electric vehicles

Abstract

To provide an electric vehicle which can improve rigidity and reduction in the weight.SOLUTION: An electric vehicle includes: two cross members which are separated from each other in a front and rear direction; a battery pack which is positioned between the two cross members and stores a battery; a metal cover which is formed of metal, at least partially covers the upper surface of the battery pack, and is coupled to the two cross members; and a resin cover which is formed of a synthetic resin, and at least partially covers the upper face of the battery pack.SELECTED DRAWING: Figure 3

Description

[Technical Field]

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

[0002] Conventionally, electric vehicles equipped with a battery pack that houses batteries are known. The battery pack is mounted, for example, under the rear seat and is protected from the outside by a metal frame and trim of the rear seat. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-41783 Summary of the Invention [Problem to be solved by the invention]

[0004] In conventional electric vehicles, a metal frame covers almost the entire battery pack, which improves the rigidity of the vehicle body around the battery pack but also increases the weight of the electric vehicle.

[0005] An object of the present invention is to provide an electric vehicle that can improve rigidity and reduce weight. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the electric vehicle of the present invention comprises two cross members spaced apart from each other in the longitudinal direction, a battery pack located between the two cross members and accommodating a battery, a metal cover formed of metal and at least partially covering the top surface of the battery pack and fastened to the two cross members, and a resin cover formed of synthetic resin and at least partially covering the top surface of the battery pack.

[0007] With this configuration, the weight of the electric vehicle is lighter than when the battery pack is protected only by a metal cover. Furthermore, if the vehicle is subjected to an impact from the front or rear, for example, the metal cover supports the cross member and prevents the two cross members from moving closer to each other, which causes the vehicle body to deform. As a result, this embodiment makes it possible to improve the rigidity and reduce the weight of the electric vehicle.

[0008] In addition, the electric vehicle of the present invention further comprises a seat which is a driver's seat or a passenger seat, a mount which supports a battery pack and is fastened to two cross members, and two seat rails which extend in the fore-and-aft direction at positions spaced apart from each other in the vehicle width direction and are fastened to the two cross members respectively to support the seat, and the mount and metal cover are fastened to the two cross members between the two seat rails in the vehicle width direction.

[0009] With this configuration, for example, if the vehicle is subjected to a longitudinal impact, the metal cover and the seat rails can prevent the two cross members from approaching each other and causing the vehicle body to deform. This further improves the rigidity of the electric vehicle against longitudinal impacts. [Effects of the Invention]

[0010] According to the present invention, it is possible to improve the rigidity and reduce the weight of an electric vehicle. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is an exploded perspective view showing a partial configuration of an electric vehicle according to this embodiment. [Figure 2] FIG. 2 is a perspective view showing a partial configuration of the electric vehicle of this embodiment. [Figure 3] FIG. 3 is a plan view showing a partial configuration of the electric vehicle of this embodiment. [Figure 4] FIG. 4 is a plan view showing the configuration of the electric vehicle with the metal cover and resin cover removed according to this embodiment. [Figure 5] FIG. 5 is an enlarged perspective view of a portion of the electric vehicle of this embodiment. [Figure 6] FIG. 6 is a perspective view showing the configuration of the electric vehicle with a part of the resin cover removed according to this embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] (Embodiment) An electric vehicle 1 according to this embodiment will be described below with reference to the drawings. The configuration of the embodiment described below, as well as the actions and results (effects) brought about by this configuration, are merely examples and are not limited to the following description. Note that in this specification, ordinal numbers are used only to distinguish between parts and components, and do not indicate order or priority.

[0013] FIG. 1 is an exploded perspective view showing a partial configuration of an electric vehicle 1 according to this embodiment. As shown in FIG. 1, the electric vehicle 1 includes two seats 2, a vehicle body 3, a battery pack 4, a metal cover 5, a resin cover 6, and a center cover 7. The electric vehicle 1 according to this embodiment is an electric vehicle (BEV). However, the electric vehicle 1 is not limited to this and may be, for example, a hybrid vehicle (HEV) or a fuel cell vehicle (FCV).

[0014] For convenience, three mutually orthogonal directions are defined in the following drawings. The X direction is the front-to-rear direction of the electric vehicle 1. The Y direction is the width direction of the electric vehicle 1 and may also be referred to as the left-to-right direction. The Z direction is the height direction of the electric vehicle 1 and may also be referred to as the up-down direction.

[0015] The two seats 2 are, for example, a driver's seat and a passenger seat of the electric vehicle 1. Each of the two seats 2 is attached to the vehicle body 3 via two seat rails 21. The two seat rails 21 extend in the front-rear direction (X direction) and support the seat 2 so that it can move in the front-rear direction. Furthermore, the two seat rails 21 are provided spaced apart from each other in the left-right direction (Y direction).

[0016] In this embodiment, the battery pack 4, metal cover 5, and resin cover 6 are mounted, for example, under two seats 2. Therefore, the battery pack 4, metal cover 5, and resin cover 6 are each at least partially positioned between the seat rails 21 of each seat 2 in the left-right direction (Y direction).

[0017] Fig. 2 is a perspective view showing a partial configuration of the electric vehicle 1 of this embodiment, and Fig. 3 is a plan view showing a partial configuration of the electric vehicle 1 of this embodiment. As shown in Figs. 2 and 3, the vehicle body 3 has a floor panel 31 and two cross members 32.

[0018] 2, floor panel 31 forms the bottom surface of electric vehicle 1. Floor panel 31 extends in a direction (XY plane) perpendicular to the up-down direction (Z direction). The surface of floor panel 31 has projections and recesses.

[0019] The two cross members 32 are attached to the floor panel 31 so as to protrude upward (in the +Z direction) from the floor panel 31. As shown in Fig. 3, each cross member 32 extends in the left-right direction (in the Y direction). The two cross members 32 are spaced apart from each other in the front-rear direction (in the X direction).

[0020] As shown in Fig. 1, each seat rail 21 is fastened to two cross members 32. For example, a box-shaped base or the like is provided on the upper surface of the cross member 32. The two cross members 32 are connected to each other by the seat rails 21 of the seat 2 via the base.

[0021] Fig. 4 is a plan view showing the configuration of the electric vehicle 1 of this embodiment with the metal cover 5 and the resin cover 6 removed. Fig. 5 is an enlarged perspective view of a portion of the electric vehicle 1 of this embodiment. Fig. 5 is an enlarged perspective view of a portion between the cross member 32 and the battery pack 4 in the forward direction (+X direction).

[0022] As shown in Figures 4 and 5, the vehicle body 3 further has two reinforcements 33 and four brackets 34. The brackets 34 are an example of a mount. The reinforcements 33 are members that reinforce, for example, the portions where the floor panel 31 and the brackets 34 are attached to each other. As shown in Figure 5, the reinforcements 33 are mounted on the floor panel 31 and welded to the floor panel 31 and the lower end of one of the cross members 32.

[0023] 4, the four brackets 34 are, for example, members that support the battery pack 4. Note that the number of brackets 34 may be, for example, less than four or more than four.

[0024] As shown in Fig. 5, for example, two of the four brackets 34 protrude forward (+X direction) from the battery pack 4. The two brackets 34 are attached to the reinforcement 33 with stud bolts. In other words, the two brackets 34 located in front of the battery pack 4 are fastened to one of the cross members 32 via the reinforcement 33. The brackets 34 may also be attached directly to the cross member 32.

[0025] 4, two of the four brackets 34 protrude rearward (-X direction) from the battery pack 4. The two brackets 34 are fastened to the other cross member 32. That is, the four brackets 34 are fastened to two cross members 32.

[0026] The battery pack 4 is located between the two cross members 32 in the front-to-rear direction (X direction). The battery pack 4 further includes a battery 41, a container 42, a battery management system (BMS) 43, and a junction box (JB) 44.

[0027] The battery 41 is, for example, a secondary battery such as a lithium-ion battery. As shown in Fig. 2, the container 42 is formed in a box shape and houses the battery 41. In other words, the battery pack 4 is a unit that houses the battery 41. As shown in Fig. 4, the bottom surface of the container 42 is supported by four brackets 34.

[0028] The battery pack 4 is supported on a waterproof tray by, for example, four brackets 34, and is mounted on the vehicle body 3 via the waterproof tray. Note that the battery pack 4 may be mounted on the vehicle body 3 without using the waterproof tray, or may be mounted on the vehicle body 3 by another method.

[0029] The battery management system 43 is, for example, a system that controls the battery 41. The junction box 44 has, for example, terminals inside the battery pack 4 and a box that protects the terminals.

[0030] In the left-right direction (Y direction) of the battery pack 4, the battery management system 43 is located near the right end 42a, which is the end on the right side (-Y direction) of the container 42. On the other hand, the junction box 44 is located near the left end 42b, which is the end on the left side (+Y direction) of the container 42. In other words, the battery management system 43 and the junction box 44 are provided spaced apart from each other in the left-right direction.

[0031] The metal cover 5 is a cover made of, for example, metal. As shown in Fig. 2, the metal cover 5 is mounted on the vehicle body 3 and covers the top surface 4a of the battery pack 4. The top surface 4a is the outer surface of the battery pack 4 facing upward (+Z direction). It is sufficient that the metal cover 5 at least partially covers the top surface 4a of the battery pack 4.

[0032] 6 is a perspective view showing the configuration of the electric vehicle 1 with part of the resin cover 6 of this embodiment removed. That is, FIG. 6 is a perspective view showing the state in which part of the resin cover 6 and the center cover 7 have been removed from the battery pack 4 shown in FIG. 2. As shown in FIG. 6, the metal cover 5 has a first metal cover 51 and a second metal cover 52.

[0033] The first metal cover 51 covers the battery pack 4 from the front-to-rear direction (X direction) and from above (+Z direction). Furthermore, the first metal cover 51 covers the right end 42a of the container 42 in the left-to-right direction (Y direction). In other words, the first metal cover 51 covers the battery management system 43 built into the battery pack 4 from above.

[0034] The second metal cover 52 covers the battery pack 4 from the rear (-X direction) and also covers part of the battery pack 4 from the front (+X direction) and top (+Z direction). Furthermore, the second metal cover 52 covers the left end 42b of the container 42 in the left-right direction (Y direction). The second metal cover 52 covers the junction box 44 built into the battery pack 4 from above.

[0035] In other words, the metal cover 5 covers the battery management system 43 and the junction box 44 built into the battery pack 4, and also covers the battery pack 4 from the rear. However, the metal cover 5 is not limited to this, and it is sufficient that the metal cover 5 covers the battery pack 4 at least partially.

[0036] 3, the first metal cover 51 and the second metal cover 52 of the metal cover 5 extend in the front-rear direction (X direction) and are fastened to the two cross members 32 with screws or the like. In other words, the metal cover 5 extends in the front-rear direction and is fastened to the two cross members 32 with screws or the like.

[0037] As shown in Figures 3 and 4, fastening portion 5a, which is the fastening portion between metal cover 5 and two cross members 32 in the front-to-rear direction (X direction), is located near fastening portion 34a, which is the fastening portion between two cross members 32 and bracket 34.

[0038] In the left-right direction (Y direction), the fastening portion 5a of the metal cover 5 and the fastening portion 34a of the bracket 34 are located between the two seat rails 21. In other words, the metal cover 5 and the bracket 34 are fastened to the two cross members 32 between the two seat rails 21 in the left-right direction.

[0039] The fastening portion 5a of the metal cover 5 and the fastening portion 34a of the bracket 34 at the rear of the battery pack 4 are positioned so as not to overlap each other. For example, in this embodiment, a cutout is provided in part of the metal cover 5 so as to avoid the fastening portion 34a of the bracket 34.

[0040] The resin cover 6 is a cover made of, for example, synthetic resin. As shown in Fig. 2, the resin cover 6 extends in a direction (XY plane) substantially perpendicular to the up-down direction (Z direction) and covers the top surface 4a of the battery pack 4. In this way, the resin cover 6 protects the battery pack 4 from, for example, liquid that may enter from above the vehicle body 3. Note that it is sufficient that the resin cover 6 at least partially covers the top surface 4a of the battery pack 4.

[0041] In this embodiment, the resin cover 6 is provided adjacent to the first metal cover 51 of the metal cover 5 in the left-right direction (Y direction). Note that it is sufficient that at least a portion of the metal cover 5 and the resin cover 6 are adjacent to each other in the left-right direction.

[0042] The resin cover 6 has a first resin cover 61 and a second resin cover 62. The first resin cover 61 is attached to the first metal cover 51 of the metal cover 5 with a clip or the like, and covers the battery pack 4 from above.

[0043] The first resin cover 61 covers the vicinity of the center of the container 42 in the left-right direction (Y direction). For example, the first resin cover 61 covers the battery pack 4 between the first metal cover 51 and the second metal cover 52 of the metal cover 5 in the left-right direction (Y direction). In other words, the first resin cover 61 covers parts other than the battery management system 43 and the junction box 44 built into the battery pack 4. Furthermore, the first resin cover 61 is adjacent to each of the first metal cover 51 and the second metal cover 52 in the left-right direction (Y direction).

[0044] The second resin cover 62 is attached to the second metal cover 52 of the metal cover 5 with clips or the like, and covers the upper side of the second metal cover 52 and at least a portion of the second metal cover 52 from the front. Furthermore, the second resin cover 62 covers a portion of the first resin cover 61 from above. In other words, the second resin cover 62 at least partially covers the second metal cover 52 of the metal cover 5 and the first resin cover 61 of the resin cover 6.

[0045] Furthermore, the second resin cover 62 is provided with an opening 621. The opening 621 is a hole that opens to the outer surface of the second resin cover 62. The opening 621 allows the outside and the inside of the second resin cover 62 to communicate with each other.

[0046] 2 and 6, the battery pack 4 further includes an air intake device 45, a filter 46, and a filter case 47. The air intake device 45 is a device that supplies air from inside the vehicle body 3 to the battery 41 to cool the battery 41.

[0047] The intake device 45 is covered from above and from the right by the second resin cover 62 of the resin cover 6, and is disposed adjacent to the junction box 44 in the left-right direction (Y direction). Furthermore, the intake device 45 is covered from the rear by the second metal cover 52 of the metal cover 5.

[0048] In other words, the second metal cover 52 of the metal cover 5 covers the rear of the intake device 45 but does not cover the top of the intake device 45. As a result, the intake device 45 is protected by the second metal cover 52 from impacts from the rear of the vehicle, for example.

[0049] 6, the intake device 45 has a blower 451 and a duct 452. The blower 451, for example, takes in air from inside the vehicle body 3 and supplies the air to the container 42 that houses the battery 41, thereby cooling the battery 41. The duct 452 is a curved pipe that connects the opening 621 of the second resin cover 62 to the blower 451 and guides the air that has passed through the opening 621 to the blower 451. Furthermore, the duct 452 protects the blower 451 from, for example, an impact from the front of the vehicle body 3.

[0050] 2, the filter 46 is provided in the opening 621 and attached to the second resin cover 62 by the filter case 47. The filter case 47 sandwiches the filter 46 between the filter case 47 and the outer surface of the second resin cover 62, and is attached to the second resin cover 62 with screws or the like.

[0051] The center cover 7 is a cover made of, for example, metal, etc. Above the center cover 7, for example, a shift lever and a holder for storing drinking water, etc. are provided.

[0052] 3, the center cover 7 extends in the front-rear direction (X direction) and is fastened to the two cross members 32 with screws or the like. The center cover 7 is located between the first metal cover 51 of the metal cover 5 and the second resin cover 62 of the resin cover 6 in the left-right direction (Y direction), and covers the first resin cover 61 of the resin cover 6 from above.

[0053] Generally, when a battery pack is installed under a rear seat of a vehicle, the battery pack is covered with a metal frame or trim to improve the rigidity of the vehicle body around the battery pack. However, the driver's seat or passenger seat of the vehicle can move, for example, in the front-to-rear direction. Therefore, it is difficult to cover the battery pack from above with a metal frame. Therefore, when a battery pack is installed under the driver's seat or passenger seat, it is difficult to improve the rigidity of the vehicle body with a metal frame or trim.

[0054] In conventional electric vehicles, when a battery pack is placed under the driver's seat or passenger seat, the battery pack is protected from external impacts by a case. The rigidity of the case that protects the battery pack is increased to improve the rigidity of the vehicle body. However, increasing the rigidity of the case increases the weight of the case, which in turn increases the weight of the electric vehicle.

[0055] On the other hand, in the electric vehicle 1 of this embodiment, the battery pack 4 is located between two cross members 32 in the fore-and-aft direction (X direction), and is covered from above (+Z direction) by a metal cover 5 and a center cover 7 made of metal, and a resin cover 6 made of synthetic resin.

[0056] For example, when the electric vehicle 1 of this embodiment receives an impact from the front (+X direction), the impact is received by the cross member 32 located in the front. Upon receiving the impact, the cross member 32 attempts to deform in the rear (-X direction).

[0057] In this embodiment, the seat rails 21 of the seat 2, the metal cover 5, and the center cover 7 extend in the front-rear direction (X direction) and are fastened to two cross members 32, connecting the two cross members 32. In other words, the seat rails 21, the metal cover 5, and the center cover 7 form a rigid body that is substantially integrated with the two cross members 32, and maintain a distance between the two cross members 32.

[0058] Therefore, each seat rail 21, metal cover 5, and center cover 7 support the cross members 32 located in the forward direction (+X direction) (cross members 32 that tend to deform in the rearward direction (-X direction)) with the cross members 32 located in the rearward direction (-X direction). This allows each seat rail 21, metal cover 5, and center cover 7 to prevent the two cross members 32 from deforming and moving closer to each other due to an impact from the front.

[0059] Furthermore, as described above, the distance between the fastening portion 5a of the metal cover 5 and the fastening portion 34a of the bracket 34 is short. As a result, for example, when an impact is applied from the front-to-rear direction of the vehicle body 3, the amount of relative positional change between the fastening portion 5a of the metal cover 5 and the fastening portion 34a of the bracket 34 is reduced, and the metal cover 5 and the two cross members 32 function as a substantially integrated rigid body, which makes it easier to improve rigidity.

[0060] As described above, the electric vehicle 1 of this embodiment protects the battery pack 4 with the metal cover 5 and connects the two cross members 32. This allows the electric vehicle 1 of this embodiment to have improved rigidity, similar to conventional electric vehicles in which the battery pack is protected by a case.

[0061] Furthermore, in the electric vehicle 1 of this embodiment, the battery pack 4 is protected by a metal cover 5 and a resin cover 6. That is, by improving the rigidity of the electric vehicle 1 with limited parts such as the metal cover 5, it is possible to form some parts from materials with lower rigidity. This makes the electric vehicle 1 of this embodiment lighter than conventional electric vehicles. Therefore, in this embodiment, it is possible to improve the rigidity and reduce the weight of the electric vehicle 1.

[0062] As described above, the electric vehicle 1 of this embodiment has two cross members 32, a battery pack 4, a metal cover 5, and a resin cover 6. The two cross members 32 are spaced apart from each other in the front-to-rear direction (X direction). The battery pack 4 is located between the two cross members 32 and houses a battery 41. The metal cover 5 is made of metal, at least partially covers the upper surface 4a of the battery pack 4, and is fastened to the two cross members 32. The resin cover 6 is made of synthetic resin, at least partially covers the upper surface 4a of the battery pack 4.

[0063] At least the top surface 4a of the battery pack 4 of this embodiment is covered with the metal cover 5 and the resin cover 6. That is, the top surface 4a of the battery pack 4 is protected by the metal cover 5 and the resin cover 6. Therefore, the weight of the electric vehicle 1 of this embodiment is lighter than when the battery pack 4 is protected only by the metal cover 5.

[0064] Furthermore, the metal cover 5 is fastened to two cross members 32 that are spaced apart from each other in the longitudinal direction (X direction). That is, the metal cover 5 forms a rigid body that is substantially integral with the two cross members 32, maintaining the distance between the two cross members 32. Therefore, for example, if the vehicle body 3 receives an impact from the longitudinal direction, the metal cover 5 supports the cross members 32 and prevents the vehicle body 3 from being deformed by the impact, causing the two cross members 32 to move closer to each other. As a result, the metal cover 5 improves the rigidity of the vehicle body 3 against an impact from the longitudinal direction. In other words, the rigidity of the vehicle body 3 can be improved by the metal cover 5 that covers the battery pack 4, and other members for improving rigidity can be omitted. Therefore, in this embodiment, the rigidity and weight of the electric vehicle 1 can be improved.

[0065] The electric vehicle 1 of this embodiment also includes a seat 2, which is a driver's seat or a passenger seat, a bracket 34, and two seat rails 21. The bracket 34 supports the battery pack 4 and is fastened to the two cross members 32. The two seat rails 21 extend in the front-to-rear direction (X direction) at positions spaced apart from each other in the vehicle width direction (Y direction), and are fastened to the two cross members 32, respectively, to support the seat 2. The bracket 34 and the metal cover 5 are fastened to the two cross members 32 between the two seat rails 21 in the vehicle width direction.

[0066] In this embodiment, the seat rails 21 for the driver's seat or passenger seat extend in the fore-and-aft direction (X direction) of the vehicle body 3 and are fastened to two cross members 32 that are spaced apart in the fore-and-aft direction. In other words, the seat rails 21 form a rigid body that is substantially integrated with the two cross members 32 that are spaced apart in the fore-and-aft direction. Therefore, for example, when the vehicle body 3 receives an impact from the fore-and-aft direction, the seat rails 21 as well as the metal cover 5 can prevent the vehicle body 3 from deforming in such a way that the two cross members 32 approach each other. This allows the electric vehicle 1 to further improve the rigidity of the vehicle body 3 against an impact from the fore-and-aft direction.

[0067] Although the embodiments of the present invention have been described above, the above embodiments are merely examples and are not intended to limit the scope of the invention. The above embodiments can be implemented in various other forms, and various omissions, substitutions, combinations, and modifications can be made without departing from the spirit of the invention. Furthermore, the specifications of each configuration, shape, and the like (structure, type, direction, format, size, length, width, thickness, height, number, arrangement, position, material, etc.) can be modified as appropriate. [Explanation of symbols]

[0068] 1 electric car 2 seats 21 Seat rail 32 Cross member 34 Bracket (mount) 4 Battery pack 4a Top side 41 Batteries 5 Metal cover 6 Resin cover

Claims

1. Two cross members spaced apart from each other in the front-rear direction; a battery pack located between the two cross members and housing a battery; a first metal cover and a second metal cover formed of metal, at least partially covering an upper surface of the battery pack and a plurality of electrical components housed in the battery pack, and fastened to the two cross members; a first resin cover and a second resin cover formed of synthetic resin and at least partially covering an upper surface of the battery pack; Equipped with the first resin cover is disposed so as to cover portions other than the plurality of electrical components, The second resin cover is arranged to cover either the first metal cover or the second metal cover.

2. a seat that is a driver's seat or a passenger seat; a mount that supports the battery pack and is fastened to the two cross members; two seat rails extending in the front-rear direction at positions spaced apart from each other in the vehicle width direction, fastened to the two cross members respectively, and supporting the seat; Furthermore, the mount, the first metal cover, and the second metal cover are fastened to the two cross members between the two seat rails in the vehicle width direction; The electric vehicle according to claim 1.

3. A center cover extending in the fore-and-aft direction of the vehicle and fastened to the two cross members, the center cover is located between the first metal cover and the second metal cover and covers the first resin cover from above; The electric vehicle according to claim 1.

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