Vehicle structure of electric vehicles

Abstract

In the event of a vehicle collision, it protects vehicle components such as brake lines, electrical wiring, drive shafts, and exhaust pipes. [Solution] In an electric vehicle structure, a battery 10 is provided under the floor of the vehicle body 1, and the battery 10 has portions that are divided and arranged in a left battery area 11a and a right battery area 11b in the width direction of the vehicle body, one or more vehicle equipment E selected from brake piping, electrical wiring, drive shaft and exhaust pipe are arranged along the front-rear direction of the vehicle body 1 in the space between the left battery area 11a and the right battery area 11b, and a bracket 20 that restricts proximity to the vehicle equipment E in the event of a floor collision is attached to the left battery area 11a and the right battery area 11b or either thereof.

Description

Technical Field

[0001] This invention relates to a vehicle structure of an electric vehicle equipped with a battery.

Background Art

[0002] Conventionally, electric vehicles equipped with an electric motor as a driving source for traveling have become widespread. Electric vehicles use the electrical energy stored in a battery as the driving force for traveling. Electric vehicles include electric vehicles (Electric Vehicle) equipped only with an electric motor as a driving source for traveling, hybrid vehicles (Hybrid Vehicle) that use both an engine and an electric motor as a driving source for traveling, fuel cell vehicles equipped with a fuel cell (fuel-cell vehicle), and the like.

[0003] In these electric vehicles, a structure in which a battery is mounted under the floor of the vehicle body is common. The battery has a portion divided into a left battery region part and a right battery region part with respect to the width direction of the vehicle body, and brake pipes, electrical wiring, etc. may be arranged in the space between the left battery region part and the right battery region part. Also, in the case of a rear-wheel drive vehicle, a propeller shaft or the like may be arranged in the space between the left battery region part and the right battery region part. Furthermore, in the case of a hybrid vehicle, an exhaust pipe or the like may also be arranged in that space.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] Incidentally, when a vehicle collides with some kind of obstacle, the floor of the vehicle body may become deformed. For example, this could happen if the side of the vehicle body collides with a structure such as a utility pole or various support pillars. When the floor of the vehicle body is deformed, the space between the left and right battery compartments may shrink. As a result, the battery may collide with vehicle equipment located in that space, such as brake lines, electrical wiring, drive shafts such as propeller shafts, and exhaust pipes, potentially damaging these components.

[0006] Therefore, the objective of this invention is to protect vehicle equipment such as brake lines, electrical wiring, drive shafts, and exhaust pipes in the event of a vehicle collision. [Means for solving the problem]

[0007] To solve the above problems, this invention provides an electric vehicle structure in which a battery is provided under the floor of the vehicle body, and the battery has portions that are divided into a left battery area and a right battery area in the width direction of the vehicle body, and in the space between the left battery area and the right battery area, one or more vehicle equipment selected from brake lines, electrical wiring, drive shafts and exhaust pipes are arranged along the longitudinal direction of the vehicle body, and brackets that restrict proximity to the vehicle equipment in the event of a collision are attached to the left battery area and the right battery area or either thereof (Configuration 1).

[0008] In configuration 1, the bracket has a recess facing the vehicle equipment side, and when the vehicle equipment and the bracket come close together during a collision, the vehicle equipment can be configured to fit into the recess (configuration 2).

[0009] In configuration 1 or configuration 2, the vehicle equipment has an arcuate surface that protrudes toward the bracket side in a cross section perpendicular to the longitudinal direction of the vehicle body, and when the vehicle equipment and the bracket approach each other during a collision, the bracket can be configured to make contact with the arcuate surface at least three points (configuration 3).

[0010] In any one of configurations 1 to 3, the bracket may have a hollow section inside (configuration 4).

[0011] In any one of configurations 1 to 4, a configuration can be adopted in which an impact energy absorbing material with lower strength than the bracket is provided between the left battery area and the right battery area or either thereof and the bracket, or on the widthwise outer side of the left battery area and the right battery area or either thereof of the vehicle body (configuration 5).

[0012] In any one of configurations 1 to 5, the left battery area and the right battery area, or either thereof, may be provided with a cross member extending in the width direction of the vehicle body, and the bracket and the cross member may be configured to have overlapping positions with respect to the front-rear direction of the vehicle body (configuration 6). [Effects of the Invention]

[0013] According to this invention, vehicle equipment such as brake lines, electrical wiring, drive shafts, and exhaust pipes can be protected in the event of a vehicle collision. [Brief explanation of the drawing]

[0014] [Figure 1] This is a diagram showing the configuration of an electric vehicle (vehicle) equipped with the vehicle structure of an embodiment of this invention. [Figure 2A] This is a cross-sectional view showing the vehicle structure of the electric vehicle in this embodiment. [Figure 2B] This is a cross-sectional view showing the vehicle structure after a side collision. [Figure 3] This is a perspective view of the main components showing the positional relationship between the battery and vehicle equipment (exhaust pipe). [Figure 4] This is a plan view of the main components showing the positional relationship between the battery and the vehicle equipment (exhaust pipe). [Figure 5A] This is a cross-sectional view showing a modified example of the bracket. [Figure 5B] This is a cross-sectional view showing a modified example of the bracket. [Figure 5C]It is a cross-sectional view showing a modified example of a bracket.

Embodiments for Carrying Out the Invention

[0015] Embodiments of this invention will be described based on the drawings. FIG. 1 is a configuration diagram conceptually showing an electric vehicle A (hereinafter referred to as vehicle A) having the vehicle structure of this embodiment.

[0016] This vehicle A is a hybrid vehicle equipped with an engine 3 and an electric motor 7 as power sources for driving force during travel. The control device of vehicle A includes a battery (secondary battery) 10 that supplies power to the electric motor 7, an inverter that converts the power from the battery 10 into characteristics corresponding to the electric motor 7, a generator (alternator) that generates electricity by the rotation of the engine 3, and the like.

[0017] Vehicle A can select each operation mode including an electric driving mode using only the electric motor 7 as a power source, a series mode using only the electric motor 7 as a power source and simultaneously operating the engine 3 to supply power to the battery 10 and the electric motor 7, and a parallel mode using both the engine 3 and the electric motor 7 or only the engine 3 as a power source.

[0018] The engine 3 includes an intake passage that sends intake air into the combustion chamber and an exhaust passage that sends exhaust out from the combustion chamber. The exhaust passage includes an exhaust manifold connected to an exhaust port in the cylinder head and an exhaust pipe extending downstream from the exhaust manifold. An exhaust purification device and a muffler are provided in the middle of the exhaust pipe.

[0019] The battery 10 is provided under the floor of the vehicle body 1. The battery 10 is configured by housing a large number of cells and necessary control units in a flat rectangular parallelepiped battery pack along the lower surface of the floor.

[0020] The battery 10 is divided into a left battery area 11a, which is located on the left side when facing forward of the vehicle body in the width direction of the vehicle body 1 (hereinafter referred to as the vehicle width direction), and a right battery area 11b, which is located on the right side when facing forward of the vehicle body. As shown in Figure 2B, the floor member 5 of the vehicle body 1 has flat sections 5b provided on the left and right sides in the vehicle width direction, and a saddle-shaped section 5a provided between the left and right flat sections 5b. The saddle-shaped section 5a has an arc shape that protrudes upward from the left and right flat sections 5b and extends in the front-rear direction of the vehicle body 1 (hereinafter simply referred to as the front-rear direction). Side sills 6 are connected to the outer ends 5c of the left and right flat sections 5b. The side sills 6 have a longitudinal hollow section that extends in the front-rear direction and together with the floor member 5, constitute a part of the vehicle body 1.

[0021] The left battery area 11a and the right battery area 11b are fixed to the left and right flat areas 5b, respectively. Therefore, directly below the saddle-shaped area 5a, there is a longitudinal space extending in the front-to-back direction between the left battery area 11a and the right battery area 11b.

[0022] The left battery area 11a and the right battery area 11b are each supported by a base member 12 made of a plate-shaped member. The outer end of the base member 12 in the vehicle width direction is fixed to the side sill 6 via bolts 13, and the inner end is fixed to the saddle-shaped portion 5a or the flat portion 5b via bolts 14. In this embodiment, the bolts 14 at the inner end are inserted vertically into a raised portion 16 provided at the inner end of the base member 12 in the vehicle width direction and are screwed into a mounting portion 5d provided on the lower surface of the floor member 5. The movement of the battery 10 toward the center in the vehicle width direction is restricted by the raised portion 16 at the inner end, and its movement toward the outside in the vehicle width direction is restricted by the raised portion 15 provided at the outer end in the vehicle width direction.

[0023] In the space between the left battery area 11a and the right battery area 11b, longitudinal vehicle equipment E (relatively small diameter equipment indicated by the symbol e2 in Figures 2A and 2B; hereinafter referred to as small-diameter vehicle equipment e2) such as brake lines and electrical wiring, and longitudinal vehicle equipment E (relatively large diameter equipment indicated by the symbol e1 in Figures 2A and 2B; hereinafter referred to as large-diameter vehicle equipment e1) such as drive shafts and exhaust pipes are arranged along the longitudinal direction. Gaps exist between the vehicle equipment E and the side surface of the left battery area 11a, and between the vehicle equipment E and the side surface of the right battery area 11b. These gaps exist continuously along the longitudinal direction.

[0024] When a vehicle collides with some kind of obstacle, if the floor member 5 of the vehicle body 1 deforms, the space between the left battery area 11a and the right battery area 11b will shrink, and there is a risk that the battery 10 will collide with the vehicle equipment E. Therefore, in this invention, brackets 20 are attached to the side of the left battery area 11a and the side of the right battery area 11b, facing the vehicle equipment E. The brackets 20 restrict the approach to the vehicle equipment E during a collision. This prevents damage to the vehicle equipment E during a collision.

[0025] Here, one could also consider a method to restrict the proximity of the left battery area 11a and the right battery area 11b by extending and connecting the inner end of the base member 12 supporting the left battery area 11a and the inner end of the base member 12 supporting the right battery area 11b. However, covering the lower part of the vehicle equipment E with the base member 12 may reduce the heat dissipation effect. In particular, if the vehicle equipment E is an exhaust pipe, ensuring heat dissipation is important. For this reason, it is advantageous to provide a bracket 20 on the battery 10, as in this invention. Furthermore, if it is not necessary to cover the lower part of the vehicle equipment E with the base member 12, it is not necessary to remove the battery 10 from the vehicle body 1 when replacing components of the vehicle equipment E, thereby improving work efficiency.

[0026] In this embodiment, the bracket 20 has a recess 22 on the side of the block-shaped structure 21 facing the vehicle equipment E, that is, a recess 22 that opens laterally toward the vehicle equipment E. Therefore, when the vehicle equipment E and the bracket 20 come into close proximity due to a collision, the vehicle equipment E can be held in place by entering the recess 22. This creates a so-called energy path that disperses the collision energy along the longitudinal direction of the vehicle equipment E. As a result, the impact acting on each part can be mitigated.

[0027] As shown in Figure 3, the recess 22 of the embodiment has a V-shaped cross-section, comprising an inclined surface 22a that slopes upward toward the center in the vehicle width direction and an inclined surface 22b that slopes downward toward the center in the vehicle width direction. Therefore, when the vehicle equipment E enters the recess 22, the vehicle equipment E is guided to the bottom of the recess 22 along the upper inclined surface 22a and the lower inclined surface 22b, and the bracket 20 can reliably capture the vehicle equipment E.

[0028] In this embodiment, the vehicle equipment E is an exhaust pipe and therefore has a circular cross-section. For this reason, the vehicle equipment E has an arcuate surface that protrudes toward the bracket 20 side in a cross-section perpendicular to the front-rear direction. Since the outer surface of the vehicle equipment E is an arcuate surface, the contact point between the arcuate surface and the inclined surface of the recess 22 slides easily, and guidance to the bottom of the recess 22 is smooth.

[0029] The material of the bracket 20 can be freely selected as long as the required strength and durability are ensured; for example, metal, resin, rubber, etc., can be used.

[0030] Furthermore, in this embodiment, an impact energy absorbing material (EA material) with lower strength than the bracket 20 is provided between the side surface of the left battery area 11a and the bracket 20, and between the side surface of the right battery area 11b and the bracket 20. In this embodiment, the rising portion 16 is made of impact energy absorbing material, but the impact energy absorbing material may also be attached to the side surface of the rising portion 16 (the side surface on the vehicle equipment E side). By providing the impact energy absorbing material, the energy of the impact can be absorbed more efficiently, and if the input exceeds this, the bracket 20 can also absorb the energy.

[0031] Furthermore, impact energy absorbing material is also provided on the outer side in the vehicle width direction of the left battery area 11a and the outer side in the vehicle width direction of the right battery area 11b. Therefore, it can exert a similar effect in the event of a collision. In this embodiment, the impact energy absorbing material on the outer side in the vehicle width direction is made up of the side sill 6, but impact energy absorbing material may be provided separately from the side sill 6.

[0032] While well-known materials can be used as shock energy absorbers, for example, metal components with hollow interiors or other foamed resin components can be employed.

[0033] To explain the action during a collision, when there is a lateral input to the vehicle body 1 (an input of a collision load to the side of the vehicle body 1), the side of the left battery area 11a and the vehicle equipment E come into contact, and the side of the right battery area 11b and the vehicle equipment E come into contact, and the vehicle equipment E is sandwiched between the batteries 10 on both sides in the vehicle width direction and absorbs energy. As a result, the amount of deformation of the vehicle body 1 is reduced, and the intrusion of the obstacle into the vehicle body 1 can be suppressed. At this time, the impact energy absorbing material attached to the battery 10 on the obstacle B side absorbs the collision energy and contributes to mitigating the impact G. Subsequently, if the vehicle equipment E in the center in the vehicle width direction deforms, the impact energy absorbing material attached to the battery 10 on the opposite side of obstacle B contributes to further energy absorption. Since the EA stroke in the vehicle width direction is increased compared to conventional designs, the damage caused by the impact G to the battery pack and occupants can be reduced.

[0034] Furthermore, in the embodiment, as shown in Figures 3 and 4, cross members 13 extending in the vehicle width direction are provided inside the left battery area 11a and the right battery area 11b, respectively. The cross members 13 are provided within the body that constitutes the battery pack and connect the rising portion 16 at the inner end in the vehicle width direction and the rising portion 15 at the outer end in the vehicle width direction.

[0035] Here, the bracket 20 and the cross member 13 are set to have overlapping positions in the longitudinal direction (see Figure 4). Therefore, when there is a lateral impact on the vehicle body 1 during a collision, the impact load is transmitted through the cross member 13 in the battery pack. As a result, the impact load is more easily transmitted to the bracket 20, and the cells in the battery pack can be protected more reliably.

[0036] In Figure 4, the bracket 20 and the cross member 13 are shown to have the same width in the front-rear direction and to be perfectly aligned in the front-rear direction. However, the bracket 20 and the cross member 13 may also be configured to partially overlap each other in the front-rear direction.

[0037] Modified examples of the bracket 20 are shown in Figures 5A to 5C. In all of the examples in Figures 5A to 5C, a hollow section 20a is set inside the bracket 20. By providing the hollow section 20a, the bracket 20 itself functions as an impact energy absorber. For example, methods such as sheet metal forming, extrusion forming, and casting can be used to manufacture the bracket 20.

[0038] The bracket 20 in Figure 5A is composed of a sheet metal structure 21 formed by welding together three metal plate-shaped members. The circles in the figure indicate the welding points. Its structure consists of a base plate 23 fixed to the battery 10 side and two inner and outer members 30 and 33 fixed to the base plate 23. The inner member 30 has a U-shaped cross-section with a pair of support parts 31 rising from the base plate 23 away from the battery 10 and a top part 32 connecting the pair of support parts 31. The outer member 33 also has a U-shaped cross-section with a pair of support parts 24 rising from the base plate 23 away from the battery 10 and a top part 29 connecting the pair of support parts 24.

[0039] A recess 22 is formed in the middle of the top portion 29 in the vertical direction. A pair of inclined members 25 provided on the top portion 29 form an inclined surface 22a that slopes upward toward the center in the vehicle width direction and an inclined surface 22b that slopes downward toward the center in the vehicle width direction. A flat bottom surface 22c is formed by a bottom portion 26 provided on the top portion 29, connecting the inclined surfaces 22a and 22b, and the recess 22 is formed by the inclined surfaces 22a and 22b and the bottom surface 22c. The gap between these members is a hollow portion 20a.

[0040] In this configuration, during a collision, the vehicle equipment E and the bracket 20 will come into contact at at least three points: the inclined surfaces 22a and 22b and the bottom surface 22c, as indicated by the arrows in Figure 5A. Since the vehicle equipment E has an arcuate surface, this three-point contact is smooth. Three-point contact allows the bracket 20 to more reliably capture the vehicle equipment E, and since the load transmission is distributed based on three-point contact, the cross-section of the bracket 20 can be made slimmer. This can therefore contribute to improved productivity.

[0041] Figure 5B shows a bracket 20 using a structure 21 made of extruded material. Extruded material is a material produced by plastic deformation of metal, where heated metal is passed through a die mold and extruded to form a desired shape. Specifically, for example, aluminum extruded material can be used. In addition to extrusion molding, the bracket 20 can also be formed by rolling or drawing.

[0042] The bracket 20 in Figure 5B has a shape comprising a base plate portion 23 fixed to the battery 10 side, a pair of support portions 24 rising from the base plate portion 23 away from the battery 10, and a top portion 29 connecting the pair of support portions 24.

[0043] A recess 22 is formed in the middle of the top portion 29 in the vertical direction. A pair of inclined portions 25 provided on the top portion 29 form an inclined surface 22a that slopes upward toward the center in the vehicle width direction and an inclined surface 22b that slopes downward toward the center in the vehicle width direction. A flat bottom surface 22c is formed by a bottom portion 26 provided on the top portion 29, connecting the inclined surfaces 22a and 22b, and the recess 22 is formed by the inclined surfaces 22a and 22b and the bottom surface 22c. The inclined portions 25 are connected to the base portion 23.

[0044] The inclined portion 25 and the base portion 23 are connected by a lateral reinforcing portion 27. The inclined portion 25 and the support portion 24 are connected by a vertical reinforcing portion 28. Furthermore, the area near the joint between the base portion 23 and the support portion 24, and the area near the joint between the inclined portion 25 and the bottom portion 26 are connected by a diagonal reinforcing portion 34. The gaps between these members form a hollow portion 20a.

[0045] In the event of a collision, as shown by the arrows in Figure 5B, the vehicle equipment E and the bracket 20 will come into contact at at least three points: the inclined surfaces 22a, 22b and the bottom surface 22c, similar to the case in Figure 5A.

[0046] Figure 5C shows a bracket 20 made of a cast structure 21. The bracket 20 in Figure 5C has a base plate portion 23 that is fixed to the battery 10, a pair of support portions 24 that rise from the base plate portion 23 away from the battery 10, and a top portion 29 that connects the pair of support portions 24.

[0047] A recess 22 is formed in the middle of the top portion 29 in the vertical direction. A pair of inclined portions 25 provided on the top portion 29 form an inclined surface 22a that slopes upward toward the center in the vehicle width direction and an inclined surface 22b that slopes downward toward the center in the vehicle width direction. A flat bottom surface 22c is formed by a bottom portion 26 provided on the top portion 29, connecting the inclined surfaces 22a and 22b, and the recess 22 is formed by the inclined surfaces 22a and 22b and the bottom surface 22c. The inclined portions 25 are connected to the base portion 23.

[0048] In the above embodiment, brackets 20 are provided in both the left battery area 11a and the right battery area 11b. However, the brackets 20 can exert the predetermined effect if they are provided in either the left battery area 11a or the right battery area 11b. Similarly, the impact energy absorbing material is provided on both sides in the vehicle width direction in both the left battery area 11a and the right battery area 11b. However, the impact energy absorbing material can exert the predetermined effect if it is provided on at least one side in the vehicle width direction.

[0049] Furthermore, in the above embodiment, the battery 10 is configured to be divided into a left battery area 11a and a right battery area 11b along its entire length in the front-to-rear direction. However, the portion of the battery 10 that is divided into the left battery area 11a and the right battery area 11b may be the entire battery 10 in the front-to-rear direction, or only a part of it. For example, the battery 10 may be divided into the left battery area 11a and the right battery area 11b only towards the rear in the front-to-rear direction, and may be an undivided, integrated battery 10 towards the front in the front-to-rear direction.

[0050] In the above embodiment, the configuration of this invention was explained using an exhaust pipe as an example of vehicle equipment E. However, vehicle equipment E may also be small-diameter vehicle equipment e2 such as brake piping or electrical wiring, or a drive shaft (propeller shaft) may be set as large-diameter vehicle equipment e1 other than an exhaust pipe. The drive shaft (propeller shaft) is also used when the rear wheels are the drive wheels.

[0051] In the above embodiment, the configuration of the present invention was described using a hybrid vehicle equipped with an engine 3 and a motor 7 as the power source for driving force as an example. However, this hybrid vehicle may also be, for example, a plug-in hybrid vehicle equipped with an external charging device having an external charging function and an external power supply device having an external power supply function. Furthermore, the present invention can be applied to various electric vehicles other than hybrid vehicles, such as electric vehicles (EVs) equipped only with an electric motor as the driving source, and fuel cell vehicles (FCVs) equipped with a fuel cell, in which the battery 10 is mounted under the floor member 5. [Explanation of symbols]

[0052] 1. Vehicle body 10 batteries 11a Left side battery area 11b Right-side battery area 20 brackets 20a Hollow part 22 recess E. Vehicle Equipment

Claims

1. In a vehicle structure for an electric vehicle, the battery is located under the floor of the vehicle body, and the battery is divided into a left battery area and a right battery area in the width direction of the vehicle body, A vehicle structure for an electric vehicle, wherein one or more vehicle components selected from brake lines, electrical wiring, drive shafts, and exhaust pipes are arranged along the longitudinal direction of the vehicle body in the space between the left battery area and the right battery area, and brackets that restrict proximity to the vehicle components in the event of a collision are attached to the left battery area and the right battery area or either thereof.

2. The vehicle structure of an electric vehicle according to claim 1, wherein the bracket has a recess facing the vehicle equipment side, and when the vehicle equipment and the bracket come into close proximity during a collision, the vehicle equipment fits into the recess.

3. The vehicle structure for an electric vehicle according to claim 1, wherein the vehicle equipment has an arcuate surface that protrudes toward the bracket side in a cross section perpendicular to the longitudinal direction of the vehicle body, and when the vehicle equipment and the bracket come into close proximity during a collision, the bracket contacts the arcuate surface at at least three points.

4. The vehicle structure of an electric vehicle according to claim 1, wherein the bracket has a hollow portion inside.

5. The vehicle structure of an electric vehicle according to claim 1, wherein an impact energy absorbing material with lower strength than the bracket is provided between the left battery area and the right battery area or either thereof and the bracket, or on the widthwise outer side of the left battery area and the right battery area or either thereof of the vehicle body.

6. The vehicle structure of an electric vehicle according to any one of claims 1 to 5, wherein the left battery area and the right battery area, or either thereof, are provided with a cross member extending in the width direction of the vehicle body, and the bracket and the cross member overlap in position with respect to the front-rear direction of the vehicle body.

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