SYSTEM FOR ABSORBING AND DISTRIBUTING SIDE IMPACT ENERGY UTILIZING AN INTEGRATED BATTERY PACK

• US 20150239331A1
• Filed: 05/04/2015
• Published: 08/27/2015
• Est. Priority Date: 12/22/2010
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Rawlinson, Peter D., Clarke, Alan, Sumpf, Robert D. Jr., Edwards, Bruce P., Gadhiya, Hitendra L.
• Granted Patent: US 10,023,038 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/0438 Arrangement under the floor
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60R 16/04 Arrangement of batteries
• CPC Class Codes: B62D 21/157 for side impacts
• CPC Class Codes: B62D 25/025 Side sills thereof
• CPC Class Codes: B62D 25/20 Floors or bottom sub-units sub-frames for mounting engine or suspensions B62D21/11; drip trays F16N31/006
• CPC Class Codes: B62D 25/2036 the subunits being side panels, sills or pillars B62D21/157 takes precedence
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

An energy absorbing and distributing side impact system for a vehicle includes: first and second side sills, each of the first and second sills comprising multiple longitudinal channels, at least an upper longitudinal channel positioned above a vehicle floor panel and at least a lower longitudinal channel positioned below the vehicle floor panel; a battery enclosure mounted between front and rear suspensions of the vehicle, the battery enclosure having a first side member attached to the first side sill, and a second side member attached to the second side sill; cross-members integrated into the battery enclosure; and one or more bolts each extending though a respective opening in one of the cross-members and extending to an opposite side of the vehicle floor panel from the cross-member.

Claims

1. An energy absorbing and distributing side impact system for a vehicle, the system comprising:

first and second side sills, each of the first and second sills comprising multiple longitudinal channels, at least an upper longitudinal channel positioned above a vehicle floor panel and at least a lower longitudinal channel positioned below the vehicle floor panel;

a battery enclosure mounted between front and rear suspensions of the vehicle, the battery enclosure having a first side member attached to the first side sill, and a second side member attached to the second side sill;

cross-members integrated into the battery enclosure; and

one or more bolts each extending though a respective opening in one of the cross-members and extending to an opposite side of the vehicle floor panel from the cross-member.

2. The energy absorbing and distributing side impact system of claim 1, wherein the battery enclosure is an aerodynamic device having a design that improves aerodynamic performance of the vehicle.

3. The energy absorbing and distributing side impact system of claim 2, wherein a bottom of the battery enclosure is substantially flat.

4. The energy absorbing and distributing side impact system of claim 2, wherein front wheel arch edges on the battery enclosure are radiused to allow air from a front wheel to transition to an underside of the vehicle.

5. The energy absorbing and distributing side impact system of claim 1, further comprising a gasket material that covers a gap formed between a top of the battery enclosure and an underside of the vehicle floor panel.

6. The energy absorbing and distributing side impact system of claim 1, further comprising a seat mounting structure on the opposite side of the vehicle floor panel from the cross-member, the seat mounting structure held by at least the one or more bolts.

7. The energy absorbing and distributing side impact system of claim 6, wherein the seat mounting structure further comprises at least one threaded seat mount.

8. The energy absorbing and distributing side impact system of claim 6, wherein the bolt is held by a nut on a same side of the vehicle floor panel as the seat mounting structure.

9. The energy absorbing and distributing side impact system of claim 1, further comprising a sub-frame mount integrated into the battery enclosure.

10. The energy absorbing and distributing side impact system of claim 9, further comprising a sub-frame bushing mounted in double shear with a structure on a bottom plate of the battery enclosure.

11. The energy absorbing and distributing side impact system of claim 1, wherein the battery enclosure is an integral part of a load path for managing loads in frontal impact.

12. The energy absorbing and distributing side impact system of claim 11, configured so that a majority of the loads are fed from rails at a front of the vehicle into a torque box.

13. The energy absorbing and distributing side impact system of claim 12, further comprising a secondary load path that feeds loads from a lower portion of the vehicle along a sub-frame and into a rear mount of the sub-frame coupled to the battery enclosure and to the torque box.

14. The energy absorbing and distributing side impact system of claim 12, wherein the battery enclosure is configured to feed the loads along its members to the first and second side sills.

15. The energy absorbing and distributing side impact system of claim 1, wherein a bottom plate of the battery enclosure is configured to provide sheer stiffness to mounting locations of a steering rack.

16. The energy absorbing and distributing side impact system of claim 1, wherein the first side member is attached to the lower longitudinal channel of the first side sill and the second side member is attached to the lower longitudinal channel of the second side sill.

17. The energy absorbing and distributing side impact system of claim 1, wherein each of the cross-members comprises an upper portion and a lower portion, wherein a spacing between the upper and lower portions is configured to receive a mounting bracket for at least one battery module in the battery enclosure.

18. The energy absorbing and distributing side impact system of claim 1, wherein each of the first and second side members comprises at least first through fourth lumens, wherein at least the first, second and third lumens are arranged in an essentially vertical configuration, and wherein at least the fourth lumen is arranged outward of the third lumen.

19. The energy absorbing and distributing side impact system of claim 1, wherein the cross-members segregate the battery enclosure into full-width sections and at least one other section, each of the full-width sections fitting two battery modules side-by-side in a direction of travel, the other section fitting two stacked modules.

20. An energy absorbing and distributing side impact system for a vehicle, the system comprising:

first and second side sills, each of the first and second sills comprising multiple longitudinal channels, at least an upper longitudinal channel positioned above a vehicle floor panel and at least a lower longitudinal channel positioned below the vehicle floor panel; and

means for improving aerodynamic performance of the vehicle, for providing noise and thermal insulation, for providing a mounting structure for a seat in the vehicle, for providing an attachment for a sub-frame, for providing a load path for loads in a frontal impact, for providing protection of an occupant in a side impact, and for providing stiffness to a mounting location of a steering rack.