KR-102961792-B1 - Hybrid energy absorption for vehicle battery pack frames

KR102961792B1KR 102961792 B1KR102961792 B1KR 102961792B1KR-102961792-B1

Abstract

A vehicle battery pack frame for a vehicle, comprising: a base having a length and a width; side members located on both sides of the base, extending along the length of the base and attached to the periphery of the base; and a cross beam extending across the width of the base between the side members; each side member comprising a profiled body having a side wall having a first surface facing the cross beam and a second surface on the opposite side; and a polymer reinforcement attached to the profiled body and facing the second surface of the side wall of the profiled body.

Inventors

문주룰리마나, 디네시
나관시, 다넨드라 쿠마르
칼러, 커티스
티와리, 아닐
페레이라, 카를로스

Assignees

사빅 글로벌 테크놀러지스 비.브이.

Dates

Publication Date: 20260507
Application Date: 20200701
Priority Date: 20190701

Claims (15)

As a vehicle battery pack frame (11), A base (14) having length and width; Side members (30) located on both sides of the base, extending along the length of the base, and attached to the periphery of the base; and It includes a plurality of cross beams (16) extending across the width of the base between the side members; Each side member is A profiled body (32) comprising a side wall (42) having a first surface facing the cross beam and a second surface on the opposite side; and It includes a polymer reinforcement (60) attached to the profile-type body and facing the second surface of the side wall of the profile-type body, A profile-type body includes a channel (35) extending away from a cross beam, the channel includes an upper wall (34) and a bottom wall (36), and the channel exists between them; a polymer reinforcement is placed in the channel, a vehicle battery pack frame.
A vehicle battery pack frame according to claim 1, further comprising a cover (20) extending between side members, and a cross beam positioned between the cover and the base.
In claim 1, the polymer reinforcement is a vehicle battery pack frame adjacent to a second surface of the side wall.
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A vehicle battery pack frame according to claim 1, wherein the profile-type body includes a box structure (38) adjacent to the channel, and the box structure is formed by a side wall (42) spaced apart from the channel, a first connector wall (44) extending between the side wall (42) and the top wall of the channel, and a second connector wall (46) extending between the side wall and the bottom wall of the channel.
In paragraph 1, the box structure is formed by a side wall, a connector wall, and a rear wall (40) of a channel, or the rear wall extends between the top wall and the bottom wall; the box structure is a vehicle battery pack frame that passes through the channel.
In paragraph 5, the side wall has a height greater than the height of the channel and/or greater than the height of the rear wall, and accordingly, the height of the box structure is greater than the height of the channel, a vehicle battery pack frame.
In claim 5, the vehicle battery pack frame, wherein the first connector wall and the second connector wall extend from the side wall toward the channel at an angle (θ) of 90 degrees or less.
A vehicle battery pack frame according to claim 1, wherein the profile body includes a reinforcing support element (70) extending between the top wall and the bottom wall, the first support wall (54) extending from the top wall away from the channel, the second support wall (56) extending from the bottom wall away from the channel, and the reinforcing support element provided at the location of the first support wall and the second support wall.
In claim 9, the second polymer reinforcement (64) is attached to the first support wall (54) and/or the second support wall (56), forming a vehicle battery pack frame.
In paragraph 1, Each profiled body additionally includes a flange (52); The flange of one side member extends from the side wall toward the flange of the other side member; A vehicle battery pack frame, the base extends between side members and is positioned on the flange of each side member.
A vehicle battery pack frame according to claim 1, wherein the polymer reinforcement comprises an alveolar structure having columns (33) oriented perpendicular to the longitudinal axis of the channel.
A vehicle battery pack frame (11) according to any one of paragraphs 1 through 3 and paragraphs 5 through 12; and A vehicle battery pack assembly (10) comprising a plurality of battery modules (12) within a vehicle battery pack frame.
A vehicle comprising a vehicle battery pack assembly according to Paragraph 13.
A method for forming a vehicle battery pack frame (11) according to any one of claims 1 to 3 and claims 5 to 12, A step of combining a polymer reinforcing material (60) and a profiled body (32) to form a side member (30); and A method comprising the step of attaching a cross beam (16) and a profiled body to each other.

Description

Hybrid energy absorption for vehicle battery pack frames Due to strict global regulations on carbon dioxide emissions, more attention is being focused on the development and use of electric vehicles, such as all-electric vehicles ("EVs"), plug-in hybrid vehicles ("PHEVs"), and hybrid vehicles ("HEVs"; that is, vehicles that utilize multiple propulsion sources, one of which is an electric drive system). Since reducing the weight of an electric vehicle can increase its driving range on a single charge, weight reduction is critical to the viability of electric vehicles. One of the key areas focused on for weight reduction is the vehicle battery pack assembly, which includes, for example, battery modules and the vehicle battery pack frame. Currently, most vehicle battery pack frames use aluminum or high-strength steel designs. While these designs provide structural integrity and protection during collisions, they are heavy. It would be desirable to provide a lightweight vehicle battery pack frame for a battery module that can protect the battery module during a side impact collision. The present invention provides a vehicle battery pack frame, a vehicle battery pack assembly including the vehicle battery pack frame and a battery module, and an electric vehicle including the vehicle battery pack assembly. In one embodiment, the vehicle battery pack frame may include a base having a length and a width; side members located on both sides of the base, extending along the length of the base and attached to the periphery of the base; a cross beam extending across the width of the base between the side members; and a cover enclosing a plurality of battery modules in the vehicle battery pack frame. Each side member is a frame having a flange extending from a first side and a channel on a second side, wherein the base includes a frame extending between the side members and across the flange of each side member; and a polymer reinforcement located in the channel. The following drawing is an exemplary embodiment in which similar elements have similar symbols. FIG. 1 is a perspective view of a typical electric vehicle battery pack including a vehicle battery pack frame and a battery module including the side member of FIG. 5. FIG. 2 is a representative side view of a vehicle including a vehicle battery pack assembly. FIG. 3 is a partial side view taken along line AA of FIG. 2 illustrating a vehicle battery pack assembly attached to a vehicle floor rocker. FIG. 4 is a side view illustrating a cross beam attached to a side member of a vehicle battery pack assembly. FIG. 5 is a partial perspective view of one embodiment of a side member including a hybrid structure. FIG. 6 is an enlarged front view of another embodiment of a side member including a polymer reinforcement and a frame. FIG. 7a is a partial perspective view of another embodiment of a polymer reinforcement. Figure 7b is a cross-sectional view of the polymer reinforcement of Figure 7a taken along line 7B-7B. FIG. 7c is a side view of another embodiment of a side member and frame including the polymer reinforcement of FIG. 7a and FIG. 7b. FIG. 8a is a perspective view of another embodiment of a side member including another embodiment of a polymer reinforcement having a structural reinforcing element. FIG. 8b is a side cross-sectional view of an embodiment of FIG. 8a. FIG. 9 is an enlarged perspective view of another embodiment of a side member illustrating an assembly of a frame having polymer reinforcement. FIG. 10 is a partial perspective view of another embodiment of the side member. FIG. 11 is a schematic top view illustrating four battery packs of Examples 1 to 3 and a comparative example, each having different side members before a crash test. FIG. 12 is a top view illustrating the four battery packs of FIG. 11 after a side impact test at 30 kilometers per hour (km/h) against a pole. FIGS. 13a through 13c illustrate progressive details of a crash test for the side member embodiment shown in FIGS. 8a and 8b. Figure 14 is a graph showing force (kilonewtons (kN)) versus intrusion (millimeters (mm)) for Examples 1 to 3 and Comparative Example representing the results of a crash test. Figure 15a is a graph showing force (kilonewtons (kN)) versus penetration (millimeters (mm)) for Example 4, representing the results of a collision test at low temperature. Figure 15b is a graph showing absorbed energy (in Joules (J)) versus temperature (°C) for Example 4. Figure 16a is a graph showing force (kN) versus penetration (mm) for Example 5, representing the results of a collision test at low temperature. Figure 16b is a graph showing absorbed energy (J) versus temperature (°C) for Example 5. An energy-absorbing and dispersing vehicle battery pack frame is provided. The vehicle battery pack frame comprises side members, cross beams, a base, optionally a cover, optionally partition(s), optionally a rear external support, and optionally a secondary battery support area. The s