DE102021126606A1 - Vehicle frame for an electrically powered vehicle and vehicle with such a vehicle frame - Google Patents

Abstract

The invention relates to a vehicle frame (2) for an electrically driven vehicle, in particular a tilting vehicle, with at least one tubular frame element (4) through which a load acting on the vehicle frame (2) can be absorbed and transmitted, which is formed as a one-piece component and which has at least one layer of fiber composite material, and with at least one electrical energy storage device (6), which comprises at least one energy storage cell and at least one electrical contact means functionally assigned to the at least one energy storage cell, which is arranged in the frame element (4) designed as a one-piece component and which is connected by means of Casting is fixed inextricably to the frame element (4) with a resin and/or by means of foaming with a foaming agent.

Description

The invention relates to a vehicle frame for an electrically driven vehicle and a vehicle with such a vehicle frame.

Electrically driven vehicles, in particular tilting vehicles, are known from the prior art, in which an energy store is permanently installed in the vehicle frame. In the known vehicles, the energy store is inserted and/or clipped into a frame element of the vehicle frame.

It has been found to be disadvantageous here that the vehicle frame, in particular the frame element, must be structurally so generously dimensioned that the energy store can be inserted into it. This leads to large sections of the vehicle frame, in order to be able to insert and accommodate the energy store, and to increased weight.

If the vehicle frame comprises a fiber composite material, the force-carrying frame element in the area of the energy store must be dimensioned particularly large in order to be able to absorb and transmit forces acting on the vehicle frame.

An object of an embodiment of the invention is to propose a vehicle frame for an electrically powered vehicle, a vehicle with such a vehicle frame and a method for producing such a vehicle frame, in which the dimensioning of the vehicle frame is reduced with the same or improved ability to absorb loads.

This object is achieved by a vehicle frame for an electrically driven vehicle, in particular a tilting vehicle, with at least one tubular frame element through which a load acting on the vehicle frame can be absorbed and passed on, which is formed as a one-piece component and which has at least one layer made of fiber composite material , and with at least one electrical energy store, which comprises at least one energy storage cell and at least one of the at least one energy storage cell functionally assigned electrical contact means, which is arranged in the frame element designed as a one-piece component and which cannot be detached by means of casting with a resin and/or by means of foaming with a foaming agent fixed to the frame member

Due to the fact that the energy store is arranged in the frame element designed as a one-piece component and is permanently fixed by means of casting and/or foaming, an integral connection is produced between the energy store and the frame element. As a result, the energy store forms a load-bearing component, through which the load absorption of the frame element of the vehicle frame can be supported. This enables a compact design of the frame element.

In addition, by arranging the energy store in the frame element designed as a one-piece component, a housing for the energy store can be dispensed with, as a result of which installation space can also be saved.

A tilting vehicle is understood to mean bicycles, motorcycles or motor vehicles similar to motorcycles, such as motor scooters, in particular two-, three- or four-wheeled motor scooters, scooters, tiltable trikes, quads or the like.

In the case of the frame element designed as a one-piece component, the frame element can comprise a down tube of a tilting vehicle, in particular a bicycle.

Embodiments of the vehicle frame are conceivable in which only the frame element is designed as a one-piece component. Furthermore, the vehicle frame may comprise a one-piece common component in its entirety, in which the frame member forms a portion of the vehicle frame.

Embodiments of the vehicle frame are conceivable in which the energy store is accessible from the outside at least in some areas. In such a case, it can protrude through the frame element to the outside. In one embodiment of the vehicle frame, it is provided that the energy store is at least partially or completely surrounded by the frame element along a circumferential direction with respect to the tubular frame element and directly or indirectly bears against it at least partially.

In such a case, the energy store is not accessible from the outside when it is completely surrounded by the frame element.

If the energy storage is partially surrounded by the frame element, this can be accessible from the outside, which facilitates maintenance or repair of the energy storage if necessary.

At least one energy storage cell of the energy store can bear directly or indirectly on the frame element. If the energy storage indirectly on the frame element applied, the foaming agent can be arranged between the energy storage device and the frame element.

It has proven to be advantageous if the frame element comprises one or more layers of fiber composite material, in particular glass fiber or a carbon fiber reinforced plastic, and/or if the one or more layers of fiber composite material are woven or braided around the energy store, in particular with one layer or the multiple layers of fiber composite material is impregnated with a resin and cured.

If the frame element comprises several layers of fiber composite material, in particular glass fiber or a carbon fiber reinforced plastic, the ability of the frame element to absorb loads and pass them on can be improved. If the energy store is surrounded by one or more layers of the fiber composite material, a compact design of the frame element or the vehicle frame in the area of the energy store can be ensured even before the casting.

In order to electrically insulate the energy store from the frame element, one embodiment of the vehicle frame has at least one layer made of glass or fiberglass, which rests directly on the energy store and is arranged between the energy store and at least one other layer made of fiber composite material.

In one embodiment of the vehicle frame, it is provided that the energy storage device comprises at least two energy storage cells, which are electrically connected to one another via the respective functionally assigned electrical contact means, and that the at least two energy storage cells are in direct contact with one another or with one another through at least one intermediate space extending transversely to the circumferential direction of the energy storage device are spaced.

If the at least two energy storage cells are arranged adjacent to one another, the vehicle frame, in particular the energy storage, can be of compact design.

If the at least two energy storage cells are spaced apart from one another by at least one intermediate space extending transversely to the circumferential direction of the energy storage device, the energy storage cells can be thermally decoupled from one another in a simplified manner. In such a case, if an energy storage cell overheats, the neighboring energy cell can be protected from overheating.

Alternatively or in addition to the latter development of the invention, the vehicle frame includes at least one fixing means by which two spaced-apart energy cells are fixed against moving transversely to the circumferential direction of the energy store, in particular the fixing means comprising the foaming agent.

In order to be able to charge the energy store with electrical energy and to supply energy stored in the electrical energy store to a consumer, one exemplary embodiment of the vehicle frame comprises at least one cable-like electrical line element which can be connected or is connected to the energy store and an electrical consumer and which is located in a cavity in the frame element is arranged and/or is woven or braided into the at least one layer of fiber composite material, in particular wherein the one layer or the several layers of fiber composite material is impregnated with a resin and cured.

The cable-like electrical line element can be arranged in a cavity of the frame element. In addition, the cable-like electrical line element can be permanently attached to the frame element if it is surrounded by at least one layer of fiber composite material. In addition, in such a case the electrical line element can also be cast with the frame element.

Embodiments of the vehicle frame are conceivable in which heat from the energy store can be dissipated. In such a case, an embodiment of the vehicle frame can comprise at least one cooling element, which can be connected or is connected to the energy store and an active or passive heat exchanger and which is arranged in a cavity of the frame element and/or is fixed in the at least one layer of fiber composite material with a weave or braid around it, In particular, the one or more layers of fiber composite material are impregnated with a resin and cured.

An active heat exchanger can be understood to mean a cooling unit in which the temperature prevailing at the energy store can be actively reduced or increased. A passive heat exchanger can be understood to mean, for example, cooling fins in which heat can be emitted to the environment.

In addition, it is conceivable in one embodiment of the vehicle frame that the cooling element is inserted in at least one layer of fiber composite material, surrounded by it and cast with it.

In order to save weight, the frame element can have a cavity on the inside, which adjoins the energy store on one or both sides. In order to further improve the stationary fixing of the energy store relative to the frame element, in one embodiment of the vehicle frame at least one stop means can be provided, on which the energy store rests at least in a direction transverse to the circumferential direction of the tubular frame element, the stop means being formed by a recessed section of the frame element and/or formed by the foaming agent such as polyurethane foam.

By forming a stop means, the energy store is held in addition to its encapsulated arrangement in the frame element by a form fit against movement transverse to the circumferential direction.

If the stop means is formed by a recessed section of the frame element, the shape of the frame element can prevent movement transverse to the circumferential direction of the energy store. In such a case, the vehicle frame can be produced with fewer components and can be produced in a simplified manner. If the stop means comprises a hardened foam means, a visually appealing appearance can be achieved and a weight-reduced stop means prevents the energy store from moving transversely to the circumferential direction.

1. a. Anordnen des Faserverbundwerkstoffs zum Bilden des Fahrzeugrahmens, insbesondere des Rahmenelements, und Anordnen des Energiespeichers, insbesondere der Energiespeicherzellen, im zu bildenden Fahrzeugrahmen, insbesondere Rahmenelement, wobei der Energiespeicher durch mindestens eine Lage aus Faserverbundwerkstoff umgeben wird;
2. b. Hinzufügen eines Harz-Härter Gemisches und
3. c. Aushärten des Fahrzeugrahmens, insbesondere des Rahmenelements.

In addition, the object is achieved by a method for producing a vehicle frame for an electrically driven vehicle, in particular a tilting vehicle, which has at least one frame element through which a load acting on the vehicle frame can be absorbed and transmitted and which is formed as a one-piece component that has at least has a layer of fiber composite material, and which comprises at least one electrical energy storage device, which is permanently fixed in the frame element of the vehicle frame, which is designed as a one-piece component, with the steps:

1. a. Arranging the fiber composite material to form the vehicle frame, in particular the frame element, and arranging the energy store, in particular the energy storage cells, in the vehicle frame to be formed, in particular frame element, the energy store being surrounded by at least one layer of fiber composite material;
2. b. Adding a resin-hardener mixture and
3. c. Curing of the vehicle frame, in particular the frame element.

Individual layers of fiber composite material are laid to form the vehicle frame. Here, the energy store is placed in a tool on fiber composite material that has already been laid and surrounded by other layers.

The individual layers of fiber composite material are saturated by adding a resin-hardener mixture. In addition, the resin-hardener mixture also reaches the transition from the energy store to the first layer of fiber composite material. Curing creates a material connection between the energy store and the frame element.

Arranging the fiber composite material to form the vehicle frame, in particular the frame element, and arranging the energy store in the vehicle frame to be formed, in particular frame element, can take place in a tool or a tool mold.

Arranging the energy store, in particular the energy storage cells, in the vehicle frame to be formed can include arranging one or more energy storage cells and their contact means.

Furthermore, it can be provided in a further step, in particular before adding a resin-hardener mixture, that a foaming agent is added and cured to fix the energy store.

In particular when the energy store comprises a plurality of energy storage cells, these can be spaced apart from one another by a fixing means, it being possible for the fixing means to be formed by the foaming agent.

In a further development of the method, it proves to be advantageous if the energy store is surrounded by fiber composite material by braiding, weaving, folding and/or inserting and/or if the resin-hardener mixture is added by casting under pressure, in particular a resin Transfer Molding (RTM).

In addition, it can be provided in a further step that a foam, in particular a polyurethane foam (PU) is added to a cavity in the vehicle frame, in particular the frame element, and is cured there.

Finally, the object is achieved by an electrically driven vehicle, in particular a tilting vehicle, with at least one vehicle frame having at least one of the features mentioned above male and/or which is produced by a method with the aforementioned features.

Further features, details and advantages of the invention result from the appended patent claims, from the drawing and the following description of a preferred embodiment of the vehicle frame and the method.

• 1 Eine schematische geschnittene Ansicht eines Rahmenelement eines ersten Ausführungsbeispiels des Fahrzeugrahmens;
• 2 Eine schematische geschnittene Ansicht eines Rahmenelement eines zweiten Ausführungsbeispiels des Fahrzeugrahmens;
• 3 Eine geschnittene Draufsicht entlang der Linie AA gemäß 2,
• 4 Ein Ablaufdiagramm einer Ausführungsform eines erfindungsgemäßen Verfahrens.

In the drawing shows:

• 1 A schematic sectional view of a frame element of a first exemplary embodiment of the vehicle frame;
• 2 A schematic sectional view of a frame element of a second embodiment of the vehicle frame;
• 3 A sectional top view along line AA according to FIG 2 ,
• 4 A flow chart of an embodiment of a method according to the invention.

The 1 until 3 show two exemplary embodiments of a vehicle frame, each provided with the reference numeral 2, for an electrically driven vehicle, in particular a tilting vehicle (not explicitly shown in the figures). The vehicle frame 2 comprises a tubular frame element 4, through which a load acting on the vehicle frame 2 can be received and passed on. The frame element 4 comprises a one-piece component and, in the exemplary embodiment shown in the figures, several layers of different fiber composite materials.

An electrical energy store 6 is arranged in the frame element 4 and fixed inseparably on the frame element 4 by means of casting.

The frame element 4 completely surrounds the energy store 6 with respect to a circumferential direction of the tubular frame element 4 .

The frame member 4 includes the in the 1 until 3 shown embodiments each have a first layer of glass or glass fiber 8, which rests directly on the energy store 6 and between the energy store 6 and another layer of fiber composite material. The other layer of fiber composite material includes the in the 1 until 3 shown embodiments a carbon fiber reinforced plastic 10.

In order to prevent the electrical energy store 6 from moving with respect to a direction of movement transverse to the circumferential direction of the tubular frame element 4, in the case of the FIGS 1 until 3 shown embodiments are each provided a stop means 12, which is formed by a hardened foam 14, such as polyurethane foam.

In order to store electrical energy in the energy storage device 6 and to supply stored energy in the energy storage device 6 to a consumer, the vehicle frame 2 comprises a cable-like electrical conductor 16 which can be connected to the energy storage device 6 and an electrical consumer. The line element 16 is arranged in a cavity 18 of the tubular frame element 4 .

At the in 1 shown embodiment, the energy store 6 comprises a single energy storage cell 20.

2 shows a second exemplary embodiment of the vehicle frame 2, in which the energy storage device 6 is formed from two energy storage cells 20. FIG. The individual energy storage cells 20 include contact means 22 with which they can be connected to one another and to the line element 16 .

An intermediate space 24 is arranged between two energy storage cells 20, through which the energy storage cells 20 are spaced apart from one another. A fixing means 26 is arranged in the intermediate space 24, by means of which the energy storage cells 20 can be fixed against movement transversely to the circumferential direction. At the in the 2 and 3 shown embodiment, the fixing means 26 comprises the foaming agent 14.

• In einem ersten Schritt 100 wird Faserverbundwerkstoff 8,10 zum Bilden des Fahrzeugrahmens 2, insbesondere des Rahmenelements 4, angeordnet und der Energiespeicher 6 im zum bildenden Fahrzeugrahmen 2, insbesondere Rahmenelement 4, angeordnet. Hierbei wird der Energiespeicher 6 durch mindestens eine Lage aus Faserverbundwerkstoff 8, 10 umgeben.

Based on the in 1 The exemplary embodiment shown is shown below in accordance with the schematic flowchart 2 described:

• In a first step 100, fiber composite material 8 , 10 is arranged to form the vehicle frame 2 , in particular the frame element 4 , and the energy store 6 is arranged in the vehicle frame 2 , in particular the frame element 4 , to be formed. In this case, the energy store 6 is surrounded by at least one layer of fiber composite material 8 , 10 .

In a subsequent step 101, a resin-hardener mixture is added.

In a step 102, the resin-hardener mixture is cured.

Correlating to the embodiment according to 1 is in accordance with the procedure 2 a step 103 is provided, in which the stop means 12 in the form of the foam agent 14 in the hollow space 18 of the frame member 4 is added and cured.

The features of the invention disclosed in the above description, in the claims and in the drawing can be essential both individually and in any combination in the implementation of the invention in its various embodiments.

Reference List

2

vehicle frame

4

frame element

6

energy storage

8th

glass fiber

10

plastic

12

slings

14

foaming agent

16

line element

18

cavity

20

energy storage cells

22

contact means

24

space

26

fixing means

100-103

process steps

Claims (10)

Vehicle frame (2) for an electrically driven vehicle, in particular a tilting vehicle, with at least one tubular frame element (4) through which a load acting on the vehicle frame (2) can be absorbed and transmitted, which is formed as a one-piece component and has at least one layer made of fiber composite material, and with at least one electrical energy store (6), which comprises at least one energy storage cell (20) and at least one of the at least one energy storage cell (20) functionally assigned electrical contact means (22), which is designed as a one-piece component in the frame element (4) is arranged and is undetachably fixed to the frame element (4) by means of casting with a resin and/or by means of foaming with a foam agent (14). Vehicle frame (2) according to claim 1 , characterized in that the energy store (6) is at least partially or completely surrounded by the frame element (4) along a circumferential direction with respect to the tubular frame element (4) and at least partially bears directly or indirectly on it. Vehicle frame (2) according to claim 1 or 2 , characterized in that the frame element (4) comprises one or more layers of fiber composite material, in particular glass fiber (8) or a carbon fiber reinforced plastic (10), and/or that the energy store (6) consists of one or more layers of fiber composite material is woven or braided, in particular wherein the one or more layers of fiber composite material is impregnated with a resin and cured. Vehicle frame (2) according to one of the preceding claims, characterized by at least one layer of glass or glass fiber (8) which is in direct contact with the energy store (6) and which is arranged between the energy store (6) and at least one further layer of fiber composite material. Vehicle frame (2) according to one of the preceding claims, characterized in that the energy store (6) comprises at least two energy storage cells (20) which are electrically connected to one another via the respective functionally assigned electrical contact means (22) and in that the at least two energy storage cells (20 ) are in direct contact with one another or are spaced apart from one another by at least one intermediate space (24) extending transversely to the circumferential direction of the energy store. Vehicle frame (2) according to claim 5 characterized by at least one fixing means (26) by which two spaced-apart energy storage cells (20) are fixed against moving transversely to the circumferential direction of the energy store (6), in particular wherein the fixing means (26) comprises the foaming agent (14). Vehicle frame (2) according to one of the preceding claims, characterized by at least one cable-like electrical line element (16) which can be connected or is connected to the energy store (6) and an electrical consumer and which is arranged in a cavity (18) of the frame element (4). and/or is woven or braided into the at least one layer made of fiber composite material, in particular wherein the one layer or the several layers made of fiber composite material is impregnated with a resin and cured. Vehicle frame (2) according to any one of the preceding claims, characterized by at least one cooling element with the energy store (6) and an active or passive heat exchanger can be connected or is connected and which is arranged in a cavity (18) of the frame element (4) and/or is fixed in the at least one layer of fiber composite material in a manner woven or braided around it, in particular the one layer or the several layers of fiber composite material having a resin soaked and hardened. Vehicle frame (2) according to one of the preceding claims, characterized by at least one stop means (12) against which the energy store (6) rests at least in a direction transverse to the circumferential direction of the tubular frame element (4), the stop means (12) being formed by a recessed Section of the frame member (4) and / or formed by the foam means (14), such as polyurethane foam. Electrically driven vehicle, in particular a tilting vehicle, with at least one vehicle frame (2) according to one of Claims 1 until 9 .

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