Cross member for vehicle battery tray

Abstract

A cross member for a vehicle battery tray is provided with a beam having a closed cross-sectional shape, the beam having a top wall connected to parallel side walls along the length of the beam. A reinforcing top cover is provided along the beam, wherein the C-shaped cross-sectional shape of the top cover has a central section provided along the top wall, and top cover legs welded to the side walls. The legs include inwardly angled tabs that bias the beam and are welded thereto. The top wall of the beam and the central section of the top cover have aligned fastener openings that are spaced along the length of the beam and are configured to receive fasteners that secure at least one of a battery module or a tray cover to the cross member.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 USC §119(e) to U.S. Provisional Patent Application No. 62 / 856,804, filed on June 4, 2019, the disclosure of which is made a part of this application and is incorporated by reference in its entirety into this application. Technical Field

[0003] The present disclosure relates generally to structural members and beams, and more particularly to vehicle cross members such as for use in a vehicle battery tray or box. Background Art

[0004] Electric vehicles are typically designed to house and package battery modules within a battery tray or box that protects the batteries from damage while driving in a variety of climates and environments, and protects the batteries from different types of collisions. The vehicle battery tray is typically located on the vehicle frame or part of the vehicle substructure, such as between the axles and near the vehicle floor, which can distribute the weight of the batteries on the frame and establish a lower center of gravity for the vehicle. To increase the battery carrying capacity and improve the battery tray's lateral intrusion resistance from, for example, a side collision, the battery tray may include a cross-member bracket that spans laterally within the battery tray housing. Summary of the invention

[0005] The present disclosure provides a cross member for a vehicle battery tray, such as for an all-electric or hybrid electric vehicle. The structure of the vehicle battery tray may include a cross member that crosses or is above the battery tray floor and is attached to the inner side of the peripheral wall of the battery tray. The battery module can be arranged between the cross members in the battery receiving area of ​​the tray structure and can be fixed to the cross member to maintain stability. The battery receiving area can also be substantially enclosed with a cover that can be attached to the cross member. The cross member is designed with a portion that can engage and support the battery module and / or the cover of the battery tray, and the portion also provides an optimized width that does not affect the available space for the battery module in the battery receiving area, as well as other necessary considerations. For example, the upper portion of the cross member can be reinforced by the cross-sectional geometry of the beam, such as a roll-formed closed cross-section beam, which increases the material mass along the upper portion of the beam. As another example, the upper portion of the cross member can be reinforced, such as using a top cover that increases the top wall material thickness and overall strength. The top cover can be fixed to the cross member by welding an inwardly offset tab to the outer surface of the beam. As another example, the upper portion of the cross member can be equipped with a top wall that is attached to the upper edge of the beam side wall so that the top wall can be thicker than the side wall. The top wall and side wall can also be attached together to form a T-joint on opposite sides of a threaded receiver provided along the upper portion of the beam.

[0006] According to one aspect of the present disclosure, a cross member for a vehicle battery tray includes a beam having a closed cross-sectional shape, the beam having a top wall connected to parallel side walls along the length of the beam. A reinforced top cover has a C-shaped cross-sectional shape, the C-shaped cross-sectional shape having a center section disposed along the top wall of the beam and legs extending from opposite sides of the center section. The legs are attached to the side walls of the beam, wherein each leg includes a plurality of tabs welded to the side walls. The top wall of the beam and the center section of the top cover have aligned fastener openings disposed at intervals along the length of the beam. In some embodiments, a plurality of threaded receivers are disposed at the aligned fastener openings to engage fasteners inserted through the fastener openings to secure at least one of the battery module or the tray cover to the cross member.

[0007] According to another aspect of the present disclosure, a cross member for a vehicle battery tray includes a beam having side walls spaced apart from one another along the length of the beam. A reinforcement cap is disposed along an upper portion of the beam and spans between the side walls. The reinforcement cap includes a series of tabs disposed along the length of the beam and extending downward from opposite sides of a center section of the cap to attach to the side walls of the beam. The series of tabs are each individually welded to a corresponding side wall. The reinforcement cap includes fastener openings extending through the center section of the cap at intervals along the length of the beam. Optionally, the tabs of the reinforcement cap may extend toward each other at an inward angle to bias toward an outer surface of the beam as the tabs of the reinforcement cap extend downward from the center section, thereby providing stable welding conditions.

[0008] According to another aspect of the present disclosure, a cross member for a vehicle battery tray includes a beam having side walls spaced apart from one another along the length of the beam. A top wall is connected to an upper edge of the side wall along the length of the beam, wherein the top wall has a greater thickness than the side wall. The top wall includes fastener openings arranged at certain intervals along the length of the beam. A plurality of threaded receivers are attached to the top wall, aligned with the fastener openings, and configured to threadably engage fasteners inserted through the fastener openings to secure at least one of a battery module or a tray cover to the top wall. A plurality of threaded receivers may be arranged between the side walls, and the side walls may be spaced apart at a constant spacing along the length of the beam. In some examples, the plurality of threaded receivers include at least one of a pin nut, a slot nut, a self-tapping nut, or a weld nut.

[0009] These and other objects, advantages, purposes and features of the present disclosure will become apparent after reading the following description in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a side view of the vehicle showing the location of the battery tray;

[0011] Figure 2 is an upper perspective view of a vehicle battery tray showing a cross member;

[0012] Figure 3 yes Figure 2 an upper perspective view of the cross member shown;

[0013] Figure 3A yes Figure 3 a cross-sectional view of the cross member shown;

[0014] Figure 4 is an upper perspective view of the cross member;

[0015] Figure 5 showing cross-sectional views of a number of exemplary cross members;

[0016] Figure 6 yes Figure 4 an upper perspective view of the end of the cross member shown;

[0017] Fig. 6A yes Figure 6 a top view of the end of the cross member shown;

[0018] Figure 7 is an upper perspective view of the end of the cross member;

[0019] Fig. 7A yes Figure 7 a side view of the end of the cross member shown;

[0020] Figure 8 is a side view of the end of the cross member;

[0021] Fig. 9 is an upper perspective view of the cross member;

[0022] Fig. 9A yes Fig. 9 an upper perspective view of the end of the cross member shown;

[0023] Fig. 9B yes Fig. 9 a cross-sectional view of the cross member shown;

[0024] Fig.10 is an upper perspective view of the cross member;

[0025] Fig. 10A yes Fig.10 a cross-sectional view of the cross member shown;

[0026] Fig.11 is a cross-sectional view of a cross member with welded nuts;

[0027] Fig.11A yes Fig.11A perspective view of the weld nut shown;

[0028] Fig.12 is a cross-sectional view of a cross member with welded nuts;

[0029] Fig.13 is a cross-sectional view of a cross member with welded nuts;

[0030] Fig.14A is an upper perspective view of a cross member having a T-slot nut;

[0031] Fig. 14B yes Fig.14A a lower perspective view of the cross member shown;

[0032] Fig. 14C yes Fig.14A a cross-sectional view of the cross member shown;

[0033] Fig.14D yes Fig.14A An exploded cross-sectional view of the cross member shown;

[0034] Fig.15A is an upper perspective view of the cross member with the pin nuts exploded from the beam; and

[0035] Fig. 15B yes Fig.15A An upper perspective view of the cross member is shown with the pin nuts attached to the beam. DETAILED DESCRIPTION

[0036] With reference to the drawings and the illustrative embodiments described therein, a vehicle battery tray or structure 10 is provided for supporting and protecting batteries, such as battery packs or battery modules, etc., which are used to power and operate the motor and other electrical components of an electric or hybrid electric vehicle, such as Figure 1 A battery powered electric vehicle 12 (BEV) is shown. The battery tray 10 can be attached or mounted to or near a lower portion of the vehicle 12, such as at a lower frame or rocker rail, which can also enable the batteries contained in the battery tray 10 to be centrally located on the vehicle 12. This low and central location can be spaced from possible collision locations on the frame, such as areas near the front and rear bumpers, to avoid damage and interference with the batteries. In addition, this hanging and mounting position of the tray 10 that straddles the interior compartment below the vehicle 12 can allow for large battery capacities and can evenly distribute the battery weight on the frame and provide a relatively low center of gravity for the vehicle 12 due to the considerable weight of the batteries held in the battery tray 10. The battery tray 10 can be separated or removed from the rocker rails or other frame structure of the vehicle 12, for example, to replace or maintain the batteries or related electrical components.

[0037] like Figure 2 As shown, the battery tray 10 is provided with a floor panel 14, which forms the bottom of the containment area of ​​the battery tray 10. When the battery tray 10 is engaged with the lower portion of the vehicle 12, the floor panel 14 of the battery tray 10 is able to span below the interior compartment and be substantially parallel to the floor of the interior compartment of the vehicle 12, so that the floor panel 14 of the battery tray 10 is able to form the bottom or lowermost chassis surface of the vehicle 12. The battery tray 10 also includes a peripheral containment wall 16, which is arranged around the edge of the floor panel 14 to substantially surround the battery containment area of ​​the battery tray 10. The peripheral containment wall 16 is formed by at least one peripheral reinforcement member, which extends along at least one section or side of the edge of the floor panel 14 to provide a protective barrier around the battery containment area. Therefore, the peripheral wall 16 can be a single beam or segmented into separate members or beams attached together at the ends. As shown in FIG. Figure 2 As shown, when viewed from above, the peripheral shape of the peripheral wall 16 can be generally rectangular or square, wherein the corners of the peripheral wall 16 are approximately 90 degrees. However, it is contemplated that the peripheral containment wall and the entire battery tray can be formed into a variety of shapes, such as to accommodate various vehicle body types and designs.

[0038] like Figure 2 As shown, the floor panel 14 is a generally planar structure and may include formations adapted to increase the structural rigidity of the floor panel 14 and to enable the floor panel 14 to support the battery modules. Figure 2 The illustrated floor panel 14 has a set of elongated recesses 18 extending transversely on the floor panel 14 below a section of the battery receiving area and each of which is directly below the battery module. Such elongated recesses 18 increase the lateral stiffness of the floor panel 14 while also providing air flow channels below the battery module. The floor panel 14 may also have a sealed connection along the bottom surface of the peripheral wall 16, such as by welding, adhesives, fasteners, etc. The sealed connection between the floor panel 14 and the peripheral wall 16 may be reinforced or supplemented with a sealant or sealing material, such as an epoxy resin, a silicone sealant, a gasket material, etc.

[0039] Further references Figure 2 The battery tray 10 has a cross member 20 that spans along or on the floor panel 14 of the battery tray and is attached between the inner surfaces of the perimeter walls 16. Figure 2As shown, the cross member 20 can extend laterally between the sides of the peripheral wall 16 to transfer lateral loads and impact forces along the cross member 20 through a generally linear load path, thereby preventing the peripheral wall 16 from deforming laterally inward and thereby limiting damage to the battery receiving area. The battery modules can be arranged between the cross members 20 in the battery receiving area of ​​the tray structure and can be attached or fixed to the cross members 20 to maintain stability. The battery receiving area can also be substantially enclosed with a cover that can be attached to the cross member 20. The cross member 20 can be formed with a height less than or equal to the height of the peripheral wall 16, so that the cross member 20 can be used as a barrier between sections of the battery receiving area.

[0040] like Figure 3 and 3A As shown, the cross member 20 can be a beam having an open cross-sectional shape that is capable of engaging and supporting the cover of the battery module and / or battery tray. The top wall 22 of the cross member 20 is generally planar and has a width that allows fastener openings 24 to be formed through the top wall 22 at certain intervals along the length of the beam. The beam of the cross member can be integrally formed, such as a roll-formed sheet material (i.e., a high-strength steel alloy) or an extruded sheet material (i.e., an aluminum alloy), wherein the top wall 22 can be integrally connected to the side walls 26 of the beam, which extend downward from opposite edges of the top wall 22 toward the floor of the battery tray. As shown Figure 3A As shown, the side walls 26 are generally planar and parallel to each other so as to provide approximately equal spacing between the side walls 26 along the length of the beam. The lower end of each side wall 26 is integrally connected with a stepped section 28, which is configured to be attached to the floor panel 14 of the battery tray 10, such as by welding. The stepped section 28 can also provide an upwardly facing surface 30, which is configured to support a portion of the battery modules stored in the battery tray.

[0041] like Figure 4 and 6 , an additional example of a cross member 120 having a closed cross-sectional shape is shown that is configured to support a cover of a battery module and / or battery tray at a top wall 122 of the beam. Figure 4 and 6The top wall 122 of the beam shown in FIG is reinforced by the cross-sectional shape of the beam having an increased width along the upper portion 130 of the beam. The width of the lower portion 132 located below the upper portion 130 of the beam is reduced to provide an optimized width that does not affect the available space for the battery module in the battery receiving area. The increased width at the top wall 122 of the beam also increases the material mass along the upper portion 130 of the beam. The transition bend 134 at the opposite side walls 126 of the beam between the upper portion 130 and the lower portion 132 of the beam can provide increased bending stiffness along the length of the cross member 120, which also allows the use of thinner gauge materials such as high strength steel, aluminum or other metals.

[0042] Depending on the load requirements of the cross member, the tray design and desired materials, and other conceivable factors, different examples of cross members may have a variety of different cross-sectional shapes that can be used to improve the lateral loading of the cross member, such as through battery module and cover engagement, while maintaining a narrow profile to optimize the battery carrying capacity of the tray. For example, Figure 5 As shown, a variety of cross-sectional shapes can be formed from roll-formed sheet material, such as high-strength steel, which provides options for various load properties.

[0043] The axial ends of the cross members may also be configured to be uniformly attached along the inner surface of the peripheral wall of the battery tray so that there is constant contact along the edges of the axial ends of the beams. Such contact may be made with an intermediate weld or bonding material, such as a sealant or adhesive, etc. For battery tray sections having peripheral walls with non-parallel opposing portions, the axial ends of the beams may be cut or trimmed, such as with a laser cutter, so that the peripheral edges of the axial ends correspond to the shape of the inner surface of the opposing portion of the peripheral wall. Figure 6 and 6A As shown, the beam of the cross member 120 has an axial end, the edge of which is formed into an inclined portion 136a, which is arranged along a vertical plane that is angled with a vertical plane perpendicular to the longitudinal extent of the beam and forms another part 136b of the edge of the axial end of the beam. Therefore, the axial end of the beam can be cut at one or more inclined vertical planes to correspond to the surface of the peripheral side wall joined by the axial end.

[0044] Furthermore, for portions of the peripheral wall that do not have a vertical or planar inner surface, the axial ends of the beams may also or alternatively be formed with an inclined or non-linear shape so that the edges of the axial ends correspond to such an inner surface. Figure 7 and 7A As shown, the beam of the cross member 220 has an axial end whose edge is formed with an upper inclined portion 236a arranged along a lateral plane that is inclined upward from a vertical plane perpendicular to the longitudinal extent of the beam. Fig. 7AThe axial end edge of the cross member 220 shown also has a lower inclined portion 236b arranged along a lateral plane that is inclined downward from a vertical plane perpendicular to the longitudinal extent of the lower portion of the beam. Thus, the axial end of the cross member can be cut or trimmed at various angles and shapes in multiple planes to provide the desired edge contact and engagement with the peripheral wall of the battery tray.

[0045] In addition to or as an alternative to cutting or trimming the axial ends of the beams of the cross-member, the cross-member may include end brackets that engage against the inner surface of the peripheral wall of the battery tray. Figure 8 As shown, the cross member 320 includes axial ends cut perpendicular to the length of the cross member so that end brackets can be attached to the side wall 326 of the beam. The exemplary end brackets can extend toward the peripheral wall at a certain angle and configuration that fits on the inner surface of the peripheral wall in a constant contact manner. By attaching the end brackets to the axial ends of the beam, the beam can be cut in a plane perpendicular to the longitudinal extent of the beam, which can be done in-line on a roll forming machine.

[0046] like Figures 9 to 9B As shown, another example of a cross member 420 has an upper portion reinforced by a top cap 442. The top cap 442 can provide an increased material thickness relative to the top wall 422 of the beam and can increase the overall strength of the upper portion of the beam 421. Fig. 9A As shown, the beam 421 has a closed cross-sectional shape wherein a top wall 422 is connected to parallel side walls 426 along the linear length of the beam 421 . Fig. 9A The closed cross-sectional shape of the beam 421 shown is further defined by the roll-formed geometry, which may be referred to as Figure 5 As shown in the single beam, this provides two adjacent tubular profiles with hollow openings separated by a common center wall of the beam that is generally parallel to the top wall 422. With this single beam profile, the upper tubular profile can have a smaller hollow interior area than the lower tubular profile, such as Fig. 9 As shown, this provides increased mass in the upper portion of the beam and increases bending strength along the top wall 422. However, it is contemplated that the top cap may be attached to various types or shapes of cross member beams to increase the load bearing capacity of the cross member along the top wall.

[0047] The top cover 442 may have a C-shaped cross-sectional shape having a central section 444 disposed along the top wall 422 of the beam and legs 446 secured to the side walls 426 of the beam. The legs 446 of the top cover 442 may be angled inwardly to mount and secure the top cover 442 to the beam of the cross member 420 while allowing for dimensional tolerance variations in the width of the upper portion of the beam. To further accommodate such tolerance variations, the legs 446 of the top cover 442 may bend outwardly when pressed against the beam, which results in the legs 446 having an inward biasing force on the side walls 426 of the beam. Fig. 9B As shown, the upper corners 450 of the beam extending along the opposite sides of the top wall 422 may include a bending radius that provides a curved outer surface at the corner 450. In order to install the top cover 442 on the beam, the top cover 442 can be pressed onto the upper portion of the beam so that the lower edges of the legs 446 or tabs 448 contact the curved outer surface at the corners 450 of the beam. When a force is applied to the top cover 442, the curved corners 450 of the beam cause the legs 446 of the top cover 442 to gradually open outward to allow the legs 446 to slide over the corners 450 and slide down along the side walls 426 of the beam. The outward resilient bending of the legs 446 and / or tabs 448 can result in an inwardly biased retention, which helps provide consistent contact of the edges of the legs 446 or tabs 448 along the side walls 426, which is a preferred welding condition. Therefore, the bending range of the legs allows for relevant tolerances in the width of the beam.

[0048] like Fig. 9A As shown, the legs 446 of the top cap 442 may include tabs 448 spaced at generally uniform intervals along the lower edges of the legs 446. The top cap 442 may be secured or attached to the cross member beam by welding the lower edges of the legs 446 to the outer surface 426 of the beam. The lower edge relief provided by the tabs 448 provides a greater available welding area and potential edge contact between the top cap 442 and the beam than a linear lower edge of the top cap. Fig. 9A As shown, the tab 448 has a generally rectangular shape with rounded corners so that a weld 452 can be formed along the tab 448 (i.e., by laser welding or resistance welding), such as by forming a C-shaped weld 452 along a lower edge portion of the tab 448. The tab shape and orientation on the outer surface of the beam may be different, or may be provided in an alternative shape to provide the desired weld. As another example, Fig. 9B As shown, weld 452a is formed at the lower edge of tab 448 that contacts beam sidewall 426, due to the inward bias provided by the inward angle of the legs or tabs, for example.

[0049] like Fig. 9A and 9BAs shown, the top wall 422 of the beam and the center section 444 of the top cover 442 have aligned fastener openings 454a, 454b that are spaced apart along the linear length of the cross member 420. The axially aligned openings 454a, 454b are configured to receive fasteners that secure at least one of the battery module or the tray cover to the cross member 420. One or both of the fastener openings 454a, 454b may be formed by pre-splicing sheet metal. A threaded receiver 456, such as a self-tapping, self-locking (SPAC) nut, may be installed and attached to at least one of the aligned fastener openings 454a, 454b, for example, prior to roll forming or by attaching the top cover to the beam via a splicing process. As shown in FIG. Fig. 9B As shown, the threaded receiver 456 is configured to threadably engage a fastener 458 inserted through the fastener opening to secure at least one of the battery module or the tray cover to the cross member.

[0050] Further references Fig. 9B , the diameter of the upper fastener opening 454a formed in the central section 444 of the top cover 442 may be smaller than the diameter of the lower fastener opening 454b formed in the top wall 422 of the beam. The larger diameter of the lower fastener opening 454b allows for tolerance in the alignment of the openings, because the top cover 442 and the beam may be roll formed with pre-punched openings in the sheet material, and therefore at least some tolerance may be required to consistently align the openings 454a, 454b. In addition, the top cover 442 may be formed of a more formable material than the beam, such as a 1500 MPa martensitic steel sheet material that is capable of bending at a radius of 1T (1 times the material thickness) at the corner between the central section 444 and the leg 446, as opposed to the beam material, which may only be able to form the corner 450 along the top wall 422 with a radius of 3T (3 times the material thickness). Due to the angular bending restrictions of the beam, the planar upper surface of the top cover 442 may be larger than the planar upper surface of the beam, so that the threaded receiver 456 can engage the top cover 442 without engaging the beam, such as Fig. 9B shown.

[0051] like Fig.10 and 10A As shown, another example of a cross member 520 has an upper portion reinforced by a top cap 542, although the beam has no top wall. Fig. 10A As shown, the beam 521 has an open cross-sectional shape having parallel side walls 526 extending integrally upward from a lower wall 527 of the beam 521 along the linear length of the beam 521 . Fig. 10AThe open cross-sectional shape of the beam 521 is shown as a U-shape, so that the top cover 542 is an inverted U-shape, which is connected to the upper portion of the side wall 526. The top cover 542 can be formed from a plate having a greater thickness than the plate forming the beam 541 to provide increased mass in the upper portion of the beam and increase the bending strength along the top cover.

[0052] Fig. 10A The reverse U-shape of the top cover 542 shown in FIG. 5 may have a central section 544 and legs 546 that integrally extend downward from opposite corners of the central section 544 to attach to the side walls 526 of the beam 521. The legs 546 of the top cover 542 may be inclined inwardly at an inward transition section 529 near the lower edge of the legs 546 to mount and secure the top cover 542 to the interior of the beam 521. Fig. 10A As shown, to install the top cap 542 on the beam 521, the top cap 542 can be pressed downward into the exposed upper opening of the beam 521 so that the lower edge of the leg 546 contacts the inner surface of the side wall 526 of the beam 521. When a force is applied to the top cap 542, the top cap 542 can slide downward into the beam until the inward transition section 529 of the top cap 542 engages the upper edge of the beam side wall 526. The resulting inward elastic bending of the leg 546 can maintain an outward bias, which helps to provide consistent contact of the leg 546 along the side wall 526, which is a stable and preferred welding condition. The top cap 542 can be fixed to the cross member beam 521 by welding the upper edge of the side wall 526 to the outer surface of the leg (for example, by laser welding or resistance welding, etc.).

[0053] like Fig.10 and 10A As shown, the top cap 542 can have fastener openings 554 that are spaced apart along the linear length of the cross member 520. The fastener openings 554 can be formed by pre-splicing the sheet metal of the top cap 542 before or after roll forming the top cap 542. A threaded receiver 556, such as a self-tapping, self-locking (SPAC) nut, can be installed and attached to each fastener opening 554, for example, before roll forming or before attaching the top cap to the beam by a splicing process. Fig. 10A As shown, the threaded receiver 556 is configured to threadably engage a fastener 558 inserted through the fastener opening to secure at least one of the battery module or the tray cover to the cross member.

[0054] like Fig.11 As shown, another example of a cross member 620 has a beam 621 that is reinforced with a threaded receiver 656 along an upper portion of the cross member 620. The beam 621 has an open cross-sectional shape with parallel side walls 626 extending integrally upward along a lower wall 627 of the beam 621. Fig.11The open cross-sectional shape of the beam 621 shown in FIG. 6 is generally U-shaped, whereby the threaded receiver 656 engages between the upper portions of the side walls 626 of the beam 621. The side walls 626 are spaced apart at a constant pitch along the linear length of the beam 621, and the constant pitch is configured to mount the threaded receiver between the side walls, for example Fig.11 6. The 9.6 mm pitch shown in FIG. 6. A threaded receiver 656, such as a lug nut, can be welded to the upper surface of a metal strip, which is then placed within the U-shaped cross-section of the beam 621. The metal strip is then welded to the inner surface of the side wall 626, such as by positioning the lug nut in a desired position, thereby clamping the metal strip and lug nut in place by pushing the side walls toward each other, and welding along the upper edge of the metal strip. It is also contemplated that the threaded receiver can be other types of nuts or the like. The threaded receiver 656 is configured to threadably engage a fastener inserted into the lug nut through the fastener opening to secure at least one of the battery module or the tray cover to the cross member.

[0055] Likewise Fig.12 and 13 As shown, another example of a similar cross member 720 has a beam 721 that is reinforced by a top cap 742 that provides a threaded receiver 756 along an upper portion of the beam 720 . Fig.12 and 13 The beam 721 shown in FIG. Fig.11 , for example, having parallel side walls 726a extending upwardly from the lower wall 727 of the beam 721. Fig.12 ) and a symmetrical side wall 726b ( Fig.13 These different cross-sectional shapes can provide different bending strengths for the cross members and can make different battery modules suitable for the associated battery trays. Fig.12 and 13 The open cross-sectional shape of the beam 721 shown in FIG. 7 is generally U-shaped, whereby the threaded receiver 756 is engaged between the upper portions of the side walls 726 of the beam 721. The side walls 726 are spaced apart at a constant pitch along the linear length of the beam 721, and the constant pitch is configured to mount the threaded receiver 756 between the upper portions of the side walls 726a, 726b.

[0056] like Fig.12 and 13 As shown, the top cap 742 can be a metal strip joined to the upper portion of the side wall 726. The top cap 742 can be formed from a sheet material having a greater thickness than the sheet material forming the beam 721 in order to provide increased mass at the upper portion of the beam and increase the bending strength along the top cap 742. Fig.12 and 13As shown, the top cover 742 may have fastener openings arranged at certain intervals along the linear length of the top cover, so that before the top cover 742 is connected to the beam 721, a threaded receiver 756 (such as an M5 nut, etc.) can be assembled and attached to each fastener opening. Similarly, the threaded receiver can be other types of nuts or the like. Fig.12 and 13 As shown, the top cover 742 is disposed in a generally perpendicular orientation relative to the side walls 726 so that they can be attached together to form a T-joint on opposite sides of a threaded receiver 756 disposed along an upper portion of the beam 741. Thus, the top cover 742 can extend laterally beyond the upper edge of the side walls 726 to provide an externally visible weld 752 between the top cover 742 and the side walls 726a, 726b.

[0057] like Figures 14A to 14D As shown, another example of a cross member 820 has a beam 821 that is reinforced with a cap 842 along the upper portion of the cross member 820. The beam 821 has an open cross-sectional shape with parallel side walls 826 extending integrally upwardly along a lower wall 827 of the beam 821 so as to provide a generally U-shape. Figures 14A to 14D The top cover 842 is shown as a metal strip that is joined to the upper portion of the side wall 826. Specifically, as shown in FIG. Fig. 14C As shown, the planar extent of the top cap 842 is disposed in a generally perpendicular orientation relative to the side walls 826 such that the upper edges of the side walls 826 contact the top cap 842 to form a T-joint at each side wall 826. The top cap 842 extends laterally beyond the upper edges of the side walls 826 to provide an externally visible weld 852 between the top cap 842 and the side walls 826, such as by laser welding or resistance welding. The top cap 842 may be formed of a sheet material having a greater thickness than the sheet material forming the beam 841 to provide increased mass at the upper portion of the beam 821 and increased bending strength along the top cap 842.

[0058] Further Figures 14A to 14D As shown, the top cover 842 may have fastener openings 854 disposed at intervals along the linear length of the top cover 842, so that before the top cover 842 is connected to the beam 821, a threaded receiver 856 (e.g., a T-slot nut, etc.) may be assembled in a slot disposed along the upper edge of the side wall 826 and disposed below the fastener openings 854. Fig.14DAs shown, the side walls 826 may be slightly over-bent toward each other, and then the tool 860 may be inserted between the side walls 826 to keep the side walls 826 spaced apart at a spacing corresponding to the spacing of the T-slot nuts 856. With the side walls 826 spaced apart, the T-slot nuts 856 may then be inserted into the slots in the upper edges of the side walls 826. Optionally, the T-slot nuts 856 may be loaded onto the tool prior to installation of the tool between the side walls, provided that the installation of the tool also aligns the nuts on the beam, for example, at the slots. The top cap 842 may be disposed over the nuts and against the upper edges of the side walls 826 to form a T-joint at each side wall 826. The assembled beam 821, tool 860, nuts 856, and top cap 842 may then be held in place with at least some clamping force to form a weld 852 between the side walls 826 and the top cap 842. After welding, the tool 860 may be removed.

[0059] like Fig.15A and 15B As shown, an additional example of a cross member 920 having a closed cross-sectional shape is shown that is configured to support a cover of a battery module and / or battery tray at a top wall 922 of the beam. Fig.15A The top wall 922 of the beam shown in FIG. 1 is reinforced by the cross-sectional shape of the beam having an increased amount of material along the upper portion 930 of the beam. Specifically, Fig.15A The closed cross-sectional shape of the beam 921 shown has a roll-formed geometry that provides two adjacent tubular profiles with hollow openings separated by a common center wall of the beam that is generally parallel to the top wall 922. With this single beam profile, the tubular profile at the upper portion 930 has a smaller hollow interior area than the lower tubular profile, which provides increased bending strength along the top wall 922 at the upper portion of the beam.

[0060] Furthermore, if Fig.15A and 15B As shown, the threaded receiver 956 disposed at the upper portion 930 of the beam is shown as a pin nut extending transversely between the side walls 926 of the beam. The pin nut 956 has a threaded transverse opening 962 that is aligned with the fastener openings 954 disposed in the top wall 922 at certain intervals along the linear length of the beam. The aligned openings 954, 962 are configured to receive fasteners that secure at least one of the battery module or the tray cover to the cross member 920. The pin nut 956 can be welded or otherwise secured to the beam 921 to maintain the alignment of the openings 954, 962. Optionally, in addition to or as an alternative to securing the pin nut to the beam, the pin nut and / or the lateral opening in the side wall that receives the pin nut can include a non-circular structure that prevents the pin nut from rotating relative to the beam so that the alignment of the openings is maintained.

[0061] The cross-member disclosed herein can be incorporated into various applications of different structural components, such as the vehicle floor frame itself. The cross-member can also be designed to support and withstand different load conditions, such as for supporting certain axial load conditions. The cross-sectional geometry, material type selection, and material thickness within the cross-sectional profile of the cross-member component can be configured for this specific application and the desired load and performance characteristics of the beam, such as beam weight, beam load capacity, beam force deflection performance, and beam impact performance, etc.

[0062] For the purpose of this disclosure, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", "inner", "outer", "facing inwardly", "facing outwardly" and their derivatives shall be used in conjunction with Figure 1 The invention is oriented as described herein. However, it should be understood that the invention may take various alternative orientations unless expressly specified to the contrary. It should also be understood that the specific devices and methods shown in the drawings and described in this specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Therefore, specific dimensions and other physical characteristics associated with the embodiments disclosed herein should not be considered limiting unless the claims expressly state otherwise.

[0063] Without departing from the principles of the present invention, the specifically described embodiments may be changed and modified, and the principles of the present invention are limited only by the scope of the appended claims interpreted in accordance with the principles of patent law. The disclosure of the present invention has been described above in an illustrative manner, and it should be understood that the terms used are intended to have the nature of descriptive words rather than restrictive words. In accordance with the above teachings, many modifications and variations of the present disclosure are possible, and the present disclosure can be implemented in a manner different from that specifically described.

Claims

1. A cross member for a vehicle battery tray, the cross member comprising: a beam having a closed cross-sectional shape and having a top wall connected to parallel side walls along the length of the beam; a reinforcing cap comprising (i) a central section disposed along the top wall of the beam and (ii) legs extending from opposite sides of the central section and attached to the side walls of the beam, wherein the reinforcement top cover has a C-shaped cross-sectional shape, the C-shaped cross-sectional shape being defined by the central section and the legs extending from opposite sides of the central section; wherein the legs of the reinforced top cover each include a plurality of tabs welded to the side walls of the beam; and Wherein the top wall of the beam and the central section of the reinforcing cap have axially aligned fastener openings spaced apart along the length of the beam.

2. The cross member of claim 1 , further comprising a plurality of threaded receivers disposed at the aligned fastener openings and configured to engage fasteners inserted through the fastener openings to secure at least one of a battery module or a tray cover to the cross member.

3. A cross member according to claim 2, wherein: The upper portions of the side walls are spaced apart at a constant spacing along the length of the beam, the constant spacing being sized to fit the threaded receivers between the upper portions of the side walls.

4. The cross member according to claim 2, wherein: The plurality of threaded receivers are attached to at least one of the top wall or the side walls of the beam.

5. The cross member according to claim 1, wherein: Lower portions of the legs of the reinforcement cap are angled inwardly toward each other to provide a biasing force against the side walls of the beam.

6. The cross member according to claim 1, wherein: The reinforcing cap includes a bend radius between the central section and the legs that is smaller than a bend radius between the top wall and the side walls of the beam.

7. A cross-member according to any one of the preceding claims, wherein: The top wall and the side walls of the beam are formed together as a single integral piece, and wherein the top wall of the beam is disposed in a perpendicular orientation relative to the side walls of the beam.

8. A cross member for a vehicle battery tray, the cross member comprising: a beam having side walls spaced apart from one another along a length of the beam; a reinforcement top cover disposed along an upper portion of the beam and spanning between the side walls; wherein the reinforcement cap includes a series of tabs disposed along the length of the beam and extending downwardly from opposite sides of a central section of the reinforcement cap to attach to the side walls of the beam; wherein the reinforcement top cover comprises a C-shaped cross-sectional shape, wherein the C-shaped cross-sectional shape is defined by the central section and the tabs extending from the central section; wherein each of the series of tabs is individually welded to a corresponding side wall; and Wherein the reinforcement cap includes fastener openings extending through the central section of the reinforcement cap at intervals along the length of the beam.

9. A cross member according to claim 8, wherein: The beam includes a top wall connected between upper edges of the side walls and a bottom wall connected between lower edges of the side walls to together provide a closed cross-sectional shape extending along the length of the beam.

10. A cross member according to claim 9, wherein: The top wall includes a plurality of openings aligned with the fastener openings in the reinforced top cover, and wherein the plurality of openings in the top wall have a larger diameter than the fastener openings.

11. The cross member according to claim 9, wherein: The top wall, the side walls and the bottom wall of the beam are together a single integral piece roll formed from sheet metal.

12. A cross member according to claim 11, wherein: The thickness of the central section of the reinforcing cap is greater than the thickness of the sheet metal of the beam.

13. The cross member according to claim 9, wherein: The bend between the central section and the series of tabs has a smaller bend radius than the bend between the top wall and the side walls of the beam.

14. The cross member of claim 8, further comprising a plurality of threaded receivers disposed at the reinforcement cap, aligned with the fastener openings, and configured to threadably engage fasteners inserted through the fastener openings.

15. A cross member according to claim 14, wherein: The side walls are spaced apart from one another at a constant spacing along the length of the beam, and wherein the constant spacing between the side walls is sized to enable the plurality of threaded receivers to fit between the side walls.

16. A transverse member according to any one of claims 8 to 15, wherein: As the tabs of the reinforcement cap extend downwardly from the central section, the tabs of the reinforcement cap extend at an inward angle toward each other to bias the outer surface of the beam to provide stable welding conditions.

17. A cross member for a vehicle battery tray, the cross member comprising: a beam having side walls spaced apart from one another along a length of the beam; a reinforcement top cap including a top wall and legs extending from the top wall to define a cross-sectional shape having a C-shape, wherein the top wall is connected to upper edges of the side walls along the length of the beam, wherein the top wall has a greater thickness than the side walls, and wherein the top wall includes fastener openings disposed at intervals along the length of the beam; and A plurality of threaded receivers are attached to the top wall, aligned with the fastener openings, and configured to threadably engage fasteners inserted through the fastener openings to secure at least one of a battery module or a tray cover to the top wall.

18. A cross member according to claim 17, wherein: The plurality of threaded receivers are disposed between the side walls, and wherein the side walls are spaced apart at a constant pitch along the length of the beam, the constant pitch being substantially equal to a width of the plurality of threaded receivers, and wherein the plurality of threaded receivers comprise at least one of a pin nut, a slot nut, a self-tapping nut, or a weld nut.

19. The cross member according to claim 17, wherein: The top wall includes a metal strip welded to an upper portion of the side walls.

20. The cross member of claim 17, wherein: The reinforcing cap includes (i) a central section defining the top wall and (ii) the legs extending from opposite sides of the central section and attached to the side walls of the beam, wherein the legs each include a plurality of tabs welded to the side walls.

21. A cross member for a vehicle battery tray, the cross member comprising: a beam having side walls spaced apart from one another along a length of the beam; a reinforcing canopy comprising (i) a central section, and (ii) legs extending from opposite sides of the central section and attached to the side walls of the beam, wherein the reinforced top cover comprises a C-shaped cross-sectional shape defined by the central section and the legs extending from opposite sides of the central section; and a plurality of threaded receivers attached between upper edges of the side walls at intervals from one another along the length of the beam; and Wherein, the plurality of threaded receivers include internal threads configured to threadably engage a fastener inserted vertically downward to secure at least one of a battery module or a tray cover to the beam.

22. A cross member according to claim 21, wherein The side walls are spaced apart at a constant pitch along the length of the beam, the constant pitch being substantially equal to a width of the plurality of threaded receivers.

23. A cross member according to claim 21, wherein: The plurality of threaded receivers include at least one of a pin nut, a slot nut, a self-threading nut, or a weld nut.

24. The cross member of claim 21, wherein: The reinforcing cap is connected to the upper edge of the side wall along the length of the beam, and wherein the reinforcing cap has a greater thickness than the side wall.

25. A cross member according to claim 24, wherein The reinforcement cap includes fastener openings disposed at intervals along the length of the beam, the fastener openings being aligned with openings defined by the internal threads of the plurality of threaded receivers.

26. A cross member according to claim 24, wherein: The legs extend from opposite sides of the center section and are attached to the side walls of the beam, wherein the legs each include a plurality of tabs welded to the side walls.

27. The cross member of claim 21, wherein: The plurality of threaded receivers include slot nuts that engage slots disposed at intervals along the upper edge of the side wall.

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