DE102019101637B4 - Battery tray with molded bead - Google Patents

Abstract

Battery carrier (1) for an electric motor vehicle, comprising a trough (2) with a base (3) and a circumferential side wall (4) and optionally a flange (6) projecting outwardly from the side wall (4), with the base (3 ) The tub (2) has at least one molded bead (9) extending over the width (10) or length, such that the bead (9) functions as a molded cross member or longitudinal member and as a stiffener and / or connection surface for a battery module assembly is used, characterized in that at least one segment (12, 13, 14) of the tub (2), preferably the entire tub (2) is made as a folding component in one piece and made of the same material from a plate and that a height (H9) of the bead (9 ) Corresponds to 20% to 80% of the height (H4) of the side wall (4).

Description

The present invention relates to a battery carrier according to the features in the preamble of claim 1.

Electromobility has become more and more relevant in the use of motor vehicles. Electric vehicles are powered exclusively by electrical energy. In order to store this electrical energy in the electric motor vehicle, batteries, also called accumulators, high-voltage batteries, or drive batteries, are necessary, which have a considerable volume share and a relatively high dead weight. Such batteries are arranged in the underfloor area of a motor vehicle so that a sufficient amount of energy can be stored, for example to achieve a range of 300 km with one battery charge. The batteries themselves are housed in a battery tray, so that they are protected against external weather conditions on the one hand, and substances contained in the batteries are prevented from leaking into the environment on the other.

For this purpose, battery housings are known from the prior art, which are made from plastic materials, fiber composite materials or also from metallic materials. The battery trays are also referred to as "battery trays".

Such a battery housing is mostly mounted from below on a motor vehicle and extends significantly over a large part of the vehicle width and also part of the motor vehicle length.

The battery housing essentially consists of a battery holder and a housing cover.

A battery carrier is characterized by a trough-shaped housing in which a plurality of batteries are arranged. The requirements in terms of tightness and production tolerances are high. However, the manufacturing costs of the battery tray are subject to massive cost pressure.

The tub-shaped battery carrier of a battery housing is sometimes manufactured as a sheet metal component. A generic publication for this is the US 2016/0263639 A1 .

Furthermore, battery trays are from the DE 10 2017 102 699 A1 and DE 10 2016 120 826 A1 as well as the post-published DE 10 2017 130 859 A1 known.

The object of the present invention is to provide a battery carrier that has improved manufacturing behavior, but at the same time also has improved rigidity / crash behavior.

The aforementioned object is achieved according to the invention in a battery carrier with the features in claim 1.

Advantageous design variants of the present invention are the subject of the dependent claims.

Accordingly, the battery carrier for an electric vehicle has a tub with a floor and a circumferential side wall. The side wall is preferably completely circumferential. The side wall is thus composed of four wall sections, especially in the case of a battery carrier that is rectangular in plan view. Optionally, an outwardly oriented flange protrudes from the side wall. The flange is also preferably optionally designed to protrude completely around the circumference. Furthermore, a frame is preferably part of the battery carrier. For this purpose, in particular the flange protruding from the outside rests on the frame. The frame is preferably formed from hollow profiles.

According to the invention, it is provided that the battery carrier is made in one piece with respect to at least the base and two wall sections, preferably the complete, circumferential side wall, from a plate or from a sheet metal plate. Steel or aluminum materials are used as sheet materials. However, the battery carrier can also be divided into at least two, preferably three, segments in plan view. The segments are then each designed to be flat. At least one wall section can also be made from an additional or separate profile.

According to the invention, however, it is provided that at least one molded bead extending over the width or length is formed in the base of the entire battery carrier, or at least one segment of the battery carrier, made in one piece and made of the same material.

The bead itself is designed in such a way that it functions as a molded cross member or longitudinal member. The bead thus serves to additionally stiffen the battery tray and also as a force path. Furthermore, the bead can serve as a connection surface for a battery module assembly in the interior of the battery carrier.

In the following, the battery tray can also be referred to as a battery tray. Preferably can the battery tray or the battery tray must be closed with a hood or cover.

The bead itself is configured essentially rectangular in its cross section. This means that, in cross section, the bead has a web running transversely to the longitudinal direction of the bead and legs protruding from the web. The legs then merge with the rest of the floor. Both legs can be designed in parallel.

The bead itself has a height which corresponds to 20% to 80%, in particular 30% to 60%, particularly preferably 40% to 55% of the height of the side wall. At each end of the bead, the web and the legs are cohesively coupled to the side wall by a thermal joining process. In the case of a one-piece side wall made of the same material, a preform is thus initially provided by bending or folding, i.e. sheet metal forming. A thermal joining process is then carried out on the resulting edges, so that the well of the battery tray is made tight. In the case of an externally produced side wall, this is welded to the end walls formed in one piece with the base and beads and also in the area of the bead to the web and the legs.

In a further preferred embodiment variant of the present invention, an additional step is formed on the battery carrier on at least one wall section of the side wall. The step is also used for stiffening and / or mounting the battery module.

A thickness of the material of the blank is preferably between 0.5 mm and 5 mm, preferably 1 mm and 4 mm, particularly preferably 1.5 mm to 3.5 mm.

• 1 einen erfindungsgemäß hergestellten Batterieträger ohne umlaufenden Rahmen,
• 2 a und b eine jeweilige Querschnittsansicht entlang der Schnittstelle II aus 1 einmal ohne Rahmen und einmal mit Rahmen,
• 2 c bis e alternative Ausgestaltungsvarianten zu 2 b, bei einem mit der Wanne gebauten Rahmen,
• 3 a und b eine Seitenansicht einmal mit Rahmen und einmal ohne Rahmen,
• 4 eine Draufsicht mit seitlich umlaufendem im Querschnitt L-förmigen Rahmen,
• 5 eine perspektivische Ansicht auf eine Sicke von außen,
• 6 eine Draufsicht auf einen Blechzuschnitt für eine einstückig, werkstoffeinheitlich ausgebildete Wanne als Faltbauteil

Further advantages, features, properties and aspects of the present invention are the subject of the following description. Preferred design variants are shown in the figures. These serve for a simple understanding of the invention. Show it:

• 1 a battery carrier manufactured according to the invention without a surrounding frame,
• 2 a and b a respective cross-sectional view along the interface II from 1 once without frame and once with frame,
• 2 c to e alternative design variants 2 B , with a frame built with the tub,
• 3 a and b a side view once with a frame and once without a frame,
• 4th a top view with laterally circumferential frame L-shaped in cross section,
• 5 a perspective view of a bead from the outside,
• 6th a plan view of a sheet metal blank for a one-piece, uniformly formed tub as a folding component

In the figures, the same reference symbols are used for identical or similar components, even if a repeated description is omitted for reasons of simplicity.

1 shows a battery carrier according to the invention 1 in perspective view. This battery tray 1 has a tub 2 on, taking the tub 2 through a floor 3 as well as a circumferential side wall 4th is trained. The side wall 4th is each through a wall section 4.1 to 4.4 educated. The wall sections 4.3 and 4.4 have an additional molded step 5 on. The wall sections 4.1 and 4.2 are each straight in their cross-section. The wall sections with step 5 , so wall sections 4.3 , 4.4 , are stepped or S-shaped in cross-section. There is also a circumferential flange 6th shown. However, this one would be here in 1 frame not shown 16 rest. The flange 6th is thus also designed circumferentially.

The tub 2 can be made in one piece and made of the same material from a plate. For this purpose, for example in plan view according to 6th a sheet metal blank 7th shown. On the sheet metal blank 7th are an example of the later flange 6th , the floor 3 who have favourited Wall Sections 4.4 , 4.3 as well as the laterally resulting cutouts 8th the beads according to the invention 9 registered as a reference number.

Furthermore, in 6th the later folding or reshaping points, where the sheet metal blank is folded, are marked with dashed lines. In the case of the beads that are created later, however, a further folding process, not shown here, is necessary in order to produce the bead in height and width.

The beads 9 are in the ground 3 molded in one piece and made of the same material. The beads 9 themselves are preferably configured rectangular in cross section. The beads 9 extend across the width in this example 10 the tub 2 . The beads 9 could also extend in the longitudinal direction. The beads 9 thus act as cross members. Forces introduced from the side can be passed through the beads 9 be transmitted as a force path. The beads 9 thus serve to stiffen the tub 2 . Can also be used in the interior 11 the tub 2 Batteries or battery modules not shown in detail are mounted. The Beads 9 can also be provided here for battery module assembly.

In an alternative embodiment, the in 1 pictured tub 2 from three segments 12 , 13 , 14th be trained. The individual segments 12 , 13 , 14th are then preferably form-fitting at coupling points 15th coupled together. Each segment is then again preferred 12 , 13 , 14th designed in one piece and made of the same material for itself.

Between the beads 9 can be formed transversely to separate longitudinal beams and extend between the beads and end faces. A side member can also encompass the beads.

In a further alternative and / or additional design variant, wall sections of the side wall 4th also as an external component with the floor 3 and coupled to the adjacent wall sections.

2 FIG. 11 shows a cross-sectional view according to section line II-II from FIG 1 . According to 2 a is the cross-section without a surrounding frame 16 shown, according to 2 B is a circumferential frame 16 L-shaped even in cross-section. The frame 16 is formed from hollow profiles, for example extruded hollow profiles.

The flange 6th lies on one side 17th of the frame 16 on. The bead 9 extends over the entire width 10 the tub 2 . So from frame to frame and thus serves as a cross member. It can also be seen that the height H9 the bead 9 compared to the height H4 the side wall 4th is less. The bead 9 however, preferably extends over 30% to 60%, in particular 40% to 55% of the height of the side wall 4th .

In 2 c through e are shown alternative design variants in which one with the tub 2 built frame 16 is trained.

2 c shows an alternative design variant in which an outer shell component 23 from the outside to the side wall 4th and the flange 6th is set. This shell component 23 can itself be L-shaped in cross-section or configured as another profile component. It is then preferably cohesive with a flange 6th and / or side wall 4th and / or the ground 3 coupled. The result is a frame 16 in the form of a closed hollow profile. This design can also be used as a surrounding frame 16 around the tub 2 of the battery tray 1 be trained.

At 2 c the shell component is coupled to the upper flange on the one hand and to the underside of the bottom on the other. A flange 24 of the additional component is directed into the hollow chamber of the surrounding frame.

Alternatively, in 2 d shown that a flange 24 in relation to the frame is directed outwards and with the flange 6th is coupled.

An alternative is in 2 e then a lower flange 25th formed on the shell member which is coupled to the side wall. Depending on the required size of the volume of the frame, an embodiment according to 2 c to e, as well as with regard to a corresponding packaging from the outside with regard to an external flange or a coupling with the bottom from below or with the side wall from the side.

3 a and b show a side view of the battery carrier according to the invention 1 , in case of 3 a without a surrounding frame 16 , in case of 3 b with surrounding frame 16 . The frame 16 is formed here in cross section as a hollow chamber profile, but not shown L-shaped in cross section. The side cutouts can be seen 8th to form the beads 9 . It can also be seen that the beads 9 are themselves configured to be substantially rectangular in cross section. Furthermore, the respective molded step is 5 to recognize.

Furthermore, the width B9 the bead shown. This is preferably 10 mm to 100 mm, in particular 20 mm to 80 mm and particularly preferably 40 mm to 60 mm.

4th shows the battery tray 1 in plan view. The surrounding frame 16 is presented, layed out. This is circumferentially designed in cross section in each case L-shaped, so the flange is located 6th on a top 17th of the frame. From the frame 16 Then there is the outwardly protruding L-shaped web 18th from. There are mounting holes 19th provided with which the frame 16 is coupled in the underfloor area of a motor vehicle, for example to motor vehicle side members or sills. The corners E. are welded fluid-tight.

5 each shows a perspective view of a bead 9 , in case of 5 inside the battery tray 1 the tub 2 and at 6th from outside. The bead 9 has an overhead transverse web 20th and from the jetty 20th protruding legs 21st on. The thigh 21st then go into the ground 3 above. The bead 9 is configured to be rectangular in cross section. Between the bridge 20th and thighs 21st and especially between legs 21st and respective soil 3 a folding radius, also called a bending radius or transition radius, is preferably formed. Not shown, especially in 6th is that jetty 20th and thighs 21st at the end of the bead 9 with the side wall 4th coupled, in particular continuously welded, so that an interior 11 is fluid-tight to the environment.

List of reference symbols

1 -

Battery tray

2 -

Tub

3 -

ground

4 -

Side wall

5 -

step

6 -

flange

7 -

Sheet metal cutting

8th -

Cutout

9 -

Bead

10 -

Width too 2

11 -

Interior too 2

12 -

segment

13 -

segment

14 -

segment

15 -

Coupling point

16 -

frame

17 -

Top closed 16

18 -

L-shaped bridge too 16

19 -

Mounting holes

20 -

web

21 -

leg

22 -

radius

23 -

Shell component

24 -

flange

25 -

flange

H4 -

Height too 4th

H9 -

Height too 9

B9 -

width 4.1 to 4.4 - wall section too 4th

α -

angle

U -

Surroundings

E -

corner

Claims (11)

Battery carrier (1) for an electric motor vehicle, comprising a trough (2) with a base (3) and a circumferential side wall (4) and optionally a flange (6) projecting outwardly from the side wall (4), with the base (3 ) the trough (2) has at least one molded bead (9) extending over the width (10) or length, such that the bead (9) functions as a molded cross member or longitudinal member and as a stiffener and / or connection surface for a battery module assembly is used, characterized in that at least one segment (12, 13, 14) of the tub (2), preferably the entire tub (2) is made as a folding component in one piece and made of the same material from a plate and that a height (H9) of the bead (9 ) Corresponds to 20% to 80% of the height (H4) of the side wall (4). Battery tray (1) Claim 1 , characterized in that the side wall (4) is formed in one piece and made of the same material from the plate. Battery tray (1) Claim 1 , characterized in that the side wall (4) is formed at least in sections from a further component and is coupled to the base (3), the further component is preferably a profile component with a cross-section. Battery tray (1) according to one of the Claims 1 to 3 , characterized in that a step (5) is molded into one end of the tub (2), the step (5) being molded from the plate in one piece and of the same material. Battery tray (1) according to one of the Claims 1 to 4th I denote that the bead (9) is configured essentially rectangular in its cross section. Battery carrier (1) according to one of the preceding claims, characterized in that the circumferential side wall (4) of the tub (2) has corners (E) which are connected to one another in a fluid-tight manner and / or which the circumferential side wall (4) with the bead ( 9) is connected in a fluid-tight manner, in particular welded. Battery carrier (1) according to one of the preceding claims, characterized in that the battery carrier (1) is formed from two, in particular three segments (12, 13, 14), the segments being connected to one another by fluid-tight coupling, in particular the segments ( 12, 13, 14) are welded with a continuous, thermal joint seam. Battery carrier (1) according to one of the preceding Claims 1 , characterized in that a height (H9) of the bead (9) corresponds to 30% to 60% of the height (H4) of the side wall (4). Battery carrier (1) according to one of the preceding claims, characterized in that a flange (6) protrudes around the outside. Battery carrier (1) according to one of the preceding claims, characterized in that an externally encircling frame (16) is formed, the frame (16) being formed by hollow profiles and preferably the flange (6) resting on the frame (16) or that the frame (16) is designed at least in sections in cross section as a hollow profile, the side wall (4) being coupled to a single-layer half-shell to form the frame (16). Battery carrier (1) according to one of the preceding claims, characterized in that at the end of the bead (9) the web (20) and the legs (21) are coupled to the side wall (4) in a fluid-tight manner.

Images