Frame assembly and integral battery structure

Patent metadata

Field	Value
Publication number	US-12502944-B2
Application number	US-202418931830-A
Country	US
Kind code	B2
Filing date	Oct 30, 2024
Priority date	Jan 21, 2020
Publication date	Dec 23, 2025
Grant date	Dec 23, 2025

Abstract

A frame assembly for an automobile includes a pair of front frame rails disposed in spaced relationship with a pair of rear frame rails. An upper cover is connected to and extends between the pair of front frame rails and the pair of rear frame rails to define a roof portion. The upper cover includes a pair of longitudinal sidewalls and a pair of cross sidewalls each extending downwardly from the roof portion to define an upper pocket bounded by each of the roof portion, the pair of longitudinal sidewalls and the pair of cross sidewalls. A base plate includes a plate portion for supporting at least one battery module. The base plate is disposed in abutting and connected relationship with the upper cover to dispose the at least one battery module within the upper pocket.

First claim

What is claimed is:

1 . A frame assembly for an automobile comprising:
a pair of front frame rails disposed in spaced relationship with a pair of rear frame rails; an upper cover connected to and extending between said pair of front frame rails and said pair of rear frame rails to define a roof portion; said upper cover including a pair of longitudinal sidewalls and a pair of cross sidewalls each extending downwardly from said roof portion to define an upper pocket bounded by each of said roof portion, said pair of longitudinal sidewalls and said pair of cross sidewalls; a base plate including a plate portion for supporting at least one battery module; said base plate disposed in abutting and connected relationship with said upper cover to dispose said at least one battery module within said upper pocket; and a pair of longitudinal reinforcement members extending along and in abutting relationship with an interior wall surface of a respective one of said pair of longitudinal sidewalls.

2 . The frame assembly as set forth in claim 1 , wherein said pair of longitudinal reinforcement members are each connected to a respective one of said pair of front frame rails and a respective one of said pair of rear frame rails.

3 . The frame assembly as set forth in claim 1 , wherein said at least one reinforcement member includes at least one intermediate reinforcement member extending in spaced and parallel relationship with said pair of longitudinal reinforcement members to define a plurality of columns in said upper pocket each defined by adjacent ones of said pair of longitudinal reinforcement members and said at least one intermediate reinforcement member.

4 . The frame assembly as set forth in claim 3 , wherein said base plate portion of said base plate supports a plurality of battery modules each disposed in one of said plurality of columns of said upper pocket.

5 . The frame assembly as set forth in claim 1 , wherein said plate portion includes an interior plate surface supporting said at least one battery module and an exterior plate surface disposed opposite said interior plate surface, and at least one support beam extending along said exterior plate surface.

6 . The frame assembly as set forth in claim 5 , wherein said at least one support beam includes a pair of longitudinal support beams disposed in spaced and parallel relationship with one another.

7 . The frame assembly as set forth in claim 6 , wherein said at least one support beam further includes at least one transverse support beam extending between said pair of longitudinal support beams.

8 . The frame assembly as set forth in claim 1 , wherein said roof portion is arranged flush with an upper rail surface of said pair of front frame rails and said pair of rear frame rails.

9 . The frame assembly as set forth in claim 1 , further comprising:
said roof portion of said upper cover including a lower upper surface and a raised upper surface being at a higher elevation than said lower upper surface; said plate portion of said base plate including an upper base surface and a lower base surface being at a lower elevation than said upper base surface and disposed in aligned relationship with said raised upper surface of said roof portion; and said at least one battery module including at least one row of vertically stacked battery modules supported between said lower base surface of said plate portion and said raised upper surface of said roof portion.

10 . The frame assembly as set forth in claim 9 , wherein said raised upper surface of said roof portion and said lower base surface of said plate portion are disposed adjacent said pair of rear frame rails.

11 . A frame assembly for an automobile comprising:
a pair of front frame rails disposed in spaced relationship with a pair of rear frame rails; an upper cover connected to and extending between said pair of front frame rails and said pair of rear frame rails to define a roof portion; said upper cover including a pair of longitudinal sidewalls and a pair of cross sidewalls each extending downwardly from said roof portion to define an upper pocket bounded by each of said roof portion, said pair of longitudinal sidewalls and said pair of cross sidewalls; a base plate including a plate portion for supporting at least one battery module; said base plate disposed in abutting and connected relationship with said upper cover to dispose said at least one battery module within said upper pocket; said pair of longitudinal sidewalls and said pair of cross walls extending downwardly to an upper connection flange; and said base plate including a lip extending upwardly from said base plate portion to a base connection flange disposed in abutting and connected relationship with said upper connection flange.

12 . The frame assembly as set forth in claim 11 , further comprising a seal extending between said upper and base connection flanges to seal said upper pocket from an outside environment of the frame assembly.

13 . The frame assembly as set forth in claim 12 , wherein said upper and base connection flanges are connected via a plurality of fasteners.

Assignees

• Langworthy Kevin R
• Yaldo Joseph
• Warpup Ryan
• Kharbanda Sunny
• Gujjal Shrikanth
• Magna Int Inc

Inventors

• Langworthy Kevin R
• Yaldo Joseph
• Warpup Ryan
• Kharbanda Sunny
• Gujjal Shrikanth

Classifications

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title

• B62D21/09

  Means for mounting load bearing surfaces · CPC title

• B60K2001/0438

  Arrangement under the floor · CPC title

• H01M50/271

  Lids or covers for the racks or secondary casings · CPC title

• H01M50/204

  Racks, modules or packs for multiple batteries or multiple cells · CPC title