Single piece vehicle rocker panel

• US 8,960,781 B2
• Filed: 11/30/2011
• Issued: 02/24/2015
• Est. Priority Date: 12/20/2010
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Rawlinson, Peter Dore, Baldwin, Michael John, Gadhiya, Hitendra Laxmidas, Charbonneau, Alexi
• Primary Examiner(s): Dayoan, Glenn
• Assistant Examiner(s): CHENEVERT, PAUL A
• Application Number:
  US13/308,206
• Publication Number:
  US 20120153682A1
• Time in Patent Office: 1,182 Days
• Field of Search: 296/187.12, 296/193.05, 296/203.03, 296/209, 903/903, 903/907, 903/952, 180/68.5
• US Class Current: 296/209
• CPC Class Codes: B60J 10/24 having tubular parts
• CPC Class Codes: B60J 10/85 with additional seals on the body side
• CPC Class Codes: B62D 25/02 Side panels B62D33/046 takes precedence; sideboards for open load compartments B62D33/023
• CPC Class Codes: Y10S 903/907 Electricity storage, e.g. battery, capacitor

Abstract

A vehicle rocker panel is provided that is extruded as a single piece. As extruded, the rocker panel may include one or more interior reinforcing walls as well as interior and exterior design features.

Claims

1. A single piece, extruded, vehicle rocker panel, said vehicle rocker panel extruded as a single piece, said vehicle rocker panel comprised of at least an exterior wall, an interior wall and at least one enclosed cavity running longitudinally throughout the vehicle rocker panel, wherein said vehicle rocker panel is configured to provide a mounting surface for a battery pack enclosure, and wherein said mounting surface of said vehicle rocker panel is configured to allow said battery pack enclosure to be bolted to said vehicle rocker panel.

2. The single piece, extruded, vehicle rocker panel of claim 1, further comprising an upper wall and a lower wall.

3. The single piece, extruded, vehicle rocker panel of claim 2, further comprising a reinforcing wall, wherein said reinforcing wall couples an inner surface of said upper wall to an inner surface of said lower wall, and wherein said reinforcing wall divides said at least one enclosed cavity into at least two side-by-side cavities.

4. The single piece, extruded, vehicle rocker panel of claim 1, further comprising a reinforcing wall, said reinforcing wall dividing said at least one enclosed cavity into a first cavity and a second cavity.

5. The single piece, extruded, vehicle rocker panel of claim 4, wherein said reinforcing wall couples an inner surface of said exterior wall to an inner surface of said interior wall, and wherein said first cavity is located within an upper portion of said vehicle rocker panel and said second cavity is located within a lower portion of said vehicle rocker panel.

6. The single piece, extruded, vehicle rocker panel of claim 1, wherein said at least one enclosed cavity is divided into multiple cavities by at least one horizontal reinforcing wall and at least one vertical reinforcing wall.

7. The single piece, extruded, vehicle rocker panel of claim 6, wherein said at least one horizontal reinforcing wall couples an inner surface of said exterior wall to an inner surface of said interior wall, and wherein said at least one vertical reinforcing wall couples an inner surface of an upper wall to an inner surface of a lower wall.

8. The single piece, extruded, vehicle rocker panel of claim 1, wherein said vehicle rocker panel is fabricated from a material selected from the group of materials consisting of aluminum, aluminum alloys, and steel.

9. The single piece, extruded, vehicle rocker panel of claim 1, further comprising a mounting flange extending inwardly from said interior wall towards a vehicle centerline.

10. The single piece, extruded, vehicle rocker panel of claim 9, wherein said mounting flange is configured to provide a mounting surface for a vehicle floor panel.

11. The single piece, extruded, vehicle rocker panel of claim 10, wherein said vehicle floor panel is welded to said mounting flange.

12. The single piece, extruded, vehicle rocker panel of claim 10, wherein said vehicle floor panel is bolted to said mounting flange.

13. The single piece, extruded, vehicle rocker panel of claim 1, further comprising an interior, non-reinforcing wall that extends from an inner surface of at least one wall of said vehicle rocker panel into said at least one enclosed cavity.

14. The single piece, extruded, vehicle rocker panel of claim 13, wherein said interior, non-reinforcing wall is configured to locate and position a channel nut retainer within said at least one enclosed cavity.

15. The single piece, extruded, vehicle rocker panel of claim 13, wherein said interior, non-reinforcing wall extends from a single inner surface of said vehicle rocker panel.

16. The single piece, extruded, vehicle rocker panel of claim 1, wherein said vehicle rocker panel is comprised of an upper rocker section and a lower rocker section, wherein said upper and lower rocker sections are staggered.

17. The single piece, extruded, vehicle rocker panel of claim 16, wherein said interior wall is comprised of a first interior wall portion corresponding to said upper rocker section and a second interior wall portion corresponding to said lower rocker section, and wherein said first interior wall portion is offset from said second interior wall portion.