Frame supporting device

Abstract

A frame support device may include a body having a plurality of walls dividing the body into a plurality of sections along a height of the body. The first wall and the opposing second wall may define a section of the plurality of sections. A middle portion of the first wall may be disposed closer to the second wall than an end portion of the first wall in the first direction. The first wall and the second wall are movable toward each other in the first direction in response to a force exerted on the body in the second direction.

Description

[0001] introduction

[0002] Electric vehicles may include various electrical components that provide power to the vehicle. These electrical components may be electrically coupled to vehicle components to power the vehicle. Summary of the invention

[0003] The frame rail support device may include a body having a plurality of sections separated by walls. At least two of the walls may flex and move toward each other in response to a force applied to the body to support the structure of the body. When the walls move toward each other, the two walls may at least partially contact each other. The disclosed solution has the technical advantage of absorbing the energy of the force applied to the body to facilitate minimizing the amount of force applied to the battery positioned adjacent to or near the body. For example, the contact between the arcuate walls may facilitate providing support to the body and distributing the load throughout the body to facilitate absorbing the energy of the force. The body may include a plurality of second sections connected to the body. The second sections may be disposed between the sections of the body and the battery pack to further facilitate absorbing the energy of the force applied to the body.

[0004] At least one aspect relates to a device. The device may include a body having a plurality of walls that divide the body into a plurality of sections along a height of the body. A first wall and an opposing second wall may define a section of the plurality of sections. A middle portion of the first wall may be disposed closer to the second wall than an end portion of the first wall in a first direction. The first wall and the second wall may move toward each other in a first direction in response to a force applied to the body in a second direction.

[0005] At least one aspect relates to a vehicle. The vehicle may include an apparatus. The apparatus may include a body having a plurality of walls dividing the body into a plurality of sections along a height of the body. A first wall and an opposing second wall may define a section of the plurality of sections. A middle portion of the first wall may be disposed closer to the second wall than an end portion of the first wall in a first direction. The first wall and the second wall may move toward each other in a first direction in response to a force applied to the body in a second direction.

[0006] At least one aspect relates to a device. The device may include a body having a plurality of walls that divide the body into a plurality of first sections and a plurality of second sections. A first wall and an opposing second wall may define a section of the plurality of first sections. A middle portion of the first wall may be disposed closer to the second wall than an end portion of the first wall in a first direction. The first wall and the second wall may move toward each other in a first direction in response to a force applied to the body in a second direction.

[0007] These and other aspects and implementations are discussed in detail below. The foregoing information and the following detailed description include illustrative examples of various aspects and implementations, and provide an overview or framework for understanding the nature and characteristics of the protected aspects and implementations. The accompanying drawings provide illustration and further understanding of various aspects and implementations, and are incorporated into and constitute a part of this specification. The foregoing information and the following detailed description and the accompanying drawings include illustrative examples and should not be considered limiting. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The drawings are not intended to be drawn to scale. Like reference numbers and names indicate similar elements in the various drawings. For clarity, not every component may be labeled in every drawing. In the drawings:

[0009] Figure 1 An exemplary side view of an electric vehicle is depicted in accordance with an implementation.

[0010] Figure 2A Depicted is an exemplary perspective view of a battery pack according to a particular implementation.

[0011] Figure 2B Depicted are exemplary perspective views of battery modules according to implementations.

[0012] Figure 3 Depicts a proximity to a specific implementation Figure 1 An exemplary front view of a frame support apparatus for positioning a battery pack of an electric vehicle.

[0013] Figure 4 Describes the specific implementation Figure 3 An exemplary perspective view of a portion of a device.

[0014] Figure 5 Describes the specific implementation Figure 3 An exemplary front view of a portion of a device.

[0015] Figure 6 Describes the specific implementation Figure 3 An exemplary perspective view of a portion of a device in a first state.

[0016] Figure 7 Describes the specific implementation Figure 3 An exemplary perspective view of a portion of a device in a second state.

[0017] Figure 8 Exemplary illustrations of procedures according to specific implementations are depicted.

[0018] Fig. 9 Exemplary illustrations of procedures according to specific implementations are depicted. DETAILED DESCRIPTION

[0019] The following is a more detailed description of various concepts and implementations related to methods, devices, and systems for frame rail support devices. As described herein, the device can at least partially wrinkle or buckle to absorb the energy of a force applied to at least a portion of the frame. The device can include at least one body. The body can include a plurality of walls that divide the body into a first section or a second section (e.g., a generally rectangular section). At least one first section can include two walls (e.g., a top wall and a bottom wall) that are configured to be at least partially biased toward each other. The two walls can be configured to bend or bow toward each other when a force is applied to the body. The two walls can contact each other at or near the center of the first section to facilitate distributing the load of the force applied to the body throughout the body (e.g., by forming two generally triangular shaped sections from the rectangular section). The body can be disposed at or near a frame rail (e.g., a rocker panel) to support the frame rail when, for example, a force is applied to the frame rail. The various concepts introduced above and discussed in more detail below can be implemented in any of a variety of ways.

[0020] The present disclosure relates to systems and methods for frame rail support devices. The device may include a body having a plurality of first sections. A plurality of walls may divide the first sections along the height of the body. At least two of the walls may bend toward each other (e.g., flex) and may move toward each other in response to a force applied to the body to support the structure of the body. A first wall of the at least two walls may include a first protrusion, and a second wall of the at least two walls may include a second protrusion. When the walls move toward each other, the first protrusion and the second protrusion may at least partially contact each other.

[0021] The disclosed solution has the technical advantage of absorbing the energy of the force applied to the body to promote minimizing the amount of force applied to the battery positioned adjacent to or near the body. For example, the contact between the first protrusion and the second protrusion can promote the distribution of the load of the force over the entire body. For example, when the two walls move toward each other, the wall of the body can receive a first force level and receive a second force level after the first protrusion contacts the second protrusion, wherein the second force level is greater than the first force level. In other words, the body can distribute the load over the entire body to promote the energy of absorbing the force. The body may include a plurality of second sections coupled to the body. The second section may be disposed between the section of the body and the battery pack to further promote the absorption of the energy of the force applied to the body. The body may include an extrusion made of aluminum to promote buckling, wrinkling and energy absorption.

[0022] Figure 1An exemplary cross-sectional view 100 of an electric vehicle 105 with at least one battery pack 110 installed is depicted. The electric vehicle 105 may include an electric truck, an electric sport utility vehicle (SUV), an electric van, an electric car, an electric car, an electric motorcycle, an electric scooter, an electric passenger car, an electric passenger or commercial truck, a hybrid vehicle or other vehicle, such as a marine or air vehicle, an airplane, a helicopter, a submarine, a ship, or a drone, among other possibilities. The battery pack 110 may also be used as an energy storage system to power a building such as a residential or commercial building. The electric vehicle 105 may be fully electric or partially electric (e.g., a plug-in hybrid), and further, the electric vehicle 105 may be fully autonomous, partially autonomous, or unmanned. The electric vehicle 105 may also be manually operated or non-autonomous. The electric vehicle 105 (such as an electric truck or car) may include an onboard battery pack 110, a battery 115 or a battery module 115, or a battery cell 120 to power the electric vehicle. The electric vehicle 105 may include a chassis 125 (e.g., a frame, an internal frame, or a support structure). The chassis 125 may support various components of the electric vehicle 105. The chassis 125 may span a front portion 130 (e.g., a hood or lid portion), a body portion 135, and a rear portion 140 (e.g., a luggage compartment, payload, or trunk portion) of the electric vehicle 105. The battery pack 110 may be mounted or placed within the electric vehicle 105. For example, the battery pack 110 may be mounted within one or more of the front portion 130, the body portion 135, or the rear portion 140 on the chassis 125 of the electric vehicle 105. The battery pack 110 may include or be connected to at least one bus bar, such as a current collector element. For example, the first busbar 145 and the second busbar 150 may include conductive materials to connect or otherwise electrically couple the battery 115 , battery module 115 , or battery cell 120 to other electrical components of the electric vehicle 105 to provide power to various systems or components of the electric vehicle 105 .

[0023] Figure 2A An exemplary battery pack 110 is depicted. Figure 2A, among other things, the battery pack 110 may provide power to the electric vehicle 105. The battery pack 110 may include any arrangement or network of electrical, electronic, mechanical, or electromechanical devices to power any type of vehicle, such as the electric vehicle 105. The battery pack 110 may include at least one housing 205. The housing 205 may include at least one battery module 115 or at least one battery cell 120, as well as other battery pack components. The battery module 115 may be or may include one or more groups of prismatic cells, cylindrical cells, pouch cells, or other form factors of battery cells 120. The housing 205 may include a shield on or below the bottom of the battery module 115 to protect the battery module 115 and / or the battery cell 120 from external conditions, for example, when the electric vehicle 105 is traveling on rough terrain (e.g., off-road sites, ditches, rocks, etc.). The battery pack 110 may include at least one cooling line 210 that can distribute fluid through the battery pack 110 as part of a heat / temperature control or heat exchange system that can also include at least one thermal component (e.g., cold plate) 215. The thermal component 215 can be located relative to the top submodule and the bottom submodule, such as between the top submodule and the bottom submodule, among other possibilities. The battery pack 110 can include any number of thermal components 215. For example, there can be one or more thermal components 215 per battery pack 110 or per battery module 115. The at least one cooling line 210 can be coupled to, partially coupled to, or independent of the thermal component 215.

[0024] Figure 2BAn exemplary battery module 115 including one or more battery cells 120 is depicted. The battery module 115 may include at least one submodule. For example, the battery module 115 may include at least one first (e.g., top) submodule 220 or at least one second (e.g., bottom) submodule 225. At least one thermal component 215 may be disposed between the top submodule 220 and the bottom submodule 225. For example, one thermal component 215 may be configured to exchange heat with one battery module 115. The thermal component 215 may be disposed or thermally coupled between the top submodule 220 and the bottom submodule 225. One thermal component 215 may also be thermally coupled to more than one battery module 115 (or more than two submodules 220, 225). The thermal components 215 shown as being adjacent to each other may be combined into a single thermal component 215 that spans the size of one or more submodules 220 or 225. The thermal component 215 may be positioned below the submodule 220 and above the submodule 225, between the submodules 220 and 225, on one or more sides of the submodules 220, 225, and other possibilities. The thermal component 215 may be disposed in a sidewall, a cross member, a structural beam, among various other components of a battery pack such as the battery pack 110 described above. The battery submodules 220, 225 may collectively form a battery module 115. In some examples, each submodule 220, 225 may be considered a complete battery module 115 rather than a submodule.

[0025] The battery modules 115 may each include a plurality of battery cells 120. The battery modules 115 may be disposed within the housing 205 of the battery pack 110. For example, the battery module 115 may include a battery cell 120 that is a cylindrical unit or a prismatic unit. The battery module 115 may operate as a modular unit of the battery cell 120. For example, the battery module 115 may collect current or power from the battery cells 120 included in the battery module 115, and may provide current or power as an output of the battery pack 110. The battery pack 110 may include any number of battery modules 115. For example, the battery pack may have one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve, or other number of battery modules 115 disposed in the housing 205.

[0026] Each battery module 115 may include a top submodule 220 and a bottom submodule 225, for example, with a thermal component 215 between the top submodule 220 and the bottom submodule 225. The battery pack 110 may include or define a plurality of areas for positioning the battery modules 115 and / or the battery cells 120. The battery modules 115 may be square, rectangular, circular, triangular, symmetrical, or asymmetrical. In some examples, the battery modules 115 may be of different shapes, such that some battery modules 115 are rectangular, while other battery modules 115 are square, among other possibilities. The battery module 115 may include or define a plurality of slots, holders, or containers for a plurality of battery cells 120. It should be noted that the illustrations and descriptions herein are provided for example purposes and should not be construed as limiting. For example, the battery cells 120 may be inserted into the battery pack 110 without the battery modules 220 and 225. Battery cells 120 may be provided in battery pack 110 in a cell-pack configuration without modules 220 and 225 , among other possibilities.

[0027] The battery cell 120 has a variety of form factors, shapes, or sizes. For example, the battery cell 120 can have a cylindrical, rectangular, square, cubic, flat, pouch-shaped, elongated, or prismatic form factor.

[0028] Figure 3 An exemplary front view of the device 300 is depicted. The device 300 may include or be disposed in a portion of the vehicle 105. For example, the device 300 may include or may be positioned adjacent to a portion of the rocker panel 155 of the vehicle 105 (e.g., at or near the side of the vehicle 105, under a door, between the front and rear wheels, etc., such as at least Figure 1 ). For example, the device 300 may include or may be positioned within a portion of a frame rail 160 of the vehicle 105 (e.g., a skid plate or frame supporting one or more components of the vehicle 105). As described herein, when a force is applied to the rocker panel 155, the device 300 may facilitate supporting the rocker panel 155 of the vehicle 105 (e.g., at least at Figure 1 The device 300 or a portion of the device 300 may be coupled to the vehicle 105 via various components including, but not limited to, fasteners.

[0029] The device 300 may include a first end 320 and a second end 325. The first end 320 of the device 300 may be located at or near the sidemost portion of the vehicle 105 (e.g., at or below a door of the vehicle 105, at the first side 170 of the vehicle 105, directly adjacent to the rocker panel 155 of the vehicle 105, such as Figure 1). The second end 325 can be at least partially opposite the first end 320 and can be located near the center of the vehicle 105 (e.g., adjacent to the battery pack 110, closer to the second side 165 of the vehicle 105, such as Figure 1 ). For example, the vehicle 105 may include a first device 300 disposed adjacent to the frame rocker panel 155 of the first side 170 of the vehicle 105 and a second device 300 disposed adjacent to the frame rocker panel 155 of the second side 165 of the vehicle 105, wherein the battery pack 110 is disposed between the first device and the second device 300. The device 300 may include a body 305 disposed at or near the second end 325 of the device 300 (or at or near the first end 320).

[0030] As described herein, the body 305 may include a plurality of walls extending along the height of the body 305 (e.g., at least Figure 4 The body 305 may be divided into a plurality of sections along a height direction 455 depicted in the vehicle 105. For example, the body 305 may include at least one first section 310. The body 305 may include a plurality of first sections 310 (e.g., one first section 310, two first sections 310, three first sections 310, or more than three first sections 310 along the height of the body 305, each first section separated by one or more corresponding walls). The device 300 may include at least one second body 330 positioned adjacent to or near the body 305. The body 305 may be integrally formed with the second body 330, or the second body 330 may be formed separately and coupled to the body 305 within the vehicle 105. The second body 330 may include a plurality of sections that may be at least partially deformed in response to a force applied to the second body 330.

[0031] The body 305 or another portion of the device 300 may include at least one second segment 315. For example, the device 300 may include a plurality of second segments 315, each of which is positioned adjacent to a corresponding first segment 310 in a direction toward the second end 325 of the device 300. In some examples, at least one second segment 315 may be positioned adjacent to the first segment 310 in a direction toward the first end 320 of the device 300. The body 305 may include each of the first segment 310 and the second segment 315 that are integrally formed with each other (e.g., such that each of the plurality of first segments 310 has an adjoining wall with one of the plurality of second segments 315), or the second segment 315 may be independent of the body 305 and positioned adjacent to the body 305 (e.g., coupled to the body 305). Each of the first segment 310 and the second segment 315 may be made of the same material, or at least one of the second segments 315 may be at least partially or completely different in material from at least one of the first segments 310. The device 300 may include the same number of second segments 315 as the first segments 310 (e.g., defining a total of six segments as depicted in the figure), or the device 300 may include a different number of second segments 315 and first segments 310. For example, the body 305 may include a plurality of second segments 315 (e.g., one second segment 315, two second segments 315, three second segments 315, or more than three second segments 315).

[0032] The body 305 can be formed by a variety of different manufacturing processes. For example, the body 305 can be an extrusion or can include an extrusion. For example, the body 305 can be at least partially formed via an extrusion process to form one or more first sections 310 or second sections 315. The body 305 or one or more portions of the body 305 can be formed from a variety of metallic materials, including but not limited to aluminum or steel. The body 305 can additionally or alternatively include a variety of non-metallic materials, including but not limited to plastics. One or more portions of the device 300 can be formed using one or more additional or alternative manufacturing processes, including but not limited to additive manufacturing, stamping, or other processes.

[0033] Figure 4 An exemplary perspective view of a body 305 of the device 300 is depicted, and Figure 5 An exemplary front view of the body 305 is depicted. The body 305 can be formed via an extrusion process such that the body 305 extends longitudinally along a portion of the vehicle 105 (e.g., at least partially between a front end of the vehicle 105 and a rear end of the vehicle 105). For example, the body 305 can extend longitudinally in the length direction 445, such as Figure 4Each of the first segment 310 or the second segment 315 can extend longitudinally at least partially or completely the longitudinal length of the body 305 in the length direction 445 (eg, between a front end of the vehicle 105 and a rear end of the vehicle 105 ).

[0034] like Figure 4 and Figure 5 , and among other things, the body 305 can also include a plurality of walls (e.g., walls 420, 425, 430, 435, 460, 465, 470, or adjoining walls described or shown herein) that can divide the body 305 into a first section 310 or a second section 315 in the height, length, or width of the body 305. For example, the plurality of walls of the body 305 can divide the body into the first sections 310 along the height direction 455 (e.g., such that the first sections 310 are at least partially stacked on top of each other). For example, at least one first section 310 can include a first wall 420, an opposing second wall 425, a third wall 430 extending at least partially between the first wall 420 and the second wall 425, and a fourth wall 435 opposing the third wall 430. Each wall can be formed integrally with each other. The first wall 420 and the second wall 425 may include a greater width (e.g., in the width direction 450, in a direction from the second end 325 of the device toward the first end 320) than the height of the third wall 430 and the fourth wall 435 (e.g., in the height direction 455) to form a generally rectangular shape. In other words, the at least one first section 310 may include an aspect ratio between 1:1 and 10:1 (e.g., 2:1, 3:2, etc.). The first section 310 may include a larger or smaller aspect ratio (e.g., less than 1:1 or greater than 10:1). The body 305 of the device 300 may include a greater height than width. In other words, the body 305 may include an aspect ratio between 1:10 and 1:1 (e.g., 1:2, 2:3, etc.). The body 305 may include a larger or smaller aspect ratio (e.g., less than 1:10 or greater than 1:1).

[0035] The first wall 420 (or the second wall 425) may extend from one end portion to another end portion (e.g., from an end connected to the third wall 430 to another end connected to the fourth wall 435). A middle portion of the first wall 420 (e.g., a midpoint between the third wall 430 and the fourth wall 435) may be positioned closer to the second wall 425 than end portions of the first wall 420 in a first direction (e.g., in a height direction 455 as shown and described herein). For example, the first wall 420 may be bowed, curved, arcuate, pointed, or otherwise shaped such that at least a portion of the middle of the first wall 420 is positioned closer to the second wall 425 than another portion of the first wall 420. A middle portion of the second wall 425 (e.g., a midpoint between the third wall 430 and the fourth wall 435) may be positioned closer to the first wall 420 than end portions of the second wall 425. For example, the second wall 425 can be bowed, curved, arcuate, pointed, or otherwise shaped such that at least a portion of the middle of the second wall 425 is located closer to the first wall 420 than another portion of the second wall 425 .

[0036] As described herein, at least two of the plurality of walls (e.g., the first wall 420 and the second wall 425) may bend or move toward each other along a first direction (e.g., along the height direction 455) in response to a force applied to the body 305 along a second direction (e.g., a direction that may not be parallel to the height direction 455, such as substantially along the width direction 450 described herein, along the length direction 445 described herein, or along another direction) (e.g., in response to a force applied to a portion of the frame rail 160 of the vehicle 105). At least two of the plurality of walls (e.g., the first wall 420 and the second wall 425) may include a protrusion. For example. At least one of the first sections 310 may include at least one protrusion on one or more walls. For example, at least one of the first sections 310 may include a first protrusion 405 and a second protrusion 410. The first protrusion 405 may protrude from an inner surface of the first wall 420 of the first section 310, and the second protrusion 410 may protrude from an opposite inner surface of the second wall 425. The first protrusion 405 can contact the second protrusion 410 in response to a force applied to the body 305. The first protrusion 405 or the second protrusion 410 can include a flat face or surface (e.g., at an angle that matches the angle of the wall 465 or is perpendicular to the wall 435) even when the corresponding first wall 420 or second wall 425 is bowed (e.g., to contact each other along a flat plane).

[0037] As shown, the first protrusion 405 and the second protrusion 410 may extend from the respective first wall 420 and the second wall 425 at the approximate (e.g., ±10%) center of the wall in the width direction 450. The first protrusion 405 may be substantially opposite the second protrusion 410, or the first protrusion 405 may be offset from the second protrusion 410 in the height direction 455. The first protrusion 405 may extend longitudinally along the first wall 420 in the length direction 445, and the second protrusion 410 may extend longitudinally along the second wall 425 in the length direction 445. One or more first sections 310 may not have protrusions. For example, every other first section 310 in the height direction 455 may include a protrusion (e.g., a first protrusion 405 or a second protrusion 410), and each section therebetween may not include a protrusion, as depicted throughout the drawings. In other words, each first segment 310 having at least two walls (e.g., the first wall 420 and the second wall 425) that can bend toward each other may include at least one protrusion on the inner surface of the corresponding wall. The outer surface of the corresponding wall (e.g., the outer surface of the first wall 420 or the second wall 425) may not include the protrusion. The size (e.g., area or volume) of the first segment 310 that does not include the protrusion on the inner surface of the first segment 310 may be greater than or equal to the size of the first segment 310 that includes the protrusion. For example, when the first wall 420 or the second wall 425 moves inward into a portion of one first segment 310, the same wall may move outward away from a portion of another first segment 310 (e.g., the first segment 310 that is immediately adjacent in the height direction 455) to define a larger open space without the protrusion within the segment 310 (e.g., as Figure 7 as depicted in ).

[0038] Each of the first wall 420, the second wall 425, the third wall 430, or the fourth wall 435 of the first section 310 may have approximately the same thickness. For example, the thickness may be in the range between 1 mm and 5 mm (e.g., the thickness may be 2.5 mm). One or more walls may have different thicknesses. The thickness may be substantially greater or less than between 1 mm and 5 mm. For example, the thickness may be less than 1 mm (e.g., 0.5 mm) or greater than 5 mm (e.g., 10 mm). The smaller thickness of the wall of the first section 310 may facilitate increased manufacturability while reducing excess material.

[0039] The first protrusion 405 may protrude from the inner surface of the first wall 420 by a distance in the range of 1 mm to 5 mm, or the first protrusion 405 may protrude from the inner surface of the first wall 420 by a distance substantially greater than or less than 1 mm to 5 mm. The second protrusion 410 may protrude from the inner surface of the second wall 425 by a distance in the range of 1 mm to 5 mm, or the second protrusion 410 may protrude from the inner surface of the second wall 425 by a distance substantially greater than or less than 1 mm to 5 mm.

[0040] A portion of at least one first section 310 of the body 305 can be configured to facilitate movement of the first protrusion 405 toward the second protrusion 410 (or cause the second protrusion 410 to move toward the first protrusion 405) when a force is applied at or near the third wall 430 (e.g., generally in the width direction 450, from the first end 320 toward the second end 325 of the device 300). For example, the first wall 420 or the second wall 425 of the first section 310 can include at least one recess 415 that can cause the first wall 420 or the second wall 425 to bow (e.g., flex) toward each other in response to the force applied to the body 305. The first wall 420 can include a first recess 415 positioned on a first side of the first protrusion 405 along the width direction 450 and a second recess 415 positioned on a second side of the first protrusion 405 along the width direction 450. The first wall 420 may have a third recess 415 at a first end of the first segment 310 (e.g., adjacent to the second segment 315) along the width direction 450 and a fourth recess 415 at the other end of the first segment 310 along the width direction 450. In some examples, the first wall 420 or the second wall 425 may not include any recess 415.

[0041] The recess 415 may include a discontinuity in the wall (e.g., a partial cutout, a slot, an opening) that may facilitate reducing the rigidity of the first wall 420 or increasing the flexibility of the wall 420. For example, as depicted in the figure, the recess 415 may facilitate (or further facilitate) biasing the first protrusion 405 toward the center of the first section 310 (e.g., by causing the first wall 420 to slightly bow, fold, or bend toward the center due to the recess 415). The second wall 425 may include one or more recesses 415 similarly positioned relative to the second protrusion 410 to bow the second wall 425 toward the center of the first section 310 and bias the second protrusion 410 (e.g., by causing the second wall 425 to slightly fold or bow toward the center). The recess 415 may or may not facilitate biasing the first wall 420 or the second wall 425. For example, when a force is applied to the body 305, the recess 415 may facilitate movement of the protrusions 405, 410 toward each other, but when the body 305 is stationary, the shape of the first wall 420 or the second wall 425 may or may not facilitate. In an example without the recess 415 (not shown), when a force is applied to the body 305, the movement of the protrusions 405, 410 toward each other is facilitated by the shape of the first wall 420 or the second wall 425 (e.g., an arcuate shape), as described above with reference to Figure 4 discussed.

[0042] When a force is applied at or near the third wall 430 (e.g., in a direction from the first end 320 of the device 300 or from the second end 325 of the device 300), the force can further facilitate causing the first wall 420 and the first protrusion 405 to bow or bend toward the second wall 425 and the second protrusion 410. For example, the arcuate shape or recessed portion 415 of the first section 310 encourages the first wall 420 to flex or the second wall 425 to flex toward each other under the force applied to the body 305. Through this flexing, the first protrusion 405 can at least partially contact the second protrusion 410. The first wall 420 or the second wall 425 may not include any protrusions 405, 410, such that the flexing causes a portion of the first wall 420 and the second wall 425 to directly contact (e.g., with or without the protrusions 405, 410).

[0043] The flexing of the first wall 420 and the second wall 425 toward each other when a force is applied to the body 305 can facilitate the body 305 to absorb the energy of the force applied to the body 305 and distribute the load of the force throughout the body 305 by, for example, providing additional stability to the structure of the body 305 after the first wall 420 and the second wall 425 contact (e.g., at the first protrusion 405 and the second protrusion 410). For example, at a first moment in time in which an initial force is applied to the body 305 substantially parallel to the width direction 450, the fourth wall 435 of the one or more first sections 310 may have a first proportion of the total force applied to the body 305. At a second moment in time, when the first wall 420 and the second wall 425 move toward each other so that the first protrusion 405 is about to contact the second protrusion 410, the fourth wall 435 may have a second proportion of the total force applied to the body 305. At a third moment in time after the first protrusion 405 contacts the second protrusion 410, the fourth wall 435 may have a third proportion of the total force applied to the body 305. Thus, the first wall 420 and the second wall 425 (e.g., at the first protrusion 405 and the second protrusion 410) facilitate distributing lateral force loads (e.g., along the width direction 450) throughout the first section 310 to reduce or distribute a portion of the total force applied to the fourth wall 435 over time (e.g., to reduce potential forces applied to the battery pack 110 adjacent to or in line with the fourth wall 425).

[0044] The body 305 can absorb the energy of the force, so that the body 305 helps prevent or significantly reduce the possibility of deformation of the battery pack 110 of the vehicle 105 in response to the force, and the battery pack 110 is disposed adjacent to the body 305. For example, the first wall 420 and the second wall 425 of the first section 310 can be allowed to wrinkle or buckle to promote the absorption of the energy of the force, while the contact between the first protrusion 405 and the second protrusion 410 promotes the stability of the structure of the body 305. For example, the protrusions 405, 410 and the curved first wall 420 and the second wall 425 can offset the neutral buckling axis, which can define a specific direction of buckling and thus reduce or eliminate uncontrolled buckling of the body 305. As described herein, the body 305 can form one or more stable triangular sections in response to the force on the body 305, which can cause secondary peak reaction forces during load displacement. The material, geometry, and structure of the body 305 can facilitate the absorption of the energy of the force applied to the body 305. For example, using aluminum to at least partially form the body 305 via an extrusion can allow for high energy absorption of the material when a force is applied to the body 305. For example, the body 305 provides a large amount of energy absorption with a total of six segments (e.g., three first segments 310 and three second segments 315) having relatively low wall thicknesses (e.g., between 1 mm and 5 mm), as opposed to a body with more segments at higher wall thicknesses. Additionally, the aspect ratio of the first segment 310 can allow for contact between the protrusions 405, 410, which can provide a secondary reaction when a force is applied to the body 305, which in turn can provide additional support to the body 305 when the force is applied.

[0045] One or more second segments 315 may be joined to the first segment 310 at a shared wall. For example, each of the plurality of second segments 315 may include one or more parallel walls (e.g., a first parallel wall 465 and a second parallel wall 470). The first parallel wall 465 of one second segment 315 may be joined at the end of the first wall 420 of the first segment 310, and the second parallel wall 470 of one second segment 315 may be joined at the end of the second wall 425 of the first segment 310. For example, the first parallel wall 465 may be integrally formed with the first wall 420, and the second parallel wall 470 may be integrally formed with the second wall 425. In some examples, the first parallel wall 465 may be formed independently of the first wall 420 and coupled to the first wall 420, and the second parallel wall 470 may be formed independently of the second wall 425 and coupled to the second wall 425. The first parallel wall 465 may be substantially parallel to the first wall 420 (eg, when the first wall 420 does not move toward the second wall 425), and the second parallel wall 470 may be substantially parallel to the second wall 425 (eg, when the second wall 425 does not move toward the first wall 420).

[0046] At least one second segment 315 may be defined by the fourth wall 435 of at least one first segment 310, so that the second segment 315 may be positioned adjacent to the first segment 310. The second segment 315 may include at least one wall having a thickness greater than that of the wall of the first segment 310. For example, the first parallel wall 465, the second parallel wall 470, or the second segment wall 460 extending between the first parallel wall and the second parallel wall may include a thickness greater than or equal to that of the third wall 430 or the first wall 420 of the at least one first segment 310. For example, the second segment wall 460 (or the first parallel wall 465 or the second parallel wall 470) may be within a range of 2 mm and 6 mm (e.g., 3 mm). At least one wall of at least one second segment 315 may not include a recessed portion 415 (e.g., be a substantially planar or curved surface), so that at least one wall of the second segment 315 has a higher stiffness than the first wall 420 or the second wall 425 of the first segment 310. With this configuration, the second section 315 may facilitate providing additional stability to the first section 310 of the body 305. The second segmented wall 460 may be substantially perpendicular to the first parallel wall 465 (or first wall 420) and the second parallel wall 470 (or second wall 425).

[0047] The body 305 may include at least one extension 440 protruding from an outer wall of the body 305 to facilitate orienting or positioning the body 305 relative to the vehicle 105. For example, the extension 440 may be used as a reference feature for aligning the body 305 or another portion of the device 300 with a portion of the vehicle 105. The extension 440 may facilitate reducing relative movement between the body 305 and the vehicle 105 when the body 305 is coupled to the vehicle 105.

[0048] Figure 6 The subject 305 is depicted at a first moment in time, wherein a force is applied to the subject 305 (e.g., in a general direction from left to right). Figure 6 As shown, when a force is exerted on the body 305, the walls 420, 425 of the first section 310 begin to move toward each other. Figure 7 The subject 305 is depicted at a second time instant, wherein a force has been applied to the subject 305 (e.g., in a general direction from left to right). For example, the second time instant may be later than the first time instant. Figure 7As shown, the walls 420, 425 of the first section 310 can move toward each other so that at least a portion of the walls (e.g., the first protrusion 405 and the second protrusion 410) can at least partially contact each other. The first wall 420 and the second wall 425 can move toward each other so that at least a portion of the first section 310 forms a triangular area that defines at least one angle 705 between the third wall 430 and the first wall 420. The size and shape of the first section 310 can be different or varied so that the angle 705 is within the range of 1 degree and 89 degrees. For example, the angle 705 can be within the range of 15 degrees and 75 degrees (e.g., 25 degrees, 35 degrees, 45 degrees, etc.). When the first protrusion 405 contacts the second protrusion 410, the angle 705 can facilitate distributing the load of the force applied to the body 305 over the entire body 305. For example, as the angle 705 increases, the ability of the segment 310 to resist forces on the body 305 decreases until the contact of the protrusions 405 , 410 provides a stable triangular segment 310 .

[0049] Figure 8 An exemplary method 800 of installing a body 305 within a vehicle 105 is depicted. The method 800 may include providing a body 305, as depicted in act 805. Providing the body 305 may include receiving the body 305 after manufacturing the body 305 (e.g., via an extrusion). Providing the body 305 may include manufacturing the body 305 (e.g., via an extrusion or various other processes). The body 305 may include a plurality of walls defining one or more first sections 310. At least two walls of the body 305 (e.g., a first wall 420 and a second wall 425) may be configured to flex and move toward each other when a force is applied to the body 305. For example, the first wall 420 may include a first plurality of recesses 415 that reduce the stiffness of the first wall 420 (e.g., relative to a wall without recesses, such as a planar wall of the same thickness) and at least partially bias the first wall 420 toward the second wall 425. The second wall 425 may include a second plurality of recesses 415 that reduce the stiffness of the second wall 425 and at least partially bias the second wall 425 toward the first wall 420 .

[0050] The first wall 420 may include a first protrusion 405 extending from an inner surface of the first wall 420 toward the second wall 425. The second wall 425 may include a second protrusion 410 extending from an inner surface of the second wall 425 toward the first wall 420. When a force is applied to the body 305, the curved first wall 420 and the curved second wall 425 may move toward each other so that the first protrusion 405 may contact the second protrusion 410. The contact between the first protrusion 405 and the second protrusion 410 may facilitate distributing the load of the force applied to the body 305 throughout the body 305 and provide stability to the body 305 to absorb energy.

[0051] The method 800 may include coupling the body 305 to a portion of the vehicle 105, as depicted in act 810. For example, the body 305 may form a portion of or may be coupled to a frame rail 160 positioned in the vehicle 105 adjacent to or near a battery pack 110 of the vehicle 105 (e.g., between the battery pack 110 and an exterior of the vehicle 105). The body 305 may be coupled to the vehicle 105 in a variety of ways, including, but not limited to, utilizing various types of fasteners. For example, the body 305 may form or may be coupled to a portion of a rocker panel of the vehicle 105.

[0052] Fig. 9 An exemplary method 900 is depicted. The method 900 may include providing a device 300, as depicted in act 905. The device 300 may include at least one body 305. The body 305 may include a plurality of walls defining one or more first sections 310 along a height or length direction of the body 305. At least two walls (e.g., a first wall 420 and a second wall 425) of the body 305 may be configured to flex and move toward each other when a force is applied to the body 305. For example, the first wall 420 may include a first plurality of recesses 415 that reduce the stiffness of the first wall 420 (e.g., relative to a wall without recesses, such as a planar wall) and at least partially bias the first wall 420 toward the second wall 425. The second wall 425 may include a second plurality of recesses 415 that reduce the stiffness of the second wall 425 and at least partially bias the second wall 425 toward the first wall 420.

[0053] The first wall 420 may include a first protrusion 405 extending from an inner surface of the first wall 420 toward the second wall 425. The second wall 425 may include a second protrusion 410 extending from an inner surface of the second wall 425 toward the first wall 420. When a force is applied to the body 305, the curved first wall 420 and the curved second wall 425 may move toward each other so that the first protrusion 405 may contact the second protrusion 410. The contact between the first protrusion 405 and the second protrusion 410 may facilitate distributing the load of the force applied to the body 305 throughout the body 305 and provide stability to the body 305 to absorb energy.

[0054] The device 300 may include at least one second section 315 positioned substantially adjacent to at least one first section 310 of the body 305. The second section 315 may include at least one wall having a higher stiffness than at least one wall of the first section 310 (e.g., the first wall 420). The second section 315 may include at least one wall having a greater thickness than at least one wall of the first section 310 (e.g., the second section wall 460 may be thicker than the first wall 420). The second section 315 may include a lower aspect ratio than the first section 310. The second section 315 may define a generally rectangular shape. The second section 315 may be disposed between the first section 310 and the battery pack 110 of the vehicle 105. For example, at least a portion of the device 300 may be coupled to a frame rail 160 of the vehicle 105 to absorb energy of a force applied to the body 305, thereby reducing or eliminating the force applied to the battery pack 110 (e.g., so that the battery pack 110 is not deformed or damaged).

[0055] Although operations are depicted in a particular order in the drawings, these operations need not be performed in the particular order shown or in sequential order, and not all of the operations shown need be performed. The actions described herein may be performed in a different order.

[0056] Now that some exemplary implementations have been described, it is apparent that the foregoing is illustrative rather than restrictive and has been presented by way of example. Specifically, although many of the examples presented herein relate to specific combinations of method actions or system elements, these actions and these elements may be combined in other ways to achieve the same purpose. The actions, elements, and features discussed in conjunction with one implementation are not intended to be excluded from similar roles in other implementations.

[0057] The words and terms used herein are for descriptive purposes and should not be construed as limiting. The use of "including," "comprising," "having," "containing," "involving," "characterized by," and variations thereof herein is intended to encompass the items listed thereafter, their equivalents and additional items, and alternative implementations consisting solely of the items listed thereafter. In one implementation, the systems and methods described herein consist of one, each combination of more than one, or all of the elements, acts, or components described.

[0058] Any implementation or element or action of the system and method mentioned in the singular form herein may also include an implementation comprising a plurality of these elements, and any plural form of any implementation or element or action herein may also include an implementation comprising only a single element. Reference in the singular or plural form is not intended to limit the currently disclosed system or method, its parts, actions or elements to a single or multiple configurations. Reference to any action or element based on any information, action or element may include a specific implementation in which the action or element is based at least in part on any information, action or element.

[0059] Any implementation disclosed herein may be combined with any other implementation or embodiment, and references to "an implementation," "some implementations," "an implementation," etc. are not necessarily mutually exclusive, but are intended to indicate that a particular feature, structure, or characteristic described in conjunction with an implementation may be included in at least one implementation or embodiment. Such terms as used herein do not necessarily all refer to the same implementation. Any implementation may be combined, inclusively or exclusively, with any other implementation in any manner consistent with the aspects and implementations disclosed herein.

[0060] References to "or" may be interpreted as inclusive, such that any term described using "or" may indicate any of a single, more than one, and all of the terms. References to at least one of a conjunctive list of terms may be interpreted as inclusive OR to indicate any of a single, more than one, and all of the terms. For example, references to "at least one of 'A' and 'B'" may include only "A," only "B," and both "A" and "B." Such references used in conjunction with "including" or other open-ended terms may include additional items.

[0061] Where a technical feature in the drawings, detailed description or any claims is followed by a reference numeral, the reference numeral is included to enhance the intelligibility of the drawings, detailed description and claims. Therefore, the presence or absence of a reference numeral has no limiting effect on the scope of any claim element.

[0062] Without departing substantially from the teachings and advantages of the subject matter disclosed herein, modifications may be made to the elements and actions, such as changes in size, dimensions, structure, shape and proportion, parameter values, mounting arrangements, use of materials, color, orientation of the various elements. For example, an element shown as being integrally formed may be composed of multiple parts or elements, the position of elements may be reversed or otherwise changed, and the nature or number or position of discrete elements may be changed or varied. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the disclosed elements and operations without departing from the scope of the present disclosure.

[0063] For example, the body may include more or fewer sections than shown in the figure. An element described as a negative element may be configured as a positive element, while an element described as a positive element may be configured as a negative element. For example, an element described as having a first polarity may have a second polarity, while an element described as having a second polarity may have a first polarity. Further relative parallel, vertical, vertical or other positioning or orientation descriptions include changes within + / -10% or + / -10 degrees of pure vertical, parallel or vertical positioning. Unless otherwise expressly stated, references to "approximately", "substantially" or other degree terms include changes of + / -10% with a given measurement, unit or range. The connected elements may be electrically connected, mechanically connected or physically connected to each other directly or through an intermediate element. Therefore, the scope of the systems and methods described herein is indicated by the appended claims rather than the foregoing description, and changes falling within the meaning and scope of the equivalents of the claims are included therein.

Claims

1. A device comprising: a body having a plurality of walls dividing the body into a plurality of sections along a height of the body; A first wall and an opposing second wall define a segment of the plurality of segments, a middle portion of the first wall being disposed closer to the second wall than end portions of the first wall in a first direction; and The first wall and the second wall move toward each other along the first direction in response to a force applied to the body along the second direction.

2. The device according to claim 1, comprising: The first wall includes a first protrusion, and the second wall includes a second protrusion; and The first protrusion contacts the second protrusion in response to the force.

3. The device according to claim 1, comprising: The segment further includes a third wall connected to the first wall and the second wall, the third wall receiving a first force when the first wall and the second wall move toward each other and receiving a second force after the first protrusion of the first wall contacts the second protrusion of the second wall; and The first force is different from the second force.

4. The device according to claim 1, comprising: The plurality of segments include a plurality of first segments; The body includes a plurality of second sections; and Each of the plurality of first segments and one of the plurality of second segments have an adjacent wall of the plurality of walls.

5. The device according to claim 1, comprising: The plurality of segments include a plurality of first segments; The body includes a plurality of second sections, each second section of the plurality of second sections includes a plurality of parallel walls; A first parallel wall of the plurality of parallel walls joins at an end of the first wall of the segment; and A second parallel wall of the plurality of parallel walls joins at an end of the second wall of the segment.

6. The device according to claim 1, comprising: The plurality of segments include a plurality of first segments; and The body includes a plurality of second segments integrally formed with the plurality of first segments.

7. The device according to claim 1, comprising: The plurality of segments include a plurality of first segments; and A plurality of second segments are independent of the main body and coupled to the main body.

8. The device according to claim 1, comprising: The body comprises an extrusion.

9. The device according to claim 1, comprising: The body includes a frame rail positioned adjacent to the battery.

10. The device according to claim 1, comprising: The plurality of segments include a plurality of first segments; a plurality of second segments coupled to the body; and The plurality of second segments include a different material than the plurality of first segments.

11. A vehicle comprising: Device, the device comprising: a body having a plurality of walls dividing the body into a plurality of sections along a height of the body; A first wall and an opposing second wall define a segment of the plurality of segments, a middle portion of the first wall being disposed closer to the second wall than end portions of the first wall in a first direction; and The first wall and the second wall move toward each other along the first direction in response to a force applied to the body along the second direction.

12. The vehicle according to claim 11, comprising: The first wall includes a first protrusion, and the second wall includes a second protrusion; and The first protrusion contacts the second protrusion in response to the force.

13. The vehicle of claim 11, comprising: The segment further includes a third wall connected to the first wall and the second wall, the third wall receiving a first force when the first wall and the second wall move toward each other and receiving a second force after the first protrusion of the first wall contacts the second protrusion of the second wall; and The first force is different from the second force.

14. The vehicle of claim 11, comprising: The plurality of segments include a plurality of first segments; The body includes a plurality of second sections; and Each of the plurality of first segments and one of the plurality of second segments have an adjacent wall of the plurality of walls.

15. The vehicle of claim 11, comprising: The plurality of segments include a plurality of first segments; The body includes a plurality of second sections, each second section of the plurality of second sections includes a plurality of parallel walls; A first parallel wall of the plurality of parallel walls joins at an end of the first wall of the segment; and A second parallel wall of the plurality of parallel walls joins at an end of the second wall of the segment.

16. The vehicle of claim 11, comprising: The plurality of segments include a plurality of first segments; and The body includes a plurality of second segments integrally formed with the plurality of first segments.

17. The vehicle of claim 11, comprising: The plurality of segments include a plurality of first segments; and A plurality of second segments are independent of the main body and coupled to the main body.

18. The vehicle of claim 11, comprising: The body comprises an extrusion.

19. An apparatus comprising: a body having a plurality of walls dividing the body into a plurality of first sections and a plurality of second sections; A first wall and an opposing second wall define a segment of the plurality of first segments, a middle portion of the first wall being disposed closer to the second wall than end portions of the first wall in a first direction; and The first wall and the second wall move toward each other along the first direction in response to a force applied to the body along the second direction.

20. The apparatus according to claim 19, comprising: The first wall includes a first protrusion, and the second wall includes a second protrusion; and The first protrusion contacts the second protrusion in response to the force.

Images