Abstract
The invention relates to a manufacturing method for a crash frame of a battery compartment for electric drive vehicles by using metallic sheets which are arranged on top of one another and fixed together and which form in a following step a space by using an inner active media forming process to create walls of a crash frame whereby the space works as a deformation space to protect the battery modules inside the battery compartment against an impact. The invention further relates to the use of the crash frame for a battery compartment.
Claims
1. A method for manufacturing a crash frame for a battery compartment for electric drive vehicles, comprising the steps of providing at least two metallic sheets and arranging the at least two metallic sheets on top of each other joining the at least two metallic sheets together essentially at the circumference of at least one sheet introducing a medium between at least two sheets which have been joined together applying a pressure to the medium, causing the deformation of at least one sheet and forming a component comprising a space between at least two sheets.
2. The method according to claim 1, wherein at least two sheets being essentially planar.
3. The method according to claim 1, wherein at least two sheets being joined by welding or folding.
4. The method according to claim 1, further comprising the step of bending a component along at least two axis to produce a compartment having at least a bottom wall and side walls.
5. The method according to claim 1, further comprising the step of joining a plurality of components to produce a compartment having at least a bottom wall and side walls.
6. The method according to claim 5, wherein the joining is being carried out by welding.
7. The method according to claim 1, wherein two joined metallic sheets having different thicknesses.
8. The method according to claim 7, wherein the sheet having the larger thickness is located at the inside of the battery compartment.
9. The method according to claim 1, wherein at least two components are arranged on top of each other providing at least two independent spaces between sheets.
10. The method according to claim 1, wherein a space is adapted for use for thermal management.
11. The method according to claim 1, wherein indentations for accommodating a sealing compound are provided in a wall of a component.
12. The method according to claim 1, further comprising the step of filling up the created space with an insulating material as a further crash and thermal protection for the battery modules of the internally located battery compartment.
13. The method according to claim 1, wherein the metallic sheets are stainless steel.
14. Use of a crash frame manufactured according to claim 1 in electric drive vehicles.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The present invention is illustrated in more detail referring to the attached drawings where
[0024] FIG. 1 shows a schematic side view of one wall of a battery compartment having a crash frame manufactured out of two flat metallic sheets by using an inner active media forming process as one embodiment of the invention,
[0025] FIG. 2 shows a schematic top view of another wall as another embodiment of the invention,
[0026] FIG. 3 shows another schematic top view of a flat metallic sheet-arrangement as another embodiment of the invention for bend-forming,
[0027] FIG. 4 shows a schematic side view of an arrangement where a component manufactured from two metallic sheets according to the invention has been bent to form two walls of a crash frame for a battery compartment,
[0028] FIG. 5 shows a schematic side view of a battery compartment as a preferred embodiment of the invention,
[0029] FIG. 6 shows a schematic side view of another battery compartment having a crash frame according to another preferred embodiment of the invention,
[0030] FIG. 7 shows a schematic side view of a battery compartment manufactured in accordance with a further embodiment of the invention,
[0031] FIG. 8 shows two detailed drawings of preferred sealing embodiments schematically seen from a side view, and
[0032] FIG. 9 shows an option for seaming two metal sheets together in connection with a process according to the invention.
EMBODIMENTS ILLUSTRATING THE INVENTION
[0033] FIG. 1 illustrates two flat metallic sheets 1, 2 which are arranged on top of one another, then welded together at locations 3 and which form, by using an inner active media forming process, a defined inner space with the height h.sub.i 4 so that a unitary wall element results which can be used for a battery compartment and is further called “component” (c).
[0034] FIG. 2 illustrates another embodiment of the invention to manufacture a component which can be used for a battery compartment, schematically seen as a view from above to the surface of a sheet 2, whereby limitation elements 5 created by welding are introduced. At these limitation elements 5, the sheets 1, 2 are fixed together. As a result, the limitation elements 5 limit the possible height h.sub.i of the space and determine the resulting geometry.
[0035] FIG. 3 illustrates, as a top view, that a component as basically described in FIG. 2 can be manufactured to form a battery compartment with a bottom wall 6 and different side walls 7 by using a bend-forming process at the bending lines 8. The resulting side walls 7 can be welded together at their contact surfaces 9.
[0036] FIG. 4 shows in a side detail view how a component manufactured according to the invention, e.g. as shown in FIG. 3, has been bent at a straight angle to form a bottom 6 and a side wall 7, respectively, of a crash frame. Alternatively, separate single components as described in FIGS. 1 and 2 can be welded together at 10 to create a resulting battery compartment crash frame with a bottom wall and side walls.
[0037] FIG. 5 illustrates how a component manufactured according to the invention, as shown in e.g. FIG. 3, has been bent to form a crash frame, into which a battery housing 11 is inserted with installed battery modules 12. The system is covered by a closing plate 13.
[0038] FIG. 6 illustrates the arrangement of two separate components 14, 15 arranged on top of each other to create at least two independent inner spaces used for different functionalities, preferably the outer one 15 as a crash protection and the inner one 14 for thermal management functions like cooling.
[0039] FIG. 7 illustrates as a side view the use of thinner outer sheets 16 in combination with thicker inner sheets 17 so that mainly the outer sheets are deformed during the inner active media forming process. The battery modules 12 in casing 11 can be assembled onto the nearly flat thicker inner sheet 17.
[0040] FIG. 8a-b illustrate as detail side views of two sealing embodiments at the side walls, providing a closed battery compartment. Both embodiments comprise a thinner outer sheet 16, a thicker inner sheet 17 and the internally located battery modules 12. Further, indentations 18, 19 are provided in the outer surface of the internal active media-formed side walls to create spaces for a sealing layer 20 so that a removable closing plate 21 can be fixed tightly onto the battery compartment. In FIG. 8a, the indentation 18 is created by impressing the internal active media-formed side wall from the outside of the thinner outer sheet 16. In FIG. 8b, the indentation 19 is created by having a thinner outer sheet 16, the edge of which protrudes outside the thicker inner sheet 17 and is subsequently formed to accommodate the seal material 20.
[0041] FIG. 9 illustrates the fixing of at least one area of the circumferential fixing with a non-welding forming procedure, here folding. Two flat metallic sheets 22, 23 arranged on top of one another are bent and folded into each other, creating a sealed seam along their circumference.
