Reinforcing kit for a motor vehicle battery assembly

Abstract

The invention relates to a reinforcing kit (6) for a motor vehicle battery assembly (2), the kit comprising: - two primary reinforcing elements (8) having a generally elongate shape with a U-shaped cross-section; - two secondary reinforcing elements (10) having a generally elongate shape with a U-shaped cross-section, each secondary reinforcing element (10) having two assembly notches which are each configured to receive one end of one of the primary reinforcing elements (8) so as to form a generally rectangular frame in an assembled state, in which the primary reinforcing elements (8) extend into the assembly notches of the secondary reinforcing elements (10).

Description

Reinforcement kit for a motor vehicle battery assembly

[0001] The invention relates to a battery assembly, in particular for a motor vehicle. More particularly, the invention relates to a reinforcement kit for a motor vehicle battery assembly, a battery assembly equipped with such a reinforcement kit, as well as methods for reinforcing and disassembling a battery assembly.

[0002] There are regulations setting out tests that a battery pack must pass in order to be approved. Some of these tests are designed to verify that the battery pack has mechanical strength characteristics that enable it to withstand forces and stresses that could occur during an accident involving a vehicle equipped with such a battery pack. Examples of battery packs are disclosed in CN 112 805 870 A, US 2015 / 171390 A1 and CN 209 071 457 U.

[0003] One of these tests is the so-called "crush force" test, which is presented in the ECE R100 standard. According to this test, the battery pack is crushed using a crushing plate of a specific shape with a force between 100 and 105 kN for a maximum of 10 seconds. After this, the crushing plate is removed, and then the condition and operation of the battery pack are observed. For the battery pack to pass the test, it is necessary that it continues to operate normally, under the conditions set out in the standard.

[0004] The battery pack, as such, is generally manufactured with components and materials that do not allow it to pass the crushing force test. It is therefore necessary to equip it with reinforcement means allowing it to withstand the crushing test. To this end, it may be considered to equip the battery pack with a shell or external frame specifically dedicated to improving the mechanical resistance properties of the battery pack.

[0005] While such elements can enable the crushing force test to be passed, they do have several drawbacks. Indeed, the battery assembly must be easily disassembled to allow for maintenance or replacement operations. Reinforcing means surrounding the battery assembly and / or fixed in a non-removable manner to the battery assembly thus considerably complicate these operations, so it is preferable to avoid such means. In addition, the reinforcing means represent an additional cost for the manufacture of the battery assembly, which is why it is preferable to make the reinforcing means as inexpensive as possible.

[0006] The invention aims in particular to provide reinforcement means for a battery assembly which make it possible to improve its resistance to crushing, which are easily removable and which are as inexpensive as possible.

[0007] To this end, the invention relates to a reinforcement kit for a motor vehicle battery assembly comprising:

[0008] - two primary reinforcing elements, generally elongated in shape with a straight “U”-shaped section formed by two wings connected to each other by a web,

[0009] - two secondary reinforcing elements, generally elongated in shape with a straight “U”-shaped section formed by two wings connected to each other by a web,

[0010] each secondary reinforcing element having two assembly notches each configured to receive one end of one of the primary reinforcing elements, so as to form a generally rectangular frame in an assembled state in which the primary reinforcing elements extend into the assembly notches of the secondary reinforcing elements and in which the wings of the "U"-shaped cross-section of the primary reinforcing elements and the secondary reinforcing elements are oriented towards the inside of the generally rectangular frame.

[0011] Thus, the reinforcement kit consists of two primary reinforcement elements and two secondary reinforcement elements that can be manufactured separately. Their simple construction makes them simple to manufacture and inexpensive. The reinforcement elements assemble around the battery assembly to form a frame around the battery assembly, the assembly notches preventing disassembly of the primary reinforcement elements as long as the secondary reinforcement elements are assembled on the battery assembly. This form-fitting assembly makes it easy to disassemble the reinforcement kit, which facilitates maintenance or replacement operations of the battery assembly.

[0012] A "primary reinforcing element" means a first reinforcing element configured to fit a battery assembly.

[0013] A "secondary reinforcement element" means a second reinforcement element configured to fit a battery assembly.

[0014] The term "assembly notch" refers to a housing for receiving one end of a primary reinforcement element.

[0015] Preferably, the two wings are substantially parallel to each other. This makes it easier to assemble the reinforcing elements.

[0016] Preferably, the web that connects two wings together has rounded edges to form a rounded connection. This improves the rigidity of the reinforcement kit in the assembled state.

[0017] Advantageously, the secondary reinforcing elements comprise, at the edge of each of their assembly notches, at least one secondary bearing face configured to bear against primary bearing faces provided on the primary reinforcing elements when the reinforcement kit is in the assembled state.

[0018] This increases the area of ​​the contact surfaces between the primary and secondary reinforcing elements, which helps to improve the rigidity of the reinforcement kit in the assembled state.

[0019] According to one embodiment of the invention, said at least one secondary support face is oriented towards the inside of the frame when the reinforcement kit is in the assembled state.

[0020] An external force applied to a secondary reinforcement element thus transmits a force to at least one of the primary reinforcement elements which presses it towards the inside of the frame, in the direction of the battery assembly, which improves the cohesion of the frame formed by the reinforcement kit.

[0021] According to one embodiment of the invention, said at least one secondary support face is oriented towards the outside of the frame when the reinforcement kit is in the assembled state.

[0022] An external force applied to a primary reinforcement element thus transmits a force to at least one of the secondary reinforcement elements which presses it towards the inside of the frame, in the direction of the battery assembly, which improves the cohesion of the frame formed by the reinforcement kit.

[0023] Preferably, the secondary reinforcing elements comprise, at the edge of each of their assembly notches, at least two secondary bearing faces configured to bear against primary bearing faces provided on the primary reinforcing elements when the reinforcing kit is in the assembled state, at least one secondary bearing face being oriented towards the inside of the frame when the reinforcing kit is in the assembled state and at least one secondary bearing face being oriented towards the outside of the frame when the reinforcing kit is in the assembled state.

[0024] It can be provided that the assembly notches are of the general shape of a disc sector with an angle strictly less than 90°, preferably less than 60°.

[0025] The assembly notches are thus simple to produce and allow the primary reinforcement elements to be effectively retained in the assembled state.

[0026] Provision may be made for the primary and secondary reinforcement elements to have mounting notches provided towards the inside of the frame when the reinforcement kit is in the assembled state.

[0027] The primary and secondary reinforcement elements can thus accommodate fastening means provided on the battery assembly, these fastening means extending through the mounting notches during assembly of the reinforcement kit on the battery assembly. In other words, the mounting notches allow the reinforcement kit not to be hindered by fastening components of the battery assembly during its assembly.

[0028] Advantageously, the secondary reinforcing elements each have at least one support opening provided with at least one fin extending from the support opening.

[0029] The secondary reinforcing elements can thus cooperate with the battery assembly to be fixed to the battery assembly or to produce an assembly stop by shape cooperation by means of the at least one fin.

[0030] Advantageously, the primary and secondary reinforcing elements are made of metal, for example aluminum or steel.

[0031] These materials allow the reinforcement kit to easily pass the crushing force test once assembled on the battery assembly.

[0032] It may be provided that the primary and secondary reinforcing elements are each produced by cutting, stamping, molding or folding from a metal sheet.

[0033] The reinforcement elements are thus manufactured using simple and inexpensive processes. In particular, compared to a reinforcement kit that would be presented in the form of a single-piece frame, the material losses due to manufacturing are much less significant because to produce the single-piece frame, the material occupying the interior of the frame is generally machined, and therefore lost.

[0034] Advantageously, the primary reinforcing elements each comprise at least one primary tab partially surrounding the secondary reinforcing element in the assembled state.

[0035] Advantageously, the secondary reinforcing elements each comprise at least one secondary tab partially surrounding the primary reinforcing element in the assembled state.

[0036] These primary and secondary tabs help maintain the cohesion of the reinforcement kit in the assembled state of absorbing force by preventing the reinforcement elements from separating from each other. These primary and secondary tabs thus help improve the rigidity of the reinforcement kit in the assembled state.

[0037] The invention also provides a battery assembly comprising a housing and a reinforcement kit as defined above, the primary and secondary reinforcement elements being coupled to the housing of the battery assembly, as well as a motor vehicle comprising such a battery assembly.

[0038] The invention also provides a method for reinforcing a battery assembly, in which the following successive steps are implemented:

[0039] - a battery pack is made available, comprising a case and a reinforcement kit as defined above, then

[0040] - the primary reinforcement elements are inserted into the housing by translating the primary reinforcement elements towards the housing, then

[0041] - the secondary reinforcing elements are inserted into the housing by translating the secondary reinforcing elements towards the housing so as to house the primary reinforcing elements in the assembly notches of the secondary reinforcing elements.

[0042] The invention also provides a method for disassembling a battery assembly, in which the reinforcement method according to the preceding claim is implemented and then the following successive steps are implemented:

[0043] - the secondary reinforcement elements are removed from the housing, then

[0044] - the primary reinforcement elements are removed from the housing. Brief description of the figures

[0045] The invention will be better understood on reading the following description, given solely by way of example and with reference to the appended drawings in which:

[0046] is a perspective view of a battery assembly according to one embodiment of the invention,

[0047] is a perspective view of a reinforcement kit, according to one embodiment of the invention, for the battery assembly of the,

[0048] is an enlarged view of a secondary reinforcement element of the reinforcement kit of the,

[0049] is an enlarged view of a primary reinforcement element of the reinforcement kit of the,

[0050] is an enlarged view of the battery pack assembly illustrating the assembly of the reinforcement kit,

[0051] is a perspective view of a reinforcement kit, according to an alternative embodiment of the invention, for the battery assembly of the, and

[0052] is an enlarged view of a primary reinforcement element and a secondary reinforcement element of the reinforcement kit of the. Detailed description

[0053] A battery assembly 2 according to an embodiment of the invention intended to equip a motor vehicle is shown. The battery assembly 2 comprises a housing 4 housing battery cells and components ensuring their proper functioning. Since the battery cells and these components are not essential to a good understanding of the invention, they have not been shown in the figures and will not be described further in the following. The battery assembly 2 comprises a reinforcement kit 6 which is assembled on the housing 4 of the battery assembly 2 in the configuration of the, so that the reinforcement kit 6 is in the assembled state in this figure. The reinforcement kit 6 is assembled around the housing 4, here at the base thereof.

[0054] The reinforcement kit 6 is shown in more detail in the , which represents it in a disassembled state. The reinforcement kit 6 comprises two primary reinforcement elements 8, each of which is generally elongated in shape with a “U”-shaped cross-section, as well as two secondary reinforcement elements 10, each of which is generally elongated in shape with a “U”-shaped cross-section. By bringing the reinforcement elements 8, 10 into contact with each other, it is possible to form a generally rectangular frame whose dimensions are compatible with the housing 4, in the sense that the frame can surround the housing 4 and be in contact with the housing 4 over the entire periphery of the housing 4. The open “U” shape of each of the primary 8 and secondary 10 reinforcement elements is oriented towards the inside of the frame so as to form a housing for receiving the housing 4.In other words, the U-shaped cross-section of each of the primary 8 and secondary 10 reinforcing elements is formed by two wings 8a, respectively 10a, connected to each other by a web 8b, respectively 10b, the wings 8a, 10a being oriented towards the inside of the frame. In the disassembled state, the reinforcing elements are distant from each other.

[0055] The primary 8 and secondary 10 reinforcing elements are made of metal, here aluminum or steel. The primary 8 and secondary 10 reinforcing elements are each made by cutting, stamping, molding or folding from a metal sheet, which minimizes losses due to falling material.

[0056] One of the secondary reinforcing elements 10 is shown on a larger scale, knowing that the other secondary reinforcing element 10 of the reinforcement kit 6 is functionally identical to it. The secondary reinforcing element 10 has two assembly notches 12 each configured to receive one of the primary reinforcing elements 8. Each assembly notch 12 has the general shape of a disc sector with an angle strictly less than 90°. Here, the angle of this disc sector is even less than 60° to be approximately equal to 45°.

[0057] The secondary reinforcing element 10 has, at the edge of each of its assembly notches 12, at least one secondary bearing face 14 configured to bear against the primary reinforcing elements 8 when the reinforcement kit 6 is in the assembled state. This will be presented in more detail below.

[0058] The secondary reinforcing element 10 has two bearing openings 16 each provided with at least one fin 18 extending from the bearing opening 16, towards the inside of the secondary reinforcing element 10. The fin 18 is configured to bear against a wall or an edge of the housing 4 of the battery assembly 2 in the assembled state to form either an assembly stop, facilitating the positioning of the secondary reinforcing element 10, or a mechanical retainer making it possible to maintain the secondary reinforcing element 10 in the assembled state. This depends on the position of the fin 18 in the bearing opening 16. In the configuration of the, the fin 18 extends on one side of the bearing opening 16 close to the inside of the frame, so that it forms an assembly stop. In the event that it extends on one side of the support opening 16 opposite the inside of the frame, it would form a mechanical retainer.It can be provided that the secondary reinforcement element 10 comprises, for each support opening 16, several fins 18 so as to ensure the two functions presented.

[0059] The secondary reinforcement element 10 has mounting notches 20 arranged towards the inside of the frame when the reinforcement kit 6 is in the assembled state. These mounting notches 20 allow the secondary reinforcement element 10 not to abut against fixing means 26, such as screw-nut pairs, provided on the housing 4 for the assembly of the battery assembly 2 as such. In other words, the mounting notches 20 allow the reinforcement kit 6 to be assembled on the housing 4 of the battery assembly 2 in a particularly easy manner.

[0060] One of the primary reinforcing elements 8 is shown on a larger scale, knowing that the other primary reinforcing element 8 of the reinforcement kit 6 is functionally identical to it. The primary reinforcing element 8 has two ends 24 of a shape complementary to that of the assembly notches 12 provided on the secondary reinforcing elements 10. The primary reinforcing element 8 has, at the edge of each of its ends 24, at least one primary bearing face 22 configured to bear against the secondary bearing faces 14 provided on the secondary reinforcing elements 10 when the reinforcement kit 6 is in the assembled state. This will be presented in more detail below.

[0061] The primary reinforcing element 8 has mounting notches 20 arranged towards the inside of the frame when the reinforcing kit 6 is in the assembled state, similar to those present on the secondary reinforcing elements 10. These mounting notches 20 allow the primary reinforcing element 8 not to abut against fixing means 26, such as screw-nut pairs, provided on the housing 4 for the assembly of the battery assembly as such. In other words, the mounting notches 20 allow the reinforcing kit 6 to be assembled on the housing 4 of the battery assembly 2 in a particularly easy manner.

[0062] The primary reinforcing element 8 of the and the secondary reinforcing element 10 of the in the assembled state on the housing 4 of the battery assembly 2 are shown. The illustrates the fin 18 which extends inside the bearing opening 16 and bears against an edge of the housing 4 to form an assembly stop. The also illustrates the cooperation of the primary 22 and secondary 14 bearing faces. In the assembled state, each primary bearing face 22 of one of the primary reinforcing elements 8 is in contact with one of the secondary bearing faces 14 of one of the secondary reinforcing elements 10. The reinforcement kit 6 has two types of bearing. Some of the secondary bearing faces 14 are oriented towards the inside of the frame when the reinforcement kit 6 is in the assembled state. This is the case for the one at the bottom of the. The other secondary support faces 14 are oriented towards the outside of the frame when the reinforcement kit is in the assembled state. This is the case for the top one.

[0063] We will now present a method for reinforcing the battery assembly 2. We begin by providing the battery assembly 2 and the reinforcement kit 6. The latter is initially in a disassembled state.

[0064] Then, the primary reinforcement elements 8 are inserted onto the battery assembly 2, more precisely onto the housing 4 thereof, by translation of the primary reinforcement elements 8 towards the battery assembly 2. Some of the fixing means 26 provided on the housing 4 are housed in the mounting notches 20 of the primary reinforcement elements 8.

[0065] Then, the secondary reinforcing elements 10 are inserted onto the battery assembly 2, more precisely onto the housing 4 thereof, by translating the secondary reinforcing elements 10 towards the battery assembly 2 so as to house the primary reinforcing elements 8 in the assembly notches 12 of the secondary reinforcing elements 10. The secondary bearing faces 14 come into contact with the primary bearing faces 22 or, at the very least, are positioned opposite them and close to them. This allows the secondary reinforcing elements 10 to prevent the primary reinforcing elements 8 from disassembling from the housing, thanks to the shape of the assembly notches 12 which can be compared to that of an undercut. Some of the fixing means 26 provided on the housing 4 are housed in the mounting notches 20 of the secondary reinforcing elements 10.Furthermore, the fins 18 of the secondary reinforcing elements 10 come into contact with the housing 4 to perform the assembly stop and / or mechanical retaining functions presented above. The fins 18 can deform elastically to adapt to the shape of the housing 4. Provision may be made for the reinforcement kit 6 to cooperate with an additional element intended to fix it in its assembled state.

[0066] After implementing the reinforcement method, the battery assembly 2 has the configuration illustrated in Figures 1 and 5. In this assembled state, the battery assembly 2 can be subjected to a crushing force test. A force is then applied to one of the primary 8 or secondary 10 reinforcement elements in a direction oriented towards the housing 4 of the battery assembly 2.

[0067] A force applied to a secondary reinforcing element 10 transmits a force to the primary reinforcing elements 8 which presses them towards the housing 4 thanks to the secondary bearing faces 14 oriented towards the inside of the frame, which tends to tighten the frame formed by the reinforcement kit 6. Conversely, a force applied to a primary reinforcing element 8 transmits a force to the secondary reinforcing elements 10 which presses them towards the housing 4 thanks to the secondary bearing faces oriented towards the outside of the frame, which also tends to tighten the frame formed by the reinforcement kit 6. It is thus understood that the different orientations of the primary 22 and secondary 14 bearing faces improve the cohesion of the frame formed by the reinforcement kit 6.The properties of the primary 8 and secondary 10 reinforcement elements, in particular their constituent materials, their dimensions and their shapes, can be adapted to allow the battery assembly 2 to successfully pass the crushing force test under the conditions imposed by the ECE R100 standard when the reinforcement kit 6 is assembled on the casing 4 of the battery assembly.

[0068] To disassemble the reinforcement kit 6 from the battery assembly 2, the secondary reinforcement elements 10 are first removed from the battery assembly 2, then the primary reinforcement elements 8 are removed from the battery assembly 2. Disassembly of the reinforcement kit 6 is thus very simple to carry out, so that the battery assembly 2 is thus easily accessible for maintenance or replacement operations.

[0069] A reinforcement kit 6' according to an alternative embodiment of the invention is shown. This reinforcement kit 6' is configured to be assembled on the housing 4 of the battery assembly in the same way as on the. Similarly, the methods of assembling and disassembling this reinforcement kit 6' implements the same steps as the methods of assembling and disassembling the reinforcement kit 6 of the previous embodiment. In the following, only the elements of the reinforcement kit 6' which distinguish them from the reinforcement kit 6 of the previous embodiment will be presented. The other constituent elements of the reinforcement kit 6' are identical to those of the reinforcement kit 6 of the previous embodiment, in particular with regard to the notches and the bearing faces.

[0070] The reinforcement kit 6' comprises two primary reinforcement elements 8. Each primary reinforcement element 8 comprises two primary tabs 28, preferably attached to the primary reinforcement element 8, extending at each of the ends of the primary reinforcement element 8 and outside the "U" shape of the primary reinforcement element 8.

[0071] The reinforcement kit 6' comprises two secondary reinforcement elements 10. Each secondary reinforcement element 10 comprises two secondary tabs 30, preferably attached to the secondary reinforcement element 10, extending at each of the ends of the secondary reinforcement element 10 and outside the “U” shape of the secondary reinforcement element 10.

[0072] One of the primary tabs 28 and one of the secondary tabs 30 of the reinforcement kit are shown in more detail on the figure. As illustrated in this figure, the primary tab 28 partially surrounds the secondary reinforcement element 10. In addition, the secondary tab 30 partially surrounds the primary reinforcement element 8. Due to this configuration, the primary and secondary reinforcement elements are prevented from separating from each other when absorbing a force. Such a separation could indeed expose the housing of the battery assembly to said force. It is thus understood that the primary tabs 28 and the secondary tabs 30 contribute, by their configuration, to protecting the housing 4 of the battery assembly 2 from mechanical stresses which could damage it.

[0073] The invention is not limited to the embodiments presented and other embodiments will become apparent to those skilled in the art. List of references

[0074] 2: battery assembly4: housing6; 6': reinforcement kit8: primary reinforcement element8a: wings of the primary reinforcement element8b: core of the primary reinforcement element10: secondary reinforcement element10a: wings of the secondary reinforcement element10b: core of the secondary reinforcement element12: assembly notch14: secondary bearing face16: bearing opening18: fin20: mounting notch22: primary bearing face24: end26: means of fixing the housing28: primary tab30: secondary tab

Claims

Reinforcement kit (6; 6') for a motor vehicle battery assembly (2) characterized in that it comprises:- two primary reinforcement elements (8), of generally elongated shape with a cross section in the shape of a "U" formed by two wings (8a) connected to each other by a core (8b),- two secondary reinforcement elements (10), of generally elongated shape with a cross section in the shape of a "U" formed by two wings (10a) connected to each other by a core (10b),each secondary reinforcement element (10) having two assembly notches (12) each configured to receive one end (24) of one of the primary reinforcement elements (8), so as to form a frame of generally rectangular shape in an assembled state in which the primary reinforcement elements (8) extend into the assembly notches (12) of the secondary reinforcement elements (10) and in which the wings (8a,10a) of the U-shaped cross-section of the primary reinforcing elements (8) and the secondary reinforcing elements (10) are oriented towards the inside of the generally rectangular frame., Reinforcement kit (6; 6') according to the preceding claim, in which the secondary reinforcement elements (10) comprise, at the edge of each of their assembly notches (12), at least one secondary bearing face (14) configured to bear against primary bearing faces (22) provided on the primary reinforcement elements (8) when the reinforcement kit (6; 6') is in the assembled state. Reinforcement kit (6; 6') according to claim 2, wherein said at least one secondary bearing face (14) is oriented towards the inside of the frame when the reinforcement kit (6; 6') is in the assembled state. Reinforcement kit (6; 6') according to claim 2, wherein said at least one secondary bearing face (14) is oriented towards the outside of the frame when the reinforcement kit (6) is in the assembled state. Reinforcement kit (6; 6') according to any one of the preceding claims, wherein the secondary reinforcement elements (10) each have at least one support opening (16) provided with at least one fin (18) extending from the support opening (16). Reinforcement kit (6; 6') according to any one of the preceding claims, wherein the primary (8) and secondary (10) reinforcing elements are made of metal, for example aluminum or steel. A reinforcement kit (6') according to any preceding claim, wherein the primary reinforcement elements (8) each comprise at least one primary tab (28) partially surrounding the secondary reinforcement element (10) in the assembled state. A reinforcement kit (6') according to any preceding claim, wherein the secondary reinforcement elements (10) each comprise at least one secondary tab (30) partially surrounding the primary reinforcement element (8) in the assembled state. Battery assembly (2) comprising a housing (4) and a reinforcement kit (6; 6') according to any one of the preceding claims, the primary (8) and secondary (10) reinforcement elements being coupled to the housing (4) of the battery assembly (2). Motor vehicle comprising a battery assembly (2) according to the preceding claim. Method for reinforcing a battery assembly (2), in which the following successive steps are implemented: - a battery assembly (2) is provided comprising a housing (4) and a reinforcement kit (6; 6') according to any one of claims 1 to 8, then - the primary reinforcement elements (8) are inserted onto the housing (4) by translation of the primary reinforcement elements (8) towards the housing (4), then - the secondary reinforcement elements (10) are inserted onto the housing (4) by translation of the secondary reinforcement elements (10) towards the housing (4) so ​​as to house the primary reinforcement elements (8) in the assembly notches (12) of the secondary reinforcement elements (10). Method for disassembling a battery assembly (2), in which the reinforcement method according to the preceding claim is implemented and then the following successive steps are implemented: - the secondary reinforcement elements (10) are removed from the housing (4), then - the primary reinforcement elements (8) are removed from the housing (4).

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