the faces, it is possible to prevent the sealing material provided on the upper edge portion of the sealing shelf from getting caught in the lid body.

[0024] Similarly, when the bottom plate that covers the inside of the battery frame from below when viewed from above the vehicle is joined to the front part of the inner edge portion at the lower edge of one of the faces, it is possible to prevent the sealing material provided at the lower edge portion of the sealing shelf from getting caught in the bottom plate.

[0025] In another aspect of the present invention, the sealing material has an adhesive function of adhering the fastening surface and the fastened surface, the fastening means is a bolt, the bolt has a shaft portion that runs along the longitudinal direction and has a threaded portion formed on the outer periphery, and a flange portion that protrudes radially from the shaft portion, and when the second frame is fastened to the first frame with the bolt, the sealing shelf may be located in a position that overlaps with the radial outer end of the flange portion or outside the radial outer end when viewed from the front of one of the faces.

[0026] According to this configuration, the fastening force of the bolt and the adhesive force of the sealing material work together to firmly join the fastening surface and the fastened surface. Specifically, when the second frame is fastened to the first frame, the fastening force of the bolt can be effectively applied in the area of ​​the one surface that overlaps with the flange in a front view. Meanwhile, in the area outside the area that overlaps with the flange in a front view of the one surface, i.e., the area outside the area where the fastening force of the bolt can be effectively applied, the adhesive strength of the sealing material provided on the seal shelf can be utilized to firmly bond the fastening surface and the fastened surface.

[0027] Therefore, when joining the fastening surface and the fastened surface, the bolt and the sealing material, which has adhesive function, work together to firmly and efficiently join the entire joint, including the outer periphery, while reducing the amount of sealing material used. [Effects of the Invention]

[0028] According to this invention, it is possible to provide a vehicle battery structure that can improve the rigidity of a battery frame that has a frame shape when viewed from above, while ensuring sealing between the vertical frames and horizontal frames that are joined to each other to form the battery frame. [Brief explanation of the drawings]

[0029] [Figure 1] FIG. 1 is a perspective view showing the appearance of a vehicle undercarriage as viewed from above in front of the vehicle; [Figure 2] FIG. 1 is a plan view showing the appearance of the battery unit with the lid removed; [Figure 3] 3 is a perspective view of the external appearance as seen from above in the direction of arrow A in FIG. 2; [Figure 4] FIG. 4 is a perspective view of the exterior of the device shown in FIG. 3 with the vertical frame removed. [Figure 5] FIG. 4 is a perspective view of the exterior of the vehicle with the horizontal frame removed in FIG. 3. [Figure 6] (a) is an enlarged cross-sectional view showing the main part along the line CC in Figure 3, and (b) is an enlarged cross-sectional view showing the main part along the line DD. DETAILED DESCRIPTION OF THE INVENTION

[0030] An embodiment of the present invention will be described in detail below with reference to the drawings. In the drawings, arrow Y indicates the fore-and-aft direction of the vehicle body, arrow W indicates the width direction of the vehicle, and arrow Z indicates the up-and-down direction. Furthermore, arrow Yf indicates the front of the vehicle, arrow Yr indicates the rear of the vehicle, arrow Wr indicates the right side of the vehicle, arrow Wl indicates the left side of the vehicle, arrow Zu indicates the top of the vehicle, and arrow Zd indicates the bottom of the vehicle. Furthermore, in the following description, unless otherwise specified, the front, rear, left, right, up, and down directions respectively indicate the front, rear, left, right, up, and down directions of the vehicle body, and each of the above directions of the vehicle body is based on a passenger seated in the driver's seat.

[0031] 1, the vehicle 1 of this embodiment is an electrically powered vehicle, such as an electric vehicle or a hybrid vehicle, that is equipped with at least a motor as a power source. A battery unit 10 is disposed below a floor panel 90 that forms the floor surface of the vehicle 1, and supplies and receives power to and from the driving motor.

[0032] The battery unit 10 includes a battery module (not shown) and a battery case 20. The battery module is a rectangular parallelepiped battery assembly in which multiple rectangular parallelepiped battery cells (battery elements) with a standard voltage are arranged in a stacked configuration. The battery cells in this embodiment are, for example, lithium-ion batteries, which are a type of secondary battery, but other secondary batteries such as all-solid-state batteries may also be used.

[0033] The above-described battery module is housed inside a battery case 20. In this example, the battery case 20 has a generally rectangular parallelepiped shape that is flat in the vertical direction of the vehicle. By providing the battery case 20 in almost the entire lower area of ​​the floor panel 90, it is possible to mount a large-capacity battery on the vehicle 1 as an electric vehicle.

[0034] 1 and 2, the battery case 20 is made of metal and includes a battery frame 21, a bottom plate 12, and a lid 13. In Fig. 2, the battery modules housed inside are not shown, and a plan view of the battery case 20 with the lid 13 removed is shown.

[0035] As shown in FIG. 2, the battery frame 21 has a pair of vertical frames 22 and a pair of horizontal frames 31, and is configured as a rectangular frame whose length is longer in the front-to-rear direction than in the vehicle width direction so that the battery, i.e., the battery module, can be stored as a whole.

[0036] The pair of vertical frames 22 face each other at a distance in the vehicle width direction on both sides of the battery frame 21 in the vehicle width direction, and extend linearly along the front-to-rear direction. The pair of horizontal frames 31 face each other at a distance in the vehicle width direction on both sides of the battery frame 21 in the vehicle width direction, and extend linearly along the vehicle width direction. The pair of vertical frames 22 are formed to have the same length, and the pair of horizontal frames 31 are formed to have the same length, but the vertical frames 22 are formed to be longer than the horizontal frames 31.

[0037] The vertical frame 22 is an extruded member made of metal, for example, an aluminum alloy, and has a plurality of parallel closed cross-sectional portions 22a penetrating the interior in the longitudinal direction (front-rear direction) as shown in Fig. 3. The closed cross-sectional portions 22a are formed when the vertical frame 22 is manufactured by extrusion molding, and by giving the vertical frame 22 such a closed cross-sectional structure, the rigidity against a side collision load is increased.

[0038] The horizontal frames 31 are made of metal, for example, aluminum alloy castings. Because the horizontal frames 31 are made of aluminum alloy castings, which allow for a high degree of freedom in shape, they are configured to have higher torsional rigidity than the vertical frames 22 when the vehicle 1 is running, for example, by providing multiple reinforcing ribs 31a in the vertical and transverse directions.

[0039] In addition to the reinforcing ribs 31a, as described above, the horizontal frame 31 takes advantage of the high degree of freedom in shape of the casting, and has a more complex shape than the vertical frame 22 by providing insertion holes (not shown) for routing wiring for transmitting and receiving power and signals between the motor and ECU (not shown) provided on the vehicle body side and the battery unit 10 side.

[0040] As shown in Fig. 2, the pair of vertical frames 22 are each rectangular in shape with the vertical length longer than the vehicle width direction so that their orthogonal cross sections perpendicular to the longitudinal direction are L-shaped or inverted L-shaped. The pair of horizontal frames 31 are each rectangular in shape with the vertical length longer than the front-rear direction so that their orthogonal cross sections perpendicular to the longitudinal direction are L-shaped or inverted L-shaped. The pair of vertical frames 22 and the pair of horizontal frames 31 have the same vertical length (height).

[0041] 2 and viewed from above, the battery frame 21 has four corners, for example, as shown in the front and left corners in FIG. 3, in which longitudinal ends 22t of the vertical frames 22 are fastened to longitudinal ends 31t of the corresponding horizontal frames 31 in the longitudinal direction of the horizontal frames 31 using bolts B as fastening means. As a result, the battery frame 21 is integrally formed in a frame shape in plan view by a pair of vertical frames 22 and a pair of horizontal frames 31, as shown in FIG. The fastening structure between the end portions 22t, 31t of the vertical frame 22 and the horizontal frame 31 will be described later.

[0042] 1, in the battery frame 21 configured as described above, the front lateral frame 31 under the floor of the vehicle 1 is fastened and fixed to the left and right torque boxes 91 (only the left side of the vehicle is shown). By connecting the left and right torque boxes 91 by the front lateral frame 31 under the floor of the vehicle 1 in this way, the torsional rigidity of the vehicle body is increased by utilizing the battery frame 21.

[0043] Furthermore, the left and right vertical frames 22 are fastened and fixed to the corresponding left and right side sills 92. Furthermore, the horizontal frame 31 of the battery frame 21 on the rear side of the vehicle is connected to a floor cross member 93 (also referred to as "No. 4 cross member") via a bracket (not shown).

[0044] The above-described side sills 92, torque boxes 91, and floor cross members 93 are all body frame members that form the body frame of the vehicle 1. Supplementally, a pair of torque boxes 91 are provided on the left and right sides in front of the battery module to connect the front side frames 94 and the side sills 92 in the vehicle width direction, and each has a closed cross-sectional portion that extends in the vehicle width direction.

[0045] A pair of side sills 92 are provided on the left and right ends of the floor panel 90, each having a closed cross-section extending in the fore-and-aft direction of the vehicle. Furthermore, the floor cross member 93 has a closed cross-section extending in the vehicle width direction at the rear end of the floor panel 90 so as to connect the left and right rear side frames 95 in the vehicle width direction. The battery frame 21 is fixed to a vehicle body frame member, and the battery module is supported by the vehicle body via the battery frame 21.

[0046] 2, the bottom plate 12 covers the battery modules housed inside the battery case 20 from below so as to form the bottom surface of the battery case 20. Furthermore, the bottom plate 12 extends substantially horizontally, including the area on the inner side (center side) of the battery frame 21, which has a rectangular shape in plan view, and the area directly below the battery frame 21, and is fixed to the lower surfaces of the pair of vertical frames 22 and the pair of horizontal frames 31 that constitute the battery frame 21.

[0047] 1, the lid 13 covers the battery modules housed inside the battery case 20 from above so as to form the upper surface of the battery case 20. Furthermore, the lid 13 includes an area inside the battery frame 21, which has a rectangular shape in a plan view, and an area directly above the battery frame 21, and is fixed to the upper surfaces of the pair of vertical frames 22 and the pair of horizontal frames 31 that make up the battery frame 21.

[0048] The battery case 20 defines an internal storage space 20s for the battery modules by the battery frame 21, which is rectangular in plan view, the bottom plate 12, and the lid 13 (see FIG. 2). In this embodiment, the bottom plate 12 and the lid 13 are fixed to the battery frame 21 by bolting, but this is not limiting and other fixing means such as welding may also be used.

[0049] As shown in FIG. 2, the interior (accommodation space 20s) of the battery case 20 is provided with reinforcing members, such as lateral reinforcing members 14 extending in the vehicle width direction and vertical reinforcing members 15 extending in the front-rear direction. In this example, four lateral reinforcing members 14 are provided in the storage space 20s, and are arranged at intervals in the front-rear direction so as to divide the storage space 20s into approximately five equal parts in the front-rear direction. Furthermore, each lateral reinforcing member 14 extends over the entire length of the storage space 20s in the vehicle width direction until both end portions reach the left and right vertical frames 22, and is erected like a vertical wall from the bottom plate 12 so that each is slightly lower than the height of the battery frame 21.

[0050] One vertical reinforcing member 15 is provided in each storage space 20s, and is disposed at a middle position in the vehicle width direction of the storage space 20s so as to divide the storage space 20s into approximately two equal parts in the vehicle width direction. Furthermore, the vertical reinforcing member 15 extends over the entire length of the storage space 20s in the front-rear direction, with both ends reaching the front and rear cross frames 31, and stands upright like a vertical wall from the bottom plate 12 at a height slightly lower than that of the battery frame 21.

[0051] Next, the fastening structure between the end portions 22t, 31t of the vertical frame 22 and the horizontal frame 31 will be described. The fastening structure is the same at each of the four corners of the battery frame 21, so the corner indicated by arrow A in Fig. 2 will be used as an example for explanation. In the following explanation, "bolt B fastening state" refers to "a state in which the vertical frame 22 is fastened to the horizontal frame 31 by bolt B" unless otherwise specified.

[0052] 2 and 4, fastening surfaces 32 that are substantially entirely flat along the up-down and front-rear directions are provided on both longitudinal end portions 31t of the lateral frame 31. The fastening surfaces 32 are provided on both longitudinal end surfaces of the lateral frame 31 so as to face outward in the vehicle width direction.

[0053] As shown in FIGS. 2 and 5, both longitudinal end portions 22t of the vertical frame 22 are provided with fastening surfaces 24 that are generally flat along the up-down and front-rear directions. The fastened surfaces 24 are provided on the inner end surfaces in the vehicle width direction of both longitudinal end portions 22t of the vertical frame 22 so as to face the inner side in the vehicle width direction.

[0054] As shown in Figures 3 and 6(a) and (b), the longitudinal end 22t of the vertical frame 22 is fastened to the longitudinal end 31t of the horizontal frame 31 using bolt B with the fastening surface 24 of the vertical frame 22 and the fastening surface 32 of the horizontal frame 31 abutting against each other (i.e., in a face-to-face contact state).

[0055] In detail, as shown in Figures 6(a) and 6(b), bolt B is a known bolt having a male thread portion B2a formed on its outer peripheral surface, a shaft portion B2 that extends along the longitudinal direction (vehicle width direction) of the horizontal frame 31 when bolt B is fastened, and a bolt head B3 that protrudes radially outward from the base end of shaft portion B2, i.e., in a flange-like shape, away from shaft portion B2.

[0056] 4 and 6(a) and (b), bolt insertion holes 33 (so-called threaded holes), into which the shanks B2 of the bolts B can be screwed, are formed in both longitudinal end portions 31t of the horizontal frame 31, and are drilled inward in the vehicle width direction from the fastening surfaces 32 along the vehicle width direction (the longitudinal direction of the horizontal frames 31). An internal thread 33a that screws into the external thread B2a of the bolt B is provided on the inner surface of the bolt insertion holes 33.

[0057] In this example, when viewed from the front of the fastening surface 32, a pair of bolt insertion holes 33 are provided adjacent to each other in the front and rear at the same height on the fastening surface 32, and a pair of bolt insertion holes 33 is disposed at each of the upper, middle, and lower parts in the vertical direction (see FIG. 6). As a result, a total of six openings 34 of the bolt insertion holes 33 are provided on the fastening surface 32, as shown in FIG.

[0058] On the other hand, as shown in Figures 5 and 6(a)(b), bolt insertion holes 25 (so-called clearance holes) into which bolts B can be inserted are formed in both longitudinal end portions 22t of the vertical frame 22, penetrating along the vehicle width direction (the longitudinal direction of the horizontal frame 31). The bolt insertion holes 25 are provided at positions corresponding to the six bolt insertion holes 33 provided in the fastening surface 32 when the bolt B is fastened, i.e., at positions communicating in the vehicle width direction with the bolt insertion holes 33. As a result, as shown in Figures 5, 6(a) and 6(b), and as shown in Figure 6, openings 26 of a total of six bolt insertion holes 25 are opened inward in the vehicle width direction on the fastened surface 24.

[0059] When fastening the longitudinal end 22t of the vertical frame 22 to the longitudinal end 31t of the horizontal frame 31, the fastening surface 32 of the horizontal frame 31 and the fastened surface 24 of the vertical frame 22 are brought into contact with each other so that the horizontal frame 31 and the vertical frame 22 form a right angle in a plan view, and the bolt B is inserted into the bolt insertion hole 25 of the vertical frame 22 from the outer side in the vehicle width direction and screwed into the bolt insertion hole 33 of the horizontal frame 31. As a result, as shown in Figures 3 and 6(a) and (b), the male thread portion B2a of the bolt B and the female thread portion 33a of the bolt insertion hole 33 are threadedly engaged, and the longitudinal end 22t of the vertical frame 22 is fastened to the longitudinal end 31t of the horizontal frame 31 in the longitudinal direction of the horizontal frame 31.

[0060] Also, as shown in Figures 4 and 6(a)(b), the fastening surface 32 of the horizontal frame 31 is provided with a seal shelf 40 that is concave relative to the fastened surface 24 of the vertical frame 22 (i.e., toward the inside in the vehicle width direction). The seal shelf 40 in this example has a chamfered shape with the corners removed along the outer peripheral edge of the fastening surface 32, and includes a seal shelf inner edge portion 40a (see Figure 6(a)), a seal shelf outer edge portion 40b, a seal shelf upper edge portion 40c, and a seal shelf lower edge portion 40d.

[0061] The chamfered shape is not limited to a squared surface (C surface) as shown in Figures 4 and 6(a)(b), but may be, for example, a rounded surface (R surface).Furthermore, the seal shelf 40 is not limited to a chamfered shape, and may be other shapes such as a stepped shape as long as it has a concave shape, and may be provided in a location other than the edge portion of the fastening surface 32.

[0062] Furthermore, when casting the horizontal frame 31, not only the fastening surface 32 but also a chamfered seal shelf 40 may be formed at the longitudinal end 31t of the horizontal frame 31, but this is not limited to this. After only the fastening surface 32 is formed at the longitudinal end 31t of the horizontal frame 31, additional processing may be performed to remove the edge portion corresponding to the formation location of the seal shelf 40, thereby forming the seal shelf 40.

[0063] As shown in Figures 4 and 6(a), the inner edge portion 40a of the seal shelf is provided in a linear manner continuously over approximately the entire length of the inner edge portion in the vertical direction on the inner edge portion located on the inner (central) edge portion of the fastening surface 32, which is rectangular in plan view, of the battery frame 21.

[0064] As shown in the same figure, the seal shelf outer edge portion 40b is provided in a linear manner continuously over approximately the entire length of the outer edge portion in the vertical direction on the outer edge portion located on the fastening surface 32, which is a rectangular frame-shaped portion in a plan view, on the outer edge portion in a plan view of the battery frame 21.

[0065] 4 and 6(b), the upper seal shelf edge 40c extends continuously in the front-rear direction from the upper end of the outer edge along the upper edge to just before the inner edge on the fastening surface 32. The lower seal shelf edge 40d extends continuously in the front-rear direction from the lower end of the outer edge along the lower edge to just before the inner edge on the fastening surface 32.

[0066] The outer edge portion 40b of the seal shelf, the upper edge portion 40c of the seal shelf, and the lower edge portion 40d of the seal shelf are continuous so that their opposing ends butt together, and when viewed from the front of the fastening surface 32, they open toward the inner edge portion and are formed in a U-shape with corners at both ends in the vertical direction.

[0067] 4, in this example, the upper edge portion 40c of the seal shelf is provided in a portion corresponding to one half of the upper edge portion closer to the outer edge. Meanwhile, the other half of the upper edge portion closer to the inner edge is set as an upper edge non-sealed area 41c where no seal shelf 40 is provided. Similarly, the lower edge portion 40d of the seal shelf is provided in a portion corresponding to one half of the lower edge portion closer to the outer edge, while the other half of the lower edge portion closer to the inner edge is set as a lower edge non-sealed area 41d where no seal shelf 40 is provided.

[0068] As shown in Figures 3 and 6(a) and (b), a sealant 60, which has adhesive properties in addition to waterproofing properties when the bolt B is fastened, is continuously applied to the above-mentioned seal ledge 40. The sealant 60 is tightly packed between the seal ledge 40 on the fastening surface 32 and the fastened surface 24 opposite the seal ledge 40. In this example, the sealant 60 hardens while exerting its adhesive properties when exposed to air. Therefore, the fastening surface 32 is firmly bonded to the fastened surface 24 via the sealant 60 along the edge portion corresponding to the seal ledge 40.

[0069] In this example, the sealing material 60 is provided on the sealing shelf 40 by being applied along the sealing shelf 40 immediately before the vertical frame 22 and the horizontal frame 31 are fastened together with the bolts B. In this way, the vertical frame 22 and the horizontal frame 31 are fastened together with the bolts B before the sealing material 60 hardens, but it is not excluded that the sealing material 60 can be applied after the bolts B are fastened.

[0070] 6(a) and 6(b), the sealing material 60 is applied only to the seal ledge 40 in a front view of the fastening surface 32, and is not provided on the flat portion directly facing the fastened surface 24. As a result, in a front view of the fastening surface 32, in the flat portions other than the seal ledge 40, the sealing material 60 is not interposed between the fastened surface 24 and the flat portion other than the seal ledge 40, even when bolt B is fastened, and the surfaces of the two surfaces are in direct contact with each other.

[0071] 3, when bolt B is fastened, substantially the entire seal ledge 40 is located outside the radial outer end of bolt head B3 in a front view of fastening surface 32. In this example, the end of seal ledge 40 on the side having bolt B overlaps with the radial outer end of bolt head B3 in a front view of fastening surface 32. However, in the present invention, the end of seal ledge 40 on the side having bolt B may be located outside the radial outer end of bolt head B3.

[0072] The battery case 20 as the battery structure of the vehicle 1 of the above-described embodiment is provided below the floor panel 90 of the vehicle as shown in FIG. 1, and as shown in FIG. 2, has a pair of vertical frames 22 extending along the front-to-rear direction on both sides of the vehicle width direction, and a pair of horizontal frames 31 extending along the vehicle width direction on both sides of the front-to-rear direction, and is provided with a rectangular frame-shaped battery frame 21 capable of storing a battery module (battery).

[0073] Furthermore, the vertical frame 22 is fastened to a longitudinal end 31t of a horizontal frame 31, which has higher rigidity than the vertical frame 22, in the longitudinal direction of the horizontal frame 31 by a bolt B as fastening means. That is, a fastening surface 32 for fastening the vertical frame 22 is provided at the longitudinal end 31t of the horizontal frame 31, and a fastened surface 24 for fastening the horizontal frame 31 is provided at the longitudinal end 22t of the vertical frame 22.

[0074] As shown in Figure 4, of the fastening surface 32 and the fastened surface 24, the fastening surface 32 is provided with a sealing shelf 40 that is concave relative to the fastened surface 24, and as shown in Figures 3 and 6(a)(b), a sealing material 60 is applied to the sealing shelf 40.

[0075] According to the above configuration, the vertical frame 22 is mechanically fastened to the horizontal frame 31, which has higher rigidity than the vertical frame 22, thereby improving the rigidity of the entire battery frame 21, such as torsional rigidity when the vehicle is running, and by providing the sealing material 60 on the sealing shelf 40, watertightness can be ensured between the fastening surface 32 and the fastened surface 24, which are pressed against each other.

[0076] In detail, by firmly connecting the vertical frame 22 to the horizontal frame 31, which has higher rigidity than the vertical frame 22, by mechanical fastening, the rigidity of the horizontal frame 31 can be utilized to increase the rigidity of the vertical frame 22, and as a result, the rigidity of the entire battery frame 21, including torsional rigidity when the vehicle is running, can be improved.

[0077] In particular, when fastening the vertical frame 22 to the longitudinal end 31t of the horizontal frame 31 with the bolt B, the vertical frame 22 is fastened in the longitudinal direction of the horizontal frame 31, and therefore the fastening force can be applied along the longitudinal direction of the horizontal frame 31. In other words, the fastening force of the bolt B fastening the vertical frame 22 can be firmly received by the horizontal frame 31 along its longitudinal direction. Therefore, the rigidity of the horizontal frame 31 can be effectively used to improve the rigidity of the vertical frame.

[0078] As described above, by fastening the joints between the vertical frame 22 and the horizontal frame 31 in the circumferential direction of the battery frame 21, which has a rectangular frame shape when viewed from above, which tend to be weaker than other parts, by mechanical fastening in the longitudinal direction of the horizontal frame 31, it is possible to increase the torsional rigidity of the entire battery frame 21, which has a rectangular frame shape when viewed from above.

[0079] Furthermore, by providing the sealing material 60 on the sealing shelf 40, even if the sealing material 60 is interposed between the fastening surface 32 and the fastened surface 24, the sealing material 60 will not form a gap between the fastening surface 32 and the fastened surface 24, and the fastening surface 32 and the fastened surface 24 can be mechanically fastened by the bolt B in a surface contact state, a so-called "zero touch" state.

[0080] In other words, bolt B mechanically fastens the fastening surface 32 and the fastened surface 24 together, minimizing any gap between them, while the sealing shelf 40 provided on the fastening surface 32 allows the sealing material 60 to be provided with the desired sealing thickness, thereby ensuring watertightness between the fastening surface 32 and the fastened surface 24.

[0081] In one embodiment of the present invention, the horizontal frame 31 is a cast member, and the vertical frame 22 is an extruded member. According to the above configuration, the horizontal frame 31 is made into a cast member having characteristics that make it easy to control the rigidity according to the mold and have a high degree of freedom in shape, thereby making it possible to obtain a horizontal frame 31 with excellent torsional rigidity when the vehicle 1 is running.

[0082] Furthermore, by using the vertical frame 22 as an extruded member, a closed cross-sectional structure along the front-rear direction can be easily formed as shown in FIG. 5, so that the vertical frame 22 can have excellent rigidity against a side collision load.

[0083] Furthermore, by mechanically fastening the vertical frame 22 to the horizontal frame 31, the rigidity of the vertical frame 22 can be increased by utilizing the rigidity of the horizontal frame 31 as described above, which not only increases the rigidity of the entire battery frame 21, but also further improves the rigidity of the vertical frame 22 against side impact loads.

[0084] Furthermore, as described above, the seal shelf 40 is provided on the fastening surface 32 of the horizontal frame 31, which is a cast member with a high degree of freedom in shape, so that the seal shelf 40 can be easily provided on the fastening surface 32 by utilizing the mold used when casting the horizontal frame 31 without requiring additional processing.

[0085] It is preferable to provide the seal shelf 40 on the fastening surface 32 of the horizontal frame 31, as this has the above-mentioned advantages. However, the present invention is not limited to a configuration in which the seal shelf 40 is provided only on the fastening surface 32, as in the above-mentioned embodiment, but the seal shelf 40 can be provided on at least one of the fastening surface 32 and the fastened surface 24; for example, it may be provided on both the fastening surface 32 and the fastened surface 24.

[0086] In another aspect of the present invention, as shown in Figures 4 and 6(a), the seal shelf inner edge portion 40a is provided continuously over approximately the entire length of the inner edge portion in the vertical direction on the inner edge portion of the fastening surface 32, which is located on the rectangular inner edge of the battery frame 21 in a plan view.

[0087] According to the above configuration, by providing a sealing shelf 40 along almost the entire vertical length of the inner edge portion of the fastening surface 32, even if water penetrates between the fastening surface 32 and the fastened surface 24 from the outside of the battery frame 21 when viewed in a plane, further penetration of water into the storage space 20s on the inside of the battery frame 21 when viewed in a plane can be reliably prevented.

[0088] Furthermore, by providing the seal shelf 40 on the inner edge portion of the fastening surface 32, it is possible to prevent the seal material 60 from unintentionally falling off from the seal shelf 40 due to the effect of physical external forces such as cleaning from the outside in a plan view of the battery frame 21, compared to when the seal shelf 40 is provided on the outside of the fastening surface 32. Therefore, the seal material 60 can be maintained in a state where it is attached to the seal shelf 40, and the waterproof function can be maintained for a long period of time.

[0089] In another aspect of the present invention, as shown in Figures 4 and 6(a)(b), the seal shelf 40 is formed of a seal shelf outer edge portion 40b that is continuously provided along almost the entire vertical length of the outer edge portion of the fastening surface 32, which is located on the rectangular outer edge of the battery frame 21 in a planar view, a seal shelf upper edge portion 40c that extends from the upper end of the outer edge portion along the upper edge portion of the fastening surface 32, and a seal shelf lower edge portion 40d that extends from the lower end of the outer edge portion along the lower edge portion of the fastening surface 32.

[0090] According to the above configuration, by providing the seal ledge outer edge portion 40b along substantially the entire vertical length of the outer edge portion of the fastening surface 32, the sealant 60 provided on the seal ledge outer edge portion 40b can reliably prevent water from seeping in between the fastening surface 32 and the fastened surface 24 at the outer edge side of the fastening surface 32. This makes it possible to prevent the bolts B and other components that fasten the fastening surface 32 and the fastened surface 24 from rusting due to water.

[0091] Furthermore, the sealing material 60 provided on the upper edge portion 40c of the sealing shelf can prevent water from entering from the upper edge portion of the fastening surface 32, and the sealing material 60 provided on the lower edge portion 40d of the sealing shelf can prevent water from entering from the lower edge portion.

[0092] Furthermore, the upper edge portion 40c of the seal shelf extends from the outer edge portion to just before the inner edge portion, and the portion of the upper edge portion closer to the inner edge portion is set as the upper edge non-sealed area 41c, so that when the lid body 13 is fixed to the top surface of the battery frame 21 with bolts or the like, the sealing material 60 provided on the upper edge portion 40c of the seal shelf can be prevented from getting caught in the lid body 13.

[0093] Similarly, the lower edge portion 40d of the seal shelf extends from the outer edge portion to just before the inner edge portion, and the portion of the lower edge portion closer to the inner edge portion is set as the lower edge non-sealed area 41d. Therefore, when the bottom plate 12 is fixed to the underside of the battery frame 21 with bolts or the like, the sealing material 60 provided on the lower edge portion 40d of the seal shelf can be prevented from getting caught in the bottom plate 12.

[0094] Furthermore, when joining the lid body 13 and the battery frame 21 by welding, welding is performed in the upper edge non-sealed area 41c at the upper edge of the fastening surface 32, so that the lid body 13 can be firmly fixed to the battery frame 21 without the sealing material 60 melting due to the heat of welding.

[0095] Similarly, when joining the bottom plate 12 and the battery frame 21 by welding, welding is performed in the lower edge non-sealed area 41d at the lower edge of the fastening surface 32, so that the bottom plate 12 can be firmly fixed to the battery frame 21 without the sealing material 60 melting due to the heat of welding.

[0096] In another embodiment of the present invention, as shown in Figures 3 and 6(a)(b), when the vertical frame 22 is fastened to the horizontal frame 31 with the bolt B, when viewed from the front of the fastening surface 32, the seal shelf 40 is almost entirely located outside the radial outer end of the bolt head B3.

[0097] According to the above-described configuration, the fastening force of the bolt B and the adhesive force of the sealing material 60 work together to firmly and efficiently bond the fastening surface 32 and the fastened surface 24 over the entire surface. Specifically, when the vertical frame 22 is fastened to the horizontal frame 31, the fastening force of the bolt B can be effectively applied to the area of ​​the fastening surface 32 that overlaps with the bolt head B3 in a front view. On the other hand, in the area outside the area of ​​the fastening surface 32 that overlaps with the bolt head B3 in a front view, the fastening force of the bolt B is weaker than in the area overlapping with the bolt head B3. However, to compensate for this, the adhesive force of the sealing material 60 provided on the sealing shelf 40 can be utilized to bond the fastening surface 32 and the fastened surface 24 together.

[0098] In this example, the fastening means is constituted by the bolt B, but a washer may also be provided. In that case, the "radial outer end of the flange" in the present invention refers to the outer end of the washer. Furthermore, the fastening means of the present invention may include a nut instead of or together with the bolt B, as long as it is configured to fasten the vertical frame 22 and the horizontal frame 31, and may also include a screw shaft or a rivet instead of the bolt B.

[0099] In the correspondence between the configuration of this invention and the above-mentioned embodiment, the battery structure of the vehicle corresponds to the battery case 20, and similarly, The battery corresponds to the battery module, The fastening means corresponds to bolt B, The flange of the fastening means corresponds to the bolt head B3, The threaded portion of the fastening means corresponds to the male threaded portion B2a, One surface corresponds to the fastening surface 32; The other surface corresponds to the fastened surface 24, The first frame corresponds to the horizontal frame, The second frame corresponds to the vertical frame, The first direction corresponds to the front-to-rear direction of the vehicle, The second direction corresponds to the vehicle width direction, but the present invention is not limited to the configurations of the above-described embodiments, and many other embodiments can be obtained. [Explanation of symbols]

[0100] 20...Battery case (vehicle battery structure) 21...Battery frame 22...Vertical frame (second frame) 24... Fastening surface of vertical frame (other surface) 31...Horizontal frame (first frame) 31t...Longitudinal end of horizontal frame 32... Fastening surface of horizontal frame (one side) 40...Sticker shelf 40b...Outer edge of seal shelf 40c...Seal shelf upper edge 40d...Bottom edge of sticker shelf 60...Sealing material 90...Floor panel B...Bolt (fastening means) B2…Shaft part B2a...Male thread (threaded part of fastening means) B3...Bolt head (flange part of fastening means) B3a... Radial outer end of the bolt head (radial outer end of the flange)

Claims

1. a battery frame that is provided below a floor panel of the vehicle, has a first frame that faces each other across a first direction that is either a front-rear direction or a width direction of the vehicle, and a second frame that faces each other across a second direction that is different from the first direction, and has a rectangular frame shape in a plan view of the vehicle, and is capable of storing a battery; the second frame is fastened to an end portion of the first frame in the longitudinal direction by a fastening means, a fastening surface of the first frame that fastens the second frame; A seal shelf is provided on at least one of the surfaces of the second frame and the surface to be fastened to the first frame, the seal shelf being recessed relative to the other surface, and the seal shelf is provided with a seal material. Vehicle battery structure.

2. the first frame is a horizontal frame extending along a vehicle width direction as the second direction, and the second frame is a vertical frame extending along a vehicle front-rear direction as the first direction, The horizontal frames are cast members, and the vertical frames are extruded members. The vehicle battery structure according to claim 1 .

3. The one surface on which the seal shelf is provided is set as the fastening surface of the horizontal frame.

3. The vehicle battery structure according to claim 2.

4. The seal shelf is provided continuously over substantially the entire length of the inner edge portion in the vertical direction on the inner edge portion located on the inner edge of the battery frame, which is rectangular in plan view of the vehicle, on the one surface. The vehicle battery structure according to claim 1 .

5. The seal shelf is A seal shelf outer edge portion is provided continuously over substantially the entire length of the outer edge portion in the up-down direction on the outer edge portion located on the outer edge of the rectangular frame shape of the battery frame on the one surface in a vehicle plan view; a seal shelf upper edge portion extending inward from an upper end of the outer edge portion along the upper edge portion of the one surface; a seal shelf lower edge portion extending inward from the lower end of the outer edge portion along the lower edge portion of the one surface, The vehicle battery structure according to claim 1 .

6. The seal shelf upper edge portion and the seal shelf lower edge portion extend to a position just before an inner edge portion located on an inner edge of the battery frame having a rectangular frame shape in a plan view of the vehicle.

6. The vehicle battery structure according to claim 5.

7. the sealing material has an adhesive function of adhering the fastening surface and the fastened surface, the fastening means is a bolt, The bolt has a shaft portion that extends along the longitudinal direction and has a thread portion formed on an outer periphery thereof, and a flange portion that protrudes radially from the shaft portion, When the second frame is fastened to the first frame with the bolts, the seal shelf is provided at a position overlapping with the radial outer end of the flange portion or outside the radial outer end in a front view of the one surface.

7. The vehicle battery structure according to claim 6.

Images