Vehicle chassis shear panel

Abstract

The present disclosure provides a vehicle including a battery system arranged in a central region. The battery system includes a corner that corresponds to a corner of an end of the vehicle, and a respective chassis component is arranged at each corner. A respective shear bracket is attached to the vehicle frame and to the respective chassis component. The shear bracket is configured to absorb energy from the chassis component during a deceleration event. The chassis component can include a knuckle configured to interface with the frame at an interface at which the shear bracket can be added. Each shear bracket is formed of a metal, such as sheet metal, and includes mounting features, such as holes or bolts for attachment to the frame. The shear bracket is configured to limit intrusion of the chassis component into the battery system by absorbing energy. Bolts or fasteners that attach the chassis component to the frame are reinforced by the shear bracket.

Description

[0001] introduction

[0002] This disclosure relates to a shear bracket for preventing or limiting the intrusion of chassis components or assemblies into a battery pack. Chassis components intruding into the battery system due to malfunction or displacement may cause damage during a collision event. The shear bracket is configured to absorb energy from the event to protect the battery system. Summary of the Invention

[0003] This disclosure relates to a shear bracket for preventing or limiting the intrusion of chassis components or assemblies into a battery pack. The shear bracket is attached to the vehicle frame and at least one chassis component, which may itself be an assembly, to resist displacement that hardens the joint between the chassis component and the frame element.

[0004] In some embodiments, this disclosure relates to a vehicle component including a shear bracket. The shear bracket is attached to chassis components and frame elements and is configured to absorb energy associated with deceleration events from the chassis components to reduce energy transfer to the battery system.

[0005] In some embodiments, the component may further include at least one frame element configured to provide structural rigidity to the vehicle and a chassis component configured to be attached to the frame element. In some embodiments, the battery system is attached to the frame element, and a shear bracket is configured to absorb energy to maintain a gap between the battery system and the chassis component.

[0006] In some embodiments, the vehicle includes components, wheels, a passenger compartment, and a battery system. The shear bracket is configured to attach to at least one frame element in a first lateral position and a second lateral position. The shear bracket is also attached to a chassis component and is configured to provide anti-displacement stiffness to the chassis component during an event. In some embodiments, the chassis component forms a gap with the battery system, and the shear bracket is configured to provide stiffness against intrusion of the chassis component into the battery system. In some embodiments, the chassis component includes a steering knuckle, and the shear bracket in the second lateral position is bolted to a mounting feature on a frame element of the vehicle frame via a steering knuckle bolt to reduce energy transfer to the battery system. For example, the chassis component may be a cast metal component having a steering knuckle configured to be bolted to a frame or a frame element thereof.

[0007] In some embodiments, the shear bracket includes a first hole configured to align with a first lateral position and a second hole configured to align with a second lateral position. For illustration, the shear bracket is configured to absorb energy between the first and second lateral positions. In some embodiments, the shear bracket is formed of or otherwise comprises a sheet metal material configured to provide anti-displacement stiffness of the chassis component toward the first lateral position, which further reduces the energy transferred to the battery system. In some embodiments, the shear bracket is configured to snap between the first and second positions under loading from an event.

[0008] In some embodiments, the frame element includes a first hole disposed at a first lateral position and a second hole disposed at a second lateral position. In some embodiments, the assembly includes a first bolt and a second bolt, the first bolt engaging the first hole to attach a shear bracket at the first lateral position, and the second bolt engaging the second hole to attach the shear bracket at the second lateral position and to attach a chassis component at the second lateral position. The first and second lateral positions may be separated by a span distance, and the attachment points or joints may be vertically offset. The shear bracket may engage with the first and second bolts to reduce the energy transferred to the battery system (e.g., the bolts may attach shear plates to the frame element and chassis component).

[0009] In some embodiments, this disclosure relates to a vehicle including a battery system and a shear bracket. The shear bracket is attached to a frame element in a first lateral position and to a chassis component in a second lateral position, wherein the shear bracket is configured to absorb energy from the chassis component to reduce energy transfer to the battery pack. In some embodiments, for example, the chassis component includes a steering knuckle, and the shear bracket is bolted to the frame element in the second lateral position via a steering knuckle bolt to reduce energy transfer to the battery pack. In some embodiments, the shear bracket includes a sheet metal material configured to reduce displacement of the chassis component toward the first lateral position, which further reduces energy transfer to the battery pack. In some embodiments, the shear bracket is configured to snap between the first and second lateral positions to reduce energy transfer to the battery pack. In some embodiments, the shear bracket is bolted to the frame element at both the first and second lateral positions to absorb energy. For example, in some embodiments, the vehicle includes a first bolt and a second bolt, the first bolt engaging a first hole to attach a shear bracket in a first lateral position, and the second bolt engaging a second hole to attach the shear bracket in a second lateral position and to a chassis component in the second lateral position. In some embodiments, the shear bracket is a first shear bracket, and the vehicle includes a second shear bracket attached to a second chassis component and configured to absorb energy from the second chassis component to reduce the energy transferred to the battery pack.

[0010] In some embodiments, this disclosure relates to a vehicle apparatus including a battery system, a first chassis component and a second chassis component, and a first shear bracket and a second shear bracket. The battery system includes a first end portion, such as a front or rear portion, corresponding to a first corner and a second corner of the vehicle, such as a right rear corner and a left rear corner. The first chassis component corresponds to a first wheel disposed at a first corner of the vehicle and is attached to a frame at a first connector. The second chassis component corresponds to a second wheel disposed at a second corner of the vehicle and is attached to the frame at a second connector. For illustration, in some embodiments, the first wheel and the second wheel are rear wheels disposed on opposite sides of the vehicle. The first and second shear brackets are configured to absorb energy from the corresponding first and second connectors to reduce the energy positively transferred to the battery system. The first shear bracket is attached to the first chassis component and the frame and is configured to resist displacement of the first connector. The second shear bracket is attached to the second chassis component and the frame and is configured to resist displacement of the second connector.

[0011] In some embodiments, the device includes a first frame element corresponding to a first corner, and a first shear bracket is attached to the first frame element at a first lateral position and a second lateral position. In some such embodiments, the device further includes a second frame element corresponding to a second corner, and a second shear bracket is attached to the second frame element at a third lateral position and a fourth lateral position.

[0012] In some embodiments, the first connector is disposed at a second lateral position, and the second connector is disposed at a fourth lateral position. In some embodiments, the first chassis component includes a steering knuckle, and the device includes a first fastener that attaches the first shear bracket to the first steering knuckle and the first frame element at the second lateral position. In some embodiments, the first shear bracket is configured to maintain a first clearance between the battery system and the first chassis component, and the second shear bracket is configured to maintain a second clearance between the battery system and the second chassis component. Attached Figure Description

[0013] The present disclosure is described in detail with reference to the following accompanying drawings, which illustrate one or more various embodiments. The drawings are provided for illustrative purposes only and show only typical or exemplary embodiments. These drawings are provided to facilitate understanding of the concepts disclosed herein and should not be considered as limitations on the breadth, scope, or applicability of these concepts. It should be noted that these drawings are not necessarily drawn to scale for clarity and ease of illustration.

[0014] Figure 1A top view of the arrangement of the vehicle and obstacles prior to a collision is shown according to some embodiments of the present disclosure;

[0015] Figure 2 A bottom view of a vehicle having a battery system, chassis components, and shear brackets according to some embodiments of this disclosure is shown;

[0016] Figure 3 A bottom view of a portion of a vehicle with a shear bracket according to some embodiments of the present disclosure is shown;

[0017] Figure 4 Some embodiments according to this disclosure are shown. Figure 3 A perspective view of the vehicle from below;

[0018] Figure 5 A bottom view of a portion of a vehicle having a battery system and a chassis system according to some embodiments of the present disclosure is shown, with the frame removed for clarity purposes;

[0019] Figure 6 A bottom view of a portion of a vehicle with a shear bracket according to some embodiments of the present disclosure is shown;

[0020] Figure 7 Some embodiments according to this disclosure are shown. Figure 6 A side view of a portion of the vehicle;

[0021] Figure 8 Some embodiments according to this disclosure are shown. Figure 6 A perspective view of a portion of the vehicle from below;

[0022] Figure 9 Some embodiments according to this disclosure are shown. Figure 6 A bottom-view perspective view of a portion of the vehicle, magnified to show the shear bracket more clearly;

[0023] Figure 10 Some embodiments according to this disclosure are shown. Figure 6 A cross-sectional side view of a portion of the vehicle, showing a bolt-fixed shear bracket;

[0024] Figure 11 Some embodiments according to this disclosure are shown. Figure 6 A top-down perspective view of a portion of the vehicle;

[0025] Figure 12 A bottom perspective view of a portion of a vehicle having a shear bracket undergoing deformation, according to some embodiments of the present disclosure, is shown.

[0026] Figure 13Some embodiments according to this disclosure are shown. Figure 12 A side view of a portion of the vehicle, showing the shear bracket undergoing deformation;

[0027] Figure 14 This diagram shows a bottom view of the assembly progress of an assembly with a shear bracket according to some embodiments of the present disclosure; and

[0028] Figure 15 A side view of the assembly progress of an assembly with a shear bracket according to some embodiments of the present disclosure is shown. Detailed Implementation

[0029] This disclosure relates to a rear chassis structure for protecting a battery pack in a vehicle. In some embodiments, the chassis structure includes shear brackets to absorb energy from a collision event before transferring energy to the battery pack. To illustrate, even in the event of accidental fracture of the rear chassis casting, the shear brackets can help ensure repeatability of crash performance. To further illustrate, the dimensions and thickness of the shear brackets, and the chassis and body mounting strategy of these shear brackets, can affect the protection of the battery pack. In some embodiments, the structure of this disclosure addresses the problem of preventing chassis components from intruding into the battery system during an impact, as well as the loading and deformation of the vehicle. In exemplary examples, the structure of this disclosure includes one or more shear brackets. For example, a vehicle may include two shear brackets, each on one side of the vehicle, to prevent intrusion.

[0030] Figure 1 A top view of an arrangement 100 of a vehicle 101 and an obstacle 102 prior to a collision, according to some embodiments of the present disclosure, is shown. The vehicle 101 includes a chassis structure according to the present disclosure. The arrangement 100 corresponds to a pre-event arrangement where the vehicle 101 and the obstacle 102 are approaching each other (e.g., either or both may be moving). For example, the vehicle 101 and the obstacle 102 (e.g., the obstacle may be another vehicle) may be approaching head-on, one vehicle may be stationary and the other vehicle is approaching, or alternatively (not shown), the obstacle 102 may be a generally rigid obstacle. In any of these scenarios, the vehicle 101 is configured to prevent or otherwise limit intrusion of chassis components 120 into the battery system 110. A collision can cause significant damage to the vehicle, including intrusion into the battery system, which may damage battery cells, power electronic components, DC bus systems, or other aspects of the battery system. For illustration, chassis components 120 may include cast parts that may crack or break, bolts that may break, or other components that may break or deform. This disclosure relates to a chassis shear bracket that helps prevent or otherwise mitigate the effects of failures in chassis components.

[0031] Figure 2 A bottom view of a vehicle 200 having a battery system 210, chassis components 220 and 230, and shear brackets 250 and 251 according to some embodiments of the present disclosure is shown. Shear brackets 250 and 251 are configured to absorb energy associated with deceleration events from the respective chassis components 220 and 230 to reduce energy transferred to the battery system 210. Chassis components 220 and 230 are attached to the frame 201 of the vehicle 200 and coupled to the respective wheels 202 and 203. Frame elements form, accommodate, or otherwise correspond to wheel wells 212 in which the wheels 202 are arranged. The battery system 210 is also attached to the frame 201 of the vehicle 200 (e.g., by means of lateral members, fasteners, or combinations thereof). Clearances 255 and 256 exist in a nominal configuration (e.g., substantially undeformed, normal, or otherwise before an event) between the battery system 210 and the respective chassis components 220 and 230. In some implementations, for example, the battery system 210 is attached to a frame element of the frame 201, and either or both of shear brackets 250 and 251 are configured to absorb energy to maintain corresponding gaps 255 and 256 between the battery system 210 and the respective chassis components 220 and 230. Shear brackets 250 and 251 are configured to provide anti-displacement stiffness to the respective chassis components 220 and 230. During an event, the presence of gaps 255 and 256 can be mitigated or stopped due to loading of the frame 201, chassis components 220 and 230, other components of the vehicle 200, or combinations thereof. Shear brackets 250 and 251 help prevent or otherwise mitigate any reduction in gaps 255 and 256, and prevent fracture-type failures of fasteners or other interfaces between chassis components 220 and 230 and the frame 201. For example, chassis components 220 and 230 may include cast components or other components that may fracture. If chassis components 220 and 230 are bolted to frame 201, the bolts may be prone to shear breakage. Such breakage or failure of chassis components 220 and 230 or their corresponding fasteners may result in discontinuous force loading, which could generate shocks. Shear brackets 250 and 251 mitigate the chance of such failures, thereby providing a smoother load transfer (e.g., ensuring that chassis components 220 and 230 do not affect or intrude into battery system 210). In an exemplary example, chassis components 220 and 230 may include suspension components (e.g., springs, struts, dampers, anti-roll bars), control arms (e.g., A-arms), steering components (e.g., connecting rods, spindles, steering knuckles), and braking components (e.g., rotors, drums, calipers, hubs, bearings, etc.).

[0032] Mounting elements, universal drive connectors, any other suitable components or subsystems, or any combination thereof.

[0033] In an exemplary example, the arrangement of components of vehicle 200 may correspond to an end of battery system 210. For example, battery system 210 may include a front end and a rear end, and each end may correspond to two corners (e.g., right rear and left rear, and right front and left front). Thus, chassis components 220 and 230 are arranged at the first and second corners corresponding to wheels 202 (e.g., the first wheel) and 203 (e.g., the second wheel).

[0034] Figure 3 A bottom view of a portion of a vehicle 300 with a shear bracket according to some embodiments of the present disclosure is shown. Figure 4 Some embodiments according to this disclosure are shown. Figure 3 A bottom perspective view of a portion of the vehicle 300. Shear brackets 350 and 351 are connected to corresponding chassis components 320 and 330 (e.g., each an assembly of the component shown in the figure), and also to the frame 301. Furthermore, shear brackets 350 and 351 are configured to prevent the corresponding chassis components 320 and 330 from encroaching into the battery system 310. Figure 4 As shown, the shear bracket 350 includes two holes, one corresponding to the frame 301 (e.g., bolted to the frame 301) and the other corresponding to the chassis component 320 (e.g., bolted to both the chassis component 320 and the frame 301). The chassis component 320 includes element 325, as well as steering, suspension, and braking components. As shown, element 325 may include a casting with a steering knuckle bolted to the shear bracket 350 (e.g., the shear bracket is fixed to the frame 301). The shear bracket 350 is also fixed to the frame 301 by another bolt. Similarly, shear bracket 351 is attached to both the chassis component 330 and the frame 301. Shear brackets 350 and 351 provide shear strength to the joint between the frame 301 and element 325, thereby preventing or otherwise reducing the tendency for the corresponding bolts to break. To further illustrate, during an event, shear brackets 350 and 351 also prevent or otherwise reduce the intrusion of chassis components 320 and 330 into the battery system 310 by applying anti-deformation stiffness (e.g., to limit the intrusion of element 325 into the battery system 310 or other components). In some embodiments, shear brackets 350 and 351 may be retrofitted into the vehicle 300, or otherwise included without redesigning chassis components 320 and 330. For example, shear brackets 350 and 351 may be additional components configured to reinforce existing components. For illustration, chassis components 320 and 330 may be configured to be attached to frame 301 (e.g., to first frame element 302 and second frame element 303, respectively) in the absence of shear brackets 350 and 351, which may be added to provide material strength.

[0035] In an exemplary example, the arrangement of components of vehicle 300 may correspond to an end of battery system 310. For example, battery system 310 may include a front end and a rear end, and each end may correspond to two corners (e.g., right rear and left rear, and right front and left front). Thus, chassis components 320 and 330 are arranged at the first and second corners corresponding to the rear end.

[0036] Figure 5 A bottom view of a portion of a vehicle 500 having a battery system 510 and a chassis system (e.g., including chassis components 520 and 530) according to some embodiments of this disclosure is shown, with the frame removed for clarity. The rear of the vehicle 500 faces right, as shown. Figure 5 As shown. Shear brackets 550 and 551 are connected to chassis components 520 and 530 and the frame (e.g., its frame elements) and are configured to maintain gaps 555 and 556 (e.g., by absorbing energy to maintain corresponding gaps 555 and 556 between the battery system 510 and the respective chassis components 520 and 530). Enlarged portion 599 shows shear bracket 551 more clearly, which has holes 552 and 553 (e.g., at a first lateral position and a second lateral position). Shear bracket 550 also includes two mounting positions (e.g., at a third lateral position and a fourth lateral position). For illustration, hole 552 is configured (e.g., via bolts or other fasteners or attachments) to engage with chassis component 530, while hole 553 is configured (e.g., via bolts or other fasteners or attachments) to engage with the frame of vehicle 500. In some embodiments, shear brackets 550 and 551 are made of steel (e.g., less prone to fracture than brittle materials) and are configured to provide some stiffness to deformation of the joints, corresponding fasteners, or combinations thereof between the frame and chassis components 520 and 530. As shown, shear brackets 550 and 551 each include two holes and are elliptical in shape. It should be understood that shear brackets can be elliptical, triangular, circular, rectangular, irregular, or any other suitable shape, having any suitable number of holes or mounting features, or any combination thereof. For example, mounting brackets can be configured to be mounted in two locations (e.g., chassis components and frame) or more than two locations.

[0037] Figure 6 A bottom view of a portion of a vehicle 600 having a shear bracket 650 according to some embodiments of the present disclosure is shown. Figure 7 Some embodiments according to this disclosure are shown. Figure 6 A side view of a portion of vehicle 600. Figure 8 Some embodiments according to this disclosure are shown. Figure 6 A perspective view of part of vehicle 600 from below. Figure 9Some embodiments according to this disclosure are shown. Figure 6 A bottom-view perspective view of a portion of vehicle 600, magnified to show the shear bracket 650 more clearly. Figure 10 Some embodiments according to this disclosure are shown. Figure 6 A cross-sectional side view of a portion of vehicle 600, showing bolts 1058 and 1059 securing shear bracket 650. Figure 11 Some embodiments according to this disclosure are shown. Figure 6 A top perspective view of a portion of a vehicle 600. The frame includes frame elements 601 and 603 and a body element 602. Although not shown, the vehicle 600 may include another shear bracket on a side of the frame different from frame element 601 (e.g., on the passenger side, bolted to a second frame element 603). It may be similar to... Figure 5 Shear brackets 550 and 551, and shear bracket 650 of 551, are connected to chassis component 620 and frame element 601, and are configured to prevent chassis component 620 from encroaching into battery system 610 (e.g., including metal or plastic parts attached to the frame or chassis component 620). As shown, shear bracket 650 includes two holes, one corresponding to frame 601 (e.g., bolted to frame element 601) and one corresponding to chassis component 620 (e.g., bolted to chassis component 620). Chassis component 620 includes element 625, strut 622, rotor 621, and buffer device 623. As shown, element 625 may include a casting having a steering knuckle 627 bolted to shear bracket 650 (e.g., the shear bracket is fixed to frame element 601) by bolts 659. Shear bracket 650 is also fixed to frame 601 by bolts 658. To illustrate, during an event, the shear bracket 650 provides shear strength to the bolt 659, thereby preventing or otherwise reducing the tendency of the bolt 659 to break. To further illustrate, during an event, the shear bracket 650 also prevents or otherwise reduces intrusion (e.g., to limit the encroachment of element 625 into the battery system or other components) by applying anti-deformation stiffness. In some embodiments, the shear bracket 650 can be retrofitted into the vehicle 600, or otherwise included without redesigning the chassis component 620. For example, the shear bracket 650 can be an add-on configured to reinforce existing components. Body component 602 in Figure 8 As shown in the figure, it is attached to frame element 601.

[0038] Figure 10 Some embodiments according to this disclosure are shown. Figure 6 A cross-sectional side view of a portion of vehicle 600, showing bolts 1058 and 1059 securing shear bracket 650. For illustrative purposes, some parts are not shown. Figure 10 As shown (e.g., to provide an unobstructed view). Bolt 1058 is configured to hold shear bracket 650 (in...) Figure 10 (Not shown) is fixed to frame element 601. For example, frame element 601 includes a hole 1071 (e.g., in a lateral position) that may include a female thread or through hole configured to receive bolt 1058 (e.g., if a threaded nut is used). Additionally, frame element 601 includes a hole 1072 (e.g., in another lateral position) shown having a threaded insert 1073 configured to receive bolt 1059 (e.g., a mounting feature). In some embodiments, shear bracket 650 is configured to prevent or otherwise limit failure of bolt 1059 (e.g., at the interface between bolt 1059 and hole 1072), thereby preventing or otherwise limiting displacement of element 625 toward the battery system or other components. In some embodiments, hole 1072 may be threaded or include a bolt, and does not need to include threaded insert 1073.

[0039] Figure 12 A bottom perspective view of a portion of a vehicle 1200 having a deformed shear bracket according to some embodiments of the present disclosure is shown. Figure 13 Some embodiments according to this disclosure are shown. Figure 12 A side view of a portion of vehicle 1200, showing the shear bracket undergoing deformation. The shear bracket 1250 is configured to absorb energy associated with a deceleration event (e.g., also referred to as an event) from chassis component 1220 to reduce energy transfer to battery system 1210. For illustration, vehicle 1200 and... Figures 6 to 10The vehicle 1200 is identical to vehicle 600, in which the vehicle structure undergoes an event from event loading. Although not shown, vehicle 1200 may include another shear bracket on the other side of frame 1201. Shear bracket 1250 is coupled to chassis component 1220 and frame 1201 and is configured to prevent chassis component 1220 from intruding into battery system 1210 (e.g., including a metal sheet or plastic component attached to frame 1201). As shown, shear bracket 1250 includes two holes, one corresponding to frame 1201 (e.g., bolted to frame 1201) and one corresponding to chassis component 1220. As shown, chassis component 1220 includes element 1225 having steering knuckle 1227, suspension component 1222, and braking component 1221. Shear bracket 1250 is secured to frame 1201 in a first position by bolts 1258. Component 1225 may be a casting, and steering knuckle 1227 may be bolted to shear bracket 1250 (e.g., shear bracket fixed to frame 1201) in a second position via bolt 1259. For illustration, during an event, shear bracket 1250 provides shear strength to bolt 1259, thereby preventing or otherwise reducing the tendency of bolt 1259 to break. As shown, during an event, shear bracket 1250 may deform, thereby dissipating energy from chassis components and preventing or otherwise reducing intrusion (e.g., to limit element 1225 from encroaching on the battery system or other components) by applying anti-displacement stiffness to component 1225 of chassis component 1220. Compared to shear bracket 650 (e.g., pre-event bracket), shear bracket 1250 has deformed (e.g., shortened), continuously applying resistance to deformation rather than fracture or other impacts. Although shown as being fastened under the constraint of flat bolt ends, the shear bracket can be configured to deform in any suitable manner, such as, for example, bending, twisting, fastening, folding, or combinations thereof. The shear bracket can include any suitable stiffness and can be configured to deform substantially, not significantly, or fail in a prescribed manner. For example, the shear bracket can be stiffer or less stiff than other parts of the vehicle that may undergo deformation during an event. In some embodiments, the shear bracket is configured to absorb and dissipate energy through plastic deformation (e.g., in a controlled or otherwise prescribed manner). For illustration, the shear bracket can be configured to deform less than surrounding components or deform to a certain limit to restrict intrusion into the battery system. In exemplary examples, in some embodiments, the shear bracket 1250 is configured to fasten between a first and a second position (e.g., corresponding to bolts 1258 and 1259) of the vehicle frame (e.g., frame 1201) to reduce energy transfer to the battery system 1210.

[0040] Figure 14A bottom-view assembly progression view of an assembly with a shear bracket 1450 according to some embodiments of the present disclosure is shown. Panel 1490 shows a completely unassembled state (e.g., exploded view), panel 1491 shows the chassis component 1420 arranged in place, panel 1492 shows the shear bracket 1450 arranged in place, and panel 1493 shows the shear bracket 1450 attached in place. The shear bracket 1450 may be formed of sheet metal material (e.g., steel sheet) or any other suitable material of a thickness suitable for hardening the joint between the chassis component 1420 and the frame element 1401 (e.g., a thickness of 1 mm-5 mm, 4 mm, or any other suitable thickness). Figure 14 As shown, lateral position is indicated by a "+" indicator (e.g., at each hole, as shown). Lateral position refers to the vehicle's positioning in the horizontal plane (e.g., Figure 14 The plane of the page, and may include vertical offsets (e.g., entering or leaving the plane of the page, such as...). Figure 15 (As shown).

[0041] Panel 1490 shows a frame element 1401 having mounting positions 1402 and 1403 (e.g., a first lateral position and a second lateral position), a chassis component 1420 having a steering knuckle 1421 and a mounting position 1422, and a shear bracket 1450 having mounting features 1452 and 1453. Mounting features 1452 and 1453 may include holes, bolts (e.g., studs), slots, pins, recessed features, boss features (e.g., protruding from the surface of body 1451), any other suitable features for mounting the shear bracket to the frame element 1401 and / or chassis component 1420, or any combination thereof. The shear bracket 1450 includes a body 1451 comprising material spanning the distance between mounting features 1452 and 1453 and material surrounding the mounting features 1452 and 1453. The distance between mounting features 1452 and 1453 may be the same as the distance between mounting positions 1402 and 1403. In some embodiments, mounting positions 1402 and 1403 include holes, bolts (e.g., stud bolts), slots, pins, recessed features, boss features (e.g., protruding from the surface of body 1451), any other suitable features for engaging with mounting features 1452 and 1453 of shear bracket 1450, or any combination thereof. Chassis component 1420 includes mounting position 1422 configured to align with mounting position 1403 of frame element 1401 and engage with mounting feature 1453 of shear bracket 1453. Frame element 1401 may include through holes, bolts (e.g., outwardly extending studs for connection to shear bracket 1450 and frame element 1401), slots, pins, alignment features, any other suitable features for engagement with shear bracket 1450 or chassis component 1420, or any combination thereof, at mounting positions 1402 and 1403.

[0042] Panel 1491 shows the chassis component 1420 in the appropriate position, wherein mounting position 1422 is aligned with mounting position 1403. For illustration, as... Figures 7 to 11 As shown, frame element 1401 can be bent (e.g., outside the page) to create an offset between mounting positions 1402 and 1403 (e.g., offset at...). Figure 15 (as shown in the figure). In some embodiments, mounting location 1422 includes a through hole disposed in steering knuckle 1421.

[0043] Panel 1492 shows a shear bracket 1450 arranged in the appropriate position, wherein mounting features 1452 and 1453 are aligned with mounting positions 1402 and 1403, respectively. Mounting feature 1453 is also aligned with mounting position 1422 of chassis component 1420.

[0044] Panel 1493 shows a shear bracket 1450 attached in place, wherein fasteners 1462 and 1463 (e.g., bolts, screws, threaded nuts, welds, pins, or other suitable attachments) engage mounting positions 1402 and 1403, respectively. In some embodiments, the shear bracket may include fasteners 1462 and 1463 (e.g., as bolts or other protrusions), and therefore, the shear bracket 1450 and fasteners 1462-1463 may be a single component (e.g., formed as a single component or welded together).

[0045] In an exemplary example, if the shear bracket 1450 is not included, the chassis component 1420 can still be secured to the frame 1401 (e.g., using mounting location 1403). Therefore, adding the shear bracket 1450 utilizes an existing mounting location (e.g., mounting location 1403), requiring only one additional mounting location (e.g., mounting location 1402) to mount the shear bracket 1450. In another exemplary example, in some embodiments, the shear bracket 1450 may be attached to a separate, dedicated location on the chassis component 1420 (e.g., as opposed to reusing existing mounting locations such as mounting locations 1402 or 1403). In some embodiments, the shear bracket 1450 is configured to snap between a first location and a second location (e.g., locations 1402 and 1403) on the vehicle frame (e.g., frame 1401) to reduce the energy transferred to the battery system. In some implementations, for example, the shear bracket 1450 is configured to engage with the first and second bolts (e.g., fasteners 1462 and 1463) to absorb energy associated with deceleration events from the chassis component 1420 (e.g., by fastening or otherwise deforming) (e.g., to prevent energy from being transferred to the battery system).

[0046] In an exemplary example, a shear bracket 1450 and a chassis component 1420 are arranged at a first corner of the vehicle, and the chassis component 1420 is attached to a frame (e.g., frame element 1401) at a first joint located at a mounting position 1403. A second chassis component (corresponding to a second wheel and arranged at a second corner of the vehicle) may be included. Figure 14 Not shown in the image, but... Figure 3 (As shown in the diagram). The second chassis component may be attached to the frame at a second joint (e.g., the same as shown in mounting position 1403). In some such embodiments, a first shear bracket is attached to the first chassis component and the frame, and the first shear bracket is configured to resist displacement of the first joint. Furthermore, in some such embodiments, a second shear bracket is attached to the second chassis component and the frame, and the second shear bracket is configured to resist displacement of the second joint.

[0047] Figure 15A side view of the assembly progress of an assembly having a shear bracket 1550 according to some embodiments of the present disclosure is shown.

[0048] Panel 1590 shows a frame element 1501 having mounting positions 1502 and 1503 (e.g., a first mounting position and a second mounting position), and a chassis component 1520 having a steering knuckle 1521 and a mounting position 1522. The chassis component 1520 includes mounting position 1522, which is configured to align with mounting position 1503 of the frame element 1501. For illustration, panel 1590 shows a configuration where a shear bracket is not installed (e.g., prior to shear bracket installation, or in a system where a shear bracket can be retrofitted). The frame 1501 may include through holes, bolts, slots, pins, alignment features, any other suitable features for engaging with the chassis component 1520, or any combination thereof, at mounting positions 1502 and 1503. The chassis component 1520 may include through holes, bolts, slots, pins, alignment features, any other suitable features for engaging with the frame element 1501, or any combination thereof, at mounting position 1522.

[0049] Panel 1591 shows the chassis component 1520 in the appropriate position, wherein mounting position 1522 is aligned with mounting position 1503. For illustration, as... Figures 7 to 11 As shown, frame element 1501 is bent (e.g., outside the page) to form an offset 1599 (e.g., vertical offset) between mounting positions 1502 and 1503, wherein mounting positions 1502 and 1503 are laterally spaced apart by a span 1598. In some embodiments, mounting position 1522 includes a through-hole disposed in steering knuckle 1521. Shear bracket 1550 includes a body 1551 comprising material spanning the distance between mounting features 1552 and 1553 and material surrounding mounting features 1552 and 1553. The distance between mounting features 1552 and 1553 may be the same as the distance between mounting positions 1502 and 1503 (e.g., span 1598).

[0050] Panel 1592 shows a shear bracket 1550 attached in place, wherein fasteners 1562 and 1563 (e.g., bolts, screws, threaded nuts, welds, pins, or other suitable attachments) engage with mounting positions 1502 and 1503, respectively. Mounting feature 1553 is also aligned with mounting position 1522 of chassis component 1520. In some embodiments, the shear bracket may include fasteners 1562 and 1563 (e.g., as bolts or other protrusions), and therefore, the shear bracket 1550 and fasteners 1562-1563 may be a single component (e.g., formed as a single component or welded together).

[0051] In the exemplary example, Figures 14 to 15 The shear brackets 1450 and 1550 can be additional components. For example, regardless of how the shear brackets are mounted, chassis components 1420 and 1520 can be designed to provide steering, suspension, braking, drivetrain, any other suitable functions, or any combination thereof. In another example, the shear brackets may not perform any function during normal operation (e.g., in the absence of events), but under load from an event, the shear brackets can provide displacement stiffness at the joint between the chassis components and the frame elements.

[0052] In some embodiments, this disclosure relates to a method for manufacturing vehicles with battery systems. Figures 1 to 15 Methods for assembling components. In some embodiments, chassis components, such as castings, are configured to be attached to frame elements at one or more locations to connect the frame elements to wheels. A shear bracket can be mounted by attaching a shear bracket to both the chassis component and the frame element. For example, in some embodiments, the shear bracket is attached to the chassis component at one of the locations where the chassis component is attached to the frame element (e.g., using the same bolt, wherein the shear bracket includes holes for receiving the bolt). In another example, in some embodiments, the shear bracket is attached to the chassis component at a dedicated location different from one or more locations where the chassis component is attached to the frame element. The shear bracket is attached to the frame element at a second location to absorb energy from the chassis component, thereby undergoing deformation or displacement toward the second location. For illustration, the shear bracket does not need to affect the operation of the chassis component and can be an additional component for protecting the vehicle's battery system. During deceleration events (e.g., a collision such as at least one of the vehicles decelerating), the shear bracket can absorb energy to prevent the energy from being absorbed, converted, or otherwise affecting the battery system.

[0053] The foregoing is merely illustrative of the principles of this disclosure, and various modifications can be made by those skilled in the art without departing from the scope of this disclosure. The above embodiments are presented for illustrative purposes and not for limitation. This disclosure may also take many forms other than those expressly described herein. Therefore, it should be emphasized that this disclosure is not limited to the methods, systems, and instruments expressly disclosed, but is intended to include variations and modifications thereof, which are within the spirit of the following claims.

Claims

1. A shear bracket for preventing or limiting the intrusion of chassis components into a battery system, characterized in that, The shear bracket includes: A shear bracket, attached to chassis components and frame elements, wherein the shear bracket is configured to absorb energy associated with deceleration events from the chassis components to reduce energy transferred to the battery system; The battery system is attached to the frame element, and the shear bracket is configured to absorb the energy to maintain a gap between the battery system and the chassis component. The chassis components mentioned above include steering knuckles; The shear bracket includes: A first hole, configured to align with a first lateral position of the frame element; and A second hole is configured to align with a second lateral position of the frame element, wherein the shear bracket is configured to absorb the energy between the first lateral position and the second lateral position; The shear bracket mentioned above comprises a sheet of metal. The shear bracket further includes: A first bolt, the first bolt being used to attach the shear bracket at a first lateral position of the frame element; and A second bolt is used to attach the shear bracket at a second lateral position of the frame element, wherein the second bolt also attaches the shear bracket and the chassis component at the second lateral position, and wherein the first bolt and the second bolt attach the shear bracket to the frame element to reduce the energy transferred to the battery system.

2. The shearing bracket according to claim 1, characterized in that, The shear bracket is connected to the mounting feature of the frame element at a second lateral position of the frame element via the steering knuckle bolts to reduce the energy transferred to the battery system.

3. The shearing bracket according to claim 1, characterized in that, The sheet metal is configured to provide anti-displacement stiffness to the chassis component in a first lateral position toward the frame element, wherein the stiffness further reduces the energy transferred to the battery system.

4. The shearing bracket according to claim 1, characterized in that, The shear bracket is configured to snap between a first lateral position and a second lateral position of the frame element to reduce the energy transferred to the battery system.

5. The shearing bracket according to claim 1, characterized in that, The shear bracket is configured to engage with the first bolt and the second bolt to absorb the energy associated with the deceleration event from the chassis component.

6. A vehicle, characterized in that, The vehicles include: A battery system, the battery system being attached to a frame element; A shear bracket, which is attached to the frame element at a first lateral position and to the chassis component at a second lateral position, wherein the shear bracket is configured to absorb energy from the chassis component to reduce the energy transferred to the battery system. The battery system is attached to the frame element, and the shear bracket is configured to absorb the energy to maintain a gap between the battery system and the chassis component. The chassis components mentioned above include steering knuckles; The shear bracket includes: A first hole, configured to align with a first lateral position of the frame element; and A second hole is configured to align with a second lateral position of the frame element, wherein the shear bracket is configured to absorb the energy between the first lateral position and the second lateral position; The shear bracket mentioned above comprises a sheet of metal. The shear bracket further includes: A first bolt, the first bolt being used to attach the shear bracket at a first lateral position of the frame element; and A second bolt is used to attach the shear bracket at a second lateral position of the frame element, wherein the second bolt also attaches the shear bracket and the chassis component at the second lateral position, and wherein the first bolt and the second bolt attach the shear bracket to the frame element to reduce the energy transferred to the battery system.

7. The vehicle according to claim 6, characterized in that, The shear bracket is connected to the frame element at the second lateral position via the steering knuckle bolts to reduce the energy transferred to the battery system.

8. The vehicle according to claim 6, characterized in that, The sheet metal is configured to reduce the displacement of the chassis component toward the first lateral position, wherein the reduced displacement further reduces the energy transferred to the battery system.

9. The vehicle according to claim 6, characterized in that, The shear bracket is configured to snap between the first lateral position and the second lateral position to reduce the energy transferred to the battery system.

10. The vehicle according to claim 6, characterized in that, The shear bracket is bolted to the frame element at the first lateral position and the second lateral position to absorb the energy.

11. The vehicle according to claim 10, characterized in that, The first bolt engages with the first hole to attach the shear bracket at the first lateral position; and The second bolt engages with the second hole to attach the shear bracket at the second lateral position and the chassis component at the second lateral position.

12. The vehicle according to claim 6, characterized in that, The shear bracket is a first shear bracket, and the vehicle includes a second shear bracket attached to a second chassis component and configured to absorb energy from the second chassis component to reduce the energy transferred to the battery system.

13. A device for a vehicle, characterized in that, The device includes: A battery system, the battery system including a first end, the first end corresponding to a first corner and a second corner of the vehicle; Chassis components, the chassis components including: A first chassis component, corresponding to a first wheel disposed at the first corner of the vehicle, wherein the first chassis component is attached to a frame element at a first joint; and A second chassis component, corresponding to a second wheel disposed at the second corner of the vehicle, wherein the second chassis component is attached to the frame element at a second joint; and Shear bracket, the shear bracket comprising: A first shear bracket, attached to the first chassis component and the frame element, wherein the first shear bracket is configured to absorb energy from the first connector to reduce the energy transferred to the battery system; and A second shear bracket is attached to the second chassis component and the frame element, wherein the second shear bracket is configured to absorb energy from the second connector to reduce the energy transferred to the battery system; The battery system is attached to the frame element, and the shear bracket is configured to absorb the energy to maintain a gap between the battery system and the chassis component. The chassis components mentioned above include steering knuckles; The shear bracket includes: A first hole, configured to align with a first lateral position of the frame element; and A second hole is configured to align with a second lateral position of the frame element, wherein the shear bracket is configured to absorb the energy between the first lateral position and the second lateral position; The shear bracket mentioned above comprises a sheet of metal. The shear bracket further includes: A first bolt, the first bolt being used to attach the shear bracket at a first lateral position of the frame element; and A second bolt is used to attach the shear bracket at a second lateral position of the frame element, wherein the second bolt also attaches the shear bracket and the chassis component at the second lateral position, and wherein the first bolt and the second bolt attach the shear bracket to the frame element to reduce the energy transferred to the battery system.

14. The apparatus according to claim 13, characterized in that, The device further includes: A first frame element, corresponding to the first corner portion, wherein the first shear bracket is attached to the first frame element at a first lateral position and a second lateral position; and A second frame element, corresponding to the second corner portion, wherein the second shear bracket is attached to the second frame element at a first lateral position and a second lateral position.

15. The apparatus according to claim 14, characterized in that, The first connector is arranged at the second lateral position, and the second connector is arranged at the second lateral position of the second frame element.

16. The apparatus according to claim 14, characterized in that, The device includes a first fastener that attaches the first shear bracket to the steering knuckle and the first frame element at a second lateral position of the first frame element.

17. The apparatus according to claim 13, characterized in that, The first shear bracket is configured to maintain a first gap between the battery system and the first chassis component, and wherein the second shear bracket is configured to maintain a second gap between the battery system and the second chassis component.

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