Motor vehicle having a battery housing comprising at least one battery housing longitudinal beam mounted on the vehicle-exterior side

Abstract

The invention relates to a motor vehicle (10) having at least one battery housing (16) which has at least one battery compartment for mounting battery cells and / or battery modules. When viewed in the vehicle transverse direction, at least one battery housing longitudinal beam (24) is mounted on the vehicle-exterior side of the battery housing (16), and a plurality of openings for connecting the at least one longitudinal beam (24) to the vehicle body (12) of the motor vehicle (10) are provided in or on the battery housing longitudinal beam (24). A sliding incline (38) is formed at least over a majority of the length of the at least one longitudinal beam (24) and at least over a majority of the height of the at least one longitudinal beam (24), the angle (α) of the sliding incline ranging from 45° to 90° with respect to the horizontal plane.

Description

[0001] Description

[0002] Motor vehicle with battery housing comprising at least one battery housing longitudinal member arranged on the outside of the vehicle

[0003] The invention relates to a motor vehicle with a battery housing comprising at least one battery compartment, according to the preamble of claim 1. At least one longitudinal support beam is arranged on the outside of the battery housing in the transverse direction of the vehicle, wherein several openings are provided in or on the longitudinal support beam for connecting the at least one longitudinal support beam and / or other elements of the battery housing to the vehicle body of the motor vehicle, in particular by means of a positive and non-positive connection. A positive and non-positive connection can be achieved, in particular, by bolting the longitudinal support beam and / or the other elements to the vehicle body.

[0004] Preferably, the battery housing has at least one longitudinal support beam on each of its outer sides. More preferably, the invention relates to a motor vehicle that is at least partially electrically powered, wherein the battery housing serves to accommodate at least one drive energy storage device, or battery cells and / or battery modules are arranged in the battery housing as drive energy storage devices.

[0005] US Patent 9,981,541 B2 discloses a battery module for a vehicle which, in the region of its rear end (viewed in the longitudinal direction of the vehicle), has a ramp-like area with a relatively shallow ramp angle. This ramp is designed to deflect objects impacting the vehicle from behind upwards, so that in a rear-end collision, the battery module is protected from directly acting longitudinal forces when the ramp-like area is in effect. The design of a battery housing with externally arranged longitudinal beams is not described.

[0006] From JP 2004-262412 A, an arrangement in connection with a battery module in a vehicle is known, comprising a similarly acting ramp-like area arranged longitudinally behind the battery module to provide impact protection against forces acting on the vehicle from behind. The design of a battery housing with externally arranged longitudinal beams is not described. From US 2020 / 0282845 A1, a relative arrangement in a vehicle is known between a battery module, a seat support arranged laterally next to the battery module in the transverse direction of the vehicle and partially overlapping the battery module when viewed vertically, and a vehicle floor arranged vertically above the seat support.The battery module features a shallow ramp angle on its upper surface to reduce intrusion forces on the battery module when the seat support is shifted laterally in the vehicle direction. A battery housing design with externally mounted longitudinal beams is not described.

[0007] The invention is based on the objective of providing a motor vehicle with a battery housing whose battery housing is better protected against intrusion by forces acting laterally on the motor vehicle.

[0008] The problem is solved according to the invention with the features of claim 1. Further practical embodiments and advantages of the invention are described in connection with the dependent claims.

[0009] A motor vehicle according to the invention comprises at least one battery housing, which has at least one battery compartment for arranging battery cells and / or battery modules. Viewed in the transverse direction of the vehicle, at least one longitudinal support beam is arranged on the outside of the battery housing, wherein several openings are provided in or on the longitudinal support beam and / or on other elements of the battery housing for connecting the at least one longitudinal support beam to the vehicle body of the motor vehicle – in particular by means of a positive and non-positive connection. Furthermore, in the motor vehicle according to the invention, a sliding slope is formed over at least a majority of the length and at least a majority of the height of the at least one longitudinal support beam, the angle of which to the horizontal plane is between 45° and 90°.

[0010] The angle of the sliding slope is preferably between 60° and 85°, more preferably between 70° and 80°.

[0011] The battery housing can be screwed to the battery housing longitudinal members and / or to subsequently inserted battery housing cross members and / or to a bottom section, a cover section, and / or to an additional longitudinal member. This screwing can be done from only one side (especially from above or below) and / or as a through-bolt, i.e., a screw connection that completely penetrates the battery housing. For this purpose, corresponding screw bosses can also be provided in the battery housing to create a particularly high-strength and rigid screw connection.

[0012] The phrase "at least over a large part" means that the sliding slope extends over at least 50 percent of the respective area, preferably over at least 70 percent, more preferably over at least 80 percent, and particularly preferably over at least 90 percent. With the vehicle according to the invention, forces acting on the vehicle from the outside in the transverse direction are predominantly diverted upwards in the vehicle direction due to the sliding slope, thereby achieving a force exerted by the battery housing longitudinal member against the vehicle body in the vehicle direction. This allows – given sufficiently large forces – a relative displacement of the battery housing upwards or downwards in the vehicle direction, thus better protecting the battery housing from intrusion.

[0013] The foregoing applies in particular if, in a motor vehicle, the arrangement consisting of at least one battery housing longitudinal member with a sliding slope and a vehicle sill adjoining it on the outside of the vehicle is designed such that, when forces act on the sill from the outside of the vehicle in a transverse direction, leading to contact between the sill and the battery housing longitudinal member, a force is generated that pulls the battery housing downwards or upwards out of the load path of the at least one vehicle sill in the vertical direction of the vehicle. This is because, in this case, the battery housing can be completely moved out of a load path extending from the vehicle sill across the battery housing – again, if sufficiently large forces are applied.Preferably, the sliding ramp is designed such that it is oriented upwards in the vehicle's vertical direction, so that the force resulting from contact between the vehicle sill and the sliding ramp, acting in the vehicle's vertical direction, acts downwards in the direction of gravity.

[0014] The wording that at least one battery housing longitudinal member is "arranged" encompasses both the variant that the battery housing longitudinal member is a separate element that is arranged externally and optionally also connected to the battery housing, and the alternative variant that the battery housing longitudinal member represents the one-piece formation of a battery housing longitudinal member as part of the battery housing.

[0015] In another practical embodiment of a motor vehicle according to the invention, the battery housing comprises a battery frame formed by at least two longitudinal battery housing members and at least one cross member extending in the transverse direction of the vehicle, connecting the two longitudinal battery housing members. In the simplest embodiment with such a battery frame, the frame has an H-shaped structure when viewed from above and consists of two longitudinal battery housing members arranged on the outside of the housing and a cross member connecting these longitudinal members. In another simple embodiment, two cross members are provided, resulting in at least one rectangular basic structure (viewed from above) which is associated with high rigidity, thereby providing particularly good protection for the battery cells and / or battery modules arranged within the basic structure.In practice, a large number of battery housing cross members and additional battery housing longitudinal members can also be provided, so that the battery frame is formed from a large number of rectangular basic structures and has a high overall stiffness with a large number of longitudinal and transverse load paths.

[0016] If, in a motor vehicle according to the invention, the at least one battery housing longitudinal member is manufactured as a steel roll profile, as an extruded profile or as a steel deep-drawn part, corresponding advantages associated with the respective manufacturing process can be used for the protection and / or manufacture of the battery housing.

[0017] Steel rolled sections can be manufactured relatively cost-effectively, especially compared to extruded sections. Furthermore, steel rolled sections exhibit particularly high tensile strength, especially values ​​exceeding 1,000 MPa.

[0018] Battery housing longitudinal beams, manufactured as extruded profiles, have a relatively low weight and can be designed with relative geometric flexibility, especially in the design of the respective profile cross-section.

[0019] Battery housing longitudinal beams manufactured as deep-drawn steel parts can also be produced relatively cost-effectively using established manufacturing techniques. The manufacturing costs are comparable to the average manufacturing costs for extrusion profiles, so the decision between the latter manufacturing methods can be made depending on the desired geometry and the associated costs and / or other properties related to the geometry.

[0020] Alternatively, in a motor vehicle according to the invention, the at least one battery housing longitudinal member can also be manufactured as a cast part, in particular part of a cast frame, or as a plastic part, in particular as part of a plastic frame.

[0021] If the battery housing support is manufactured as a casting, particularly as part of a cast frame, a high degree of functional integration is achieved. This means that a multitude of additional functions can be prepared or fully incorporated during the creation of the mold with relatively little effort. Examples include openings for attaching the at least one longitudinal member and / or other elements of the battery housing to the vehicle body. Furthermore, a longitudinal member manufactured as a casting has no joints, even when a complete cast frame is formed. This offers advantages in terms of crash rigidity because the cast frame has no weak points due to joints.Finally, a cast part can also be designed with relative geometric flexibility, so that special shapes required by the installation space, especially for omitting certain areas or for opening up additional volume to accommodate additional battery cells, can be realized relatively easily and cost-effectively.

[0022] If at least one longitudinal support beam of the battery housing is manufactured as a plastic part, flexible geometries can also be achieved relatively easily. Furthermore, the component weight is low compared to metallic versions, and there is no risk of corrosion. Manufacturing as plastic parts also includes production from fiber-reinforced plastics, in particular as glass fiber reinforced plastic (GFRP) parts and as carbon fiber reinforced plastic (CFRP) parts, including FRP.

[0023] Preferably, in a motor vehicle according to the invention, the sliding ramp, the battery housing longitudinal member, the vehicle sill, and the connection between the battery housing and the vehicle body formed by the openings are designed such that, in a pole side impact according to Euro NCAP, the connection is released and the battery housing is moved completely downwards out of the area of ​​effect of the side sill due to the sliding ramp. Reference is made in this respect to the framework conditions valid at the time of filing according to Euro NCAP Side Pole Impact, in particular to a side pole impact with a speed of 32 km / h, a pole diameter of 254 mm, and an impact angle of 75 degrees. For further details of Euro NCAP, reference is made to the following document, accessed on the internet on October 16, 2024, which defines the framework conditions of the pole side impact test:

[0024]

[0025] In another practical embodiment of a motor vehicle according to the invention, the battery housing is secured to the vehicle body by at least one additional element designed to withstand higher forces than the connection made with the openings. In this regard, reference is made, for example, to the possibility that a longitudinal member fastened to the vehicle body by means of screw connections can be designed such that, above a certain force level, for example in the event of a pole side impact, the screw connections are released so that the battery housing as a whole can move relative to the vehicle body.Additionally, for example, a steel cable, several steel cables, or other equivalent auxiliary elements can be used to ensure that the relative movement after the failure of the bolted connection does not exceed a value specified by the auxiliary element (resulting additional distance to the vehicle body). This ensures that the battery housing does not completely detach from the vehicle and thus become a moving hazard to other road users.

[0026] If the connection of a motor vehicle according to the invention via the openings for connecting the battery housing longitudinal members to the vehicle body has at least a partial separating element that supports the separation of the connection, the loosening of a connection made with the aid of said openings can be passively or actively supported.

[0027] For example, in a first variant, at least partially splitting screws and / or separating screws can be provided as passive separating elements, which are designed in such a way that an application of force causes premature failure of the screws, so that the connection between the battery housing and the vehicle body is released at least in the area of ​​the screw connection.

[0028] In a second variant, which can be used as an alternative or supplement, at least one pyrotechnic, pneumatic, electric, and / or hydraulic drive element is provided as an active separating element, which can be actively activated. For example, such an active separating element can initiate an active separation of the connection between the battery housing and the vehicle body, depending on acceleration values, when it is detected that an impact in the transverse direction of the vehicle is imminent or has just occurred. An active separating element differs from a passive separating element in that the separation effect can be implemented and activated independently of the actual application of a force, e.g., due to a pole-side impact. This requires an (active) drive element that can exert its effect to activate the separation action.An active separation element can be controlled in a manner analogous to or similar to a side airbag deployment. Acceleration sensors and / or camera-based systems are typically used for this purpose.

[0029] Further practical embodiments of the invention are described below in connection with the drawings. They show:

[0030] Fig. 1 shows a vehicle body with a schematically represented battery housing in an isometric view from a slant above,

[0031] Fig. 2 shows the vehicle body of the motor vehicle shown in Figure 1 from below, looking at the underside of the battery housing.

[0032] Fig. 3 shows a section of the battery housing from Figures 1 and 2, shown in the transverse direction of the vehicle (y-direction).

[0033] Fig. 4 shows a section of the arrangement of the battery housing shown in Figures 1 to 3 with the battery housing longitudinal member and a laterally adjoining vehicle sill in a view cut in the transverse direction of the vehicle (y-direction),

[0034] Fig. 5 shows only the area of ​​the battery housing side support of the battery housing from Figures 1 to 4 and

[0035] Fig. 6 shows only the area of ​​a battery housing side carrier of an alternative embodiment of a motor vehicle according to the invention.

[0036] Figure 1 shows a vehicle body 12 of a motor vehicle 10, which includes, among other things, vehicle sills 14 arranged on the outside of the vehicle 10, each extending in the longitudinal direction (x-direction) of the vehicle between a front wheel arch 18 and a rear wheel arch 20. A battery housing 16 is arranged on the inside of the vehicle sills 14, extending substantially over the width B remaining between the vehicle sills 14.

[0037] The battery housing 16 has a battery frame 22, which is formed from two outer longitudinal battery housing members 24 extending in the longitudinal direction (x-direction) of the vehicle and transverse battery housing members 26 extending in the transverse direction (y-direction) of the vehicle. An additional longitudinal member 28 is arranged centrally in the vehicle 10 and divides each of the battery housing transverse members 26 into two sections.

[0038] Figure 1 also shows a pole 30 as used in the Euro NCAP pole side impact test, in which a relative movement between pole 30 and vehicle 10, indicated by arrows A, leads to an intrusion of the pole 30.

[0039] Figure 2 shows the vehicle body 12 of the motor vehicle 10 shown in Figure 1 from below, looking at the underside of the battery housing 16. It can be seen that the battery housing 16 has screw points 32 on its outer sides in the area of ​​the longitudinal members 24 and the outer cross members 26. These screw points are used to fasten the longitudinal members 24 and cross members 26 to the vehicle body 12 using screws. In addition, several through-bolt points 34 are provided in the central area of ​​the battery housing. In the area of ​​these through-bolt points, the screws (not shown) used to fasten the battery housing 16 to the vehicle body 12 pass through the battery housing 16.

[0040] Accordingly, in the area of ​​the screw points 34 a different type of connection is created, in particular a connection of the battery housing 16 to an upper part of the vehicle body 12, in particular to a vehicle floor.

[0041] Figures 3 to 5 show further details of the vehicle body 12 and the battery housing 16, which will be discussed in more detail below.

[0042] Figures 3 to 5 clearly show the geometric design of the battery housing 16. The battery housing comprises longitudinal battery housing members 24 arranged on the outside of the vehicle, with a flat flange section 36 extending only over a small portion of the vehicle's vertical direction (z-direction) and a sliding slope 38 extending over a significantly larger area, covering most of the height. Battery modules 40 are arranged only schematically within the battery housing 16.

[0043] The sliding chamfer 38 extends from the flange section 36 to a top surface 42 of the battery housing 16. The height H of the battery housing 16, extending in the vehicle's vertical direction (z-direction), extends from a bottom surface 44 of the battery housing 16 to the top surface 42. In the illustrated embodiment, the sliding chamfer 38 extends over approximately 80 percent of the height H, and thus over a large portion of the height H. Viewed in the vehicle's longitudinal direction (x-direction), the sliding chamfer 38 extends over the entire length of the battery housing 16, i.e., over 100 percent.

[0044] As can be clearly seen in Figures 4 and 5, the battery housing longitudinal member 24 in the embodiment shown is formed from a profile comprising surfaces 46 forming the outer contour and a plurality of support webs 48 extending between them.

[0045] Figure 4 also shows that the vehicle sill 14 is formed by an outer shell 50, an inner shell 52, and a closed sill insert profile 54. This is a known and technically feasible geometric design for a vehicle sill 14, but it is not essential for the realization of the invention. The same applies to the specific design of the longitudinal member, which is shown in Figures 3 to 5. The specific design can be suitably varied within the scope of the claims, with particular reference made to the possibility of hollow profiles, solid profiles, or profiles of other shapes and filled completely or partially.

[0046] The angle α between the horizontal plane HE and the sliding slope 38 is shown in Figure 3 and is 70° in the embodiment shown. In the embodiment shown, the sliding slope 38 is oriented upwards in the vehicle's vertical direction (z-direction), which results in a net force being generated when forces act on the vehicle 10 and, in particular, the vehicle sill 14 from the outside in the vehicle's transverse direction (y-direction), as indicated by arrow S in Figure 3. This net force is predominantly oriented downwards in the direction of gravity, as indicated by arrow g.

[0047] The design is chosen such that in a pole side impact according to Euro NCAP, the battery housing 16 is deflected downwards to such an extent that, viewed in the vertical direction (z-direction), it is moved into the area below the vehicle sill 14, so that the battery housing 16 is moved out of the load path of the vehicle sill 14.

[0048] Accordingly, the battery modules 40 arranged in the battery housing 16 or alternatively individual battery cells (not shown) are protected against intrusion by the vehicle sill 14.

[0049] The alternative embodiment shown in Figure 6 functions identically to the one described above, but omits a flange, so that the sliding ramp 38 extends over the entire height H of the battery housing 16. Openings for screw connections (not shown) can still be provided in the same way as in a flange. In this case, however, it is advisable to provide blind holes to create bearing surfaces for screw bolts.

[0050] The features of the invention disclosed in the present description, the drawings, and the claims can be essential for realizing the invention in its various embodiments, both individually and in any combination. The invention can be varied within the scope of the claims and taking into account the knowledge of the person skilled in the art.

[0051] 10 motor vehicle

[0052] 12 Vehicle body

[0053] 14 vehicle sills

[0054] 16 battery cases

[0055] 18 front wheel arch

[0056] 20 rear wheel arch

[0057] 22 battery frames

[0058] 24 battery housing longitudinal supports

[0059] 26 Battery housing crossbeams

[0060] 28 additional longitudinal beams

[0061] 30 stakes

[0062] 32 screw points

[0063] 34 through-bolt points

[0064] 36 Flange section

[0065] 38 Sliding slope

[0066] 40 battery modules

[0067] 42 Top

[0068] 44 Underside

[0069] 46 the outer surface

[0070] 48 Support bridge

[0071] 50 outer shell

[0072] 52 inner shell

[0073] 54 Sill insert profile

[0074] a Angle between horizontal plane and slip slope A Arrow

[0075] B width

[0076] g arrow

[0077] H height

[0078] HE Horizontal plane

[0079] S arrow

Claims

Patent claims 1. Motor vehicle (10) with at least one battery housing (16) which has at least one battery compartment for arranging battery cells and / or battery modules, wherein, viewed in the transverse direction of the vehicle, at least one battery housing longitudinal member (24) is arranged on the outside of the battery housing (16), wherein several openings for connecting the at least one longitudinal member (24) to the vehicle body (12) of the motor vehicle (10) are provided in or on the battery housing longitudinal member (24) and / or on other elements of the battery housing (16), characterized by that at least over a large part of the length of the at least one longitudinal beam (24) and at least over a large part of the height of the at least one longitudinal beam (24) a sliding slope (38) is formed, the angle (a) of which is between 45° and 90° to the horizontal plane.

2. Motor vehicle (10) according to the preceding claim, characterized in that the arrangement comprising the at least one battery housing longitudinal member (24) with sliding slope (38) and a vehicle sill (14) adjoining the outside of the vehicle is designed such that, in the case of forces acting on the sill (14) from the outside of the vehicle in a transverse direction, which lead to contact between the sill (14) and the battery housing longitudinal member (24), a force is generated that leads the battery housing (16) downwards in the upward direction of the vehicle out of the load path of the at least one vehicle sill (14).

3. Motor vehicle (10) according to one of the preceding claims, characterized in that the battery housing (16) comprises a battery frame (22) which is formed by at least two battery housing longitudinal members (24) and at least one battery housing cross member (26) extending in the transverse direction of the vehicle, connecting these at least two battery housing longitudinal members (24).

4. Motor vehicle (10) according to one of the preceding claims, characterized in that the at least one battery housing longitudinal member (24) is manufactured as a steel roll profile, as an extruded profile or as a steel deep-drawn part.

5. Motor vehicle (10) according to one of claims 1 to 4, characterized in that the at least one battery housing longitudinal member (24) is manufactured as a casting or as a plastic part.

6. Motor vehicle (10) according to one of the preceding claims, characterized in that the sliding slope (38), the battery housing longitudinal member (24) and the sill (14) as well as the connection between the battery housing (16) and the vehicle body (12) made with the openings are designed such that in the event of a pole side impact according to Euro NCAP the connection is released and the battery housing (16) is moved completely downwards out of the area of ​​effect of the side sill due to the sliding slope (38).

7. Motor vehicle (10) according to one of the preceding claims, characterized in that the battery housing (16) is secured against the vehicle body (12) by at least one additional element designed to withstand higher forces than the connection made with the openings.

8. Motor vehicle (10) according to one of the preceding claims, characterized in that the connection via the openings for connecting the battery housing longitudinal members (24) to the vehicle body (12) has at least partially a separating element to support the separation of the connection.

9. Motor vehicle (10) according to the preceding claim, characterized in that at least partially splitting screws and / or separating screws are provided as a passive separating element.

10. Motor vehicle (10) according to one of the two preceding claims, characterized in that at least one pyrotechnic, pneumatic, electric and / or hydraulic drive element is provided as an active separating element.

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