Abstract
The invention relates to a frame structure of a battery housing for a vehicle driven by an electric motor, said frame structure being composed of individual profiled hollow-chamber sections which are designed to be at least two-chambered in the z-direction and are welded together to enclose a battery volume. The end faces 14, 14.1 of two profiled hollow-chamber sections 3, 3.1; 3.1, 3.2; 3.2, 3.3; 3.3, 3 are designed to be stepped, such that an end face 14, 14.1 portion of each of the two profiled hollow-chamber sections 3, 3.1; 3.1, 3.2; 3.2, 3.3; 3.3, 3 borders a lateral surface portion 4, 4.1 of the respective other profiled hollow-chamber section 3, 3.1; 3.1, 3.2; 3.2, 3.3; 3.3, 3.
Claims
1. A frame structure of a battery housing for a vehicle driven by an electric motor, said frame structure (R) being composed of individual profiled hollow-chamber sections (3, 3.1, 3.2, 3.3) which are designed to be at least two chambered in the z-direction and are welded together in order to enclose a battery volume (B), characterized in that the end faces (14, 14.1) of two profiled hollow-chamber sections (3, 3.1; 3.1, 3.2; 3.2, 3.3; 3.3, 3) adjoining each other in order to form a corner are designed to be stepped, such that an end face (14, 14.1) portion of each of the two profiled hollow-chamber sections (3, 3.1; 3.1, 3.2; 3.2, 3.3; 3.3, 3) borders a lateral surface portion (4.4.1) of the respective other profiled hollow-chamber section (3, 3.1; 3.1, 3.2; 3,2, 3.3; 3.3, 3).
2. The frame structure of claim 1, characterized in that the end faces (14, 14.1) of each two adjacent profiled hollow-chamber sections (3, 3.1) are provided with two steps.
3. The frame structure of claim 1, characterized in that the end face (16) of one profiled hollow-chamber section (15) has a number of steps which is 1 step greater than the one of the end face (16.1) of the other profiled hollow-chamber section (15.1).
4. The frame structure of claim 3, characterized in that the end face (16) of one profiled hollow-chamber section (15) is provided with three steps and the end face (16) of the other profiled hollow-chamber section (1.5) is provided with two steps, the profiled hollow-chamber section (15) provided with three steps being provided with steps on the end face (16), so that the middle step (17) is set back with respect to the two outer steps (17.1, 17.2) and the lateral surface of the other profiled hollow-chamber section (15.1) pointing towards the profiled hollow-chamber section (15) is stepped in such a way that as a result of this stepped construction said lateral surface portion (19) borders on the middle step (17) of the other profile (15).
5. The frame structure of any of claims 1 to 4, characterized in that the lateral surfaces (6, 8, 9, 10, 6.1, 8.1, 9.1, 10.1) of the profiled hollow-chamber sections (3; 3.1, 3.2; 3.2, 3.3; 3.3, 3) facing away from the enclosed battery volume (B) are provided with steps, so that the profiled hollow-chamber sections have an L-shaped cross-sectional geometry and that the horizontal leg of the profiled hollow-chamber sections (3, 3.1; 3.2; 3.3) points outwards.
6. The frame structure of any of claims 1 to 5, characterized in that one of two profiled hollow-chamber sections (3.4, 3.5) adjoining each other to form corners is provided with a web (16) following its longitudinal extension as a weld pool support, in order to increase its lateral surface (4.4), which is adjoined by an end face portion of the other profiled hollow-chamber section (3.5).
7. The frame structure of any of claims 1 to 6, characterized in that the end face portion of one profiled hollow-chamber section (3.5) is arranged at a small distance from the end face (14.4) of the other profiled hollow-chamber section (3.4).
8. The frame structure of any of claims 1 to 7, characterized in that the lateral surfaces (4, 4.1, 4,2, 4.3) of the profiled hollow-chamber sections (3, 3.1, 3.2, 3.3) pointing towards the battery volume (B) have a connecting web (5, 5.1, 5.2, 5.3) for providing a connection flange for a base part or a cover part of the battery housing part.
9. The frame structure of any of claims 1 to 8, characterized in that the profiled hollow-chamber sections (3, 3.1, 3.2, 3.3) of the frame structure (R) are extruded aluminum profiles.
Description
[0020] The invention is described in the following with reference to the attached figures using several exemplary embodiments. In the drawings:
[0021] FIG. 1 is a perspective view of a frame structure according to the invention as part of a battery housing,
[0022] FIG. 2 is an end view of a profiled hollow-chamber section as part of the frame structure of FIG. 1,
[0023] FIG. 3 is a perspective view of two profiled hollow-chamber sections to be connected to create a corner construction of the frame structure of FIG. 1,
[0024] FIG. 4 shows the railed hollow-chamber sections of FIG. 3 assembled to form the corner,
[0025] FIG. 5 is the representation of FIG. 4 supplemented by a weld seam, with which the two profiled hollow-chamber sections shown are connected,
[0026] FIGS. 6a, 6b are an end view of another profiled hollow-chamber section (FIG. 6a) and in an illustration in which an end face portion of a complementary profiled corner-forming hollow-chamber section is arranged on the lateral surface of this profiled hollow-chamber section (FIG. 6b),
[0027] FIG. 7 shows two profiled hollow-chamber sections to be connected to one another to form corners of a further frame structure as part of a battery housing according to a further embodiment,
[0028] FIG. 8 shows the profiled hollow-chamber sections of FIG. 7 assembled together to form corners,
[0029] FIG. 9 is a top view of two prior art corner designs of frame structures as part of battery housings, in which adjacent profiled hollow-chamber sections are mitered to form the corner (left) and in which a profiled hollow-chamber section is supported with its end face on the lateral surface of the adjacent profiled hollow-chamber section (right).
[0030] FIG. 9 shows two different corner configurations of frame structures as part of battery housings or battery housing parts according to the prior art. In the illustration on the left, the two profiled corner-forming hollow-chamber sections 1, 1.1 adjoining each other are connected to one another on their entire end face at the miter joint. According to a further previously known embodiment for corner construction on a frame structure of a battery housing or a battery housing part, a profiled hollow-chamber section 2 borders with its end face on a lateral surface of the adjoining profiled hollow-chamber section 2.1 (right illustration). In both cases, the impact energy in the event of a crash has a considerable effect on the weld seams connecting the two hollow-chamber profiles. In the configuration shown on the right in FIG. 9, it is unlikely that energy will be transmitted in a form-fitting manner from one profiled hollow-chamber section 2 or 2.1 to the other profiled hollow-chamber section 2.1 or 2, so that in this case too, in the event of a crash, a considerable amount of energy is transmitted to the weld seam connecting the two profiled hollow-chamber sections 2, 2.1.
[0031] The frame structure R according to the invention shown in FIG. 1 comprises four profiled hollow-chamber sections 3, 3.1, 3.2, 3.3 which are connected to each other at right angles and enclose a battery volume B. The battery volume B is used to receive one or more battery modules. If there are several battery modules, they can be separated from each other by a compartment. The frame structure R is part of a battery housing for accommodating batteries or battery modules for a vehicle driven by an electric motor. The frame profiles 3, 3.1, 3.2, 3.3 have straight inner lateral surfaces 4, 4.1, 4.2, 4.3 extending in the vertical direction. At the lower end of the profiled hollow-chamber sections 3, 3.1, 3.2, 3.3, which can be seen in FIG. 1, connecting webs 5, 5.1, 5.2, 5.3 projecting into the frame structure R from the lateral surfaces 4, 4.1, 4,2, 4.3 are formed. These connecting webs (5, 5.1, 5.2, 5.3) are used to connect a base part, either by inserting it into the battery volume B and then resting on the top side of the connecting webs, or by connecting it on their underside. If the frame structure R is part of a cover part, a cover part is connected to the connecting webs instead of a base part.
[0032] It is already clear from the illustration in FIG. 1 that the profiled hollow-chamber sections 3, 3.1, 3.2, 3.3 are L-shaped. The lower, horizontally extending leg points away from the battery volume B towards the outside. In the top sides 6, 6.1, 6.2, 6.3 of these legs of the profiled hollow-chamber sections 3, 3.1, 3.2, 3.3, fastening holes 7 are introduced, which pass through these legs. These are used to fasten a cover part, not shown in the figures, and also to fasten the frame structure R to the chassis of a vehicle.
[0033] FIG. 2 shows an end view of the end face of the profiled hollow-chamber section 3 of FIG. 1. The L-shaped cross section is clearly visible, as well as the connecting web 5, which is not visible in FIG. 1 for perspective reasons. In this exemplary embodiment, the lateral surface 4 is straight in the vertical direction (z-direction) and is therefore not provided with a step. The outward-facing lateral surface of this profiled hollow-chamber section 3 is stepped and, in addition to the surface 6 extending in the x-y direction, has two adjacent lateral surface portions 8, 9 extending in the z direction, wherein both lateral surface portions 8, 9 each represent a step (see also FIG. 3). In the end view of FIG. 2, these steps are identified by reference numerals 11, 12. The end faces are identified by reference numerals 13, 13.1.
[0034] The vertical leg in the z-direction in FIG. 2 is a multi-chamber leg, wherein the middle longitudinal plane of a chamber web S lies in the plane of surface 6. This design of the profiled hollow-chamber section 3 means that the step 12 can be removed in an end portion from the step 11 formed by the lower leg without one of the two profiled hollow-chamber section parts being opened by removing this end portion of the step 12. This improves the dimensional stability during welding.
[0035] FIG. 3 shows the profiled hollow-chamber section 3 with the profiled hollow-chamber section 3.1 adjoining it for corner construction, with stepped end faces 13, 13.1. The stepped design has been transformed into its two-stepped configuration in the case of the profiled hollow-chamber section 3 by removing the originally present end portion of step 12. The two face portions of this stepped formation are identified by the reference numerals 14, 14.1. It can be clearly seen that removing this portion of step 12 does not open any of the remaining chambers of profiled hollow-chamber section 3. In the case of the profiled hollow-chamber section 3.1, on the other hand, the step 12,1 has been maintained with respect to the lower step 11.1. Consequently, an end portion of step 11.1 has been removed from the original extruded profile section in the same parting plane as in the case of the profiled hollow-chamber section 3. Thus, the end face 13.1 of the profiled hollow-chamber section 3.1 is also designed in two steps, so that the profiled hollow-chamber section 3.1 also has two end face portions 14.2, 14.3 at the end shown in FIG. 3. FIG. 3 shows the two profiled hollow-chamber sections 3, 3.1 before their assembly for the desired corner construction of the frame structure R.
[0036] In order to obtain the desired corner construction, the two profiled hollow-chamber sections 3, 3.1 are brought together so that the end face portion 14 of the profiled hollow-chamber section 3 borders on the portion of the lateral surface 4.1 which remains after removing the end portion of step 11.1. The end face portion 14.2 of the profiled hollow-chamber section 3.1 is brought up to the lateral surface 4, so that this end face portion 14.2 is supported on the complementary lateral surface portion of the profiled hollow-chamber section 3.
[0037] FIG. 6a shows the assembly of the two profiled hollow-chamber sections 3, 3.1 before welding. This corner construction is welded along the profiled hollow-chamber sections 3, 3.1, as shown schematically in FIG. 5. The weld seam is identified therein by the reference numeral 15.
[0038] The assembly of the two profiled hollow-chamber sections 3, 3.1 to form the corner construction shown in figures clearly shows that the two profiles are adjacent to each other forming a positive fit in the x and y direction and that there is also a positive fit between the two profiled hollow-chamber sections 3, 3.1 in a z-direction, in particular in relation to a movement of the two profiled hollow-chamber sections 3, 3.1 towards each other.
[0039] FIG. 8 shows another profiled hollow-chamber section 3.4, which is constructed like the previously described profiled hollow-chamber section 3.1. The profiled hollow-chamber section 3.4 differs from the profiled hollow-chamber section 3 in that it has a web 16 formed thereon which extends its inner lateral surface 4.4 and projects beyond its surface 10.2. This web 16 forms a weld pool support when this profiled hollow-chamber section 3.4 is assembled with a complementary profiled hollow-chamber section 3.5. The complementary profiled hollow-chamber section 3.5 is designed like the profiled hollow-chamber section 3. The assembly of the two profiled hollow-chamber sections 3.4, 3.5 is shown in FIG. 6b in a longitudinal section looking at the lateral surface 4.4 of the profile hollow-chamber section 3.4, which is facing the battery volume B. The web 16 projects beyond the top 10.3 of the profiled hollow-chamber section 3,5, thus providing a weld pool support. In order to also provide a weld pool support for the end face portion 14.4 of the profiled hollow-chamber section 3.4, the profiled hollow-chamber section 3.5 is slightly set back with its outwardly pointing lateral surface portion with respect to the end face 14.4. The concept of providing a weld pool support through the web 16, which protrudes beyond the actual top side 10.2, 10.3, is based on the fact that this upper side is machined anyway in a step following the welded connection in order to provide a flat upper side. In the course of this processing, the web 16 is removed.
[0040] The profiled hollow-chamber sections 17, 17.1 shown in FIG. 7, which relate to a further development of the present invention, form the corners of a frame structure of a battery housing. In this corner design of the frame structure, one profiled hollow-chamber section 17 has a three-step design of its end face 18. The end face portions each forming a step are denoted by 19, 19.1, 19.2. The configuration of the profiled hollow-chamber section 17 differs from the profiled hollow-chamber section 3.1 of the exemplary embodiment described above in that the lower step is divided into two individual steps—the steps with the end face portions 19, 19.1. As can be seen from FIG. 7, the lower step of the previously described profiled hollow-chamber section 3,1 is also designed in two steps in the z-direction. A portion of the upper chamber is removed over the entire width of the profiled hollow-chamber section 17 in a way that has already been described for the exemplary embodiment in FIGS. 1 to 5, without a profile chamber having been opened as a result. The end face portion 19 of the middle step is set back with respect to the end face portions 19.1 and 19.2, This receptacle, which is open in the direction of the profiled hollow-chamber section 17.1, receives a leg 20 formed by a single hollow chamber (seen in the z-direction) in the exemplary embodiment shown. This is formed by removing the lower side wall portion and the adjacent base portion to open the corresponding hollow chamber. On the upper side, the leg is provided by removing an end portion of the upper step, as was already described with respect to the previous exemplary embodiment.
[0041] While the end face 18 of the profiled hollow-chamber section 17 is provided with three steps, the end face 21 of the profiled hollow-chamber section 17.1 is provided with two steps, just like the end face of the profiled hollow-chamber section 3. Due to the engagement of the leg 20 in the U-shaped receptacle under the end face portion 19.2, both profiled hollow-chamber sections 17, 17.1 are positively interlocked in the z-direction in both directions.
[0042] FIG. 8 shows the two profiled hollow-chamber sections 17, 17.1 assembled to form a corner before the provision of a welded connection.
[0043] The invention has been described using several exemplary embodiments with reference to the figures. Without departing from the scope of the present claims, further optional implementations of the invention will become clear to a person skilled in the art, without having to explain them in greater detail in the present specification.
LIST OF REFERENCE NUMERALS
[0044] 1, 1.1 profiled hollow-chamber section [0045] 2, 2.1 profiled hollow-chamber section [0046] 3, 3.1, 3.2, 3.3 profiled hollow-chamber section [0047] 4, 4.1, 4.2, 4.3 lateral surface [0048] 5, 5.1, 5.2, 5.3 connecting web [0049] 6, 6.1, 6.2, 6.3 surface [0050] 7 fastening hole [0051] 8, 8.1 lateral surface portion [0052] 9, 9.1 lateral surface portion [0053] 10, 10.1 surface [0054] 11 step [0055] 12 step [0056] 13, 13.1 end face [0057] 14, 14.1, 14,2, 14.3 end face portion [0058] 15 weld [0059] 16 web [0060] 17.1 profiled hollow-chamber section [0061] 18 end face [0062] 19, 19.1, 19.2 lateral surface portion [0063] 20 leg [0064] B battery space [0065] R frame structure [0066] S chamber web
