DE102017217814A1 - Battery housing for a vehicle - Google Patents

Abstract

The invention relates to a battery housing (1) for a vehicle, comprising - a box (2), which is formed of a particular laterally encircling outer frame (3) and at least a first floor (4), - a support frame (6) with a laterally circumferential boundary (6.1) and a within the lateral boundary by at least one cross member (6.2) and / or at least one longitudinal member (6.3) formed compartment structure (6.4) for receiving battery elements, which integrally made of plastic, in particular by injection molding, in the interior ( 2.1) of the box (2) is arranged, - a cover (9) for at least partially covering the interior (2.1) of the box (2).

Description

Technical Field

The invention relates to a battery housing for a vehicle.

Technical Background (Background Art)

The increasing or prolonged electrification of vehicles, in particular of automobiles, and the simultaneous customer request for long ranges of such vehicles, require the development of powerful battery concepts. In particular, battery housing, which receive the batteries or in which the batteries are integrated, usually have a substantial extent over the vehicle floor, which is located in particular substantially below the passenger compartment of the vehicle. This results in complex requirements with regard to the factors installation space, crash performance, weight, tightness, etc.

The battery case is of particular importance in order to ensure high reliability even in the event of a crash. The battery case must be able to withstand not inconsiderable mechanical loads, which can act both laterally, frontally, rearwardly or from below. The occurring loads can be represented by quasistatic substitute load cases, but their treatment can be very demanding, since no damage to the battery or individual battery elements should occur as possible.

Battery housings for vehicle batteries are well known. Essentially, two prior art designs are known. The first construction forms a so-called built battery case made of sheet metal, cast and / or profile components. This has a good ratio of crash performance and space requirements based on the effective for the battery respectively battery elements usable, substantially sealed interior of the battery case. A major challenge is the sealing of the interior of the battery case, especially in the corners, since in the corners several components must be joined together, so that thereby the tightness can be impaired. The second construction form battery housing, in which the sealed interior of the battery case is provided by a trough-like, substantially integrally formed component. The trough-like component is relatively easy to seal by a substantially flat overlying lid, which can optionally be reinforced within and / or outside by additional components in terms of better crash performance. A major disadvantage of especially deep-drawn, tub-like components is that Entformschrägen and along the edges and in the corners large radii must be provided, which reduce the space inside the housing.

In both designs, the accessibility for mounting the battery or battery elements is also very limited and only one-sided, mostly only from above possible. It is usually a variety of different small parts, such as Anschraubdome, plates or consoles needed, which must be connected in complex processes in the manufacture of the battery case. The mounting clearances are typically small. In both constructions, a cover must be used to cover the interior of the battery case, which must be made removable for repair and maintenance, which makes a complex sealing solution necessary.

With respect to the prior art, there is a need for a battery case, which in particular combines the advantages of the two designs and at the same time simplifies the manufacturing process and the installation effort when inserting the battery or battery elements.

Summary of Invention

The invention is based on the object to provide an improved compared to the prior art battery housing for a vehicle.

This object is achieved by a battery housing for a vehicle with the features of claim 1. Further advantageous embodiments of the invention are listed in the dependent claims.

• - einen Kasten, welcher aus einem insbesondere seitlich umlaufenden Außenrahmen und zumindest einem ersten Boden gebildet ist,
• - einen Trägerrahmen mit einer seitlich umlaufenden Begrenzung und einer innerhalb der seitlichen Begrenzung durch mindestens einen Querträger und/oder mindestens einen Längsträger gebildete Fachstruktur zur Aufnahme von Batterieelementen, welcher einstückig aus einem Kunststoff, insbesondere im Spritzgussverfahren hergestellt, im Innenraum des Kastens angeordnet ist,
• - einen Deckel zum zumindest bereichsweisen Abdecken des Innenraums des Kastens, umfasst.

According to the invention, a battery housing is provided for a vehicle, which

• a box, which is formed from an in particular laterally encircling outer frame and at least one first floor,
• a support frame having a laterally encircling boundary and a compartment structure formed within the lateral boundary by at least one cross member and / or at least one longitudinal member for receiving battery elements, which is integrally formed from a plastic, in particular by injection molding, in the interior of the box,
• - A lid for at least partially covering the interior of the box comprises.

The inventors have found that by providing a support frame made of plastic, which is produced in particular by injection molding, a better utilization of the installation space compared to the prior art by a circumferential substantially vertically continuous, substantially in the direction of the interior of the box facing lateral Limiting and a largely substantially rectangular shape formed by a formed within the lateral boundary by at least one cross member and / or at least one longitudinal member compartment structure for receiving battery elements can be provided. Due to the one-piece, circumferentially running lateral boundary a substantially dense design in the corners of the support frame / battery case is guaranteed, so that the outer frame is no longer subject to the very high requirements in terms of tightness and the cost of manufacturing in particular the corners. The geometry, in particular the cross section of the circumferential lateral boundary, is essentially unlimited due to the preferably injection molding process. For example, recesses may be provided on the outer side of the lateral boundary facing away from the interior so that in particular stiffening structures, for example in the form of ribs and / or honeycombs, may be formed.

The interior of the facing side of the lateral boundary may be at least partially substantially flat and formed in the corners almost sharp-edged. The support frame can be reinforced at least regionally and / or as needed with fillers suitable for the injection molding process and the selected material. Furthermore, the above and optionally open bottom design of the support frame simplifies the accessibility and associated with the mounting of the battery elements considerably. The cover and the second floor, which acts as an underrun protection, consist in particular of a metallic material, preferably of a steel material, particularly preferably of a steel material with a tensile strength of at least 780 MPa. Alternatively, the cover and / or the underrun protection may be made of a plastic, whereby although the total weight of the battery case can be reduced, but the use of plastic can go at the expense of crash performance, which is inferior compared to the use of metallic materials. The outer frame is preferably assembled from one or more profiles, which in particular consist of a metallic material, preferably of a steel material with a tensile strength of at least 1000 MPa, more preferably of a hardened steel material with a tensile strength of at least 1500 MPa. As the tensile strength increases, so does the resistance in the event of a crash, especially if the outer frame is not allowed to deform slightly in the event of a crash, in order to protect the carrier frame or the battery elements received in the carrier frame from damage.

According to a first embodiment are on the support frame in one or more points of intersection of the cross member or with the longitudinal beams and / or in one or more points of intersection of the cross member or with the lateral boundary and / or in one or more points of intersection of the longitudinal beams or with the lateral boundary each integrated at least one functional element. On the carrier frame, which is preferably produced by injection molding, functional elements can be injected and / or injected, in particular integrated, directly into the injection molding process. Functional elements may be, for example mounting elements for battery elements, in particular in the form of injected nuts in Anschraubböcken; Fastening elements for mechanical joining of cover and / or floor, in particular for positive and / or non-positive joining, for example in the form of snap hooks, latching hooks and / or Anschraubdome; Spacer; Fasteners for electrical and / or cooling elements, in particular terminals for cables, cooling pipes, etc.

To increase the crash performance and in particular to prevent buckling or failure of the cross member and / or the or the side members, according to a further embodiment, metallic inserts are provided in the compartment structure of the support frame respectively integrated. The inserts can in the manner of a lattice structure in the support frame preferably produced by injection molding, in particular injection molded directly or inserted in the finished molded support frame in designated cavities or received, optionally fixed and / or optionally encapsulated, so that the inserts in the or the cross members and / or in the or the longitudinal members of the support frame are integrated and serve to reinforce the interior of the box.

According to a further embodiment, the circumferential lateral boundary of the support frame, at least in the upper region, has an essentially flat upper flange surface for the in particular sealing connection with the cover. Preferably, the lid is joined to the upper flange surface of the support frame, in particular materially bonded, preferably glued and / or mechanically joined with sealing means, in particular by a positive and / or non-positive, preferably releasable connection. Regardless of the connection between the lid and upper Flange surface of the support frame, a tight connection must be ensured to prevent ingress of foreign substances, especially splash water during operation in the installed state of the battery case, in the interior or battery compartment.

According to a further embodiment, the circumferential essentially flat upper flange surface has a seal already integrated in the support frame. This can be inserted as a separate component in an optional groove in the flange or in the lid.

According to a further embodiment, an at least partially arranged for connection of the battery case to the vehicle profile, also called mounting profile, attached to the outer frame. The mounting profile may be composed of one or more parts and in particular of a metallic material, preferably made of a steel material with a tensile strength of at least 980 MPa. The mounting profile is in particular materially connected to the outer frame. Preferably, the outer frame and the mounting profile are welded together to provide a particularly stable design of the battery case can.

According to a further embodiment, the circumferential lateral boundary of the support frame in the lower region has a substantially flat bottom flange surface for the particular sealing connection with a second bottom. Preferably, the second bottom is joined to the lower flange surface of the support frame, in particular materially bonded, preferably glued and / or mechanically joined with sealing means, in particular by a positive and / or non-positive, preferably releasable connection. The second floor consists in particular of a metallic material, preferably of a steel material with a tensile strength of at least 780 MPa. Regardless of the type of connection between the second floor and lower flange surface of the support frame, a tight connection must be ensured in order to prevent ingress of foreign substances, in particular splashes during operation in the installed state of the battery case, in the interior or battery compartment.

According to a further embodiment, a seal is molded onto the flange surface in the upper and / or lower region of the support frame. The integration provides a seal for a releasable connection to the cover and / or the second floor, in particular captive with sufficient tightness.

In order to simplify a seal down, according to an alternative embodiment, the support frame may be integral with a second floor. This is preferably taken into account in the injection molding of the support frame, so that a only upwardly open, laterally and downwardly dense support frame can be provided in a battery case. Particularly preferred in the second floor on the side facing away from the compartment structure channels integrally formed respectively integrated, so that in the injection molding preferably also cooling channels for later passing cooling media are taken into account, whereby the number of parts and the assembly cost can be reduced. An advantage of the integrated cooling channels compared to a cooling arranged under the second floor is the avoidance of component transitions and thus a more effective heat transfer. For example, the channels can be manufactured by an injection molding process.

The first floor or underrun protection and the second floor together form, in particular with the lower part of the peripheral outer frame, a space, also called cooling space, in which, in particular, cooling elements for cooling the interior or the cooling space and other elements are arranged. In order to allow easy access to these elements or to the cooling chamber, in particular in the installed state of the battery case, the first floor or underrun protection according to a further embodiment is releasably connected to the outer frame.

Between the first floor or underrun protection and the second floor elements can be used, which pass from below to the underrun protection acting stresses in the adjacent structure. These may be, for example, profile-like carrier, which are attached to the underrun protection or on the second floor. In the embodiment in which the support frame is formed integrally with a second floor, for this purpose, at least one support rib, which is integrated in the bottom on the side facing away from the compartment structure of the support frame, exposed by the injection molding down and / or over, for example the provision of metallic inserts down to the underride protection are extended.

Some large battery cases are not only connected to the mounting profile with the body but may have additional attachments to the body within the battery compartment. In these cases, for example, sleeves are used, which the interior or battery compartment to the lid and the first and / or second Seal the bottom so that it can be screwed from below through the sleeve. The production and integration of sleeves made of metal is complex manufacturing technology. In a carrier frame made of plastic, the at least one sleeve can be integrated without additional manufacturing effort. The at least one sleeve is provided at the top of the contact surface to the cover and at the bottom of the contact surface to the first and / or second bottom respectively the underrun protection with a seal, which is preferably molded. Preferably, a plurality of sleeves in the compartment structure of the support frame are integrated respectively embodied in one piece with the support frame.

• - Geringere Entformschrägen und kleinere Radien entlang der Kanten und in den Ecken gegenüber beispielsweise tiefgezogenen Wannen ermöglichen mehr Bauraum für die Batterie respektive Batterieelemente,
• - Gute Zugänglichkeit bei der Montage der Batterieelemente,
• - Der einstückige Trägerrahmen ist entlang des Rahmens dicht und gegenüber dem Boden und dem Deckel steht eine ebene, ununterbrochene Dichtfläche zur Verfügung,
• - Trennung von Innenraum/Batterieraum und Kühlraum,
• - Aufgrund der geringen Dichte ist der Kunststoff Gewichtseffizient,
• - Das Kunststoffbauteil ermöglicht die Integration von Funktionen z.B. die Anbindungsstellen der Batterieelemente oder Fixierungsmöglichkeiten für Kabel und/oder Schläuche,
• - Da der Kunststoff isolierend ist, wird die Gefahr von Kurzschlüssen bei Beschädigung des Batteriegehäuses reduziert.

The preferred use of a support frame formed in one piece from a plastic has the following advantages over known battery housings:

• - Lower Entformschrägen and smaller radii along the edges and in the corners opposite, for example, deep-drawn trays allow more space for the battery or battery elements,
• Good accessibility when mounting the battery elements,
• - The one-piece support frame is sealed along the frame and opposite the bottom and the lid is a flat, uninterrupted sealing surface available,
• - Separation of interior / battery compartment and refrigerator,
• Due to the low density of the plastic weight efficiency,
• - The plastic component allows the integration of functions such as the connection points of the battery elements or fixing options for cables and / or hoses,
• - Since the plastic is insulating, the risk of short circuits in case of damage to the battery case is reduced.

list of figures

• 1) eine Explosionsdarstellung eines ersten Beispiels eines Batteriegehäuses,
• 2 a, b) das erste Beispiel des Batteriegehäuses in unterschiedlichen Darstellungen,
• 3 a - c) ein zweites Beispiel eines Batteriegehäuses in unterschiedlichen Darstellungen,
• 4) ein drittes Beispiel eines Batteriegehäuses in einer Teilschnittdarstellung und
• 5) ein viertes Beispiel eines Batteriegehäuses in einer Teilschnittdarstellung.

In the following the invention will be explained in more detail with reference to drawings. Identical parts are always provided with the same reference numerals. In detail show:

• 1 ) an exploded view of a first example of a battery case,
• 2 a, b ) the first example of the battery case in different representations,
• 3 a - c) a second example of a battery case in different representations,
• 4 ) A third example of a battery case in a partial sectional view and
• 5 ) A fourth example of a battery case in a partial sectional view.

Description of the Preferred Embodiments (Best Mode for Carrying Out the Invention)

In 1 is an exploded view of a first example of a battery case ( 1 ). The battery case ( 1 ) comprises a box ( 2 ), which from an insbesodnere laterally encircling outer frame ( 3 ) and a first floor / underrun protection ( 4 ) is formed. The outer frame ( 3 ) is preferably assembled from one or more profiles, which in particular consist of a metallic material, preferably steel material. The first floor / underrun protection ( 4 ) consists in particular of a metallic material, preferably steel material and is preferably detachable with the outer frame ( 3 ) connected. On the outer frame ( 3 ) is at least partially arranged for connection of the battery case to a vehicle profile / mounting profile ( 5 ). The profile / mounting profile ( 5 ) may be composed of one or more parts, which in particular consist of a metallic material, preferably steel material. The battery housing further comprises a support frame ( 6 ) with a laterally encircling boundary ( 6.1 ) and one within the lateral boundary ( 6.1 ) by at least one cross member ( 6.2 ) and / or at least one longitudinal member ( 6.3 ) ( 6.4 ) for receiving battery elements (not shown), which integrally made of plastic, in particular by injection molding, in the interior ( 2.1 ) of the box ( 2 ) is arranged. Furthermore, metallic inserts ( 7.1 ) to reinforce the interior ( 2.1 ) of the box in the subject structure ( 6.4 ) of the support frame ( 6 ), which in the manner of a grid structure ( 7 ) especially in the finished molded support frame ( 6 ) are inserted or received in designated cavities, optionally fixed and / or possibly encapsulated, so that the inserts ( 7.1 ) in the cross members ( 6.2 ) and in the longitudinal members ( 6.3 ) of the support frame ( 6 ) are introduced. Furthermore, a second floor ( 8th ), which from below with the support frame ( 6 ) is connected and in particular consists of a metallic material, preferably steel material. For partial covering of the interior ( 2.1 ) of the box ( 2 ) or the interior of the specialized structure ( 6.4 ) is a lid ( 9 ), which from above with the support frame ( 6 ) is connected and in particular consists of a metallic material, preferably steel material. The inside of the lateral boundary ( 6.1 ) of the support frame ( 6 ) is preferably flat, in particular substantially vertical (+/- 5 °) executed and the Outside preferably has recesses, so that in particular stiffening structures, for example in rib and / or honeycomb form ( 6.13 ) are formed. Other elements, such as elements of cooling, electrical, etc. are not shown for clarity, not even in the following figures.
The 2a) and 2 B) show the first example of the battery case ( 1 ) in plan view, without lid ( 9 ) for a better representation ( 2a) ), and a partial sectional view ( 2 B) ) along the line AA in 2a) , in particular in the assembled state. In partial section ( 2 B) ) it can be seen that the mounting profile ( 5 ) is composed of two parts, which with the outer frame ( 3 ) are connected. The upper part of the mounting profile ( 5 ) is flat for connection to a vehicle, in particular horizontally executed. Means for releasable connection, for example, be screws that by the in the mounting profile ( 5 ) introduced through holes ( 5.1 ) are durchsteckbar. In the corners of the lateral boundary ( 6.1 ) and in the crossing points of the cross members ( 6.2 ) with the longitudinal members ( 6.3 ) and in the crossing points of the cross members ( 6.2 ) with the lateral boundary ( 6.1 ) and in the crossing points of the longitudinal members ( 6.3 ) with the lateral boundary ( 6.1 ) are functional elements ( 6.5 ) integral with the support frame ( 6 ) trained respectively integrated. The functional elements ( 6.5 ) are, for example, Anschraubböcke, which are designed as a negative shape of a screw through which a screw (not shown) can be pushed through from below, the screw head by a corresponding portion in the negative mold in particular against rotation recorded respectively can be sunk in this, and the shaft or the thread of the screw into the interior ( 2.1 ) respectively battery room stands out. The battery elements, for example, at their corners in turn connection elements with through holes, through which in each case the shank of a screw is pushed through and the battery elements can be screwed by means of nuts firmly against the Anschraubböcke. Alternatively and not shown, nuts can also be integrated in the mounting blocks, in particular injected. In the crossbeams ( 6.2 ) and in the longitudinal members ( 6.3 ) of the support frame ( 6 ) are metallic inserts ( 7.1 ), optionally by means of an optional casting compound ( 10 ) within the transverse and longitudinal members ( 6.2 . 6.3 ) are fixed. The outside of the lateral boundary ( 6.1 ) of the support frame ( 6 ) has a ribbed and / or honeycomb form ( 6.13 ) on. The circumferential lateral boundary ( 6.1 ) of the support frame ( 6 ) has in the upper region a substantially planar upper flange surface ( 6.11 ) and in the lower area a substantially planar running lower flange surface ( 6.12 ) on. Both in the upper and in the lower flange surface ( 6.11 . 6.12 ) is in each case a groove ( 6111 . 6121 ), in each of which a sealing means, for example in the form of a sealing ring or band, is arranged. Preferably, the lid ( 9 ) with the upper flange surface ( 6.11 ) of the support frame ( 6 ) connected by a positive and / or non-positive, preferably releasable connection. The second floor ( 8th ) is, for example, materially bonded to the lower flange surface ( 6.12 ) of the support frame ( 6 ), in particular glued. The first floor ( 4 ) can, for example, positive and / or non-positive, preferably releasably connected to the outer frame ( 3 ). In between the floors ( 4 . 8th ) formed space / cold room ( K ) can be accommodated elements of cooling, electrical, etc. (not shown). Since metals have a higher thermal conductivity compared to plastics, covers ( 9 ) and second floor ( 4 ) made of metal, in order to prevent the heat generated by the battery elements in operation from the interior / battery compartment ( 2.1 ) to dissipate better.

The 3a) to 3c) show a second example of a battery case ( 1 ) in plan view, without lid ( 9 ) for a better representation ( 3a) ), a partial sectional view ( 3b) ) along the line AA in 3a) , and a partial sectional view ( 3c) ) along the line BB in 3a) especially in the assembled state. Unlike the first example in the 2a) and 2 B) is the support frame ( 6 ) in one piece with a second floor ( 6.6 ). This is preferably by injection molding of the support frame ( 6 ), so that an upwardly open, laterally and downwardly tight support frame ( 6 ) in the battery case ( 1 ) can be provided. In the second floor ( 6.6 ) are based on the subject structure ( 6.4 ) opposite side channels ( 6.7 ) integrally formed respectively integrated, which can be preferably taken into account by injection molding, through which cooling media can be passed during operation.

4 ) shows a partial sectional view of a third example of a battery case ( 1 ). In the subject structure ( 6.4 ) of the support frame ( 6 ) is at least one sleeve ( 6.8 ), which are integral with the support frame ( 6 ) is formed, which can be taken into account in particular by injection molding. The sleeve ( 6.8 ) seals the battery compartment ( 2.1 ). Through the sleeve ( 6.8 ) additional screws can be made to the body of a vehicle (not shown).

5 ) shows a partial sectional view of a fourth example of a battery case ( 1 ). In particular, at least one support rib ( 6.9 ) in the ground ( 6.6 ) on the subject structure ( 6.4 ) facing away, which down into the refrigerator ( K ) and thereby loads the underride protection ( 4 ) can forward into the structure. In the support rib ( 6.9 ) can also be provided with a threaded opening, for example, an additional connection or screwing the underrun protection ( 4 ) with the support frame ( 6 ).

The invention is not limited to the embodiments shown, but the individual features can be combined with each other. Particularly preferably, the battery housing ( 1 ) are used in passenger vehicles, commercial vehicles, trucks, special vehicles, buses, buses, whether with hybrid or pure electric drive, but also in track-bound vehicles, such as trams or passenger-carrying wagons.

LIST OF REFERENCE NUMBERS

1

battery case

2

box

2.1

Interior of the box, battery room

3

outer frame

4

first floor, underride protection

5

Profile, mounting profile

5.1

Through holes

6

support frame

6.1

lateral boundary

6.11, 6.12

upper, lower flange surface

6.111,6.121

groove

6.13

reinforcing structure

6.2, 6.3

Cross member, side member

6.4

multiple structure

6.5

functional element

6.6, 8

second floor

6.7

Channel, cooling channel

6.8

integrated sleeve

6.9

support rib

7

lattice structure

7.1

metallic inserts

9

cover

10

Sealing compound

K

Room, fridge

Claims (12)

Battery housing (1) for a vehicle, comprising a box (2), which is formed from an in particular laterally encircling outer frame (3) and at least one first floor (4), - A support frame (6) with a laterally encircling boundary (6.1) and within the lateral boundary by at least one cross member (6.2) and / or at least one longitudinal member (6.3) formed compartment structure (6.4) for receiving battery elements, which integrally made of plastic , in particular produced by injection molding, in the interior (2.1) of the box (2) is arranged, - A cover (9) for at least partially covering the interior (2.1) of the box (2). Battery housing after Claim 1 , characterized in that on the support frame (6) in one or more points of intersection of the cross member (s) (6.2) with the longitudinal members (6.3) and / or in one or more crossing points of the cross member (s) (6.2) with the lateral boundary ( 6.1) and / or in one or more points of intersection of the longitudinal member (6.3) with the lateral boundary (6.1) in each case at least one functional element (6.5) are integrated. Battery housing according to one of the preceding claims, characterized in that metallic inserts (7.1) in the compartment structure (6.4) of the support frame (6) are integrated. Battery housing according to one of the preceding claims, characterized in that the circumferential lateral boundary (6.1) of the support frame (6) at least in the upper region has a substantially flat running upper flange (6.11) for sealing in particular with the cover (9). Battery housing after Claim 4 , characterized in that the cover (9) with the flange (6.11) of the support frame (6) joined, in particular cohesively and / or mechanically joined with sealing means. Battery housing according to one of the preceding claims, characterized in that on the outer frame (3) an at least partially arranged for connection of the battery case to the vehicle profile (5) is connected. Battery housing according to one of the preceding claims, characterized in that the circumferential lateral boundary (6.1) of the support frame (6) in the lower region of a substantially flat running flange (6.12) for in particular has a sealing connection with a second bottom (8). Battery housing according to one of the preceding claims, characterized in that on the flange surface (6.11, 6.12) in the upper and / or lower region of the support frame (6) a seal is molded Battery case after one of Claims 1 to 6 , characterized in that the support frame (6) is made in one piece with a second bottom (6.6). Battery housing after Claim 9 , characterized in that in the bottom (6.6) on the side facing away from the compartment structure (6.4) side channels (6.7) and / or at least one support rib (6.9) are integrated. Battery housing according to one of the preceding claims, characterized in that the first floor (4) is detachably connected to the outer frame (3). Battery housing according to one of the preceding claims, characterized in that at least one sleeve (6.8) in the compartment structure (6.4) of the support frame (6) is integrated.

Images