System for Absorbing and Distributing Side Impact Energy Utilizing an Integrated Battery Pack

Abstract

An energy absorbing and distributing side impact system for use with a vehicle is provided, the system utilizing a battery pack enclosure that includes a plurality of cross-members that transverse the battery pack enclosure and absorb and distribute at least a portion of the load received when either the first or second side of the vehicle receives a side impact. The battery pack enclosure is positioned between the front and rear vehicle suspension assemblies and mounted between, and mechanically coupled to, vehicle structural members (e.g., rocker panels) located on either side of the vehicle. In addition to providing rigidity, strength and impact resistance, the battery pack cross-members segregate the batteries contained within the battery pack enclosure into battery groups.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]The present application claims benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61 / 426,254, filed Dec. 22, 2010, the disclosure of which is incorporated herein by reference for any and all purposes.FIELD OF THE INVENTION[0002]The present invention relates generally to vehicle structures and, more particularly, to means for enhancing the side impact performance of a vehicle.BACKGROUND OF THE INVENTION[0003]Modern vehicles use a variety of structures to protect the vehicle's occupants during a crash. Some of these structures are used to control the transmission of the crash energy to the passenger compartment while other structures, such as seat belts, head restraints, and air bags, are intended to restrain passenger movement during a crash, thereby preventing the passengers from hurting themselves as their bodies react to the crash forces. Side impact collisions present a particularly challenging problem to vehicle...

AI Technical Summary

Benefits of technology

The present invention is a system for absorbing and distributing the impact force in a side impact of a vehicle. It uses a battery pack enclosure with cross-members that absorb and distribute the force. The battery pack enclosure is positioned between the vehicle's suspension assemblies and mounted between vehicle structural members. The cross-members are designed to provide strength and impact resistance, and to segregate battery groups. The battery pack enclosure is preferably mounted below the vehicle floor panel. The cross-members can be made from aluminum or other materials, and may have cavities filled with materials of high melting temperature or low thermal conductivity. The battery pack enclosure is designed to be airtight and can be fabricated from aluminum or other materials. The battery pack top panel is bolted to the enclosure side members, and the battery pack bottom panel may be welded, brazed, soldered, or bonded to the enclosure side members.

Problems solved by technology

Side impact collisions present a particularly challenging problem to vehicle safety engineers, both due to the relatively low position of the rocker panels on many small vehicles as well as the difficulty of implementing an impact resistant side structure while taking into account vehicle doors and doorways.

Although vehicle manufacturers use a variety of structures and components to protect a vehicle's occupants during a side impact collision, typically these approaches provide only limited protection while significantly increasing vehicle weight.

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