CN113497298A

CN113497298A - Vehicle battery holder

Info

Publication number: CN113497298A
Application number: CN202110282894.8A
Authority: CN
Inventors: 鲍里斯·劳舍尔; 克里斯蒂安·汉鼎; 哈拉尔德·克伦策; 弗罗德·保尔森
Original assignee: Benteler Automobiltechnik GmbH
Current assignee: Benteler Automobiltechnik GmbH
Priority date: 2020-03-19
Filing date: 2021-03-16
Publication date: 2021-10-12
Also published as: DE102020107635A1

Abstract

The invention relates to a vehicle battery holder for holding a plurality of battery modules in an electric vehicle, comprising a holding tray for holding a plurality of battery modules, wherein the holding tray has a base plate and a circumferential outer wall which is arranged on or around the base plate in the circumferential direction, and a plurality of internal supports which are arranged on the base plate, wherein adjacent internal supports delimit a module receptacle for accommodating a battery module, wherein the internal supports are formed as elongated extruded hollow profiles and are fixed at the ends at the circumferential outer wall, each internal support having an internal support underside which rests on the base plate and an internal support upper side which faces away from the internal support underside, the internal support upper sides of the internal supports each having a fastening projection which extends from the respective internal support upper side.

Description

Vehicle battery holder

Technical Field

The present invention relates to a holder for holding a battery module in an electric vehicle.

Background

In order to hold a battery module for supplying electric power in an electric vehicle, a battery holding structure provided between axles of the vehicle is generally used.

A battery holder suitable for use as a battery tray is described, for example, in document DE 102016115647B 3.

Furthermore, document DE 102016213832B 4 discloses a lower housing for a battery housing of a traction battery.

In document DE 102018210126 a1, structural components of a battery housing for an electric motor vehicle are described.

Disclosure of Invention

It is an object of the present invention to provide a more efficient battery holder.

This object is achieved by the features of the independent claims. Advantageous embodiments are the subject matter of the dependent claims, the description and the figures.

The present invention is based on the finding that the above object can be achieved by a battery holder having a holding tray and a plurality of internal supports arranged on a base plate of the holding tray. On the upper side of the inner supports, each inner support comprises a fastening projection which is formed in particular to mechanically connect the respective inner support to the cover of the battery holder, so that a stable connection, in particular a fluid-tight connection and/or a gas-tight connection, between the retaining tray in the battery holder and the cover can be ensured.

Furthermore, according to the present invention, the internal support is formed as an elongated, extruded hollow profile, which can be produced in small quantities without using expensive casting tools, and is therefore inexpensive, compared to conventional internal supports consisting of castings. In addition, since there is no need to change the casting tool, the structure of the internal support formed as an elongated extruded hollow profile can be flexibly changed. Furthermore, the fastening opening can already be introduced into the internal support formed as an elongated extruded hollow profile before the extrusion process, so that the internal support of the invention does not have to be disadvantageously drilled.

The inner support according to the present invention is fixed at the end portion at the circumferential outer wall of the holding tray, so that in the event of a vehicle collision, impact energy acting on the holding tray can be effectively absorbed in the longitudinal direction of the inner support to prevent damage to the battery module housed in the battery holder. Since the interior support is formed as an elongated extruded hollow profile according to the invention, zero intrusion and transmission of side impact forces to the opposite outer wall and underbody structure above the battery holder can be ensured.

According to a first aspect, the invention relates to a battery holder for holding a plurality of battery modules in an electric vehicle, the battery holder comprising a holding tray for holding the plurality of battery modules, wherein the holding tray has a base plate and a circumferential outer wall which is arranged on or circumferentially around the base plate, and a plurality of internal supports of the battery holder, wherein the internal supports are arranged on the base plate, wherein adjacent internal supports define module receiving parts for receiving the battery modules, wherein the inner supports are formed as elongated extruded hollow profiles and are fixed at the ends at the circumferential outer wall, each inner support having an inner support underside on the base plate and an inner support upper side facing away from the inner support underside, the inner support upper side of each inner support having fastening projections extending from the respective inner support upper side.

This has the technical advantage that a mechanically stable fixing of the cover of the battery holder to the internal support arranged in the holding tray can be ensured and the internal support is adapted as an elongated extruded hollow profile, which makes the production of the internal support cheaper and thus flexible to the installation situation possible, and the fixing of the end side of the internal support to the circumferential outer wall effectively absorbs the impact energy acting on the holding tray in the longitudinal direction of the internal support in the event of a vehicle collision.

In particular, a circumferential outer wall arranged on the base plate or circumferentially surrounding the base plate completely surrounds the base plate.

In particular, the internal supports are arranged adjacent to each other, in particular parallel to each other, on the base plate.

In particular, only some of the plurality of internal supports are arranged on the base plate, in particular adjacent to each other, in particular parallel, and the plurality of internal supports comprises at least one internal support arranged at an angle, in particular at right angles, or diagonally to the other internal supports. In particular at right angles or diagonally to the internal support, the other internal supports being arranged in particular adjacent to one another on the base plate.

In particular, a single module receptacle or a plurality of module receptacles, which are arranged in particular adjacent to one another, are arranged between adjacent internal supports.

In particular, the module receiving portions are respectively disposed between two adjacent inner support frames of the plurality of inner supports. In particular, a single module receptacle or a plurality of module receptacles arranged adjacent to one another is arranged between two adjacent internal supports.

In particular, the module housing is limited by at least one inner support and a circumferential outer wall. In particular, a single module receptacle or a plurality of module receptacles arranged adjacent to one another is delimited by at least one inner support and a circumferential outer wall.

An inner support formed as an elongated extruded hollow profile is fixed at the end at the circumferential outer wall. In particular, one end of each inner support rests on the circumferential outer wall, and the other end of each inner support can be fixed by a tolerance compensation element and/or a tolerance gap.

In particular, the inner supports, in particular one end of each inner support, formed as elongated extruded hollow profiles, are connected to the circumferential outer wall at this end. In particular, the inner supports, in particular one end of each inner support, which are formed as elongated extruded hollow profiles, are connected at this end to the circumferential outer wall by a material connection, in particular by a welded connection, by a form-fitting connection, in particular by a joining element, and/or by a force-fitting connection, in particular by a fastening element.

In particular, the inner support underside of the inner support is connected to the base plate. In particular, the inner support underside of the inner support is firmly connected to the base plate, in particular by a welded connection, by a form-fitting connection, in particular by a connecting element and/or a force-fitting element, in particular by a fastening element.

In particular, a receiving recess is formed between adjacent fastening projections of the respective inner support upper side of the respective inner support, wherein the receiving recess is formed to receive an electrical line for electrical contact with the battery module and/or the heating line and/or the cooling line.

In particular, the fastening projection protrudes beyond the respective inner support upper side of the respective inner support.

Furthermore, the base plate may have a heat exchanger structure for temperature control of the battery module, in particular having a hollow fluid channel which is formed within the base plate and is adapted to conduct a fluid.

In one embodiment, the battery holder has a cover which rests on fastening projections which are formed as a cover which mechanically connects the respective internal support to the battery holder, wherein the battery holder in particular has fastening elements which are formed together with the fastening projections to mechanically connect the respective internal support to the cover.

In particular, the cover of the battery holder may be placed on the fastening protrusions of the internal support and on the circumferential outer wall, and the fastening protrusions are formed to mechanically connect the respective internal support to the cover of the battery holder.

In particular, the fastening projections are formed to connect the respective internal support to the cover of the battery holder in a force-fitting, form-fitting and/or material-connecting manner.

In particular, the battery holder comprises a plurality of fastening elements adapted to connect the fastening protrusions of the internal support to the cover of the battery holder.

In particular, the fastening element comprises a fastening screw adapted to connect the fastening projection of the internal support to the cover of the battery holder in a force-fitting manner, and/or the fastening element comprises a fastening pin adapted to connect the fastening projection of the internal support to the cover of the battery holder in a form-fitting manner.

In particular, fastening openings are formed in the fastening projections, into which fastening elements, in particular fastening screws and/or fastening pins, respectively, are inserted in order to mechanically connect the fastening projections to the cover.

In particular, a respective fastening element, in particular a fastening screw and/or a fastening pin, is inserted into a respective fastening opening formed in the fastening projection.

In particular, fastening elements, in particular fastening screws and/or fastening pins, connect the fastening projections of the internal support to the cover of the battery holder.

In particular, the fastening element is adapted to press the cover onto the fastening projection and/or the circumferential outer wall by a force-fit and/or form-fit connection in order to provide a fluid-tight and/or gas-tight seal between the cover element and the inner support and/or the circumferential outer wall.

In particular, the lid is suitable as a stamped part, roll-formed part or thermoformed part.

In particular, the cover, the base plate, the circumferential outer wall and/or the plurality of internal supports are formed from metal, in particular aluminium, steel and/or an aluminium alloy.

In particular, the base plate and/or the circumferential outer wall are formed as extruded parts.

In particular, the base plate is suitable as a heat exchange element, in particular a cooling plate, or is connected to a heat exchange element, in particular a cooling plate, in particular in the form of a sandwich structure.

In particular, the base plate is suitable as an underbody protection for vehicles, in particular when made of a high-strength, impact-resistant, crack-inhibiting material or a composite material (e.g. made of a fiber fabric) with a penetration-resistant intermediate layer, or in a hollow cavity filling, or as an underbody protection by providing a further protective plate under the base plate.

In one embodiment, the circumferential outer wall has a front side, a rear side opposite the front side, a first lateral side and a second lateral side opposite the first lateral side, the internal support extending between the front side and the rear side and/or between the first lateral side and the second lateral side of the circumferential outer wall.

This has the technical advantage that a particularly effective stabilization of the holding tray is ensured by the internal support.

The internal support may extend between the front side and the rear side of the circumferential outer wall, or may extend between the first lateral side and the second lateral side of the circumferential outer wall. Alternatively, the internal support may extend both between the front side and the rear side of the circumferential outer wall and between the first lateral side and the second lateral side of the circumferential outer wall.

In one embodiment, the inner support comprises a plurality of transverse supports fixed at the ends on the first or second transverse side of the circumferential outer wall, and/or the inner support comprises a plurality of longitudinal supports fixed at the ends on the front and rear side of the circumferential outer wall.

According to a first possibility, the inner support, in particular serving as a longitudinal support, extends between the front side and the rear side of the circumferential outer wall and is in particular fixed at an end at the front side and/or the rear side of the circumferential outer wall, thereby ensuring an effective stabilization of the holding tray in the longitudinal direction of the holding tray.

According to a second possibility, the inner support, in particular serving as a transverse support, extends between the first and second transverse sides of the circumferential outer wall and is in particular fixed at an end at the first and/or second transverse side of the circumferential outer wall, thereby ensuring an effective stabilization of the holding tray in the transverse direction of the holding tray.

According to a third possibility, the inner support, in particular as a transverse support, extends between the first and second transverse sides of the circumferential outer wall and is in particular fixed at an end at the first and/or second transverse side of the circumferential outer wall, and the inner support, in particular as a longitudinal support, extends between the front and rear side of the circumferential outer wall and is in particular fixed at an end at the front and/or rear side of the circumferential outer wall, thereby ensuring an effective stabilization of the holding tray in the transverse and longitudinal direction of the holding tray.

In one embodiment, the plurality of internal supports comprises a plurality of transverse supports fixed at the ends on the first and/or second transverse side of the circumferential outer wall, and wherein the plurality of internal supports comprises at least one longitudinal support extending between, and in particular fixed with, the front surface of the front side and the rear surface of the rear side of the circumferential outer wall.

This has the technical advantage that the transverse supports ensure an effective transverse stabilization of the holding tray and that the at least one longitudinal support ensures an effective longitudinal stabilization of the holding tray.

The end-side fixing of the transverse supports and/or longitudinal supports on the outer wall can be achieved by connecting the respective transverse supports and/or longitudinal supports directly to the outer wall or by fixing the respective transverse supports and/or longitudinal supports with tolerance compensation elements or tolerance gaps.

In one embodiment, the plurality of transverse supports includes a first set of transverse supports extending from a first transverse side of the outer wall to the at least one longitudinal member, and the plurality of transverse supports includes a second set of transverse supports extending from the at least one longitudinal support to a second transverse side of the outer wall.

This achieves the technical advantage that a particularly effective stabilization is achieved by the two sets of transverse members arranged in the holding pan on different sides of the longitudinal members.

In particular, the transverse struts of the first set of transverse struts are fixed at the ends on the first transverse side, and the transverse struts of the first set of transverse struts are fixed with their end faces on the at least one longitudinal strut.

In particular, the transverse supports of the second set of transverse supports are fixed at their ends to the second transverse side and the transverse supports of the second set of transverse supports are fixed at their front surfaces to the front side of the at least one longitudinal support.

In one embodiment, the plurality of internal supports comprises a plurality of longitudinal supports fixed at the ends at the front side and/or the rear side of the circumferential outer wall, and the plurality of internal supports comprises at least one transverse support located between the first transverse side and the second transverse side of the circumferential outer wall, and in particular at the first transverse side and the second transverse side of the circumferential outer wall, respectively, at its two lateral end faces.

This has the technical advantage that the longitudinal supports ensure an effective longitudinal stability of the holding tray and that the at least one transverse support ensures an effective transverse stability of the holding tray.

In one embodiment, the plurality of longitudinal supports includes a first set of longitudinal supports extending from the front side to the at least one lateral support, and the plurality of longitudinal supports includes a second set of longitudinal supports extending from the at least one lateral support to the back side.

This achieves the technical advantage that a particularly effective stabilization is achieved by the two sets of longitudinal members arranged on different sides of the transverse support in the holding tray.

In particular, the end face of a longitudinal support of the first set of longitudinal supports is fixed on the front side, while the rear side of a longitudinal support of the first set of longitudinal supports is fixed on at least one transverse support.

In particular, the end face of a longitudinal support of the second set of longitudinal supports is fixed on the rear side, while the front face of a longitudinal support of the second set of longitudinal supports is fixed on at least one transverse support.

In one embodiment, the inner supports are each formed by an at least partially open elongated extruded hollow profile, wherein the at least partially open elongated extruded hollow profile has in particular an at least partially open inner support upper side and/or an at least partially open inner support transverse side facing the circumferential outer wall.

This achieves the technical advantage that the interior support is formed from an elongated extruded hollow profile, so that advantageously the weight of the interior support is reduced, but without causing an adverse effect on the stability of the interior support.

In particular, the at least partially open inner support upper side is open in the region of the inner support upper side, wherein no fastening projection extends from the respective inner support upper side.

In an embodiment, the internal support is formed by an elongated extruded single-or multi-lumen hollow profile, respectively, in particular by an elongated extruded two-lumen hollow profile or an elongated extruded three-lumen hollow profile.

This has the technical advantage that the stability of the internal support can be advantageously adjusted by selecting the hollow profile to be a single-or multi-lumen hollow profile.

In particular, the two-cavity hollow profile of the inner support comprises a first hollow cavity, which is arranged in particular in a region of the inner support facing the base plate, and a second hollow cavity, which is arranged in particular in a region of the inner support facing the cover. The first hollow chamber and the second hollow chamber are at least partially separated from each other by a chamber web, wherein the chamber web extends only partially or continuously, in particular over the entire length of the respective inner support.

In particular, the three-cavity hollow profile of the inner support comprises a first hollow cavity, in particular arranged in a region of the inner support facing the base plate, a second hollow cavity, in particular arranged in a region of the inner support facing the cover, and a third hollow cavity located between the first hollow cavity and the second hollow cavity. In this case, adjacent hollow chambers are at least partially separated from one another by a respective chamber web, which in particular extends only partially or continuously over the entire length of the respective inner support.

In one embodiment, adjacent fastening projections each have a receiving recess which is formed to receive an electrical line for electrically contacting the battery module and/or a heating line and/or a cooling line, wherein the receiving recess is in particular at least partially open on the upper side of the inner support.

This has the technical advantage that space for guiding the electrical lines and/or heating lines and/or cooling lines can be provided by the receiving recesses between the fastening projections. Since the receiving recess is at least partially open, in particular at the upper side of the inner support, the weight of the inner support can be effectively reduced.

In an embodiment, the respective elongated extruded hollow profile of the inner support has an at least partially closed inner support upper side and/or an at least partially closed inner support front side facing the circumferential outer wall of the holding tray, in particular the front side of the holding tray, and/or an at least partially closed inner support rear side facing the circumferential outer wall of the holding tray, in particular the rear side of the holding tray.

The technical advantage is thereby obtained that the at least partially closed upper side of the inner support, the front side of the inner support and/or the rear side of the inner support ensure sufficient mechanical stability of the respective inner support in order to be able to effectively absorb the impact energy acting on the inner support.

In particular, the front side of the inner support is adapted to be completely closed. In particular, the rear side of the inner support is adapted to be completely closed.

In particular, the inner support upper side is adapted to be closed in the region of the fastening projection.

In one embodiment, the fastening projections each have a closed fastening projection upper side which faces away from the lower side of the inner support, wherein in particular a fastening opening for receiving a fastening element is formed in the closed fastening projection upper side, wherein in particular a blind rivet nut, a pierce nut, a weld nut or an internal thread for receiving a fastening screw is assigned to the fastening opening.

This achieves the technical advantage that the cover can be effectively fastened to the fastening projection through the fastening opening for accommodating the fastening element.

In particular, fastening elements, in particular fastening screws and/or fastening pins, are inserted into the fastening holes, respectively, in order to mechanically connect the fastening projections to the cover.

In particular, the respective fastening element, in particular the fastening screw and/or the fastening pin, engages in a respective fastening opening formed in the upper side of the fastening projection.

In particular, a respective fastening element, in particular a fastening screw and/or a fastening pin, connects the respective fastening projection of the internal support to the cover of the battery holder.

In an embodiment, the fastening protrusions comprise a first set of fastening protrusions without fastening openings and a second set of fastening protrusions with fastening openings.

This achieves technical advantages in that the connection between the inner support and the cover can be simplified, since not all fastening projections have fastening openings.

In particular, the fastening projection upper sides of the fastening projections in the first fastening projection group are completely closed, and at least one fastening opening is formed in each of the fastening projection upper sides of the fastening projections in the second fastening projection group.

In particular, the cover is arranged not only on the upper side of the completely closed fastening projection in the first fastening projection group, but also on the upper side of the fastening projection having at least one fastening opening in the fastening projections in the second fastening projection group, wherein the fixing of the cover to the upper side of the fastening projection in the second fastening projection group can be effected by means of fastening elements, in particular fastening screws and/or fastening pins.

In particular, the respective fastening projection extends with its upper side parallel to the cover and/or parallel to the base plate.

In particular, a front side of the fastening projection facing the front side of the circumferential outer wall is closed and/or a rear side of the fastening projection facing the rear side of the circumferential outer wall is closed.

In particular, a first fastening projection transverse side of the fastening projection facing a first transverse side of the circumferential outer wall is open and/or a second fastening projection transverse side of the fastening projection facing a second transverse side of the circumferential outer wall is open.

In one embodiment, the internal supports each have a plurality of module fastening elements which are suitable for connecting the respective internal support to the battery module, wherein the module fastening elements are arranged in particular at a front side of the internal support facing a front side of the circumferential outer wall and/or in particular at a rear side of the internal support facing a rear side of the circumferential outer wall.

This has the technical advantage that the module fastening elements ensure a particularly effective fastening of the respective battery module to the respective internal support.

In particular, the module fastening element comprises a flange extending from the internal support, in particular from the front side of the internal support and/or the rear side of the internal support, wherein the flange is adapted to be positioned at the battery module.

In particular, the flange is integrally formed with the inner support or the flange is firmly connected with the inner support.

In particular, the module fastening elements, in particular the flanges, extend parallel to the base plate and/or obliquely with respect to the base plate.

In particular, the module fastening element is matched with a threaded block or a threaded hollow block.

In one embodiment, the module fastening elements, in particular the flanges, each have at least one module fastening opening for receiving a module fastening member for fastening the battery module to the internal support, wherein the module fastening member comprises in particular a module fastening screw.

This achieves the technical advantage that the module fastening member ensures effective fastening of the battery module to the module fastening element.

In particular, the module fastening element comprises a first module fastening element extending from the front side of the internal support and a second module fastening element extending from the rear side of the internal support. In particular, the first module fastening element and the second module fastening element are formed symmetrically with respect to the inner support, in particular the transverse support.

In particular, the module fastening element comprises a first module fastening element group which is formed on a first end of the internal support, in particular the transverse support, and the module fastening element comprises a second module fastening element group which is formed on a second end of the internal support, in particular the transverse support, which is remote from the first end.

In particular, the first and second sets of module fastening elements each comprise a first module fastening element extending from the front side of the internal support and a second module fastening element extending from the rear side of the internal support.

In an embodiment, the respective internal support has at least one substrate fastening projection which is placed on the substrate and is connected to the substrate, in particular in a material-bonded manner.

In an embodiment, the inner supports, in particular the longitudinal supports and/or the transverse supports, each have an inner support height which increases towards the circumferential outer wall, the inner support height extending from the inner support underside to the inner support upper side.

This has the technical advantage that a particularly effective structural stability of the internal supports is ensured.

In one embodiment, the inner support, in particular the longitudinal support and/or the transverse support, is connected in a form-fitting manner, in particular by a joining element, in a firmly connected manner, in particular by an adhesive or welded connection, or in a force-fitting manner, to the circumferential outer wall, and/or the inner support, in particular the longitudinal support and/or the transverse support, in particular by a welded connection, is connected in a force-fitting manner or in a form-fitting manner, in particular by a joining element, to the base plate.

This has the technical advantage that a particularly effective mechanical connection between the respective inner support and the circumferential outer wall or base plate is ensured.

In an embodiment, the outer wall has a plurality of flanges, the plurality of base plate flanges being adapted for fixing the battery holder to a body of an electric vehicle, and the plurality of base plate flanges particularly having a plurality of flange openings into which flange fastening elements, particularly flange screws, can be inserted.

According to a second aspect, the invention relates to a method for manufacturing an internal support of a cell holder, comprising the method steps of extruding an elongated hollow profile to obtain an internal support precursor formed by the extruded hollow profile, forming a plurality of fastening protrusions in the internal support precursor, in particular comprising trimming the closed upper side of the internal support precursor and/or reshaping at least one side wall of the open upper side of the internal support precursor.

This has the technical advantage that the manufacturing process of the inner support is simplified. After extrusion of the interior support precursor formed by the extruded hollow profile, the plurality of fastening protrusions can be obtained, for example, by trimming the closed upper side of the interior support precursor, wherein the upper side of the interior support precursor is removed, thus obtaining an open upper side of the interior support precursor. Subsequently, at least one side wall of the open upper side can be shaped, in particular bent, to form a fastening projection.

In an embodiment according to the second aspect, the forming of the plurality of fastening protrusions comprises forming two side walls of the open upper side of the internal support precursor, the two formed side walls being welded to each other so as to form the plurality of fastening protrusions.

Here, the two side walls of the open upper side of the interior support precursor can be obtained by pre-trimming the closed upper side of the interior support precursor.

In an embodiment according to the second aspect, the manufacture of the inner support comprises as a further method step, at least partial trimming of the closed upper side of the inner support precursor formed as a multi-lumen hollow profile.

In this case, it is possible to obtain an area in which the upper side of the inner support is at least partially open, which is not formed in particular in the area of the fastening projections.

The embodiments mentioned in relation to the first aspect also apply to the embodiments according to the object of the second aspect.

Drawings

Other embodiments will be described with reference to the accompanying drawings, in which:

fig. 1 is a perspective view of a battery holder of a first embodiment;

fig. 2 is a perspective view of an internal support of the battery holder of the first embodiment shown in fig. 1;

fig. 3 is a perspective view of an internal support of the battery holder of the second embodiment;

fig. 4 is a perspective view of an internal support of the battery holder of the third embodiment;

fig. 5 is a perspective view of an internal support of the battery holder shown in fig. 1 in a first embodiment;

fig. 6 is a perspective view of an internal support of the battery holder of the fourth embodiment;

fig. 7 is a schematic view of an internal support of a fifth embodiment battery holder;

fig. 8 is a schematic view of an internal support of a battery holder of a sixth embodiment;

FIGS. 9A-9E are schematic views of an internal support of a battery holder of a seventh embodiment;

10A and 10B are schematic cross-sectional views of the internal support of the battery holder of various embodiments;

FIG. 11 is a schematic view of a method of manufacturing an internal support.

Reference numerals:

100 holder

101 holding tray

103 substrate

105 circumferential outer wall

105-1 circumferential outer wall front side

105-2 circumferential outer wall rear side

105-3 first lateral side of circumferential outer wall

105-4 second lateral side of the circumferential outer wall

107 internal support

107-1 transverse support

107-1a first set of transverse supports

107-1b second set of transverse supports

107-1N Nth set of transverse supports

107-2 longitudinal support

107-2a first set of longitudinal support members

107-2b second set of longitudinal supports

107-2N Nth set of longitudinal supports

108 under the internal support

109 module accommodating part

110-1 maximum height of outer wall

110-2 minimum height of fastening projection

111 fastening projection

111-1 fastening projection front side

111-2 fastening lug backside

111-3 first fastening projection lateral sides

111-4 second fastening projection lateral side

111-5 fastening projection upper side

111-6 first fastening projection group

111-7 second fastening projection group

112 base plate flange

113 upper side of inner support

114 flanged opening

115 accommodating recess

117-1 first hollow cavity

117-2 second hollow cavity

117-3 Chamber Web

117-4 third hollow cavity

118 inner support lateral sides

119 interior support front side

121 rear side of inner support

123 fastening hole

125 module fastening element

125-1 first module fastening element

125-2 second module fastening element

125-3 first module fastening element group

125-4 second Module fastening elements group

125-5 third module fastening element

125-6 fourth module fastening element

127 module securing opening

129 first end of internal support

131 second end of the inner support

133 substrate fastening projection

135 closed part

137 another fastening opening

139 support opening

141 cover

143 vertical axis of longitudinal support

145 impact energy

147-1 first cross-sectional axis

147-2 second section axis

147-3 third section axis

149 recess

151 base

153 hollow cavity

155 base web

200 method of manufacturing an internal support for a battery holder

201 extrusion of elongated hollow profiles

203 formation of a plurality of fastening protrusions

Detailed Description

Fig. 1 is a perspective view of a battery holder of a first embodiment, particularly a battery holder for accommodating a plurality of battery modules in an electric vehicle. The battery holder 100 has a plurality of holding trays 101 for accommodating battery modules. The holding tray 101 has a base plate 103 and a circumferential outer wall 105 arranged on the base plate 103. Alternatively, the circumferential outer wall 105 may also surround the base plate 103 (circularly), in particular on the edge of the base plate 103. The base plate 103 of the holding tray 101 accommodates a plurality of battery modules, which are not shown in fig. 1. A plurality of battery modules may be particularly placed on the substrate 103.

The peripheral outer wall 105 of the holding tray 101 has a front side 105-1, a rear side 105-2 opposite the front side 105-1, a first lateral side 105-3 and a second lateral side 105-4 opposite the first lateral side 105-3.

The battery holder 100 also has a plurality of internal supports 107, the plurality of internal supports 107 being for securing a cover (not shown in fig. 1) of the battery holder 100. The inner support 107 is formed as an elongated extruded hollow profile and is fixed at the ends to the circumferential outer wall 105. The interior support 107 can effectively absorb impact energy acting on the battery holder 100 in the event of a vehicle collision.

The internal supports 107 are arranged on the base plate 103, respectively, and rest on the base plate 103 with their undersides 108 (not shown in fig. 1). The inner supports 107 are each connected to the circumferential outer wall 105. Here, a direct connection between the inner support 107 and/or the circumferential outer wall 105, or an indirect connection via tolerance compensation elements, is possible. The internal support 107 may extend between the anterior side 105-1 and the posterior side 105-2 of the circumferential outer wall 105 and/or between the first lateral side 105-3 and the second lateral side 105-4.

In the embodiment of the battery holder 100 shown in fig. 1, the internal support 107 is adapted as a lateral support 107-1 extending between the first lateral side 105-3 and the second lateral side 105-4 of the circumferential outer wall 105.

Alternatively or additionally, the interior support 107 may also be adapted as a longitudinal support 107-2 extending between the front side 105-1 and the rear side 105-2 of the circumferential outer wall 105.

Adjacent inner supports 107, in particular transverse supports 107-1, define a module receiving portion 109 (only schematically shown in fig. 1) for receiving one or more battery modules, thereby forming niches or slots for the respective battery modules.

The battery module can also be fixed to the base plate 103, in particular in a force-fitting, form-fitting or material-bonding manner.

The substrate 103 may have additional functionality and may be adapted to act as an underbody panel of a vehicle, thereby providing underbody protection for the vehicle.

The substrate 103 is in particular made of steel and/or aluminum, in particular of a steel alloy and/or an aluminum 6000 alloy.

The base plate 103 may also have a heat exchanger structure (not shown in fig. 1) for controlling the temperature of the battery module, the heat exchanger structure having, in particular, a hollow fluid channel formed within the base plate 103 and adapted to conduct a fluid.

The substrate 103 may also have cable connectors (not shown in fig. 1) for electrical contact with the battery modules.

In the embodiment shown in fig. 1, the plurality of internal supports 107 (particularly arranged adjacent to each other) comprises a plurality of transverse supports 107-1 (particularly arranged adjacent to each other), which transverse supports 107-1 extend between a first transverse side 105-3 and a second transverse side 105-4 of the circumferential outer wall 105, and the battery holder 100 has at least one longitudinal support 107-2, which longitudinal support 107-2 extends between the front side 105-1 and the rear side 105-2 of the circumferential outer wall 105.

As can be seen from the embodiment shown in FIG. 1, a majority of the transverse supports 107-1 (particularly arranged adjacent to each other) extend from the first transverse side 105-3 to the at least one longitudinal support 107-2, including the transverse supports 107-1 of the first set 107-1a (particularly arranged adjacent to each other), and a plurality of the transverse supports 107-1 (particularly arranged adjacent to each other) extend from the at least one longitudinal support 107-2 to the second transverse side 105-4, including the transverse supports 107-1 of the second set 107-1b (particularly arranged adjacent to each other).

Even if not shown in fig. 1, if at least one longitudinal support 107-2 comprises a plurality of longitudinal members 107-2, the plurality of transverse supports 107-1 arranged adjacent to each other comprises several groups 107-1n of transverse supports 107-1 extending from a first transverse side 105-3 to one of the plurality of longitudinal members 107-2, respectively, or between the plurality of longitudinal members 107-2, respectively, or from another one of the plurality of longitudinal members 107-2 to a second transverse side 105-4, respectively.

According to an alternative embodiment, not shown in fig. 1, the plurality of internal supports 107 arranged adjacent to each other may comprise a plurality of longitudinal supports 107-2 arranged adjacent to each other, extending between the front side 105-1 and the rear side 105-2 of the circumferential outer wall 105, and the battery holder 100 has at least one transverse support 107-1, which transverse support 107-1 extends between the first transverse side 105-3 and the second transverse side 105-4 of the circumferential outer wall 105.

In an alternative embodiment not shown in FIG. 1, the plurality of longitudinal supports 107-2 arranged adjacent to each other includes a first set 107-2a of longitudinal supports 107-2 arranged adjacent to each other that extend from the front side 105-1 to at least one of the transverse supports 107-1, and the plurality of longitudinal members 107-2 arranged adjacent to each other includes a second set 107-2b of longitudinal supports 107-2 arranged adjacent to each other that extend from the at least one of the transverse supports 107-1 to the rear side 105-2.

In an alternative embodiment, not shown in fig. 1, if the at least one transverse support 107-1 comprises several transverse supports 107-1, the plurality of longitudinal supports 107-2 arranged adjacent to each other may comprise several groups 107-2n of longitudinal supports 107-2 arranged adjacent to each other, each of these longitudinal supports 107-2 extending from the front side 105-1 to one of the plurality of transverse supports 107-1, or each extending between the plurality of transverse supports 107-1, or each extending from another one of the plurality of transverse supports 107-1 to the rear side 105-2.

As can be seen in the embodiment shown in fig. 1, the inner support 107, in particular the transverse support 107-1, has a plurality of fastening protrusions 111 formed to connect the respective inner support 107, in particular the transverse support 107-1 and/or the longitudinal member 107-2, to a cover (not shown in fig. 1) of the battery holder 100.

In this case, the respective inner support upper sides 113 of the respective inner supports 107 have respective fastening projections 111, which extend from the inner support upper sides 113. A cover (not shown in fig. 1) of the battery holder 100 may be placed on the fastening protrusions 111, and the fastening protrusions 111 are formed to mechanically connect the respective internal supports 107 to the cover of the battery holder 100.

The cover (not shown in fig. 1), the base plate 103, the circumferential outer wall 105 and the inner support 107 delimit a module housing 109 (only schematically shown in fig. 1) for housing one or more battery modules.

Even though not shown in fig. 1, the cover is connected to the holding tray 101 and the inner support 107 in a fluid-tight manner, and serves as a sealing cover of the module accommodating portion 109. The cap is formed in particular as a component made of steel and/or aluminum, in particular an aluminum 6000 alloy, which is formed in particular in a pressing process, a hot forming process or an extrusion process.

For a detailed description of the structure and function of the fastening protrusion 111 of the internal support 107, reference is made to the following detailed description.

Even if not shown in fig. 1, the inner support 107, in particular the transverse support 107-1 and/or the longitudinal support 107-2, is formed by an elongated extruded hollow profile.

The internal support 107 formed of an elongated extruded hollow profile according to the present embodiment enables a significant cost reduction by inexpensively and easily producing the internal support 107 formed of an elongated extruded hollow profile, as compared to the conventionally used internal support 107 formed of a casting. In addition, the internal support 107 formed from an elongated extruded hollow profile can be easily changed in shape and design without changing the casting tooling, as compared to the conventionally used internal supports 107 formed from a casting.

In addition, with the conventionally used internal support 107 formed of a casting, there arises a problem that, when drilling a hole in the internal support 107 formed of a casting, undesirable cutting debris occurs in the interior of the battery holder 100. Corresponding holes can be introduced into the internal support 107 consisting of an elongated extruded hollow profile before or during the extrusion process, so that no drilling in the finished component is necessary anymore.

As can also be seen from fig. 1, the receiving wall 105 of the battery holder 100 has, in particular, a plurality of flanges 112, the plurality of base flanges 112 being suitable for fixing the battery holder 100 on the body of an electric vehicle. For this purpose, most base plate flanges 112 have in particular a plurality of flange openings 114, which flange openings 114 can be penetrated by flange fastening elements (not shown in fig. 1), in particular flange screws.

Fig. 2 shows a perspective view of the internal support of the battery holder of the first embodiment shown in fig. 1.

The inner support 107 shown in fig. 2 corresponds to the transverse support 107-1 shown in fig. 1, in particular the transverse support 107-1 of the second set of transverse supports 107-1b shown in fig. 1 arranged adjacent to each other, which extends from the longitudinal support 107-2 to the second transverse side 105-4 of the holding tray 101.

The inner support 107, in particular the transverse support 107-1, has an inner support underside 108, which is located on the base plate 103 (not shown in fig. 2).

The internal support 107, in particular the transverse support 107-1, shown in fig. 2, has a plurality of fastening protrusions 111 adapted to connect the transverse support 107-1 to a cover (not shown in fig. 2) of the battery holder 100.

The fastening projection 111 is arranged on an upper side 113 of the inner support 107, in particular of the transverse support 107-1, facing away from the lower side 108.

In particular, the inner support 107, in particular the transverse support 107-1, has accommodating recesses 115 between the fastening projections 111, the accommodating recesses 115 being adapted to accommodate electrical lines (not shown in fig. 2) for electrical contact with the battery module and/or the heating line and/or the cooling line, wherein in particular the accommodating recesses 115 are at least partially open at the inner support upper side 113.

As can be seen from fig. 2, the internal support 107, in particular the transverse support 107-1, is formed by an elongated extruded hollow profile, including in particular a two-cavity hollow profile.

The two-chamber hollow profile of the internal support 107 shown in fig. 2 comprises in particular one first hollow chamber 117-1, which is in particular arranged in the region of the internal support 107 facing the base plate 103, and in particular a second hollow chamber 117-2, which is in particular arranged in the region of the internal support 107 facing the cover 103. Here, the first hollow cavity 117-1 and the second hollow cavity 117-2 are separated from each other at least partially by a cavity web 117-3.

In particular, the chamber web 117-3 may extend the entire length of the inner support 107 such that the hollow cavities 117-1, 117-2 are completely separated from each other. Alternatively, the chamber web 117-3 may extend only partially over the length of the inner support 107, in which case the hollow cavities 117-1, 117-2 are at least partially connected to each other.

Even if not shown in fig. 2, the internal support 107 may also be formed by a single-cavity hollow profile, in this case without the chamber web 117-3. Even if not shown in fig. 3, the inner support 107 may also be formed by a multi-chamber hollow profile having more than two hollow chambers 117-1, 117-2, in which case there are at least two chamber webs 117-3 separating the respective hollow chambers 117-1, 117-2 from each other, respectively.

Furthermore, it can be seen from fig. 2 that the internal support 107, in particular the transverse support 107-1, is formed by an at least partially open elongated extruded hollow profile, the respective elongated extruded hollow profile (in particular having an internal support upper side 113) being at least partially open and facing the cover of the battery holder 100, and/or having an internal support transverse side 118, the internal support transverse side 118 being at least partially open and facing the circumferential outer wall 105 (not shown in fig. 2).

In particular, the inner support 107, in particular the transverse support 107-1, has an inner support front side 119, which inner support front side 119 is at least partially closed and faces the circumferential outer wall 105 (not shown in fig. 2), and the inner support 107, in particular the transverse support 107-1, has an inner support rear side 121, which inner support rear side is at least partially closed and faces the circumferential outer wall 105, in particular the rear side 105-2, of the holding tray 101.

In particular, the fastening projection front side 111-1 of the fastening projection 111 faces the front side 105-1 (not shown in fig. 2) of the circumferential outer wall 105 of the holding tray 101, and the fastening projection rear side 111-2 of the fastening projection 111 opposite the rear side 105-2 of the circumferential outer wall 105 of the holding tray 101 is closed.

In particular, a first fastening projection lateral side 111-3 of the fastening projection 111 facing the first lateral side 105-3 of the circumferential outer wall 105 is open, and/or a second lateral side 105-4 of the fastening projection 111 facing the circumferential outer wall 105 is open and a second fastening projection lateral side 111-4 is open.

As can be seen from fig. 2, each fastening projection 111 has a closed fastening projection upper side 111-5 which faces away from the base plate 103 (not shown in fig. 2) of the battery holder 100, wherein on the closed fastening projection upper side 111-5 a fastening opening 123 is formed in particular for accommodating a fastening element (not shown in fig. 2). In the fastening opening 123, in particular, blind rivet nuts, pierce nuts, weld nuts or internal threads for receiving a fastening screw as a fastening element are assigned.

As can also be seen from fig. 2, the fastening protrusions 111 include a first fastening protrusion group 111-6 and a second fastening protrusion group 111-7, wherein the fastening protrusion upper sides 111-5 of the fastening protrusions 111 of the first fastening protrusion group 111-6 are completely closed, and wherein fastening holes 123 are respectively formed in the fastening protrusion upper sides 111-5 of the fastening protrusions 111 of the second fastening protrusion group 111-7.

Here, a cover (not shown in fig. 2) is in particular seated not only on the completely closed fastening projection upper side 111-5 of the first fastening projection group 111-6, but also on the fastening projection upper side 111-5 of the second fastening projection 111-7 with the fastening opening 123. The cover is fastened to the fastening projection upper sides 111-5 of the fastening projections 111 of the second fastening projection group 111-7 by means of fastening elements, in particular fastening screws.

In particular, each fastening projection upper side 111-5 extends parallel to the base plate 103.

Fig. 3 is a perspective view of an internal support of the battery holder of the second embodiment.

The inner support 107 shown in fig. 3, in particular the transverse support 107-1 according to the second embodiment, substantially corresponds to the inner support 107, in particular the transverse support 107-1, of the first embodiment, thus providing a detailed description corresponding to the embodiment of fig. 2.

However, as shown in FIG. 3, the internal support 107, and in particular the lateral support 107-1, comprises a three-lumen hollow profile having a first hollow lumen 117-1, a second hollow lumen 117-2, and a third hollow lumen 117-4. Wherein the hollow cavities 117-1, 117-2, 117-4 are separated from each other by a cavity web 117-3, respectively.

As shown in fig. 3, the internal support 107, in particular the transverse support 107-1, according to the second embodiment has a plurality of module fastening elements 125 adapted to connect the internal support 107 to a battery module (not shown in fig. 3). The module fastening elements 125 are arranged in particular on an inner support front side 119, which inner support front side 119 faces the front side 105-1 of the circumferential outer wall 105 (not shown in fig. 3), and/or on an inner support rear side 121, which inner support rear side 121 faces the rear side 105-2 of the circumferential outer wall 105.

The module fastening element 125 comprises, inter alia, a flange extending from the internal support 107, in particular from the internal support front side 119 and/or the internal support rear side 121, which is adapted to be placed at a battery module (not shown in fig. 2). The module fastening element 125, in particular the flange, in particular has module fastening openings 127 for receiving module fastening components, in particular module fastening screws, for fastening the battery module to the internal support 107.

Even if only schematically shown in fig. 3, the module fastening element 125 may alternatively or additionally be adapted as a threaded block or a threaded hollow block, which is in particular welded to the inner support 107.

As can be seen from fig. 3, the module fastening element 125, in particular the flange, is integrally formed with the inner support 107, or the module fastening element 125, in particular the flange, is integrally connected, in particular welded, with the inner support 107.

In particular, the module fastening element 125, in particular the flange, extends parallel to the base plate 103.

As can also be seen in fig. 3, the module securing element 125 comprises in particular a first module securing element 125-1 extending from the front side 119 of the internal support and a second module securing element 125-2 extending from the rear side 121 of the internal support. Here, the first module fastening element 125-1 and the second module fastening element 125-2 are formed symmetrically with respect to the inner support 107, in particular the transverse support 107-1.

As can also be seen in fig. 3, module fastening element 125, in particular a first module fastening element group 125-3, is formed on a first end 129 of internal support 107, in particular of transverse support 107-1, module fastening element 125 in particular comprising a second module fastening element group 125-4, which second module fastening element group 125-4 is formed on a second end 131 of internal support 107, in particular of transverse support 107-1, which second end 131 faces away from first end 129. First module fastening element group 125-3 and second module fastening element group 125-4 specifically include first module fastening element 125-1 extending from interior support front side 119 and second module fastening element 125-2 extending from interior support back side 121, respectively.

Fig. 4 is a perspective view of an internal support of the battery holder of the third embodiment.

The internal support 107 of the third embodiment of fig. 4 corresponds to the internal support 107 of the second embodiment of fig. 3, except that in fig. 4 the module fastening element 125, in particular the first module fastening element group 125-3 and/or the second module fastening element group 125-4, has a third module fastening element 125-5 and a fourth module fastening element 125-6.

The third module fastening element 125-5 extends in particular from the inner support underside 108 and the inner support front side 119 of the inner support 107 to the first module fastening element 125-1, and the fourth module fastening element 125-6 extends in particular from the inner support underside 108 and the inner support rear side 121 of the inner support to the second module fastening element 125-2.

The third module securing element 125-5 and the fourth module securing element 125-6 extend obliquely with respect to the base plate 103 (not shown in fig. 4), in particular obliquely upwards from the internal support 107.

Furthermore, the internal support 107 has a substrate fastening projection 133, which substrate fastening projection 133 rests on the substrate 103 (not shown in fig. 4) and is connected to the substrate 103, in particular in a material-bonded manner.

Fig. 5 is a perspective view of the internal support of the battery holder shown in fig. 1 of the first embodiment.

In the perspective view of the first embodiment shown in fig. 5, the holding tray 101 of the battery holder 100 is not shown, the holding tray 101 comprising a base plate 103 and a circumferential outer wall 105.

The inner support 107 comprises a plurality of transverse supports 107-1 arranged adjacent to each other and fixed at the ends, i.e. at the first and second transverse sides 105-3, 105-4 of the circumferential outer wall 105 with their respective second ends 131, and in particular fixed in a form of a firm connection to the first or second transverse side 105-3, 105-4 of the circumferential outer wall 105. The interior support 107 also includes at least one longitudinal support 107-2 that extends between the front side 105-1 and the back side 105-2 of the circumferential outer wall 105.

In particular, a first set 107-1a of the transverse supports 107-1 extends from the first transverse side 105-3 of the outer wall 105 to the at least one longitudinal support 107-2, and a second set 107-1b of the transverse supports 107-1 extends from the at least one longitudinal support 107-2 to the second transverse side 105-4 of the outer wall 105. The transverse support 107-1 is attached with its end face (i.e. including the first end 129) to at least one longitudinal support 107-2, and in particular is firmly connected to the longitudinal support 107-2.

The longitudinal support member 107-2 shown in fig. 5 has a plurality of fastening protrusions 111, each having a fastening opening 123. On the inner support upper side 113 of the longitudinal support 107-2, a plurality of closing parts 135 are arranged, in each of which a further fastening opening 137 is formed for accommodating a further fastening element.

Fig. 6 is a perspective view of an internal support of the battery holder of the fourth embodiment.

The inner support 107 of the fourth embodiment shown in fig. 6 corresponds to the inner support 107 according to the first embodiment shown in fig. 5, except that a plurality of support openings 139 are formed in at least one longitudinal support 107-2, and the lateral supports 107-1 are inserted into the plurality of support openings 139, respectively.

In particular, in the support openings 139, the respective transverse supports 107-1 of the first and second sets 107-1a, 107-1b are connected, in particular welded, to each other at their end faces.

Alternatively, each lateral support 107-1 may also be integrally formed, i.e., each lateral support 107-1 includes only a single set 107-1a, 107-1b of lateral supports 107-1 extending from the first lateral side 105-3 to the second lateral side 105-4 of the holding tray 101.

Fig. 7 is a schematic view of an internal support of a battery holder of a fifth embodiment.

The inner supports 107, in particular the transverse supports 107-1 and/or the longitudinal supports 107-2, which are only schematically shown in fig. 7, rest on the base plate 103 (only schematically shown) of the holding tray 101 and at the ends rest on the circumferential outer wall 105 of the holding tray 101.

The cover 141 of the battery holder 100, which is only schematically shown in fig. 7, rests on the fastening projections 111 of the internal support 107, wherein a receiving recess 115 is formed between two adjacent fastening projections 111, which receiving recess 115 serves for receiving an electrical line for electrical contact with the battery module.

The inner support 107, in particular the transverse support 107-1 and/or the longitudinal support 107-2, shown in fig. 7, is in particular integrally formed, the inner support 107 being formed symmetrically with respect to the longitudinal support vertical axis 143.

The internal support 107, in particular the transverse support 107-1 and/or the longitudinal support 107-2, shown in fig. 7, leads to an advantageous mechanical stabilization of the holding tray 101, so that, for example in the event of a vehicle collision, impact energy 145 introduced into the holding tray 101 in the transverse and/or longitudinal direction can be advantageously absorbed by the internal support 107, in particular the transverse support 107-1 and/or the longitudinal support 107-2.

Fig. 8 is a schematic view of an internal support of a battery holder of a sixth embodiment.

The internal support 107 of the sixth embodiment shown in fig. 8 corresponds to the internal support 107 of the fifth embodiment shown in fig. 7, except that the fastening protrusions 111 of the sixth embodiment shown in fig. 8 are different in height. Therefore, a wide accommodation recess 115 is formed for accommodating an electrical wiring for electrical contact with the battery module.

Maximum height 110-1 (H) relative to outer wall 105_max) Minimum height 110-2 (H) of fastening protrusion 111 of inner support 107_min) Especially at 0.4H_max～0.8H_maxWithin the range.

In addition, a cover 141 fastened to the fastening protrusion 111 is schematically illustrated in fig. 8.

Fig. 9A-9E are schematic views of the internal support 107 of the battery holder 100 of the seventh embodiment. The internal support 107 shown in fig. 9A, in particular the transverse support 107-1 and/or the longitudinal support 107-2, extends in the holding tray 101 and has a fastening projection 111 for fastening a cover 141 (not shown in fig. 9A and 9B) of the battery holder 100.

FIG. 9B illustrates sections I-I, II-II, III-III formed along the first section axis 147-1, the second section axis 147-2, and the third section axis 147-3 of FIG. 9A.

The section I-I in fig. 9B, which is formed along the first section axis 147-1, shows the open interior support upper side 113 of the elongated extruded hollow profile, which is obtained in particular by trimming the closed upper side of the interior support precursor.

The section II-II in fig. 9B, which is formed along the second cutting axis 147-2, shows the closed inner support upper side 113 of the elongated extruded hollow profile, which closed inner support upper side 113 is obtained in particular by reshaping the open at least one side wall of the inner support precursor. By means of corresponding recesses in the side walls, fastening holes 123 can be obtained in the closed interior support upper side 113 without drilling.

The section III-III, formed along the third section axis 147-3, shown in fig. 9B, shows the closed inner support upper side 113 of the elongated extruded hollow profile, which closed inner support upper side 113 is obtained in particular by trimming, in particular by cutting off the open top side wall of the inner support precursor.

FIG. 9C illustrates a section III-III of yet another embodiment formed along a third section axis 147-3. In this case, the inner support underside 108 has a recess 149 which serves as a reservoir for accommodating an adhesive in order to provide a material connection between the inner support 107 and the base plate 103 (not shown in fig. 9).

FIG. 9D illustrates a section III-III of yet another embodiment formed along a third section axis 147-3. In this case, the inner support underside 108 of the inner support 107 is extruded integrally with the base 151. It may be friction welded (resistively welded) to a further, in particular flat base (not shown) to provide a flat substrate.

FIG. 9E illustrates a section III-III of yet another embodiment formed along a third section axis 147-3. Here, the inner support underside 108 of the inner support 107 is extruded integrally with the base 151, which floor part is suitably a hollow cavity profile. It may be friction stir welded (not shown) to a further, in particular flat base (not shown) in order to again provide a flat substrate 103. The hollow cavity (or one of the hollow cavities) may be adapted as a heat exchanger structure for passing a cooling or heating fluid to control the temperature of the battery module.

Fig. 10A and 10B are schematic cross-sectional views of the internal support of the battery holder of each embodiment.

The longitudinal supports A-1 and A-2 shown in FIG. 10A correspond to the cross-sections I-I and II-II, respectively, of the longitudinal support 107 shown in FIG. 9B formed along the first cross-sectional axis 147-1 and along the second cross-sectional axis 147-2.

The longitudinal support a-3 or a-4 shown in fig. 10A is obtained by shaping at least one side wall of the open upper side of the internal support precursor. The fastening hole 123 can be obtained in the inner support upper side 113 without drilling by a corresponding cut-out on the side wall (longitudinal support a-3) or two corresponding cuts on the side wall (longitudinal support a-4).

The longitudinal support B-1 or B-2 shown in FIG. 10B has a closed inner support upper side 113, while the longitudinal support B-3 or B-4 is obtained by trimming, in particular cutting off, the open upper side wall of the inner support precursor.

The longitudinal supports a-1, a-2, a-3 and/or a-4 shown in fig. 10A and 10B, and the longitudinal supports B-1, B-2, B-3 and/or B-4 may alternatively or additionally also be applicable to the features shown in fig. 9C, 9D and 9E.

Fig. 11 shows a schematic view of a method for manufacturing an internal support of a battery holder.

The method 200 comprises as a first method step an extrusion 201 of an elongated hollow profile to obtain an internal support precursor formed by an elongated extruded hollow profile.

The method 200 comprises as a second method step the formation 203 of a plurality of fastening protrusions 111 in the internal buttress precursor, which in particular comprises trimming the closed upper side of the internal buttress precursor and/or reshaping at least one side wall of the open upper side of the internal buttress precursor.

Claims

1. A battery holder (100) for holding a plurality of battery modules in an electric vehicle, comprising:

a holding tray (101) for accommodating the plurality of battery modules, the holding tray (101) having a base plate (103) and a circumferential outer wall (105), the circumferential outer wall (105) being arranged on the base plate (103) or circumferentially around the base plate (103),

a plurality of internal supports (107, 107-1, 107-2) arranged on the base plate (103), adjacent ones of the internal supports (107, 107-1, 107-2) defining a module receiving part (109) for receiving the battery module,

wherein the inner supports (107, 107-1, 107-2) are formed as elongated extruded hollow profiles and are fixed at the ends at the circumferential outer wall (105), the inner supports (107, 107-1, 107-2) each having an inner support underside (108) resting on the base plate (103) and an inner support upper side (113) facing away from the inner support underside (108), the inner support upper sides (113) of the inner supports (107, 107-1, 107-2) each having a fastening projection (111, 111-6, 111-7) extending from the respective inner support upper side.

2. The battery holder (100) according to claim 1, comprising a cover (141), said cover (141) resting on said fastening protrusions (111, 111-6, 111-7), said fastening protrusions (111, 111-6, 111-7) being formed to mechanically connect the respective internal support (107, 107-1, 107-2) to the cover (141) of the battery holder (100), and in particular comprising at least one fastening element formed with said fastening protrusions (111, 111-6, 111-7) to mechanically connect each of said internal supports (107, 107-1, 107-2) to said cover (141).

3. The battery holder (100) according to claim 1 or 2, wherein the circumferential outer wall (105) has a front side (105-1), a rear side (105-2) opposite to the front side (105-1), a first lateral side (105-3) and a second lateral side (105-4) opposite to the first lateral side (105-3), the internal support (107, 107-1, 107-2) extending between the front side (105-1) and the rear side (105-2) and/or between the first lateral side (105-3) and the second lateral side (105-4) of the circumferential outer wall (105).

4. The battery holder (100) according to any of the preceding claims, wherein the internal supports (107, 107-1, 107-2) are all formed by at least partially open elongated extruded hollow profiles, in particular having at least partially open internal support upper sides (113) and/or at least partially open internal support lateral sides facing the circumferential outer wall (105).

5. The battery holder (100) according to any of the preceding claims, wherein the internal supports (107, 107-1, 107-2) are all formed by elongated extruded single or multi-cavity hollow profiles, in particular by elongated extruded two-cavity or three-cavity hollow profiles.

6. The battery holder (100) according to any of the preceding claims, characterized in that adjacent fastening protrusions (111, 111-6, 111-7) each have a receiving recess (115) formed for receiving an electrical line for electrical contact of the battery module and/or a heating line and/or a cooling line, the receiving recess (115) being in particular at least partially open on the inner support upper side (113).

7. The battery holder (100) according to any of the preceding claims, the respective elongated extruded hollow profile of the internal support (107, 107-1, 107-2) has an at least partially closed internal support upper side (113), and/or an at least partially closed internal support front side (119), in particular facing the circumferential outer wall (105) of the holding bracket (101), in particular the front side (105-1) of the circumferential outer wall (105) of the holding bracket (101), and/or an at least partially closed inner support rear side (121), the inner support is at its rear side facing the circumferential outer wall (105) of the holding tray (101), in particular the rear side (105-2) of the circumferential outer wall (105) of the holding tray (101).

8. The battery holder (100) according to one of the preceding claims, characterized in that the fastening projections (111, 111-6, 111-7) each have a closed fastening projection upper side (111-5) which faces away from the inner support underside (108), in which closed fastening projection upper side (111-5) a fastening opening (123) is formed in particular for accommodating a fastening element, which fastening opening (123) is assigned in particular a blind rivet nut, a pierce nut, a weld nut or an internal thread for accommodating a fastening screw.

9. The battery holder (100) according to claim 8, wherein the fastening protrusions (111, 111-6, 111-7) comprise a first set of fastening protrusions (111-6) without the fastening openings (123) and a second set of fastening protrusions (111-7) with the fastening openings (123).

10. The battery holder (100) according to any of the preceding claims, the internal supports (107, 107-1, 107-2) each having a plurality of module fastening elements (125, 125-1, 125-2, 125-3, 125-4, 125-5, 125-6) adapted to connect the respective internal support (107, 107-1, 107-2) to the battery module, the module fastening elements (125, 125-1, 125-2, 125-3, 125-4, 125-5, 125-6) are arranged in particular on an inner support front side (119) facing the front side (105-1) of the circumferential outer wall (105), and/or in particular on an inner support rear side (121) facing the rear side (105-2) of the circumferential outer wall (105).

11. The battery holder (100) according to claim 10, wherein the module fastening elements (125, 125-1, 125-2, 125-3, 125-4, 125-5, 125-6) each have at least one module fastening opening (127) for receiving a module fastening member for fixing the battery module to the internal support (107, 107-1, 107-2), in particular comprising a module fastening screw.

12. The battery holder (100) according to any of the preceding claims, wherein the internal supports (107, 107-1, 107-2), in particular longitudinal supports (107-2) and/or transverse supports (107-1), each have an internal support height increasing towards the circumferential outer wall (105), which internal support height extends from the internal support underside (108) to the internal support upper side (113).

13. The battery holder (100) according to any of the preceding claims, characterized in that the internal supports (107, 107-1, 107-2), in particular the longitudinal support (107-2) and/or the transverse support (107-1), are each connected to the circumferential outer wall (105) in a form-fitting manner, in particular by an adhesive or welded connection, or in a force-fitting manner, in particular by joining elements, in a form-fitting manner, in particular by an adhesive or welded connection, or in a force-fitting manner, and/or the internal supports (107, 107-1, 107-2), in particular the longitudinal support (107-2) and/or the transverse support (107-1), in each case are connected in a secure manner, in particular by an adhesive or welded connection, in a force-fitting manner or in a form-fitting manner, in particular by joining elements, is connected to the substrate (103).

14. The battery holder (100) according to any of the preceding claims, wherein the circumferential outer wall (105) has a plurality of flanges (112), the plurality of flanges (112) being adapted to fix the battery holder (100) to a body of the electric vehicle, the plurality of flanges (112) having in particular a plurality of flange openings through which flange fastening elements, in particular flange screws, can be inserted.

15. A method (200) for manufacturing an internal support (107, 107-1, 107-2) of a battery holder (100), characterized in that the method (200) comprises the method steps of extruding (201) an elongated hollow profile to obtain an internal support precursor formed by the extruded hollow profile; forming (203) a plurality of fastening protrusions (111, 111-6, 111-7) in the internal support precursor, the forming (203) process comprising, inter alia, trimming the closed upper side of the internal support precursor and/or reshaping at least one side wall of the open upper side of the internal support precursor.

16. The method (200) according to claim 15, wherein said forming (203) of said plurality of fastening protrusions (111, 111-6, 111-7) comprises forming two side walls of an open upper side of said internal support precursor, welding the two deformed side walls to each other to form a plurality of fastening protrusions (111, 111-6, 111-7).

17. The method (200) according to claim 15 or 16, wherein the manufacturing of the internal support (107, 107-1, 107-2) comprises a further method step: the closed upper side of the interior support precursor formed as a multi-chamber hollow profile is trimmed at least partially.