Electric vehicles

Abstract

This invention provides an electric vehicle that can suppress deformation of the fender panel when charging from an external power source, even in a configuration where the lid box and charging inlet are fixed to the fender panel via a bracket. [Solution] The electric vehicle comprises a body frame, a battery, and a fender panel having an outer surface and an inner surface. The fender panel has an opening that penetrates from the outer surface to the inner surface and accommodates a lid panel. The electric vehicle further comprises a bracket fixed to the periphery of the opening on the inner surface, a lid box to which the lid panel is attached and which is fixed to the bracket, a charging inlet that supplies external power to the battery by inserting an external power connector and is fixed to the lid box at a position further away from the lid panel than the lid box, and a reinforcing member that is connected to the bracket and the body frame and fixes the bracket to the body frame.

Description

Technical Field

[0001] The present disclosure relates to an electric vehicle.

Background Art

[0002] Conventionally, electric vehicles such as electric cars and hybrid cars are known. Such electric vehicles run by driving an electric motor with electric power stored in a battery. The battery is charged by electric power supplied from an external power source (for example, a household power source, a charging stand). For example, as shown in Japanese Patent Application Laid-Open No. 2016-107680 (Patent Document 1), charging is performed by connecting an external charging connector connected to an external power source to a charging inlet of the electric vehicle.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] With a lid box that functions as a cover for the charging inlet (specifically, a quasi-exterior panel design part) attached to the charging inlet, by attaching the lid box to a bracket provided inside the fender panel, the lid box and the charging inlet can be fixed to the fender panel. However, in this case, if the external charging connector is strongly inserted into the charging inlet or a large force is applied to the external charging connector in any of the vertical, horizontal, or lateral directions, the fender panel may be deformed.

[0005] The present disclosure provides an electric vehicle capable of suppressing deformation of a fender panel during charging by an external power source, even in a configuration where a lid box and a charging inlet are fixed to a fender panel via a bracket. [Means for solving the problem]

[0006] The electric vehicle of this disclosure comprises a body frame, a battery, and a fender panel having an outer surface exposed to the outside and an inner surface which is the back surface of the outer surface. The fender panel has an opening that penetrates from the outer surface to the inner surface and accommodates a lid panel. The electric vehicle further comprises a bracket fixed to the periphery of the opening on the inner surface, a lid box to which the lid panel is attached and which is fixed to the bracket, a charging inlet that supplies external power to the battery by inserting an external power connector and is fixed to the lid box at a position further away from the lid panel than the lid box, and a reinforcing member that is connected to the bracket and the body frame and fixes the bracket to the body frame.

[0007] With this configuration, even if a force is applied to the fender panel by the external power connector when plugging or unplugging the external power connector from the charging inlet, the reinforcing member can suppress the deformation of the fender panel.

[0008] Preferably, the charging inlet has a base on the lid box side and a tip on the opposite side of the base. The charging inlet is fixed to the lid box with the tip inclined so that it points diagonally downward.

[0009] With this configuration, it becomes easier for the person performing the charging operation on the electric vehicle to plug the external power connector into the charging inlet.

[0010] Preferably, the reinforcing member extends in the longitudinal direction of the electric vehicle and is connected to the bracket and the body frame at multiple points.

[0011] With this configuration, compared to a case where the reinforcing member is connected to both the bracket and the body frame at one point, the deformation of the fender panel when a force that deforms the fender panel is applied by the charging connector during charging can be more effectively suppressed.

[0012] Preferably, the reinforcing member is a metal fitting with an L-shaped cross-section, having a bottom portion parallel to the horizontal plane and a side portion extending vertically upward from the bottom portion. The bottom portion is fastened to the bracket with a first bolt that penetrates the bottom portion vertically. The side portion is fastened to the body frame with a second bolt that penetrates the side portion horizontally.

[0013] This configuration allows for the acquisition of reinforcing strength with a lightweight and simple design. Furthermore, during the manufacturing of electric vehicles, the process of fastening the first and second bolts while they are inserted at an angle is eliminated. Therefore, the reinforcing member improves the workability when attaching the reinforcing member to the bracket and the body frame. [Effects of the Invention]

[0014] According to this disclosure, even in electric vehicles in which the lid box and charging inlet are fixed to the fender panel via a bracket, deformation of the fender panel can be suppressed when charging with an external power source. [Brief explanation of the drawing]

[0015] [Figure 1] This diagram shows the schematic configuration of electric vehicle 1. [Figure 2] This is a perspective view showing the exterior near the opening. [Figure 3] This is a perspective view showing the interior of the vehicle near the opening. [Figure 4] This diagram illustrates how to secure the charging inlet to the lid box and how to secure the lid box to the bracket. [Figure 5] This is a cross-sectional view taken along the VV line in Figure 4. [Figure 6]It is a cross-sectional view taken along the line VI-VI of FIG. 4.

Mode for Carrying Out the Invention

[0016] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the following description, the same members are denoted by the same reference numerals. Their names and functions are also the same. Therefore, detailed descriptions thereof will not be repeated.

[0017] FIG. 1 is a diagram showing a schematic configuration of an electric vehicle 1 according to the present embodiment. FIG. 1 shows a state immediately before charging the electric vehicle 1. The electric vehicle 1 is a hybrid vehicle capable of traveling using at least one of the power of a motor and an engine, or an electric vehicle that travels with a driving force obtained by electric energy.

[0018] As shown in FIG. 1, the electric vehicle 1 includes a battery 2, a fender panel 3, a bracket 4, a charging connector 5, a lid panel 6, and a cable 7. The charging connector 5 includes a lid box 51 and a charging inlet 52. The lid box 51 has a main body portion 511 and a movable portion 512 that is movable with respect to the main body portion 511. The configuration of the lid panel 6 and the lid box 51 combined is also referred to as a "charging lid".

[0019] The fender panel 3 has an outer surface 31 exposed to the outside and an inner surface 32 that is the back surface of the outer surface 31. An opening 33 is formed in the fender panel 3 that penetrates from the outer surface 31 toward the inner surface 32 and houses the lid panel 6. In this example, the opening 33 is formed around the right front wheel. It is not limited to this, and depending on the specifications of each country, the opening 33 may be formed around the left front wheel. The opening 33 is an opening for the charging lid and is also referred to as a "charging port".

[0020] The power supply device 900 includes an external power source 901, a cable 902, and an external power connector 903. The external power connector 903 is also referred to as a "charging gun" or a "charging link". The external power connector 903 is connected to the external power source 901 via the cable 902.

[0021] The bracket 4 is attached to the inner surface 32 of the fender panel 3. Specifically, the bracket 4 is fixed around the opening 33 on the inner surface 32. The bracket 4 is fixed to the inner surface 32 of the fender panel 3 by mechanical fastening such as welding or bolt fastening.

[0022] The lid box 51 serves as an opening and closing mechanism for the lid panel 6 and as a cover (quasi-exterior panel design part) for covering the charging inlet 52. By the lid box 51, it is possible to prevent the charging inlet 52 from being exposed in the vicinity of the opening 33.

[0023] Specifically, the lid box 51 is fixed to the bracket 4. The lid panel 6 is attached to the lid box 51. Specifically, the main body 511 of the lid box 51 is fixed to the bracket 4. The main body 511 is located inside the vehicle of the electric vehicle 1. The movable part 512 of the lid box 51 is attached to the main body 511 by a hinge (not shown) as an opening and closing mechanism. The lid panel 6 is attached to the movable part 512. The movable part 512 is movable in the direction of arrow A1 together with the lid panel 6.

[0024] In the state where the lid panel 6 is closed, the lid panel 6 is accommodated in the opening 33 of the fender panel 3. When the lid panel 6 is closed, the opening 33 is blocked. The movable part 512 is accommodated inside the vehicle more than the lid panel 6.

[0025] The charging inlet 52 is fixed to the lid box 51 at a position further from the lid panel 6 than the lid box 51. Therefore, the lid box 51 and the charging inlet 52 are fixed to the fender panel 3 via a bracket 4. The charging inlet 52 is located on the interior side of the vehicle than the lid box 51. The charging inlet 52 supplies power to the battery 2 from an external power source 901 via an external power connector 903. More specifically, the charging inlet 52 supplies power from the external power source 901 to the battery 2 via a cable 7. The cable 7 is connected to the battery 2 and the charging inlet 52.

[0026] If the electric vehicle 1 is a North American specification, the charging inlet 52 has a common inlet for both AC charging and DC charging (see Figure 2). If the electric vehicle 1 is a European, Chinese, or Japanese specification, the charging inlet 52 includes separate inlets for AC charging and DC charging. In the European specification, the AC charging inlet and the DC charging inlet are arranged vertically. In the Chinese and Japanese specifications, the AC charging inlet and the DC charging inlet are arranged horizontally.

[0027] During the manufacturing of the electric vehicle 1, the charging inlet 52 is attached to the electric vehicle 1 by the following process. The following process is performed by a worker or an assembly robot (hereinafter also referred to as "worker, etc."). The worker, etc. first fixes the lid box 51 and the charging inlet 52 to each other with bolts or the like. This forms an assembly (specifically, a charging connector 5) including the lid box 51 and the charging inlet 52. Next, the worker, etc. fixes the bracket 4 to the inner surface 32 of the fender panel 3 by the mechanical fastening described above. Furthermore, the worker, etc. fixes the lid box 51 to the bracket 4 with bolts or the like from the inside of the vehicle. With this fixing, the charging inlet 52 is fixed in position to the fender panel 3 together with the lid box 51. In this way, the charging connector 5 is fixed to the bracket 4 attached to the inner surface 32 of the fender panel 3 from the inside of the electric vehicle 1.

[0028] The person performing the charging operation of the electric vehicle 1 (for example, the driver of the electric vehicle 1 or a service technician at the store) moves the external power connector 903 in the direction of the opening 33 (direction of arrow A2) with the lid panel 6 open as shown in Figure 1, and inserts the external power connector 903 into the charging inlet 52. After this, the person performing the charging operation selects the charging start button, and charging of the battery 2 from the external power source 901 begins.

[0029] Figure 2 is a perspective view showing the exterior near the opening 33. For ease of explanation, the lid panel 6 and the movable part 512 of the lid box 51 are not shown in Figure 2.

[0030] As shown in Figure 2, the electric vehicle 1 further comprises a body frame 8, an A-pillar 9, and a reinforcing member 10, in addition to the fender panel 3, bracket 4, lid box 51, and charging inlet 52. The opening 33 is formed below the lower end of the A-pillar 9. The body frame 8 is located inside the electric vehicle 1. In the figure, UPR refers to the vertically upward direction. FR refers to the forward direction of the electric vehicle 1. LH refers to the left direction as viewed from the driver seated in the seat.

[0031] As described above, the charging inlet 52 is located further inside the vehicle than the lid box 51. In this example, the lid box 51 and the charging inlet 52 are located below the A-pillar 9 and above the front wheels (not shown).

[0032] Figure 3 is a perspective view showing the interior of the vehicle near the opening 33. As shown in Figure 3, the reinforcing member 10 is connected to the bracket 4 and the body frame 8, and also fixes the bracket 4 to the body frame 8. The reinforcing member 10 fixes the bracket 4, which holds the charging inlet 52 and the lid box 51, to the body frame 8. The reinforcing member 10 plays a role in bridging the gap between the bracket 4 and the body frame 8.

[0033] More specifically, the reinforcing member 10 is connected to the upper end of the bracket 4. The reinforcing member 10 extends in the longitudinal direction of the electric vehicle 1. The reinforcing member 10 is connected to both the bracket 4 and the body frame 8 at multiple points. In this example, the reinforcing member 10 is connected to the bracket 4 at two points and to the body frame 8 at two points. More specifically, the reinforcing member 10 is fixed to the bracket 4 with two bolts 801 and 802. The reinforcing member 10 is fixed to the body frame 8 with two bolts 803 and 804.

[0034] More specifically, in this example, the reinforcing member 10 is a metal fitting with an L-shaped cross-section. The reinforcing member 10 has a bottom portion 101 parallel to the horizontal plane and a side portion 102 extending vertically upward from the bottom portion 101. The bottom portion 101 is fastened to the bracket 4 with bolts 801 and 802. The side portion 102 is fastened to the body frame 8 with bolts 803 and 804. Bolts 801 and 802 penetrate the bottom portion 101 vertically. Bolts 803 and 804 penetrate the side portion 102 horizontally. Note that the cross-section of the reinforcing member 10 is not limited to an L-shape.

[0035] During the manufacturing of the electric vehicle 1, the reinforcing member 10 is fixed to the bracket 4 and the body frame 8 before the charging connector 5 is attached to the bracket 4.

[0036] Figure 4 illustrates the method of fixing the charging inlet 52 to the lid box 51 and the method of fixing the lid box 51 to the bracket 4. Figure 4 is a view from the charging inlet 52 side to the bracket 4 side. In other words, Figure 4 is a view from the inside of the vehicle to the outside of the vehicle. Figure 5 is a cross-sectional view taken along the VV line in Figure 4. Figure 6 is a cross-sectional view taken along the VI-VI line in Figure 4.

[0037] As shown in Figure 4, the charging inlet 52 is pre-secured to the lid box 51 by several bolts 811, 812, 813, and 814. As shown in Figures 4 and 5, the lid box 51 has several metal pins 821 and 822. Each metal pin 821 and 822 extends vertically upward. The metal pins 821 and 822 protrude upward from the upper end surface of the lid box 51.

[0038] When attaching the lid box 51 to the bracket 4, the worker inserts the metal pins 821 and 822 into the through holes 490 (Figure 5) of the bracket 4 from below, as shown in Figures 4 and 5. Then, as shown in Figure 4, the worker temporarily fastens the lower end of the lid box 51 to the bracket 4 with the clip 891.

[0039] Next, the worker secures the lower end of the lid box 51 to the bracket 4 with multiple bolts 831 and 832, as shown in Figures 4 and 5. After that, the worker removes the clip 891 from the lid box 51.

[0040] Finally, the worker attaches the upper end of the lid box 51 to the bracket 4 using a bolt 841, a weld nut 842, and an adjustable nut 843 (Figure 6) that allows for gap adjustment. Specifically, the adjustable nut 843 is pre-fixed to a bracket 880 (Figure 6) which is welded to the bracket 4.

[0041] More specifically, as shown in Figure 6, the worker inserts the bolt 841 into the through hole 590 formed at the upper end of the lid box 51 and tightens the bolt 841. When the bolt 841 is tightened, the adjustment nut 843 expands in the direction of extension (axial direction) of the lower part of the bolt 841's neck. When the adjustment nut 843 contacts the lid box 51, the adjustment work is completed.

[0042] In the above explanation, an example was given in which the lower end of the lid box 51 is fixed to the bracket 4 with two bolts 831 and 832, but the number of bolts is not limited to two. It is sufficient to fix the lid box 51 to the bracket 4 with at least one bolt.

[0043] Furthermore, as shown in Figure 6, the charging inlet 52 has a base portion 521 on the lid box side and a tip portion 522 on the opposite side of the base portion 521. The charging inlet 52 is fixed to the lid box 51 with the tip portion 522 tilted downwards. A cable 7 (Figure 1) is attached to the tip portion 522.

[0044] <Advantages> The electric vehicle 1 with the above configuration has the following advantages.

[0045] (1) If the person performing the charging operation pushes the external power connector 903, which has been inserted into the charging inlet 52, with strong force, for example in the direction of the charging inlet 52 (in the direction of arrow A2 in Figure 6), the force applied to the charging inlet 52 is transmitted to the bracket 4 via the lid box 51. Since the bracket 4 is fixed to the fender panel 3 by welding or the like, the force is transmitted to the fender panel 3. Therefore, a force is applied to the fender panel 3 that attempts to deform it. Such a force that attempts to deform the fender panel 3 acts on the fender panel 3 in the same way if the external power connector 903 is moved with strong force in the vertical direction (in the direction of arrow A3 in Figure 6) or if the external power connector 903 is moved with strong force in the horizontal direction.

[0046] In this regard, the electric vehicle 1 is equipped with a reinforcing member 10 that is connected to the bracket 4 and the body frame 8, and that fixes the bracket 4 to the body frame 8. Therefore, when plugging or unplugging the external power connector 903 to the charging inlet 52, even if a force is applied to the fender panel 3 by the external power connector 903 that would otherwise deform the fender panel 3, the reinforcing member 10 can suppress deformation of the fender panel 3. More specifically, the reinforcing member 10 can suppress rigid deformation (i.e., deflection) or plastic deformation of the fender panel 3.

[0047] (2) The electric vehicle 1 is configured such that the lid box 51 and the charging inlet 52 are attached to a bracket 4 mounted on the inner surface 32 of the fender panel 3 from the inside of the electric vehicle 1. Therefore, the opening 33 can be made smaller compared to a configuration in which the lid box 51 and the charging inlet 52 are attached from the outside of the electric vehicle 1. Thus, the design freedom of the electric vehicle 1 is increased, and it becomes possible to use larger tires.

[0048] (3) As described above, the charging inlet 52 is fixed to the lid box 51 with its tip 522 tilted downwards. Therefore, it is easier for the person performing the charging operation to plug the external power connector 903 into the charging inlet 52.

[0049] (4) As described above, the reinforcing member 10 extends in the longitudinal direction of the electric vehicle. The reinforcing member 10 is connected to both the bracket 4 and the body frame 8 at multiple points. Therefore, compared to the case where the reinforcing member 10 is connected to both the bracket 4 and the body frame 8 at one point each, the deformation of the fender panel 3 when a force is applied by the external power connector 903 to deform the fender panel 3 during charging can be suppressed more effectively.

[0050] (5) Since the reinforcing member 10 is a metal fitting with an L-shaped cross-section, strength can be obtained with a lightweight and simple structure. The bottom portion 101 of the reinforcing member 10 is fastened to the bracket 4 with bolts 801 and 802 that penetrate vertically through the bottom portion 101. The side portion 102 is fastened to the body frame 8 with bolts 803 and 804 that penetrate horizontally through the side portion 102. The bottom portion 101 is parallel to the horizontal plane, and the side portion 102 extends vertically upward from the bottom portion 101.

[0051] Therefore, during the manufacturing of the electric vehicle 1, the work of fastening each bolt 801 to 804 while inserting each bolt 801 to 804 from an oblique direction is not required. Consequently, the reinforcing member 10 improves the workability when attaching the reinforcing member 10 to the bracket 4 and the body frame 8.

[0052] (6) In the electric vehicle 1, the charging inlet 52 is fixed to the fender panel 3 via the lid box 51 and the bracket 4. The charging inlet 52 is not fixed to the body frame 8 directly or by a bracket dedicated to the charging inlet.

[0053] Therefore, if a force is applied from the front to the right side of the electric vehicle 1 due to a collision, the charging inlet 52 can be detached from the electric vehicle 1 along with the fender panel 3. Thus, it is possible to prevent a situation in which the charging inlet 52 is fixed to the body frame 8 in a crushed state. Specifically, by considering the strength of the reinforcing member 10 and the mounting method of the reinforcing member 10 so that the reinforcing member 10 breaks in the event of a collision and the bracket 4 is no longer held by the body frame 8, the charging inlet 52 can be detached from the electric vehicle 1.

[0054] <Variation> In the above explanation, the case in which the reinforcing member 10 is a single metal fitting was used as an example, but it is not limited to this. The reinforcing member 10 may be composed of multiple metal fittings. In this case, from the viewpoint of improving the strength of the reinforcement, it is preferable that the extension directions of all the metal fittings are not the same. For example, it is preferable that the reinforcing member 10 includes a metal fitting that extends horizontally and a metal fitting that extends vertically, as shown in Figure 3. In this case, in a side view of the electric vehicle 1, it is preferable to provide a metal fitting that extends vertically at, for example, the left end or right end of the bracket 4. Furthermore, in a side view of the electric vehicle 1, a metal fitting that extends horizontally may be provided at, for example, the lower end of the bracket 4.

[0055] The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The scope of this disclosure is indicated by the claims and all modifications within the meaning and scope of the claims are intended to be included. [Explanation of Symbols]

[0056] 1 Electric vehicle, 2 Battery, 3 Fender panel, 4,880 Bracket, 5 Charging connector, 6 Lid panel, 7,902 Cable, 8 Body frame, 9 Pillar, 10 Reinforcement member, 31 Outer side, 32 Inner side, 33 Opening, 51 Lid box, 52 Charging inlet, 101 Bottom, 102 Side, 490 Through hole, 511 Main body, 512 Movable part, 521 Base, 522 Tip, 590 Through hole, 801, 802, 803, 804, 811, 812, 813, 814, 831, 832, 841 Bolt, 821, 822 Metal pin, 842 Weld nut, 843 Adjustment nut, 891 Clip, 900 Power supply device, 901 External power source, 903 External power connector.

Claims

1. It is an electric vehicle, Body structure and Battery and A fender panel having an outer surface exposed to the outside and an inner surface which is the back surface of the outer surface, The fender panel has an opening that penetrates from the outer surface to the inner surface and accommodates the lid panel. The aforementioned electric vehicle is A bracket fixed to the periphery of the opening on the inner surface, The lid box to which the lid panel is attached and fixed to the bracket, External power is supplied to the battery when an external power connector is plugged in, and a charging inlet is fixed to the lid box at a position further away from the lid panel than the lid box, An electric vehicle further comprising a reinforcing member connected to the bracket and the body frame, and fixing the bracket to the body frame.

2. The charging inlet has a base on the lid box side and a tip on the opposite side of the base, The electric vehicle according to claim 1, wherein the charging inlet is fixed to the lid box in a state inclined such that its tip is angled downwards.

3. The electric vehicle according to claim 1 or 2, wherein the reinforcing member extends in the longitudinal direction of the electric vehicle and is connected to the bracket and the body frame at multiple locations.

4. The reinforcing member is a metal fitting with an L-shaped cross-section, and has a bottom portion parallel to the horizontal plane and a side portion extending vertically upward from the bottom portion. The bottom portion is fastened to the bracket by a first bolt that penetrates the bottom portion vertically. The electric vehicle according to claim 3, wherein the side portion is fastened to the body frame by a second bolt that penetrates the side portion horizontally.

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