WO2022269459A1

WO2022269459A1 - Improved impact support structure for a heavy vehicle

Info

Publication number: WO2022269459A1
Application number: PCT/IB2022/055706
Authority: WO
Inventors: Jürgen SPITZLBERGER; Patrick CIBICKI; Marco BARBI
Original assignee: Iveco Magirus Ag
Priority date: 2021-06-21
Filing date: 2022-06-20
Publication date: 2022-12-29

Abstract

Impact support structure (10) for protecting electrical battery modules (2) of a heavy vehicle (100), and comprising a fixation element (11) configured to be fixedly carried by a chassis (1) of the vehicle (100), the fixation element (11) being placed in front of an electrical battery module (2) of the vehicle (100) and extending parallel to a longitudinal axis (A) of the vehicle (100), the fixation element (11) having a "M" cross-section, the cross-section being dimensioned to deform under the action of an impact force acting on the impact support structure (10) to avoid contact with the electrical battery module (2).

Description

"IMPROVED IMPACT SUPPORT STRUCTURE FOR A HEAVY VEHICLE"

Cross-Reference to Related Applications

This patent application claims priority of Italian Patent Application No. 102021000016178 filed on June 21, 2021, the entire disclosure of which is incorporated herein by reference.

Technical Field of the Invention

The present invention concerns an impact support structure for a vehicle, in particular for a heavy vehicle.

The present invention finds its preferred, although not exclusive, application in protection of batteries of a heavy vehicle having at least partial electric traction.

State of the Art Heavy vehicles such as trucks are more and more electrified in order to reduce the use of internal combustion engine in view of their polluting emissions.

The electrification foresees the presence of electrical machines configured to provide torque to the wheels of the vehicle and related batteries configured to store electrical energy to be used/provided by the electric machines.

The batteries are usually carried by the chassis of the vehicle and are therefore exposed to the loads acting on this latter.

In particular, it may be possible that lateral impacts due to collisions with other vehicles or due to incidents may lead to damages to the batteries. Such damages may incur into an increase of the temperature of the battery that may lead to fire, the so-called "runaway" phenomenon.

Furthermore, during the aforementioned impacts or due to the possible fire, dangerous elements may be released in the environment thereby leading to pollution and possible health risk to the peoples in the neighboring of the vehicle.

However, the aforementioned batteries tend to occupy a large space on the chassis and therefore the addition of other security means will incur into an increase of the lateral gabarit of the vehicle and of its weight.

Therefore, the need is felt to increase the safety of the installation of the batteries on heavy vehicle without increasing the gabarit of the vehicle, manufacturing costs and its weight.

An aim of the present invention is to satisfy the above mentioned needs in a cost effective and optimized way.

Subject and Summary of the Invention

The aforementioned aim is reached by an impact support structure and a vehicle as claimed in the appended set of claims.

Brief Description of the Drawings

For a better understanding of the present invention, a preferred embodiment is described in the following, by way of a non-limiting example, with reference to the attached drawings wherein:

• Figure 1 is a perspective view of an impact support structure of the present invention;

• Figure 2 is a perspective view of a portion of an element of the impact support structure according to a first embodiment of the present invention;

• Figure 3 is an exploded perspective view the element of figure 2;

• Figure 4 is a perspective view of a portion of an element of the impact support structure according to a first embodiment of the present invention;

• Figure 5 is an exploded perspective view the element of figure 4;

• Figure 6 is an enlarged upper perspective view of a portion of the element of figure 4;

• Figure 7 is an enlarged lower perspective view of a portion of the element of figure 4;

• Figure 8 is a perspective enlarged view of a portion of the impact support structure with parts removed for sake of clarity;

• Figure 9 is a perspective enlarged view of a further portion of the impact support structure with parts removed for sake of clarity; and

• Figure 10 is a perspective schematized view of a vehicle provided with an impact support structure of the present invention during a possible impact with a further vehicle.

Detailed Description of Preferred Embodiments of the Invention

Figure 1 discloses a chassis 1 for a heavy vehicle 100, such as a truck. Such heavy vehicle 100 has at last a partial electric traction and therefore comprises a plurality of battery modules 2 carried by chassis 1 in a suspended way (see figure 10).

In particular, as per se known, the chassis 1 comprises a pair of side members 3, 4 extending parallel with respect to a longitudinal axis A of the vehicle and preferably symmetrically with respect to this latter. In particular, referring to the provided drawings, it may be defined a right side member 3 and a left side member 4, with reference to axis A.

The vehicle is provided with a battery support structure 5 that is carried by side members 3, 4 and that defines a plurality of housings 6 disposed longitudinally and transversally adjacent one with respect to the other, in particular, as shown in the present embodiment they are disposed as a chessboard. Housings 6 are configured to house a battery module2 (see figure 10).

In particular, the battery support structure 5 comprises transversal walls 7 that are fixedly carried by the respective side member 3, 4 and extend transversally with respect to longitudinal axis A towards the environment. In particular, in the disclosed embodiment the support structure 5 comprises eight transversal walls 7 defining three rows of housings 6 across longitudinal axis A. The support structure 5 further comprise cross-member elements that connects the side members 3, 4 but that are not further described herein for sake of brevity.

In detail, the transversal walls 7 comprises a fixation portion 7a configured to be fixedly secured to the side members 3,4 via mechanical coupling means, e.g. threaded means, and a coupling portion 7b. This latter is placed opposite to the fixation portion 7a in transversal direction, i.e. in the farthest transversal point with respect to side member 3, 4.

The transversal walls 7 are preferably placed longitudinally along axis A at the same distance one with respect to the other. Preferably, the transversal walls 7 are two for each housing 6. Accordingly the vehicle comprises single transversal walls 7 in the longitudinal extremities and faced pair of transversal walls 7 between such single transversal walls 7.

The coupling portion 7b preferably comprises a longitudinal wall 7c that extends longitudinally cantilevered with respect to an outer edge of the transversal wall 7. In particular, the longitudinally wall 7c extends parallel to axis A towards the opposite transversal wall 7.

The vehicle 1 further comprises at least an impact support assembly 10 for each housing 6 that is fixedly carried by chassis 1 in face of a battery 2, in particular by a pair of transversal walls 7, and that is essentially configured to absorb energy due to an impact force acting on itself to avoid damages to the battery module 2 housed into housing 6.

According to the above, each housing 6 is longitudinally delimited, front and rear, from a pair of transversal walls 7 and transversally by a side member 3, 4 and by the at least one impact support assembly 10. In the exemplarily disclosed embodiment, the vehicle comprises two impact support assemblies 10 vertically placed one adjacent to the other.

Figures 2 and 4 discloses two different embodiments of the aforementioned impact support assembly 10.

In both the embodiments, the impact support assembly 10 comprises a fixation element 11 configured to be fixed to the transversal walls 7 and extending along longitudinal direction A of vehicle 100.

The fixation element 11 is preferably a metallic element having a "double omega"/"M" cross-section. In particular, the fixation element 11 comprises a pair of terminal portions 11a a central portion 11c and a pair of protruding portions lib comprised between the pair of terminal portions 11a and the central portion 11c. In particular, the terminal portions 11a, the protruding portions lib are symmetrical with respect to a longitudinal axis of the fixation element 11. In particular, the terminal portions 11a and the central portion 11c are both flat plates and preferably coplanar one with respect to the other.

The protruding portions lib, instead, extends transversally outer from the terminal portions 11a and the central portion 11c and preferably are equal in shape. In particular, they have a trapezoidal shape, i.e. each comprises a pair of inclined walls lib' extending inclined from the terminal portions 11a and the central portion 11c and an upper wall lib'' that is preferably flat and parallel to the terminal portions 11a and the central portion 11c.

The inclined walls lib' and the upper wall lib'' therefore delimit a space 12 that vertically delimited by inclined walls lib' and transversally delimited by the upper wall lib'' and opened on the opposite side, i.e. towards the respective side member 3, 4.

Advantageously, the terminal portions 11a, and preferably the central portion 11c, each defines holes 13 configured to allow the fixation, e.g. via threaded elements, to the transversal walls 7.

Advantageously, the central portion 11c defines a plurality of through holes 14. Such holes 14 have preferably the same shape and are longitudinally aligned along a direction parallel to longitudinal axis of the fixation element 11. More preferably, they are equally distanced one with respect to the other along such direction.

Conveniently, the impact support assembly 10 comprises a lateral cover 16 that is configured to be connected to protruding portions lib to cover the central portion 11c. Preferably, lateral cover 16 is welded, thanks to a layer of fixation glue 17, on the upper walls lib of the protruding portion lib.

Preferably, the impact support assembly 10 comprises a pair of longitudinal covers 18 configured to be connected to the protruding portions lib and the central portion 11c. Similarly to the above, the longitudinal covers 18 may be welded thanks to a layer of fixation flue to the inclined walls lib' of the protruding portion lib and to the central portion 11c.

According to the above description, a space delimited is created between longitudinal walls 18 and lateral cover 16 and opened towards the central plate 11c.

In both embodiments, the fixation element 11 defines further holes 20 configured to allow the fixation of other functional elements of the vehicle as described in the following. In the disclosed examples, holes 20 are realized mainly in terminal portions 11a, but also in central portion 11c and in the inclined walls lib' of the protruding portions lib.

Advantageously, the impact support assembly 10 is realized in metal and, in particular, the transversal extension of protruding portions lib and the thickness of lateral cover 16 are design to support an impact force with a preset deformation, i.e. a deformation that avoid to touch the battery module 2 housed in housing 6. More preferably, fixation plate 11 is realized as a single metal piece, e.g. as a profiled element or a bent metal sheet.

The embodiment of figure 4 differentiates with respect to the embodiment of figure 2 by comprising at least a through opening 19 that has different dimensions with respect to the other openings 14 realized in central portion 11c.

In particular, in the disclosed embodiment, the additional through opening 19 is single and placed equally spaced with respect to the remaining openings 14. In greater detail, the vertical extension of such single opening 19 is the same of the other openings 14, i.e. extending substantially all over the space comprised between the pair of protruding portions lib, while its extension in longitudinal direction is greater with respect to the extension of other openings 14.

According to the above, the lateral cover 16 defines a hole 21 configured to be faced to the opening 19 of the fixation element 11, thereby allowing to pass through impact support assembly 10. Such opening 21 is defined by a peripheral edge having a shape correspondent to the opening 19, i.e. in the disclosed example a rectangular shape.

Preferably, lateral cover 16 comprises longitudinal inner walls 22 extending from longitudinal edges of the peripheral edge of the opening 21 towards the fixation element 11. Such longitudinal inner walls 22 close the space that is delimited between longitudinal walls 18 and lateral cover 16 and opened towards the central plate 11c.

The impact support assembly 10 also accomplish to the function of providing support to a plurality of functional elements of the vehicle.

According to an embodiment, shown in figures 6 and 7 and referring to the embodiment of figures 4 and 5, the impact support assembly 10 provides support for a step 25.

In particular, the step 25 comprises a step plate 26 that defines, on an upper surface, an anti-sliding finishing 27, e.g. comprising a plurality of holes having protruding edges.

The step plate 26 is configured to be housed through hole 21 and opening 19 and is configured to be fixed to the fixation element 11, preferably via holes 20 realized on the protruding portion lib. In the disclosed examples, two holes 20 are foreseen for the fixation of the step plat 26 with two corresponding threaded elements.

In the embodiment of figure 6, the step plate 26 extends all over the transversal protrusion defined by the protruding portion lib. In the embodiment of figure 7, the step plate 26 extends cantilevered with respect to protruding portion lib.

Accordingly, the step plate 26 may be fixed to the fixation element 11 thanks to a support bracket 28 having a main portion 28a provided with a profile that is configured to match with the profile of the protruding portion lib and suitable to be connected to the latter via holes 20 and via further holes 20 realized on the adjacent terminal portion 11a. Such support bracket 28 may further comprise a support portion 28b extending cantilevered from the main portion 28a in transversal direction and configured to define a further fixation point 29 for the step plate 26.

According to an embodiment, shown in figures 8 and referring to the both embodiments of figures 2 to 5, the impact support assembly 10 provides support for electrical cables 30.

The batteries 2 are connected between them and to other electrical elements, such as inverters, power distribution units, converters or electrical control units by electrical cables 30. According to the invention, the space 12 has a channel shape thereby providing guidance to cables 30, as shown in detail in figure 8. The holes 20 distributed over the central portion 11c, the protruding portions lib or the terminal portions 11a allows the securing of such cables 30 via securing means 31 such as clips or cable ties.

According to an embodiment, shown in figures 9 and referring to the both embodiments of figures 2 to 5, the impact support assembly 10 provides support for fixing side skirts 35 of the external body of the vehicle 100.

According to the invention, the holes 20 realized in terminal portions 11a of fixing element 11, namely upper and lower terminal portions of a single or different impact support assembly 10, may be user for providing the fixation of coupling brackets 36 connected to the side skirts of the vehicle 100.

According to an embodiment, visible in figure 1 and referring to the both embodiments of figures 2 to 5, the impact support assembly 10 provides support for fixing protection plates 37 for protecting batteries 2 from objects in impact coming from the ground during vehicle motion.

Protection plates 37 may be fixed to the fixing element 11 and to the transversal walls 7 in order to delimit housing 6 on its lower extremity.

The operation of an impact support assembly according to the invention is the following, making reference to figure

10.

If a vehicle 101, or an object, impacts on the vehicle 100 that is traveling, the impact will be absorbed by assembly support structure 10.

As said, the thickness of lateral cover 16 and the shape and extension in transversal direction of protruding portion lib are design to deform without contacting batteries 2 housed within housing 6.

During the use of the vehicle, as described, the assembly support structure 10 provides support for steps 25, for cables 30, for side skirts 35 and for protection plates 37 to avoid damages coming from ground.

Moreover, during its use, the impact support assembly 10, being fixed to walls 7, help support structure 5 to transmit loads between batteries 2.

In view of the foregoing, the advantages of an impact support assembly according to the invention are apparent.

The impact support assembly 10 allows to absorb the energy of an impact due to an object colliding with vehicle 100, thereby protecting the batteries 2. In particular, the provided assembly may support an impact on the vehicle, that is standstill, of a test vehicle having a collision mass of about 1367 kg having a velocity of about 54km/h and being incident with respect to longitudinal axis of the vehicle of about 27°.

In particular, the peculiar shape and the provided thickness allows to provide an optimized energy absorption in a limited lateral space, thereby not increasing vehicle gabarit.

Moreover, as demonstrated, the peculiar shape and openings allows to provide comfortable and useful support for fixing steps, cables, skirts, and other protection elements for batteries 2.

Moreover, during its use, the impact support assembly improves the load transmission between batteries 2 thanks to the peculiar fixation to support structure 5, i.e. to walls

7.

It is clear that modifications can be made to the described impact support assembly which do not extend beyond the scope of protection defined by the claims.

For example, the different described embodiments may be combined together to provide, or not, the described functionalities .

Moreover, the space of the disclosed portions of the fixation element 11 may vary, i.e. its cross-section.

Furthermore, the number and disposition of the impact support assemblies 10 may vary according to the number of batteries carried by vehicle 100 and their dimensions.

Claims

1.- Impact support structure (10) for protecting electrical battery modules (2) of a heavy vehicle (100), said impact support structure (10) comprising a fixation element (11) configured to be fixedly carried by a chassis (1) of said vehicle (100), said fixation element (11) being dimensioned to be placed in front of an electrical battery module (2) of said vehicle (100) and extending parallel to a longitudinal axis (A) of said vehicle (100), said fixation element (11) having a "M" cross-section, said cross-section being dimensioned to deform under the action of an impact force acting on said impact support structure (10), wherein said fixation element (11) comprises a central portion (11c), a pair of terminal portions (11a) and a pair of protruding portions (lib) comprised between the central portion (11) and the pair of terminal portions (11a), said protruding portions (lib) extending over said central portion (11c) and sand terminal portions (11a) wherein said fixation element (11) is fixed to said chassis (1) on longitudinal extremities of said terminal portions (11a), wherein said terminal portions (11a) defines holes (13) realized in said longitudinal extremities to fix said fixation element (11) to said chassis (1).

2.- Impact support structure according to claim 1, wherein said central portion (11c) and said pair of terminal portions (11a) are parallel and contained in the same plane.

3.- Impact support structure according claims 1 or 2, wherein said protruding portions (lib) are equal.

4.- Impact support structure according to any of the preceding claims, wherein said protruding portions (lib) each comprises an upper wall (llb^,f) that is parallel to said central portion (11c), a pair of inclined walls (lib') that connects said upper wall (lib') to respectively said central portion (11) and said terminal portion (11a). 5.- Impact support structure according any of the preceding claims further comprising at least a cover (16, 18) that is secured to said protruding portions (lib).

6.- Impact support structure according to any of the preceding claims, wherein said fixation element (11) comprises a plurality of openings (14) realized into said central portion (11c), said openings (14) being equal and equally spaced one with respect to the other along said longitudinal direction.

7.- Impact support structure according to claim 5, wherein said fixation element (11) comprises at least an opening (19) realized into said central portion (11c) and wherein said cover (16) defines at least an opening (21) realized in correspondence of said opening (19), said at least one openings (19, 21) having an extension on a direction perpendicular to said longitudinal direction equal to the space comprised between said protruding portions (lib).

8. Impact support structure according to claim 7, wherein said impact support structure comprises a step (25) configured to be housed in said openings (19, 21), said step

(25) comprising a step plate (26) that is configured to be fixed to said protruding portion (lib).

9.- Impact support structure according to claim 8, wherein said step (25) may comprise a support bracket (28) configured to be fixed on said terminal portions (11a), said support bracket (28) providing support to said step plate

(26) when extending cantilevered towards the environment out from said openings (19, 21).

10.- Impact support structure according to any of the preceding claims, wherein said protruding portions (lib) defines a space (12) faced to said electrical battery module (2), said protruding portions (lib) and/or said terminal portions (11a) defining a plurality of holes (13, 20), said space (12) being dimensioned to house electrical cables (30) configured to be secured to said protruding portions (lib) via said holes (13, 20).

11.- Impact support structure according to any of the preceding claims, wherein said terminal portions (11a) defines a plurality of holes (13, 20), said holes (13, 20) being dimensioned to support brackets (36) for supporting side skirts (35) of said vehicle (100).

12.- Vehicle (100) having at least a partial electrical traction, said vehicle (100) comprising a chassis (1) provided with a pair of side members (3, 4) extending along a longitudinal axis (A) of said vehicle (100), said chassis (1) comprising a support structure (5) for supporting a plurality of electrical battery modules (2), said support structure (5) being fixedly carried by said chassis (1), said vehicle (100) comprising at least an impact support structure (10) according to any of the preceding claims in face of each of said electrical battery modules (2).

13. Vehicle according to claim 12, wherein said support structure (5) comprises transversal walls (7) extending transversally from said side members (3, 4) to the environment, said impact support structure (10) being fixed to said transversal walls (7), at least some of said electrical battery modules (2) being housed between said transversal walls (7), said impact support structure (10) and said side member (3, 4). 14. Vehicle according to claim 13 further comprising protection plates (37) configured to be fixedly secured to said transversal walls (7) below said battery modules (2).