Vehicle floor reinforcement with shear panel for rechargeable energy storage system

Abstract

The invention relates to vehicle floor reinforcement with shear panels for rechargeable energy storage systems. A reinforced vehicle floor and rechargeable energy storage system cover having a lower cover panel and an upper cover panel, the lower cover panel having a plurality of first structural formations including at least one of dimples and corrugations such that the lower cover panel includes an upwardly protruding portion and a downwardly protruding portion, the upper cover panel has a second structural formation including at least one of dimples and corrugations such that the upper cover panel includes downwardly protruding portions and upwardly protruding portions, the downwardly protruding portions of the upper cover panel being secured to respective ones of the upwardly protruding portions of the lower cover panel. A vehicle floor panel having a plurality of third structural formations such that the vehicle floor panel includes downwardly projecting portions and upwardly projecting portions, the downwardly projecting portions of the vehicle floor panel being secured to respective ones of the upwardly projecting portions of the upper cover panel.

Description

[0001] introduction

[0002] The information provided in this section is for the purpose of generally presenting the background of the present disclosure. To the extent described in this section, the work of the presently named inventors, and aspects that may not qualify as prior art at the time of filing, are neither explicitly nor implicitly admitted to be prior art to the present disclosure. Technical Field

[0003] The present disclosure relates to vehicle floor reinforcement with shear panels having a rechargeable energy storage system. Background Art

[0004] The top plate of the rechargeable energy storage system and the vehicle floor are currently designed as two separate components, wherein the top plate of the rechargeable energy storage system is a non-structural component mounted below the vehicle floor, which is also largely non-structural. In order to ensure a strong connection that can withstand side impact loads, the mounting strategy between these two components requires various reinforcing longitudinal beams / cross beams. This sandwiched assembly results in a large total number of parts and a high mass. The vehicle floor and the top plate of the rechargeable energy storage system do not provide structural support and only act as sealing panels. Summary of the invention

[0005] The proposed vehicle floor reinforcement with shear panels of a rechargeable energy storage system eliminates the additional structure in traditional installation strategies. The purpose of the present disclosure is to implement a single structural strategy that acts as both a rechargeable energy storage system roof and a vehicle floor and provides all necessary sealing. By incorporating efficient structures directly into the rechargeable energy storage system, the rechargeable energy storage system can reduce its reliance on beams and potting for structural purposes and increase its volume utilization.

[0006] A rechargeable energy storage system for a vehicle, including a rechargeable energy storage system housing having a rechargeable battery cell therein. A structural rechargeable energy storage system cover disposed above the rechargeable energy storage system housing. The structural rechargeable energy storage system cover includes: a lower cover panel having a plurality of first structural formations, the first structural formations including at least one of dimples and corrugations, such that the lower cover panel includes an upwardly projecting portion and a downwardly projecting portion; and an upper cover panel having a second structural formation, the second structural formation including at least one of dimples and corrugations, such that the upper cover panel includes a downwardly projecting portion and an upwardly projecting portion, the downwardly projecting portion of the upper cover panel being fixed to a corresponding upwardly projecting portion of the upwardly projecting portion of the lower cover panel. A vehicle floor panel, including a plurality of third structural formations, the third structural formations including at least one of dimples and corrugations, such that the vehicle floor panel includes a downwardly projecting portion and an upwardly projecting portion, the downwardly projecting portion of the vehicle floor panel being fixed to a corresponding upwardly projecting portion of the upwardly projecting portion of the upper cover panel.

[0007] According to another aspect, a seat mounting structure is mounted to an upwardly projecting portion of a vehicle floor panel.

[0008] According to another aspect, the downwardly protruding portions of the upper cover panel are fixed to corresponding upwardly protruding portions of the upwardly protruding portions of the lower cover panel by welding.

[0009] According to another aspect, the upwardly projecting portions of the upper cover panel are secured to corresponding downwardly projecting portions of the downwardly projecting portions of the vehicle floor panel by mechanical fasteners.

[0010] According to another aspect, a vehicle side rail is adjacent to the rechargeable energy storage system housing, wherein the vehicle floor panel and the rechargeable energy storage system housing are connected to the vehicle side rail.

[0011] According to another aspect, the lower cover panel and the upper cover panel each include a combination of corrugations and dimples.

[0012] According to another aspect, a rechargeable energy storage system for a vehicle includes a rechargeable energy storage system housing having rechargeable battery cells therein. A structural rechargeable energy storage system cover disposed above the rechargeable energy storage system housing, the structural rechargeable energy storage system cover panel having a plurality of first structural formations including at least one of dimples and corrugations such that the cover panel includes upwardly projecting portions and downwardly projecting portions. A vehicle floor panel having a plurality of second structural formations including at least one of dimples and corrugations such that the vehicle floor panel includes downwardly projecting portions and upwardly projecting portions, the downwardly projecting portions of the vehicle floor panel being secured to corresponding upwardly projecting portions of the upwardly projecting portions of the cover panel.

[0013] According to another aspect, a seat mounting structure is mounted to an upwardly projecting portion of a vehicle floor panel.

[0014] According to another aspect, the upwardly projecting portion of the cover panel is secured to a corresponding downwardly projecting portion of the downwardly projecting portion of the vehicle floor panel by a mechanical fastener.

[0015] According to another aspect, a vehicle side rail is adjacent to the rechargeable energy storage system housing, wherein the vehicle floor panel and the rechargeable energy storage system housing are connected to the vehicle side rail.

[0016] According to another aspect, the base panel and the cover panel each include a combination of corrugations and dimples.

[0017] According to another aspect, a rechargeable energy storage system for a vehicle includes a rechargeable energy storage system housing having rechargeable battery cells therein, a structural rechargeable energy storage system cover disposed above the rechargeable energy storage system housing, the structural rechargeable energy storage system cover having a lower cover panel and an upper cover panel, the upper cover panel including a structural formation including at least one of dimples and corrugations such that the upper cover panel includes a downwardly projecting portion and an upwardly projecting portion, the downwardly projecting portion of the upper cover panel being secured to the lower cover panel. A vehicle floor panel comprises: an upper floor panel having a plurality of second structural formations, the second structural formations including at least one of dimples and corrugations, such that the upper floor panel comprises downwardly projecting portions and upwardly projecting portions; and a lower floor panel having a plurality of second structural formations, the second structural formations including at least one of dimples and corrugations, such that the lower floor panel comprises downwardly projecting portions and upwardly projecting portions, the downwardly projecting portions of the upper floor panel being fixed to corresponding upwardly projecting portions of the upwardly projecting portions of the lower floor panel, and the upwardly projecting portions of the upper cover panel of a structural rechargeable energy storage system cover being fixed to the upwardly projecting portions of the lower floor panel.

[0018] According to another aspect, the seat mounting structure is mounted to the upwardly projecting portion of the upper floor panel.

[0019] According to another aspect, the downwardly protruding portion of the upper cover panel is fixed to the lower cover panel by welding.

[0020] According to another aspect, the upwardly projecting portions of the upper cover panel are secured to corresponding ones of the upwardly projecting portions of the lower floor panel by mechanical fasteners.

[0021] According to another aspect, a vehicle side rail is adjacent to a rechargeable energy storage system housing, wherein the vehicle floor and the rechargeable energy storage system housing are connected to the vehicle side rail.

[0022] According to another aspect, the upper floor panel and the lower floor panel each include a combination of corrugations and dimples.

[0023] The present invention proposes the following technical solutions:

[0024] 1. A rechargeable energy storage system for a vehicle, comprising:

[0025] a rechargeable energy storage system housing having rechargeable battery cells therein;

[0026] a structural rechargeable energy storage system cover disposed over the rechargeable energy storage system housing, the structural rechargeable energy storage system cover having a lower cover panel and an upper cover panel, the lower cover panel having a plurality of first structural formations, the first structural formations including at least one of dimples and corrugations, such that the lower cover panel includes an upwardly projecting portion and a downwardly projecting portion, the upper cover panel having a second structural formation, the second structural formations including at least one of dimples and corrugations, such that the upper cover panel includes a downwardly projecting portion and an upwardly projecting portion, the downwardly projecting portions of the upper cover panel being secured to corresponding upwardly projecting portions of the upwardly projecting portions of the lower cover panel;

[0027] A vehicle floor panel having a plurality of third structural formations, the third structural formations comprising at least one of dimples and corrugations, including downwardly projecting portions and upwardly projecting portions, the downwardly projecting portions of the vehicle floor panel being secured to corresponding upwardly projecting portions of the upwardly projecting portions of the upper cover panel.

[0028] 2. The rechargeable energy storage system for a vehicle according to technical solution 1 also includes a seat mounting structure mounted to the upwardly protruding portion of the vehicle floor panel.

[0029] 3. The rechargeable energy storage system for a vehicle according to technical solution 1, wherein the downwardly protruding portion of the upper cover panel is fixed to the corresponding upwardly protruding portion of the upwardly protruding portion of the lower cover panel by welding.

[0030] 4. A rechargeable energy storage system for a vehicle according to technical solution 3, wherein the upward protruding portion of the upper cover panel is fixed to the corresponding downward protruding portion of the downward protruding portion of the vehicle floor panel by mechanical fasteners.

[0031] 5. A rechargeable energy storage system for a vehicle according to technical solution 1, wherein the upward protruding portion of the upper cover panel is fixed to the corresponding downward protruding portion of the downward protruding portion of the vehicle floor panel by mechanical fasteners.

[0032] 6. The rechargeable energy storage system for a vehicle according to Technical Solution 1 further includes a vehicle side beam adjacent to the rechargeable energy storage system housing, wherein the vehicle floor panel and the rechargeable energy storage system housing are connected to the vehicle side beam.

[0033] 7. A rechargeable energy storage system for a vehicle according to technical solution 1, wherein each of the lower cover panel and the upper cover panel includes a combination of corrugations and pits.

[0034] 8. A rechargeable energy storage system for a vehicle, comprising:

[0035] a rechargeable energy storage system housing having rechargeable battery cells therein;

[0036] a structural rechargeable energy storage system cover disposed over the rechargeable energy storage system housing, the structural rechargeable energy storage system cover panel having a plurality of first structural formations, the first structural formations comprising at least one of dimples and corrugations such that the cover panel includes upwardly projecting portions and downwardly projecting portions; and

[0037] A vehicle floor panel having a plurality of second structural formations including at least one of dimples and corrugations such that the vehicle floor panel includes downwardly projecting portions and upwardly projecting portions, the downwardly projecting portions of the vehicle floor panel being secured to corresponding ones of the upwardly projecting portions of the cover panel.

[0038] 9. The rechargeable energy storage system for a vehicle according to technical solution 8 also includes a seat mounting structure mounted to the upwardly protruding portion of the vehicle floor panel.

[0039] 10. A rechargeable energy storage system for a vehicle according to technical solution 8, wherein the upward protruding portion of the cover panel is fixed to a corresponding downward protruding portion of the downward protruding portion of the vehicle floor panel by a mechanical fastener.

[0040] 11. A rechargeable energy storage system for a vehicle according to technical solution 8, wherein the upward protruding portion of the cover panel is fixed to the corresponding downward protruding portion of the downward protruding portion of the vehicle floor panel by welding.

[0041] 12. The rechargeable energy storage system for a vehicle according to Technical Solution 8 further includes a vehicle side beam adjacent to the rechargeable energy storage system shell, wherein the vehicle floor panel and the rechargeable energy storage system shell are connected to the vehicle side beam.

[0042] 13. A rechargeable energy storage system for a vehicle according to Technical Solution 8, wherein each of the floor panel and the cover panel includes a combination of corrugations and pits.

[0043] 14. A rechargeable energy storage system for a vehicle, comprising:

[0044] a rechargeable energy storage system housing having rechargeable battery cells therein;

[0045] a structural rechargeable energy storage system cover disposed over the rechargeable energy storage system housing, the structural rechargeable energy storage system cover having a lower cover panel and an upper cover panel, the upper cover panel including a structural formation, the structural formation including at least one of dimples and corrugations such that the upper cover panel includes a downwardly projecting portion and an upwardly projecting portion, the downwardly projecting portion of the upper cover panel being secured to the lower cover panel; and

[0046] A vehicle floor panel, comprising an upper floor panel and a lower floor panel, the upper floor panel having a plurality of second structural formations, the second structural formations comprising at least one of dimples and corrugations, such that the upper floor panel comprises downwardly projecting portions and upwardly projecting portions, the lower floor panel having a plurality of second structural formations, the second structural formations comprising at least one of dimples and corrugations, such that the lower floor panel comprises downwardly projecting portions and upwardly projecting portions, the downwardly projecting portions of the upper floor panel being fixed to corresponding upwardly projecting portions of the upwardly projecting portions of the lower floor panel, and the upwardly projecting portions of the upper cover panel of the structural rechargeable energy storage system cover being fixed to the upwardly projecting portions of the lower floor panel.

[0047] 15. The rechargeable energy storage system for a vehicle according to technical solution 14 also includes a seat mounting structure mounted to the upwardly protruding portion of the upper floor panel.

[0048] 16. A rechargeable energy storage system for a vehicle according to technical solution 14, wherein the downward protruding portion of the upper cover panel is fixed to the lower cover panel by welding.

[0049] 17. A rechargeable energy storage system for a vehicle according to technical solution 16, wherein the upward protruding portion of the upper cover panel is fixed to the corresponding upward protruding portion of the upward protruding portion of the lower floor panel by mechanical fasteners.

[0050] 18. A rechargeable energy storage system for a vehicle according to technical solution 14, wherein the upward protruding portion of the upper cover panel is fixed to the corresponding upward protruding portion of the upward protruding portion of the lower floor panel by mechanical fasteners.

[0051] 19. The rechargeable energy storage system for a vehicle according to Technical Solution 14 further includes a vehicle side beam adjacent to the rechargeable energy storage system housing, wherein the vehicle floor and the rechargeable energy storage system housing are connected to the vehicle side beam.

[0052] 20. A rechargeable energy storage system for a vehicle according to technical solution 14, wherein each of the upper floor panel and the lower floor panel includes a combination of corrugations and pits.

[0053] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The present disclosure will be more fully understood from the detailed description and accompanying drawings, in which:

[0055] Figure 1 is an exploded perspective view of a three-layer reinforced floor panel and a top plate of a rechargeable energy storage system according to the principles of the present disclosure;

[0056] Figure 2 is a cross-sectional view of a three-layer reinforced floor panel and a top plate of a rechargeable energy storage system according to the principles of the present disclosure;

[0057] Figure 3a-3c illustrates exemplary assembly steps for assembling a three-layer reinforced floor panel and a rechargeable energy storage system top panel to a rechargeable energy storage system and a rocker panel according to an alternative embodiment of the present disclosure;

[0058] Figure 4a is a cross-sectional view of a two-layer reinforced floor panel and a top plate of a rechargeable energy storage system according to the principles of the present disclosure;

[0059] Figure 4b is a schematic cross-sectional view of a two-layer reinforced floor panel and a rechargeable energy storage system top panel assembled to a rechargeable energy storage system and a rocker panel in accordance with the principles of the present disclosure;

[0060] Figure 5a is a schematic cross-sectional view of a four-layer reinforced floor panel and a rechargeable energy storage system top panel assembled to a rechargeable energy storage system and a rocker panel in accordance with the principles of the present disclosure;

[0061] Figure 5b yes Figure 5a Detailed view of

[0062] Figure 6a-6d illustrates an alternative fastening and reinforcement arrangement for assembling layers of reinforced floor panels and a rechargeable energy storage system top plate in accordance with the principles of the present disclosure; and

[0063] Figure 7 is a schematic diagram of a liquid cooled reinforced floor panel and top plate of a rechargeable energy storage system according to the principles of the present disclosure.

[0064] In the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0065] refer to Figure 1 -3, the reinforced vehicle floor and rechargeable energy storage system cover 10 will now be described. Figure 3b and 3c The rechargeable energy storage system 12 best shown in FIG. 1 includes a housing 14 in which a plurality of battery cells may be included. The housing 14 is enclosed and sealed by a reinforced vehicle floor and a rechargeable energy storage system cover 10. Figure 2 , the reinforced vehicle floor and rechargeable energy storage system cover 10 includes a lower cover panel 16 having a plurality of structural formations, the structural formations including at least one of dimples and corrugations, such that the lower cover panel 16 includes an upwardly projecting portion 20a and a downwardly projecting portion 20b, with an inclined sidewall 22 extending vertically therebetween. The upper cover panel 24 includes further structural formations including at least one of dimples and corrugations, such that the upper cover panel 24 includes a downwardly projecting portion 28a and an upwardly projecting portion 28b, with an inclined sidewall 30 extending vertically therebetween. The downwardly projecting portion 28a of the upper cover panel 24 is fixed to a corresponding upwardly projecting portion of the upwardly projecting portion 20a of the lower cover panel 16.

[0066] The vehicle floor panel 32 includes a plurality of structural formations including at least one of dimples and corrugations such that the vehicle floor panel 32 includes a downwardly projecting portion 36a and an upwardly projecting portion 36b with the inclined sidewall 38 extending vertically therebetween. The downwardly projecting portion 36a of the vehicle floor panel 32 is fixed to a corresponding upwardly projecting portion of the upwardly projecting portion 28b of the upper cover panel 24.

[0067] The structural formations of the lower deck panel 16 , the upper deck panel 24 , and the vehicle floor 32 may include various forms, including corrugations and dimples, and combinations thereof. Figure 6a Structural formations all comprising elongated corrugations C are illustrated. Figure 6b A structural formation such as comprising laterally outwardly directed corrugations C and centrally disposed dimples D is illustrated. Figure 6c Structural formations are shown that all include elongated spaced dimples D. Figure 6d The structural formation is illustrated as comprising laterally outward dimples D and centrally disposed corrugations C. Note that the dimples D may have a variety of shapes including, but not limited to, circular, elliptical, and polygonal.

[0068] refer to Figure 2 , one or more seat mounting structures 40 are mounted to the upwardly projecting portion 36b of the vehicle floor panel 32. The seat mounting structures 40 are designed as cross beams extending transversely across the vehicle floor panel 32, and vehicle seats can be mounted to the seat mounting structures 40.

[0069] refer to Figure 3a-3c , the assembly of the reinforced vehicle floor and rechargeable energy storage system cover 10 will now be described. Figure 3a It is shown that the downwardly projecting portion 28 a of the upper cover panel 24 may be secured to a corresponding upwardly projecting portion 20 a of the upwardly projecting portion of the lower cover panel 16 by spot welds 42 . Figure 3b The upper cover panel 24 and the lower cover panel 16 are shown sealingly connected to the housing 14 of the rechargeable energy storage system 12 by mechanical fasteners 44 . Figure 3c It is shown that the downwardly projecting portion 36a of the vehicle floor panel 32 can be secured to a corresponding one of the upwardly projecting portions 28b of the upper cover panel 24 by mechanical fasteners or adhesive 44. Figure 3c , the vehicle side rail 46 is adjacent to the rechargeable energy storage system housing 14. The vehicle floor panel 32 is connected to the flange 48 of the vehicle side rail 46 by a welded connection 50. The rechargeable energy storage system housing 14 is connected to the vehicle side rail 46 by a mounting bracket 52, which can be connected to the housing 14 and the vehicle side rail 46 by mechanical fasteners or adhesives 54.

[0070] refer to Figure 4a and 4b The double panel reinforced vehicle floor and rechargeable energy storage system cover 110 will now be described. Figure 4a As shown, a reinforced vehicle floor and rechargeable energy storage system cover 110 for mounting to a housing 14 of a rechargeable energy storage system 12 includes a cover panel 116 having a plurality of structural formations, the structural formations including at least one of dimples and corrugations, such that the cover panel 116 includes an upwardly projecting portion 120a and a downwardly projecting portion 120b, with an inclined sidewall 122 extending vertically therebetween. A vehicle floor panel 132 includes a plurality of structural formations including at least one of dimples and corrugations, such that the vehicle floor panel 132 includes a downwardly projecting portion 136a and an upwardly projecting portion 136b, with an inclined sidewall 138 extending vertically therebetween. The downwardly projecting portions 136a of the vehicle floor panel 132 are secured to corresponding upwardly projecting portions of the upwardly projecting portions 120a of the cover panel 116. Reference Figure 4b , the vehicle side rail 46 is adjacent to the rechargeable energy storage system housing 14. The vehicle floor panel 132 is connected to the vehicle side rail 46 via a weld or fastener connection 140 directly or through a bracket. The rechargeable energy storage system housing 14 is also connected to the vehicle side rail 46 by a mounting bracket 152, which can be connected to the housing 14 and the vehicle side rail 46 by mechanical fasteners or adhesives 154.

[0071] The structural formations of the cover panel 16 and the vehicle floor panel 132 may include various forms, including corrugations and dimples and combinations thereof, as described with reference to Figure 6a-6d discussed.

[0072] refer to Figure 5a , an alternative four-panel reinforced vehicle floor and rechargeable energy storage system cover 210 for mounting to the housing 14 of the rechargeable energy storage system 12 will now be described. The structural rechargeable energy storage system cover 210 includes a lower cover panel 212 and an upper cover panel 214. The upper cover panel 214 includes a structural formation that includes at least one of dimples and corrugations such that the upper cover panel 214 includes a downwardly protruding portion 218a and an upwardly protruding portion 218b. The upper cover panel 214 may include cutouts to have a shape such as Figure 5bThe grid structure shown. The grid structure has a reduced weight. The downward protrusion 218a of the upper cover panel 214 is fixed to the lower cover panel 212. The vehicle floor includes an upper floor panel 220 and a lower floor panel 226, the upper floor panel 220 has a plurality of second structural formations including at least one of pits and corrugations, so that the upper floor panel 220 includes a downward protrusion 224a and an upward protrusion 224b, and the lower floor panel 226 has a plurality of second structural formations including at least one of pits and corrugations, so that the lower floor panel includes a downward protrusion 230a and an upward protrusion 230b. The downward protrusion 230b of the upper floor panel is fixed to a corresponding upward protrusion in the upward protrusion 230b of the lower floor panel 226, and the upward protrusion 218b of the upper cover panel 214 is fixed to the upward protrusion 230a of the lower floor panel 226. One of the upper vehicle floor panel 220 and the lower vehicle floor panel 226 is connected to the flange 248 of the vehicle side rail 46 by a welded connection 250. The rechargeable energy storage system housing 14 is connected to the vehicle side rail 46 by a mounting bracket 252, which can be connected to the housing 14 and the vehicle side rail 46 by mechanical fasteners or adhesives 254.

[0073] Reference Figure 7 , the exemplary water cooling channels 60 may be nested beneath patterns on the reinforced vehicle floor and panels 16 , 24 , 32 of the rechargeable energy storage system cover 10 , 110 , 210 .

[0074] The reinforced vehicle floor and rechargeable energy storage system cover 10, 110, 210 of the present disclosure minimizes reliance on floor cross members and cross member / structural potting and increases volume utilization of the battery pack. This design can prevent the RESS cover from buckling without a doubler.

[0075] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because other modifications will become apparent after studying the drawings, the specification and the claims below. It should be understood that one or more steps within the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. In addition, although each embodiment is described above as having certain features, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented in the features of any other embodiment and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the permutation of one or more embodiments with each other is still within the scope of the present disclosure.

[0076] The spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "next to," "on top," "above," "below," and "disposed." Unless explicitly described as "direct," when describing the relationship between a first and a second element in the above disclosure, the relationship may be a direct relationship between the first and second elements with no other intervening elements, but may also be an indirect relationship between the first and second elements with one or more intervening elements (spatially or functionally) present. As used herein, the phrase at least one of A, B, and C should be interpreted as meaning a logical (A or B or C), using a non-exclusive logical "or," and should not be interpreted as meaning "at least one of A, at least one of B, and at least one of C."

Claims

1. A rechargeable energy storage system for a vehicle, comprising: a rechargeable energy storage system housing having rechargeable battery cells therein; a structural rechargeable energy storage system cover disposed over the rechargeable energy storage system housing, the structural rechargeable energy storage system cover having a lower cover panel and an upper cover panel, the lower cover panel having a plurality of first structural formations, the first structural formations including at least one of dimples and corrugations, such that the lower cover panel includes an upwardly projecting portion and a downwardly projecting portion, the upper cover panel having a second structural formation, the second structural formations including at least one of dimples and corrugations, such that the upper cover panel includes a downwardly projecting portion and an upwardly projecting portion, the downwardly projecting portions of the upper cover panel being secured to corresponding upwardly projecting portions of the upwardly projecting portions of the lower cover panel; A vehicle floor panel having a plurality of third structural formations, the third structural formations comprising at least one of dimples and corrugations, including downwardly projecting portions and upwardly projecting portions, the downwardly projecting portions of the vehicle floor panel being secured to corresponding upwardly projecting portions of the upwardly projecting portions of the upper cover panel.

2. The rechargeable energy storage system for a vehicle of claim 1 , further comprising a seat mounting structure mounted to the upwardly projecting portion of the vehicle floor panel.

3. The rechargeable energy storage system for a vehicle according to claim 1, wherein: The downwardly protruding portions of the upper cover panel are fixed to corresponding upwardly protruding portions of the upwardly protruding portions of the lower cover panel by welding.

4. The rechargeable energy storage system for a vehicle according to claim 3, wherein: The upwardly projecting portions of the upper cover panel are secured to corresponding downwardly projecting portions of the downwardly projecting portions of the vehicle floor panel by mechanical fasteners.

5. The rechargeable energy storage system for a vehicle according to claim 1, wherein: The upwardly projecting portions of the upper cover panel are secured to corresponding downwardly projecting portions of the downwardly projecting portions of the vehicle floor panel by mechanical fasteners.

6. The rechargeable energy storage system for a vehicle of claim 1, further comprising a vehicle side rail adjacent to the rechargeable energy storage system housing, wherein: The vehicle floor panel and the rechargeable energy storage system housing are connected to vehicle side rails.

7. The rechargeable energy storage system for a vehicle according to claim 1, wherein: The lower cover panel and the upper cover panel each include a combination of corrugations and dimples.

8. A rechargeable energy storage system for a vehicle, comprising: a rechargeable energy storage system housing having rechargeable battery cells therein; a structural rechargeable energy storage system cover disposed over the rechargeable energy storage system housing, the structural rechargeable energy storage system cover panel having a plurality of first structural formations, the first structural formations comprising at least one of dimples and corrugations such that the cover panel includes an upwardly projecting portion and a downwardly projecting portion; and A vehicle floor panel having a plurality of second structural formations including at least one of dimples and corrugations such that the vehicle floor panel includes downwardly projecting portions and upwardly projecting portions, the downwardly projecting portions of the vehicle floor panel being secured to corresponding ones of the upwardly projecting portions of the cover panel.

9. The rechargeable energy storage system for a vehicle of claim 8, further comprising a seat mounting structure mounted to the upwardly projecting portion of the vehicle floor panel.

10. The rechargeable energy storage system for a vehicle according to claim 8, wherein: The upwardly projecting portions of the cover panel are secured to corresponding downwardly projecting portions of the downwardly projecting portions of the vehicle floor panel by mechanical fasteners.

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