Electric vehicles

Abstract

To provide an electric vehicle that can save space in the engine compartment while protecting high-voltage components from the load during a frontal collision. [Solution] The drive unit 30 comprises a case 40 having a cylindrical portion 40A extending in the vehicle width direction and a bulging portion 40B that bulges forward from one end of the cylindrical portion 40A in the vehicle width direction. A right front bracket 11 is connected to the other end of the cylindrical portion 40A in the vehicle width direction. The right front bracket 11 extends inclined from the other end of the cylindrical portion 40A in the vehicle width direction toward the front of the vehicle and toward the other side in the vehicle width direction. A mount insulator 15 is connected to the front end of the right front bracket 11. The high-voltage component 16 is located in front of the cylindrical portion 40A in a first space S1 behind a first virtual line L1 that passes through the front end position of the mounting device consisting of the mount insulator 15 and the right front bracket 11 and the front end position of the bulging portion 40B.

Description

Technical Field

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

Background Art

[0002] Patent Document 1 describes a technique of arranging an inverter above a case of a drive device that houses a motor for the purpose of preventing a high-voltage inverter from being damaged and leaking electricity when the vehicle collides head-on.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, what is described in Patent Document 1 has a problem that it becomes difficult to save space in the engine room by arranging the inverter above the drive device.

[0005] Therefore, an object of the present invention is to provide an electric vehicle that can protect high-voltage components from the load during a vehicle head-on collision while achieving space savings in the engine room.

Means for Solving the Problems

[0006] To solve the above problems, the present invention provides an electric vehicle comprising: a drive unit arranged in an engine room formed in the front of the vehicle and generating motor torque for driving; and a bracket for supporting the end of the drive unit in the vehicle width direction with the vehicle body, wherein a high-voltage component is arranged on the front of the drive unit, the drive unit comprises a case having a cylindrical portion extending in the vehicle width direction and a bulging portion that bulges forward from one end of the cylindrical portion in the vehicle width direction, the bracket is connected to the other end of the cylindrical portion in the vehicle width direction, the bracket extends inclined from the other end of the cylindrical portion in the vehicle width direction toward the front of the vehicle and toward the other side in the vehicle width direction, a mount insulator having an elastic member is connected to the front end of the bracket, and the high-voltage component is arranged in front of the cylindrical portion in a first space behind a first imaginary line passing through the front end position of a mount device consisting of the mount insulator and the bracket and the front end position of the bulging portion. [Effects of the Invention]

[0007] Thus, according to the present invention, it is possible to provide an electric vehicle that can save space in the engine compartment while protecting high-voltage components from loads during a frontal collision. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a plan view of the drive system of an electric vehicle according to one embodiment of the present invention. [Figure 2] Figure 2 is a rear view of the drive unit of an electric vehicle according to one embodiment of the present invention. [Figure 3] Figure 3 is a right side view of the drive unit of an electric vehicle according to one embodiment of the present invention. [Figure 4] Figure 4 is a front view of the drive unit of an electric vehicle according to one embodiment of the present invention. [Figure 5] Figure 5 is a cross-sectional view of the electric vehicle shown in Figure 3, taken along the VV direction. [Figure 6] Figure 6 is a plan view of the drive unit, front bracket, and high-voltage components of an electric vehicle according to one embodiment of the present invention. [Figure 7] Figure 7 is a left side view of the drive unit, front bracket, and high-voltage components of an electric vehicle according to one embodiment of the present invention. [Modes for carrying out the invention]

[0009] An electric vehicle according to one embodiment of the present invention is an electric vehicle comprising a drive unit that generates motor torque for driving and is arranged in an engine room formed in the front of the vehicle, and a bracket that supports the end of the drive unit in the vehicle width direction on the vehicle body, wherein a high-voltage component is arranged on the front of the drive unit, the drive unit comprises a case having a cylindrical portion that extends in the vehicle width direction and a bulging portion that bulges forward from one end of the cylindrical portion in the vehicle width direction, the bracket is connected to the other end of the cylindrical portion in the vehicle width direction, the bracket extends inclined from the other end of the cylindrical portion in the vehicle width direction toward the front of the vehicle and toward the other side in the vehicle width direction, a mount insulator having an elastic member is connected to the front end of the bracket, and the high-voltage component is arranged in front of the cylindrical portion in a first space behind a first imaginary line passing through the front end position of the mount device consisting of the mount insulator and the bracket and the front end position of the bulging portion. As a result, the electric vehicle according to one embodiment of the present invention can save space in the engine room while protecting the high-voltage component from loads during a vehicle front collision. [Examples]

[0010] Hereinafter, an electric vehicle according to one embodiment of the present invention will be described with reference to the drawings. Figures 1 to 7 show an electric vehicle according to one embodiment of the present invention.

[0011] In Figures 1 to 7, the up, down, front, rear, left, and right directions are based on the electric vehicle as it is positioned on the vehicle, with the front-rear direction of the vehicle being the front-rear direction, the left-right direction (vehicle width direction) being the left-right direction, and the up-down direction (vehicle height direction) being the up-down direction.

[0012] As shown in Figure 1, a drive unit 30 that generates motor torque for driving is provided in the engine compartment 3 at the front of the vehicle 1. The drive unit 30 is positioned transversely in the engine compartment 3 such that its internal motor output shaft 51 (see Figure 5) extends in the vehicle width direction. The vehicle 1 in this embodiment constitutes an electric vehicle.

[0013] Drive wheels (not shown) are located to the left and right of the drive unit 30, and the rotation output from the drive unit 30 is transmitted to the drive wheels. The vehicle 1 comprises a body 2, which has a subframe 2A and a body member 2B. The subframe 2A and body member 2B constitute the bottom of the body 2 and support the drive unit 30. The subframe 2A supports the rear of the drive unit 30 and lower arms (not shown), etc. The body member 2B supports the ends of the drive unit 30 in the vehicle width direction, etc.

[0014] As shown in Figure 5, the drive unit 30 comprises a motor 50, a reduction mechanism 53, a differential device 54, and a split case 40 that serves as a housing for these components.

[0015] Case 40 comprises a first case 41 that constitutes the left end of the drive unit 30, a second case 42 fastened to the right end of the first case 41, a third case 43 fastened to the right end of the second case 42, a fourth case 44 connected to the right end of the third case 43, and a cover member 45 fastened to the right end of the fourth case 44.

[0016] The first case 41 has a partition member 41A at its right end, and the partition member 41A extends in the front-to-back and up-to-down directions so as to separate the internal space of the first case 41 from the internal space of the second case 42. The partition member 41A rotatably supports the left end of the motor output shaft 51 of the motor 50 and the right end of the differential device 54, and the reduction shaft 53A of the reduction mechanism 53 passes through it.

[0017] In the third case 43, a motor 50 is disposed. At the center of the motor 50, a hollow motor output shaft 51 for outputting motor torque is provided. The motor output shaft 51 extends in the vehicle width direction from the inside of the second case 42 to the inside of the fourth case 44.

[0018] The second case 42 is provided with a bearing 57 that rotatably supports a portion of the motor output shaft 51 to the left of the motor 50. The fourth case 44 is provided with a bearing 58 that rotatably supports a portion of the motor output shaft 51 to the right of the motor 50.

[0019] In the first case 41 and the second case 42, a speed reduction mechanism 53 for reducing the rotation transmitted from the motor 50 and a differential device 54 for differentially and rotatably transmitting the rotation reduced by the speed reduction mechanism 53 to the left and right drive shafts 55, 56 are arranged.

[0020] The differential device 54 is arranged to the left of the left end of the motor output shaft 51. The differential device 54 includes a ring gear 54A to which rotation is transmitted from the speed reduction mechanism 53. The left drive shaft 55 is connected to the left end of the differential device 54. The right drive shaft 56 is connected to the right end of the differential device 54. This drive shaft 56 is coaxially arranged inside the hollow motor output shaft 51.

[0021] The speed reduction mechanism 53 has a speed reduction shaft 53A, a large-diameter first reduction gear 53B provided on the speed reduction shaft 53A, and a small-diameter second reduction gear 53C. The speed reduction shaft 53A is arranged in front of the differential device 54 and parallel to the motor output shaft 51. The first reduction gear 53B meshes with a gear 51A on the motor output shaft 51, and the second reduction gear 53C meshes with the ring gear 54A of the differential device 54.

[0022] The case 40 is formed with a roughly circular cross-sectional shape and has a cylindrical portion 40A extending in the vehicle width direction and a bulging portion 40B that bulges forward from the left end of the cylindrical portion 40A. The cylindrical portion 40A is the part that houses the motor 50, the motor output shaft 51 and the differential device 54. The bulging portion 40B is the part that houses the reduction mechanism 53. In a left side view, the case 40 has an oval shape formed by the combination of the cylindrical portion 40A and the bulging portion 40B, and in a plan view, it has an L-shape formed by the intersection of the cylindrical portion 40A and the bulging portion 40B.

[0023] As shown in Figures 1, 2, 3, and 4, a left front bracket 10 is fixed to the left end of the drive unit 30 to support the drive unit 30 on the vehicle body 2, and a mount insulator 14 is connected to the front end 10E of the left front bracket 10. The mount insulator 14 is fixed to the vehicle body member 2B.

[0024] An elastic member 14A, such as a mounting rubber, is provided inside the mount insulator 14, and the left front bracket 10 and the mount insulator 14 are elastically connected via the elastic member 14A. Therefore, the left end of the drive unit 30 is elastically supported by the vehicle body member 2B via the left front bracket 10 and the mount insulator 14.

[0025] The left front bracket 10 has three fastening parts 10A, 10B, and 10C that are fastened to the left end of the first case 41. Fastening part 10A is located in front of the center position of the drive unit 30 (the axial center position of the motor output shaft 51) at the left end of the first case 41, and is positioned at the front end of the cylindrical part 40A. Fastening part 10B is located in front of and above fastening part 10A. Fastening part 10C is located in front of and below fastening part 10A.

[0026] A right front bracket 11, which supports the drive unit 30 on the vehicle body 2, is fixed to the right end of the drive unit 30, and a mount insulator 15 is connected to the front end 11E of the right front bracket 11. The mount insulator 15 is fixed to the vehicle body member 2B.

[0027] An elastic member 15A, such as a mounting rubber, is provided inside the mount insulator 15, and the right front bracket 11 and the mount insulator 15 are elastically connected via the elastic member 15A. Therefore, the right end of the drive unit 30 is elastically supported by the vehicle body member 2B via the right front bracket 11 and the mount insulator 15.

[0028] The right front bracket 11 has four fastening parts 11A, 11B, 11C, and 11D that are fastened to the right end of the fourth case 44. Fastening part 11A is fastened to the right end of the fourth case 44 at a position behind and above the center of the drive unit 30. Fastening part 11B is fastened to the right end of the fourth case 44 at a position in front and below the center of the drive unit 30.

[0029] An upper support portion 44A is formed on the upper front of the fourth case 44, to which the upper part of the right front bracket 11 and the upper part of the high-voltage component 16 are fixed. The upper support portion 44A extends from the front outer periphery of the fourth case 44 toward the front and above the vehicle. The front end surface of the upper support portion 44A forms a flat surface that extends in the vertical direction.

[0030] A lower support portion 44B is formed at the lower front of the fourth case 44, to which the lower part of the right front bracket 11 and the lower part of the high-voltage component 16 are fixed. The lower support portion 44B extends from the front outer periphery of the fourth case 44 toward the front and downward of the vehicle. The front end surface of the lower support portion 44B forms a flat surface that extends in the vertical direction.

[0031] The fastening portion 11C is fastened to the right end of the upper support portion 44A of the fourth case 44 at a position forward and above the center of the drive unit 30. The fastening portion 11D is fastened to the right end of the lower support portion 44B of the fourth case 44 at a position forward and below the center of the drive unit 30.

[0032] A rear bracket 12 is fixed to the center of the rear of the drive unit 30 in the vehicle width direction, supporting the drive unit 30 to the vehicle body 2. The rear bracket 12 has a main body portion 12E that is fastened to the drive unit 30, and two vehicle body side connecting portions 12F that extend rearward from the main body portion 12E. A dash panel 2C is provided behind the rear bracket 12, and the dash panel 2C separates the engine room 3 from the passenger compartment behind it (not shown).

[0033] The main body 12E is formed in a roughly box shape with the longer side in the vehicle width direction when viewed from above and from the rear. A mount insulator 20 is connected to the rear end of the vehicle body side connecting part 12F. The mount insulator 20 is fixed to the subframe 2A.

[0034] An elastic member 20A, such as a mounting rubber, is provided inside the mount insulator 20, and the rear bracket 12 and the mount insulator 20 are elastically connected via the elastic member 20A. Therefore, the rear surface of the drive unit 30 is elastically supported by the subframe 2A via the rear bracket 12 and the mount insulator 20.

[0035] The main body 12E has four fastening parts 12A, 12B, 12C, and 12D that are fastened to the case 40. Fastening part 12A is located in the upper left corner of the main body 12E and is fastened to the rear surface of the partition member 41A of the first case 41. Fastening part 12B is located in the upper right corner of the main body 12E and is fastened to the rear surface of the third case 43.

[0036] The fastening portion 12C is located at the lower left corner of the main body portion 12E and is fastened to the rear surface of the partition member 41A of the first case 41. The fastening portion 12D is located at the lower right corner of the main body portion 12E and is fastened to the rear surface of the third case 43.

[0037] A high-voltage component 16 is fixed to the front of the drive unit 30, near the right end in the vehicle width direction. The high-voltage component 16 consists of an inverter that converts power from a battery (not shown) to a predetermined voltage and frequency and supplies it to the motor 50. The high-voltage component 16 is formed in a roughly square, box-like shape when viewed from the front. The high-voltage component 16 has four fastening parts 16A, 16B, 16C, and 16D that are fastened to the case 40.

[0038] Fastening portion 16A is located in the upper left corner of the high-voltage component 16 and fastens to the upper front of the second case 42. Fastening portion 16C is located in the lower left corner of the high-voltage component 16 and fastens to the lower front of the second case 42.

[0039] The fastening portion 16B is located at the upper right corner of the high-voltage component 16 and is fastened to the front end of the upper support portion 44A on the front of the fourth case 44. The fastening portion 16D is located at the lower right corner of the high-voltage component 16 and is fastened to the front end of the lower support portion 44B on the front of the fourth case 44.

[0040] An electric water pump 17 is positioned in front of the left end of the drive unit 30, above the left front bracket 10. The water pump 17 pumps coolant cooled by a radiator (not shown) to the drive unit 30. The water pump 17 has a coolant inlet pipe 17A for taking in coolant, and a coolant outlet pipe 17B that extends perpendicular to the coolant inlet pipe 17A and discharges the coolant. A support portion 10F for supporting the water pump 17 from below is formed integrally with the left front bracket 10 on the upper part of the left front bracket 10.

[0041] As shown in Figures 6 and 7, the right front bracket 11 is connected to the other end (right end) in the vehicle width direction of the cylindrical portion 40A of the case 40. The right front bracket 11 extends inclined from the other end in the vehicle width direction of the cylindrical portion 40A toward the front of the vehicle and toward the other side (right side) in the vehicle width direction. The right front bracket 11 constitutes the bracket in the present invention.

[0042] The high-voltage component 16 is located in front of the cylindrical portion 40A, in a first space S1 behind a first imaginary line L1 that passes through the front end position of the mounting device, which consists of the mounting insulator 15 and the right front bracket 11, and the front end position of the bulging portion 40B. Here, the front end position of the mounting device is equal to the position of the front end of the mounting insulator 15.

[0043] The high-voltage component 16 may be located in the second space S2 behind the second virtual line L2 that passes between the connecting portion of the mounting device and the front end position of the bulge portion 40B. Here, the connecting portion of the mounting device is at the same position as the front end portion 11E of the right front bracket 11.

[0044] The right front bracket 11 is curved in an arc so as to curve outwards to the other side in the vehicle width direction. In other words, the right front bracket 11 is not extended in a straight line, but is curved in an arc so that the left front is on the outside of the curve and the right rear is on the inside of the curve.

[0045] The right front bracket 11 is the other end (right end) of the cylindrical portion 40A in the vehicle width direction, and extends inclined toward the front of the vehicle and toward the other side in the vehicle width direction from a position behind the rear end position of the high-voltage component 16.

[0046] The mount insulator 15 is positioned to the right of the other end (right end) of the high-voltage component 16 in the vehicle width direction. In other words, the mount insulator 15 is not positioned to overlap the high-voltage component 16 in the front-to-back direction, but rather to the right of the high-voltage component 16 in the vehicle width direction.

[0047] As described above, in this embodiment, a high-voltage component 16 is positioned on the front of the drive unit 30. The drive unit 30 comprises a case 40 having a cylindrical portion 40A extending in the vehicle width direction and a bulging portion 40B that bulges forward from one end of the cylindrical portion 40A in the vehicle width direction. A right front bracket 11 is connected to the other end of the cylindrical portion 40A in the vehicle width direction, and the right front bracket 11 extends inclined from the other end of the cylindrical portion 40A in the vehicle width direction toward the front of the vehicle and toward the other side in the vehicle width direction. A mount insulator 15 having an elastic member 15A is connected to the front end 11E of the right front bracket 11, and the high-voltage component 16 is positioned in front of the cylindrical portion 40A in a first space S1 behind a first virtual line L1 that passes between the front end position of the mounting device consisting of the mount insulator 15 and the right front bracket 11 and the front end position of the bulging portion 40B.

[0048] As a result, the first space S1 behind the first imaginary line L1, which passes through the front end of the mount insulator 15 (the front end position of the mounting device) and the front end of the bulge 40B, becomes a recess surrounded by the bulge 40B in front of the case 40, the right front bracket 11, and the mount insulator 15. By placing the high-voltage component 16 in the first space S1, which was previously dead space, the engine compartment 3 can be made more compact. Furthermore, the load during a vehicle collision can be absorbed by the mount insulator 15, the right front bracket 11, and the bulge 40B of the case 40, protecting the high-voltage component 16 from the load during a vehicle collision. Additionally, the elastic member 15A of the mount insulator 15 can absorb the load and impact during a vehicle collision. As a result, the engine compartment 3 can be made more compact while protecting the high-voltage component 16 from the load during a vehicle collision. In addition, because the high-voltage component 16 is positioned in front of the drive unit 30, it can be efficiently cooled by the airflow while driving.

[0049] In this embodiment, the high-voltage component 16 may also be positioned in the second space behind the second virtual line passing through the connecting portion of the mounting device and the front end position of the bulging portion 40B.

[0050] As a result, the second space S2 behind the second imaginary line L2, which passes through the front end 11E of the right front bracket 11 (the connecting part of the mounting device) and the front end of the bulge 40B, becomes a recess surrounded by the bulge 40B in front of the case 40 and the right front bracket 11. By placing the high-voltage component 16 in the second space S2, which was previously dead space, the engine compartment 3 can be made more compact. Furthermore, the load during a vehicle collision can be absorbed by the right front bracket 11 and the bulge 40B of the case 40, protecting the high-voltage component 16 from the load during a vehicle collision. In addition, the high-voltage component 16 can be protected from the load during a vehicle collision while the engine compartment 3 is made more compact.

[0051] Furthermore, in this embodiment, the right front bracket 11 is curved in an arc shape so as to bend toward the other side (right side) in the vehicle width direction.

[0052] As a result, the right front bracket 11 is curved in an arc shape, so when a load is applied to the tip of the right front bracket 11 due to the impact of a vehicle collision, the right front bracket 11 deforms so that its front part is displaced to the other side (right side) and rearward in the vehicle width direction, thereby dissipating the impact of the vehicle front collision at the tip. This prevents the right front bracket 11 from deforming toward the high-voltage component 16 on one side in the vehicle width direction, thus protecting the high-voltage component 16.

[0053] Furthermore, in this embodiment, the right front bracket 11 is the other end of the cylindrical portion 40A in the vehicle width direction, and extends inclined toward the front of the vehicle and toward the other side in the vehicle width direction from a position behind the rear end position of the high-voltage component 16.

[0054] This allows for a sufficiently large gap in the vehicle width direction between the right front bracket 11 and the high-voltage component 16, preventing the right front bracket 11 from coming into contact with the high-voltage component 16 during a vehicle collision.

[0055] Furthermore, in this embodiment, the mount insulator 15 is positioned on the other side of the other end of the high-voltage component 16 in the vehicle width direction.

[0056] This prevents the mount insulator 15 from coming into contact with the high-voltage component 16 when it is pushed backward during a frontal collision.

[0057] While embodiments of the present invention have been disclosed, it will be apparent to those skilled in the art that modifications can be made without departing from the scope of the invention. All such modifications and equivalents are intended to be included in the following claims. [Explanation of symbols]

[0058] 1 vehicle 2 car bodies 3. Engine Room 11 Right front bracket (bracket) 11E Front end 15 Mount Insulators 15A Elastic member 16 High-voltage components 30 Drive unit 40 cases 40A Cylindrical section 40B Bulge L1 First Virtual Line L2 Second Virtual Line S1 1st space S2 2nd space

Claims

1. A drive unit is located in the engine compartment formed at the front of the vehicle and generates motor torque for driving, An electric vehicle comprising a bracket that supports the vehicle body at the end of the drive unit in the vehicle width direction, High-voltage components are arranged on the front of the aforementioned drive unit. The drive device comprises a case having a cylindrical portion extending in the vehicle width direction and a bulging portion that protrudes forward from one end of the cylindrical portion in the vehicle width direction. The bracket is connected to the other end of the cylindrical portion in the vehicle width direction. The bracket extends from the other end of the cylindrical portion in the vehicle width direction, inclined toward the front of the vehicle and toward the other side in the vehicle width direction, A mount insulator having an elastic member is connected to the front end of the bracket. The electric vehicle is characterized in that the high-voltage component is located in front of the cylindrical portion and in a first space behind a first imaginary line passing through the front end position of the mounting device consisting of the mounting insulator and the bracket and the front end position of the bulging portion.

2. The electric vehicle according to claim 1, characterized in that the high-voltage component is located in a second space behind a second imaginary line passing through the connecting portion of the mounting device and the front end position of the bulging portion.

3. The electric vehicle according to claim 1 or 2, characterized in that the bracket is curved in an arc so as to curve toward the other side in the vehicle width direction.

4. The electric vehicle according to claim 3, characterized in that the bracket extends from the other end of the cylindrical portion in the vehicle width direction, at a position behind the rear end position of the high-voltage component, inclined toward the front of the vehicle and toward the other side in the vehicle width direction.

5. The electric vehicle according to claim 2, characterized in that the mount insulator is positioned on the other side of the other end of the high-voltage component in the vehicle width direction.

Images