Search

JP-2026514512-A - How to install a battery pack in a vehicle

JP2026514512AJP 2026514512 AJP2026514512 AJP 2026514512AJP-2026514512-A

Abstract

A method for mounting a battery pack to the body of a passenger car is provided. The method includes the step of providing a vehicle frame that defines at least the floor portion of the vehicle body. A battery pack is provided and is placed within the floor portion of the vehicle body. The battery pack is then bonded to the frame using at least one adhesive joint located at the interface between the battery pack and the frame.

Inventors

  • クラウディオ・サントニ

Assignees

  • シルバーストーン・パフォーマンス・テクノロジーズ・リミテッド

Dates

Publication Date
20260511
Application Date
20240426
Priority Date
20230426

Claims (20)

  1. A method for attaching a battery pack to the body of a passenger car, The steps include providing a vehicle frame that defines at least the floor portion of the vehicle body, The steps include providing the battery pack, The steps include: placing the battery pack on the floor portion of the vehicle body, The steps of joining the battery pack to the frame using at least one adhesive joint located at the interface between the battery pack and the frame, Methods that include...
  2. The method according to claim 1, wherein the one or more adhesive joints are arranged along the peripheral edge of the battery pack.
  3. The method according to claim 2, wherein the one or more adhesive joints are arranged along at least two opposing peripheral edges of the battery pack.
  4. The method according to any one of claims 1 to 3, wherein the one or more adhesive joints substantially surround the central region of the battery pack.
  5. The method according to any one of claims 1 to 4, wherein the battery pack includes one or more peripheral flanges configured to form at least a portion of the interface with the frame, and the one or more adhesive joints are arranged along one or more of the peripheral flanges.
  6. The method according to any one of claims 1 to 5, wherein the interface between the battery pack and the frame includes one or more portions defining a substantially stepped interface, and preferably, the at least one adhesive joint is positioned on one or at least two different surfaces of the portions defining the substantially stepped interface.
  7. The method according to any one of claims 1 to 6, wherein the floor portion of the vehicle generally defines a plane, the interface between the battery pack and the frame includes one or more portions positioned at a predetermined angle to the plane defined by the floor portion, and the at least one adhesive joint is positioned on one or more portions of the interface positioned at a predetermined angle to the plane defined by the floor portion.
  8. The method according to claim 7, wherein the interface between the battery pack and the frame includes portions positioned at different angles with respect to the plane defined by the floor portion, and the at least one adhesive joint is positioned in the portion of the interface positioned at different angles with respect to the plane defined by the floor portion.
  9. The method according to claim 7 or 8, wherein one or more portions of the interface between the battery pack and the frame are arranged at an angle that is generally inclined toward or away from the center of the battery pack.
  10. The method according to any one of claims 1 to 9, wherein the thickness of each adhesive joint is at least 0.5 mm, preferably at least 1 mm, more preferably at least 2 mm, and most preferably at least 3 mm.
  11. The adhesive joint or each adhesive joint is elongated, according to the method according to any one of claims 1 to 10.
  12. The method according to any one of claims 1 to 11, wherein the frame defines an opening in the floor portion through the frame, and the battery pack closes the opening, thereby defining at least the area of the floor of the vehicle.
  13. The method according to any one of claims 1 to 11, wherein the frame defines a substantially continuous floor surface in the floor portion of the vehicle body, and the battery pack is disposed substantially adjacent to the floor surface.
  14. The method according to any one of claims 1 to 13, wherein the step of positioning the battery pack on the floor portion of the vehicle body includes engaging one or more mechanical fasteners to guide the battery pack to a predetermined location on the frame.
  15. The method according to any one of claims 1 to 14, wherein the step of joining the battery pack to the frame includes the step of clamping the battery pack to the frame using one or more mechanical fasteners while the adhesive is curing.
  16. The method according to claim 14 or 15, wherein the one or more mechanical fasteners include one or more spacing elements configured to prevent direct contact between the battery pack and the frame.
  17. The method according to any one of claims 1 to 16, wherein the frame includes opposing structural members, and the method includes the steps of positioning the battery pack between the opposing structural members and joining the battery pack to each of the opposing structural members, preferably, the step of joining the battery pack to one or more of the opposing structural members includes joining the battery pack to the structural member using an adhesive joint located at the interface between the battery pack and the structural member.
  18. The method according to claim 17, as dependent on any one of claims 7 to 9, wherein the opposing structural members define one or more portions arranged at a predetermined angle with respect to the plane defined by the floor portion, preferably, each opposing structural member defines a portion arranged at a predetermined angle with respect to the plane defined by the floor portion, and the at least one adhesive joint is preferably arranged in each of the portions arranged at a predetermined angle with respect to the plane defined by the floor portion.
  19. The frame defines at least a portion of the floor surface in the floor portion of the vehicle body and a structural member extending away from the floor surface, and the method further comprises the steps of joining the battery pack to the structural member and joining the battery pack to the floor surface of the frame, preferably the step of joining the battery pack to the structural member includes joining the battery pack to the structural member using an adhesive joint located at the interface between the battery pack and the structural member, and/or, preferably the step of joining the battery pack to the floor surface includes joining the battery pack to the floor surface using an adhesive joint located at the interface between the battery pack and the floor surface, according to any one of claims 1 to 18.
  20. The method according to any one of claims 1 to 19, wherein the frame includes opposing longitudinal structural members arranged along opposing longitudinal edges of the floor portion of the vehicle body, and the step of placing the battery pack in the floor portion of the vehicle body includes the step of substantially placing the battery pack between the opposing longitudinal structural members.

Description

This invention relates to a method for mounting a battery pack to the body of a passenger car. In particular, this invention relates to a method for mounting a traction battery (used to supply power to an electric motor) to the body of an electric or hybrid passenger car. In electric and hybrid passenger vehicles, it is necessary to integrate a considerably large battery pack into the vehicle body. The manner in which the battery pack is integrated affects the vehicle's structure, safety, comfort, and performance. Battery packs are typically manufactured separately from the vehicle frame and then mounted to the frame. Prior art methods for joining battery packs to the vehicle body are based on mechanical fasteners to provide the battery pack's serviceability. Specifically, battery packs are generally attached to the frame by mechanical fasteners (e.g., bolts), which can be quickly and easily engaged and disengaged for mounting the battery during manufacturing and for subsequent removal, for example, for repair. One of the biggest differences between electric or hybrid passenger cars and internal combustion engine vehicles is the need to maintain the safety of both occupants and the battery by avoiding pack intrusion during a crash. This is generally achieved in part by transferring the crash load around the battery pack, in the case of frontal and rear-end collisions. One of the biggest design challenges is ensuring that the battery pack is protected during a side-impact crash or collision. This is particularly difficult because there is limited space within the rocker or sill for the crumple zone required to absorb the side-impact crash load without damaging the battery pack. Mechanical fasteners for mounting battery packs to the vehicle body are typically oriented substantially vertically for ease of access during manufacturing and repair. This joint orientation also allows the interface between the battery pack and the vehicle body to be positioned substantially horizontally and planarly, avoiding the risk of accumulating manufacturing tolerances that would create undesirable gaps between adjacent components (in this case, the battery pack and the vehicle body). Furthermore, this joint orientation accommodates substantially vertical mounting of heavy battery packs. However, mechanical fasteners used to enable vertical mounting orientations are typically inefficient in transmitting or responding to loads (i.e., shear loads) applied perpendicular to their main axis. Therefore, to ensure the battery pack remains secure during impact, the number and size of fasteners must be increased to prevent all possible failure modes, including bolt shear failure, joint slip failure, and failure at the edges of the bolt holes. Of particular importance is the shear load generated inside the vehicle from a side crash (especially a side pole crash). Strengthening mechanical fasteners to prevent all possible failure modes can lead to a significant increase in vehicle weight. This is particularly disadvantageous in the context of electric vehicles, where weight reduction is a critical consideration, and achieving the target range is a mandatory design consideration. The solution often involves adding more batteries and consequently adding more weight. European Patent Application Publication No. 4011668U.S. Patent Application Publication No. 2023/026490China Utility Model No. 214280109 This is a top view of a portion of the vehicle body, including the installed battery pack.This figure shows a schematic cross-section passing through the vehicle body and battery pack.This is a schematic top view of the battery pack shown in Figure 1, with the vehicle body omitted.This figure shows an alternative schematic cross-section of the vehicle body with the installed battery pack.This figure shows an alternative schematic cross-section of the vehicle body with the installed battery pack.This figure shows an alternative schematic cross-section of the vehicle body with the installed battery pack.This figure shows an alternative schematic cross-section of the vehicle body with the installed battery pack.This figure shows an alternative schematic cross-section of the vehicle body with the installed battery pack.This figure shows a magnified detail of a schematic cross-section of the vehicle body, including the installed battery pack.This is a schematic top view of the installed battery pack, with the vehicle body omitted.This is a schematic top view of the installed battery pack, with the vehicle body omitted.This is a flow diagram illustrating how to attach a battery pack to the vehicle body.This is a flow diagram illustrating the method for removing the battery pack installed in the vehicle. Here, the embodiment will be described in detail with reference to Figures 1 to 3. Figure 1 shows a portion of the vehicle body 1. The vehicle body includes a frame 10. This frame can be a so-called body-in-white (BIW). Figure 1 shows a floor frame se