WO2022249782A1 - バッテリーケース構造およびバッテリーケース構造の製造方法 - Google Patents

バッテリーケース構造およびバッテリーケース構造の製造方法 Download PDF

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Publication number
WO2022249782A1
WO2022249782A1 PCT/JP2022/017662 JP2022017662W WO2022249782A1 WO 2022249782 A1 WO2022249782 A1 WO 2022249782A1 JP 2022017662 W JP2022017662 W JP 2022017662W WO 2022249782 A1 WO2022249782 A1 WO 2022249782A1
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WO
WIPO (PCT)
Prior art keywords
battery case
case structure
cross
section
closed cross
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2022/017662
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English (en)
French (fr)
Japanese (ja)
Inventor
匠 根岸
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
G Tekt Corp
Original Assignee
G Tekt Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by G Tekt Corp filed Critical G Tekt Corp
Priority to US18/556,009 priority Critical patent/US20240213606A1/en
Priority to CN202280037372.4A priority patent/CN117480677A/zh
Priority to JP2023523348A priority patent/JP7526364B2/ja
Priority to EP22811056.5A priority patent/EP4350855A4/en
Publication of WO2022249782A1 publication Critical patent/WO2022249782A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/242—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries against vibrations, collision impact or swelling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B62D25/2009—Floors or bottom sub-units in connection with other superstructure subunits
    • B62D25/2036—Floors or bottom sub-units in connection with other superstructure subunits the subunits being side panels, sills or pillars
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/222—Inorganic material
    • H01M50/224—Metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/244—Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/262—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/262—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks
    • H01M50/264—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks for cells or batteries, e.g. straps, tie rods or peripheral frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • B60K2001/0405—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion characterised by their position
    • B60K2001/0438—Arrangement under the floor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • a battery case structure for supporting a drive battery under the floor of an electric vehicle, wherein a first steel plate portion having a groove-shaped cross section is provided with a second steel plate portion. It has a first closed cross-sectional portion formed by joining steel plate portions in an overlapping state, and has a closed cross-sectional shape, and a cross section adjacent to the first closed cross-sectional portion has a groove-shaped concave portion.
  • a peripheral frame and a box portion that opens upward to accommodate the battery, the box portion closing the recess and being adjacent to the first closed cross-sectional portion and having a closed cross-sectional shape. It forms a second closed cross section.
  • forming the second closed cross-section adjacent to the first closed cross-section of the outer frame by covering it with the box means that it can be rationally formed with a small amount of material (steel plate portion). do. Therefore, adopting this configuration is advantageous for reducing the weight of the vehicle body.
  • a plurality of closed cross-sectional structures can be formed by roll-forming a thin plate, or by welding together an outer member and an inner member made of press-formed products. Therefore, the outer frame can be made light and inexpensive.
  • FIG. 1 is a perspective view of the battery case structure of the first embodiment.
  • FIG. 2 is an exploded perspective view of the battery case structure of the first embodiment.
  • FIG. 3 is a cross-sectional view of the left end portion of the battery case structure of the first embodiment as seen from the rear.
  • FIG. 4 is a cross-sectional view of the left end portion of the battery case structure of the first embodiment as seen from the rear.
  • FIG. 5 is a cross-sectional view of the cross member portion of the battery case structure of the first embodiment as seen from the left side.
  • FIG. 6 is a flow chart for explaining the manufacturing method of the battery case structure of the first embodiment.
  • FIG. 7A is a cross-sectional view for explaining the manufacturing method of the battery case structure of the first embodiment.
  • FIG. 7B is a cross-sectional view for explaining the manufacturing method of the battery case structure of the first embodiment.
  • FIG. 8 is a flow chart for explaining the manufacturing method of the battery case structure of the second embodiment.
  • FIG. 9A is a cross-sectional view of an outer member used to carry out the manufacturing method of the battery case structure of the second embodiment;
  • FIG. 9B is a cross-sectional view of an inner member used for explaining the manufacturing method of the battery case structure of the second embodiment.
  • FIG. 9C is a cross-sectional view for explaining the manufacturing method of the battery case structure of the second embodiment.
  • FIG. 10 is a sectional view showing a modification of the box portion of the third embodiment.
  • FIG. 11 is a cross-sectional view for explaining the configuration of the bracket of the fourth embodiment.
  • FIG. 12 is a perspective view showing how the bracket of the fifth embodiment is used.
  • FIG. 13 is a perspective view of the bracket of the fifth embodiment.
  • FIG. 14 is an exploded perspective view of the bracket of the fifth embodiment.
  • FIG. 15 is a perspective view of the bracket of the fifth embodiment.
  • FIG. 16 is a perspective sectional view of the bracket of the fifth embodiment.
  • FIG. 17 is a plan view of the box portion and bracket of the fifth embodiment.
  • FIG. 18 is a cross-sectional view of the left end portion of the battery case structure of the sixth embodiment as seen from the rear.
  • FIG. 19 is a cross-sectional view of the left end portion of the battery case structure of the seventh embodiment, viewed from the rear.
  • FIG. 20 is a cross-sectional view for explaining pole collision.
  • FIG. 20 is a cross-sectional view for explaining pole collision.
  • FIG. 29 is a cross-sectional view of the rear cross member.
  • FIG. 30 is a perspective view showing the connecting portion between the front end portion of the side frame and the front cross member.
  • FIG. 31 is a perspective view showing the connecting portion between the front end portion of the side frame and the front cross member.
  • FIG. 32 is a perspective view showing a connecting portion between the rear end portion of the side frame and the rear cross member.
  • FIG. 33 is a perspective view showing a connecting portion between the rear end portion of the side frame and the rear cross member.
  • FIG. 34A is a cross-sectional view for explaining that the second closed cross-sectional portion of the side frame continues to the closed cross-sectional portion of the front cross member.
  • FIG. 34B is a cross-sectional view for explaining that the second closed cross-sectional portion of the side frame continues to the closed cross-sectional portion of the rear cross member.
  • FIG. 35 is a perspective cross-sectional view showing a recessed portion of the side frame.
  • the battery case structure 1 is attached to the vehicle body (not shown) in a posture in which the diagonally upper left side in FIG. 1 faces the front of the electric vehicle.
  • directions are shown when the battery case structure 1 is attached to the vehicle body. That is, in FIG. 1, the upper left side is the front side, and the lower right side is the rear side. Also, the lower left side will be referred to as the left side, and the upper right side will be referred to as the right side.
  • the plurality of functional parts attached to the box portion 3 include a front frame 4 attached to the front end of the box portion 3, a rear frame 5 attached to the rear end of the box portion 3, a box A pair of left and right outer frames 6 and 7 attached to the left and right sides of the portion 3, a cover 8 attached to the lower surface of the box portion 3, and three cross members 10 attached to the inside of the box portion 3 via brackets 9. , a plate-like cover (not shown) for closing the opening of the box portion 3, and the like.
  • Each of the outer frames 6 and 7 is formed in a predetermined shape using one or two steel plates.
  • Peripheral frames 6 and 7 according to this embodiment are formed of a single steel plate 14 (see FIG. 3).
  • the outer frames 6 and 7 according to this embodiment are made of a material having a higher tensile strength than the box portion 3 (for example, high tensile strength steel plate).
  • Forming one sheet of steel plate 14 into a predetermined shape is carried out by roll forming, press forming, bending forming, and the like. A method of forming the outer peripheral frames 6 and 7 will be described later.
  • the left peripheral frame 6 and the right peripheral frame 7 are formed so as to be symmetrical in the left-right direction. Therefore, the outer frame 6 will be described below, and the description of the outer frame 7 will be omitted.
  • the one end portion 14a of the steel plate corresponds to the "first steel plate portion” in the present invention.
  • the lap joint portions 27 and 28 are provided at the overlapping portion between the upper lateral wall 31 and the other end portion 14b of the steel plate 14 and the overlapping portion between the lower lateral wall 32 and the other end portion 14b of the steel plate 14 .
  • the other end portion 14b of the steel plate 14 corresponds to the "second steel plate portion” in the present invention.
  • the upper lap joint 27 overlaps the other end 14b of the steel plate 14 with a projecting piece 34 extending upward from the tip of the upper lateral wall 31, and welds the overlapping portion by spot welding.
  • the lower lap joint portion 28 is formed by overlapping a lower vertical wall 35 extending downward from the tip of the lower horizontal wall 32 on the other end portion 14b of the steel plate 14 and welding the overlapping portion by spot welding.
  • spot welding is used to form the lap joints 27 and 28 as described above, but the welding method may be changed as appropriate, such as arc welding or laser welding.
  • a cover 8 that covers the box part 3 from below is attached to the bottom part 42 including the bottom wall 11 of the box part 3 .
  • the cover 8 is composed of a plate-shaped cover body 43 and a plurality of reinforcing members 44 adhered to the upper surface of the cover body 43 so as to overlap each other.
  • the cover body 43 is adhered to the front frame 4, the rear frame 5, and the left and right outer frames 6 and 7 of the battery case structure 1 from below to increase the support strength of the battery case structure 1 that supports a heavy battery.
  • the box portion 3 is protected from collisions with bumps on the road surface and pebbles bounced from the tires.
  • the fourth closed cross-sectional portion 46 includes a box-shaped bottom wall 48 that is connected to the lower end of the lower vertical wall 35 and opens upward, and closes the opening of the bottom wall 48. It is formed by a bottom lateral wall 49 extending in the left-right direction. For this reason, the outer frame 6 is formed in a substantially L shape by two closed cross-sectional portions, a fourth closed cross-sectional portion 46 and a first closed cross-sectional portion 21 located above it.
  • the outer peripheral frame 6 becomes a hollow body extending in the front-rear direction.
  • the above-described lower overlapping joint portion 28 is provided between the first closed cross-section portion 21 and the fourth closed cross-section portion 46.
  • the first closed cross-sectional portion 21 faces the cross member 10 arranged along the upper surface of the bottom portion 42 of the box portion 3 .
  • the configuration of the cross member 10 will be described later.
  • the fourth closed cross-section portion 46 faces the reinforcing member 44 arranged along the upper surface of the cover 8 .
  • the reinforcing member 44 is provided so as to extend forward and rearward with respect to the cross member 10 .
  • the cross-sectional shape of the reinforcing member 44 positioned below the cross member 10 is substantially W-shaped extending in the left-right (vehicle width) direction.
  • the steel plate 14 is bent into a valley fold with the two end portions of the bottom wall 48 as bending fulcrums A and B, thereby forming a predetermined shape that stands up as shown in FIG. 7B.
  • the projecting piece 34 and the lower vertical wall 35 are welded to the other end portion 14b of the steel plate 14 by arc welding or laser welding, arc welding or laser welding or spot welding, respectively.
  • arc welding or laser welding arc welding or laser welding or spot welding
  • the outer member 51 is overlaid on the inner member 52, and the lapped portion 53 and the lapped portion 54 are welded by spot welding to form the lap joint 55, and one end of the inner member 52 is welded. and the lower vertical wall 35 are welded to the outer member 51 by arc welding or laser welding, arc welding or laser welding or spot welding to form the lap joints 27 and 28, respectively.
  • the outer frame 6 is completed by forming the three lap joints 27, 28, and 55 in this manner.
  • the box portion can be formed as shown in FIG. In FIG. 10, members that are the same as or equivalent to those explained with reference to FIGS.
  • the box portion 3 shown in FIG. 10 is composed of an upper side wall 61 closing the recess 22 and a box-shaped bottom wall 62 connected to the upper side wall 61 .
  • the upper side wall 61 constitutes the upper half of the box portion 3 and is made of a steel plate.
  • the bottom wall 62 constitutes the lower half of the box portion 3, and is made of, for example, a plastic material and is shaped like a box that opens upward.
  • the bottom wall 62 is made of a plastic material
  • the bottom wall 62 and the upper side wall 61 can be joined together using, for example, an adhesive and bolts and nuts (not shown).
  • the side wall 13 mentioned above is constituted by an upper side wall 61 and a bottom wall 62 .
  • the cross member 10 is arranged on the bottom wall 11 of the box portion 3 so as to extend in one direction (horizontal direction) and to face the side walls 13 at both ends. . Both ends of the cross member 10 are fixed to side walls 13 via brackets 9 .
  • a basic configuration of the bracket 9 is shown in FIG.
  • the bracket 9 is formed to have a substantially triangular shape in plan view.
  • a fitting portion 63 into which the cross member 10 is fitted is formed at the top end portion of the bracket 9 .
  • a pair of brace portions 64 are provided that are inclined so that the interval in the front-rear direction gradually increases toward the side wall 13 .
  • the bracing portion 64 supports the body portion 10a of the cross member 10 before the end thereof.
  • the bracket 9 is specifically constructed as shown in FIGS. 12 to 17.
  • FIG. As shown in FIGS. 12 and 13, the bracket 9 according to this embodiment includes a case joint portion 71 welded to the side wall 13 of the box portion 3 and a core material 72 cast in the case joint portion 71. It is composed by The case joint portion 71 is made of an aluminum alloy and welded to the side walls 13 of the box portion 3 at both ends in the front-rear direction. This welding is welding of aluminum materials.
  • the core member 72 is formed by bending a steel plate into a predetermined shape, as shown in FIG. The core member 72 is welded to the cross member 10 while the cross member 10 is fitted in the fitting portion 63 . This welding is welding of steel materials.
  • a case-side welded portion 73 which is a welded portion between the case joint portion 71 and the side wall 13, is provided in a region hatched downward to the left in FIG. It extends from top to bottom.
  • a cross-member-side welded portion 74 which is a welded portion between the core member 72 and the cross member 10, is provided in a region hatched downward to the right in FIG. ing. That is, the bracket 9 is joined to the cross member 10 and the side wall 13 of the box portion 3 on a straight line extending vertically.
  • the bracket 9 according to this embodiment has at least the first closed cross-sectional portion 21 of the hollow peripheral frame 6 and the hollow cross member 10 horizontally aligned. are connected like
  • the battery case structure 1 it is possible to provide a battery case structure that can be made lightweight, can be manufactured at a low cost, and does not allow water to enter the case. .
  • the outer frame 6 according to this embodiment is formed into a predetermined shape by roll forming or press molding, the length of the outer frame constituent parts (steel plates) for vehicles with different front and rear and left and right sizes is reduced. Easy to change.
  • a third closed section 45 is formed by connecting the cover 8 arranged along the bottom 42 of the box 3 to the outer peripheral frame 6 . Therefore, by combining the outer peripheral frame 6 with the cover 8, a more complicated closed cross-section can be formed.
  • the side impact load F1 applied from the side sill 47 can be supported by the cross member 10 via the first closed section portion 21.
  • the side impact load F2 applied from the fourth closed cross-section portion 46 is transmitted from the overlapping joint portion 28 to the first closed cross-section portion 21, and is further supported by the cross member 10 via the first closed cross-section portion 21. be done. Therefore, even if the outer peripheral frame 6 is made of a thin plate, the side impact load can be sufficiently supported, and deformation of the box portion 3 (battery case) can be suppressed.
  • the first closed cross-sectional portion 21 is formed by forming the outer peripheral frame 6 by roll forming and then welding the lap joint portion.
  • the thin steel plate 14 By roll-forming the thin steel plate 14, a plurality of closed cross-section structures can be constructed, and by combining with the box portion 3, a more complicated closed cross-section can be constructed.
  • the outer peripheral frame 6 By forming the outer peripheral frame 6 by roll forming, it is possible to easily change the length of the outer peripheral frame constituent parts (steel plates) for vehicles having different front, rear, left and right sizes.
  • the outer frame 6 according to this embodiment is made of a material having a higher tensile strength than the box portion 3. Therefore, the outer frame 6 can be made of a thin plate such as high-tension steel to reduce its weight. Since the box portion 3 has low strength and high ductility, the deep box portion 3 can be easily formed by press molding.
  • the box part 3 shown in FIG. 10 partially covers the recessed part 22 of the outer peripheral frame 6 and forms the second closed cross-sectional part 38 as a steel plate. Therefore, the bottom wall 62 of the box portion 3 can be changed to a lightweight material such as a plastic material, and further weight reduction can be achieved.
  • the outer frame 6 has an opening 39 on the outer surface 6a. Therefore, the side wall 13 of the box portion 3 and the outer frame 6 can be fixed through the opening 39 by spot welding or mechanical fastening to form the lap joint portion 41 .
  • the box portion 3 for accommodating the battery 2 is formed in a box shape having at least a bottom wall 11 and side walls 13 extending along the outer edge 12 to the entire circumference.
  • a cross member 10 is provided on the bottom wall 11 so as to extend in one direction and to face the side walls 13 at both ends.
  • Cross member 10 is fixed to side wall 13 via bracket 9 .
  • the bracket 9 has a substantially triangular shape in a plan view, and a cross member 10 is fitted to the top end of the bracket 9 .
  • the front and rear bracing portions 64 of the bracket 9, which is substantially triangular in plan view, have a reinforcing function, the load can be transmitted to the cross member 10 even in the event of a local collision such as a pole collision, and the battery case structure 1 and the battery can be connected to each other. 2 can be prevented. Also, the braces 64 are deformed to absorb the impact energy.
  • the term "pole collision” as used herein refers to a collision in which a columnar body extending in the vertical direction locally collides with an electric vehicle from the side.
  • the bracket 9 has a pair of bracing portions 64 and an insertion portion 63 sandwiched between them.
  • the bracing portion 64 supports the main body portion 10a positioned centrally from the end portion of the cross member 10. As shown in FIG. Therefore, since the load can be transmitted from the bracing portion 64 to the main body portion 10a of the cross member 10, the cross member 10 does not bend starting from the tip.
  • the bracket 9 according to this embodiment is a bent product whose substantially W-shaped cross section continues in the cross-sectional direction, and has at least one cross-section retaining wall 76 . Therefore, the strength of the bracing portion 64 can be easily adjusted by the cross-section holding wall 76 .
  • the bracket 9 has a through hole 77 in the bracing portion 64 .
  • the cross-section holding wall 76 is locked in the through hole 77 . Therefore, the cross-section holding wall 76 can also be set in the center of the brace portion 64 .
  • the bracket 9 according to this embodiment is joined to the cross member 10 and the side wall 13 of the box portion 3 on a straight line extending vertically. Therefore, since the bending strength in the vertical direction is increased, the transmissibility of the side impact load to the cross member 10 can be improved.
  • the bracket 9 according to this embodiment is arranged between the outer end 2a of the battery 2 and the side wall of the case (side wall 13 of the box portion 3). Therefore, even if the brace portion 64 is deformed by side impact, it does not interfere with the battery 2 .
  • the outer frame 6 is fixed to the vehicle body of the electric vehicle and is a hollow body extending in the front-rear direction, and the cross member 10 is a hollow body extending in the left-right direction. Therefore, the cross member 10 is not crushed by side impact in the left-right direction, and the outer frame 6 and the bracket 9 are crushed and deformed. The outer frame 6 and the bracket 9 can absorb the impact energy that could not be absorbed by the .
  • the hollow peripheral frame 6 and the cross member 10 according to this embodiment are aligned horizontally. Therefore, the outer peripheral frame 6 made of a hollow body is easily crushed and deformed.
  • Any joining method other than spot welding such as fastening by rivets, fastening by bolts and nuts, laser welding, and MIG welding, can be adopted as a joining method for forming the lap joints 27 and 28 .
  • the joining method for joining the lap joint portion 41 between the upper vertical wall 33 and the side wall 13 can be changed from spot welding to fastening with bolts and nuts or fastening with rivets, and the opening 39 on the outer surface can be omitted.
  • FIG. 18 is a cross-sectional view of the left end portion of the battery case structure of the sixth embodiment as seen from the rear.
  • Peripheral frames 81 shown in FIG. 18 are side frames 82 provided on the left and right sides of the box portion 3 .
  • the side frame 82 is composed of an outer portion 83 made of a high-strength steel plate and an inner portion 84 made of a high-strength steel plate and thinner than the outer portion 83 .
  • the outer portion 83 and the inner portion 84 are each formed into a predetermined shape by a hot stamp molding method.
  • the shape of the outer part 83 and the inner part 84 is such that the first closed cross-section part 21 and the fourth closed cross-section part 46 are formed by overlapping and welding them.
  • Welding between the outer portion 83 and the inner portion 84 is performed by spot welding and MIG welding.
  • the spot welds are indicated by W1
  • the MIG welds are indicated by W2.
  • the lower lap joint 85 is joined by spot welding. Since the upper lap joint 86 is the most loaded portion, it is joined by continuous MIG welding.
  • the continuous joining here means that the welded portion is continuous from the front end to the rear end of the side frame 82 without interruption in the longitudinal direction (front-rear direction) of the side frame 82 .
  • the box portion 3 shown in FIG. 18 is formed by press forming a steel plate into a box shape.
  • a second closed section portion 38 is formed by coupling the box portion 3 to the side frame 82 .
  • a overlapping portion 87 that joins the side wall 13 of the box portion 3 and the inner portion 84 is joined by spot welding.
  • a welding gun (not shown) that performs this spot welding is passed through an opening 39 formed in the outer portion 83 and pressed against the inner portion 84 .
  • the openings 39 are formed in the outer portion 83 at predetermined intervals in the longitudinal direction of the side frame 82 .
  • the upper end flange 37 of the box portion 3 and the upper wall 88 of the outer portion 83 are mechanically coupled by a rivet 89 or the like.
  • the cover 8 provided at the lower end of the box portion 3 and the fourth closed section portion 56 are joined together using an adhesive 90 so as to seal the two.
  • the battery case structure shown in FIG. 18 has a full steel battery case structure in which the side frames 82 and the box portion 3 are all made of steel.
  • FIG. 19 is a cross-sectional view of the left end portion of the battery case structure of the seventh embodiment, viewed from the rear.
  • Peripheral frames 91 shown in FIG. 19 are side frames 92 provided on the left and right sides of the box portion 3 .
  • the side frame 92 is formed into a shape having a first closed cross-section portion 21 and a fourth closed cross-section portion 46 by subjecting one high-strength steel plate to roll forming. Therefore, the outer portion 93 and the inner portion 94 of the side frame 92 are integrally formed.
  • a lap joint 95 between the first closed cross section 21 and the fourth closed cross section 46 and a lap joint 96 where the tip of the inner portion 94 is joined to the outer portion 93 are formed by overlapping two steel plates. They are joined together by laser welding.
  • the box portion 3 shown in FIG. 19 is a press-formed product made of an aluminum alloy in order to reduce the weight. In FIG. 19, the laser welded portion is indicated by W3.
  • a superposed portion 97 that joins the side wall 13 of the box portion 3 and the inner portion 94 is mechanically joined using a self-piercing rivet 98 or the like.
  • the battery case structure shown in FIG. 19 is a multi-material battery case structure having side frames 92 made of a steel plate and a box portion 3 made of an aluminum alloy.
  • the side frame 92 is connected to the first closed cross-section portion 21 via an overlap joint portion 95, is offset outwardly, and is connected to the lower surface 47a of the side sill 47 of the vehicle body. It has a rectangular fourth closed section 46 projecting outward in the direction.
  • the fourth closed section 46 shown in FIG. 20 has an upper horizontal wall facing the lower surface 47a of the side sill 47 and is connected to the side sill 47 via a connecting member 101.
  • the fourth closed section 46 is deformed as indicated by the dashed line in FIG. More specifically, the fourth closed cross-section 46 has upper and lower horizontal walls seated within the cross-section so that the fourth closed cross-section 46 rotates clockwise around the lap joint 95 in response to a pole collision. succumb
  • the fourth closed cross-section 46 absorbs the collision energy by buckling itself and moving away from the bottom corner of the box 3 and rotating toward the first closed cross-section 21 .
  • the deformation of the fourth closed cross-section portion 46 can prevent the battery 2 from being damaged by the collision with the pole.
  • a peripheral component storage space 103 for arranging cooling pipes, electric cables, and the like. Therefore, even if the fourth closed cross-section portion 46 enters the inside of the vehicle body due to a collision with a pole or the like, it is possible to prevent damage to cooling pipes, electric cables, and the like.
  • the cross member 10 is fixed to the side wall 13 of the box portion 3 via brackets 111 .
  • Bracket 111 shown in FIG. 22 is formed by combining a plurality of steel plates, and is welded to box portion 3 made of steel plate at welded portion 116 and to cross member 10 at welded portion 115 by MIG welding.
  • the upper end of the cross member 10 is positioned at the same height as the second closed section 38 formed by the box portion 3 and the side frame 92, as shown in FIG.
  • the lower end of the cross member 10 is positioned at the same height as the bottom surface 112 of the box portion 3 .
  • the cross member 10 also has a front wall 113 (see FIG. 22) and a rear wall 114 extending vertically from the upper end to the lower end.
  • the front wall 113 and the rear wall 114 are vertically and continuously joined to the side walls 13 of the box portion 3 by the welded portions 115 via the brackets 111.
  • Cross-member-side welded portion 115 which is a welded portion between cross member 10 and bracket 111, extends from the upper end to the lower end of front wall 113 and rear wall 114 at the connection portion between front wall 113 and rear wall 114 and bracket 111.
  • a case-side welded portion 116 that is a welded portion between the bracket 111 and the side wall 13 extends from the upper end to the lower end of the bracket 111 .
  • This welding is performed by MIG welding. Since the cross member 10 is joined to the side walls 13 via the brackets 111 in this way, the front wall 113 and the rear wall 114 of the cross member 10 receive first, second, and second impacts due to side collisions (pole collisions). The entire surface is supported through the third closed section portions 21 , 38 , 45 .
  • the front cross member 121 and the rear cross member 122 have front walls 121a and 122a located on the front side of the electric vehicle and rear walls 121b and 122b located on the rear side of the electric vehicle relative to the front walls 121a and 122a.
  • the wall farther from the box portion 3 is the outer wall 82a of the side frame 82.
  • the portion 125 forming the first closed cross-section portion 21 of the side frame 82 is formed in a protruding shape protruding toward the box portion.
  • the other wall (the rear wall 121b of the front cross member 121 and the front wall 122a of the rear cross member 122) closer to the box portion 3 is the first wall of the side frame 82. It has notches 126 and 127 shaped to receive the projecting portion 125 forming the closed cross-section portion 21, and the projecting portion 125 inserted into the notches 126 and 127 is welded and connected.
  • the upper surfaces of the front cross member 121 and the rear cross member 122 according to this embodiment, and the upper surface (upper wall) formed by horizontally bending the upper end of the outer wall 82a of the side frame 82 are the upper end of the box portion 3.
  • a mounting surface 128 is formed on which the flange 37 is mounted over the entire circumference. Therefore, when the box portion 3 is attached to the mounting surface 128 , the side frame 82 is connected to the front cross member 121 and the rear cross member 122 via the box portion 3 . Therefore, by adopting this configuration, the second closed cross sections 38, 38 of the left and right side frames extend along the opening of the box portion while effectively utilizing the existing parts to reduce the weight.
  • the strength and rigidity of the battery case structure can be improved by forming the ring-shaped skeleton continuously with the closed cross-sections 123 and 124 of the rear cross member.
  • the closed cross-section portion 123 of the front cross member 121 is connected to the first closed cross-section portion 21 and the second closed cross-section portion 38 by connecting the front cross member 121 to the side frame 92 .
  • the closed cross-section portion 124 of the rear cross member 122 is connected to the first closed cross-section portion 21 and the second closed cross-section portion 38 by connecting the rear cross member 122 to the side frame 92 . become.
  • the portions between the fourth closed cross-section portion 46 and the first closed cross-section portion 21 of the outer peripheral frames 6, 81, and 91 shown in the above-described embodiments are groove-shaped depressions as shown in FIG. It is formed to form a portion 131 .
  • FIG. 35 is drawn using the outer peripheral frame 91 (side frame 92) shown in the seventh embodiment. This recessed portion 131 is opened toward the box portion 3 and extends in the front-rear direction.
  • the first closed cross-section portion 21 and the fourth closed cross-section portion 46 are overlapped and joined, so that the first closed cross-section portion 21 and the fourth closed cross-section portion 46 are arranged vertically. 4 is interrupted.
  • the recessed portion 131 reinforces the structure of the battery case. Can supplement strength and rigidity.
  • cooling pipes 132, high-voltage electric wires 133, and the like can be accommodated in this recessed portion 131. As shown in FIG. 35, cooling pipes 132, high-voltage electric wires 133, and the like can be accommodated in this recessed portion 131. As shown in FIG. 35, cooling pipes 132, high-voltage electric wires 133, and the like can be accommodated in this recessed portion 131. As shown in FIG.
  • Case side weld part 74 Cross member side weld part 76... Section holding wall 77... Through hole 82... Side frame 92... Side frame 103... Deformation allowance space 121... Front Cross member 122 Rear cross member 123, 124 Closed cross section 125 Protruding portion 126, 127 Notch 131 Recess 132 Cooling pipe 133 High voltage wire S1 Roll forming Forming step, S11... Press forming step, S12... Bending step, S2, S13... Welding step.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Electrochemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Body Structure For Vehicles (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)
  • Battery Mounting, Suspending (AREA)
PCT/JP2022/017662 2021-05-24 2022-04-13 バッテリーケース構造およびバッテリーケース構造の製造方法 Ceased WO2022249782A1 (ja)

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US18/556,009 US20240213606A1 (en) 2021-05-24 2022-04-13 Battery case structure and manufacturing method of battery case structure
CN202280037372.4A CN117480677A (zh) 2021-05-24 2022-04-13 电池壳体结构和电池壳体结构的制造方法
JP2023523348A JP7526364B2 (ja) 2021-05-24 2022-04-13 バッテリーケース構造およびバッテリーケース構造の製造方法
EP22811056.5A EP4350855A4 (en) 2021-05-24 2022-04-13 BATTERY CASE STRUCTURE AND METHOD FOR PRODUCING BATTERY CASE STRUCTURE

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JP2021086711 2021-05-24
JP2021-086711 2021-05-24

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CN116494751A (zh) * 2023-06-26 2023-07-28 中国第一汽车股份有限公司 车辆
WO2024259255A3 (en) * 2023-06-15 2025-04-17 Magna International Inc. Single piece sidewall for a battery housing
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EP4657533A1 (en) * 2024-05-30 2025-12-03 Eve Energy Co., Ltd. Battery pack frame and battery pack
JP2025540796A (ja) * 2023-08-22 2025-12-16 エルジー エナジー ソリューション リミテッド バッテリーセルアセンブリーおよびそれを含むバッテリーパック

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KR102623254B1 (ko) * 2022-04-29 2024-01-10 주식회사 엘지에너지솔루션 배터리팩 및 배터리팩을 포함하는 전기차량
US12358567B2 (en) * 2022-10-19 2025-07-15 Ford Global Technologies, Llc Integrated skid plate heat dissipator
DE102024204687A1 (de) * 2024-05-21 2025-11-27 Volkswagen Aktiengesellschaft Fahrzeugbodenstruktur eines Kraftfahrzeuges, insbesondere eines elektrisch angetriebenen Kraftfahrzeuges, das über Antriebsenergiezellen verfügt
CN119786848B (zh) * 2024-12-31 2025-09-23 蜂巢能源科技股份有限公司 电池包边梁结构、电池包及电池包边梁结构制作方法

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Cited By (8)

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Publication number Priority date Publication date Assignee Title
US12415569B2 (en) 2022-01-07 2025-09-16 Shape Corp. Rocker insert with corrugated structure
CN116454515A (zh) * 2023-06-15 2023-07-18 中创新航科技集团股份有限公司 电池包
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WO2024259255A3 (en) * 2023-06-15 2025-04-17 Magna International Inc. Single piece sidewall for a battery housing
CN116494751A (zh) * 2023-06-26 2023-07-28 中国第一汽车股份有限公司 车辆
CN116494751B (zh) * 2023-06-26 2023-09-22 中国第一汽车股份有限公司 车辆
JP2025540796A (ja) * 2023-08-22 2025-12-16 エルジー エナジー ソリューション リミテッド バッテリーセルアセンブリーおよびそれを含むバッテリーパック
EP4657533A1 (en) * 2024-05-30 2025-12-03 Eve Energy Co., Ltd. Battery pack frame and battery pack

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EP4350855A4 (en) 2025-07-23
JP7526364B2 (ja) 2024-07-31
JPWO2022249782A1 (https=) 2022-12-01
CN117480677A (zh) 2024-01-30

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