System for Absorbing and Distributing Side Impact Energy Utilizing an Integrated Battery Pack

Abstract

An energy absorbing and distributing side impact system for use with a vehicle is provided, the system utilizing a battery pack enclosure that includes a plurality of cross-members that transverse the battery pack enclosure and absorb and distribute at least a portion of the load received when either the first or second side of the vehicle receives a side impact. The battery pack enclosure is positioned between the front and rear vehicle suspension assemblies and mounted between, and mechanically coupled to, vehicle structural members (e.g., rocker panels) located on either side of the vehicle. In addition to providing rigidity, strength and impact resistance, the battery pack cross-members segregate the batteries contained within the battery pack enclosure into battery groups.

1 . An energy absorbing and distributing side impact system for a vehicle, comprising a battery pack enclosure configured to hold a plurality of batteries, said battery pack enclosure mounted between a first vehicle structural side member located adjacent to a first side of said vehicle and a second vehicle structural side member located adjacent to a second side of said vehicle, said battery pack enclosure mounted between a front vehicle suspension assembly and a rear vehicle suspension assembly, wherein said battery pack enclosure transverses the distance between said first vehicle structural side member and said second vehicle structural side member, wherein a first side member of said battery pack enclosure is mechanically coupled to said first vehicle structural side member and a second side member of said battery pack enclosure is mechanically coupled to said second vehicle structural side member, wherein said battery pack enclosure further comprises a plurality of cross-members integrated into said battery pack enclosure, wherein each of said plurality of cross-members transverses the distance between said first and second side members of said battery pack enclosure, wherein said plurality of cross-members segregate said plurality of batteries into groups of batteries, wherein each of said plurality of cross-members extends from said first side member of said battery pack enclosure to said second side member of said battery pack enclosure, and wherein a side impact load received on either said first side or said second side of said vehicle is transferred to at least some of said plurality of cross-members. 
     
     
         2 . The energy absorbing and distributing side impact system of  claim 1 , wherein said battery pack enclosure is mounted below a vehicle floor panel. 
     
     
         3 . The energy absorbing and distributing side impact system of  claim 1 , wherein said first vehicle structural side member is a left side rocker panel, and wherein said second vehicle structural side member is a right side rocker panel. 
     
     
         4 . The energy absorbing and distributing side impact system of  claim 1 , said first side member of said battery pack enclosure further comprising an extended region mechanically coupled to a first vehicle structural side member lower surface, and said second side member of said battery pack enclosure further comprising an extended region mechanically coupled to a second vehicle structural side member lower surface. 
     
     
         5 . The energy absorbing and distributing side impact system of  claim 4 , wherein said extended region of said first side member of said battery pack enclosure is bolted using a first plurality of bolts to said first vehicle structural side member lower surface, and wherein said extended region of said second side member of said battery pack enclosure is bolted using a second plurality of bolts to said second vehicle structural side member lower surface. 
     
     
         6 . The energy absorbing and distributing side impact system of  claim 1 , wherein said battery pack enclosure is substantially airtight. 
     
     
         7 . The energy absorbing and distributing side impact system of  claim 1 , wherein each of said plurality of cross-members includes at least one cavity extending an entire length of said corresponding cross-member. 
     
     
         8 . The energy absorbing and distributing side impact system of  claim 7 , wherein each of said plurality of cross-members is fabricated from an extruded aluminum. 
     
     
         9 . The energy absorbing and distributing side impact system of  claim 7 , wherein each of said plurality of cross-members is fabricated from an extruded aluminum alloy. 
     
     
         10 . The energy absorbing and distributing side impact system of  claim 7 , wherein each cavity of said at least one cavity corresponding to each cross-member of said plurality of cross-members is filled with a high melting temperature, low thermal conductivity material. 
     
     
         11 . The energy absorbing and distributing side impact system of  claim 7 , wherein a liquid is contained within each cavity of said at least one cavity corresponding to each cross-member of said plurality of cross-members. 
     
     
         12 . The energy absorbing and distributing side impact system of  claim 1 , wherein each of said plurality of cross-members is comprised of an upper member and a lower member. 
     
     
         13 . The energy absorbing and distributing side impact system of  claim 12 , wherein said upper member of each of said plurality of cross-members includes at least one cavity extending an entire upper member length, and wherein said lower member of each of said plurality of cross-members includes at least one cavity extending an entire lower member length. 
     
     
         14 . The energy absorbing and distributing side impact system of  claim 12 , wherein said upper member of each of said plurality of cross-members is mechanically coupled to a battery pack enclosure top panel, and wherein said lower member of each of said plurality of cross-members is mechanically coupled to a battery pack enclosure bottom panel. 
     
     
         15 . The energy absorbing and distributing side impact system of  claim 1 , wherein each of said plurality of cross-members is fabricated from a material selected from the group of materials consisting of aluminum, aluminum alloys and steel. 
     
     
         16 . The energy absorbing and distributing side impact system of  claim 1 , wherein said battery pack enclosure further comprises a battery pack bottom panel and a battery pack top panel, wherein said first and second side members of said battery pack enclosure, said battery pack bottom panel and said battery pack top panels are each fabricated from a material selected from the group of materials consisting of aluminum, aluminum alloys and steel. 
     
     
         17 . The energy absorbing and distributing side impact system of  claim 16 , wherein said battery pack bottom panel is welded, brazed, soldered or bonded to said first and second side members of said battery pack enclosure. 
     
     
         18 . The energy absorbing and distributing side impact system of  claim 16 , wherein said battery pack top panel is bolted to said first and second side members of said battery pack enclosure.