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EP-4742396-A1 - BATTERY SUPPORT STRUCTURE

EP4742396A1EP 4742396 A1EP4742396 A1EP 4742396A1EP-4742396-A1

Abstract

The present invention relates to a battery support structure, comprising a lower part, in particular adapted as underrun protection, an upper part, in particular adapted as battery cell holder, and a load transfer structure between the two parts, wherein the load transfer structure comprises a first element and a second element, wherein the first element is arranged below the second element and is connected to the lower part and wherein one of the elements, preferably the first element, has a higher shear modulus and/or higher Young's modulus than the other element, preferably the second element, and has a higher shear modulus and/or higher Young's modulus than the second element and wherein the first element is arranged such that a force from the lower part is transmitted via the first element to the second element and from the second element to the upper part.

Inventors

  • Neuhaus, Jonas
  • DAHL, ERIK
  • GREBEL, KARSTEN

Assignees

  • Röchling Automotive SE

Dates

Publication Date
20260513
Application Date
20241107

Claims (15)

  1. Battery support structure (1), comprising a lower part (2), in particular adapted as underrun protection, an upper part (3), in particular adapted as battery cell holder, and a load transfer structure (10) between the two parts (2, 3), wherein the load transfer structure (10) comprises a first element (11) and a second element (12), wherein the first element (11) is arranged below the second element (12) and is connected to the lower part (2) and wherein one of the elements (11, 12), preferably the first element (11), has a higher shear modulus and/or higher Young's modulus than the other element (11, 12), preferably the second element (3), and wherein the first element (11) is arranged such that a force from the lower part (2) is transmitted via the first element (11) to the second element (12) and from the second element (12) to the upper part (3).
  2. Battery support structure according to claim 1, characterized in that the upper part (3) and the first element (11) are adapted for an at least partial form-fit engagement (20).
  3. Battery support structure according to claim 2, characterized in that the upper part (3) comprises at least one protrusion (5), which is engageable in a corresponding reception structure (13) of the first element (11) upon load, preferably wherein the reception structure (13) is provided in form of one or more U-shaped ribs.
  4. Battery support structure according to claim 2, characterized in that the upper part (3) comprises at least one protrusion (5), which is engaged in a corresponding reception structure (13) of the first element (2), preferably wherein the reception structure is provided in form of one or more U-shaped ribs.
  5. Battery support structure according to one of the claims 1-4, characterized in that the second element (12) comprises at least one of an elastomer, preferably a thermoplastic elastomer, silicone, preferably liquid silicone rubber, LSR, nitrile butadiene rubber, NBR.
  6. Battery support structure according to claim 5, characterized in that the second element (12) is provided as a foamed and/or non-foamed element.
  7. Battery support structure according to one of the claims 1-6, characterized in that the first element (11) comprises at least one opening (14).
  8. Battery support structure according to one of the claims 1-7, characterized in that the first element (11) is ring-shaped.
  9. Battery support structure according to claims 7 and 8, characterized in that a plurality of openings (14, 14a) is provided, in particular symmetrically to an axis of the ring-shaped first element (11).
  10. Battery support structure according to claims 1-9, characterized in that the first element (11) comprises at least two regions (18, 19) having a different thickness, in particular in case of a ring-shaped first element (11) the at least two regions (18, 19) have different diameters.
  11. Battery support structure according to one of the claims 1-10, characterized in that a plurality of load transfer structures (10, 10a, 10b) is provided, preferably for each battery cell (4) a load transfer structure (10, 10a, 10b) is provided.
  12. Battery support structure according to claim 11, characterized in that at least two of the load transfer structures (10a, 10b) are connected with each other, preferably wherein the first elements (11) of said at least two load transfer structures (10a, 10b) are connected with each other.
  13. Battery support structure according to one of the claims 11-12, characterized in that said plurality of load transfer structures (10, 10a, 10b) are formed such to provide at least one venting channel (16), preferably a plurality of venting channels (16, 16a, 16b), in particular wherein at least two of the venting channels (16, 16a, 16b) are formed parallel to each other.
  14. Battery support structure according to one of the claims 1-13, characterized in that the first element (11) and/or the second element (12) is injection-molded.
  15. Battery (100) comprising at least one battery cell (4) arranged in a battery support structure (10, 10a, 10b) according to one of the claims 1-14.

Description

The invention relates to a battery support structure, comprising a lower part, in particular adapted as underrun protection, an upper part, in particular adapted as battery cell holder, and a load transfer structure between the two parts, wherein the load transfer structure comprises a first element and a second element. The invention further relates to a battery comprising at least one battery cell arranged in a battery support structure. Battery support structures are used to give battery cells stability in terms of forces or load acting on the battery cells. In particular forces acting upon the battery cells for instance in case of an underrun event should be distributed and transferred such that the mechanical load carrying capacity of each cell is used to a large extent to avoid damage. DE 10 2022 116 978 B3 shows an underrun protection device for a battery electric vehicle, with a sandwich arrangement comprising a core layer arranged between an upper cover layer and a lower cover layer made of a fiber-reinforced plastic material. Ribs are arranged on the top cover layer, which ribs are connected to the top cover layer in a material-locking manner, wherein the ribs arranged on the top cover layer are each surrounded by a top layer, which is connected to the top cover layer in a material-locking manner at two retaining sections. One of the problems however is that overloading can not efficiently be prevented due to the stiffness of the ribs. Further due to the usually limited deformation space the mechanical performance of the underrun can not fully utilized. One of the objectives of embodiments of the present invention is therefore to provide a battery support structure and a battery with a battery support structure having an enhanced mechanical performance, enable an efficient transfer of forces and load such that the load carrying capacity of each cell is used to a larger extent. One of the further objectives of embodiments the present invention is therefore to provide an alternative battery support structure and an alternative battery with a battery support structure. In an embodiment the present invention solves the afore-mentioned objectives by a battery support structure, comprising a lower part, in particular adapted as underrun protection, an upper part, in particular adapted as battery cell holder, and a load transfer structure between the two parts, wherein the load transfer structure comprises a first element and a second element, wherein the first element is arranged below the second element and is connected to the lower part and wherein one of the elements, preferably the first element, has a higher shear modulus and/or higher Young's modulus than the other element, preferably the second element, and has a higher shear modulus and/or higher Young's modulus than the second element and wherein the first element is arranged such that a force from the lower part is transmitted via the first element to the second element and from the second element to the upper part. In an embodiment, the present invention solves the afore-mentioned objectives by a battery comprising at least one battery cell arranged in a battery support structure according to one of the claims 1-14. One of the advantages is that an optimized mechanical performance of the battery support structure can be achieved. A further advantage is that the probability for a damage due to mechanical overload can be reduced. An even further advantage is that a simple and cost-effective manufacturing can be provided. Further features, advantages and preferred embodiments are disclosed or may become apparent in the following. According to a preferred embodiment of the invention, the upper part and the first element are adapted for an at least partial form-fit engagement. In case of load event, the upper part for instance extends into the first element allowing a secure guiding. According to a further preferred embodiment of the invention the upper part comprises at least one protrusion, which is engageable in a corresponding reception structure of the first element upon load, preferably wherein the reception structure is provided in form of one or more U-shaped ribs. This allows in a simple and effective way a form-fit engagement for secure guiding and transfer of shear load in case of a load event. According to a further preferred embodiment of the invention, the upper part comprises at least one protrusion, which is engaged in a corresponding reception structure of the first element, preferably wherein the reception structure is provided in form of one or more U-shaped ribs. One of the advantages is a reliable transfer of shear loads even in the case of a low load event. The ribs may have any form, in particular a different form than being U-shaped. According to a further preferred embodiment of the invention, the second element comprises at least one of an elastomer, preferably a thermoplastic elastomer, silicone, preferably liquid silico