Form Fit Of A Housing Of A Traction Battery Of An Electric Vehicle With A Chassis Of The Electric Vehicle

An electric vehicle includes a chassis and a housing for holding a traction battery of the electric vehicle. The chassis includes a beam having a projection protruding from the beam. The housing includes a lateral flange section protruding from the housing. The lateral flange section has a recess receiving the projection of the beam of the chassis. The recess of the lateral flange section defines a shape complementary to a shape of the projection of the beam such that the recess of the lateral flange section and the projection of the beam are brought into a form-fitting engagement. The recess and the projection collectively define a passage for receiving a screw.

TECHNICAL FIELD

The present disclosure relates to a chassis for an electric vehicle, which comprises a beam, and a housing for a traction battery of an electric vehicle, which comprises a lateral flange section protruding from the housing. Furthermore, the present disclosure relates to a system for an electric vehicle which comprises a chassis of the electric vehicle and a housing for a traction battery of the electric vehicle, an electric vehicle, and a method for mounting a traction battery of an electric vehicle.

BACKGROUND

During each normal journey of a vehicle, i.e., a motor vehicle and, in particular, a passenger vehicle (car), the vehicle and with it each of its assemblies are exposed to many longitudinal accelerations, i.e., accelerations in a front-rear direction of the vehicle, and transverse accelerations, i.e., accelerations in a left-right direction of the vehicle. Accordingly, each assembly is subjected to a mass-proportional force during each acceleration of the vehicle.

For maintaining vehicle integrity, an arrangement of each assembly relative to the vehicle must be maintained under the effect of the force associated with acceleration. In other words, for each assembly of the vehicle, a vehicle holder must be provided which receives the acting force and keeps the assembly constantly at a given location relative to the vehicle.

The assemblies of a vehicle driven by an internal combustion engine include a fuel tank.

DE 10 2017 001 123 A1 therefore discloses a system for a vehicle which comprises a body part of the vehicle, a fuel tank of the vehicle, and a holder for the fuel tank. The holder comprises a projection which engages in a corresponding recess in the fuel tank and fixes the fuel tank between the body part and a cladding element of the holder.

Accordingly, a traction battery, which usually comprises a housing and a plurality of battery cells arranged in the housing, belongs to the assemblies of an electric vehicle. The housing can have a lateral flange section protruding from the housing. To fasten the traction battery to a chassis of the vehicle, the flange section is connected to a beam of the chassis by means of a plurality of screws.

Due to a large mass of the traction battery, a connection between the traction battery and the chassis, in particular in the event of a rear impact, e.g., from an accident, must absorb a large force. However, a possible number of screws may not be sufficient due to a mounting space that is limited in principle. Apart from this, stability of the screws cannot be ensured with sufficient safety against shearing, in particular in the event of a rear impact.

SUMMARY OF INVENTION

It is therefore an object of the embodiments of the present disclosure to provide a chassis for an electric vehicle and a housing of a traction battery of the electric vehicle which ensure a fixed connection between the chassis and the housing even in the event of a rear impact. Additional objects of the embodiments of the present disclosure are to propose a system comprising a chassis and a housing of a traction battery for an electric vehicle, and an electric vehicle, and to propose a method for mounting a traction battery of an electric vehicle.

An object of the embodiments of the present disclosure is a chassis for an electric vehicle which comprises a beam. The beam of the chassis is designed to absorb force arising in the event of a rear impact. In addition, the beam is provided for attaching a traction battery of the electric vehicle.

According to an embodiment of the present disclosure, the beam comprises a projection protruding from the beam, which projection is designed for a three-dimensional form fit with a corresponding recess in a housing of a traction battery of the electric vehicle. The projection is integrally formed on the beam and provided in order to fix the housing of the traction battery by means of a form-fitting engagement in the beam. The three-dimensional form fit causes the housing to be fixed to the beam in three spatial dimensions, i.e., in an x-direction (longitudinal direction of the vehicle), a y-direction (lateral transverse direction of the vehicle) and a z-direction (vertical transverse direction of the vehicle).

The connection provided by the engagement, i.e., the form-fitting engagement connection between the beam and the housing, can absorb a rear impact, i.e., a brief major acceleration in the longitudinal direction of the vehicle. On the other hand while mounting the traction battery in the chassis, the three-dimensional form fit makes it easy to position the traction battery relative to the chassis.

The projection preferably has an internal thread for a screw, and/or the projection is at least partially designed as a cone with a conical outer surface. The internal thread allows the housing to be screwed to the beam. In the event of a rear impact, the screws do not have to absorb the entire force acting in the longitudinal direction of the vehicle, since the form fit engagement connection likewise absorbs a portion of the force. As a result, the form fit engagement connection likewise counteracts a shearing of the screws.

The cone shape of the outer surface of the projection simultaneously allows the traction battery to be fixed in the vertical transverse direction of the vehicle and the traction battery to be fixed in the longitudinal direction and the horizontal transverse direction of the vehicle, thereby making it easier to mount the traction battery.

Advantageously, the beam is designed as a longitudinal beam of the chassis. The longitudinal beam is provided to absorb forces acting in the longitudinal direction of the vehicle.

Another embodiment of the present disclosure is a housing for a traction battery of an electric vehicle, which housing comprises a lateral flange section protruding from the housing. The flange section of the housing is designed to absorb a force arising in the event of a rear impact. In addition, the flange section is provided for fastening the traction battery to the chassis.

According to an embodiment of the present disclosure, the flange section has a recess formed in the flange section which is designed for a three-dimensional form fit with a corresponding projection of the chassis of the electric vehicle. The recess is integrally formed in the flange section and provided in order to fix the housing of the traction battery by means of a form fit engagement by the beam. The three-dimensional form fit causes the housing to be fixed to the beam in three spatial dimensions, i.e., in an x-direction (longitudinal direction of the vehicle), a y-direction (lateral transverse direction of the vehicle) and a z-direction (vertical transverse direction of the vehicle).

The recess preferably has a passage for a screw, and/or the recess is at least partially designed as a hollow cone with a conical inner surface. The passage allows the housing to be screwed to the beam. In the event of a rear impact, the screws do not have to absorb the entire force acting in the longitudinal direction of the vehicle, since the form fit engagement connection likewise absorbs a portion of the force. As a result, the form fit engagement connection likewise counteracts a shearing of the screws.

The cone shape of the inner surface of the recess simultaneously allows the traction battery to be fixed in the vertical transverse direction of the vehicle and the traction battery to be fixed in the longitudinal direction and the horizontal transverse direction of the vehicle, thereby making it easier to mount the traction battery.

In one embodiment, a hollow cylinder is integrally formed on the flange section, and the recess is formed in a free end of the hollow cylinder. A length of the hollow cylinder establishes a position of the traction battery relative to the chassis, i.e., a distance between the flange section and the beam, and allows a flexible positioning of the traction battery in the vertical transverse direction.

Another embodiment of the present disclosure is a system comprising a chassis and a housing for a traction battery. The system is designed to provide a connection between the chassis and the housing of the traction battery.

According to an embodiment of the present disclosure, the chassis is designed as a chassis according to the present disclosure, the housing is designed as a housing according to the present disclosure, and the system has a plurality of corresponding projections and recesses. The multiple corresponding projections and recesses distribute the force arising during a rear impact and correspondingly reduce the force acting on each individual form-fitting engagement of a projection and a recess. In this way, a fixed connection between the traction battery and the chassis is ensured.

Another embodiment of the present disclosure is an electric vehicle comprising a chassis and a housing for a traction battery which is held three-dimensionally on a beam of the chassis. Electric vehicles with a chassis and a housing for a traction battery that are held three-dimensionally on the chassis are widespread. Accordingly, the embodiments of the present disclosure have many varied implications.

According to the an embodiment of the present disclosure, the chassis is designed according to the present disclosure, the housing is designed according to the present disclosure, and a projection protruding from a beam of the chassis and a recess formed in a lateral flange section protruding from the housing are in a form-fitting engagement. The electric vehicle provides a fixed connection between the traction battery and the chassis, thereby increasing the safety of the electric vehicle in the event of a rear impact.

Another embodiment of the present disclosure is a method for mounting a traction battery of an electric vehicle, in which a housing surrounding a traction battery of an electric vehicle is mounted on a beam of a chassis of the electric vehicle. The mounting method is carried out in each production of an electric vehicle. Accordingly, the embodiments of the present disclosure have many varied implications.

According to an embodiment of the present disclosure, a projection protruding from the beam of the chassis and a recess formed in a lateral flange section protruding from the housing are brought into a form-fitting engagement. Thanks to the form-fitting engagement, the housing is fixed on the beam in three spatial dimensions, i.e., in an x-direction (longitudinal direction of the vehicle), a y-direction (lateral transverse direction of the vehicle) and a z-direction (vertical transverse direction of the vehicle), thereby making it easier to mount the traction battery.

A screw is preferably screwed through a passage in the recess into an internal thread of the projection. The screw connection further enhances the connection between the traction battery and the chassis and counteracts a movement of the traction battery relative to the chassis in the vertical transverse direction of the vehicle.

An essential advantage of the chassis according to the present disclosure and of the housing according to the present disclosure for a traction battery is that, in an interaction, they ensure a fixed connection between the chassis and the housing even in the event of a rear impact. A further advantage is that mounting the traction battery is facilitated.

DETAILED DESCRIPTION

FIG.1shows a partial side view of a system according to one embodiment of the invention for an electric vehicle (not shown). The system comprises a chassis1with a beam10and a housing2for a traction battery which has a flange section20. The chassis1and the housing2are suitable for the electric vehicle.

FIG.2shows an enlarged detail of the system shown inFIG.1with a connection according to an embodiment of the invention between the housing2and the beam10.

The chassis1comprises a beam10with a projection100protruding from the beam10. The beam10can be designed as a longitudinal beam of the chassis1. The projection100is designed for a three-dimensional form fit with a corresponding recess200in the housing2of the traction battery of the electric vehicle. Ideally, the projection100has an internal thread1000for a screw3. The projection100can be formed at least partially as a cone with a conical outer surface101.

The housing2comprises a lateral flange section20protruding from the housing2with a recess200formed in the flange section20. A hollow cylinder201can be formed on the flange section20, and the recess200can be formed at a free end of the hollow cylinder201. The recess200is designed for the three-dimensional form fit with the corresponding projection100of the chassis1. The recess200ideally has a passage2000for the screw3. The recess200can be formed at least partially as a hollow cone with a conical inner surface202.

In advantageous embodiments, the system comprises a plurality of corresponding projections100and recesses200.

The traction battery of the electric vehicle is mounted in a method as follows.

The housing2surrounding the traction battery of the electric vehicle is mounted on the beam10of the chassis1of the electric vehicle. For this purpose, each projection100protruding from the beam10of the chassis1and each recess200formed in a lateral flange section20protruding from the housing2are brought into a form-fitting engagement in pairs.

A screw3is ideally screwed into the internal thread1000of the corresponding projection100through each passage2000of the recess200.

The electric vehicle comprises the chassis1and the housing2. After being mounting as intended, the housing2is held three-dimensionally on the beam10of the chassis1. The projection100protruding from the beam10of the chassis1and the recess200formed in the lateral flange section20protruding from the housing2are in a form-fitting engagement.

FIG.3shows a further enlarged detail of the system shown inFIG.2with a connection between the housing2and the beam10belonging to the prior art.

As shown inFIG.1, the system according to an embodiment of the invention can comprise both connections known from the prior art and connections according to an embodiment of the invention. The connections according to an embodiment of the invention can alternatively or additionally be provided on a cross beam of the chassis1.

LIST OF REFERENCE NUMBERS

4Force in the event of rear impact