Support structure for vehicle batteries

Abstract

To inhibit damage to a battery during a side collision in the layout in which the battery is disposed below a side rail.SOLUTION: In a vehicle battery support structure, a battery pack 60 is disposed below a ladder frame 10. A battery bracket 40 is fixed to a vehicle width direction outer side of the battery pack 60. A suspension bracket 30 is secured to the battery bracket 40. The suspension bracket 30 includes a horizontal portion 31 and an inclined portion 32. The horizontal portion 31 extends in a vehicle width direction from an outer side in the vehicle width direction of a side rail 12. The inclined portion 32 extends outward and downward in the vehicle width direction from an outer end of the horizontal portion 31 in the vehicle width direction. A shock absorbing component 50 is disposed on the vehicle width direction outer side of the battery bracket 40.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] This specification discloses a support structure for a vehicle battery.

Background Art

[0002] In Patent Document 1, in a vehicle with a monocoque structure, a battery is disposed between a pair of rockers. Also, in Patent Documents 2 and 3, in a vehicle with a ladder frame structure, a battery is disposed between a pair of side rails.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in order to expand the mounting space for the battery, in a vehicle with a ladder frame structure, it is conceivable to dispose the battery under the side rail. According to such a layout, the battery can be disposed up to the outside in the vehicle width direction from the side rail. On the other hand, at the time of a side collision of the vehicle, it is necessary to protect the battery.

[0005] Therefore, this specification discloses a support structure for a vehicle battery. According to this support structure, in a layout in which the battery is disposed under the side rail, damage to the battery at the time of a side collision can be suppressed.

Means for Solving the Problems

[0006] This specification discloses a support structure for a vehicle battery. The structure comprises a ladder frame, a battery pack, a battery bracket, a suspension bracket, and shock-absorbing components. The ladder frame includes side rails extending in the longitudinal direction of the vehicle. The battery pack is positioned below the ladder frame. The battery bracket is fixed to the outside of the battery pack in the vehicle width direction. The suspension bracket is fixed to the battery bracket. The suspension bracket includes a horizontal section and an inclined section. The horizontal section extends in the vehicle width direction from the outside of the side rail in the vehicle width direction. The inclined section extends outward and downward in the vehicle width direction from the outside end of the horizontal section in the vehicle width direction. The shock-absorbing components are positioned on the outside of the battery bracket in the vehicle width direction.

[0007] According to the above configuration, during a side collision of the vehicle, the impact-absorbing component receives the collision load. Furthermore, this collision load is transmitted to the ladder frame via the battery bracket and suspension bracket. By providing a load transmission path that avoids the battery pack, damage to the battery pack during a side collision can be suppressed.

[0008] Furthermore, in the above configuration, the suspension bracket may be provided with a bent portion. The bent portion is provided between the horizontal portion and the inclined portion. The bent portion is also provided at a height above the top surface of the battery pack.

[0009] As a side impact progresses, the suspension bracket bends and deforms, starting from the bent section. Because the bent section is positioned above the top surface of the battery pack, the suspension bracket bends and deforms in a way that avoids the battery pack.

[0010] Furthermore, in the above configuration, at least a portion of the shock-absorbing components and at least a portion of the battery pack may be positioned at the same height. In this case, the shock-absorbing components are supported by the side rails via the battery bracket and the suspension bracket.

[0011] According to the above configuration, the transmission of collision load to the impact-absorbing components and the battery packs aligned in the vehicle width direction is suppressed.

[0012] Furthermore, in the above configuration, cab mount brackets may be provided on the side rails. The cab mount brackets support the cabin. The suspension brackets are fixed to the cab mount brackets.

[0013] According to the above configuration, the collision load is distributed to the cabin's structural components.

[0014] Furthermore, in the above configuration, a rocker extending in the longitudinal direction of the vehicle may be positioned below the cabin and outward in the vehicle width direction. In this case, the inclined portion of the suspension bracket is positioned below the rocker.

[0015] During a side collision with a vehicle, the suspension bracket bends and deforms starting from the bent section. This causes the inclined section to lift upward. Since a rocker is positioned above the inclined section, excessive upward movement of the inclined section is suppressed. [Effects of the Invention]

[0016] According to the vehicle battery support structure disclosed herein, in a layout in which the battery is located below the side rail, damage to the battery during a side collision can be suppressed. [Brief explanation of the drawing]

[0017] [Figure 1] This is an overall perspective view illustrating the support structure for a vehicle battery according to this embodiment. [Figure 2] This is an enlarged perspective view illustrating the structure around the suspension bracket. [Figure 3] This is a cross-sectional view AA in Figure 2. [Figure 4] This is a cross-sectional view illustrating the initial stages of a side impact. [Figure 5] This is a cross-sectional view showing an example of a side collision progressing. [Figure 6]It is an enlarged perspective view showing a first alternative example of a suspension bracket. [Figure 7] It is a cross-sectional view showing a second alternative example of a suspension bracket. [Figure 8] It is a cross-sectional view showing a third alternative example of a suspension bracket.

Mode for Carrying Out the Invention

[0018] Hereinafter, the support structure of the vehicle battery according to the present embodiment will be described with reference to the drawings. The shapes, materials, numbers, and numerical values described below are examples for explanation, and can be appropriately changed according to the specifications of the support structure of the vehicle battery. Also, in all the drawings below, the same reference numerals are assigned to equivalent elements.

[0019] Also, in FIGS. 1-8, in order to represent the positions and directions of each component, a rectangular coordinate system consisting of the FR axis, RW axis, and UP axis is used. The FR axis is the vehicle longitudinal axis with the vehicle front as the positive direction. RW is the vehicle width direction axis with the vehicle right side as the positive direction. The UP axis is the vehicle vertical axis with the upward direction as the positive direction.

[0020] <Overall Configuration> FIG. 1 illustrates the support structure of the vehicle battery according to the present embodiment. The vehicle illustrated in FIG. 1 includes a ladder frame 10 as a skeletal component. A body is mounted on the ladder frame 10. For example, the vehicle is a pickup truck. That is, the body includes a cab 80 and a rear deck 82.

[0021] Also, as illustrated in FIG. 1, the vehicle includes a large battery pack 60. For example, the vehicle is an electric pickup truck. That is, the vehicle includes a rotating electric machine (not shown) as a drive source. As a power source for the rotating electric machine, the battery pack 60 is mounted on the vehicle.

[0022] As will be described later, the vehicle battery support structure according to this embodiment comprises a ladder frame 10, a battery pack 60, a battery bracket 40, suspension brackets 20, 30, and shock-absorbing components 50.

[0023] <Ladder frame and its surrounding structure> Referring to Figure 1, the ladder frame 10 comprises a plurality of cross members 11 and a pair of side rails 12, 12. The pair of side rails 12, 12 extend in the longitudinal direction of the vehicle. The pair of side rails 12, 12 are spaced apart in the width direction of the vehicle.

[0024] Referring to Figures 2 and 3, each side rail 12 has a closed cross-sectional structure, for example, a rectangular cross-section. For example, the side rail 12 comprises a side rail inner 12A and a side rail outer 12B. The side rail inner 12A and the side rail outer 12B each have a U-shaped cross-section. The closed cross-sectional structure is formed by overlapping the side rail inner 12A and the side rail outer 12B.

[0025] Referring to Figures 1 and 2, the cross members 11 are structural components that extend in the vehicle width direction. Both ends of each cross member 11 in the vehicle width direction are fixed to a pair of side rails 12, 12.

[0026] Referring to Figures 1 and 2, the cab mount bracket 14 and the suspension brackets 20 and 30 are fixed to the side rail 12. The cab mount bracket 14 and the suspension brackets 20 and 30 are positioned on the outside of the side rail 12 in the vehicle width direction.

[0027] The cab mounting bracket 14 supports the cabin 80 from below. The cab mounting bracket 14 is welded to, for example, the side rail outer 12B. The cab mounting bracket 14 is, for example, hollow in structure.

[0028] The cab mount bracket 14 comprises a cab mount bracket upper 14A and a cab mount bracket lower 14B. The cab mount bracket upper 14A and the cab mount bracket lower 14B have, for example, an L-shaped cross-section. By overlapping the cab mount bracket upper 14A and the cab mount bracket lower 14B, a hollow cab mount bracket 14 is formed.

[0029] The suspension brackets 20 and 30 suspend and support the battery pack 60. For example, the suspension bracket 30 is provided on the extension of the cross member 11. For example, the suspension bracket 30 is welded to the side rail outer 12B. The suspension bracket 20 is welded to the cab mount bracket 14.

[0030] As will be described later, in the event of a side collision with the vehicle, the collision load is transmitted from the suspension bracket 30 to the side rail 12. The collision load is also transmitted from the suspension bracket 20 to the cab mount bracket 14. Furthermore, the impact load is transmitted from the cab mount bracket 14 to the rocker 90 of the cabin 80 (see Figure 3). In this way, the impact load is distributed from the suspension brackets 20 and 30 to the vehicle's structural components. The detailed structure of the suspension brackets 20 and 30 will be described later.

[0031] <Battery Pack> Referring to Figures 2 and 3, the battery pack 60 is positioned below the ladder frame 10. As described above, the vehicle is equipped with a rotating electric motor as a power source. The battery pack 60 is the power source for the rotating electric motor.

[0032] The battery pack 60 comprises multiple individual cells and a casing. These individual cells are, for example, lithium-ion batteries or nickel-metal hydride batteries. These multiple individual cells are housed in the casing.

[0033] Referring to Figure 1, the battery pack 60 is positioned, for example, below the cabin 80. The surface area of ​​the battery pack 60 is approximately equal to the floor area of ​​the cabin 80. For example, the front-to-rear dimensions of the battery pack 60 are approximately equal to the front-to-rear dimensions of the cabin 80. Also, the vehicle width dimension of the battery pack 60 is approximately equal to the vehicle width dimension of the cabin 80.

[0034] As will be described later, shock-absorbing components 50 are fixed to the battery pack 60. The shock-absorbing components 50 are positioned at both ends of the battery pack 60 in the vehicle width direction. Since the vehicle width dimension of the battery pack 60 is approximately equal to the vehicle width dimension of the cabin 80, at least a portion of the shock-absorbing components 50 protrudes outward in the vehicle width direction beyond the cabin 80. As will be described later, the shock-absorbing components 50 also function as steps used when getting on and off the cabin 80.

[0035] <Battery support structure> Referring to Figures 2 and 3, the battery pack 60 is supported on the side rail 12 via suspension brackets 20, 30, a battery bracket 40, and a mounting bracket 64. The battery bracket 40 is positioned below the suspension brackets 20, 30. More specifically, the suspension brackets 20, 30 include lower plates 20C, 30C as components. The battery bracket 40 is positioned below these lower plates 20C, 30C.

[0036] Referring to Figure 1, for example, the battery bracket 40 has approximately the same front-to-rear dimensions as the battery pack 60. The battery bracket 40 is fixed to the outside of the battery pack 60 in the vehicle width direction. Although Figures 1-8 show the support structure on the left side of the vehicle, based on the symmetrical structure of the vehicle, the right side of the vehicle has a similar structure to Figures 1-8.

[0037] Referring to Figure 3, the battery bracket 40 has a vertical grid shape in its UP-RW cross section. That is, multiple inner plates 41 are arranged inside the battery bracket 40. The inner plates 41 extend in the vertical direction. The multiple inner plates 41 are also spaced apart along the vehicle width direction. The battery bracket 40, which has this hollow structure, is crushed in the vehicle width direction during a side collision with the vehicle. This crushing absorbs the impact load.

[0038] Furthermore, bolt holes 42 and 43 are drilled vertically in the battery bracket 40. Bolt hole 42 is provided for fixing the battery bracket 40 to the suspension bracket 30. Bolt hole 43 is provided for fixing the battery pack 60 to the battery bracket 40.

[0039] A bolt 46 is inserted into a bolt hole 42. A bolt hole 30C1 is drilled in the lower plate 30C of the suspension bracket 30. A weld nut 47 is placed on the lower plate 30C coaxially with the bolt hole 30C1. The bolt 46 is screwed into this weld nut 47. Furthermore, a collar 45 is placed between the battery bracket 40 and the lower plate 30C. The collar 45 defines the separation distance between the battery bracket 40 and the lower plate 30C.

[0040] A bolt 48 is inserted into the bolt hole 43. A mounting bracket 64 is positioned on the outer side of the battery pack 60 in the vehicle width direction. The mounting bracket 64 is a component with a Z-shaped cross-section. The vehicle width direction end of the battery pack 60 rests on the lower plate of the mounting bracket 64. A weld nut 49 is also positioned on the upper plate of the mounting bracket 64. The battery pack 60 is supported by the battery bracket 40 when the bolt 48 is screwed into the weld nut 49.

[0041] Below the battery pack 60 is a mudguard battery cover 62. The battery cover 62 is supported by bolts 48 on the battery bracket 40.

[0042] A hook 44 is provided on the outer end of the battery bracket 40 in the vehicle width direction. The hook 44 is positioned upward. A hook 53 is also provided on the shock-absorbing component 50. The hook 53 is positioned downward. The hooks 44 and 53 interlock.

[0043] When the shock-absorbing component 50 is used as a step, the shock-absorbing component 50 flexes downward due to the weight of the occupant. The hook 44 of the battery bracket 40 also flexes in accordance with this flexing. For example, the hook 44 is flexed so that it opens. In this case, in the battery bracket 40, only the hook 44 flexes, while the rest of the main body is spared from flexing. By suppressing the flexing of the main body, friction between the main body and surrounding parts such as the collar 45 is suppressed.

[0044] The shock-absorbing component 50 is positioned on the outside of the battery bracket 40 in the vehicle width direction. For example, the shock-absorbing component 50 is formed to have a greater height than the battery bracket 40. In addition, each component is positioned such that the bottom surfaces of the shock-absorbing component 50, the battery bracket 40, and the battery pack 60 are at approximately the same height.

[0045] For example, the shock-absorbing component 50 has a hollow structure. For example, the shock-absorbing component has a cross-lattice shape in its UP-RW cross section. Inside the shock-absorbing component 50, inner plates 51 and 52 are provided. Inner plate 51 extends in the vertical direction. Inner plate 52 extends in the horizontal direction.

[0046] The impact-absorbing component 50 is crushed in the width direction of the vehicle during a side collision. This crushing absorbs the impact load. The impact-absorbing component 50 can also be used as a step. In order to ensure both vertical load-bearing capacity and ease of crushing during a side collision, the inner plate 51 may be formed to be thicker than the inner plate 52.

[0047] A flange 54 and a hook 53 are provided at the inner end of the shock-absorbing component 50 in the vehicle width direction. As described above, the hook 53 engages with the hook 44 of the battery bracket 40. The flange 54 abuts against the vertical portion 33 of the suspension bracket 30. Furthermore, the flange 54 is bolted to the vertical portion 33.

[0048] Referring to Figures 2 and 3, the suspension bracket 30 is fixed to the side rail 12. For example, the suspension bracket 30 is welded to the side rail outer 12B. The suspension bracket 20 is also fixed to the side rail 12 via the cab mount bracket 14. For example, the suspension bracket 20 is fixed to the cab mount bracket 14.

[0049] Referring to Figure 2, the suspension bracket 20 has a similar structure to the suspension bracket 30. More specifically, the suspension bracket 20 is shorter than the suspension bracket 30 by the width dimension of the cab mount bracket 14. Specifically, the horizontal portion 21 of the suspension bracket 20 is shorter than the horizontal portion 31 of the suspension bracket 30. However, in terms of other structures, the suspension bracket 20 has a similar structure to the suspension bracket 30. To avoid repetition in the explanation, the following will focus solely on the structure of the suspension bracket 30. However, by changing the tens digit of the reference numeral from 3 to 2, the following explanation can be replaced with a description of the structure of the suspension bracket 20.

[0050] The suspension bracket 30 has a hollow structure. For example, the suspension bracket 30 is composed of multiple parts. That is, the suspension bracket 30 comprises a suspension bracket upper 30A, a suspension bracket lower 30B, and a lower plate 30C. These components are joined to each other by welding.

[0051] The suspension bracket 30 comprises a horizontal section 31, an inclined section 32, and a vertical section 33. The horizontal section 31 extends outward in the vehicle width direction from the side rail outer 12B. The inclined section 32 is connected to the outer end of the horizontal section 31 in the vehicle width direction. The inclined section 32 extends outward and downward in the vehicle width direction. The vertical section 33 is connected to the lower end of the inclined section 32. Furthermore, a lower plate 30C is connected to the lower end of the vertical section 33. The lower plate 30C has, for example, a U-shaped cross-section and is fixed to the suspension bracket upper 30A and the suspension bracket lower 30B so as to overlap the vertical section 33.

[0052] A bent portion 34 is formed between the horizontal portion 31 and the inclined portion 32. This bent portion 34 is positioned at a height above the top surface of the battery pack 60. As shown in Figure 5, which will be described later, when a vehicle collides with the side, the suspension bracket 30 bends upward, starting from the bent portion 34. By positioning the bent portion 34 at a height above the top surface of the battery pack 60, interference between the deforming suspension bracket 30 and the battery pack 60 is suppressed.

[0053] Referring to Figure 3, the inclined section 32 is positioned below the rocker 90. The rocker 90 is a structural component positioned below the cabin 80 (see Figure 1) and outward in the vehicle width direction. The rocker 90 extends in the longitudinal direction of the vehicle.

[0054] The rocker 90 comprises a rocker inner 90A and a rocker outer 90B. Both the rocker inner 90A and the rocker outer 90B have a hat-shaped cross-section, and when the two are superimposed, a closed cross-sectional structure is formed.

[0055] As will be described later, in the event of a side collision with a vehicle, the inclined portion 32 moves upward (ascends). Since the rocker 90 is positioned above the inclined portion 32, the upward movement of the inclined portion 32 is stopped by the rocker 90. By suppressing excessive upward movement of the inclined portion 32, the deflection of the battery pack 60 supported by the suspension bracket 30 is suppressed.

[0056] <Behavior during a side collision> Figures 4 and 5 illustrate the behavior of a vehicle during a side collision. For example, the vehicle skids sideways and collides with the barrier 100. The door 93 and impact-absorbing component 50, located on the outer side of the vehicle in the vehicle width direction, are crushed and deformed. This absorbs the impact load.

[0057] Furthermore, the impact-absorbing component 50 is supported on the side rail 12 via the battery bracket 40 and the suspension brackets 20 and 30. Therefore, the impact load is transmitted from the impact-absorbing component 50 to the side rail 12. Referring to Figure 4, at least a portion of the impact-absorbing component 50 and at least a portion of the battery pack 60 are positioned at the same height. However, the impact load is diverted from the impact-absorbing component 50 to the battery pack 60 via the suspension bracket 30. In other words, the transmission of the impact load to the battery pack 60 is suppressed.

[0058] Also, referring to Figures 2 and 4, the impact load received by the suspension bracket 20 is transmitted from the cab mount bracket 14 to the rocker 90. In other words, in the ladder frame structure, the impact load is distributed to the skeletal components of the cabin 80.

[0059] Referring further to Figure 5, as the side impact progresses, the battery bracket 40 is crushed and deformed. Consequently, the suspension bracket 30 is bent and deformed starting from the bent portion 34. Also referring to Figure 2, the suspension bracket 20 is bent and deformed starting from the bent portion 24. This bending deformation is also called upward bending deformation.

[0060] The bent portion 34 is positioned at a height above the top surface of the battery pack 60. Therefore, interference between the suspension brackets 20 and 30 during upward bending deformation and the battery pack 60 is suppressed.

[0061] If the upward bend progresses excessively, the vertical portions 23 and 33 of the suspension brackets 20 and 30 will approach the battery pack 60. However, as the upward bend progresses, the inclined portion 32 will approach the rocker 90. By adopting a configuration in which the inclined portion 32 interferes with the rocker 90 before the vertical portions 23 and 33 interfere with the battery pack 60, interference between the suspension brackets 20 and 30 and the battery pack 60 is suppressed.

[0062] For example, referring to Figure 3, the shortest distance D1 between the inclined section 32 and the rocker 90 is shorter than the shortest distance D2 between the vertical section 33 and the battery pack 60. This arrangement suppresses interference between the suspension brackets 20, 30 and the battery pack 60.

[0063] <Another example of a battery support structure> Figure 6 shows another example of a battery support structure. In this example, the vehicle longitudinal length of the suspension bracket 20 is equal to the vehicle longitudinal length of the cab mount bracket 14. In this example, the number of fastening points between the battery pack 60 and the suspension bracket 20 is increased, so the battery pack 60 is supported more firmly. Furthermore, in the event of a side collision, the load transfer from the suspension bracket 20 to the cab mount bracket 14 is smoother.

[0064] Figures 7 and 8 show modified examples (second and third alternative examples) of the suspension bracket 30. In these examples, a structure is provided to suppress bending deformation below the bent portion 34. For example, in Figures 7 and 8, the axial length of the bolt 46 is longer than that of the bolt 46 in Figure 3. Here, the axial end 46A of the bolt 46 is positioned below the bent portion 34.

[0065] Referring to Figure 7, two collars 45A and 45B into which bolts 46 are inserted are provided in the battery support structure. Collar 45A is located inside the battery bracket 40. Collar 45B extends from the top surface of the battery bracket 40 into the interior of the suspension bracket 30. For example, collar 45B and the lower plate 30C are welded together.

[0066] In the example shown in Figure 8, collar 45A is positioned from the battery bracket 40 to the lower plate 30C. Furthermore, collar 45B is positioned inside the suspension bracket 30.

[0067] As shown in Figures 7 and 8, the bolt 46 and collar 45B penetrate into the interior of the suspension bracket 30. The upper ends of the bolt 46 and collar 45B are positioned below the bent portion 34. This configuration reinforces the portion below the bent portion 34. For example, the vertical portion 33 becomes less susceptible to crushing. This reinforcement makes bending deformation originating from the bent portion 34 more likely to occur. [Explanation of Symbols]

[0068] 10 Ladder frame, 12 Side rails, 14 Cab mount bracket, 20, 30 Suspension bracket, 21, 31 Horizontal section, 22, 32 Inclined section, 23, 33 Vertical section, 24, 34 Bent section, 40 Battery bracket, 50 Shock absorber, 60 Battery pack, 80 Cabin, 82 Rear deck, 90 Rocker.

Claims

[Claim 1] A ladder frame equipped with side rails extending in the longitudinal direction of the vehicle, A battery pack is located below the ladder frame, A battery bracket is fixed to the outside of the battery pack in the vehicle width direction, A suspension bracket is provided, which is fixed to the battery bracket, and comprises a horizontal portion extending in the vehicle width direction from the outer side of the side rail in the vehicle width direction, and an inclined portion extending outward and downward in the vehicle width direction from the outer end of the horizontal portion in the vehicle width direction. A shock-absorbing component is positioned on the outer side of the battery bracket in the vehicle width direction, Equipped with, The suspension bracket is provided with a bent portion between the horizontal portion and the inclined portion. The bent portion is provided at a height greater than or equal to the top surface of the battery pack. At least a portion of the shock-absorbing component and at least a portion of the battery pack are arranged at the same height. The shock-absorbing component is supported on the side rail via the battery bracket and the suspension bracket. The aforementioned side rail is provided with a cab mount bracket that supports the cabin. The suspension bracket is fixed to the cab mount bracket, Below the cabin and outward in the vehicle width direction, a rocker extending in the longitudinal direction of the vehicle is positioned. The inclined portion of the suspension bracket is positioned below the rocker. Support structure for vehicle batteries.

Images