JP2019089377A - Battery loading structure of electric vehicle - Google Patents

Abstract

To provide a battery loading structure of an electric vehicle that can protect a battery module while weight-reducing.SOLUTION: In the battery loading structure of a vehicle V, provided with a pair of left and right floor panels 4 forming a closed cross section C1 extending in a longitudinal direction below a floor panel 1 and a pair of left and right support frames 33 for supporting a battery module 20, where the pair of floor frames 4 support the pair of support frames 33 respectively from above, is provided a lower flange part 2d extending downward from a lower end part of a closed cross section C2 formed by making a side sill outer panel 2a and a side sill inner panel 2b to collaborate and is provided an outer flange part 33c extending upward from an end part outside in a vehicle width direction of a closed cross section C3 formed by making a support-frame lower panel 33a and a support-flame upper panel 33b to collaborate, where the outer flange part 33c is formed to overlap with the lower flange part 2d in a side view.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a battery mounting structure of an electric vehicle, and more particularly to a battery mounting structure of an electric vehicle in which a floor frame below the floor holds a support frame supporting a battery module from above.

Conventionally, in an electric vehicle such as a hybrid vehicle or an electric vehicle, a battery serving as a power source of an electric motor for driving a wheel is large and has a large capacity. It arranges using lower space.
When a large battery module is supported by the support frame held by the floor frame below the floor panel, the shock load at the time of the collision is easily transmitted directly to the battery module, so the battery module at the time of a collision, especially at the side collision Protection is required.

  The vehicle body lower structure of Patent Document 1 includes a battery accommodating recess formed by expanding a floor panel stretched between a pair of left and right side sills upward, and a frame-shaped peripheral frame, and arranges a battery in the battery accommodating recess A battery tray, an extension member extending in the longitudinal direction along an outer edge of a lower portion of the battery accommodation recess in the vehicle width direction outer wall, and a closed U-shaped cross section between a pair of side sills in cooperation with the upper surface of the floor panel And the peripheral frame is connected to the lower portion of the extension member, and the cross member forms a first closed cross-section structure between the vehicle width direction outer side wall of the extension member and the inner side wall of the side sill doing.

Patent No. 4858183 gazette

In the vehicle body lower structure of Patent Document 1, at the time of a side collision, the impact load input to the side sill is supported by the first closed cross-section structure between the extension member and the side sill, Diffusion to the collision side enhances the battery protection effect.
However, in the vehicle body lower structure of Patent Document 1, in addition to the first closed cross-section structure portion, the gusset connecting the extension member and the side sill is formed inside the extension member in order to increase the reaction force against impact load. The second closed cross-sectional structure and the third closed cross-sectional structure and the like formed in the upper part of the battery housing recess are respectively provided, which may increase the weight of the vehicle body as the number of parts increases.

Therefore, it is also conceivable to use a special material frame such as high strength steel as the body frame member for the purpose of weight reduction by reducing the number of parts.
However, it is uneconomical to form each vehicle body frame member from high strength special members from the viewpoint of material cost, and also from the viewpoint of setting the load path for dispersing the impact load at the time of collision. Because it is effective, it is not a realistic measure.
That is, in order to reduce the weight of the vehicle and protect the battery module, further improvement is required.

  An object of the present invention is to provide a battery mounting structure or the like of an electric vehicle capable of protecting a battery module while reducing weight.

  The battery mounting structure of the electric vehicle according to claim 1 is a left and right side disposed inward in the vehicle width direction of the pair of left and right side sills and forming a first closed cross section extending in the front and rear direction below the floor panel in cooperation with the floor panel. A pair of floor frames and a pair of left and right support frames supporting the chargeable and dischargeable battery module and extending in the front and rear direction, the pair of floor frames respectively holding the pair of support frames from the upper side In the battery mounting structure of an electric vehicle, a lower flange portion extending downward from a lower end portion of a second closed cross section formed by causing the side sill outer panel and the side sill inner panel to cooperate with the side sill is provided. And an outer end extending upward from the outer end in the vehicle width direction of the third closed cross section formed in cooperation with the support frame upper panel. The flange portion is provided, the outer flange portion, and characterized in that it is formed to overlap at the lower flange portion and the side view.

In the battery mounting structure of the electric vehicle, the side sill is provided with a lower flange portion extending downward from the lower end portion of the second closed cross section formed by cooperating the side sill outer panel and the side sill inner panel, and the support frame lower panel And the support frame upper panel cooperate with each other to form an outer flange portion extending upward from the outer end portion in the vehicle width direction of the third closed cross section. They can be arranged to be adjacent to each other visually.
Since the outer flange portion is formed to overlap the lower flange portion in a side view, in the side collision, the flange portion is configured to displace the side sill inward in the vehicle width direction using the support frame for supporting the battery module. It can suppress by contact | abutting and protection of a battery module can be aimed at.

The invention of claim 2 is such that in the invention of claim 1, the outer flange portion is formed between the lower flange portion and the first closed cross section and overlaps the first closed cross section in a side view It is characterized by being formed in
According to this configuration, at the time of a side collision, the floor frame can be used to suppress the inward displacement of the support frame in the vehicle width direction, and as a result, to suppress the inward displacement of the side sill in the vehicle width direction. it can.

The invention of claim 3 is characterized in that, in the invention of claim 1 or 2, the third closed cross section is formed in a substantially flat shape having a dimension in the vehicle width direction larger than a dimension in the vertical direction.
According to this configuration, the outer flange portion of the support frame is disposed between the lower flange portion of the side sill and the first closed cross section of the floor frame in plan view while the support frame is disposed below the floor frame. Can.

According to the invention of claim 4, in the invention of any one of claims 1 to 3, the pair of support frames are shifted outward in the vehicle width direction along the pair of floor frames. The outer flange portion is provided with a plurality of molding ridges extending in the vertical direction.
According to this configuration, it is possible to increase the bending strength of the support frame in the vehicle width direction.

The invention of claim 5 relates to the invention according to any one of claims 1 to 4 in that the pair of support frames, the front end frame connecting the front ends of the pair of support frames, and the pair of A rear end frame connecting the rear ends of the support frames forms a frame-like frame located around the battery module, and the frame-like frame cooperates with at least an upper cover covering an upper portion of the battery module And a battery pack.
According to this configuration, it is possible to efficiently disperse the impact load at the side collision to the non-collision side while protecting the battery module.

  According to the battery mounting structure of the electric vehicle of the present invention, weight reduction and protection of the battery module can be compatible without increasing the number of parts.

FIG. 1 is a bottom view of a vehicle according to a first embodiment. It is the perspective view seen from the rear side lower left. FIG. 3 is a cross-sectional view taken along line III-III of FIG. It is the IV-IV sectional view taken on the line of FIG. FIG. 5 is a cross-sectional view taken along the line V-V of FIG. It is a rear side principal part side view. It is a perspective view of the assembly unit which assembled the battery pack, the electric power generating apparatus, and the exhaust system. It is an exploded perspective view of a battery pack. It is a perspective view of the lower half part of a battery pack. It is the perspective view which abbreviate | omitted the battery module and the fuel tank from the lower half part of the battery pack. It is an exploded perspective view of a battery module. It is a perspective view of a support body. It is a principal part enlarged view of FIG. It is explanatory drawing of an air mixing means.

Hereinafter, embodiments of the present invention will be described in detail based on the drawings.
The following description exemplifies what applied this invention to the battery mounting structure of the electric vehicle V, and does not restrict this invention, its application thing, or its use.

Hereinafter, Example 1 of the present invention will be described based on FIGS. 1 to 14.
As shown in FIGS. 1 and 2, the electric vehicle V includes an electric motor M that rotationally drives drive wheels, a battery pack B, a power generation device G, an exhaust device E, and the like.
The vehicle V includes the charge-only engine 61 and the drive-only motor M, and the engine 61 continues to be stopped when the stored power of the mounted battery exceeds a predetermined threshold (for example, SOC is 30%). The electric vehicle of the range extender type performs charging by temporarily starting the engine 61 when the owned power of the vehicle is less than a predetermined threshold.

First, the premise structure which concerns on the frame member of the vehicle V is demonstrated.
Hereinafter, the arrow F is described as the front, the arrow L as the left, and the arrow U as the upper.
The floor panel 1 constitutes a floor surface of a passenger compartment, and the height position becomes higher from the rear end of the substantially horizontal front floor panel 1a on which the front seat (not shown) is disposed, and the front floor panel 1a. As described above, it has a kickup portion 1b in which a rear seat (not shown) is disposed to shift to a rearward upward slope and a rear floor panel 1c extending rearward from the kickup portion 1b.
A cross member 16 extending in the left-right direction in cooperation with the rear floor panel 1c and separating a vehicle compartment and a luggage compartment is disposed on the upper rear side of the rear floor panel 1c.

As shown in FIGS. 1 to 5, a pair of left and right side sills 2 extending in the front and rear direction are respectively connected to the left and right ends of the floor panel 1 (front floor panel 1 a).
The side sill 2 includes a side sill outer panel 2a having a hat-shaped cross section to which the side frames 3 forming the vehicle body side are connected and a side sill inner panel 2b having a hat-shaped cross section to which the floor panel 1 is connected.
The outer panel 2a and the inner panel 2b join upper side flanges together to form an upper side flange portion 2c and join lower side flanges together to form a lower side flange portion 2d. The second closed cross section is configured.
The upper flange portion 2c extends upward from a substantially central portion of the upper wall of the closed cross section C2, and the lower flange portion 2d extends downwardly from a substantially central portion of the lower wall of the closed cross section C2.

As shown in FIG. 4, on the inner side in the vehicle width direction of the pair of side sills 2, a pair of left and right floor frames 4 extending in the front and rear direction is provided. The pair of floor frames 4 are disposed such that the separation distance in the left-right direction becomes larger toward the rear side.
The floor frame 4 is formed in a hat shape in cross section, and cooperates with the floor panel 1 on the lower side of the floor panel 1 to form a closed cross section C1 (first closed cross section) having a substantially rectangular cross section.
The lower end portion of the floor frame 4 is formed to be lower in height position than the lower end portion of the side sill 2 (the lower end portion of the lower flange portion 2 d).
Further, the vehicle width direction outer side wall portion of the floor frame 4 and the vehicle width direction inner side wall portion (inner panel 2 b) of the side sill 2 are connected by the plurality of reinforcing members 5 forming a closed cross section in cooperation with the floor panel 1 It is done. Thus, the movement of the side sill 2 inward in the vehicle width direction at the time of a side collision is suppressed, and the impact load is dispersed.

A pair of left and right front side frames 7 is disposed on the front extension portion of the pair of floor frames 4 so as to extend forward via a dash panel 6 connected to the front end of the floor panel 1. At the front end of the pair of front side frames 7, crash cans that can absorb shocks are fixed by compression deformation, and bumper reinforcement and a bumper face are attached to connect these crash cans ((1) All are not shown).
In a space formed between the pair of front side frames 7, a drive motor M is disposed which rotationally drives a front wheel (not shown) which is a drive wheel.

A pair of left and right rear side frames 8 are disposed on the rear extension portions of the pair of floor frames 4 so as to extend rearward.
As shown in FIGS. 6 and 13, crush cans 9 capable of absorbing shock by compression deformation are respectively fixed to the rear end portions of the pair of rear side frames 8, and bumper lanes are connected so as to connect these crush cans 9. Forcement 10 and a bumper face (not shown) are mounted.
Below the pair of rear side frames 8, a pair of left and right first rear subframes 11 extending in the front and rear direction, and a pair of left and right second rear subs disposed below the pair of first rear subframes 11 A frame 12 and a pair of left and right third rear subframes 13 extending left and right behind the first and second rear subframes 11 and 12 are provided.

The first rear sub-frame 11 is connected to a lower portion of the rear side frame 8 and shifts downward to a gentle curve, and the second rear sub-frame 12 is inward of the first rear sub-frame 11 in the vehicle width direction , And is connected to the rear end of the battery pack B and is formed to shift upward in a gently curved shape. Rear end side portions of the first and second rear sub-frames 11 and 12 are connected to a rear end portion of the exhaust device E via a bracket 14.
As a result, at the time of rear end collision, a plurality of load paths can be formed by the rear side frame 8 and the first and second rear sub-frames 11 and 12, and a crash space required for shock absorption can be shortened. A power generator G is disposed in a space formed between the pair of rear side frames 8 and the first and second rear sub-frames 11 and 12.
As shown in FIG. 1, FIG. 2, FIG. 8 and FIG. 13, the vehicle width direction inner portions of the pair of third rear sub-frames 13 are respectively connected to the left and right ends of the exhaust system E, and the vehicle width direction outer portions are It is connected to the middle lower part of the rear side frame 8 respectively.

Next, the battery pack B will be described.
The battery pack B is required to lay out a high voltage battery in which a plurality of (for example, 16) battery modules 20 are connected in series outside the vehicle, in particular, in the space below the floor panel 1. It is constituted to secure the nature (waterproofness).
This battery pack B uses a natural air cooling system in which the heat generated in the battery module 20 is discharged directly to the outside of the vehicle using heat conduction, and a forced cooling system using cooling water or cooling air by a blower fan Is not adopted.

Here, before describing the battery pack B, the battery module 20 will be described.
As shown in FIG. 7, the battery module 20 has a rectangular parallelepiped shape in which a plurality of (for example, 12) battery cells 21 having a rectangular parallelepiped shape having a standard voltage are horizontally aligned in a stacked manner with a separator 22 interposed therebetween. A battery assembly A is provided.
The battery cell 21 is, for example, a lithium ion battery which is a type of secondary battery.
Hereinafter, an example of the battery module 20 in which the stacking direction is set in the front-rear direction will be described.

The separator 22 is a synthetic resin material excellent in heat blocking property, heat resistance and heat stability, for example, a polybutylene terephthalate (PBT) sheet so as not to propagate abnormal heat of the battery cell 21 to another normal battery cell 21. It is composed of
In this battery assembly A, since each electrode of all the battery cells 21 is arranged to face upward, the bus bar 23 (electrode connection portion) connecting adjacent electrodes, each harness and cable are on the upper surface portion It is arranged.

As shown in FIG. 7, the battery module 20 includes a pair of front and rear end plates 24, a pair of left and right aluminum alloy bind bars 25 (sandwich panel members), an upper plate 26 and the like.
One end plate 24 is overlapped so as to cover the entire front end portion of the battery assembly A, and the other end plate 24 is overlapped so as to cover the entire rear end portion of the battery assembly A.
The plate-like bind bars 25 are respectively disposed so as to cover the entire area of both side surfaces of the battery assembly A, and are configured to be able to sandwich the pair of end plates 24 in the front-rear direction.
The left bind bar 25 is provided with a pair of front and rear mounting portions 25a which are respectively bent in the right orthogonal direction from the front end portion and the rear end portion, and the pair of mounting portions 25a and the pair of end plates 24 are fastening members Each is fixed by fastening.
The right bind bar 25 is symmetrical with the left bind bar 25.

A heater unit 27 (sheet-like heater means) is attached to one of the pair of left and right bind bars 25, for example, the left side surface of the left bind bar 25.
The heater unit 27 is configured of a sheet-like electric heating wire heater that performs heat dissipation control by self-determination of the ambient temperature, for example, a PTC (Positive Temperature Coefficient) heater that can partially contact the bind bar 25.
Thereby, the heat from the heater unit 27 is propagated to the entire side surface portion of the battery assembly A via the bind bar 25 regardless of the shape of the heater unit 27.

The upper plate 26 is made of a synthetic resin plate material, and is formed so as to cover the entire upper surface portion of the battery assembly A, including the bus bars 23 and the respective harnesses.
When the battery module 20 is accommodated in the battery pack B, a silicon sheet 28 (thermal conductive sheet) having excellent thermal conductivity is attached to substantially the entire area of the lower surface of the battery assembly A. In the case of the battery module 20 in which the stacking direction is set in the left-right direction, the battery module 20 in which the stacking direction is set in the front-rear direction is rotated 90 ° around the vertical axis.

Also, the description returns to the battery pack B.
The battery pack B is integrally assembled with the power generation device G and the exhaust device E to form an assembly unit.
As shown in FIGS. 8 to 11, the battery pack B mainly includes a substantially U-shaped metal frame 30, a metal bottom plate 31, and a synthetic resin upper cover 32.
The frame-shaped frame 30 and the metal bottom plate 31 correspond to the lower cover of the battery pack B.

The frame-like frame 30 includes a pair of left and right support frames 33 extending longitudinally, a front end frame 34 connecting the front ends of the pair of support frames 33 to the left and right, and a rear end of the pair of support frames 33 And a rear end frame 35 connected to the
The pair of support frames 33 is disposed below the pair of floor frames 4 so as to be shifted outward along the pair of floor frames 4 toward the rear in the vehicle width direction.

As shown in FIG. 4, the support frame 33 includes a substantially L-shaped support frame lower panel 33 a and a substantially W-shaped support frame upper panel 33 b.
The support frame lower panel 33a and the support frame upper panel 33b are substantially formed by joining the left side (outside in the vehicle width direction) flanges to form the outer flange portion 33c and joining the right side flanges to form the inner flange portion 33d. A flat closed cross section C3 (third closed cross section) is configured. The lower frame 33a and the upper frame 33b made of steel plate are formed into respective shapes by press working, and then the flanges are welded to each other. Therefore, the outer flange 33c extends in the vertical direction. A plurality of bead-shaped forming rods 33e (see FIG. 2, FIG. 8, FIG. 10 and FIG. 11) are formed.
The closed cross section C3 is formed in a substantially flat shape in which the left and right dimensions are larger than the upper and lower dimensions, and the upper end of the closed cross section C3 and the lower end of the floor frame 4 are separated by a predetermined distance.

The outer flange portion 33c extends upward from the upper left end of the closed cross section C3 and the height position of the upper end thereof is higher than the height position of the lower end of the lower flange portion 2d of the side sill 2, in other words, The outer flange portion 33c and the lower flange portion 2d are formed to overlap in a side view. Further, the height position of the upper end portion of the outer flange portion 33c is formed to be higher than the height position of the lower end portion of the floor frame 4 (closed cross section C1).
Thereby, at the time of a side collision, the movement of the side sill 2 inward in the vehicle width direction is suppressed by the outer flange portion 33c, and further, when the impact load is large, the movement inward of the support frame 33 is suppressed by the closed cross section C1. can do.
The inner flange portion 33 d extends rightward from the lower right end lower end portion of the closed cross section C3.

As shown in FIGS. 8, 10, and 11, four bolt portions 33f to 33i for supporting the lower end portion of the opposite floor frame 4 are provided on the upper wall portion of the support frame 33.
These bolt portions 33f to 33i are sequentially disposed on the upper side of the floor panel 1 from the front to the rear, and portions where the cross members (not shown) forming the closed cross section extending in the vehicle width direction overlap the floor frame 4 In each case, they are fastened and fixed using nut members (not shown).

The front end frame 34 forms a closed cross section connecting the front ends of the pair of support frames 33. A left and right pair of bolt portions 34a are formed in the middle of the front end frame 34, and the pair of bolt portions 34a are fastened and fixed to the front of the vehicle body.
The rear end frame 35 forms a closed cross section connecting the rear ends of the pair of support frames 33. In the middle of the rear end frame 35, a pair of left and right brackets 36 is provided. The pair of brackets 36 are respectively fixed to the rear wall portion of the rear end frame 35 and formed to extend upward. These brackets 36 are respectively fastened and fixed to the lower part of the cross member 16 using a nut member (not shown).
The left and right end side portions of the rear wall portion of the rear end frame 35 abut and support the front end portions of the pair of rear sub-frames 12. As a result, the impact load input to the rear sub-frame 12 can be dispersed and damped over the entire area of the frame-like frame 30 independent of the vehicle compartment.

As shown in FIG. 11, the frame-shaped frame 30 is provided with reinforcing members 41 to 44 that cooperate with the bottom plate 31 on the upper side of the bottom plate 31 to form a closed cross section.
Of the members 41 to 44, the horizontal members 41 to 43 connect the pair of bolt portions 33f, 33g, and 33i in the left and right direction, respectively, and the vertical members 44 It is comprised so that it may connect in the front-back direction between the left-hand middle part of 35. FIG.
The front side portion of the frame-shaped frame 30 with respect to the lateral members 43 is disposed below the front floor panel 1a, and the rear side portion of the frame-shaped frame 30 with respect to the lateral members 43 is a kickup portion 1b and a rear floor panel 1c. It is located below.
In the present embodiment, the ratio of the separation distance between the vertical member 44 and the left side support frame 33 and the separation distance between the vertical member 44 and the right side support frame 33 is set to 1: 3.

The bottom plate 31 is made of a metal excellent in thermal conductivity, such as an aluminum alloy.
As shown in FIGS. 4 and 5, the left end side portion of the bottom plate 31 is formed in a crank shape and is supported by the upper wall portion of the support frame 33 and the inner flange portion 33 d. The same applies to the right end portion of the bottom plate 31. Further, the front end side portion and the rear end side portion of the bottom plate 31 are formed in a crank shape and are respectively supported by the flange portion and the upper wall portion of the front end frame 34 and the rear end frame 35.

The upper cover 32 is made of a lightweight and highly rigid synthetic resin material, for example, polypropylene (PP) containing a glass fiber reinforcement.
As shown in FIGS. 8 and 9, the upper cover 32 has a left-right asymmetry in which the front side portion is larger in left-right dimensions and smaller in top-bottom dimensions than in the rear-side portion.
A convex portion capable of housing a junction box including a relay or the like is formed on the front side upper portion of the upper cover 32, and a convex portion capable of housing a battery monitoring unit including an ECU is formed on the rear side upper portion .
The outer peripheral flange portion of the upper cover 32 is fixed in intimate contact with the inner wall of the upper wall portion of the frame 30 through a sealing gasket (not shown).

Inside the battery pack B, a plurality of battery modules 20 configured of a first battery module mounted in a one-layer arrangement and a second battery module mounted in a two-layer arrangement in the upper and lower layers are accommodated.
As shown in FIGS. 9 and 10, four of the transverse members 41 and 42 are disposed so that the laminating direction is back and forth and aligned left and right, and the laminating direction is left and right between the transverse members 42 and 43 Between the horizontal member 43 and the rear end frame 35 so that the stacking direction is in front of and behind the longitudinal member. In addition, a total of sixteen battery modules 20, in which three batteries arranged in the left and right direction are arranged in upper and lower two stages, are housed in a sealed state.
The battery modules 20 are electrically connected in series by a plurality of bus bars 29.
Hereinafter, among the six battery modules 20 disposed below the so-called kick-up portion 1b and the rear floor panel 1c between the horizontal member 43 and the rear end frame 35, in particular, the three battery modules arranged in the lower stage The lower battery module 20a and the three battery modules 20 arranged in the upper stage are referred to as upper battery modules 20b. When these are generically referred to as battery module 20.

As shown in FIGS. 3 and 5, the three upper battery modules 20b are respectively supported by the battery pack B via a support 50 made of metal, for example, an aluminum alloy.
As shown in FIG. 12, the support 50 extends downward from the left and right ends of the three plate-like placement portions 51 extending horizontally and adjacent to the left and right and adjacent to the left and right of the plate-like placement portions 51. It has four plate-like legs 52 and the like that fit.
The placement unit 51 is configured to be capable of surface contact with the bottom of the upper battery module 20 b (the lower surface of the battery cell assembly A) via the silicon sheet 28.
The leg portion 52 is formed integrally with the mounting portion 51, and is configured to be able to accommodate the lower battery module 20a mounted between the adjacent leg portions 52.
The lower end portion of the leg portion 52 is formed so as to be in surface contact with the bottom plate 31, and mounting portions 53 extending in the horizontal direction are respectively provided in middle steps of the front end wall and the rear end wall. The front end side attachment portion 53 is fastened and fixed to the horizontal member 43 via a fastening member, and the rear end side attachment portion 53 is fastened and fixed to the rear end frame 35 via the fastening member.

The leg 52 is provided with a cooling upper fin 52a having a plane orthogonal to the front and rear direction in the upper half, and the leg 52 at both left and right ends is provided with a plane orthogonal to the front and rear direction in the lower half and A lower cooling fin 52 b is provided whose surface is in surface contact with the bottom plate 31.
The rear lower fin 52b is formed to be continuous with the upper fin 52a.
Thereby, the heat of the upper battery module 20b is introduced to the placement unit 51 via the silicon sheet 28, and the introduced heat is released to the outside from the lower end of the leg 52 and the lower end of the lower fin 52b. Can.

Next, the motor M will be described.
A power unit (not shown) for driving the vehicle V is provided between the pair of front side frames 7 and immediately in front of the suspension cross member (not shown) of the front wheels.
The power unit includes, for example, a motor unit including a motor M (see FIGS. 1 and 2) and a DC-AC converter (not shown) which is an inverter for the motor, and a power transmission for transmitting the driving force of the motor unit to the front wheels. A trunk axle (not shown) including a mechanism (a speed reduction mechanism and a differential mechanism) is integrally coupled to line in the vehicle width direction.
The motor shaft center of the motor M, the shaft center of the input shaft connected to the motor shaft in the trunk axle, and the shaft center of the output shaft (joint shaft) of the power unit all extend in the vehicle width direction.

Next, the power generation device G will be described.
As shown in FIGS. 3, 6, and 8, the power generation device G includes an engine 61, a generator 62, an AC-DC converter 63, an under cover 69, a fuel tank T, and the like.
The power generation device G is disposed at a center position in the vehicle width direction near the rear end of the battery pack B. The power generation device G is integrally formed as a unit, the front end portion is fixed to the lower portion of the cross member 16 via the bracket 64, and the left and right side portions are the rear sub-frames 11 and 12 via the brackets (not shown). It is fixed to The lower part of the power generation device G is covered with an undercover 69 made of synthetic resin.

The engine 61 is a one-rotor small rotary engine, and is disposed such that the rotation shaft of the rotor extends in the front-rear direction. The engine 61 is configured as a side exhaust type in which an exhaust port is formed on a side wall, and the rotation shaft of the generator 62 connected to the rotation shaft of the rotor with energy obtained by burning the fuel supplied from the fuel tank T. Is driven to rotate.
When the stored power of the battery pack B falls below the predetermined threshold, the engine 61 is started, and the generator 62 is operated at a prescribed rotation speed set in advance to achieve the maximum power generation efficiency.
An intake pipe (not shown) forming an intake passage and an exhaust pipe 65 forming an exhaust passage are in communication with a combustion chamber of the engine 61.
An air cleaner is disposed in the middle of the intake pipe, and is connected to an insertion port provided on an inner panel of the right wheel house (not shown).
The exhaust pipe 65 is provided with a catalyst device 66 and a muffling device 67 in the middle.

As shown in FIGS. 3, 6 and 8, the generator 62 is disposed between the battery pack B and the engine 61. As a result, the front and rear dimensions including the engine 61 can be shortened, and the generator 62 can be disposed forward, thereby avoiding direct interference between the generator 62, which is a high voltage component, and the exhaust system E at the time of rear collision. doing.
The converter 63 converts the alternating current from the generator 62 into a direct current and supplies it to each battery module 20 at the time of charging by starting of the engine 61.

The fuel tank T is disposed on the bottom plate 31 on the left side of the vertical member 44 between the horizontal member 43 and the rear end frame 35, and is fixed to the horizontal member 43 and the rear end frame 35 The battery pack B is supported at an upper open state via a bracket 37 (see FIG. 11) of Inside the fuel tank T, a fuel pump, a suction strainer to the fuel pump, and the like are accommodated (all not shown).
As shown in FIGS. 5 and 8 to 10, the storage capacity of the fuel tank T is reduced as the engine 61 is downsized, and the fuel tank T is formed in a substantially vertically elongated shape in a front view. Specifically, the top of the fuel tank T is set to be substantially equal to the height position of the top of the upper battery module 20b which is the second battery module.

As shown in FIG. 5, the lower half portion of the fuel tank T is formed such that the left-right dimension (crossing area) increases toward the upper side. Thus, both the installation area and the tank capacity are secured.
Further, as shown in FIGS. 5, 8 and 9, since the middle step portion of the fuel tank T protrudes rightward, the left side of the upper cover 32 is recessed rightward so as to avoid the fuel tank T. The avoidance part 32a is provided.
Thus, the interference between the fuel tank T and the upper cover 32 can be avoided, and the damage to the upper cover 32 can be prevented, and the sealing performance to the battery module 20 can be improved.

Next, the exhaust system E will be described.
Since the exhaust gas temperature of the engine 61 driven at high speed during charging becomes high temperature, the exhaust system E stirs the exhaust gas and air (outside air) in advance before discharging the exhaust gas to the outside, The gas temperature is reduced and then released to the outside.
As shown in FIG. 3, FIG. 6, FIG. 8, FIG. 13 and FIG. 14, the exhaust pipe 65, the catalyst device 66 provided in the middle of the exhaust pipe 65, and the catalyst device 66 are provided downstream The exhaust system 70 is provided with a metal exhaust box 70 which encloses the noise reduction device 67, the air mixing means 68, the catalyst device 66, the noise reduction device 67, the air mixing means 68 and the like at predetermined intervals.
The catalyst device 66 is formed in a substantially cylindrical shape, and is disposed such that its axial center extends at substantially the same height position as the rotor axial center of the engine 61 and to the left and right.
The silencer 67 is formed in a substantially elliptic cylindrical shape. The muffler device 67 is disposed below the catalyst device 66, with its axis extending substantially parallel to the axis of the catalyst device 66 and its major axis cross-sectional shape extending in the front-rear direction.

Therefore, after the exhaust pipe 65 extends from the rear left side where the exhaust port of the engine 61 is formed to the rear upper side, it is connected to the inlet formed at the left end of the catalyst device 66 while curving to the lower right side. ing. The exhaust pipe 65 is bent downward from the outlet formed at the right end of the catalyst device 66 and connected to the inlet formed at the front end of the right end of the silencer 67 and formed at the left end rear of the silencer 67 It extends to the left from the outlet.
As a result, at the time of rear end collision, the catalyst device 66 shifts to the lower front side, and the silencer device 67 shifts to the lower front side and rotates clockwise around the inlet in a side view. Can be suppressed.

As shown in FIG. 14, the air mixing means 68 is provided at the downstream end of the exhaust pipe 65, and includes a traveling direction guiding part 68a, a main body 68b, a flat opening 68c and the like.
The traveling direction guiding portion 68 a is configured to block the path of the exhaust gas flowing from the discharge port of the silencer 67 toward the left except for the lower side, and to guide the traveling direction of the exhaust gas downward.
Specifically, a wall portion which is gently curved and extends downward is formed on the front side in the advancing direction of the exhaust gas.

The main body portion 68 b forms a substantially flat and downwardly inclined volume chamber extending to the left and right.
The traveling direction vector of the exhaust gas guided to the traveling direction guiding portion 68a has a downward vector and a rightward vector due to the reflection from the wall portion, so a part of the exhaust gas does not receive a force from the other The combined vector of the downward vector and the rightward vector forms a counterclockwise swirling flow (vortex) about the longitudinal axis as indicated by an arrow in the drawing.
Therefore, the main body 68b has sufficient vertical and horizontal lengths to form a counterclockwise swirling flow.

The flat opening 68 c is formed to extend downward and to the left and right at the lower end of the main body 68 b and to be capable of introducing ambient air (outside air).
The air mixing means 68 is a flat opening together with the air in the exhaust box 70 and around the air mixing means 68 when the vehicle stops in the absence of traveling wind, and the flow outside the turning outside jumps out from the main body 68b. By taking it into the inside of the main body 68b from 68c, it has a first temperature lowering function to lower the temperature of the exhaust gas in the main body 68b before discharge.

As shown in FIGS. 2 and 13, the exhaust box 70 is formed in a substantially rectangular box shape, the air mixing means 68 is disposed on the left side portion, and operates in synchronization with the start of the engine 61. A scavenging fan 71 (air introducing means) capable of introducing outside air to the inside is formed on the right side wall. An opening 70 a is formed at the left rear bottom of the exhaust box 70 to face the flat opening 68 c.
Thereby, even when the vehicle is stopped, the scavenging fan 71 can introduce the external air flowing leftward into the exhaust box 70, and in addition to the first temperature lowering function, the exhaust gas temperature around the air mixing means 68 is Since the temperature can be reduced, the exhaust gas temperature is further reduced in the main body 68b.

Further, since the flat opening 68c and the opening 70a are disposed close to each other, in addition to the first temperature lowering function described above when the vehicle is traveling, the exhaust gas whose temperature is lowered by being mixed with the air in the exhaust box 70 is Can be discharged out of the vehicle by the suction action by the negative pressure.
As described above, regardless of the traveling state of the vehicle V, the temperature of the gas discharged from the exhaust device E can be reduced inside the exhaust device E (main body portion 68b), and particularly when the vehicle is stopped, high temperature gas around the vehicle It is possible to avoid the discharge of air, and to eliminate the discomfort due to the hot air flow of the rear seat passenger when getting on and off.

Next, the operation and effects of the battery mounting structure of the electric vehicle will be described.
According to the battery mounting structure of the electric vehicle V according to the first embodiment, the lower flange portion 2d extending downward from the lower end portion of the closed cross section C2 formed by causing the side sill 2 to cooperate with the side sill outer panel 2a and the side sill inner panel 2b. Of the side sill 2 so that the support frame 33 is provided with the outer flange portion 33c extending upward from the outer end in the vehicle width direction of the closed cross section C3 formed by cooperating the lower support frame 33a and the upper support frame 33b. The lower flange portion 2 d and the outer flange portion 33 c of the support frame 33 can be arranged adjacent to each other in plan view.
Since the outer flange portion 33c is formed to overlap the lower flange portion 2d in a side view, the side sill 2 is displaced inward in the vehicle width direction using the support frame 33 supporting the battery module 20 at the side collision. This can be suppressed by the flange portions coming into contact with each other, and the battery module 20 can be protected.

  Since the outer flange portion 33c is formed between the lower flange portion 2d and the closed cross section C1 and formed so as to overlap the closed cross section C1 in a side view, the support frame using the floor frame 4 at the time of side collision The inward displacement of the vehicle width direction 33 can be suppressed, and as a result, the inward displacement of the side sill 2 can be suppressed.

  Since the closed cross section C3 is formed in a substantially flat shape having a vehicle width direction dimension larger than the vertical direction dimension, the outer flange portion 33c of the support frame 33 is viewed in a plan view while the support frame 33 is disposed below the floor frame 4. It can be disposed between the lower flange 2 d of the side sill 2 and the closed cross section C 1 of the floor frame 4.

  The pair of support frames 33 is disposed to move to the outer side in the vehicle width direction toward the rear side along the pair of floor frames 4, and a plurality of molding ridges 33e extending in the vertical direction are formed on the outer flange portion 33c. Thus, the bending strength of the support frame 33 in the vehicle width direction can be increased.

  The battery module 20 includes a pair of support frames 33, a front end frame 34 connecting the front ends of the pair of support frames 33, and a rear end frame 35 connecting the rear ends of the pair of support frames 33. Since the frame-shaped frame 30 located in the periphery is formed and the frame-shaped frame 30 cooperates with at least the upper cover 32 covering the upper part of the battery module 20 to constitute the battery pack B, the battery module 20 is protected The impact load at the time of a collision can be efficiently dispersed to the non-collision side.

Next, a modification in which the embodiment is partially changed will be described.
1) In the above embodiment, an example of a range extension type hybrid vehicle has been described, but it is sufficient if it is an electric vehicle supporting a battery module at least in the space below the floor panel, and among split type, series type and parallel type It can be applied to any hybrid vehicle. Also, it may be applied to an electric car.

2) In the above embodiment, the first battery module mounted in a single layer on the front side of the kickup portion and the second battery module mounted in a second layer on the rear side of the kickup portion are accommodated in the battery pack Although the example has been described, it may be a battery pack that accommodates only one of the first battery module and the second battery module.
It is also possible to provide only one layer of battery module across the front and back of the kickup portion.

3) In the above embodiment, an example of the engine started to generate electric power when the owned power of the battery module falls below the threshold has been described, but if the owned power of the battery module is not below the threshold, for example, lubrication The engine may be started when the stop period continues for a predetermined period to circulate the oil. In addition to the motor, it is possible to run by the engine, and when acceleration demand from the passenger is high, it is possible to switch to engine drive and start the engine.

4) In addition, those skilled in the art can carry out the embodiments in which various modifications are added to the embodiments or a combination of the embodiments without departing from the spirit of the present invention, and the present invention can be implemented as such It also includes various modifications.

Reference Signs List 1 floor panel 2 side sill 2a side sill outer panel 2b side sill inner panel 2d lower flange 4 floor frame 20 battery module 30 frame-like frame 32 upper cover 33 support frame 33a support frame lower panel 33b support frame upper panel 33c outer flange portion 33e Front end frame 35 Rear end frame V Vehicle B Battery pack C1, C2, C3 Closed cross section

Claims (5)

A pair of floor frames disposed on the inner side in the vehicle width direction of the pair of left and right side sills and forming a first closed cross section extending in the longitudinal direction below the floor panel in cooperation with the floor panel, and a chargeable / dischargeable battery In a battery mounting structure of an electric vehicle, comprising: a pair of left and right support frames supporting the module and extending in the front and rear direction, wherein the pair of floor frames respectively hold the pair of support frames from above;
The side sill is provided with a lower flange portion extending downward from a lower end portion of a second closed cross section formed by causing the side sill outer panel and the side sill inner panel to cooperate with each other.
The support frame is provided with an outer flange portion extending upward from an outer end in the vehicle width direction of a third closed cross section formed by cooperating the support frame lower panel and the support frame upper panel in cooperation with each other.
The battery mounting structure for an electric vehicle, wherein the outer flange portion is formed to overlap with the lower flange portion in a side view.   The outer flange portion is formed between the lower flange portion and the first closed cross section, and is formed so as to overlap the first closed cross section in a side view. Battery mounting structure of electric vehicles.   The battery mounting structure for an electric vehicle according to claim 1 or 2, wherein the third closed cross section is formed in a substantially flat shape having a vehicle width direction dimension larger than a vertical direction dimension. The pair of support frames are disposed so as to shift to the outside in the vehicle width direction toward the rear side along the pair of floor frames,
The battery mounting structure for an electric vehicle according to any one of claims 1 to 3, wherein the outer flange portion is formed with a plurality of molding ridges extending in the vertical direction. Around the battery module by the pair of support frames, the front end frame connecting the front ends of the pair of support frames, and the rear end frame connecting the rear ends of the pair of support frames Form a frame-like frame,
The battery mounting of an electric vehicle according to any one of claims 1 to 4, wherein the frame-like frame constitutes a battery pack in cooperation with at least an upper cover covering an upper portion of the battery module. Construction.

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