ELECTRIC VEHICLE

Abstract

Electric vehicle (20), comprehensive: a chassis (26) comprising a first cross member (40); and a battery pack (30) arranged below the chassis (26) and comprising a support structure with a first tubular transverse component (70); characterized by the fact that the battery pack (30) engages with the chassis (26), the tubular transverse component (70) extending along the first cross member (40) and engaging directly and rigidly with it to form a composite beam.

Description

INTRODUCTION

[0001] The subject matter of the invention relates to an electric vehicle according to the preamble of claim 1.

[0002] Vehicles typically include chassis frames designed to support a variety of vehicle components and contribute to vehicle rigidity and performance. Examples of frame configurations may include ladder frames, single-volume (i.e., monocoque) frames, wrap-around frames, and others. Many frames include opposing side members or rockers connected via a plurality of cross members. Projecting forward from the rocker, respective front rails may be connected via a front cross member, and projecting rearward from the rocker, respective rear rails may be connected via a rear cross member. Related prior art can be found, for example, in documents DE 72 29 746 U, DE 10 2004 056 102 A1, DE 103 51 137 B3, US 2017 / 0 001 507 A1 and DE 10 2012 217 248 A1.

[0003] An engine and front axle can generally be supported by the front rails and near crossmembers. A fuel tank and rear suspension can be supported by the rear rails and near crossmembers. The rocker panels and associated crossmembers can generally support a floor pan, a passenger seat, body pillars, and many other components and functions.

[0004] More modern vehicles may include hybrid vehicles, powered by a combination of batteries and internal combustion engines. However, all fully electric vehicles, or battery electric vehicles (BEVs), can operate solely on a single battery pack. Such vehicles typically support the weight of the batteries on the chassis and in a variety of locations with sufficient storage space. To maintain the desired ground clearance, the batteries are typically located above the chassis. However, batteries in a single vehicle may require a variety of shapes and sizes to utilize available storage space.

[0005] Accordingly, improvements in the battery storage setup for BEVs and the associated structural framework are required to support the battery weight while desirably maintaining and / or meeting other, more conventional structural requirements, while reducing system costs, simplifying the complexity of the design and maintenance processes, and improving robustness.

[0006] In particular, the invention is based on the object of developing a generic electric vehicle in such a way that an increased rigidity of the chassis is achieved with little effort. SUMMARY

[0007] This object is achieved with an electric vehicle which is characterized by the features of claim 1.

[0008] In another embodiment, a bushing bracket mounting reinforcement for a vehicle having a chassis includes a bushing bracket sandwiched with the chassis and a battery pack support structure sandwiched with the bushing bracket.

[0009] The above-mentioned features and advantages as well as other features and advantages of the invention will be readily apparent from the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Other features, advantages and details appear, by way of example only, in the following detailed description of the embodiments, which refers to the following drawings: Fig. 1 is a partially disassembled perspective view of an electric vehicle with parts arranged to show internal details as a non-limiting exemplary example in accordance with one of the present disclosures; Fig. 2 is a bottom view of the electric vehicle from Fig. 1, with a floor pan and battery pack removed to show internal details; Fig. 3 is a bottom view of the electric vehicle from Fig. 1 with a built-in battery pack; Fig. 4 is a partial cross-section of the electric vehicle from Fig. 1, which in the direction of arrows 4-4 in Fig. 3 shows; Fig. 5 is an enlarged cross-section of a connecting cross member of the electric vehicle from circle 5 of the Fig. 4; Fig. Figure 6 is a partial perspective bottom view of the electric vehicle with part removed to show internal details; Fig. 7 is a schematic view illustrating a truss of the electric vehicle; Fig. Figure 8 is a partial bottom view illustrating a support structure of the battery pack engaged with a chassis of the electric vehicle via a plurality of fasteners distributed along a connecting side member, with the floor pan removed, details of circle 8 of the Fig. 3 to show; Fig. 9 is a cross-section of a connecting side member taken in the direction of arrows 9-9 in Fig. 8 shows; Fig. 10 is a disassembled cross-section of the fastener in Fig. 9; Fig. 11 is a cross-sectional view of a third embodiment of a connecting side member; Fig. 12 is a partial perspective bottom view of the vehicle illustrating the one socket bracket secured to the battery pack support structure; and Fig. 13 is a cross-section of the vehicle taken in the direction of arrows 13-13 in Fig. 12 shows. DETAILED DESCRIPTION

[0011] According to an exemplary embodiment of the invention, Fig. 1 illustrates a vehicle 20, which may be a hybrid vehicle or a battery electric vehicle (BEV). The vehicle 20 may include an electrical storage device or battery pack 22, a floor pan 24, and a chassis 26, and may generally be integrated with at least a portion of a vehicle body 28. The floor pan 24 may be disposed underneath and attached to or sandwiched within the chassis 26. The battery pack 22 may include a support 30 and a plurality of electrical storage modules 32. The support structure 30 may be at least partially disposed beneath the floor pan 24 and sandwiched within the chassis 26. Each module 32 may be approximately the same size or identical to simplify design and maintenance and reduce costs.

[0012] With reference to Fig. 2, a bottom view of the chassis 26 with the battery pack 22 deployed is shown to show deployed details. The chassis 26 may include two opposing side members 34, 36 (e.g., rockers), a plurality of elongated cross members (i.e., five shown are 38, 40, 42, 44, 46) laterally spaced from one another, rear side members 48, 50, and front side members 52, 54. In one example, the cross member 38 is tensioned between and sandwiched with the front side members 52, 54, and the cross member 46 is tensioned between and sandwiched with the rear side members 48, 50. The cross members 40, 42, 44 may be cross members for seat supports and may be tensioned between and sandwiched with the side members 34, 36. The chassis 26 may further include a plurality of seat mounts 56 projecting upwardly and connected to at least the cross members 40, 42 (see Fig. 1) for inserting and supporting the passenger seats (not shown).

[0013] With reference to Fig. 3, a bottom view of the vehicle 20 with the installed battery pack 22 is shown, so that essential views of the chassis 26 in Fig. 2 can be largely eliminated or masked. However, it is best to Fig. 4 is an upright cross-section of the vehicle 20, taken along the line 4-4 of the Fig. 3, to illustrate the chassis 26 and the battery pack 22, which is generally disposed beneath the chassis. The battery pack 22 may include a floor pan 58 that may be adapted to generally protect the electrical storage modules 32 from the road surface, may be corrugated, and may at least partially support the modules. The floor pan 58 may be inlaid with the support structure and may generally be disposed beneath the support structure 30 of the battery pack 22. The support structure 30 may include an opposing side component 60, 62 (see Fig. 1 and Fig. 3), a front cross member component 64, rear cross member component 66, and a plurality of elongated cross-sectional components (i.e., four are shown as 68, 70, 72, 74) laterally spaced apart. In Fig. 3, components 60, 62, 68, 70, 72, 74 are shown as ghosts (i.e., dashed lines) because the components are located on the other side of the floor pan 58 in the illustrated example. In one embodiment, the front cross member component 64 is clamped between and sandwiched to the front end portions of the side components 60, 62 and the rear cross member component 66 and is sandwiched with the rear end portion of the side components 60, 62. Components 68, 70, 72, 74 are laterally spaced apart and can each be clamped between and sandwiched sideways with components 60, 62.

[0014] A distance (see arrow 76 in Fig. 3) is measured from the front to back direction between the transverse components 68, 70, and may approximately correspond to a distance (see arrow 78) measured between the transverse components 70, 72. Likewise, the distance 78 may substantially correspond to a distance (see arrow 80) measured between the transverse components 72, 74. In one example, each electrical storage module 32 may be sized to fit precisely between the transverse components 68, 70, 72, 74 to achieve optimal packaging. Because the distances 76, 78, 80 are substantially equivalent, each module 32 may be generally equivalent (i.e., at least in size) to facilitate reduction of manufacturing and maintenance costs through module redundancy. Composite cross member:

[0015] With reference to Fig. 5, the cross members 40 of the chassis 26 and the cross component 70 of the support structure 30 are illustrated; however, it should be understood that the same principles to be described may apply to the remaining cross members and cross components not specifically illustrated. Together, the cross member 40 and the cross component 70 form a connecting cross member 82 (i.e., an integrated cross member) that has a significantly higher strength than the individual cross member and the individual cross component individually. This is generally the strength of the cross member 82 (i.e., bending moment inertia) in a substantially vertical direction, proportional to: (bh3) / 12 where “b” is a constant and “h” is a total height (see arrow 84 in Fig. 5). This increase in vertical rigidity facilitates greater design freedom and packaging of the energy storage module 32 while maintaining the desired floor clearances and passenger roominess within the vehicle 20.

[0016] The cross component 70 may include a lower portion 86, which may be tubular, and an upper portion 88, which may generally be a portion of a spacer. The lower portion 86 may be inlaid and projects upwardly from the battery tray 58. The upper portion 88 is vertically tensioned between and is inlaid on the lower portion 86 and the cross member 40. In one embodiment, the floor pan 24 may be clamped between the upper portion 88 of the cross component 70 and the cross member 40. As best shown in Fig. 5, the lower portion 86 may have a tubular shape with opposing sidewalls 92, 94, a bottom wall 96, and a top wall 98. Similarly, the cross member 40 may have a tubular shape with opposing sidewalls 100, 102, a bottom wall 104, and a top wall 106. In the assembled state, the top wall 106 may be sandwiched with the seat support 56; and the floor pan 24 may be partially disposed therebetween and may contact the bottom wall 104 of the cross member 40 and the top portion 88 of the straddling component 70. It is further contemplated and understood that the cross member 40, the lower portion 86, and the top portion 88 may alternatively be any variety of cross-sectional shapes that provide the desired height with the desired structural integrity. An alternative example of such a structure may be a U-channel.Additionally, all or various segments of the cross member 40, the lower portion 86, and / or the upper portion 88 may be formed from a single piece (e.g., cold rolled from a steel plate) and / or the segments may be bonded or individually attached to other means.

[0017] The connecting cross member 82 may further include a plurality of fasteners 108 distributed on the member for connecting the overlapping component 70 to the cross member 40. As best shown in Fig. 5, each fastener 108 may be a double shear design and may include a bolt 110, a lower sleeve 112, and an upper sleeve 114. When the connecting cross member 82 is assembled, the bolt 110 is generally inverted and may extend along a substantially vertical centerline C. The lower sleeve 112 may be disposed generally inboard of, and axially aligned with, the upper portion 88 and may load vertically on one end against the top wall 98 of the lower portion 86 and vertically on an opposite end against the bottom wall 104 of the cross member 40.

[0018] The upper sleeve 114 may include a tubular portion 116 and a flanged segment 118. After assembly, the tubular portion 116 may be disposed substantially within the cross member 40 and may be centered about the centerline C. A bottom portion of the tubular portion 116 may bear downwardly on the bottom wall 104 of the cross member 40, and an upper portion of the tubular portion may project through the top wall 106 of the cross member 40. The flange or flanged portion 118 projects generally radially outwardly from the upper portion of the tubular portion 116 and bears down on an upwardly facing surface 120 on the top wall 106. At least a portion of the tubular portion 116 may have female threads for threaded engagement by an external thread on a threaded shank 122 of the bolt 110.The bolt 110 further includes an enlarged head 124 disposed in the lower portion 86 of the overlying component 70 and upwardly depressing the top wall 98. It is contemplated that the fastener 108 is the inverse of the fastener described above with the enlarged bearing head depressing the top wall 106 of the cross member 40 and the flange 118 pressing upwardly against the top wall 98 of the bottom portion 86. It is further contemplated and understood that the flanged segment 118, or portions thereof, may be replaced with a threaded nut.

[0019] Benefits and advantages of the present disclosure include a connecting cross member that can provide vibration reduction, improvements in seat belt anchor strength, and increased seat stiffness. Additional benefits can include weight reduction, improved packaging performance, and a flexible design strategy. Truss girders:

[0020] With reference to Fig. 1, Fig. 2 and Fig. 6, the chassis 26 may further include bushing mounts 130, 132 (e.g., coiled spring seats) for coupling to a vehicle suspension, as is known to one of ordinary skill in the art. In the present disclosure, the bushing mounts 130, 132 may be attached to or supported by forward portions of the respective rear side rails 48, 50 of the chassis 26 located adjacent and generally inboard of the rear wheel wells 134, 136 of the vehicle 20. The rear cross member 46 may be attached to the rear side rails 48, 50 immediately forward of the respective bushing mount 130, 132. It is further contemplated that the bushing mount 130, 132 may be any type of connection point where loads are transferred between the chassis 26 and the vehicle suspension system including shock absorber connection points.

[0021] With reference to Fig. 4, Fig. 6 and Fig. 7, cross members 46 of the chassis 26 can be arranged with gaps to the rear and over the adjacent cross member 44 (see Fig. 4) with spaces. The cross member 44 may generally be combined with the cross-member components 74 of the battery support structure 30 to become a connecting cross member, as previously described. In contrast, the pairing of the cross members 46 with the rear cross-member component 66 may not form a connecting cross member and may instead simultaneously form part of a truss 154 (see Fig. 7).

[0022] Just as cross member 44 is located around cross component 74, cross member 46 can be located above rear straddling component 66. However, unlike cross member 44, cross member 46 can be noticeably spaced above rear straddling component 66. Additionally, and in further contrast to the relationship of cross member 44 with straddling component 74, cross member 46 can be positioned slightly behind rear straddling component 66.

[0023] With reference to Fig. 6 and Fig. 7, the trusses 154 may further include first and second braces 138, 140 that may be elongated and angled relative to one another. The first brace includes opposite end portions 142, 144 and the second brace includes opposite end portions 146, 148. Each brace 138, 140 generally spans between the cross member 46 and the rear strut component 66 at an angle (i.e., not completely vertical and not completely horizontal). More specifically, the upper end portions 142, 146 of the respective first and second braces 138, 140 may be interleaved with the respective rear side members 48, 50 (i.e., immediately in front of, and / or near, the bushing mounts 130, 132) and the lower end portions 144, 148 may be interleaved with the rear strut component 66.

[0024] After installation, a measured first distance (see arrow 150 in Fig. 7), between the first end portions 142, 146 substantially correspond to a measured distance between the rear side members 48, 50 of the chassis 26, and substantially greater than a measured distance (see arrow 152) between the second end portions 144, 148. In one embodiment, the distance 152 may be approximately thirty percent (30) of the distance 150.

[0025] When the vehicle 20 is mounted, the rear cross member 46 of the chassis 26 with the struts 138, 140 attached thereto and the associated cross-sectional component 66 of the battery support structure 30 of a truss girder 154 (see Fig. 7). The truss 154 is constructed and arranged to provide an overall stiffer frame for the vehicle 20 in torsion (see arrows 156 for station torsional forces). It is further contemplated and understood that various structural changes to the truss 154, the chassis 26, and the structure of the battery tray 30 may be made without departing from the general structure and operation of the truss 154. For example, connection locations of the struts 138, 140 may change. In one example, the upper end portions 142, 146 may lock with the end portions of the cross member 46 located proximate the respective rear side members 48, 50.

[0026] Advantages and benefits of a truss beam improve the combined strength of the chassis and the supporting structure of a battery pack. Additional benefits include an integrated structure with a greater effective height within a more conventional rear cross member, located close to bushing mounts, thus facilitating an efficient structural load path. Other advantages include reduced vibration, improved stiffness that resists torsional forces, weight reduction, improved packaging performance, and a flexible design strategy. Composite longitudinal beams:

[0027] With reference to Fig. 8 and Fig. 9, the side rail 34 of the chassis 26 and side member 60 of the battery tray structure 30; however, the same principles can be described for the opposite side rail 36 and side member 62. The side rail 34 (i.e., rocker) of the chassis 26 can be connected to the side component 60 of the battery pack support structure 30 via a plurality of fasteners 160. The side component 60 extends coaxially and can be 'boxed' onboard of the side rail 34 such that a portion of the side component 60 is disposed beneath a portion of the side rail 34. More specifically, the boxed alignment between the side component 60 and the side rail 34 can facilitate attachment of the battery pack support structure 30 to the chassis 26 from below to improve structural integrity.In the present example, a single longitudinal member 34 or a side component 60 together may be multicellular and form a connecting side member 162 when connected together.

[0028] With reference to Fig. 9, the longitudinal member 34 of the chassis 26 may extend generally along a centerline 164 and may include an outer shell 166 that may be circumferentially continuous about the centerline 164, and an inner divider 168 that may be disposed within the outer shell 166. The divider 168 may have opposite end portions 182, 184 connected to the outer shell 166. The outer shell 166 may include first and second circumferential shell segments 170, 172 (i.e., walls). A first end portion 174 of the first shell segment is connected to (i.e., or formed coincident with) a first end portion 176 of the second shell segment 172 located proximate the end portion 182 of the inner divider 168. Likewise, an opposite second end portion 178 of the first shell segment 170 may be (ieor is formed in accordance with (in) an opposite second end portion 180 of the second shell segment 172, which is located near the end portion 184 of the inner voltage divider 168.

[0029] With the divider 168 located inside the outer shell 166, the first end portion 182 of the divider 168 can generally couple to the first end portion 174, 176 of the respective first and second shell segments 170, 172, thereby forming a first three-way connection of the end portions 174, 176, 182. Likewise, the second end portion 184 of the divider 168 can generally couple to the second end portions 178, 180 of the respective first and second shell segments 170, 172, thereby forming a second three-way connection of the end portions 178, 180, 184. It is contemplated and understood that the first and second three-way connections will generally be formed or secured by flanges connecting the end portions or other techniques known in the art.

[0030] When the connecting side support 162 is mounted, the first shell segment 170 of the outer shell 166 may be an outer wall, and the second shell segment 172 may be an inner wall (i.e., adjacent to the side panel 60). The first shell segment, or outer wall, 170 and a first side 186 of the divider 168 may define boundaries of a first cell 188. The second shell segment, or inner wall, 172 and an opposite second side 190 of the divider 168 may define the boundaries of a second cell 192.

[0031] The lateral component 60 of the support structure of the battery pack 30 may extend generally along a centerline 194, which may be substantially parallel to the centerline 164. The lateral component 60 may include an outer shell 196, which may be circumferentially continuous around the centerline 194, a first inner wall or divider 198, and a second inner wall or divider 200, both located within the outer shell 196. The outer shell 196 may include first, second, third, and outer shell segments 202, 204, 206. Each shell segment 202, 204, 206 extends circumferentially with a first end portion 208 of the first shell segment 202 connected to a first end portion 210 of the second shell segment 204, and an opposite second end portion 212 of the first shell segment 202 connected to a first end portion 214 of the third shell segment 206.For promotion, an opposite second end portion 216 of the third shell segment 206 is connected to a second end portion 218 of the second shell segment 204. It is intended and understood that the various connections are formed in a manner that is consistent with one another, that they are formed by snapping flanges onto the end portion, or by any other fastening means known to those skilled in the art.

[0032] With the understanding that the first and second inner dividers 198, 200 are located within the outer shell 196, a first end portion 220 of the first divider 198 may be generally coupled to the end portions 208, 210 of the respective shell segments 202, 204, thereby forming a three-way connection of the end portions 208, 210, 220. A second end portion 222 of the first divider 198 may be generally coupled to a first end portion 224 of the second divider 200 and may be further coupled to end portions 212, 214 of the respective first and third shell segments 202, 206, thereby forming a four-way connection of the end portions 212, 214, 222, 224. An opposite second end portion 226 of the second divider 200 may be generally coupled to end portions 216, 218 of the respective third and second shell segments 206, 204, thereby forming a three-way connection of the end portions 216, 218, 226.It is contemplated and understood that the various connections may be formed congruently, formed by indentation of the flanges of the end portions, or may be facilitated by any other fastening means known to one skilled in the art.

[0033] The lateral component 60 may further include first, second, and third cells 230, 232, 234. Boundaries of the first cell 230 may be defined by the first shell segment 202 of the outer shell 196 and a first side 235 of the first divider 198. Boundaries of the second cell 232 are defined by the second shell segment 204 of the outer shell 196, an opposite side 237 of the first divider 198, and a first side 239 of the second divider 200. Boundaries of the third cell 234 are defined by the third shell segment 206 of the outer shell 196 and an opposite side 241 of the second divider 200.

[0034] When the connecting side member 162 is installed, the side member 60 of the support structure of the battery pack 30 can be 'nested' on the side member 34 of the chassis 26. More specifically, a substantially vertical portion of the third shell segment 206 of the side component 60 can be adjacent to a substantially vertical portion of the second shell segment 172 of the side member 34; a substantially horizontal portion of the first shell segment 202 of the side component 60 can be in contact with a substantially horizontal portion of the second shell segment 172 of the side member 34; and, a substantially vertical portion of the first shell segment 202 of the side member 60 can be adjacent to a substantially vertical portion of the first shell segment 170 of the side member 34.The side components and longitudinal members may be made of cold rolled steel, stamped steel, tubular steel, and / or any other materials and structures including composites.

[0035] Benefits and advantages of the present disclosure include a connecting side beam that can offer reduced vibration and increased strength and stiffness. Additional benefits may include weight reduction, improved packaging performance, and a flexible design strategy. Multi-Sear fastening device:

[0036] With reference to Fig. 8 to 10, the fasteners 160 Multi-Shear fasteners (e.g. double shear fastener, see arrow pairs 236 in Fig. 9). The fasteners 160 are similar to, or identical to, the fasteners 108 previously described and used for mounting the cross members 82. In the illustrated example, the fasteners 160 may be used to connect the side members 34 (i.e., rockers) of the chassis 26 to the side member 60 of the battery pack support structure 30 and may be spaced or axially distributed along the side component 60 and side member 34. Each connecting member 160 may be generally elongated and disposed along a substantially vertical centerline C.

[0037] With reference to Fig. 10, each fastener 160 may include opposing first and second heads 238, 240, a shank 242, and a sleeve 244. When assembled, the sleeve 244 extends circumferentially around the shank 242 and may include opposing end portions or faces 246, 247 that may be annular and in axially opposite directions. The first head 238 may be inlaid with an end portion of the shank 242 and projects radially outward therefrom. Together, the first head 238 and the shank 242 may be a unitary, one-piece bolt. The second head 240 may be a flange that projects radially outward from an end portion or face 247 of the sleeve 244, such that the sleeve 244 and the flange 240 may be a unitary piece. An inner cylindrical surface 248 of the sleeve 244 and / or the flange 240 may carry internal threads 250 for retracted and releasable engagement with the external thread 252 carried by the shaft 242.

[0038] When the connecting side member 162 is assembled, the shaft 242 extends axially through openings 254, 256 in respective shell segments 202, 172, through the sleeve 244, and through the second head 240. The sleeve 244 may extend through an opening 258 in the divider 168 of the side member 34. With the shaft 242 engaged and tightened in the thread and to the sleeve 244, the annular face 246 of the sleeve 244 may bear on (i.e., preloaded against) an upwardly facing face 260 of the shell segment 172. An opposite side 262 of the shell segment 172 may load an upwardly facing side 264 of the shell segment 202, and an opposite side 266 of the shell segment 202 may load an upwardly facing surface 268 of the head 238, which may have an annular shape. Additionally, a downwardly facing surface 270 of the head or flange 240, which may have an annular shape, may be preloaded against the side 186 of the divider 168.

[0039] It is further contemplated and understood that in one embodiment, the head 240 may be a threaded nut that threads directly onto the shaft 242. In this example, the sleeve 244 may not extend through the divider 168 and may instead bear upon a downwardly facing side 190 of the divider 168. In another example, the head 240 may be retained or otherwise secured to side 186 of the divider 168 prior to assembly of the connecting side support 162. In this example, the shaft 242 may be tightened without rotating the head 240 and sleeve 244. In yet another example, the head 240 may be a nut that threads onto the shaft 242. In all of these examples, dual shear action on the divider 168 and the shell segments 172, 202 may be facilitated.

[0040] With reference to Fig. 11, a second embodiment of a nested, interconnected side member is illustrated, wherein similar elements to the first embodiment have similar identifying numerals except for the addition of a primary accompaniment symbol. An interconnecting side member 162' may include a longitudinal member 34' and a nested side member 60' secured together via a plurality of multi-shear fasteners 160'. The longitudinal members 34' may be cellular and include an outer shell 166' and a divider 168', both of which define boundaries of cells 188', 192'. Similarly, the side member 60' may be cellular and include an outer shell 196' and a divider 198', both of which define boundaries of cells 272, 274.

[0041] The fastener 160' may be disposed and extends through the cells 192', 272. In one example, the fasteners 160' may include at least one sleeve 244' that extends through both cells 192', 272 and is generally secured and / or loaded onto the dividers 168', 198'. In another example not shown, the sleeve 244' may generally be two separate sleeves that may generally be disposed within respective cells 192', 272. With two separate sleeves, the fastener 160' may include three shear points with the first shear point adjacent to and between the two sleeves and the other two shear points adjacent to the respective ends of a shaft 242'.

[0042] Benefits and advantages of the present disclosure include the ability to removably attach a support structure of a battery pack 30 to a chassis 26 so that the battery pack 22 is not simply a parasitic mass and instead improves the overall vehicle's structural performance. Additional benefits may include improved vehicle-level design goals, which may include vibration reduction and improvements in strength and stiffness. Other benefits may include weight reduction, improved package performance, and a flexible design strategy. Socket bracket assembly for reinforcement:

[0043] With reference to Fig. 3, the vehicle 20 may include a plurality of bushing brackets (i.e., two shown and identified as 280, 282) that may be sandwiched to the chassis 26 as is generally known to one of ordinary skill in the art. In one example, the bushing brackets 280, 282 may be A-bush suspension support structures located proximate the respective rear wheel wells 134, 136 of the vehicle 20. Also in the present disclosure, the bushing brackets 280, 282 may be sandwiched with the support of the battery pack 30, thereby facilitating further reinforcement of the bushing brackets 280, 282 and / or the support structure 30. In one example, the bushing brackets 280, 282 may receive lateral reinforcement from the support structure 30.

[0044] With reference to Fig. 12 and Fig. 13, the bushing bracket 282 is generally illustrated and described; however, it should be understood that the same principles may apply to the bushing bracket 280. The bushing bracket 282 may include first and second lugs 288, 290 spaced apart with a bushing therebetween. The first lug 288 may have an inwardly facing ear adjacent to, and spaced apart from, an inwardly facing ear of the bushing bracket 280 (not shown). The second lug 290 may be an outwardly facing ear. In one example, each lug 288, 290 may project substantially downwardly and may be snapped to a side member 36 of the chassis 26. It is contemplated and understood that the lugs 288, 290 may be interleaved with other components of the vehicle 20 in generally different directions.

[0045] The outer eyelet 290 of the socket retainer 282 may be a single wall of stamped sheet metal and may include an opening or passageway 292 that facilitates retention of the socket. The inner eyelet 288 may be generally tubular and / or may include an inner wall 294, an outer wall 296, and a bottom wall 298 (see Fig. 13). The inner and outer walls 294, 296 may be substantially downwardly extending from and sandwiched with the side member 36 of the chassis 26. The bottom wall 298 may be substantially horizontal and may be sandwiched between, and interleaved with, lower end portions of the inner and outer walls 294, 296. The inner and outer walls 294, 296 may each include an opening or passageway 300 that facilitates bushing retention. In one example, the openings 292, 300 are aligned with a common axis A, which may be substantially horizontal and may be disposed normal to the lugs 288, 290. The inner wall 294, the outer wall 296, and the bottom wall 298 may be stamped from a single piece of sheet metal. It is further contemplated and understood that the entire bushing retainer 282 may be formed from a single sheet metal piece thereby forming a generally S-shaped cross-section.

[0046] With reference to Fig. 3, Fig. 12 and Fig. 13, end sections 304, 306 of the rear overlapping component 66 of the support structure of the battery pack 30 (see Fig. 3) are generally located below and behind the respective bushing brackets 280, 282 when the vehicle 20 is mounted. Rear end portions 308, 310 of the side components 60, 62 (see Fig. 3) can be located at the bottom and connected to floor walls 298 (see Fig. 13) of the inside eyelets 288 of the respective bushing brackets 280, 282. The insertion of the side components 60, 62 with the respective inward eyelets 288 can be facilitated by the respective previously described multi-shear fasteners 160. Together, the bushing brackets 280, 282, the side members 60, 62, the drive shaft cross component 66 and the fasteners 160 can generally form a bushing support structure reinforcement assembly 302 (see also Fig. 12).

[0047] In operation, the insertion of the side parts 60, 62 of the support structure of the battery pack 30 to the inner eyelets 286, 288 of the respective socket holders 280, 282 improves the lateral strength of the holders by reducing the bending of the inner eyelets 288 and providing greater stiffness in a lateral direction (see arrow 312 in Fig. 13) relative to the vehicle 20. This provides greater rigidity in a direction extending between opposite sides of the vehicle 20. Even further, the bushing brackets 280, 282 may contribute in providing vertical support for the support structure 30. It is further contemplated that other structural orientations between the bushing brackets 280, 282 and the support structure 30 may be used. For example, end portions 304, 306 of the rear cross component 66 may be directly inserted onto the inner eyelets 188 of the respective bushing brackets 280, 282.

[0048] Benefits and advantages of the present disclosure include the ability to releasably attach a support structure of a battery pack 30 to a socket mount 280, 282 so that the battery pack 22 is not simply a parasitic mass and instead improves the structural performance of the overall vehicle. Additional benefits may include improved vehicle-level design goals, which may include vibration reduction and improvements in strength and stiffness. Other benefits may include weight reduction, improved pack performance, and a flexible design strategy.

Claims

[1] Electric vehicle (20), comprising: a chassis (26) comprising a first cross member (40); and a battery pack (30) disposed beneath the chassis (26) and having a support structure with a first tubular transverse component (70); characterized by , that the battery pack (30) is engaged with the chassis (26), the tubular transverse component (70) extending along the first cross member (40) and being in direct and rigid engagement therewith to form a composite beam. [2] Electric vehicle (20) according to claim 1, characterized by : a floor pan (24) arranged between the chassis (26) and the battery pack (30). [3] Electric vehicle (20) according to claim 1, characterized by that the chassis (26) is screwed to the supporting structure. [4] Electric vehicle (20) according to claim 1, characterized bythat the chassis (26) comprises opposing longitudinal members (34, 36) and the first cross member (40) extends between the opposing longitudinal members (34, 36) and is in engagement therewith. [5] Electric vehicle (20) according to claim 4, characterized by that the support structure comprises opposing lateral components and the first tubular transverse component (70) extends between and engages the opposing lateral components. [6] Electric vehicle (20) according to claim 1, characterized by that the chassis (26) includes a first seat support which engages the first cross member (40).

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