DE102020212682A1 - High-voltage battery for an electrically powered vehicle - Google Patents

Abstract

The invention relates to a high-voltage battery (9) for an electrically operated vehicle, having a battery housing (13) in which at least one battery cell module (21) is arranged, which has a cell stack with a large number of battery cells (23) arranged one behind the other in a stacking direction are stacked. According to the invention, at least one power transmission segment (25) is arranged in the cell stack as a component separate from the battery cells (23). In the event of a crash, the force transmission segment (25) is integrated into a crash load path (Ly, Lx), via which the crash force (FS) can be transmitted to a side of the vehicle facing away from the crash.

Description

The invention relates to a high-voltage battery for an electrically operated vehicle according to the preamble of claim 1 and an electrically operated vehicle according to claim 13.

In an electrically operated, two-track vehicle, a high-voltage battery can be inserted from below into a battery assembly space that is open on the floor. The battery mounting space may be defined upward in the vehicle vertical direction by a vehicle floor delimiting the vehicle interior and may be delimited in the vehicle width direction by side body side members.

A generic high-voltage battery has a battery housing in which at least one battery cell module is arranged with a cell stack that is made up of a large number of battery cells. The battery cells are stacked one behind the other in the cell stack in a stacking direction aligned in the vehicle longitudinal direction. If necessary, the stacking direction can also run in the transverse direction of the vehicle and then provide support in the front crash.

In current practice, the high-voltage battery, as a crash-sensitive component, has to be protected from mechanical damage, especially in the event of a side crash or if it hits the ground. Against this background, the battery cell modules made up of the battery cells are arranged in a structurally rigid battery housing in the prior art. In the event of a side crash or ground impact, the battery housing acts as a load-bearing structure, via which a side crash force is transmitted from the longitudinal body member facing the crash to the longitudinal body member facing away from the crash, or a ground impact force is introduced into the body structure via the structurally rigid battery housing, while bridging the largely force-free remaining crash-sensitive battery cells. In addition, in the prior art, the high-voltage battery can be covered towards the bottom of the vehicle by a solid floor mounting plate, which protects the battery housing of the high-voltage battery from mechanical damage caused by floor mountings.

The above safety precautions for the side crash and for the ground impact are associated with a high component cost, a high production cost and a high installation space, whereby the space remaining for the battery cells and thus the battery performance is reduced.

From the DE 10 2016 223 220 A1 a battery case for a vehicle is known. From the DE 10 2018 112 377 A1 a battery arrangement for a motor vehicle with a crash protection element is known. From the DE 10 2016 009 930 A1 a vehicle battery with at least one cross brace is known.

The object of the invention is to provide a high-voltage battery and an electrically operated vehicle in which the high-voltage battery is protected against mechanical damage in the event of a side crash and/or in the event of ground contact, compared to the prior art with reduced component complexity, reduced installation space requirements and/or reduced production costs can.

The object is solved by the features of claim 1 or claim 13. Preferred developments of the invention are disclosed in the dependent claims.

The invention relates to a high-voltage battery for an electrically operated vehicle, having a battery housing in which at least one battery cell module is arranged. The battery cell module has a cell stack with a plurality of battery cells stacked one behind the other in a stacking direction. The stacking direction can be oriented in the vehicle longitudinal direction or in the vehicle transverse direction. According to the characterizing part of claim 1, at least one power transmission segment is arranged in the cell stack as a component separate from the battery cells. In the event of a crash, the force transmission segment is integrated into a crash load path, via which the crash force can be transmitted to a side of the vehicle facing away from the crash.

According to a first aspect of the invention, the stacking direction of the cell stack may be oriented in the vehicle width direction. In this case, the power transmission segment forms a side member segment. In the event of a frontal crash, the side member segment is integrated into a longitudinal load path, via which the longitudinal crash force can be transmitted to the side of the vehicle facing away from the crash.

According to a second aspect of the invention, the stacking direction of the cell stack may be aligned in the vehicle front-rear direction. In this case, the power transmission segment forms a cross member segment. In the event of a side crash, the cross member segment is integrated into a transverse load path, via which the side crash force can be transmitted to a side of the vehicle facing away from the crash.

It should be emphasized that the core of the invention is particularly - but not exclusively - aimed at a high-voltage battery whose battery cell modules each have cell stacks in which the battery cells are specifically in one, in the vehicle longitudinally aligned stacking direction are stacked one behind the other. This may be necessary due to structural conditions of the vehicle body in order to achieve the greatest possible battery cell package density and thus the greatest possible battery performance. For this reason, at least one cross member segment is assigned to the cell stack of the respective battery cell module as a component that is separate from the battery cells. In the event of a side crash, the cross member segment is integrated into a transverse load path, via which the side crash force is transmitted to a side of the vehicle facing away from the crash.

• So können in einer technischen Umsetzung in dem Batteriegehäuse nicht nur ein Batteriezellenmodul, sondern zumindest zwei oder mehr Batteriezellenmodule in der Fahrzeugquerrichtung nebeneinander angeordnet sein. In diesem Fall können die Querträger-Segmente der Batteriezellenmodule in der Fahrzeugquerrichtung zueinander in Querflucht ausgerichtet sein, und zwar unter Bildung eines Querträgers, der im Seitencrashfall im Querlastpfad eingebunden ist. Bevorzugt kann das Querträger-Segment im Zellenstapel in der Stapelrichtung jeweils in etwa mittig positioniert sein. In diesem Fall sind in der Stapelrichtung beidseitig des Querträger-Segments jeweils die gleiche Anzahl von Batteriezellen angeordnet.

With regard to a simpler understanding, further features of the invention are described below specifically for a force transmission segment realized as a cross member segment:

• In a technical implementation, not only one battery cell module but at least two or more battery cell modules can be arranged next to one another in the vehicle transverse direction. In this case, the cross member segments of the battery cell modules can be aligned in transverse alignment with one another in the transverse direction of the vehicle, specifically with the formation of a cross member that is integrated in the transverse load path in the event of a side crash. The cross member segment can preferably be positioned approximately centrally in the cell stack in the stacking direction. In this case, the same number of battery cells are arranged on both sides of the cross member segment in the stacking direction.

In a technical implementation, the high-voltage battery can be installed in a body structure of the vehicle as follows: A body floor structure of the vehicle can have a battery assembly space open towards the bottom of the vehicle, in which the high-voltage battery can be inserted. The battery installation space can be closed off in the vehicle vertical direction towards the top of the vehicle by a vehicle floor delimiting the vehicle interior. In addition, the battery mounting space in the vehicle width direction may be limited by side body side members. In the event of a side crash, the side crash force can thus be transmitted from the body side member facing the crash via the transverse load path to the body side member facing away from the crash.

In a first embodiment variant, the cross member segments of the cross member can be components that are separate from one another. In normal driving operation, these can be spaced apart from one another by a transverse gap. In addition, the cross member segment of the cross member that is on the outside in the transverse direction of the vehicle can be spaced apart from the respective body side member in normal driving operation via a transverse assembly clearance. In this case, a side crash occurs in which, at the time of the crash, the body side member facing the crash, the cross member segments and the body side member facing away from the crash are integrated into the transverse load path in a force-transmitting manner, using up the transverse assembly clearance and/or using up the transverse gap.

In a second embodiment variant, at least one of the cross member segments can be extended with a transverse overhang in the vehicle transverse direction, specifically with at least partial, in particular complete bridging of the transverse gap even during normal driving. In this case, the cross member segment can protrude laterally beyond the battery cells in the vehicle transverse direction with its overhang.

In a third embodiment variant, the cross member segments of the cross member can no longer be implemented as components that are separate from one another. Rather, the cross member segments can be connected to one another from the same material and/or in one piece via at least one connecting web.

The at least one battery cell module arranged in the battery housing can be constructed as follows: The battery cell module can have a clamping unit with which the battery cells and the cross member segment of the cell stack are clamped against one another in the stacking direction. In this way, during battery assembly, the battery cell module can be handled easily as a compact structural unit and can be inserted into the battery housing semi-automatically or fully automatically. The tensioning unit can have two end pressure plates between which the cell stack extends. The pressure plates can be connected to one another via tensioning elements (for example tensioning straps that can be subjected to tensile stress) arranged on both sides of the cell stack, with tension building up in the cell stack. The preload within the cell stack also prevents potential buckling of the cross member. This can be made thinner compared to a free-standing "buckling rod"/crossbeam.

In a preferred embodiment variant, the pressure plates of the tensioning unit can also be designed as crossbeam segments with a dual function.

In order to protect the battery housing from mechanical damage caused by ground impact, a plate-shaped underride protection can be arranged in the vertical direction of the vehicle below the housing floor of the battery housing. the plat Ten-shaped underrun protection can be spaced from the bottom of the battery case by a deformation clearance down the vehicle. In the event of ground contact, an interfering contour on the roadway side (for example a bollard or a curb) with a ground contact force directed upwards from the vehicle can deform the plate-shaped underrun protection into the deformation free space.

To increase the deformation resistance of the plate-shaped underrun protection, a support element can be arranged in the deformation free space. The support element can be positioned in vertical alignment with the cross member segment in the vertical direction of the vehicle. In the event of ground contact, the plate-shaped underrun protection can thus be supported on the cross member segment via the support element and with the battery housing base being interposed. In this case, the ground contact force is introduced into the vehicle body via a vertical load path upwards. The plate-shaped underride protection, the support element, the battery housing base, the cross member segment and a battery cover on the top can be integrated in the vertical load path.

All of the above features of the invention are also readily applicable to a force transmission segment realized as a longitudinal member segment: With such a force transmission segment realized as a longitudinal member segment, only the spatial alignment of the force transmission segment changes in order to provide a support function in the event of a front crash. The longitudinal beam segments of the battery cell modules can be aligned in longitudinal alignment with one another in the longitudinal direction of the vehicle, to be precise with the formation of a longitudinal beam which is integrated in the longitudinal load path in the event of a longitudinal crash. In addition, the longitudinal member segments of the longitudinal member can be components that are separate from one another and are spaced apart from one another by a longitudinal gap during normal driving operation. Furthermore, the side member segments can each be extended with a projection in the longitudinal direction of the vehicle, specifically with at least partial, in particular complete, bridging of the longitudinal gap. As an alternative to this, the longitudinal member segments cannot be realized as separate components from one another, but rather the longitudinal member segments can be connected to one another in the same material and/or in one piece via at least one connecting web.

Exemplary embodiments of the invention are described below with reference to the accompanying figures.

• 1 in einer Seitenansicht mit teilweisem Aufriss ein Fahrzeug mit einer darin verbauten Hochvoltbatterie;
• 2 in einer perspektivischen Ansicht die Hochvoltbatterie in Alleinstellung sowie mit weggelassenem Batteriegehäuse-Oberteil;
• 3 in einer Explosionsdarstellung ein Batteriezellenmodul;
• 4 eine Schnittdarstellung entlang der Schnittebene A-A aus der 1;
• 5 und 6a jeweils Ansichten entsprechend der 4;
• 6b und 6c jeweils Detailansichten; und
• 7 eine perspektivische Ansicht einer Hochvoltbatterie mit plattenförmigem Unterfahrschutz.

Show it:

• 1 in a side view with partial elevation, a vehicle with a high-voltage battery installed therein;
• 2 in a perspective view, the high-voltage battery on its own and with the upper part of the battery housing omitted;
• 3 in an exploded view a battery cell module;
• 4 a sectional view along the section plane AA from FIG 1 ;
• 5 and 6a each views according to the 4 ;
• 6b and 6c detailed views in each case; and
• 7 a perspective view of a high-voltage battery with plate-shaped underride protection.

In the 1 a two-track vehicle is shown in a side view. The vehicle has a rear area 1 with an indicated rear bench seat 3 . The rear bench seat 3 is arranged on a body floor assembly that is partially visible in the vehicle 1 in the elevation. The body floor assembly is in the 1 indicated only insofar as it is necessary for understanding the invention.

In the 1 the body floor assembly has a rear sheet metal part 5, the underside of which has an assembly space 7 ( 4a or 4b) for a high-voltage battery 9 defined. The battery mounting space 7 is defined toward the vehicle outside in the vehicle width direction y by rear-side body side members 11 ( 4a or 4b) limited. How from the 4a further shows that the high-voltage battery 9 is placed at a connection point B on a plate-shaped underride protection 10 underneath the vehicle, which is attached directly to the battery and represents part of the ZSB battery system.

The following is based on the 2 until 4b the structure of the battery case 13 of the high-voltage battery 9 described: Accordingly, the battery case 13 in the 4a a peripheral housing frame 15, which can be realized as an aluminum casting. The peripheral housing frame 15 is in the, in the 4a Installation position shown positioned approximately at the same height as the rear body side member 11. A housing upper part 17 is mounted on the upper side of the housing frame 15 and a housing base 19 is mounted on its underside. These limit a battery interior in which the 2 a total of four battery cell modules 21 are arranged.

In the 3 the battery cell module 21 shown in an exploded view has a cell stack with a multiplicity of battery cells 23 . These are arranged one behind the other in a stacking direction aligned in the vehicle longitudinal direction x pelt. A cross member segment 25 is arranged approximately in the center of the cell stack as a component separate from the battery cells 23 . The cross member segment 25 can preferably be an extruded plate. Viewed in the stacking direction, the same number of battery cells 23 are positioned on both sides of the cross member segment 25 . The battery cell module 21 is also assigned a tensioning unit 27, by means of which the battery cells 23 and the cross member segment 25 of the cell stack are braced against one another in the stacking direction. The clamping unit 27 has in the 3 two end-side pressure plates 29, between which the cell stack extends. The two pressure plates 29 are connected to one another by means of tensioning straps 31 arranged on both sides of the cell stack, with tension building up in the cell stack. In the assembled state, the battery cell module 21 is fastened to the housing base 19 via screw bolts 33 . The screw bolts 33 are guided through the pressure plates 29 and in screw connection with screw domes (not shown) formed on the housing base 19 .

How from the 4 shows that the cross member segments 25 of the battery cell modules 21 are aligned in transverse alignment with one another in the vehicle transverse direction y, specifically with the formation of a cross member 35 which, in the event of a side crash, in the transverse load path L _y ( 4b) is involved. In normal driving are in the 4 shown cross member segments 25 spaced apart by a transverse gap s. The cross member segments 25 of the cross member 35 which are on the outside in the vehicle transverse direction y are spaced apart from the respective associated longitudinal body member 11 in normal driving operation via a transverse assembly clearance m. In the event of a side crash, the longitudinal body member 11 facing the crash, the cross member segments 25 and the longitudinal body member 11 facing away from the crash are integrated into the lateral load path L _y in a force-transmitting manner, using up the transverse assembly clearance m and using up the transverse gap s. To increase the crash performance, a force introduction structure 39 (only in the 2 shown) formed.

In the 5 a further embodiment variant of the invention is shown, in which the cross member segments 25 are extended with a projection 37 in the vehicle transverse direction y beyond the battery cells 23. In this way, the transverse gap s between the battery cells 23 is bridged.

To further increase the crash performance are in the 6a the cross member segments 25 are no longer implemented as separate components from one another. Rather, the cross member segments 25 are connected to one another via connecting webs 41 of the same material and/or in one piece.

In this way, a 6a or 6b shown of the same material and one-piece cross member 35, which extends inside the housing of the battery housing 13 in the vehicle transverse direction y. In the 6c the cross member 35 made of the same material and in one piece is shown with the battery cells 23 omitted. Accordingly, the cross member segments 25 are spaced apart from one another in the vehicle transverse direction y by transverse gaps s. The clamping elements 31 of the clamping units 27 of the battery cell modules 21 are guided through the transverse gaps s. The transverse gaps s are delimited at the bottom of the vehicle by the connecting webs 41 which connect the cross member segments 25 to one another.

In the 6c the pressure plates 29 of the battery cell modules 21 arranged next to one another in the vehicle transverse direction y are also implemented as cross member segments with a double function. According to the 6c the pressure plates 29 of the battery cell modules 21 are in force-transmitting contact with one another.

How from the 1 or 7 As can further be seen, the plate-shaped underrun protection 10 is arranged below the housing base 19 of the battery housing 13 in the vehicle vertical direction z. The underrun protection 10 is spaced from the housing base 19 of the battery housing 13 toward the vehicle bottom by a deformation clearance 43 . In the event of a ground impact, an interference contour on the roadway side deforms the underride protection 10 into the deformation free space 43 with a ground impact force directed upwards from the vehicle.

A support element 45 is arranged in the deformation free space 43 in order to increase the deformation resistance of the underride protection 10 . The support element 45 is implemented as a transverse hollow beam which is attached to the plate-shaped underrun protection 10 . According to the 7 the support element 45 is positioned in vertical alignment with the cross member 35 in the vehicle vertical direction z. In the event of ground contact, the plate-shaped underrun protection 10 is therefore supported on the cross member 35 via the support element 45 and with the housing base 19 being interposed.

Reference List

1

rear area

3

back seat

5

rear sheet metal part

7

battery assembly room

9

high-voltage battery

10

plate-shaped underrun protection

11

Body side member

13

battery case

15

case frame

17

housing upper part

19

caseback

21

battery cell module

23

battery cells

25

power transmission segment

27

clamping unit

29

pressure plates

31

clamping elements

33

bolts

35

cross member

37

Got over

39

force introduction structure

41

connecting bars

43

deformation clearance

45

support element

B

connection point

s

transverse gap

m

assembly clearance

Ly, Lx

crash load path

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102016223220 A1 [0006]
• DE 102018112377 A1 [0006]
• DE 102016009930 A1 [0006]

Claims (13)

High-voltage battery (9) for an electrically operated vehicle, with a battery housing (13) in which at least one battery cell module (21) is arranged, which has a cell stack with a multiplicity of battery cells (23) which are stacked one behind the other in a stacking direction, thereby characterized in that at least one power transmission segment (25) is arranged in the cell stack as a component separate from the battery cells (23), and that in the event of a crash the power transmission segment (25) is in a crash load path (L _y , L _x ) is integrated, via which the crash force (F _S ) can be transmitted to a side of the vehicle facing away from the crash. high-voltage battery claim 1 , characterized in that the stacking direction of the cell stack is aligned in the vehicle transverse direction (y), so that the power transmission segment (25) forms a longitudinal member segment, and that the longitudinal member segment (25) in a front crash in a longitudinal load path (L _x ) is integrated, via which the longitudinal crash force (Fs) can be transmitted to the side of the vehicle facing away from the crash. high-voltage battery claim 1 , characterized in that the stacking direction of the cell stack is aligned in the vehicle longitudinal direction (x), so that the force transmission segment (25) forms a cross member segment, and that the cross member segment (25) in a side crash in a transverse load path (L _y ) is involved, via which the side crash force (F _S ) can be transmitted to a side of the vehicle facing away from the crash. high-voltage battery claim 3 , characterized in that in the battery housing (13) at least two battery cell modules (21) are arranged next to one another in the vehicle transverse direction (y), and in that the cross member segments (25) of the two battery cell modules (21) in the vehicle transverse direction (y) are in Are aligned transverse alignment, with the formation of a cross member (35), which is involved in the lateral load path (L _y ) in the event of a side crash. high-voltage battery claim 3 or 4 , characterized in that the high-voltage battery (9) can be used in a battery assembly space (7) of a body floor structure of the vehicle that is open towards the bottom of the vehicle, and that the assembly space (7) in the vehicle vertical direction (z) upwards from a vehicle floor delimiting the vehicle interior (5) is closed off, and/or that the battery installation space (7) is delimited in the vehicle transverse direction (y) by lateral longitudinal body members (11), and/or that, particularly in the event of a side crash, the side crash force (Fs) from the longitudinal body member (11) facing the crash can be transmitted via the transverse load path (L _y ) to the longitudinal body member (11) facing away from the crash. high-voltage battery claim 3 , 4 or 5 , characterized in that the cross member segments (25) of the cross member (35) are separate components from one another and/or that during normal driving operation the cross member segments (25) are spaced apart from one another by a transverse gap (s) and/or that the cross member segment (25) of the cross member (35) lying on the outside in the transverse direction (y) of the vehicle is spaced apart from the respective longitudinal body member (11) in normal driving operation by a transverse assembly clearance (m), and/or that in the event of a side crash the longitudinal body member facing the crash ( 11), the cross member segments (25) and the body side member (11) facing away from the crash are integrated in the transverse load path (L _y ) in a force-transmitting manner using up the transverse assembly clearance (m) and/or the transverse gap (s). High-voltage battery according to one of the preceding claims, characterized in that at least one cross member segment (25) is extended with a projection (37) in the vehicle transverse direction (y), specifically with at least partial, in particular complete bridging of the transverse gap (s), and that in particular the cross member segment (25) protrudes laterally beyond the battery cells (23) with its overhang (37). High-voltage battery according to one of the preceding claims, characterized in that the cross member segments (25) are not realized as separate components from one another, but rather the cross member segments (25) are connected to one another from the same material and/or in one piece via at least one connecting web (41). High-voltage battery according to one of the preceding claims, characterized in that the battery cell module (21) has a tensioning unit (27) with which the battery cells (23) and the cross member segment (25) of the cell stack are braced against one another in the stacking direction, and that in particular the tensioning unit (27) has two end pressure plates (29) between which the cell stack extends, and that the pressure plates (29) are connected to one another via tensioning elements (31) arranged on both sides of the cell stack, with tension building up in the cell stack. high-voltage battery claim 9 , characterized in that the pressure plates (29) of the clamping unit (27) are also designed in a dual function as a cross member segments (25), and / or that the cross member segment (25) in the middle of Zel lens stack is positioned, and/or that the same number of battery cells (23) is arranged on both sides of the cross member segment (25) in the stacking direction. High-voltage battery according to one of the preceding claims, characterized in that in the vehicle vertical direction (z) below the housing base (19) of the battery housing (13) is arranged a plate-shaped underride guard (10) which extends around a deformation clearance (43) from the housing base (19 ) of the battery housing (13) is spaced below the vehicle, and that in the event of ground contact, an interfering contour on the roadway side, in particular a bollard or a curb, deforms the plate-shaped underrun protection (10) into the deformation free space (43) with a ground contact force directed upwards from the vehicle. high-voltage battery claim 11 , characterized in that a support element (45) is arranged in the deformation free space (43) to increase the deformation resistance of the underrun protection (10), and in that in particular the support element (45) in the vehicle vertical direction (z) is in vertical alignment with the cross member segment (25) is positioned, and that in particular if the underrun protection (10) is placed on the ground, it can be supported on the cross member segment (25) via the support element (45) and with the housing base (19) being interposed. Vehicle with a high-voltage battery (9) according to one of the preceding claims.

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