Support structure for vehicle frame-mounted battery pack

Abstract

The present disclosure provides a “support structure for vehicle frame-mounted battery pack”. The present disclosure describes in detail systems and methods for supporting and protecting a vehicle underbody-mounted battery pack. An exemplary electrified vehicle can include a frame, a battery support structure mounted to the frame, and a battery pack. The battery pack is supported by the battery support structure relative to the frame, rather than being directly coupled to the frame itself. The battery support structure can be configured to provide an under-frame mounting configuration, cross-member positioning, skid plate positioning for battery pack protection, weight-optimized sub-components, unique shapes for ground clearance, etc.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to electrically powered vehicle battery packs, and more particularly to a battery support structure for supporting and protecting a vehicle underbody mounted battery pack. BACKGROUND

[0002] The need to reduce automotive fuel consumption and emissions is well documented in the literature. As a result, electrically powered vehicles that reduce or completely eliminate dependence on internal combustion engines are being developed. Generally, electrically powered vehicles differ from conventional motor vehicles in that electrically powered vehicles are selectively driven by one or more electric motors powered by a battery or batteries. In contrast, conventional motor vehicles completely rely on internal combustion engines to propel the vehicle. High voltage traction battery packs typically power the electric motors and other electrical loads of electrically powered vehicles. SUMMARY

[0003] An electrically powered vehicle according to one exemplary aspect of the present disclosure includes, among other things, a frame and a battery support structure mounted to the frame. The battery support structure includes a first mounting surface mounted outwardly of an outer side surface of a first longitudinally extending side rail of the frame and a second mounting surface mounted inwardly of the outer side surface of the first longitudinally extending side rail. A battery pack is supported by the battery support structure relative to the frame.

[0004] In another non-limiting embodiment of the foregoing electrically powered vehicle, the frame includes the first longitudinally extending side rail, a second longitudinally extending side rail, and a cross member extending between the first and second longitudinally extending side rails. The battery pack is positioned at least partially between the first and second longitudinally extending side rails.

[0005] In another non-limiting embodiment of any of the foregoing electrically powered vehicles, the battery support structure establishes a metallic outer structure that is a separate component from a housing assembly of the battery pack.

[0006] In another non-limiting embodiment of any of the foregoing electrically powered vehicles, a gap extends between a tray of the housing assembly and the battery support structure.

[0007] In another non-limiting embodiment of any of the foregoing electrically powered vehicles, the battery support structure includes a plurality of cross member assemblies and a plurality of beam segments connected between the plurality of cross member assemblies.

[0008] In another non-limiting embodiment of any of the foregoing electrically powered vehicles, each of the plurality of cross member assemblies includes a first bracket, a second bracket, and a beam extending between the first and second brackets.

[0009] In another non-limiting embodiment of any of the foregoing electrified vehicles, the first brace and the second brace each include at least one engagement portion configured to receive one of the plurality of beam segments.

[0010] In another non-limiting embodiment of any of the foregoing electrified vehicles, a first one of the plurality of cross member assemblies is positioned at a front of the battery support structure, a second one of the plurality of cross member assemblies is positioned at a rear of the battery support structure, a third one of the plurality of cross member assemblies is positioned at a first middle of the battery support structure, and a fourth one of the plurality of cross member assemblies is positioned at a second middle of the battery support structure.

[0011] In another non-limiting embodiment of any of the foregoing electrified vehicles, at least one subcomponent of the plurality of cross member assemblies is made of a material having a first specification and at least one subcomponent of the plurality of beam segments is made of a material having a second specification. The second specification is different than the first specification.

[0012] In another non-limiting embodiment of any of the foregoing electrified vehicles, a first fastener is received through an opening of the first mounting surface and a second fastener is received through an opening of the second mounting surface.

[0013] In another non-limiting embodiment of any of the foregoing electrified vehicles, the first mounting surface is mounted to a first corresponding mounting surface of a first mounting brace of the vehicle frame and the second mounting surface is mounted to a second corresponding mounting surface of a second mounting brace of the vehicle frame.

[0014] In another non-limiting embodiment of any of the foregoing electrified vehicles, the battery support structure includes a curved trim line.

[0015] In another non-limiting embodiment of any of the foregoing electrified vehicles, a first fastener mounts the battery support structure to the vehicle frame, a second fastener couples the battery pack, the isolator, and the battery support structure together, and a third fastener mounts the isolator to the battery support structure.

[0016] In another non-limiting embodiment of any of the foregoing electrified vehicles, a nonskid plate is mounted between the first cross member assembly and the second cross member assembly of the battery support structure.

[0017] In another non-limiting embodiment of any of the foregoing electrically motorized vehicles, a plurality of isolators are installed between the battery pack and the battery support structure.

[0018] A method according to another exemplary aspect of the present disclosure includes, among other things, installing a battery support structure to a battery pack; and installing the battery support structure to a frame of an electrically motorized vehicle, thereby supporting the battery pack relative to the frame. The battery support structure includes a first mounting surface that is installed directly below a longitudinally extending longitudinal beam of the frame.

[0019] In another non-limiting embodiment of the foregoing method, installing the battery support structure to the battery pack includes inserting a fastener through the battery support structure, then through an isolator, and subsequently into the battery pack.

[0020] In another non-limiting embodiment of any of the foregoing methods, installing the battery support structure to the frame includes inserting a fastener through an opening of the first mounting surface and through a corresponding mounting surface of a mounting bracket of the frame; and securing the fastener with a nut.

[0021] In another non-limiting embodiment of any of the foregoing methods, the first mounting surface is installed inward of an outer lateral surface of the longitudinally extending longitudinal beam of the frame.

[0022] In another non-limiting embodiment of any of the foregoing methods, the battery support structure includes a second mounting surface that is installed outward of the outer lateral surface of the longitudinally extending longitudinal beam of the frame.

[0023] The embodiments, examples, and alternatives of the foregoing paragraphs, claims, or the following description and drawings, including any of their various aspects or corresponding individual features, can be taken independently or in any combination of one another. Features described in connection with one embodiment can be applicable to all embodiments, unless incompatible therewith.

[0024] Various features and advantages of the present disclosure will become apparent to those of ordinary skill in the art from the following detailed description. The drawings attached hereto illustrate embodiments of the present disclosure and, together with the detailed description, serve to explain the principles of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 An electrically motorized vehicle is schematically illustrated.

[0026] Figure 2 A cross-sectional view of a battery pack of an electrically motorized vehicle.

[0027] Figure 3A selected portion of the underbody of an electrified vehicle is shown.

[0028] Figure 4 is Figure 3 A side view of the underbody of the vehicle depicted in

[0029] Figure 5 is a cross-sectional view through Figure 3 section 5-5.

[0030] Figure 6 An exemplary battery support structure for supporting and protecting an underbody-mounted battery pack of a vehicle is shown.

[0031] Figure 7 An exemplary under-rail attachment configuration provided by the battery support structure of Figure 6 is shown.

[0032] Figure 8 Another exemplary battery support structure is shown. DETAILED DESCRIPTION

[0033] The present disclosure describes in detail systems and methods for supporting and protecting underbody-mounted battery packs. An exemplary electrified vehicle can include a vehicle frame, a battery support structure mounted to the vehicle frame, and a battery pack. The battery pack is supported by the battery support structure relative to the vehicle frame, rather than being directly coupled to the vehicle frame itself. The battery support structure can be configured to provide an underframe-mounted configuration, lateral member positioning for side load protection, skid plate positioning for battery pack protection, weight-optimized sub-components, unique shapes for ground clearance, etc. These and other features are discussed in greater detail in the following paragraphs of this detailed description.

[0034] Figure 1 An electrified vehicle 10 is shown schematically. The electrified vehicle 10 can include any type of electrified powertrain. In one embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and can be extended to other electrified vehicles, including but not limited to hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, etc. Thus, although not specifically shown in this embodiment, the electrified vehicle 10 can be equipped with an internal combustion engine that can be employed alone or in combination with other energy sources to propel the electrified vehicle 10.

[0035] In one embodiment, the electrified vehicle 10 is a pickup truck. However, the electrified vehicle 10 can also be a sedan, van, sport utility vehicle, or any other type of vehicle. Although particular component relationships are shown in the drawings of the present disclosure, the drawings are not intended to limit the present disclosure. The placement and orientation of the various components of the electrified vehicle 10 are shown schematically, and can be varied within the scope of the present disclosure. Furthermore, the various drawings attached to the present disclosure are not necessarily drawn to scale, and some features can be exaggerated or minimized to emphasize certain details of particular components.

[0036] In the illustrated embodiment, the electrified vehicle 10 is a pure electric vehicle propelled solely by electric power, such as by one or more electric machines 12, without any assistance from an internal combustion engine. The electric machines 12 can operate as electric motors, generators, or both. The electric machines 12 receive electric power and provide a rotational output torque to one or more drive wheels 14.

[0037] A voltage bus 16 electrically connects the electric machines 12 to a battery pack 18. The battery pack 18 is an exemplary electrified vehicle battery. The battery pack 18 can be a high-voltage traction battery pack that includes a plurality of battery arrays 20 (i.e., a battery assembly or group of rechargeable battery cells) capable of outputting electric power to operate the electric machines 12 and / or other electrical loads of the electrified vehicle 10. Other types of energy storage and / or output devices can also be used to power the electrified vehicle 10.

[0038] The battery pack 18 can be mounted at various locations of the electrified vehicle 10. In one embodiment, the electrified vehicle 10 includes a passenger cabin 22 and a cargo space 24 (e.g., a truck bed) located rearward of the passenger cabin 22. A floor 26 can separate the passenger cabin 22 from a vehicle frame 28, which generally establishes a vehicle body floor 25. The battery pack 18 can be suspended or otherwise mounted relative to the vehicle frame 28 such that it is remote from both the passenger cabin 22 and the cargo space 24. Thus, the battery pack 18 does not occupy space that could otherwise be used to carry passengers or cargo.

[0039] Due at least in part to the mounting location at the vehicle body floor 25, the battery pack 18 can be susceptible to the effects of various vehicle loads, including but not limited to crash loads (e.g., loads imparted during, for example, vehicle collisions and ride-over events), durability loads, twist loads, bend loads, and noise, vibration, and harshness (NVH) loads. Accordingly, a novel battery support structure 30 is presented in the present disclosure. As discussed in greater detail below, the exemplary battery support structure 30 is capable of supporting and protecting the battery pack 18 and isolating the battery pack 18 from various loads that can be imparted onto the vehicle frame 28 during operation of the electrified vehicle 10.

[0040] Figure 2 isFigure 1 A schematic cross-sectional view of the battery pack 18. The battery pack 18 can accommodate multiple battery cells 32, which store various electrical loads for the electrified vehicle 10 (e.g., such as...). Figure 1 The energy is supplied by the motor 12. In one embodiment, the battery pack 18 houses prismatic lithium-ion battery cells. However, within the scope of this disclosure, battery cells having other geometries (cylindrical, pouch, etc.), other chemical substances (nickel-metal hydride, lead-acid, etc.), or both may be used alternatively.

[0041] The battery pack 18 may additionally accommodate one or more battery electronic components 34. The battery electronic components 34 may include a bus electrical center (BEC), a battery electrical control module (BECM), wiring harnesses, wiring loops, I / O connectors, or any combination of these or other battery electronic components.

[0042] The battery cells 32 can be grouped together in one or more battery arrays 20. In one embodiment, the battery pack 18 includes two battery arrays 20. However, the total number of battery cells 32 and battery arrays 20 used in the battery pack 18 is not intended to limit this disclosure.

[0043] The housing assembly 36 can accommodate the battery array 20 and battery electronics 34 of the battery pack 18. Since the battery array 20 and battery electronics 34 are housed within the housing assembly 36, these components are considered internal battery components of the battery pack 18. Although in Figure 2 An exemplary placement of the battery array 20 and battery electronics 34 is shown, but this particular placement is not intended to limit this disclosure. The internal battery components of the battery pack 18 may be arranged within the housing assembly 36 in any configuration.

[0044] In one embodiment, housing assembly 36 is a sealed housing. Within the scope of this disclosure, housing assembly 36 may include any size, shape, and construction.

[0045] The housing assembly 36 may include a tray 38 and a cover 40. The tray 38 and the cover 40 cooperate to surround and enclose the battery array 20 and the battery electronics 34. The tray 38 may provide an open area 41 for holding the battery array 20 and the battery electronics 34. After the battery array 20 and the battery electronics 34 are positioned within the open area 41, the cover 40 may be placed and sealed to the tray 38 to enclose the battery array 20 and the battery electronics 34.

[0046] In one embodiment, the housing assembly 36 is a metal-based component. For example, the tray 38 and the cover 40 may be constructed of aluminum or steel.

[0047] In another embodiment, the housing assembly 36 is a polymeric-based component. For example, the tray 38 and the cover 40 can be constructed (e.g., molded) from an expanded polymeric-based material, a solid polymeric-based material, or a combination of these materials. Exemplary expanded polymeric-based materials can include, but are not limited to, expanded polypropylene, expanded polystyrene, and expanded polyethylene. Exemplary solid polymeric-based materials can include, but are not limited to, sheet molding compound (e.g., glass fiber reinforced polyester), polypropylene, and polyamine.

[0048] In yet another embodiment, the housing assembly 36 can be constructed from both a metal-based component and a polymeric-based component. For example, the tray 38 can be a metal-based component, and the cover 40 can be a polymeric-based component. Other configurations are also contemplated within the scope of the present disclosure.

[0049] Figure 3 、 Figure 4 and Figure 5 shows a battery pack 18 mounted relative to a vehicle frame 28 at a vehicle body floor 25 of an electrified vehicle, such as the electrified vehicle 10 of Figure 1 The battery support structure 30 supports the battery pack 18 relative to the vehicle frame 28 and is configured to protect the battery pack 18 from various vehicle loads. The vehicle frame 28 (sometimes simply referred to as “frame”) is the primary support structure of the electrified vehicle 10 to which various components are attached, either directly or indirectly. The vehicle frame 28 can include a unibody construction, in which the chassis and body of the electrified vehicle 10 are integrated with one another, or can be part of a body-on-frame construction. As non-limiting examples, the vehicle frame 28 can be made from a metallic material, such as steel, carbon steel, or an aluminum alloy.

[0050] The vehicle frame 28 includes a plurality of longitudinal beams 42 (sometimes referred to as “frame rails” or “rails”). Figures 3 to 5 Two such longitudinal beams 42 are shown. The longitudinal beams 42 are spaced apart from one another and extend longitudinally (i.e., parallel to the length of the electrified vehicle 10) to establish the length of the vehicle frame 28. One or more cross members 44 can extend between the longitudinal beams 42 of the vehicle frame 28. The cross members 44 can generally extend transversely (i.e., parallel to the width of the electrified vehicle 10) relative to the longitudinal beams 42 for establishing the width of the vehicle frame 28.

[0051] The battery support structure 30 is a separate and distinct component from the housing assembly 36 of the battery pack 18. For example, the tray 38 of the housing assembly 36 can separate the battery internal components of the battery pack 18 from contacting the battery support structure 30. A gap G can extend between the tray 38 and the battery support structure 30 (see, e.g., Figure 4 ).

[0052] When the battery pack 18 is installed to the electrified vehicle 10, the battery support structure 30 can establish a relatively rigid metal outer structure to support the battery pack 18. In addition to supporting the battery pack 18, the battery support structure 30 can stiffen the vehicle frame 28 to reduce torsional twist, and can prevent various loads from being transferred to the battery pack 18.

[0053] The battery support structure 30 can be installed to the battery pack 18, and then the assembly of the battery pack 18 and the battery support structure 30 can be installed to the vehicle frame 28 to support the battery pack 18 relative to the vehicle frame 28. In Figures 3 to 5 The illustrated installation position of the battery pack 18 has the battery pack 18 positioned at least partially between the longitudinal members 42 of the vehicle frame 28, but not mechanically coupled to the vehicle frame 28. Rather, the battery pack 18 is mechanically decoupled from the vehicle frame 28. In this disclosure, the term“mechanically coupled” means fixedly connected, while the term“mechanically decoupled” indicates that there is no direct connection such that the vehicle frame 28 and the battery support structure 30 substantially absorb loads rather than the battery pack 18.

[0054] The battery support structure 30 can include a slightly curved dress line 31 (see Figure 4 ) for providing additional ground clearance and off-road capability. Additionally, in the installation position, the rear portion 33 of the battery support structure 30 can extend slightly lower relative to the ground 37 on which the electrified vehicle 10 is located than the front portion 35 of the battery support structure 30. For example, the rear portion 33 can be slightly tilted (see Figure 4 ) relative to the longitudinal axis 39 of the battery pack 18 at an angle a (e.g., greater than or equal to one degree), while the front portion 35 is not so tilted.

[0055] The battery pack 18 can be secured relative to the battery support structure 30 using a combination of isolators 46 and fasteners 48A, 48B (best shown in Figure 5 ). One or more of the isolators 46 can be positioned between the battery pack 18 and the battery support structure 30. The isolators 46, which can be referred to as bushings, are configured to dampen energy that is transmitted to the vehicle frame 28 and / or the battery support structure 30. In other words, the isolators 46 act as isolation points for isolating the battery pack 18 from vibrations and other loads that can act on the vehicle frame 28 and / or the battery support structure 30.

[0056] The isolators 46 can allow a relatively small amount of movement to occur between the battery pack 18 and the battery support structure 30. For example, the isolators 46 can allow the battery pack 18 to move slightly relative to the battery support structure 30 in multiple degrees of freedom in order to create a modal offset between the battery pack 18 and the battery support structure 30. The modal offset can effectively isolate the battery pack 18 from at least some of the loads that can act on the vehicle frame 28.

[0057] As Figure 5 As best shown in FIG. 1, the battery pack 18, the isolators 46, and the battery support structure 30 can be connected together using fasteners 48A and 48B. The total number of fasteners 48A and 48B employed can vary depending on the design, and thus is not intended to limit the disclosure. In one embodiment, one of the fasteners 48A can extend through the battery support structure 30, then through one of the isolators 46, and then into the battery pack 18 in order to securely mount each of the isolators 46 between the battery pack 18 and the battery support structure 30, and two or more of the fasteners 48B can extend through each of the isolators 46 to mount each of the isolators 46 to the battery support structure 30. Generally, the battery pack 18, the isolators 46, and the battery support structure 30 can be coupled together using the fasteners 48A, 48B prior to fixedly mounting the battery support structure 30 to the vehicle frame 28.

[0058] The insertion direction of the fasteners 48B can be opposite the insertion direction of the fasteners 48A. In one embodiment, the insertion direction of the fasteners 48B extends in a direction from the battery pack 18 toward the battery support structure 30 (i.e., top-down), while the insertion direction of the fasteners 48A extends in a direction from the battery support structure 30 toward the battery pack 18 (i.e., bottom-up).

[0059] Each of the isolators 46 can include an outer sleeve 50, an inner sleeve 52, and a damping portion 54 positioned generally between the outer sleeve 50 and the inner sleeve 52. The damping portion 54 secures the outer sleeve 50 to the inner sleeve 52. The inner sleeve 52 can be substantially cylindrical and receive a shaft of the fastener 48A. The outer sleeve 50 can receive a shaft of the fastener 48B.

[0060] The damping portion 54 can be, for example, high carbon rubber, which is an elastomer and optionally electrically conductive. In other examples, the damping portion 54 is not electrically conductive. The damping portion 54 can be made of other elastomeric materials, including polyurethane, silicone, metal-filled silicone, and the like. The damping portion 54 is compressible relative to the outer sleeve 50 and the inner sleeve 52 by an elastomeric material that allows the outer sleeve 50 to move and flex relative to the inner sleeve 52. While one example isolator 46 has been described, the disclosure extends to other isolator configurations.

[0061] After securing the battery pack 18 relative to the battery support structure 30, the battery support structure 30 can be mounted to the vehicle frame 28. The battery support structure 30 can be mounted to the vehicle frame 28 using a plurality of fasteners 56 (see FIG. 2). The fasteners 56 can extend through the battery support structure 30 and into the vehicle frame 28. The fasteners 56 can be threaded fasteners, such as bolts, that are secured to the vehicle frame 28 using nuts or other fasteners. The fasteners 56 can be spaced apart from each other along the length of the battery support structure 30. The fasteners 56 can be spaced apart from each other by a distance of about 1 inch to about 3 inches, or about 2 inches. The fasteners 56 can be spaced apart from each other by a distance of about 1 inch to about 3 inches, or about 2 inches, along the length of the battery support structure 30. The fasteners 56 can be spaced apart from each other by a distance of about 1 inch to about 3 inches, or about 2 inches, along the length of the battery support structure 30. Figure 4 and Figure 7) mechanically attached to the vehicle frame 28. In one embodiment, the longitudinal rails 42 of the vehicle frame 28 include mounting brackets 58A, 58B configured to receive fasteners 56.

[0062] The fasteners 56 can be relatively rigid bolts or screws. Other rigid fasteners can also be used within the scope of the present disclosure. The fasteners 56 provide high-strength connectors for fixedly mounting the battery support structure 30 to the vehicle frame 28.

[0063] The mounting brackets 58A can be configured to connect to portions of the front 35 and rear 33 of the battery support structure 30, and the mounting brackets 58B can be configured to connect to the middle portions MP1, MP2 of the battery support structure 30 that extend between the front 35 and rear 33. The mounting brackets 58A can be configured and arranged differently compared to the mounting brackets 58B. In one embodiment, the mounting brackets 58A are configured to extend in the outboard direction, and the mounting brackets 58B are configured to extend in the inboard direction. For example, the mounting brackets 58A can include mounting surfaces 60 that project outward (i.e., laterally outward in a direction away from the opposing longitudinal rail 42) relative to the outboard surface 62 of the longitudinal rail 42, and the mounting brackets 58B can include mounting surfaces 64 that project inward (i.e., in a direction toward the opposing longitudinal rail 42) relative to the outboard surface 62 of the longitudinal rail 42.

[0064] Reference is now made to Figure 6 Further details of the battery support structure 30 are described. The battery support structure 30 can include a plurality of cross-member assemblies 66 and a plurality of beam segments 68 that are connected longitudinally between the cross-member assemblies 66. In one embodiment, the battery support structure 30 includes four cross-member assemblies 66, and two beam segments 68 are connected between each set of adjacent cross-member assemblies 66, for a total of six beam segments 68. However, a greater or lesser number of cross-member assemblies 66 and beam segments 68 can be implemented within the scope of the present disclosure, depending on the design of the battery pack 18 and the vehicle frame 28, among other factors. The beam segments 68 can be fixedly attached to the cross-member assemblies 66, such as via a welding process.

[0065] While the specific configurations are not intended to limit the present disclosure, one cross-member assembly 66 can be arranged at each of the front 35, rear 33, and two middle portions MP1 and MP2 of the battery support structure 30. The location of the cross-member assemblies 66 of the middle portions MP1, MP2 can be specifically tailored to increase the strength and rigidity of the battery support structure 30. For example, in the illustrated embodiment, the cross-member assembly 66 of the middle portion MP1 is specifically positioned to optimize side pole crash protection once the battery support structure 30 is mounted to the battery pack 18 and the vehicle frame 28.

[0066] Each cross member assembly 66 can include a first bracket 70, a second bracket 72, and a beam 74 connected to and extending between the first bracket 70 and the second bracket 72. The beam 74 can establish a main width of the battery support structure 30. However, portions of the first bracket 70 and the second bracket 72 can protrude outside of the beam portion 68.

[0067] The first bracket 70 and the second bracket 72 can each include a mounting surface 76. The mounting surface 76 establishes a mounting point for mounting the battery support structure 30 to the mounting bracket 58A, 58B of the longitudinal beam 42 of the vehicle frame 28. The mounting surfaces 76 of the first bracket 70 and the second bracket 72 of the cross member assembly 66 can be slightly elevated relative to the beam 74.

[0068] The mounting surfaces 76 of the first bracket 70 and the second bracket 72 of the cross member assembly 66 located at the front 35 and the rear 33 of the battery support structure 30 can be mounted to the mounting surface 60 of the mounting bracket 58A, and the mounting surfaces 76 of the first bracket 70 and the second bracket 72 of the cross member assembly 66 located at the intermediate portions MP1, MP2 can be mounted to the mounting surface 64 of the mounting bracket 58B. Thus, at least a portion of the mounting surfaces 76 are mounted directly below the longitudinal beam 42 of the vehicle frame 28.

[0069] The fasteners 56 can be inserted through the openings 69 formed in the mounting surfaces 76, and subsequently through the mounting surfaces 60 or 64 (i.e., in a downward direction), and can then be secured by the nuts 78 (see, e.g., Figure 7 ) to fixedly mount the battery support structure 30 relative to the vehicle frame 28.

[0070] In one embodiment, the first bracket 70 and the second bracket 72 of the cross member assembly 66 located at the front 35 and the rear 33 are mounted to the mounting bracket 58A at a location outside of the outer side surface 62 of the longitudinal beam 42 (see, e.g., Figure 3 ), and the first bracket 70 and the second bracket 72 of the cross member assembly 66 located at the intermediate portions MP1, MP2 are mounted to the mounting bracket 58B at a location slightly inside of the outer side surface 62 of the longitudinal beam 42 (see, e.g., Figure 7 ). Thus, the cross member assembly 66 of the intermediate portions MP1, MP2 of the battery support structure 30 establishes an "under-frame" attachment configuration to reduce loads in the battery pack 18.

[0071] The first and second brackets 70, 72 of each cross member assembly 66 can additionally include one or more junctions 80. The junctions 80 establish connection points for receiving and connecting the beam segments 68. In one embodiment, the first and second brackets 70, 72 of the cross member assemblies 66 located at the front 35 and rear 33 portions each include a single junction 80, while the first and second brackets 70, 72 of the cross member assemblies 66 located at the intermediate portions MP1, MP2 each include two junctions 80.

[0072] A plurality of openings 82 can be formed in the battery support structure 30 for accommodating the isolators 46. One or more of the openings 82 can be formed within the beam segments 68, the first and second brackets 70, 72, or both the beam segments 68 and the first and second brackets 70, 72.

[0073] The various sub-components making up the battery support structure 30 can be made of stamped high-strength steel. However, other relatively rigid materials and other manufacturing techniques are also contemplated within the scope of the present disclosure. In one embodiment, at least a portion of the sub-components of the battery support structure 30 are made of a material having a different gauge than the gauge of the other sub-components of the battery support structure 30. In one embodiment, the material gauge of the components of the battery support structure 30 can be in the range of 2.4 mm (0.094 inch) to 3.5 mm (0.138 inch).

[0074] Figure 8 Another example battery support structure 130 is shown. The battery support structure 130 is similar to the battery support structure 30 described above. However, in this embodiment, the battery support structure 130 further includes a skid plate 90. The skid plate 90 is configured to protect the battery pack (not shown) from debris and projectiles that can be kicked up from the ground towards the battery pack, thereby improving the off-road capability of the vehicle. The battery support structure 130 can be installed to the battery pack and the vehicle frame 28 in the same or similar manner as described above. Figure 8

[0075] In one embodiment, the skid plate 90 extends between adjacent cross member assemblies 166 of the battery support structure 130. For example, the skid plate 90 can extend between the cross member assemblies 166 located at the intermediate portions MP1, MP2 of the battery support structure 130. The skid plate 90 can additionally extend between opposing beam segments 168 connected between the cross member assemblies 166 located at the intermediate portions MP1, MP2.

[0076] ​The battery pack support structures of the present disclosure provide unique and optimized mounting solutions for supporting battery packs relative to an electrified vehicle and for protecting the battery packs and isolating the battery packs from various vehicle loads. Exemplary battery support structures can be configured to provide various unique features including, but not limited to, underframe mounting configurations, cross member positioning, skid plate positioning for increased battery pack protection, weight optimized sub-components, unique shapes for ground clearance, etc.

[0077] While various non-limiting embodiments are shown with particular components or steps, embodiments of the present disclosure are not limited to those specific combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments.

[0078] It should be understood that the same part numbers refer to corresponding or similar elements throughout the several figures. It should be appreciated that while particular component arrangements are disclosed and shown in these example embodiments, other arrangements can benefit from the teachings of the present disclosure.

[0079] The foregoing description should be interpreted as illustrative of the nature intent rather than in any limiting sense. Those of ordinary skill in the art will understand that certain modifications can occur within the scope of the present disclosure. For these reasons, the appended claims should be studied to determine the true scope and content of the disclosure.

Claims

1. An electrified vehicle comprising: a vehicle frame; a battery support structure mounted to the vehicle frame, wherein the battery support structure includes a first mounting surface mounted outboard of an outboard surface of a first longitudinally extending rail of the vehicle frame; and a second mounting surface mounted inboard of the outboard surface of the first longitudinally extending rail; wherein the first mounting surface is mounted to a first corresponding mounting surface of a first mounting bracket of the vehicle frame, and the second mounting surface is mounted to a second corresponding mounting surface of a second mounting bracket of the vehicle frame; a first fastener received through an opening of the first mounting surface, and a second fastener received through an opening of the second mounting surface; and a battery pack supported by the battery support structure relative to the vehicle frame.

2. The electrified vehicle of claim 1, wherein the vehicle frame includes the first longitudinally extending rail, a second longitudinally extending rail, and a cross member extending between the first longitudinally extending rail and the second longitudinally extending rail, and the battery pack is positioned at least partially between the first longitudinally extending rail and the second longitudinally extending rail.

3. The electrified vehicle of claim 1, wherein the battery support structure establishes a metal outer structure that is a separate component from a housing assembly of the battery pack, and optionally wherein a gap extends between a tray of the housing assembly and the battery support structure.

4. The electrified vehicle of claim 1, wherein the battery support structure includes a plurality of cross member assemblies and a plurality of beam sections connected between the plurality of cross member assemblies, and optionally wherein each of the plurality of cross member assemblies includes a first bracket, a second bracket, and a beam extending between the first bracket and the second bracket.

5. The electrified vehicle of claim 4, wherein the first bracket and the second bracket each include at least one engagement configured to receive one of the plurality of beam sections.

6. The electrified vehicle of claim 4, wherein a first cross member assembly of the plurality of cross member assemblies is positioned at a front of the battery support structure, a second cross member assembly of the plurality of cross member assemblies is positioned at a rear of the battery support structure, a third cross member assembly of the plurality of cross member assemblies is positioned at a first midsection of the battery support structure, and a fourth cross member assembly of the plurality of cross member assemblies is positioned at a second midsection of the battery support structure, and optionally wherein at least one subcomponent of the plurality of cross member assemblies is made of a material having a first specification and at least one subcomponent of the plurality of beam sections is made of a material having a second specification, wherein the second specification is a different specification than the first specification.

7. The electrified vehicle of claim 1, comprising a plurality of isolators mounted between the battery pack and the battery support structure.

8. The electrified vehicle of claim 1, wherein the battery support structure comprises curved trim lines.

9. The electrified vehicle of claim 7, comprising first fasteners for mounting the battery support structure to the vehicle frame, second fasteners for coupling the battery pack, the isolator, and the battery support structure together, and third fasteners for mounting the isolator to the battery support structure.

10. The electrified vehicle of any preceding claim, comprising a skid plate mounted between the first and second transverse member assemblies of the battery support structure.

11. A method comprising: mounting a battery support structure to a battery pack; and mounting the battery support structure to a frame of an electrified vehicle, thereby supporting the battery pack relative to the frame, wherein the battery support structure comprises a first mounting surface that is mounted directly below a longitudinally extending longitudinal beam of the frame; wherein mounting the battery support structure to the frame comprises: inserting a fastener through an opening of the first mounting surface and through a corresponding mounting surface of a mounting bracket of the frame; and securing the fastener with a nut; wherein mounting the battery support structure to the battery pack comprises: inserting a fastener through the battery support structure, then through an isolator, and then into the battery pack.

12. The method of claim 11, wherein the first mounting surface is mounted inside an outside surface of the longitudinally extending longitudinal beam of the frame, and optionally wherein the battery support structure comprises a second mounting surface that is mounted outside the outside surface of the longitudinally extending longitudinal beam of the frame. ​

Images