Battery mounting reinforcement

Abstract

A vehicle frame and battery frame assembly is disclosed that includes a vehicle frame portion, a battery frame portion connected to the vehicle frame portion via one or more battery mounts, and one or more reinforcement devices in direct contact with the one or more battery mounts, the reinforcement device includes one or more of a foamed material, a foamable material, a polymeric support structure, or some combination thereof.

Description

[0001] Priority declaration

[0002] This application claims the benefit of the filing date of U.S. Provisional Application Serial No. 63 / 353,757, filed on June 20, 2022. The entire contents of that application are incorporated herein by reference in their entirety and for all purposes. Technical Field

[0003] The present teachings generally relate to apparatus and methods for reinforcing a vehicle battery mounting structure. The apparatus and methods described herein may be particularly advantageous in providing an improved reinforcement for a vehicle frame as compared to a standard battery mounting structure without the reinforcing apparatus. Background Art

[0004] The use of devices for increasing the strength of a vehicle structural frame is well known. In an electric vehicle, a conventional vehicle frame is connected to a battery frame. The battery frame is a very rigid subsystem. Unfortunately, the vehicle frame cannot actually benefit from this rigid component because the vehicle frame and the battery frame act as independent elements, although they are connected via a battery mount.

[0005] Vehicle mounting structures are also known. For example, mounting structures are used to connect an automobile body to a vehicle suspension. Reinforcement structures have been used to provide additional support to such mounting structures to minimize vibrations of the vehicle body. However, conventional mounting reinforcement structures do not provide a means for increasing the overall stiffness of the vehicle body-in-white.

[0006] Therefore, the vehicle frame and body-in-white are expected to benefit from the stiffness of the battery frame. Summary of the invention

[0007] The present teachings relate to a vehicle frame and battery frame assembly, which includes a vehicle frame portion, a battery frame portion connected to the vehicle frame portion via one or more battery mounts, and one or more reinforcement devices in direct contact with the one or more battery mounts, the reinforcement devices including one or more of a foamed material, a foamable material, a polymer support structure, or some combination thereof.

[0008] The one or more reinforcing devices may include a foaming material that foams and / or cures at room temperature (20°C to 25°C). The one or more reinforcing devices may include a polymer carrier that includes one or more foamable material portions. The foaming material or foamable material may adhere one or more battery mounts to a vehicle frame portion. The one or more reinforcing devices may include a polymer carrier that includes multiple surfaces that are substantially free of any foaming material or foamable material.

[0009] The cavity in the vehicle frame portion may receive one or more reinforcement means. The one or more reinforcement means may include a central portion shaped to receive a battery mount.

[0010] The central portion may be substantially circular or curved in shape.

[0011] The one or more reinforcements may include a plurality of ribs extending radially outwardly from a central portion.

[0012] The one or more reinforcement means may include a foaming material pumped into the cavity surrounding the battery mount.

[0013] The foamable material may be adapted to cure at room temperature (20°C to 25°C).

[0014] The one or more reinforcing devices may include a foam material including a phosphate ester material.

[0015] The one or more reinforcement means may comprise a foamed material and may be free of any polymeric support structure.

[0016] The one or more reinforcement means may comprise a foamable material that expands and / or cures when exposed to heat.

[0017] The one or more reinforcement devices may include an injection molded polymer support structure having a foamable material molded onto the support structure in a multi-shot molding process.

[0018] The one or more reinforcement devices may be located in a cavity formed in the vehicle frame structure, and the one or more reinforcement devices may be adhered to a portion of the cavity via a foamed or foamable material.

[0019] The vehicle frame structure and battery mounting may be metallic and the one or more reinforcements may be non-metallic.

[0020] The one or more reinforcement devices may provide an improvement in the overall static torsional stiffness of the vehicle frame from about 5% to about 10% when compared to an assembly without the one or more reinforcement devices.

[0021] The one or more reinforcement devices may include a support structure that substantially surrounds the one or more battery mounts.

[0022] The one or more reinforcing means comprise a support structure overmoulded with a foamable material.

[0023] The one or more reinforcement devices may include a polymer support structure comprising polyamide, polyvinyl chloride polyetherimide, polycarbonate, poly(methyl methacrylate), acrylonitrile butadiene styrene, polyetherketoneketone, polyaryletherketone, polyetheretherketone, polyphenylene sulfide, polyethylene terephthalate, polypropylene, polyethylene, or any combination thereof.

[0024] One or more of the foamed material, foamable material or polymer support structure comprises one or more reinforcement materials selected from the group consisting of mineral reinforcements, glass reinforcements, carbon reinforcements, polymer reinforcements, elastomeric reinforcements, core-shell polymers or any combination thereof.

[0025] The foaming material, foamable material or support structure may include one or more ribs having a uniform pattern and orientation or having varying patterns and orientations.

[0026] The one or more reinforcement members may include a foamed material substantially surrounded by a support structure.

[0027] The one or more reinforcement devices may include one or more openings for receiving mechanical fasteners, foaming materials, foamable materials, or some combination thereof.

[0028] The one or more reinforcing means may comprise a plurality of ribs extending radially outwardly from a central portion of the one or more reinforcing means.The one or more reinforcing means may comprise a plurality of ribs extending in directions substantially parallel to each other.

[0029] The one or more reinforcements may be located in a cavity formed in the vehicle frame portion, the cavity being formed by the bottom wall and the first and second side walls, and the one or more reinforcements are in direct contact with both the first and second side walls.

[0030] The one or more reinforcements may be located in a cavity formed in the vehicle frame portion, the cavity being formed by the bottom wall and the first and second side walls, and the one or more reinforcements are positioned such that they fill a cross-section of the cavity.

[0031] The vehicle battery may be positioned in contact with the battery frame portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 shows a cross-sectional view of a vehicle frame and battery assembly according to the prior art.

[0033] Figure 2 A cross-sectional view of an exemplary vehicle frame and battery assembly according to the present teachings is shown.

[0034] Figure 3 An exemplary vehicle frame and the location of battery mounts on the vehicle frame are shown.

[0035] Figure 4A , Figure 4B and Figure 4C Cross-sectional views of exemplary battery mounts without and with reinforcements are shown.

[0036] FIG. 5 shows a perspective view of a vehicle frame and battery assembly according to the prior art.

[0037] Figure 6 A perspective view of an exemplary vehicle frame and battery assembly according to the present teachings is shown.

[0038] Figure 7 A perspective view of an exemplary battery mounting reinforcement according to the present teachings is shown.

[0039] Figure 8 A cross-sectional view of an exemplary battery mounting reinforcement according to the present teachings is shown.

[0040] Fig. 9 A perspective view of an exemplary vehicle frame and battery assembly according to the present teachings is shown.

[0041] Fig. 10A and Fig. 10B Relative perspective views of exemplary battery mounting reinforcement devices are shown. DETAILED DESCRIPTION

[0042] This teaching satisfies one or more of the above-mentioned needs through the improved equipment and methods described herein. The explanations and descriptions given herein are intended to make other technical personnel in the field familiar with this teaching, its principles and its practical application. Those skilled in the art can modify and apply this teaching in its various forms, such as can be most suitable for the requirements of a specific purpose. Therefore, the specific embodiments of this teaching set forth are not intended to be exhaustive or limit this teaching. Therefore, the scope of this teaching should not be determined with reference to the above description, but should be determined with reference to the full scope of the attached claims and the equivalents of such claims. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations such as will be collected from the following claims are also possible, and the claims are also incorporated by reference in this written description.

[0043] Electric vehicles use mounting structures (fasteners) to connect the battery frame to the vehicle frame. Although the battery frame has considerable stiffness, the vehicle body cannot benefit from this stiffness. Current teachings relate to reinforcement devices that overcome this challenge and allow the vehicle body to use the stiffness of the battery frame, so that the overall static torsional stiffness of the vehicle body-in-white is improved. When the battery frame is connected to the vehicle frame, it is found that the reinforcement devices located in and / or around the mounting members increase the stiffness of the overall vehicle. In essence, the reinforcement device acts as a stiffness promoter by creating a macrostructure including the battery frame, the vehicle body-in-white and the reinforcement device itself. The reinforcement device described herein can provide significant benefits for hatchback and station wagon architectures because the most sensitive area of ​​the vehicle body that is typically used to increase the overall torsional stiffness of the body-in-white is the rear of the vehicle body. By including a reinforcement device as described herein with respect to the battery mounting member, a significant improvement in overall static torsion can be achieved, which is one of the main performance indicators of overall stiffness in electric vehicles.

[0044] Unlike conventional mounting structures used to connect pillars to the body-in-white, the use of a reinforcement device in combination with a mount for the battery frame provides a unique way to allow the body-in-white to benefit from the stiffness of the battery frame.

[0045] A battery powered (e.g., electric or hybrid) vehicle may include a battery for generating power and delivering the power to the drive wheels. The battery may be located in any part of the vehicle, including, but not limited to, under the chassis, on top of the chassis, under the seat, in the luggage compartment, in the engine compartment, or any combination thereof. For example, the battery may be substantially planar and extend completely from the left side of the vehicle to the right side of the vehicle under the chassis and completely between the rear wheel well and the front wheel well. The battery is typically positioned on a battery frame. The battery frame may be substantially planar.

[0046] The vehicle frame can be used as a structural frame for the vehicle to accommodate components of the vehicle (e.g., engine, drive train, doors, seats, etc.), absorb forces from impact events, prevent intrusion of impact objects (e.g., vehicles, signs, poles, concrete dividers, etc.), protect passengers, protect vehicle components (e.g., engine or battery), or any combination thereof. The frame can include any conventional frame components, including but not limited to: front fenders, quarter panels, A-pillars, B-pillars, C-pillars, door sills, door sill beams, bumper beams, chassis, cross members, or any combination thereof. The frame can define a frame shell, a front wheel well (i.e., in the front end of the vehicle), a rear wheel well (i.e., in the rear end of the vehicle), or any combination thereof.

[0047] The battery frame can be used to fix the battery in place, encapsulate the battery, provide a protective barrier for the battery, or any combination thereof. The battery frame can be located in the space formed by the vehicle frame or near the vehicle frame. The battery frame can be located in or near the passenger compartment, or can span more than one passenger compartment. For example, the battery frame can be located under the seat of the passenger compartment, adjacent to the rear wheel well. As another example, the battery frame can span the left and right passenger compartments of the vehicle. The battery frame can be located on the top of the floor frame, or fastened to the frame below the floor frame, or may be fastened to any other frame member. The battery frame can include a single component or multiple components. The single component battery frame can be fastened to the frame of the vehicle to form a housing (for example, a single component is fastened to the lower side of the floor frame, whereby the battery is completely encapsulated between the floor frame and the single component). The components of the multiple component battery frames can form complementary fits and encapsulate the battery. The battery frame can also accommodate components commonly found in electric drive systems, including but not limited to heaters, controllers, insulators, junction boxes, or any combination thereof.

[0048] The battery frame may be connected to the vehicle frame via one or more mounting structures. The one or more mounting structures may be formed as mechanical fasteners. The one or more mounting structures may include one or any combination of protrusions, extensions, tabs, springs, threaded fasteners, hooks and latches, snap fits, tree clips, or friction fit fasteners. The one or more mounting structures may be in contact with an adhesive. One or both of the vehicle frame and the battery frame may include an opening for receiving a mounting structure. The one or more mounting structures may include bolts. The one or more mounting structures may include a portion attached to the vehicle frame or the battery frame via a welding process.

[0049] The one or more mounting structures can connect the battery frame to the vehicle frame. The vehicle frame can include one or more sill beams, bumper beams and columns. The sill beam can include two sill beams, one for the left sill and one for the right sill. The sill beam can include polymers, metals, or both. The cooperation of the sill beam with the sill can result in the formation of a cavity that can be suitable for accommodating a carrier. The bumper beam can be used to strengthen the front end of the vehicle, the rear end of the vehicle, or both. The bumper beam can be configured to resist the intrusion of collision objects into the engine compartment of the vehicle, the luggage compartment of the vehicle, or both. The bumper beam can be located behind the rear bumper (i.e., the body panel) and the front bumper (i.e., the body panel). The bumper beam can include polymers, metals, or both. The column can be formed to support and protect other areas and structures between the passenger compartment and the floor and roof of the vehicle. The column can include polymers, metals, or both.

[0050] The one or more mounting structures may be equipped with one or more reinforcements (e.g., reinforcement devices). The reinforcement may include a foamed material, a foamable material, a carrier, or some combination thereof. The reinforcement may substantially surround the one or more mounting structures. The reinforcement may improve the strength of the connection between the vehicle frame and the battery frame so that the vehicle frame has improved overall static torsional stiffness compared to a mounting structure without a reinforcement. The reinforcement may be positioned in direct contact with one or more mounting structures, a vehicle frame, a battery frame, or any combination thereof. The reinforcement may be adhered to one or more of the mounting structure, the vehicle frame, the battery frame, or any combination thereof via an adhesive. The reinforcement may be mechanically connected to (or engaged with a friction fit connection to) one or more of the mounting structure, the vehicle frame, the battery frame, or any combination thereof.

[0051] One or more reinforcements may include a foaming material. It is possible that the foaming material may be pumped into a cavity surrounding one or more mounting structures and will foam before or while pumping. The foaming material may foam at room temperature (e.g., 20°C to 25°C) or may require heat to foam. The foaming material may be the only material forming the reinforcement. The reinforcement may be substantially free of any material or device other than the foaming material. The reinforcement may be substantially free of any carrier other than the mounting structure, the vehicle frame, and the battery frame. Alternatively, the foaming material may be located on a carrier. The foaming material may act as an adhesive and adhere to one or more of the mounting structure, the vehicle frame, or the battery frame.

[0052] The one or more reinforcements may include a foamable material. Typically, such foamable materials foam when exposed to a stimulus. Such stimuli may include, but are not limited to, heat, UV light, moisture, pressure, and the like. The foamable material may be located on a carrier that is received by a cavity adjacent to one or more mounting structures. Alternatively, the foamable material may be applied directly to the wall of a cavity adjacent to one or more mounting structures and may be substantially free of any carrier. The foamable material may act as an adhesive and adhere to one or more of a carrier, a mounting structure, a vehicle frame, or a battery frame. The one or more reinforcements may include a polymer carrier that includes one or more foamable material portions. The foamable material or foamable material may adhere one or more battery mounts to a vehicle frame portion.

[0053] Any foamable material located near or adjacent to any cell or cell frame may be present in sufficient amount to help 1) manage heat dissipation from any potential runaway heat, and 2) isolate any runaway discharge, and effectively perform electrical insulation and / or function for grounding.

[0054] If the carrier is present, the carrier may have a substantially uniform or non-uniform cross-sectional geometry along the longitudinal axis. The carrier may have a substantially uniform or non-uniform cross-sectional geometry along any transverse axis (i.e., any axis intersecting perpendicularly to the longitudinal axis, and not limited to any radial orientation). For example, the carrier may have a rectangular cross-section along the transverse axis (i.e., a uniform cross-sectional geometry) or may be an L-shaped cross-section along the transverse axis (i.e., a non-uniform cross-sectional geometry). The geometry along the longitudinal axis and the transverse cross-section may correspond substantially to the geometry of the frame member receiving the carrier. The geometry of the carrier may be radial in nature, so that the circular center portion of the carrier substantially surrounds the mounting structure. The carrier may include a flat outer surface configured to engage and contact the cavity wall (directly in contact or in contact with a foamable material layer located therebetween). The carrier may include a top edge (i.e., configured to face the roof of the vehicle) and a bottom edge (i.e., configured to face the ground). The carrier may include one or more base materials, one or more reinforcing materials, one or more additives, or any combination thereof. The carrier may include a periphery, a rib, a foamable material, or any combination thereof.

[0055] The reinforcement may include one or more ribs. The ribs may inhibit bending, torsion, or both. The ribs may protrude from a central portion of the reinforcement. The ribs may be parallel to one or more additional ribs, or may be perpendicular or offset to one or more additional ribs. One or more ribs may intersect another rib. The ribs may have a thickness of about 0.5 mm to about 2 cm.

[0056] Foaming materials and / or foamable materials can play a role in providing insulation, sealing, structural reinforcement or any combination thereof. Foaming materials and / or foamable materials can help manage heat dissipation from any potential runaway heat associated with battery use. Foaming materials and / or foamable materials can isolate any runaway discharge and effectively perform electrical insulation and / or functions for grounding. Foaming materials and / or foamable materials can be activated to solidify, expand (e.g., foam), soften, flow or any combination thereof. Foaming materials and / or foamable materials can cover most of the surface area of ​​the carrier and / or the cavity that receives the reinforcement (e.g., at least 40%, 60%, 80% or more). Various foaming and / or foamable materials can be used to form reinforcements. Foaming materials and / or foamable materials can generally be dry to the touch and substantially non-sticky, or can be sticky, and in either case, can be shaped in any form of desired pattern, arrangement or thickness, but preferably have a substantially uniform thickness. Exemplary heat-activated foamable materials include L-5520, L-5505, L-5540, L-5905, L-5920, L-5904, L-5235, L-5236 and L-5244 foams, which are commercially available through L&L Products, Inc. Exemplary foaming materials are disclosed in PCT Publication Nos. WO 2020 / 101732, WO 2020 / 205355, WO2020 / 206346 and WO 2020 / 198139, the entire contents of which are incorporated herein by reference for all purposes. Such materials relate to the use of phosphoric acid and phosphate esters for curing compositions in situ. These compositions are typically used in a wide range of room temperature activation systems, such as rigid structural foams, cavity fillings, gaskets and sealants. Benefits of such compositions may include the ability to adhere to a variety of substrates, incorporation of a variety of low volatile organic compounds (VOCs), insensitivity to dispensing temperature, insensitivity to precise mix ratios for two-part systems, the ability to adjust physical and mechanical properties, or any combination thereof.

[0057] In some applications, two or more carriers may be used for a single mounting structure. Alternatively, a single carrier may be used. When two or more carriers are used, the carriers may or may not be fastened together. The carriers may be fastened by adhesives, welding, or fasteners.

[0058] If the carrier exists, the carrier can include one or more base materials, one or more reinforcing materials, or a composite material of the two. The composite material can be layered or uniform. The layered composite material can include two or more discrete layers, and each of the discrete layers can be rigid, ductile, or both. These layers can include adhesives, sealants, tapes, or other materials for connecting composite layers. Such adhesion and / or sealing materials can also be arranged so that more ductile materials are arranged adjacent to more rigid and / or brittle (e.g., less ductile) materials. For example, via a coextrusion process, a polymer (e.g., polyethylene) with less rigidity can be layered with a polymer (e.g., polyamide) with greater rigidity. And a less rigid adhesive can be layered with a more rigid adhesive. A uniformly dispersed composite material can include two or more components that are substantially uniformly present in the entire rib, periphery, or both. For example, via a pultrusion process, glass fibers are coated with polymers (e.g., polyamides) so that glass fibers are evenly distributed in the polymer.

[0059] The carrier may include one or more base materials. The carrier may include a polymer, a metal, or both. The polymer may include polyamide ("PA"), polyvinyl chloride ("PVC"), polyetherimide ("PEI"), polycarbonate ("PC"), poly(methyl methacrylate) ("PMMA"), acrylonitrile butadiene styrene ("ABS"), polyetherketoneketone ("PEKK"), polyaryletherketone ("PAEK"), polyetheretherketone ("PEEK"), polyphenylene sulfide ("PPS"), polyethylene terephthalate ("PET"), polypropylene ("PP"), polyethylene ("PE"), or any combination thereof. The metal may include aluminum, steel, brass, magnesium, zinc, titanium, a metal alloy, or any combination thereof. The one or more base materials may be present in an amount of about 1% to about 70% by weight of the carrier. The carrier may include a single base material (i.e., a homogeneous carrier) or more than one base material (i.e., a composite carrier).

[0060] One or more reinforcing materials can be used to enhance the characteristic of carrier, for example, improve tensile strength, improve flexural strength, distribute energy in reinforcing member, or its any combination.Reinforcing material can comprise mineral reinforcing member, glass reinforcing member, carbon reinforcing member, polymer reinforcing member, elastomeric reinforcing member, core-shell polymer or its any combination.One or more reinforcing materials can exist with the amount of about 0 % by weight to about 70 % by weight of carrier.

[0061] The glass reinforcement may be selected from glass fibers, glass beads, or glass bubbles ("microspheres"). The glass reinforcement may include alumino-borosilicate glass ("E-glass"), soda-lime glass ("A-glass" or "C-glass"), electrically / chemically resistant glass ("E-CR-glass"), borosilicate glass ("D-glass"), alumino-silicate glass ("R-glass" or "S-glass"), or any combination thereof. The glass reinforcement may be chopped fibers. The glass reinforcement may be fibers chopped to a length of about 0.1 cm or more, about 0.3 cm or more, or even about 0.6 cm or more. The glass reinforcement may be a chopped length of about 2.0 cm or less, about 1.5 cm or less, or even about 1.0 cm or less.

[0062] The carbon reinforcement may comprise carbon fibres or woven fabrics.The carbon reinforcement may be 1K, 2K, 3K, 4K, 5K or even 6K (ie 1K means 1000 fibre filaments in a bundle).

[0063] The carrier may be produced by methods including injection molding, extrusion, coextrusion, pultrusion, or any combination thereof.

[0064] The carrier can be produced via injection molding. Injection molding can be suitable for producing homogeneous carriers or composite carriers. The homogeneous carrier can be obtained by injection molding of a base material. The composite carrier can be obtained by injection molding of one or more base materials and one or more reinforcing materials, or two or more base materials. The injection material can be a uniform mixture of one or more base materials and one or more reinforcing materials. For example, polyamide can be mixed with glass fiber reinforcement before being injected into the mold. As another example, a single cylinder can deliver the first base material into the mold cavity and then the second base material can be delivered into the mold cavity, resulting in the first base material being pushed to the periphery of the mold cavity by the second base material, and thus the second base material can be located in the proximal region of the mold cavity (i.e., layered distribution). As another example, a dual cylinder system can involve the first cylinder delivering the first base material to one distal end of the mold cavity, and the second cylinder delivering the second base material to the other distal end of the mold cavity, resulting in the first base material and the second base material being roughly divided into two equal parts (i.e., segmented distribution). Any combination of the above techniques may be employed to obtain a carrier having any combination of one or more base materials, one or more reinforcement materials, or both, in various layered distributions, segmented distributions, or both.

[0065] The carrier can be produced via extrusion. Extrusion can be suitable for producing homogeneous products or composite products. Extrusion can provide a continuous sheet, which leaves the die and can then be cut into a certain length to form a separate carrier. A homogeneous product can be obtained by extruding a base material. For example, the carrier can be obtained by extruding aluminum. The composite product can be obtained by extruding one or more base materials and one or more reinforcing materials. The extruded material can be a uniform mixture of one or more base materials and one or more reinforcing materials. For example, polyamide can be mixed with a glass fiber reinforcement before extrusion. The extruded material can be a combination of two or more base materials. For example, the first material and the second material can be fed into the flow channel before leaving (i.e., coextrusion) through the die, which can produce a carrier with a cross-sectional distribution of the first material and the second material. Coextrusion can be used to obtain one or more, two or more, eight or less, or even seven or less base material layers. Any combination of the above-mentioned techniques can be used to obtain a carrier with one or more base materials, one or more reinforcing materials, or any combination of the two, the one or more base materials, one or more reinforcing materials, or both in various layered distributions, segmented distributions, or both.

[0066] The carrier can be produced via pultrusion. Pultrusion can be suitable for producing composite products. Pultrusion can provide a continuous sheet that leaves the die and can then be cut into lengths to form individual carriers. Pultrusion can be used in conjunction with rovings, fabrics (e.g., unidirectional, woven, multiaxial or randomly oriented (chopped strand mat)) or films. Pultrusion can involve feeding one or more base materials, one or more reinforcing materials, or both through an impregnation tank of one or more base materials before forming the material via a die. For example, a glass fiber roving can be fed through an impregnation tank of a polyamide and then guided through a die with a cantilevered mandrel that forms gaps between the ribs. As another example, a steel wire can be fed through an impregnation tank of a polyamide and then guided through a die with a cantilevered mandrel that forms gaps between the ribs. Any combination of the above techniques may be employed to obtain a carrier having any combination of one or more base materials, one or more reinforcement materials, or both, in various layered distributions, segmented distributions, or both.

[0067] The addition of reinforcements as described herein allows the vehicle body-in-white to benefit from the stiffness of the battery tray. More specifically, the use of reinforcements as described herein improves the overall body torsional stiffness of the vehicle. Body torsional stiffness is the resistance to torsion of the body of a car when a torsional load (torsional load / twisting load) is applied to the body-in-white. In order to measure the overall static torsional stiffness, a static moment is applied to the body-in-white at the front shock tower, while the rear shock tower is constrained. The torsional angle (θ) is generally defined as the deformation angle produced between the front shock tower and the rear shock tower. The corresponding torsional stiffness can be calculated as the ratio of the applied static moment to the torsional angle. When the reinforcements described herein are added to the assembly of the battery frame, the vehicle frame, and the battery mounting, an improvement of up to 1% to about 10% in overall static torsional stiffness is achieved. This result can be further improved when similar reinforcement devices are applied to other areas of the vehicle using mountings, such as the D-pillar.

[0068] 1 depicts a cross-sectional view of an assembly 10 according to the prior art. Assembly 10 includes a vehicle frame / body in white 12, a battery 14, a battery frame 16, and a mounting structure 18. Although the battery 14 and battery frame assembly 16 have considerable stiffness, the vehicle frame 12 does not realize the benefit of the stiffness.

[0069] Figure 2 A cross-sectional view of an exemplary assembly 10 according to the teachings herein is depicted. The assembly 10 includes a vehicle frame 12, a battery 14, a battery frame 16, and a mounting structure 18. Additionally, the mounting structure 18 is in contact with a reinforcement 20.

[0070] Figure 3 An exemplary vehicle frame 12 is depicted along with the location of the battery mount 18 between the vehicle frame 12 and the battery tray 16 .

[0071] Figure 4A A cross-sectional view of an exemplary battery mount 18 without reinforcement is depicted, wherein the battery mount 18 connects the battery frame 16 to the vehicle frame 12 . Figure 4B Depicted is a cross-sectional view of an exemplary battery mount 18 having a reinforcement member including a carrier material 22 and a foamable material 24 (shown after the foamable material has been foamed). Figure 4C Depicted is a cross-sectional view of an exemplary battery mount 18 having a reinforcement member that is free of carrier material and includes a foamed material 24 that has been pumped into the cavity of the vehicle mount.

[0072] FIG5 shows a perspective view of the prior art assembly shown in FIG1 . The assembly includes a vehicle frame 12 , a battery frame 16 , and a mounting structure 18 .

[0073] Figure 6The assembly of Figure 5 is shown including a reinforcement 22, 24 as described herein. The reinforcement shown has a carrier 22 and a foamable material 24 (shown prior to foaming).

[0074] like Figure 7 As shown, the reinforcements 22, 24 may be located within a cavity formed in the vehicle frame 12. A foamable material 24 (shown prior to foaming) may be formed on a surface of the carrier 22 such that the reinforcements are in direct contact with and adhered to the wall of the vehicle frame 12. The carrier 22 is shown as substantially surrounding a portion of the mounting structure 18.

[0075] Figure 8 Shows Figure 7 The reinforcement carrier 22 is positioned so that it substantially surrounds a portion of the mounting structure 18, while the foamable material 24 (shown prior to foaming) is positioned along the wall of the vehicle frame 12. The carrier 22 and the foamable material are substantially free of any direct contact with the battery frame 16.

[0076] Fig. 9 A plurality of reinforcements 22, 24 are shown positioned in two separate cavities formed in the vehicle frame 12. A foamable material 24 (shown prior to foaming) may be formed on a surface of the carrier 22 such that the reinforcements are in direct contact with and adhered to the walls of the vehicle frame 12. The carrier 22 is shown as substantially surrounding a portion of the mounting structure 18 and having no direct contact with the battery frame 16.

[0077] Fig. 10A and Fig. 10B The reinforcement members 22 , 24 are depicted viewed from above and below and include a central portion 28 having an opening that receives a portion of a mounting structure (not shown), a plurality of ribs 26 extending radially from the central portion 28 , and a plurality of openings 30 formed in a bottom portion of the carrier 22 .

[0078] Any numerical value listed in the above application includes all values ​​with one unit increment from the lower value to the higher value, provided that there is an interval of at least 2 units between any lower value and any higher value. These are only examples of specific intent, and all possible combinations of numerical values ​​between the lowest and highest values ​​listed are considered to be clearly stated in this application in a similar manner. Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints.

[0079] The terms "substantially" or "substantially" used to describe angular measurements may mean about + / -10° or less, about + / -5° or less, or even about + / -1° or less. The terms "substantially" or "substantially" used to describe angular measurements may mean about + / -0.01° or greater, about + / -0.1° or greater, or even about + / -0.5° or greater. The terms "substantially" or "substantially" used to describe linear measurements, percentages, or ratios may mean about + / -10% or less, about + / -5% or less, or even about + / -1% or less. The terms "substantially" or "substantially" used to describe linear measurements, percentages, or ratios may mean about + / -0.01% or greater, about + / -0.1% or greater, or even about + / -0.5% or greater.

[0080] The term "consisting essentially of..." describing a combination shall include the identified elements, ingredients, components, or steps, and such other elements, ingredients, components, or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe a combination of elements, ingredients, components, or steps herein also contemplates embodiments consisting essentially of the elements, ingredients, components, or steps.

[0081] Multiple elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step can be divided into separate multiple elements, ingredients, components or steps. The disclosure describes "one" or "an" of an element, ingredient, component or step is not intended to exclude additional elements, ingredients, components or steps.

Claims

1. A vehicle frame and battery frame assembly, comprising: i) vehicle frame; ii) a battery frame portion connected to the vehicle frame portion via one or more battery mounts; iii) one or more reinforcing devices, the one or more reinforcing devices being in direct contact with the one or more battery mounts, the reinforcing devices comprising one or more of a foamed material, a foamable material, a polymer support structure, or some combination thereof.

2. An assembly according to claim 1, wherein the one or more reinforcing means comprise a foaming material that foams and / or cures at room temperature (20°C to 25°C).

3. An assembly according to claim 1 or claim 2, wherein the one or more reinforcing means comprises a polymer carrier including one or more portions of foamable material.

4. An assembly according to any one of claims 1 to 3, wherein the foamed or foamable material adheres the one or more battery mounts to the vehicle frame portion.

5. An assembly according to any one of claims 1 to 4, wherein the one or more reinforcing means comprise a polymer carrier comprising a plurality of surfaces substantially free of any foamed or foamable material.

6. An assembly according to any one of claims 1 to 5, wherein a cavity in the vehicle frame portion receives the one or more reinforcement means.

7. An assembly according to any one of claims 1 to 6, wherein the one or more reinforcement means comprises a central portion shaped to receive a battery mount.

8. The assembly of claim 7, wherein the central portion is substantially circular in shape.

9. An assembly according to claim 7 or claim 8, wherein one or more reinforcement members comprise a plurality of ribs extending radially outwardly from the central portion.

10. An assembly according to any one of claims 1 to 9, wherein the one or more reinforcing means comprises a foamed material pumped into a cavity surrounding the battery mount.

11. The assembly of claim 10, wherein the foamable material is adapted to cure at room temperature (20°C to 25°C).

12. An assembly according to any one of the preceding claims, wherein the one or more reinforcing means comprises a foamed material comprising a phosphate ester material.

13. An assembly according to any one of the preceding claims, wherein the one or more reinforcement means comprise a foamed material and are free of any polymeric support structure.

14. An assembly according to any preceding claim, wherein the one or more reinforcing means comprise a foamable material which expands and / or cures when exposed to heat.

15. An assembly according to any one of the preceding claims, wherein the one or more reinforcement means comprises an injection moulded polymer support structure having a foamable material moulded onto the support structure in a multi-shot moulding process.

16. An assembly according to any one of the preceding claims, wherein the one or more reinforcing devices are located in a cavity formed in the vehicle frame structure and the one or more reinforcing devices are adhered to a portion of the cavity via the foaming material or the foamable material.

17. An assembly according to any one of the preceding claims, wherein the vehicle frame structure and battery mounting are metallic and the one or more reinforcements are non-metallic.

18. The assembly of any of the preceding claims, wherein the one or more reinforcements provide an improvement in overall static torsional stiffness of the vehicle frame of from about 5% to about 10% when compared to an assembly without the one or more reinforcements.

19. An assembly according to any one of the preceding claims, wherein the one or more reinforcement means comprises a support structure substantially surrounding the one or more battery mounts.

20. An assembly according to any preceding claim, wherein the one or more reinforcement means comprises a support structure overmoulded with a foamable material.

21. An assembly according to any of the preceding claims, wherein the one or more reinforcement devices include a polymer support structure, the polymer support structure comprising polyamide, polyvinyl chloride polyetherimide, polycarbonate, poly(methyl methacrylate), acrylonitrile butadiene styrene, polyetherketoneketone, polyaryletherketone, polyetheretherketone, polyphenylene sulfide, polyethylene terephthalate, polypropylene, polyethylene, or any combination thereof.

22. A component according to any of the preceding claims, wherein one or more of the foamed material, the foamable material or the polymer support structure includes one or more reinforcement materials selected from the following: mineral reinforcements, glass reinforcements, carbon reinforcements, polymer reinforcements, elastomeric reinforcements, core-shell polymers or any combination thereof.

23. An assembly according to any one of the preceding claims, wherein the foaming material, the foamable material or the support structure comprises one or more ribs having a uniform pattern and orientation or having a varying pattern and orientation.

24. An assembly according to any preceding claim, wherein the one or more reinforcement members comprise a foamed material substantially surrounded by the support structure.

25. The assembly of any one of the preceding claims, wherein the one or more reinforcement means comprise one or more openings for receiving a mechanical fastener, a foaming material, a foamable material, or some combination thereof.

26. An assembly according to any one of the preceding claims, wherein the one or more reinforcing means comprises a plurality of ribs extending radially outwardly from a central portion of the one or more reinforcing means.

27. An assembly according to any one of the preceding claims, wherein the one or more reinforcement means comprise a plurality of ribs extending in directions substantially parallel to each other.

28. An assembly according to any of the preceding claims, wherein the one or more reinforcements are located in a cavity formed in the vehicle frame portion, the cavity being formed by a bottom wall and first and second side walls, and the one or more reinforcements are in direct contact with both the first and second side walls.

29. An assembly according to any of the preceding claims, wherein the one or more reinforcements are located in a cavity formed in the vehicle frame portion, the cavity being formed by a bottom wall and first and second side walls, and the one or more reinforcements are positioned so that they fill a cross-section of the cavity.

30. An assembly according to any preceding claim, wherein a vehicle battery is positioned in contact with the battery frame portion.

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