CN111525054B

CN111525054B - Battery bracket assembly

Info

Publication number: CN111525054B
Application number: CN201911370194.3A
Authority: CN
Inventors: 克里斯蒂安·布泽; 君特·福特迈耶; 卡洛琳·凯斯维特尔
Original assignee: Benteler Automobiltechnik GmbH
Current assignee: Benteler Automobiltechnik GmbH
Priority date: 2019-02-05
Filing date: 2019-12-26
Publication date: 2023-05-05
Anticipated expiration: 2039-12-26
Also published as: DE102019102754B4; DE102019102754A1; CN111525054A

Abstract

The invention relates to a battery carrier assembly for accommodating a plurality of battery modules for powering an electrically operable vehicle, the battery carrier assembly (100) comprising a cooling plate (101) adapted to cool the battery modules, the cooling plate (101) having a continuous cooling plate surface (103); a grid (105) having fixedly connected and grid-shaped webs (107, 121), wherein the grid (105) is arranged on the cooling plate surface (103) and bonded to the cooling plate surface (103) in a material-bonded manner; a deformation frame (109) surrounding the grid (105).

Description

Battery bracket assembly

Technical Field

The present invention relates to a battery carrier assembly for receiving a plurality of battery modules for powering an electrically operable vehicle.

Background

The battery carrier is usually arranged near the vehicle floor, in particular integrated in the vehicle floor below the vehicle interior. Further, the battery carrier may be integrated within the vehicle body to help maintain the structural integrity of the vehicle in the event of a vehicle collision, or to protect a battery disposed in the battery carrier. In the battery holder, an arrangement of transverse and/or longitudinal members may be arranged, which may increase the rigidity of the battery holder by means of a flange connection with the frame and/or the bottom plate of the battery holder. However, due to the flange connection, the installation space in the battery bracket is disadvantageously reduced. Furthermore, by connecting the cross members and/or the longitudinal members to the bottom plate, the introduction of a single large cooling plate may be prevented, so that, conversely, it may be necessary to introduce a plurality of separate cooling plates with increased space into the battery tray.

Disclosure of Invention

It is an object of the present invention to provide a more efficient battery carrier assembly which achieves, inter alia, increased structural integrity and efficient use of the available space for accommodating battery modules having a single large-area cooling plate.

This object is solved by the features of the independent claims. Advantageous embodiments are the subject matter of the dependent claims, the description and the figures.

The present disclosure is based on the recognition that the above object can be solved by a battery carrier assembly having a truss structure formed by a plurality of at least partially closed transverse and longitudinal profiles arranged on a cooling plate for accommodating a plurality of battery modules. The truss structure may be particularly elastically connected to the cooling plate, for example, in order to compensate for different thermal expansions of the cooling plate and the truss structure. By means of the closed design of the transverse and longitudinal profiles and the specific adhesive connection between the cooling plate and the transverse and longitudinal profiles, the rigidity of the battery carrier can advantageously be increased, whereby the impact properties of the battery carrier assembly can be improved.

According to a first aspect, the invention relates to a battery carrier assembly for accommodating a plurality of battery modules for powering an electrically operable vehicle, the battery carrier assembly having a cooling plate adapted to cool the battery modules. The cooling plate has a continuous and integral cooling plate surface.

In addition, the battery carrier assembly includes a grid having grid-like webs fixedly connected to one another. The grid is disposed on and bonded to the cooling plate surface. Further, the battery carriage assembly includes a deformation frame surrounding the grid. The deformation frame may be arranged on a cooling plate surface, in particular in one piece, and/or the deformation frame may be deformed by impact energy.

The cooling plate may in particular have channels through which a cooling medium flows in order to dissipate heat from the cooling plate. Furthermore, the cooling plate can have corresponding line connections for discharging and supplying the cooling medium. The cooling plate may also be adapted to temper the battery module, in particular also to heat. Furthermore, the cooling plate may have a higher thermal conductivity than the deformation frame and/or the grid, and may be made of, for example, steel, copper, an aluminum alloy or a copper alloy. The cooling plate may be adapted to entirely cover the bottom surface of the receiving space such that the battery module is thermally effectively coupled to the battery module at the corresponding battery bottom surface.

The cooling surface may also have a molded accommodation space, in particular an accommodation recess for accommodating a battery module. The receiving recess may be adapted to at least partially laterally restrain the respective battery module so as to prevent movement of the respective battery module when a lateral force acts on the vehicle. The cooling surface may be adapted to the corresponding bottom shape of the battery module to increase the support area of the battery module on the cooling surface. In particular, the heat transfer between the battery and the cooling plate can be advantageously increased thereby. Furthermore, a heat transfer connection layer may be arranged between the cooling surface and the battery module, which heat transfer connection layer is adapted to fill the gap between the cooling surface and the respective contact surface of the battery module. For example, the heat transfer connection layer may be a heat conductive pad, or may be formed of a heat conductive paste.

In particular, the grid may have regular grid cells, each of which may house at least one battery module. Furthermore, a plurality of battery modules may be combined in one of the regular grid units. The regular grid may be rectangular, in particular square. Furthermore, the grid cells may also be formed in the form of cylinders, hexagons or polygons. If the length and/or width of the grid does not correspond to an integer multiple of the grid cell length and/or the grid cell width, the grid cell length and/or the grid cell width of the grid cells at the edges of the grid may decrease.

In an embodiment, the grid is adapted to increase the stiffness of the battery carrier assembly. In particular, the advantage is achieved that forces acting on the battery carrier assembly can be introduced into and/or transmitted through the grid in order to prevent or reduce deformations of the battery carrier assembly. Advantageously, the grid is adapted to efficiently absorb forces acting parallel to the alignment plane of the grid.

By means of the kink-and/or bending-resistant adaptation of the grid, the advantage that in particular impact pulses introduced into the grid at the end faces of the grid are transmitted through the grid, in particular are elastically conducted, in order to avoid deformations of the battery carrier assembly can be achieved. In addition, in the event of a vehicle collision, the structural integrity of the battery assembly may also be obtained by the grid. For example, the deformation may be limited to other vehicle components that are less rigid, particularly the deformed frame.

In one embodiment, the grid may be adapted to absorb impact energy by deformation, in particular by compression and bending, to prevent or at least reduce deformation of other components of the battery carrier assembly. The webs may extend in the respective longitudinal direction and may be formed to be connected with the deformation frame at the connection points so that when forces act at the connection points in the longitudinal direction, they may be deformed, in particular folded and/or bent, to reduce or prevent further deformation, in particular in the accommodation space for the battery module. The webs may also be connected to one another at an intersection, wherein forces acting in a selected longitudinal direction of the webs may be transmitted along the intersection on other webs arranged transversely to the selected longitudinal direction. By this energy transfer, the further web may be deformed, in particular elastically deformed, by bending in order to absorb impact energy, while at the same time reducing plastic deformation of the battery carrier assembly.

In one embodiment, the grid and deformation frame are arranged directly on the cooling plate surface or simply on the cooling plate surface by receiving the tray. The receiving tray is preferably formed as a folded member or thermoformed part of sheet metal blank and has a bottom, a peripheral side wall and optionally a connecting flange. In particular, the metal plate blank of the receiving tray is made of a steel alloy. The receiving tray may accommodate a plurality of battery modules, wherein the cooling plate is disposed in the receiving tray.

Due to the modular structure of the grid and the deformation frame with the cooling plates, the grid and the deformation frame can be effectively formed with respect to the absorption of force and the cooling plates with respect to the absorption of heat from the battery upon occurrence of an impact. In particular, the grid, the deformation frame, the receiving tray and/or the cooling plate may be formed from different materials. Furthermore, the deformation frame and/or the grid may have a cross section and/or a preferred deformation direction in order to dissipate impact energy when an impact occurs, in particular to protect the battery module and/or the cooling plate from forces or deformations.

In one embodiment, a battery tray assembly includes a receiving tray for receiving a plurality of battery modules, wherein a cooling plate is disposed in the receiving tray

In one embodiment, the cooling plate may be in contact with the underside of the receiving tray. Further, the grids may be arranged in the receiving tray, in which the grids form accommodation spaces for the battery modules. The receiving tray may be used with the cooling plate and hold the cooling plate in the deformed frame.

In one embodiment, the grid and the deformation frame are directly connected to the cooling plate surface by material fit, in particular by gluing. The deformation frame may particularly form a holder for the cooling plate and/or the receiving tray. For example, a surrounding, horizontally oriented support web can be formed on the inner side of the deformation frame, on which support web the cooling plate rests with its underside. Furthermore, the bottom of the cooling plate may be glued to the support web.

In one embodiment, the receiving tray is located on the deformation frame. To this end, a peripheral retaining web may be formed on the receiving tray. The cooling plate, the deformation frame and/or the holding tray may have a rectangular basic shape, wherein the corners are inclined at a certain angle at the respective front ends.

In one embodiment, the cooling plate is arranged in the receiving tray and the grid is positioned on the cooling plate. Further, the cooling plate may be arranged with a cooling plate surface at the lower side of the deformation frame.

By connecting the receiving tray and/or the cooling plate surface to the grid and the deformation frame by means of an adhesive connection, the advantage is achieved in particular that the components can be connected to one another elastically and/or telescopically in order to compensate for different thermal expansions/vibrations and/or impact-related displacements.

In one embodiment, the webs of the grid are flangeless and have web surfaces facing the cooling plate surface or receiving tray, which are integrally connected to the cooling plate surface, in particular glued. Thus, for example, the following advantages can be achieved: the web surface has a reduced installation space, in particular advantageously a reduced contact surface for connection to the cooling plate surface. Thus, by the flangeless connection of the webs, the installation space available for the battery module space can advantageously be increased.

The web surface may particularly lie flat on the cooling plate surface or the receiving tray. An adhesive bond layer may be disposed between the web surface and the cooling plate surface, the adhesive bond layer being adapted to secure the web surface to the cooling plate surface by an adhesive connection. Furthermore, the connection layer may be formed such that the web surface is arranged in a fluid-tight and/or gas-tight manner on the cooling plate surface.

In one embodiment, the deformation frame has a circumferentially arranged frame web connected to the side wall and/or the connection flange of the receiving tray. The frame web may be formed in particular flangeless.

In one embodiment, the frame web has a web surface facing the cooling plate surface and/or receiving the tray. Furthermore, the web surface of the frame web is substantially bonded to the cooling plate surface or receiving tray. The frame webs may be bonded to the ends of the frame webs, in particular on the end faces of the frame webs, in order to form a continuously deformed frame, the frame webs also being connected to one another at an angle, in particular at right angles.

The deformation frame may form an inner receiving space for receiving the receiving tray, the cooling plate, and/or the battery element. On the side of the receiving space facing away from the frame web, a circumferential fastening projection can also be formed, which extends horizontally from the frame web and is in particular integrally connected to the frame web. The fastening projection may have a fastening means which accommodates a recess for fastening the deformation frame to the body element of the vehicle. For example, openings for receiving screws may be provided in the fastening protrusions to screw the battery bracket assembly to the body element through the fastening protrusions.

Further, a plurality of deformation regions may be formed in the fastening projection, each deformation region having a plurality of recesses arranged parallel to each other. The deformation zone is adapted to receive impact energy in the event of an impact and concentrate deformation of the deformation frame on the deformation zone. In particular, the deformation region may have a lower material stiffness and/or structural strength relative to an adjacent region of the deformation frame.

Furthermore, fastening strips may be integrally formed on the deformation frame, which fastening strips may contact the cooling plate and/or the body element in order to fasten the deformation frame, in particular to screw, rivet, bond or weld the cooling plate and/or the body element.

In one embodiment, the receiving tray is located on the cooling plate surface. Thus, for example, the following advantages can be achieved: the battery elements are fluidly insulated from the cooling plates such that liquid leaking from the cooling plates cannot contact the battery modules and/or liquid and/or gas leaking from the battery modules.

In one embodiment, the receiving tray is unitary and is defined by raised edges that form a deformed frame. In particular, the receiving tray may be integrally formed with the deformation frame, wherein the raised edge circumferentially delimits the receiving tray to provide a recess for accommodating the battery module, the cooling plate and/or the grid.

In one embodiment, the deformation frame is a separate component. Thus, for example, the following advantages can be achieved: an arrangement comprising a battery module, a cooling plate and/or a grid is detachably arranged in the deformation frame, which arrangement further comprises in particular power supply lines and/or coolant supply lines. In particular, the deformation frame may be connected to the receiving tray by screw connections, force-fit and/or form-fit connections or removable adhesive connections. First, the receiving tray may contact the deformation frame by the weight of the receiving tray, and in particular, the cooling plate and/or the battery module may be disposed in the receiving tray. In a further production step, the receiving tray can be fixed by bringing together the other body parts in the deformation, in particular under pressure with the application of a normal force.

In one embodiment, the grid has an outer web, the web-connecting surfaces of the webs, particularly the end faces, defining the grid. The deformation frame may have a frame web arranged in the circumferential direction. Furthermore, the outer webs can be fastened to the side walls of the receiving tray or to the frame webs arranged therearound, in particular by means of screw connections or rivet connections. In one embodiment, the outer web may be connected to an end face of a circumferentially arranged frame web.

The outer web is in particular flush with the side surfaces of the frame web. Furthermore, the outer webs can be fixed to one another by means of angle elements which are placed on the sides of the frame web and the outer webs. For example, a first leg of the angle element may be screwed, riveted, welded and/or glued to the frame web, while a second leg of the angle element may be screwed, riveted, welded and/or glued to the corresponding outer web.

By connecting the frame web to the outer web, an efficient transfer of forces from the frame web to the outer web and thus to the entire web can be achieved, in particular in the event of an impact. Corresponding portions of the outer web may be arranged in particular on the end-side connection of the outer web to the frame web in order to concentrate or limit the deformation of the grid to the outer web, in particular to these portions. Furthermore, it is possible to achieve an advantage in that deformation of the receiving tray, the cooling plate, and/or the battery module can be reduced or prevented.

By means of the angle elements, the outer web can be reinforced in order to achieve an increased stiffness where the outer web is attached to the frame web.

In one embodiment, each of the outer webs of the grid has a height that increases toward the deformed frame. The height at the end facing the deformation frame may be between 5% and 50%, preferably between 10% and 30%, greater than the height at the opposite end of the outer web.

In particular, an effective absorption of forces from the deformation frame to the grid can thereby be achieved. Furthermore, the deformation preferential direction of the outer web may be defined by an increased height. As the height increases, the cross-sectional area of the outer web also increases towards the deformation frame, thereby making the transfer of force from the deformation frame to the outer web more efficient. In particular, in the event of an impact, the forces from the deformation frame acting on the respective outer web can act on the increased cross section, so that the pressure acting on the respective outer web can be reduced. In particular, bending or bending of the frame web can thereby be reduced and/or prevented. In particular, the outer web may be formed to absorb the forward force by stretching, widening of the cross section or reshaping the area of increased height without deforming the portion of reduced height. In particular, the outer web may form a force introduction point of the grid. The grid may be dimensionally stable when forces act on the battery carrier assembly and/or may in particular prevent inelastic deformation of the grid.

In one embodiment, each of the outer webs of the grid has a portion at the ends, wherein the portions are connected to the frame webs. Thereby, the advantage can be achieved that the deformation of the grid can be predetermined. Furthermore, during the transfer of forces from the deformation frame to the grid through the connection points between the frame web and the outer web, the deformation of each of said parts can be triggered, while the remaining webs are not deformed or are deformed only to some extent. In particular, the absorption of forces by deformation of the portions may be achieved by localized definition.

In one embodiment, these portions are integrally formed on the outer web of the grid. In particular, the deformation of the outer web may be limited to these portions to prevent deformation of the grid in the receiving area for the battery module.

In one embodiment, the outer web is integrally formed from a bent sheet of metal. In particular, the outer web may comprise these portions or may be integrally formed with these portions. Hereby the advantage is achieved that these parts and/or the outer web can be manufactured efficiently. For example, the stiffness of the outer web may be adjusted by the shape of the outer web or bending of the sheet, respectively.

In one embodiment, the web of the grid is a hollow profile, in particular a closed or semi-open hollow profile. Furthermore, the web may be formed from an extruded profile. Thus, for example, the following advantages are achieved: the web may have a lighter weight than a solid material. Furthermore, hollow profiles can be extruded to achieve different cross-sectional profiles of the web. The web may further comprise a web receiving recess and/or a form-fitting connection portion adapted to receive a further web extending transversely to the longitudinal direction into which the respective web extends. The form-fitting connection can be suitable in particular for connecting two webs perpendicularly to one another in a form-fitting manner. The form-fitting connection can be formed by a recess in the web.

In one embodiment, the webs of the grid each have a longitudinal cross-section that is U-shaped and/or a rectangular cross-section. In the case of a rectangular, in particular closed, cross-section of the web, for example, the advantage can be achieved that the web has an increased stiffness compared to a semi-open hollow profile. In particular, deformation of the rectangular closure web can be reduced during the application of force.

In one embodiment, web-receiving beads for receiving the web of the grid are formed on the cooling plate surface.

In one embodiment, the receiving tray has beads adapted to at least partially receive the cooling channels of the cooling plates, so as to prevent the cooling plates from being tiled only on the receiving tray by means of the cooling channels. The cooling channels may in particular protrude from the planar shaped cooling plate surface. By having beads, the receiving tray may also be adapted to receive the cooling plates at least partially in a form-fitting manner, wherein the cooling channels of the cooling plates protrude into the beads. In particular, the following advantages can be achieved in this way: the cooling channel is protected from deformation by the receiving tray during the application of force due to the impact of the vehicle.

In one embodiment, the cooling plate may be adapted to function as a push plate wherein the battery carriage assembly has enhanced resistance to deformation upon impact and/or compression.

According to a second aspect, the invention relates to a method for manufacturing a battery carrier assembly with a cooling plate, which cooling plate is suitable for cooling a battery module, wherein the cooling plate has a continuous and integral cooling plate surface, the battery carrier assembly further has a grid, which is torsion-resistant and is intended to receive impact energy, wherein the grid has interconnected grid-like webs, and wherein the grid is arranged on the cooling plate surface and is connected in a material-bonded manner to the cooling plate surface, and wherein the battery carrier assembly further has a deformation frame, which surrounds the grid. The method includes providing a cooling plate and a grid.

Furthermore, the method comprises bonding the grid and the cooling plate by means of material bonding, in particular by bonding the grid and the cooling plate to the cooling plate surface and providing a deformed frame.

Furthermore, the method comprises attaching the cooling plate to the deformation frame directly by coupling the cooling plate surface to the bottom of the deformation frame and/or by coupling the cooling plate to a bottom flange of the deformation frame, or indirectly by coupling the receiving tray to the bottom of the cooling plate and the receiving tray to the deformation frame.

In one embodiment of the method, the grid has an outer web that increases its height towards the deformation frame, which outer web is U-O shaped (U-O shaped) and/or welded into hollow profiles in a plurality of stamping die stages before being coupled to the cooling plate.

In one embodiment, the method further comprises arranging the receiving tray on the deformation frame and attaching the receiving tray to the deformation frame, in particular by gluing.

Drawings

Other embodiments will be explained with reference to the drawings. The drawings show:

fig. 1 shows a battery carrier assembly profile in one embodiment.

Fig. 2A illustrates a battery carriage assembly in an embodiment.

Fig. 2B illustrates a battery carriage assembly in an embodiment.

Fig. 3A, 3B illustrate a web in one embodiment.

Fig. 3C illustrates a grid in an embodiment.

Fig. 3D illustrates a grid in an embodiment.

Fig. 4 illustrates a battery carriage assembly in an embodiment.

List of reference numerals:

100. battery bracket assembly

101. Cooling plate

103. Cooling plate surface

105. Grid structure

107-1 web

107-2 web

107-3 web

107-4 web

107-5 web

107-6 web

109. Deformation frame

111. Receiving tray

113. Web surface

115-1 frame web

115-2 frame web

115-3 frame web

115-4 frame web

117-1 web connection surface

117-2 web connection surface

117-3 web connection surface

117-4 web connection surface

117-5 web connection surface

117-6 web connection surface

117-7 web connection surface

117-8 web connection surface

117-9 web connection surface

117-10 web connection surface

117-11 web connection surface

117-12 web connection surface

119. Raised edge

121. Web plate

121-1 outer web

121-2 outer web

121-3 outer web

121-4 outer web

121-5 outer web

121-6 outer web

121-7 outer web

121-8 outer web

121-9 outer web

121-10 outer web

121-11 outer web

121-12 outer web

123. Fastening projection

125. Part of the

127. Concave part

129. Supporting web

301. Web contact surface

303-1 fastening recess

303-2 fastening recess

401-1 web

401-2 web

403. Web plate

407-1 part

407-2 part

409. Bottom part

411-1 side wall

411-2 side wall

413. Connecting flange

415. Bottom flange

Detailed Description

Fig. 1 shows a schematic perspective view of a battery carrier assembly 100, the battery carrier assembly 100 being adapted to house a plurality of battery modules for providing power to an electrically operable or electrically drivable vehicle. The battery carrier assembly 100 comprises a cooling plate 101, which cooling plate 101 is adapted to cool a battery module and has a continuous and integral cooling plate surface 103.

In addition, the battery carrier assembly 100 includes a grid 105 adapted to increase the rigidity of the battery carrier assembly 100 and having interconnecting grid-like webs 107-1-107-6. The grid 105 is arranged on the integrated cooling plate surface 103. Further, the battery carrier assembly 100 comprises a deformation frame 109 surrounding the grid 105 and arranged on the cooling plate surface 103 and connected to the cooling plate surface 103 by means of a material bond.

The grid 105 and the deformation frame 109 are arranged directly on the cooling plate surface 103. Furthermore, the grid 105 and the deformation frame 109 are directly bonded to the cooling plate surface 103 by means of a material bond, in particular by means of gluing. The webs 107-1-107-6 of the grid 105 are flangeless and have web surfaces facing the cooling plate surface 103, wherein the web surfaces of the webs 107-1-107-6 of the grid 105 are connected to the cooling plate surface 103 by means of a material bond.

Furthermore, the deformation frame 109 has a circumferentially arranged and flangeless frame web 115-1 to 115-4, which frame web 115-1 to 115-4 has a web surface facing the cooling plate surface 103, wherein the web surfaces of the frame webs 115-1 to 115-4 are bonded to the cooling plate surface 103 by means of material bonding.

The grid 105 has outer webs 121-1 to 121-12, the end faces of which outer webs 121-1 to 121-12 delimit the grid 105, wherein the outer webs 121-1 to 121-12 are connected at their front to the circumferentially arranged frame webs 115-1 to 115-4, in particular by screw connections or rivet connections. Furthermore, the outer webs 121-1 to 121-12 may be connected to the circumferentially arranged frame webs 115-1 to 115-4 at their front face.

The deformation frame 109 together with the grid 105 may form a plurality of battery receiving spaces formed on the front surface of the battery tray assembly 100, the plurality of battery receiving spaces having a reduced volume, or a reduced floor area, as compared to other battery receiving spaces. In particular, these battery receiving spaces may have at least one beveled side at the edge of the battery carriage assembly 100. These edge cell receiving spaces may be limited, for example, by frame webs 115-1, 115-4, outer webs 121-1, 121-12, and frame webs 115-1, 115-2, outer webs 121-2, 121-3, respectively. Another reduced volume receiving space may be defined by frame web 115-1, outer webs 121-1, 121-2, web 107-3, frame web 115-1.

The grid 105 and deformation frame 109 may be made of steel and may be electro-coated. In particular, an electrophoretic coating may be formed on the grid 105 and/or the deformation frame 109. Thereby, in particular, an advantage of effective bonding is obtained, since by coating, the adhesion of the adhesive on the grid 105 and the deformation frame 109 can be improved.

The deformation frame 109 may form an inner receiving space for receiving the cooling plate 101 and/or the battery element. On the side of the receiving space facing away from the frame webs 115-1 to 115-4, a circumferential fastening projection 123 can also be formed, which circumferential fastening projection 123 extends horizontally from the frame webs 115-1 to 115-4 and is bonded to the frame webs 115-1 to 115-4, in particular by means of a material bond. The fastening projection 123 may have a fastening means which accommodates a recess for fastening the deformation frame to the body element of the vehicle. For example, openings for receiving screws may be provided in the fastening protrusions in order to screw the battery carrier assembly 100 to the body element by means of the fastening protrusions 123.

In the fastening projection 123, a plurality of parallel recesses 127 may be further formed, wherein the recesses 127 are arranged in groups, in particular 5 recesses 127 spaced apart from each other are grouped.

Fig. 2A shows an exploded perspective view of the battery tray assembly 100, the battery tray assembly 100 including a grid 105, a cooling plate 101, a receiving tray 111, and a deformation frame 109. The grid 105 may be placed on the cooling plate 101, wherein the grid 105 may be glued, in particular expandable and thermally insulated, with the cooling plate 101. The cooling plate 101 may be disposed in the receiving tray 111 together with the grid 105.

The web of grid 105 has web connection surfaces 117-1-117-12, which web connection surfaces 117-1-117-12 may be connected to receiving tray 111. In particular, the webs can be fastened to the receiving tray 111 by means of connecting elements, wherein these connecting elements are adapted to compensate for tolerance ranges, in particular gaps between the grid 105 and the receiving tray 111. Further, a receiving tray 111 is arranged in the deformation frame 109, and the receiving tray 111 is located on the cooling plate surface, particularly the cooling plate bottom surface.

The receiving tray 111 is integrally formed and defined by raised edges 119, wherein the raised edges 119 are formed to contact the deformation frame 109. The deformation frame 109 and the receiving tray 111 are separate components.

Fig. 2B illustrates an exploded perspective view of the battery tray assembly 100 according to the embodiment illustrated in fig. 2A, wherein the battery tray assembly 100 does not include a receiving tray.

The cooling plate 101 is adapted to engage in a recess of the deformation frame 109. In particular, the deformation frame 109 may form a holder for the cooling plate 101. On the inner side of the deformation frame 109, a circumferentially and horizontally oriented support web 129 is formed, on which support web 129 the cooling plate 101 is placed with its underside. Furthermore, the underside of the cooling plate may be glued to the support web 129.

In the cooling plate surface 103, beads may be formed to receive the web of the grid 105.

Fig. 3A shows a schematic cross-sectional view of an outer web 121 formed by a hollow profile. The web 121 has a rectangular contour on the bottom side and an oval, in particular circular, contour on the top side. The web 121 may be made of sheet metal or a semifinished part, in particular bent or pressed. The web 121 is flangeless and has a web support surface 301 facing the cooling plate surface or receiving tray, the web support surface 301 being bonded to the cooling plate surface or receiving tray in a material bond.

Fig. 3B shows a schematic side view of the outer web 121 of the embodiment shown in fig. 3A. The outer web 121 has a height that rises to the deformation frame 109. Finally, the web 121 has a portion 125, wherein the portion 125 is connectable to the frame web. The portion 125 has on both sides thereof a pair of and opposite fastening recesses 303-1, 303-2, which fastening recesses 303-1, 303-2 are formed in particular by openings in the sheet metal material.

For example, connecting elements adapted to fasten the web 121 to the deformation frame may be fastened to the fastening recesses 303-1, 303-2.

The web 121 is free of flanges and has a web surface 113 facing the cooling plate surface 103, wherein the web surface 113 can be connected to the cooling plate surface or receiving tray in a material-bonded manner.

Fig. 3C shows a schematic perspective view of the grid 105 having webs 107-1-107-6 and outer webs 121-1-121-12. In particular, the outer webs 121-1 to 121-12 have an at least partially open contour on the side facing the receiving tray and/or the cooling plate. Further, the outer webs 121-1-121-12 at each end include portions 125 corresponding to the embodiment shown in FIG. 3B. Furthermore, the outer webs 121-1 to 121-12 may be formed in the region of the portion 125, in particular on the respective web connecting surface 117-1, in a semi-circular or U-shape and/or may have a closed contour. In particular according to the profile of the embodiment shown in fig. 3A, and can be removed from the respective portion 125. The webs 107-1 to 107-6 and 121-1 to 121-12 are formed by UO forming (U-O-forming) in a plurality of stamping tool stages, each of which is made from a single sheet of sheet metal, particularly high strength steel.

Fig. 3D shows a schematic perspective view of grid 105 having webs 107-1-107-6 and outer webs 121-1-121-12. The webs 107-1-107-6 and the outer webs 121-1-121-12 have rectangular cross sections. The webs 107-1, 107-2 are arranged parallel to each other and, in particular, at right angles, transversely to the outer webs 121-3 to 121-6 and 121-9 to 121-12. The webs 121-2 and 121-7 form end webs of the web 107-2 and are integrally formed with the web 107-2. The webs 121-1 and 121-8 form end webs of the web 107-1 and are integrally formed with the web 107-1. The webs 107-1 to 107-6 and 121-1 to 121-12 are in particular extruded profiles.

Fig. 4 shows a schematic partial perspective view of the battery carrier assembly 100, wherein the grid 105 is formed by webs 401-1, 401-2 and web 403. The webs 401-1, 401-2 correspond to the embodiment shown in fig. 3B, respectively, wherein the web 403 has a rectangular profile. The deformation frame 109 is formed by a hollow chamber profile which forms a partially form-fitting connection with the receiving tray 111. In particular, the receiving tray 111 may be screwed, riveted and/or clamped to the deformation frame 109.

The webs 401-1, 401-2 of the grid 105 each have portions 407-1, 407-2 at their ends that are connected to the frame web 115-1. Furthermore, the portions 407-1, 407-2 are formed from bent sheet metal and the respective portions 407-1, 407-2 are integrally formed with the webs 401-1, 401-2, respectively, of the grid 105.

The receiving tray 111 is formed as a folded member or formed part of sheet metal blank and includes a bottom 409, circumferential side walls 411-1, 411-2 and a connecting flange 413. The deformation frame 109 has frame webs 115-1, 115-2 arranged in the circumferential direction, which frame webs 115-1, 115-2 are connected to the side walls 411-1, 411-2 of the receiving tray 111 and to the connecting flange 413.

Furthermore, the deformation frame 109 has a bottom flange 415, which bottom flange 415 at least partially surrounds the bottom 409. The receiving tray 111 is located on the bottom flange 415 by means of the bottom 409.

Claims

1. A battery carrier assembly (100) for receiving a plurality of battery modules for powering an electrically operable vehicle, comprising:

a cooling plate (101) adapted to cool the battery module and having a continuous cooling plate surface (103);

-a grid (105) with fixedly connected grid-like webs (107, 121), wherein the grid (105) is arranged on the cooling plate surface (103) and bonded to the cooling plate surface (103) in a material-bonded manner; and

-a deformation frame (109) arranged around the grid (105);

the grid is adapted to increase the rigidity of the battery carrier assembly (100);

the battery tray assembly (100) comprises a receiving tray (111) for accommodating the plurality of battery modules, wherein the cooling plate (101) is arranged in the receiving tray (111);

the receiving tray (111) is formed from sheet metal blank as a folding or forming member, wherein the receiving tray (111) has a bottom (409), circumferential side walls (411-1, 411-2) and a connecting flange (413);

the grid (105) has outer webs (121), the height of each of the outer webs (121) of the grid (105) increasing towards the deformation frame (109).

2. The battery tray assembly (100) of claim 1, wherein the grid (105) and the deformation frame (109) are directly connected to the cooling plate surface (103) by material bonding.

3. The battery tray assembly (100) of claim 2, wherein the grid (105) and the deformation frame (109) are directly connected to the cooling plate surface (103) by gluing.

4. The battery tray assembly (100) of claim 2, wherein the webs (107, 121) of the grid (105) are flangeless and have web surfaces (113) facing the cooling plate surface (103) or the receiving tray (111), wherein the web surfaces (113) of the webs (107, 121) of the grid (105) are glued to the cooling plate surface (103).

5. The battery tray assembly (100) according to claim 1, wherein the deformation frame (109) has a frame web (115) arranged circumferentially, the frame web (115) being connected to the side wall (411) and/or the connection flange (413) of the receiving tray (111).

6. The battery tray assembly (100) according to any of the preceding claims, wherein the web connection surface (117) of the outer web (121) defines the grid (105), wherein the outer web (121) is fastened by its connection surface to a side wall (411-1, 411-2) of a receiving tray (111) or to a circumferentially arranged frame web (115).

7. The battery tray assembly (100) according to claim 6, wherein the outer web (121) is fastened to the side walls (411-1, 411-2) of the receiving tray (111) or the circumferentially arranged frame web (115) by means of a screw connection or a rivet connection through its connection surface.

8. The battery carrier assembly (100) of claim 1, wherein the outer web (121) is integrally formed from a bent metal sheet.

9. The battery carrier assembly (100) according to any one of claims 1-5, wherein the webs (107, 121) of the grid (105) are hollow profiles.

10. The battery carrier assembly (100) of claim 9, wherein the webs (107, 121) of the grid (105) are closed hollow profiles.

11. The battery carrier assembly (100) of any of claims 1-5, wherein each of the webs (107, 121) of the grid (105) has a U-shaped longitudinal section and a rectangular cross section.

12. The battery tray assembly (100) according to any one of claims 1-5, wherein beads for receiving webs (107, 121) of the grid (105) are formed in the cooling plate surface (103).

13. A method of manufacturing a battery carrier assembly, the battery carrier assembly comprising: a cooling plate adapted to cool a battery module, the cooling plate having a continuous cooling plate surface (103); -a grid (105) formed torsion-resistant and for receiving impact energy, wherein the grid (105) comprises grid-like webs (107, 121) fixedly connected to each other, the grid (105) being arranged on the cooling plate surface (103) and being connected to the cooling plate surface (103) in a material-bonded manner; a deformation frame (109) surrounding the grid (105), the method comprising:

-providing the cooling plate (101) and the grid (105);

-coupling the grid (105) and the cooling plate (101) in a material-bonded manner, in particular by gluing the grid (105) and the cooling plate (101) to the cooling plate surface (103);

-providing the deformation frame (109);

-attaching the cooling plate (101) directly to the deformation frame (109) by coupling the cooling plate surface (103) to the bottom side of the deformation frame and/or by coupling the cooling plate (101) to a bottom flange of the deformation frame (109), or-indirectly attaching the cooling plate (101) to the deformation frame (109) by coupling a receiving tray (111) to the bottom of the cooling plate (101) and coupling the receiving tray (111) to the deformation frame (109);

wherein the grid is adapted to increase the rigidity of the battery carrier assembly (100);

14. The method according to claim 13, characterized in that the grid (105) has an outer web increasing in height towards the deformation frame (109), which outer web is U-O shaped or molded into a hollow section in a plurality of stamping die stages before being coupled with the cooling plate (101).