CN111416072A

CN111416072A - Collision protection device

Info

Publication number: CN111416072A
Application number: CN201911308516.1A
Authority: CN
Inventors: J.黑德; M.吕克
Original assignee: Volkswagen AG
Current assignee: Volkswagen AG
Priority date: 2018-12-19
Filing date: 2019-12-18
Publication date: 2020-07-14
Also published as: DE102018132849B4; DE102018132849A1

Abstract

The invention relates to a crash protection device, in particular a crash protection device (2) for protecting a battery system (1) for use in a motor vehicle, comprising an outer profile (4), a damping layer (6) arranged within the outer profile (4), wherein the crash protection device (2) has a connecting element (8) for establishing a fixed connection between the crash protection device (2) and a battery module (12) and a further crash protection device (2b) and/or a further battery module (12 b).

Description

Collision protection device

Technical Field

The invention relates to a crash protection device for protecting a battery system, to a battery system and to a method for producing a battery system.

Background

Devices and systems for protecting battery systems are known from the prior art. DE 102011002650 a1 relates to a motor vehicle, in particular a hybrid vehicle or an electric vehicle, having a battery arranged between two wheel arches (Radkasten), wherein the battery is protected, in particular in the event of a side impact, by providing an elongated protective element between the wheel arches in the region of the battery, which element does not bend under a strongly applied pressure load.

DE 102016203553 a1 relates to a battery assembly having a battery housing with a trough-shaped battery carrier and a battery cover covering the battery carrier, wherein at least one battery module is arranged and fixed in the interior of the battery housing. The battery carrier, which is made of plastic or fiber-reinforced plastic, is configured with a carrier base and a carrier wall.

DE 102017000266 a1 relates to a battery module support for receiving a traction battery of a motor vehicle, having a housing basin and a housing cover, each of which is of sandwich construction and has an upper side and a lower side, each made of an organic or aluminum plate, and between which a thermoplastic plastic foam is arranged.

The disadvantage of the cited prior art is, in particular, that the cited battery housing either does not offer sufficient protection in the event of a crash or is constructed so robustly that it has an excessive weight. Furthermore, known battery systems often conflict with modular construction.

Disclosure of Invention

The object of the present invention is therefore to eliminate the disadvantages described above at least in part, and in particular to provide a device for protecting a battery system which provides a light and at the same time stable device for crash protection in a manner which is as simple and cost-effective as possible, which furthermore supports a modular construction of the battery system.

The above object is solved by a device with the features of claim 1, a system according to claim 8 and a method according to claim 10. Further features and details are given by the dependent claims, the description and the drawings. The technical features disclosed for the device according to the invention are also applicable here in connection with the system according to the invention and the method according to the invention and vice versa, so that always with regard to the disclosure for the various aspects of the invention, mutual references or mutual references are possible. Advantageous embodiments of the invention are set forth in the dependent claims.

The crash protection device according to the invention for protecting a battery system for use in a motor vehicle comprises an outer profile and a damping layer arranged within the outer profile. In this case, a typical crash protection device is distinguished by the fact that it has connecting elements for establishing a fixed connection between the crash protection device and the battery module and a further crash protection device and/or a further battery module.

A typical crash protection device can be used preferably in a motor vehicle, in particular in an electric vehicle or a hybrid vehicle, and is arranged there preferably at the bottom of the vehicle in the side region.

The exemplary outer profile of the crash protection device according to the invention can be formed at least partially from a metallic material, preferably at least partially from a ferrous material, at least partially from a titanium material or, in the context of a light and at the same time stable arrangement, in particular at least partially from an aluminum material. Furthermore, representative cushioning layers may be formed, inter alia, in the form of rigid foams or the like, for example, from polyvinyl chloride, polystyrene, or polyurethane, or the like. Alternatively, metal foams, preferably aluminum foams, can also be used as rigid foams. Metal foams have a low density due to pores and cavities, but have a high specific stiffness and strength. Additionally, the metal foam achieves an elevated kinetic energy absorption, so that the metal foam is particularly suitable for withstanding impacts. A representative cushioning layer may be designed in the form of a rigid foam slab or also in the form of a rigid foam padding. The rigid foam plate can be provided in the finished state and can be bonded, for example, in an outer profile of a typical crash protection device. In this way, particularly simple installation is ensured without contamination occurring during foaming. In a further aspect, the rigid foam filling offers the advantage of a flexibly adaptable shape and is therefore preferably suitable for use in surface-rich internal structures, in particular when a filling as complete as possible is provided. To the extent that the filling is as complete as possible by means of the rigid foam filling, recesses can also be provided in the interior of the damping layer, for example, for the introduction of connecting elements or the like.

It has been representatively recognized that not only a light and at the same time stable device for protecting a battery system can be created by the combination according to the invention of the outer profile, the damping layer and the connecting elements, but also the modular construction of the battery system is supported in such a way that the individual battery modules of the battery system can be protected both by the exemplary crash protection device and can be fixedly connected to one another. By connecting different battery modules via a collision protection device according to the invention, the movement and destruction of the modules in the event of a collision are prevented. This makes it possible to use the modular structure of the battery system without danger and thus to use a scalable (sometimes referred to as scalable) and economical electric drive system without danger.

In the context of a particularly high impact absorption capacity of the exemplary crash protection device, it can be provided according to the invention that the outer profile has an L-shaped cross section, the L-shaped contour in this case in particular realizing a wide crumple zone (sometimes referred to as a crash cushion) for protecting the battery module.

In terms of effective resistance to impacts, it can furthermore be provided according to the invention that an inner profile is provided which is arranged within the outer profile. The inner profile serves here for additional support, in particular for additional damping of impacts. The inner profile is therefore preferably at least partially designed to be elastic. The inner profile has in particular at least one, preferably more than one, damping direction for damping impacts. The material thickness of the inner profile can be substantially uniform, but it is likewise conceivable to provide theoretical bending points (solbiegestellen) in the inner profile, which can preferably be formed in the form of material recesses or the like within the scope of a simple design solution. In view of the stable design of the exemplary crash protection device, the inner profile can preferably be formed from a metallic material, in particular at least partially from an aluminum material within the scope of a weight-optimized design. In this case, it is expedient in view of corrosion protection that the inner profile is formed from the same material as the outer profile. In view of the damping of strong impacts, for example in the case of a side impact or the like, the inner profile can in particular have a layer thickness which is at least partially thicker than the outer profile. In the context of effective damping of impacts, it is also advantageous if the inner profile bears directly against a large part of the inner surface of the outer profile. The inner profile can thus be formed in its intact state in such a way that it bears against at least 30% of the inner surface of the outer profile, preferably at least 50% of the inner surface, particularly preferably more than 50% of the inner surface. In the context of an embodiment with an inner profile arranged within an outer profile, it is furthermore advantageous if the inner profile is arranged at least partially, preferably completely, between the damping element and the outer profile. In this case, the damping layer preferably rests directly, i.e., in contact, on the inner profile in the region of effective protection of the battery module.

In the context of a particularly effective damping, it can furthermore be provided according to the invention that the inner profile has an at least partially open structure. The at least partially open structure additionally ensures a particularly weight-and material-saving embodiment. In the context of such an embodiment, the inner profile can be arranged in particular within the outer profile in such a way that the inner profile bears in a surface-like manner against at least three, preferably at least four, surfaces of the outer profile.

With regard to the arrangement of the connecting element, it is likewise conceivable for the connecting element to be arranged directly on the outer profile. A direct arrangement is understood here to mean an arrangement which is directly adjacent, in contact. According to the invention, the connecting element can be fixedly connected to the outer profile with a force fit, for example by means of bolts or rivets. Alternatively, the connecting element and the outer profile can also be connected to one another in a form-fitting or material-fitting manner. In the context of a flexible connection of the individual components of the exemplary crash protection device to one another and in view of the flexible connection of the exemplary crash protection device to further crash protection devices and/or battery modules, a plurality of preferably large number of recesses can be provided in the crash protection device, in particular in the connecting element, for receiving the fastening elements. In view of the light and stable arrangement of the crash protection device according to the invention, the exemplary connecting element, like the outer profile, can advantageously be formed from a metallic material, in particular at least partially from an aluminum material.

In addition, within the scope of a light, cost-effective and component-saving variant of the crash protection device according to the invention, it can be provided that the connecting element of the crash protection device can be pushed at least partially into the outer and/or inner profile of the crash protection device and/or of a further crash protection device. The insertion of the connecting element here makes it possible in particular to dispense with additional fastening elements or the like. In view of the exemplary embodiment in which the connecting element can be pushed into the outer profile and/or the inner profile of the first and/or second impact protection device, the connecting element can preferably be adapted to the inner structure of the outer profile and/or the inner profile, in particular at least partially having a structure complementary to the outer profile and/or the inner profile.

In addition, in view of the stable and variably usable crash protection device, it can be provided according to the invention that a connecting rail is provided for connecting the connecting element to the outer profile. The connecting rail can preferably comprise a plurality of, in particular a plurality of, recesses for receiving fastening elements (e.g. bolts, rivets, etc.), by means of which the fastening of the connecting element to the outer profile and to the further connecting element can be carried out.

The invention also relates to a battery system for use in a motor vehicle, which comprises the crash protection device described above and a battery module and is distinguished in that the crash protection device is arranged on the outside of the battery module and is fixedly connected to the battery module and/or to a further crash protection device and/or to a further battery module by means of a connecting element of the crash protection device, whereby the battery system according to the invention brings the same advantages as have already been described in detail with regard to the crash protection device according to the invention.

In this case, it is also conceivable within the scope of the system according to the invention to provide a further crash protection device and a further battery module, wherein the crash protection device is fixedly connected to the battery module and/or the further crash protection device by means of a connecting element of the crash protection device, and the further crash protection device is fixedly connected to the battery module and/or the crash protection device and/or the further battery module by means of a connecting element of the further crash protection device. In this case, the exemplary connecting element can preferably have a larger area, in particular a larger length of a side, than the respective abutting or corresponding side of the battery module to be protected, so that the connecting element can be adapted to completely cover the side region of the battery module and at the same time also cover a part of the side of the further battery module. In this way, a particularly stable connection between the first connecting element and the first and second battery module can be created by, for example, providing recesses for introducing fastening elements (e.g., bolts, rivets, etc.) on the mutually opposite sides of the connecting element, and by the mutually opposite sides of the connecting element can be connected to the first and second battery module in a force-fitting manner. In the context of a uniform fixing of two adjacent battery modules by means of the connecting element, it can be provided in particular here that at least two fixing elements are arranged at the same distance from the dividing line of the battery modules within the exemplary system. In the case of a simple and at the same time stable fastening, it can furthermore be provided that the first and the further crash protection devices are additionally connected to one another by means of a connecting rail. It goes without saying that, in addition to the arrangement of the first and further battery modules, which are each fixedly connected to one another in a manner protected by the crash protection device, further battery modules protected by the crash protection device can also be arranged in a fixed connection with the two first battery modules.

The subject matter of the invention is also a motor vehicle comprising an impact protection device as described above, which in particular comprises a battery system as described above.

The invention also relates to a method for producing a battery system for use in a motor vehicle. Here, the method according to the invention comprises the steps of: connecting the impact protector to the battery module by means of the connecting element of the impact protector; connecting the crash protector to a further battery module by means of a connecting element of the crash protector; and connecting the further crash protector to the battery module and/or the crash protector and/or the further battery module by means of the connecting element of the further crash protector. Therefore, the representative method brings about the same advantages as have been described in detail with respect to the collision protection apparatus according to the present invention and the battery system according to the present invention. Within the scope of the exemplary method for producing a battery system, the individual steps can of course also be carried out in another sequence, so that the connection of the first crash protection device to the further crash protection device can be effected, for example, before the first crash protection device is connected to the first battery module.

Drawings

Additional advantages, features and details of the present invention are given in the following description, in which embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description may be essential for the invention individually as such or in any combination.

Wherein:

fig 1 shows a schematic view of a collision protection apparatus for protecting a battery system according to a first embodiment of the present invention,

figure 2 shows a schematic view of an impact protection device for protecting a battery system according to a first embodiment of the invention in a sectional view along the sectional line I-I according to figure 1,

fig 3 shows a schematic view of a collision protection apparatus for protecting a battery system according to a second embodiment of the present invention,

figure 4 shows a schematic view of an impact protection device for protecting a battery system according to a second embodiment of the invention in a sectional view along the sectional line II-II according to figure 3,

fig 5 shows a schematic view of a collision protection apparatus for protecting a battery system according to a third embodiment of the present invention,

figure 6 shows a schematic view of the connection of two collision protection apparatuses for protecting a battery system according to a third embodiment of the present invention,

fig. 7 shows a schematic view of a battery system according to the invention for use in a motor vehicle, comprising a crash protection device according to a third embodiment of the invention for protecting the battery system,

fig. 8 shows a schematic illustration of a battery system according to the invention for use in a motor vehicle, which comprises a crash protection device according to a fourth embodiment of the invention for protecting the battery system.

In the figures, the same reference numerals are used for the same features.

List of reference numerals

2 collision protection device

2b additional crash protection device

4 exterior profile

4b further outer profiles

6 buffer layer

8 connecting element

8b further connecting elements

10 interior section bar

12 cell module

12b additional Battery Module

14 fixing piece

16 connecting rail

18 recess

20 lines of demarcation.

Detailed Description

Fig. 1 shows a schematic view of a crash protection device 2 according to a first embodiment of the invention for protecting a battery system 1. The crash protection device 2 according to the invention comprises an outer profile 4 and a damping layer 6 arranged within the outer profile 4, the damping layer 6 being fastened to the outer profile 4 by means of fastening elements 14. Furthermore, the crash protection device 2 according to the first exemplary embodiment has an inner profile 10 arranged within the outer profile 4 and a connecting element 8 for establishing a fixed connection between the crash protection device 2 and the battery module 12 and the further crash protection device 2b and/or the further battery module 12 b.

The outer profile 4 represented here can be composed at least partially of a metallic material, preferably at least partially of an aluminum material. Furthermore, the exemplary damping layer 6 can be formed in particular in the form of a rigid foam or the like, for example from polyvinyl chloride, polystyrene or polyurethane, and is currently constructed in the form of a rigid foam plate, which can be adhesively bonded, for example, to the interior of the outer profile 4. The connecting element 8 provided for establishing a fixed connection between the crash protection 2 and the further crash protection 2b and/or the battery module 12 and/or the further battery module 12b is currently formed in the form of a movable connecting element which can be pushed at least partially into the outer profile and/or the inner profile of the crash protection 2. The connecting element 8 is preferably adapted to the inner structure of the outer and/or

inner profile

4,10 and in particular has a structure complementary to the outer and/or

inner profile

4,10, at least in sections.

Fig. 2 shows a schematic view of a crash protection device 2 according to the invention for protecting a battery system 1 according to a first exemplary embodiment in a sectional view along section line I-I according to fig. 1, from which in particular an L-shaped cross section or a L-shaped contour of the outer profile 4 can be seen, which L-shaped cross section or which L-shaped contour ensures in particular a particularly high impact absorption capacity, furthermore a partially open structure of the inner profile 10, which structure permits particularly effective damping of the inner profile 10 in at least one damping direction, in contrast to the outer profile 4, is seen, the damping layer 6, which is currently designed as a rigid foam plate, is here arranged directly at the inner profile 10, separately from the outer profile 4.

Fig. 3 shows a schematic view of a collision protection device 2 for protecting a battery system 1 according to a second embodiment of the present invention. According to a second exemplary embodiment, the crash protection device 2 has no inner profile 10 for additional damping of impacts. Further, unlike the first embodiment, the cushioning layer 6 is not formed in the form of a rigid foam sheet but in the form of a rigid foam filler. The rigid foam filling offers the advantage of a flexibly adaptable shape and is therefore preferably suitable for use in surface-rich internal structures, in particular when a substantially complete filling is provided as in the present case. In this case, a recess 18 for introducing the connecting element 8 or the like is also provided in the interior of the damping layer 6.

Fig. 4 shows a schematic view of an impact protection device 2 according to a second exemplary embodiment of the invention for protecting a battery system 1 in a sectional view along section line II-II according to fig. 3, from the illustration from fig. 4, the L-shaped contour of the outer profile 4 and a damping layer 6 arranged inside the outer profile 4 in the form of a rigid foam insert, which has only a centrally arranged recess 18 for the introduction of a connecting element 8, such as a rail, a cable or the like, can again be seen.

Fig. 5 shows a schematic view of a collision protection device 2 for protecting a battery system 1 according to a third embodiment of the present invention. According to a third exemplary embodiment, the connecting element 8 is completely inserted into the outer profile 4 and can be connected to the battery module 12 and/or the further battery module 12b and/or the further crash protection device 2b by means of the fastening element 14. The buffer layer 6 provided according to the invention is not currently shown according to the second embodiment for reasons of clarity of the illustration.

Fig. 6 shows a schematic view of the connection of two crash protection devices 2 according to a third embodiment of the invention for protecting a battery system 1. The outer profiles 4 of the two

crash protection devices

2,2b are in this case each arranged on a connecting

element

8,8b of the

crash protection devices

2,2b and are each fixedly connected to the connecting element by a screw connection. Furthermore, the connecting

elements

8,8b establish the connection between the two

crash protection devices

2,2b, which is currently implemented in the form of a force-fitting connection, so that the crash protection device 2 not only contributes to the stability and load absorption, but additionally to the connection to the other crash protection devices 2b and to the

battery modules

12,12 b.

Fig. 7 shows a schematic illustration of a battery system 1 according to the invention for use in a motor vehicle, which comprises a crash protection device 2 according to a third embodiment of the invention for protecting the battery system 1. The crash protection device 2 of the present battery system 1 comprises an outer profile 4, a connecting element 8 and a damping layer 6, which is not shown in the present case because of the illustration. Furthermore, the battery system 1 comprises a battery module 12, to which the impact protection device 2 is arranged on the outside and to which the impact protection device 2 is connected in a force-fitting manner by the connecting element 8. In addition to the fixed connection to the battery module 12, the connecting element 8 also has a non-positive fixed connection to the battery module 12b, which is likewise realized by the fastening 14, so that not only is the crash protection and load absorption of the battery module 12 ensured by means of the exemplary crash protection device 2 or by means of the connecting element 8 according to the invention, but additionally the connection of the

different battery modules

12,12b is also realized. Insofar as the two

battery modules

12,12b are fixed uniformly by means of the connecting element 8, the two fixing elements 14 are preferably arranged here at the same distance from the dividing line 20 of the

battery modules

12,12 b. Furthermore, the battery system 1 comprises a connecting rail 16 for connecting the connecting element 8 to the outer profile 4, by means of which connecting rail a connection to a further crash protection device 2b can now likewise be realized.

Fig. 8 finally shows a schematic illustration of a battery system 1 according to the invention for use in a motor vehicle, comprising a crash protection device 2 according to a fourth exemplary embodiment of the invention for protecting the battery system 1, according to the fourth exemplary embodiment, the outer profile 4 of the crash protection device 2 is not formed in the form of L and is currently positioned behind the connecting element 8 formed in the form of L, so that the outer profile 4 is arranged in a sandwich-like manner between the battery module 12 and the connecting element 8 according to the fourth exemplary embodiment of the crash protection device 2 or according to the second exemplary embodiment of the battery system 1.

As in the first exemplary embodiment of the exemplary battery system 1, in the second exemplary embodiment according to fig. 8, a further crash protection device 2b can also be arranged next to the first crash protection device 2.

With the aid of the crash protection device 2 according to the invention or the battery system 1 according to the invention and the method according to the invention for producing a typical battery system 1, it is possible in particular to provide a light and stable crash protection and load absorption for the battery system 1 in a simple and cost-effective manner. Furthermore, an additional connection possibility for the housing is provided by the crash protection device 2 according to the invention, so that the individual battery modules can be fixedly connected to one another and movement and destruction of the modules in the event of a crash is prevented. This makes it possible to use the modular construction of the battery system 1 without risk and thus to use a scalable and economical electric drive system without risk.

Claims

1. A crash protection device (2) for protecting a battery system (1) for use in a motor vehicle comprises

-an outer profile (4),

-a buffer layer (6) arranged inside the outer profile (4),

characterized in that the crash protection device (2) has a connecting element (8) for establishing a fixed connection between the crash protection device (2) and the battery module (12) and the further crash protection device (2b) and/or the further battery module (12 b).

2. Collision protection device (2) according to claim 1, characterized in that the outer profile (4) has a L-shaped cross section.

3. Collision protection device (2) according to claim 1 or 2, characterised in that an inner profile (10) is provided which is arranged inside the outer profile (4).

4. Collision protection device (2) according to any one of the preceding claims, characterized in that the inner profile (10) has an at least partially open structure.

5. Collision protection device (2) according to any one of the preceding claims, characterised in that the connecting element (8) is arranged directly at the outer profile (4).

6. Collision protection device (2) according to one of the preceding claims, characterized in that the connecting element (8) of the collision protection device (2) can be pushed at least partially into the outer profile (4) and/or the inner profile (10) of the collision protection device (2) and/or of a further collision protection device (2 b).

7. Collision protection device (2) according to any one of the preceding claims, characterised in that a connecting track (16) is provided for connecting the connecting element (8) with the outer profile (4).

8. A battery system (1) for use in a motor vehicle comprises

-a collision protection device (2) according to any one of claims 1 to 7,

-a battery module (12),

characterized in that the crash protection device (2) is arranged at the outer side of the battery module (12) and is fixedly connected to the battery module (12) and/or to a further crash protection device (2b) and/or to a further battery module (12b) by means of a connecting element (8) of the crash protection device (2).

9. The system according to claim 8, characterized in that a further crash protection device (2b) and a further battery module (12b) are provided, wherein the crash protection device (2) is fixedly connected to the battery module (12) and/or the further battery module (12b) and/or the further crash protection device (2b) by means of a connecting element (8) of the crash protection device (2), and the further crash protection device (2b) is fixedly connected to the battery module (12) and/or the crash protection device (2) and/or the further battery module (12b) by means of a connecting element (8b) of the further crash protection device (2 b).

10. A method for manufacturing a battery system (1) for use in a motor vehicle, comprising the steps of:

-connecting the crash protector (2) with the battery module (12) by means of a connecting element (8) of the crash protector (2),

-connecting the crash protector (2) with a further battery module (12b) by means of a connecting element (8) of the crash protector (2),

-connecting the further crash protector (2b) with the battery module (12) and/or the crash protector (2) and/or the further battery module (12b) by means of a connecting element (8b) of the further crash protector (2 b).