Frame components and integrated battery structure

Abstract

A frame assembly for an automobile and a method for assembling the frame assembly. The frame assembly includes a battery housing that is at least partially integrated with the automobile frame. The frame includes longitudinal beams extending between front frame guides and rear frame guides. The battery housing includes two parts: a top cover integrated with the longitudinal beams and a base plate connected to the top cover or the longitudinal beams via a releasable connection. The base plate includes a connecting flange that includes at least one seal. When connected, at least one battery module is enclosed within the battery housing.

Description

[0001] Cross-references to related applications

[0002] This PCT international patent application claims the benefit of U.S. Provisional Patent Application No. 62 / 963,718, filed January 21, 2020, entitled “Frame And Integral Battery Structure For A Pickup And SUV”, and U.S. Provisional Patent Application No. 63 / 008,039, filed April 10, 2020, the entire disclosure of which is incorporated herein by reference. Background of the Invention 1. Technical Field

[0004] This invention relates to a battery housing and a method of assembling the battery housing. More specifically, this invention relates to a frame assembly and a method of assembling the frame assembly, the frame assembly including a battery housing that is at least partially integrated with the frame of a vehicle. 2. Background Technology

[0006] This section provides background information in connection with this disclosure, which is not necessarily prior art.

[0007] The automotive industry is a subject of ongoing efforts to reduce weight and improve fuel efficiency without compromising performance. This desire for improved fuel efficiency is driven by both economic and environmental motivations, and has fueled advancements in the internal components of automobiles, particularly electric vehicles, as evidenced by battery development. Electric vehicles encompass a range of technologies that rely on electricity to propel them. Some electric vehicles still rely primarily on fossil fuels and use electricity as a supporting energy source to improve efficiency. Others rely primarily or entirely on electricity for propulsion. Both electric vehicles and conventional vehicles that operate entirely on fossil fuels use batteries to store electrical energy, and while electricity is a more economical and environmentally friendly technology compared to complete reliance on fossil fuels, batteries are heavier, more expensive, and relatively more susceptible to damage compared to adjacent mechanical components. Therefore, battery packaging, especially within electric vehicles, requires numerous design considerations, including weight distribution, temperature regulation, and maintainability. Regarding maintainability, there is a growing need, particularly for electric vehicles with batteries in accessible configurations.

[0008] To meet the aforementioned minimum requirements, batteries have traditionally been encased in protective housings completely independent of the vehicle's frame structure. These conventional housings have employed metal-intensive (aluminum and / or steel) designs to meet strength and fire resistance requirements, but at the cost of increased weight, leakage performance, and susceptibility to corrosion. In addition to operational drawbacks, these conventional housings require significant energy, time, and financial investment to construct. For example, many conventional housings use aluminum extrusions welded to aluminum sheets, making it difficult to meet dimensional tolerances and often requiring further machining steps. Once constructed, conventional housings can be difficult to attach to the frame, provide additional weight, create weak points within the frame, and are susceptible to electrochemical corrosion, without adding any support structure beyond that required to support the battery.

[0009] Therefore, there is a continued expectation for further development and optimization of the shell construction and operation, so that the shell is unaffected by conventional defects and provides additional structural support for the frame. Summary of the Invention

[0010] The features and technical advantages of the invention have been outlined rather broadly above so that the following detailed description of the invention can be better understood. Further features and advantages of the invention that form the subject matter of the claims will be described below. It will be understood by those skilled in the art that the disclosed concepts and specific embodiments can be readily used as the basis for modifications or the design of other embodiments for achieving the same purpose of the invention. It will also be recognized by those skilled in the art that these equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended claims. This section provides a general overview of the disclosure and should not be construed as a complete and comprehensive enumeration of all objects, aspects, features, and advantages associated with the disclosure.

[0011] According to one aspect of this disclosure, a battery housing assembly for an automobile is provided. The battery housing includes a top cover sized to abut against and connect to the top surfaces of a pair of longitudinal beams of a provided frame. A base plate includes a plate portion for carrying at least one provided battery module. The base plate is sized to abut against and connect to the bottom surfaces of the pair of longitudinal beams of the provided frame.

[0012] According to another aspect of this disclosure, a frame assembly for an automobile is provided. The frame assembly includes a pair of front frame rails and a pair of rear frame rails. A top cover spaced the pair of front frame rails from the pair of rear frame rails. A base plate is releasably attached to the top cover to form a chamber for receiving at least one battery module.

[0013] Other application areas will become apparent from the descriptions provided herein. The descriptions and specific examples in this overview are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0014] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure. The inventive concept associated with this disclosure will be more readily understood by referring to the following description in conjunction with the accompanying drawings, in which:

[0015] Figure 1 It is a 3D diagram of a traditional car frame;

[0016] Figure 2 yes Figure 1 A cross-sectional view of the frame in which a prior art non-integrated battery casing is connected;

[0017] Figure 3 This is a top perspective view of a frame assembly for an automobile having an integrated battery housing according to a first embodiment of the present disclosure.

[0018] Figure 4 This is a bottom perspective view of the battery casing in the closed position according to the first embodiment;

[0019] Figure 5 This is a bottom perspective view of the battery casing in the open position according to the first embodiment;

[0020] Figure 6 This is another bottom perspective view of the battery casing in the open position according to the first embodiment;

[0021] Figure 7 This is a front perspective view of the battery casing in the open position according to the first embodiment;

[0022] Figure 8 It is a cross-sectional view of the battery housing and the frame assembly integrally formed therewith according to the first embodiment;

[0023] Figure 9 This is an exploded view of the battery casing according to the first embodiment;

[0024] Figure 10 This is an exploded view of the frame assembly according to the first embodiment, wherein the battery casing is partially assembled;

[0025] Figure 11 This is a top perspective view of a frame assembly for an automobile according to the second embodiment;

[0026] Figure 12 This is a bottom perspective view of the frame assembly according to the second embodiment;

[0027] Figure 13 This is a top perspective view of the frame assembly in the open position according to the second embodiment;

[0028] Figure 14 This is a bottom perspective view of the frame assembly in the open position according to the second embodiment;

[0029] Figure 15 This is a bottom perspective view of the top shell of the battery casing according to the second embodiment;

[0030] Figure 16 This is a top perspective view of a frame assembly for an automobile according to a third embodiment;

[0031] Figure 17 This is a bottom perspective view of the frame assembly according to the third embodiment;

[0032] Figure 18 This is a cross-sectional view of the frame assembly according to the third embodiment;

[0033] Figure 19 This is a top perspective view of a frame assembly for an automobile according to the fourth embodiment.

[0034] Figure 20 This is a bottom perspective view of the frame assembly according to the fourth embodiment;

[0035] Figure 21 This is a top perspective view of the frame assembly in the open position according to the fourth embodiment;

[0036] Figure 22 This is a bottom perspective view of the frame assembly in the open position according to the fourth embodiment;

[0037] Figure 23 It is a bottom-view perspective view of the top cover of a frame assembly including multiple crossbeams;

[0038] Figure 24 This is a cross-sectional view of the frame assembly according to the fourth embodiment;

[0039] Figure 25 This is a cross-sectional view of a longitudinal beam having an internal web and elements according to one aspect of this disclosure;

[0040] Figure 26 It is a cross-sectional view of a longitudinal beam connected to a front frame member or a rear frame member according to one aspect of this disclosure;

[0041] Figure 27 This is an enlarged view of the top portion of the battery casing according to one aspect of this disclosure;

[0042] Figure 28 This is an enlarged cross-sectional view of the top portion of the battery housing connected to the front frame member according to one aspect of this disclosure;

[0043] Figure 29 This is a cross-sectional view of a plurality of battery modules connected to a battery housing according to one aspect of this disclosure;

[0044] Figure 30 This is a cross-sectional view of a longitudinal beam with a constant thickness and an inner web, according to one aspect of this disclosure;

[0045] Figure 31 This is a cross-sectional view of a longitudinal beam with varying thickness and an inner web, according to one aspect of this disclosure;

[0046] Figure 32 This is a method for assembling framework components according to one aspect of this disclosure; and

[0047] Figure 33 This is a method for assembling framework components according to one aspect of this disclosure. Detailed Implementation

[0048] Example embodiments will now be described more fully with reference to the accompanying drawings. Generally, the embodiments relate to a frame assembly including a battery housing at least partially integrated with a vehicle frame, and methods of assembling the frame assembly. However, only example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that example embodiments may be implemented in many different forms, and that no single example embodiment should be construed as limiting the scope of this disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known techniques have not been described in detail.

[0049] First refer to Figure 1 This presents a conventional automobile frame 10. These automobile frames 10 typically include a first longitudinal beam 12 and a second longitudinal beam 14. The two longitudinal beams 12, 14 are separated by one or more transverse members 16. Figure 2The illustration shows a prior art non-integrated battery housing 15 releasably attached to a frame 10. More specifically, the non-integrated battery housing 15 is connected to the frame 10 via a bracket 18, which is connected to longitudinal beams 12, 14. The non-integrated battery housing 15 includes a top portion 17 and a bottom portion 19, which define a chamber 13 for enclosing one or more battery modules. During use, this prior art configuration requires the removal of the entire non-integrated battery housing 15 by detaching the bracket 18 from the longitudinal beams 12, 14 and removing the top portion 17 from the bottom portion 19. Because the non-integrated battery housing 15 must be robust enough to support the entire weight of the battery modules 13, it typically requires a relatively robust and heavy construction using materials that increase the weight of the longitudinal beams 12, 14 without providing any supporting structure.

[0050] Referring to the remaining figures, a frame assembly including a battery housing is provided, which is at least partially integrated with a vehicle frame. The frame assembly is designed to provide protection for the battery module, efficient weight distribution, easy access for maintenance, elimination of component redundancy by providing structural components that support both the frame and the battery module, streamlined manufacturing, and a lightweight and relatively simple construction for integration into existing and future vehicle configurations. The frame assembly described herein can be used in electric or semi-electric vehicles, such as sedans, pickup trucks, SUVs, semi-trucks, or other vehicles.

[0051] Figure 3This is a perspective top view of a frame assembly 20 according to a first embodiment, the frame assembly 20 having a battery housing at least partially integrated with the vehicle frame. Unless otherwise stated, the first embodiment may include structures, features, and elements of other embodiments described herein. The frame assembly 20 includes a frame 22 having a pair of longitudinal beams 24, 26 (or rails) each extending between a front frame rail 27 and a rear frame rail 29. The frame 22 also includes at least one transverse member 28, wherein the pair of longitudinal beams 24, 26 are spaced apart by at least one transverse member 28. The at least one transverse member 28 preferably includes a first transverse member 28 and a second transverse member 30. The spacing between the first transverse member 28 and the second transverse member 30 and the longitudinal beams 24, 26 provides location for an integrated battery housing 32 (i.e., a battery housing assembly). More specifically, the battery housing 32 includes a top cover 34 extending between the first transverse member 28 and the second transverse member 30 and the longitudinal beams 24, 26. The cover 34 includes a top surface 37 and a sidewall 39 extending along the peripheral edge of the top surface 37 to the flange 43. The cover 34 may (e.g., by welding to the flange 43) be permanently connected to the top portions of the first transverse member 28 and the second transverse member 30, as well as the top portions of the longitudinal beams 24, 26, or be integral with the top portions of the first transverse member 28 and the second transverse member 30, as well as the top portions of the longitudinal beams 24, 26, such that an upper recess 36 is formed on the lower side of the cover 34, between the longitudinal beams 24, 26 and the transverse members 28, 30. Figure 5 The connection between the cover 34 and the frame 22 can be achieved via a weld 31 formed by a welding method. Figure 8 The welding method can be, for example, metallic inert gas (MIG), friction stir welding (FSW), cold metal transfer (CMT), laser welding, mechanical fasteners such as bolts, or combinations thereof. The cover 34 includes a shaped reinforcement 35 extending perpendicular to the longitudinal beams 24, 26, i.e., in the lateral direction of the vehicle. The shaped reinforcement 35 provides support in both the lateral and longitudinal directions of the vehicle. The shaped reinforcement 35 may be thicker than the rest of the cover 34, or may be molded from the same thickness. Figure 4 As shown, the battery housing 32 also includes a substrate 38, which is releasably connected to the frame 22 (i.e., not integral with the frame 22) and is configured to hold at least one, but preferably multiple, battery modules 40. Figure 5 The battery module 40 can be linear, prismatic, cylindrical, or other variations. The substrate 38 is connected to the lower portions of the first transverse member 28 and the second transverse member 30, as well as the lower portions of the longitudinal beams 24 and 26, to form chamber 41. Figure 8This design completely encloses the battery module 40 within the chamber 41, protecting it from external environmental influences. At least one support beam 42, comprising multiple support beams, extends below the substrate 38 and connects to two longitudinal beams 24, 26 to provide support to the underside of the substrate 38. In addition to supporting the battery module 40, the support beam 42 also provides support to the frame 22 in the longitudinal and transverse directions of the vehicle. The chamber 41 is formed by a top cover 34 that completely encloses the battery module 40, the substrate 38, the longitudinal beams 24, 26, and the first transverse member 28 and the second transverse member 30.

[0052] As in Figure 5 and Figure 6 In the best-illustrative view, frame assembly 20 is shown in the open position. Base plate 38 includes plate 46 and a flange 52 extending around the peripheral edge of plate 46, the flange 52 being seated flush with the lower portions of the first transverse member 28 and the second transverse member 30, as well as the lower portions of the longitudinal beams 24, 26. The flange 52 can be connected to frame 22 via fasteners, clamps, etc. In some embodiments, the flange 52 can be releasably connected to frame 22 via fasteners 58 extending through flange 52 and into the lower portions of the first transverse member 28 and the second transverse member 30, and the lower portions of the longitudinal beams 24, 26. When base plate 38 is fastened to frame 22, one or more seals 60 ( Figure 7 It can extend along the entire flange 52 (inside the fastener 58) to provide a sealing contact. (As in...) Figure 4 As best illustrated, support beam 42 extends between opposite sides of flange 52 such that at least some of the fasteners 58 extend through support beam 42, plate 46, and longitudinal beams 24, 26. In some embodiments, support beam 42 may be positioned adjacent to each of transverse members 28, 30 for receiving fasteners 58 passing through support beam 42.

[0053] like Figure 7 As best illustrated, one of the transverse members 28, 30 and / or longitudinal beams 22, 24 may include at least one opening 68 for connecting the battery module to the vehicle's electrical system. The opening 68 may also be located in any other structure of the battery housing 32 and frame 22, allowing the battery module 40 to be accessed without removing the base plate 38.

[0054] In use, the battery module 40 is seated on top of the plate 46 of the substrate 38. The substrate 38 is then positioned to contact the frame 22, such that the battery module 40 is positioned within the upper recess 36. More specifically, the flange 52 connects to the lower portions of the first transverse member 28 and the second transverse member 30, as well as the lower portions of the longitudinal beams 24 and 26, and is connected to the lower portions of the first transverse member 28 and the second transverse member 30, as well as the lower portions of the longitudinal beams 24 and 26, by fasteners 58. Thus, the battery module 40 is completely enclosed between the substrate 38, the top cover 34, the side portions of the longitudinal beams 24 and 26, and the side portions of the transverse members 28 and 30. In addition to enclosing and supporting the battery module 40, the top cover 34, the longitudinal beams 24 and 26, the transverse members 28 and 30, the substrate 38, and the support beams 42 all provide strength to the frame 22 as an additional function.

[0055] Figure 8 The diagram illustrates a cross-section of vertically stacked battery modules 40 within a frame assembly 20. Each of the longitudinal beams 24, 26 may include a hollow, linear housing and include at least one internal structural web 74 for additional support and forming of the respective units. In some embodiments, seven different units are present. At least one structural web 74 extends within the hollow longitudinal beams 24, 26 in both the lateral and longitudinal directions of the vehicle. In the lateral direction, at least one structural web 74 includes a central segment 76 extending between a pair of trusses 78. Each truss 78 includes two segments 79 extending at an angle to the central segment 76. Preferably, each segment 79 extends at an opposite but equal angle to another corresponding segment 79 on the same side of the central segment 76. In the longitudinal direction, the structural web 74 may extend the entire length of the longitudinal beams 24, 26. At least one structural web 74 may include multiple structural webs 74 of the same or different shapes.

[0056] Continue to refer to Figure 8 The battery modules 40 are stacked vertically and include a lower layer 40A and an upper layer 40B. A plate 46 supports the lower layer 40A, and a panel 80 supports the upper layer 40B. The panel 80 is connected to the plate 46 via connecting bolts 82. At least some of the bolts 82 extend through the support beam 42, the plate 46, and the panel 80.

[0057] Figure 9 and Figure 10 An exploded perspective view of the frame assembly 20 and the battery housing 32 is provided. The transverse members 28 and 30 may each include a U-shaped configuration with a flat surface 84 and a pair of angled legs 86. It should be understood that the U-shape can alternatively be straight, C-shaped, S-shaped, or any other shape. The battery modules 40 are arranged in rows 44 (…). Figure 10A series of lower supports 88 sit on top of and are connected to the plate 46, separating rows 44 in the lower layer 40B and supporting the panel 80. Similarly, a series of upper supports 90 sit on top of and are connected to the panel 80, separating rows 44 in the upper layer 40A. The lower supports 88 and upper supports 90 can be stacked vertically on top of each other and separated by the panel 80. Similarly, support beam 42 can also be stacked vertically with supports 88 and 90. Therefore, support beam 42 and supports 88 and 90 can be stacked on top of each other to form a stacked support structure. Support beam 42, lower supports 88, and upper supports 90 can also be connected via fasteners. Figure 10 This is an exploded view of frame assembly 20, in which the battery housing 32 is partially assembled. Front frame rail 27 and rear frame rail 29 extend from opposite sides of each longitudinal beam 24, 26.

[0058] Figures 11 to 15 A second embodiment of the framework component 120 is provided. Unless otherwise stated, the second embodiment may include the structures, features, and elements of other embodiments described herein. First refer to... Figure 11 and Figure 12 The frame assembly 120 includes a pair of front frame rails 127 and a pair of rear frame rails 129 spaced apart by the battery housing 132. The battery housing includes a top cover 134 that is directly and permanently connected to (integrated with) the front rails 127 and the rear rails 129. The top cover 134 may be generally rectangular and similar in size to the aforementioned top cover 34. The top cover 134 may include or primarily include a stamped sheet of metal material.

[0059] The top cover 134 includes a top portion 136 flush with the upper surfaces of the front rail 127 and the rear rail 129. A pair of longitudinal sidewalls 138 and transverse sidewalls 139 extend downward from the top portion 136 to a connecting flange 140. The sidewalls 138 and the top portion 136 define an upper recess 142 in which a series of battery modules 144 can be at least partially enclosed. The top cover 134 can be connected to the front rail 127 and the rear rails 127, 129 via fasteners, welding, adhesives, or two portions that have been stamped or otherwise formed from a single piece of material (e.g., stamping). Figure 13As best shown, the top portion 136 of the cover 134 includes a raised surface 146 adjacent to and connected to one of the front guide rails 127 and the rear guide rail 129, and a lower surface 148 adjacent to and connected to the other of the front guide rails 127 and the rear guide rail 129. In the example shown, the raised surface 146 is adjacent to and connected to the rear guide rail 129. The raised surface 146 is located at a height higher than the lower surface 148 and is connected to the lower surface 148 by an angled transition surface 150. The raised surface 146 is sized to accommodate at least one row of vertically stacked battery modules 144.

[0060] like Figure 14 and Figure 15 As best illustrated, at least one reinforcing member 152 extends through an upper recess 142 between transverse sidewalls 139 and parallel to the longitudinal sidewalls 138. In the illustrated example, at least one reinforcing member 152 comprises a series of longitudinal reinforcing members extending parallel to the front guide rail 127 and the rear guide rail 129. More specifically, at least one reinforcing member 152 comprises a pair of longitudinal reinforcing members 152 positioned along and contacting opposing longitudinal sidewalls 138 that may be formed by longitudinal beams 122, 124. The pair of longitudinal reinforcing members 152 extends between the respective front guide rail 127 and the rear guide rail 129 and may be integral with, for example, the transverse sidewalls 139 or otherwise directly connected to the transverse sidewalls 139 via the sidewalls 138. The configuration of the pair of longitudinal reinforcing members 152 provides a function similar to that of the longitudinal beams 24, 26 of the frame in the first embodiment. At least one reinforcing member 152 may also include an intermediate reinforcing member 154 ( Figure 15 The intermediate reinforcing members 154 extend between and are parallel to the longitudinal reinforcing members 152 for additional structural functions. Each reinforcing member 152, 154 may conform to the profile of the top portion 136. The intermediate reinforcing members 154 are spaced apart such that they are located in column 156 of the battery module 144. Figure 13 The space between them, and at least partially absorbs the loads before and after.

[0061] Now refer to Figures 12 to 14The battery housing 132 also includes a substrate 158 that supports the battery module 144 and forms the lower half of the battery housing 132. The substrate 158 includes a plate 160 on which the battery module 144 is seated, and a lip 163 extends upward from the plate 160 to the flange 164. The plate 160 includes a lower surface 166 and an upper surface 168, wherein the lower surface 166 is located at a lower height than the upper surface 168. In use, the lower surface 166 is deeper to accommodate a row of vertically stacked battery modules 144. At least one support beam 170 is located on the outer surface of the substrate 158. The at least one support beam 170 includes a pair of opposing, spaced-apart longitudinal support beams 170 that conform to the contours of the plate 160 (e.g., the lower surface 166 and the upper surface 168) and provide a function similar to the longitudinal beams 24, 26 of the frame in the first embodiment. At least one support beam 170 may further include a series of transverse support beams 172 extending between the longitudinal support beams 170. This series of transverse support beams 172 may include at least one transverse support beam 172 extending across the lower surface 166 and at least one transverse support beam 172 extending across the upper surface 168. In some embodiments, there are more transverse support beams 172 positioned across the upper surface 168 than transverse support beams 172 positioned across the lower surface 166. Therefore, at least one support beam 170 serves to hold the weight of the battery while also providing substantial structural support for the frame. The transverse support beams 172 may be centrally located below each row of battery modules 144.

[0062] During assembly, the flange 140 on the top cover 134 contacts the flange 164 on the base plate 158, and the flanges 140, 164 can be connected by fasteners, welding, adhesives, or connecting features, or combinations thereof. Seal 174 ( Figure 15 The corresponding flanges 140 and 164 can be located between the respective flanges 140 and 164 to completely seal the housing 132, thus protecting the battery module 144 from the external environment. In the illustrated embodiment, the respective flanges 140 and 164 are fastened together, allowing the substrate 158 to be removed from the top cover 134 for maintenance. When the flanges 140 and 164 are aligned, the lower surface 166 of the substrate 158 aligns with the raised surface 146 of the top cover 134, thus completely enclosing the vertically stacked battery modules 144. Similar openings and connection ports can be incorporated into the sidewalls 138, the longitudinal reinforcement 152, or a combination thereof.

[0063] Figures 16 to 18A third embodiment of the frame assembly 220 is provided. Unless otherwise stated, the third embodiment may include the structures, features, and elements of other embodiments described herein. The frame assembly 220 includes a pair of longitudinal beams 222, 224 extending between a pair of front frame rails 227 and a pair of rear frame rails 229 spaced apart by the battery housing 232. The battery housing includes a cover 234 that is directly and permanently connected to (and integral with) the front rails 227 and the rear rails 229. The cover 234 may be generally rectangular and flat. The cover 234 may include or primarily include a stamped sheet of metal material.

[0064] The top cover 234 includes a flat top surface 236. At least one sidewall may include a pair of longitudinal sidewalls 238 and transverse sidewalls 239 extending downward from the top surface 236 to the connecting flange 240. The sidewalls 238, transverse sidewalls 239, and top surface 236 define an upper recess 242 in which a series of battery modules 244 may be at least partially enclosed. The top cover 234 may be attached to the front guide rail 227 and the rear guide rail 229 via fasteners, welding, adhesives, two parts stamped from a single blank, or a combination thereof.

[0065] like Figure 16 and Figure 17 As best illustrated, at least one reinforcing member 252 extends through an upper recess 242 between the transverse sidewalls 239 and is parallel to the longitudinal sidewalls 238. In the illustrated example, at least one reinforcing member 252 comprises a series of longitudinal reinforcing members extending parallel to the longitudinal sidewalls 238. More specifically, at least one reinforcing member 252 comprises a pair of longitudinal reinforcing members 252 positioned in a spaced-apart relationship with opposing longitudinal sidewalls 238. The pair of longitudinal reinforcing members 252 extends between corresponding front guide rails 227 and rear guide rails 229 and can be directly connected to the front guide rails 227 and rear guide rails 229 via the sidewalls 238, or connected via intermediate transverse sidewalls 239. The configuration of the pair of longitudinal reinforcing members 252 provides a function similar to the longitudinal beams described herein. At least one reinforcing member 252 may also include transverse reinforcing members 254 that extend between the longitudinal sidewalls 238 and are parallel to the transverse sidewalls 239 for additional structural functionality. Each reinforcing member 252, 254 conforms to the profile of the top surface 236. The longitudinal reinforcing members 254 are spaced apart such that they are positioned in columns 256 of the battery module 244. Figure 16 The space between the reinforcing members 254 is used to absorb at least part of the loads from the front and rear of the battery module 244. Similarly, the reinforcing members 254 are spaced apart such that they are placed in rows 276 of the battery module 244. Figure 16It is located in the space between the two sides and absorbs at least part of the load on the left and right sides of the battery module 244.

[0066] The battery housing 232 also includes a substrate 258 that supports the battery module 244 and forms the lower half of the battery housing 232. The substrate 258 includes a plate 260 on which the battery module 244 is seated, and a lip 262 extends upward from the peripheral edge of the plate 260 to a flange 264.

[0067] like Figure 18 As best illustrated, at least one support beam 270 ( Figure 18 The battery module 244 is located on the inner surface 241 of the substrate 258. At least one support beam 270 includes a pair of opposing, spaced-apart outer longitudinal support beams 270 adjacent to the longitudinal sidewall 238, which provide a function similar to the longitudinal beams described herein. The at least one support beam 270 may also include a central longitudinal support beam 271, which is inwardly spaced and parallel to the outer longitudinal support beams 270. Thus, the at least one support beam 270 serves to hold the weight of the battery while also providing substantial structural support for the frame. In the event of water ingress into the battery housing 232, the at least one support beam 270 also spaces the battery module 244 from the plate 260. The battery modules 244 can be stacked vertically on top of each other in the bottom row 245 and the top row 247. The bottom row 245 includes outer support beams 280, each outer support beam 280 including a connecting flange 282 corresponding to a connecting flange 273 in the substrate 258. The lower plate 284 extends between the outer support beams 280 and rests on top of the outer longitudinal support beams 270 and the inner longitudinal support beams 271. The lower plate 284 may include orifices for drainage. The bottom row 245 also includes an intermediate support beam 286 positioned between the columns 256, which extends from the lower plate 284 above the top surface of the bottom row 245.

[0068] Continue to refer to Figure 18 The top row 247 includes a top plate 290 that rests on top of the outer support beam 280 and the intermediate support beam 286. A reinforcing member 252 contacts the upper surface of the top plate 290 adjacent to the intermediate support beam 286, which contacts the bottom surface of the top plate 290. The top cover 234 may include reinforcing material 294 located at opposing corners. The reinforcing material 294 may include a welded plate or other material attached to it. A seal 260 may be located between the top cover 234 and the base plate 258. Corresponding flanges are fastened together, allowing the base plate 258 to be removed from the top cover 234 for maintenance.

[0069] Figure 19 and Figure 20A fourth embodiment of the frame assembly 320 is provided. Unless otherwise stated, the fourth embodiment may include the structures, features, and elements of other embodiments described herein. The frame assembly 320 includes a battery housing 332 that is at least partially integral with the vehicle frame 322. The frame 322 includes a pair of longitudinal beams 324, 326 (or rails) each extending between a front frame rail 327 and a rear frame rail 329. The frame 322 also includes at least one transverse member 328, wherein the pair of longitudinal beams 324, 326 are spaced apart by the at least one transverse member 328. The at least one transverse member may include a first transverse member 328 and a second transverse member 330. The spacing between the first transverse member 328 and the second transverse member 330 and the longitudinal beams 324, 326 provides location for the battery housing 332. More specifically, the battery housing 332 includes a top cover 334 that extends between the first transverse member 328 and the second transverse member 330 and the longitudinal beams 324 and 326, and is protected by the first transverse member 328, the second transverse member 330, and the longitudinal beams 324 and 326. The top cover 334 is permanently connected to or integral with the top portions of the first transverse member 328 and the second transverse member 330 and the longitudinal beams 324 and 326, such that an upper recess 336 is formed along the lower side of the top cover 334. Figure 22 The top cover 334 includes a molded support 335, which may be formed in a cross or X shape to provide support for the longitudinal beams 324, 326 in both the lateral (i.e., vehicle transverse) and longitudinal (i.e., front-rear) directions. The molded support 335 may be thicker than the rest of the top cover 334, or may be formed as a protrusion of the same thickness. The battery housing 332 also includes a base plate 338, which may be releasably connected to or not integral with the frame 322, and the base plate 338 is formed to hold at least one, but preferably multiple, battery modules 340. Figure 22 The substrate 338 is connected to the lower portions of the first transverse member 328 and the second transverse member 330, as well as the lower portions of the longitudinal beams 324 and 326, to form a chamber 341, such that the battery module 340 is completely enclosed within the chamber 341 and protected from the external environment. At least one support beam 342, including a first support beam 342 and a second support beam 344, extends below the substrate 338 and connects to the two longitudinal beams 324 and 326 to provide support to the lower side of the substrate 338. Therefore, the chamber 341 is formed by the top cover 334 that completely encloses the battery module 340, the substrate 338, the longitudinal beams 324 and 326, and the first transverse member 328 and the second transverse member 330.

[0070] As in Figure 21and Figure 22 In the best-illustrative view, frame assembly 320 is shown in the open position. Base plate 338 includes plate 346 and a lip 348 extending around the peripheral edge of plate 346 forming a lower recess 350. Sidewalls extend from plate 346 to flange 352, which is seated flush with the lower portions of the first transverse member 328 and the second transverse member 330, as well as the lower portions of longitudinal beams 324, 326. Flange 352 may be attached to frame 322 via welding, fasteners, adhesives, or a combination thereof. In some embodiments, flange 352 is releasably attached to the first support beam 342 and the second support beam 344 with fasteners 358 extending through flange 352 and into the lower portions of the first transverse member 328 and the second transverse member 330, as well as the lower portions of longitudinal beams 324, 326. When base plate 338 is fastened to frame 322, one or more seals 360 ( Figure 24 It can extend along flange 352 to provide a sealing contact. For example... Figure 22 As best illustrated, the first support beam 342 and the second support beam 344 each include a flat section 362 corresponding to the plate 346 of the substrate 338, a pair of vertical sections 364 corresponding to the lip 348 of the substrate 338, and a lip section 366 corresponding to the flange 352 of the substrate 338. The lip section 348 includes a series of orifices 368 and a series of electrical connection ports 370 extending through the orifices 368 for connecting the battery module to the automotive electrical system.

[0071] like Figure 22 and Figure 23 As best illustrated, at least one reinforcing member 372 extends between longitudinal beams 324 and 326 and connects along the upper cover 334. The reinforcing member 372 extends into the upper recess 336. The reinforcing members 372 can be spaced apart such that they can be located in rows 376 of the battery module 340. Figure 21 The space 374 between the two sides is used to absorb left and right loads. The tubular transverse member 378 may also be included between the rear frame guide rails 329.

[0072] In use, the battery module 340 is at least partially seated within the lower recess 350 of the substrate 338. The substrate 338 is then positioned to contact the frame 322 such that the battery module 340 is also at least partially positioned within the upper recess 336 and spaced apart in rows 376 between the reinforcing members 372. More specifically, the flange 352 of the lip 348 is connected to the lower portions of the first transverse member 328 and the second transverse member 330, as well as the lower portions of the longitudinal beams 324 and 326, and is connected to the lower portions of the first transverse member 328 and the second transverse member 330, as well as the lower portions of the longitudinal beams 324 and 326, by fasteners 358. At least one support beam 342 is then positioned below the substrate 338 and contacts and is connected to the longitudinal beams 324 and 326. The battery module 340 is then completely enclosed between the base plate 338, the top cover 334, the side portions of the longitudinal beams 324 and 326, and the side portions of the transverse members 328 and 330. In addition to enclosing and supporting the battery module 340, the top cover 334, longitudinal beams 324 and 326, transverse members 328 and 330, and reinforcing member 372 provide strength to the frame 322 as additional functions. Figure 24 The diagram shows a cross-section of the vertically stacked battery modules 340 in the frame assembly 320.

[0073] Figure 25 Enlarged cross-sectional views of longitudinal beams 424 and 426 and structural web 474 are provided. The construction of longitudinal beams 424 and 426 may include extrusion processes, stamping processes including hot stamping, roll forming, casting, etc. The construction of longitudinal beams 424 and 426 can be selected based on the materials used and the desired shape and thickness. The construction of longitudinal beams may include those described herein, transverse members, and other supporting structures.

[0074] Figure 26Another enlarged cross-sectional view of the longitudinal beams 424, 426 in the plane connecting to the front frame guide rail 427 or the rear frame guide rail 429 is provided. As illustrated, the guide rails 427, 429 may have a similar but slightly larger cross-sectional shape to the longitudinal beams 424, 426, such that the longitudinal beams 424, 426 can be at least partially inserted into the guide rails 427, 429. The connection between the guide rails 427, 429 and the longitudinal beams 424, 426 may include one or more fasteners 492 extending through one of the guide rails 427, 429 and one of the longitudinal beams 424, 426 to a flange nut 494, at which the fasteners 492 can be tightened. A sleeve 496 extends across the hollow longitudinal beams 424, 426. Guide rails 427 and 429 may include portions separated by a pair of opposing C-shaped segments 498, which can be deployed on corresponding longitudinal beams 424 and 426 before being clamped by fasteners 492. In some embodiments, segments 498 may be connected to each other before the longitudinal beams 424 and 426 are introduced. The portions of guide rails 427 and 429 that overlap with longitudinal beams 424 and 426 may be coated to prevent electrochemical corrosion. A gap G1 may be located between guide rails 427 and 429 and longitudinal beams 424 and 426 in the lateral direction of the vehicle. Gap G1 is adjusted to meet coating requirements and may be less than 3 mm, less than 2 mm, less than 1 mm, less than 0.70 mm, or less than 0.50 mm. A gap G2 may be located between guide rails 427 and 429 and longitudinal beams 424 and 426 in the vertical direction. Gap G2 is selected to meet coating requirements, and gap G2 can be larger than gap G1, for example, greater than 2 mm, greater than 3 mm, or greater than 3.02 mm. Gap G2 can also be less than 3 mm, less than 2 mm, less than 1 mm, less than 0.70 mm, or less than 0.50 mm. The selection of gaps G1 and G2 can further consider tolerance requirements. The coating may include a non-metallic coating to prevent electrochemical corrosion.

[0075] Figure 27 This is an enlarged view of the cover 434 extending above one of the transverse members 428 and 430 and one of the longitudinal beams 424 and 426. Figure 28 It is intercepted along lines X and X1. Figure 27 The cross-sectional view is shown. During construction, the transverse members 428 and 430 can be connected to the longitudinal beams 424 and 426 via fasteners, welding, etc. The upper surfaces of the transverse members 428 and 430 and the longitudinal beams 424 and 426 are then machined before the cover 434 is welded to the upper surface.

[0076] Figure 29This is an enlarged cross-sectional view of the upper layer 440A and lower layer 440B of the battery module 440 connected to the battery housing 432. Bolts 482 may extend through the support beam 442, plate 446, and panel 480. Bolt 482 includes an upper sleeve 410 located between plate 446 and panel 480 and a lower sleeve 402 extending across the support beam 442. The support beam 442, lower bracket 488, and upper bracket 490 include a structural web 404 and may be formed by an extrusion process. Spacer blocks 406 may be located between the lower bracket 488 and upper bracket 490 to prevent compression between plate 446 and panel 480. In some embodiments, there are a total of 12 battery modules. Fasteners may be located in the spacer blocks 406 for further connection between the lower bracket 488 and upper bracket 490.

[0077] Figure 30 This is a cross-sectional view of one embodiment of longitudinal beams 424, 426 having a constant thickness or specification. More specifically, longitudinal beams 424, 426 include outer shells 424A, 426A having a thickness of approximately 3 mm, and structural web 474A having a thickness of approximately 2.5 mm. However, it should be understood that the thickness can be selected to optimize for specific performance requirements.

[0078] Figure 31 This is a cross-sectional view of another embodiment of the longitudinal beams 424, 426 with completely optimized thicknesses or specifications. More specifically, the outer shells 424B, 426B of the longitudinal beams 424, 426 have a thickness of approximately 2 mm, wherein the portion in the transverse direction of the interior vehicle has a thicker section, particularly in the lower inner corner, where the thickness reaches approximately 4 mm. The structural web 474B also has a thickness of approximately 2 mm, wherein the truss 78 includes a thicker portion in the transverse direction of the interior vehicle.

[0079] It should be understood that the longitudinal beams 424, 426 and / or the web configuration 474 may also adopt the same shape as the bumper assembly and / or internal web disclosed in U.S. Patent Application No. 2018 / 02252416A1 entitled "BumperBeam," which is incorporated herein by reference in its entirety. Furthermore, it should be understood that in Figures 25 to 31 The longitudinal beams 424, 426, web member 474 and / or the connection configuration between the longitudinal beams 424, 426 and the guide rails 427, 429 presented herein can be used in other embodiments described herein and for a variety of other uses, such as other automotive components included in U.S. Application No. 2018 / 02252416A1.

[0080] In one arrangement, the front frame guide rail 427 and the rear frame guide rail 429 can be formed of steel or aluminum (e.g., steel), and the longitudinal beams 424, 426 and the transverse members 428, 430 can also be formed of steel or aluminum (e.g., aluminum). The longitudinal beams 424, 426 and the transverse members 428, 430 can be formed by extrusion or other methods. The top cover 434 and the substrate 438 can also be formed of steel or aluminum (e.g., aluminum) and shaped via stamping processes or other methods. This example configuration has resulted in a weight reduction of approximately 44.8% for conventional battery casings.

[0081] Based on the above components, a method 500 for assembling framework components is provided. Method 500 in... Figure 32 The diagram illustrates and includes a vehicle frame 502 having a pair of longitudinal beams and at least two transverse members, each of the longitudinal beams extending between a front frame guide and a rear frame guide, and the at least two transverse members spaced apart from the longitudinal beams. Method 500 continues by attaching a top cover (e.g., a top cover) 504 to a top surface of the frame (e.g., connected to the top surfaces of the longitudinal beams and transverse members) such that the top cover extends between the longitudinal beams and transverse members. The length of the longitudinal beams can be increased or decreased to encapsulate the desired battery module. Therefore, mating components can be updated as needed for assembly. Method 500 continues by providing a substrate 506 that carries and at least partially encloses at least one battery module, and releasably attaching the substrate 508 to a bottom surface of the frame (e.g., connected to the bottom surfaces of the longitudinal beams and transverse members) such that the substrate extends between the longitudinal beams and transverse members. Step 508 may also include completely enclosing 510 at least one battery module using a combination of the top cover, longitudinal beams, transverse beams, and substrate.

[0082] Based on the above components, a method 600 for forming a framework component is provided. Method 600 in... Figure 33 The diagram illustrates a method 600, which includes providing a pair of front and rear guide rails at 602. At 604, method 600 includes connecting a battery housing to the front and rear guide rails. Step 604 of connecting the battery housing may include attaching a top cover (e.g., a top cover) including at least one longitudinal member 606 between the front and rear guide rails to connect the front and rear guide rails and thus provide structural support for the frame and battery housing. Next, at 608, method 600 includes releasably connecting a substrate holding at least one battery module to the top cover. Step 610 may also include step 612, which includes completely enclosing at least one battery module between the top cover and the substrate.

[0083] It should be understood that the foregoing description of the embodiments is provided for illustrative purposes. In other words, this disclosure is not intended to be exhaustive or limiting. Elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in selected embodiments, even if not specifically shown or described. Elements or features of a particular embodiment may also vary in many ways. These variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A battery housing assembly for an automobile, comprising: A pair of longitudinal beams, the pair of longitudinal beams extending from a first end to a second end in a spaced-apart relationship to define a top surface and an inner surface extending between the first end and the second end of each longitudinal beam, wherein the inner surfaces of each longitudinal beam are arranged to face each other. A first transverse member and a second transverse member, each being generally U-shaped and connected adjacent to a corresponding one of the first end or the second end to the inner surface of each longitudinal beam; A top cover is configured to abut and connect with the top surface of each of the longitudinal beams to collectively define a chamber defined by the inner surface of each longitudinal beam, the first transverse member and the second transverse member, and the top cover. A substrate, the substrate including a plate portion for supporting at least one battery module; and The substrate is configured to abut and connect with the bottom surfaces of the pair of longitudinal beams to house the at least one battery module in the room, and wherein the substrate includes at least one reinforcing member extending between the pair of longitudinal beams.

2. The battery housing assembly according to claim 1, wherein, The top cover includes a connecting surface for permanently connecting the top cover to the pair of longitudinal beams.

3. The battery housing assembly according to claim 2, wherein, The substrate includes a connection surface for releasably connecting the substrate to the pair of longitudinal beams.

4. The battery housing assembly according to claim 3, wherein, The substrate includes a seal positioned inward from the connecting surface for sealing the substrate to the pair of longitudinal beams.

5. The battery housing assembly according to claim 4, wherein, The upper cover is further configured to abut and connect with the top surfaces of the first transverse member and the second transverse member.

6. The battery housing assembly according to claim 5, wherein, The substrate is further configured to abut and connect with the bottom surfaces of the first transverse member and the second transverse member.

7. The battery housing assembly according to claim 1, wherein, The at least one reinforcing member includes at least one aperture for each of the longitudinal beams, wherein the aperture is configured to receive a fastener for releasably connecting the at least one reinforcing member to the pair of longitudinal beams.

8. The battery housing assembly according to claim 1, wherein, The upper cover is spaced apart from the base plate by the longitudinal beam.

9. The battery housing assembly according to claim 1, wherein, The substrate includes a lip extending upward from the peripheral edge of the substrate.

10. The battery housing assembly according to claim 9, wherein, The lip defines at least one aperture for receiving the electrical port of the at least one battery module.

11. The battery housing assembly according to claim 1, wherein, Each of the first transverse member and the second transverse member has a flat surface and a pair of angled legs that extend outward from the flat surface and are each connected to a corresponding inner surface of the longitudinal beam.

12. The battery housing assembly of claim 1, further comprising a front frame guide rail and a rear frame guide rail, the front frame guide rail being connected to a first end of the longitudinal beam and the rear frame guide rail being connected to a second end of the longitudinal beam.

13. The battery housing assembly according to claim 12, wherein, The pair of longitudinal beams each define an outer surface extending between the first end and the second end and in the opposite relationship to the inner surface, wherein the front frame guide is configured to cover the portion of the outer surface of the longitudinal beam adjacent to the first end, and the rear frame guide is configured to cover the portion of the outer surface of the longitudinal beam adjacent to the second end.

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