WO2007112118A2

WO2007112118A2 - Modular vehicle structure

Info

Publication number: WO2007112118A2
Application number: PCT/US2007/007682
Authority: WO
Inventors: Charles J. Warren; Shawn J. Murtha; Todd L. Summe; John W. Cobes
Original assignee: Alcoa Corporate Center
Priority date: 2006-03-27
Filing date: 2007-03-27
Publication date: 2007-10-04
Also published as: WO2007112118A3; WO2007112118A9

Abstract

The present invention in one embodiment provides a vehicle structure including a door having a longitudinal load bearing beam; a first frame post having a load bearing hinge connected to a first end of the longitudinal load bearing beam of the door, and a second frame post having a door lock pin for engaging a load bearing lock engaged to a second end of the longitudinal load bearing beam of the door. In another embodiment, the present invention provides a center module including a passenger compartment between a forward bulkhead and rear bulkhead; and at least two suspension arms each pivotably connected to at least one of the forward bulkhead and a rear bulkhead. In another embodiment, the present invention provides a floor panel housing a battery module container.

Description

MODULAR VEHICLE STRUCTURE

Cross Reference to Related Application [0001] The present invention claims the benefit of U.S. provisional patent application

60/786,320, filed March 27, 2006, the whole contents and disclosure of which is incorporated by reference as is fully set forth herein, and U.S. provisional patent application 60/786,171, filed March 27, 2006, the whole contents and disclosure of which is incorporated by reference as is fully set forth herein.

Field of the Invention

[0002] In one embodiment, the present invention relates to modular vehicle structure. In one embodiment, the modular vehicle structure includes structures to

improve vehicle crash performance. In another embodiment, the modular vehicle

structure includes provisions for integrating battery medium into load bearing components of the vehicle body.

Background of the Invention

[0003] Motor vehicle subassemblies are built into the vehicle body one piece or

component at a time. The installation of literally hundreds of different components in the motor vehicle requires the manufacturer to maintain lengthy, complex, and costly assembly lines as well as extensive tooling and fixtures. This complexity is due not only to the high number of parts involved, but also the assembly methods currently used in the automotive industry and the amount of on-line adjusting and repair that is often needed to

correct assembly defects. Additionally, the well-known assembly line process is highly labor intensive, again due mainly to the high number of parts and assembly methods

currently used in the automotive industry. Further, crash performance must be considered

in vehicle design and assembly, as well as the integration of vehicle electronics further complicating motor vehicle assembly.

Summary of the Invention

[0004] In one embodiment of the present invention, a modular vehicle structure is

provided that includes a light weight center module structured to provide sufficient crash performance, and provides for enhanced integration of the vehicles electronics. In one

embodiment, a modular vehicle structure is provided that includes a suspension system

that vertically displaces the passenger compartment of the vehicle during a collision event, wherein the passenger compartment is displaced away from the longitudinal force

of the collision. In one embodiment, the vehicle structrue includes:

[0005] a center module comprising a passenger compartment between a forward

bulkhead and rear bulkhead; and

[0006] at least two suspension arms each pivotably connected to at least one of the

forward bulkhead and a rear bulkhead.

[0007] In one embodiment, the at least two suspension arms includes a front

suspension arm connected to a lower portion of the front bulkhead, and a rear suspension

arm connected to a lower portion of the rear bulkhead. The front and rear suspension

arms correspond to a wheel, wherein the connectivity to the wheel may be provided by a knuckle and wheel bearing structure. In one embodiment, a dampening structure, such as, but not limited to, struts, springs, shocks, coil over shock, and mcpherson struts,

corresponds to each suspension arm and wheel. In one embodiment, the dampening

structure is connected to an upper portion of the corresponding front and/or rear

bulkhead.

[0008] In another embodiment, the front and rear suspension arms that are

connected to the center module by pivoting connection are configured to axially deform,

also referred to as crush, and pivot in the downward direction when subject to an longitudinal axial force from a collision event. In one embodiment, the dampening structure has a higher crush resistance than the suspension arms. Hence, in one

embodiment, during a collision event as the axial longitudinal force crushes the

suspension arm and the dampening structure maintains it's structural integrity, the

suspension arm pivots in a downward direction while lifting the center module, including the passenger compartment of the vehicle, in an upward direction away from the force of the impact. In one embodiment, the motor vehicle is of a modular construction. In yet another embodiment, the motor vehicle is of a spaceframe, body-over frame, or uni-body sheet construction.

[0009] In another aspect of the invention, a vehicle structure is provided including a door assembly having a longitudinal load beam configured to provide sufficient

longitudinal rigidity to the center module in a front or rear impact event. In one

embodiment, the vehicle structure includes:

[0010] a door having a longitudinal load bearing beam; [0011] a first frame post having a load bearing hinge connected to a first end of the

longitudinal load bearing beam of the door, and

a second frame post having a door lock pin for engaging a load bearing lock engaged to a second end of the longitudinal load bearing beam of the door.

[0012] In one embodiment, for a two door vehicle, or for the front doors of a four door vehicle, the first frame post is an A-post, and the second frame post is a B-post. In another embodiment, for the rear doors of a four door vehicle the first frame post is a B-

post, and the rear frame post is a C-post. In another embodiment, the vehicle includes

two load bearing hinges on the first frame post including an upper load bearing hinge and a lower load bearing hinge. In another embodiment, the door further comprises an anti-

intrusion beam extending from the lower load bearing hinge to the load bearing lock. The term anti-intrusion beams denotes a structre positioned within a door assembly to obstruct a side impact from breaching the passenger compartment of the vehicle. In yet another embodiment, the door further includes two locks, such as an upper lock and a lower lock.

In yet an even further embodiment, the door further includes an anti-intrusion beam extending from the upper load bearing hinge to the lower load bearing lock. In one embodiment, the motor vehicle is of a modular construction. In yet another embodiment,

the motor vehicle is of a spaceframe, body-over frame, or uni-body sheet construction.

[0013] In another aspect of the present invention, a vehicle battery system is

provided in which the battery enclosure is integrated into the floor of the vehicle. In one

embodiment, the vehicle structure includes: [0014] a floor panel including an air intake to a battery module housing;

[0015] a battery module case mounted within the housing; and

[0016] a plurality of battery cells contained within the battery module case.

[0017] In one embodiment, the floor panel and/or battery module case are composed of aluminum or an equally conductive metal. Air entering the air intake of the

floor panel is directed through the housing and over the fins of the aluminum battery

module case, hence cooling the battery module case and the battery cells contained

therein. The floor panel may include a series of fins to increase the floor's rigidity and

heat transfer in order to further aid in the cooling of the battery module case. In one

embodiment, the motor structure including the floor panel of the present invention is of a

modular construction. In yet another embodiment, the vehicle structure including the

floor panel of the present invention is of a spaceframe, body-over frame, or uni-body

sheet construction.

Brief Description of the Drawings

[0018] Figure 1 is a perspective view of one embodiment of a vehicle including a center module in accordance with the present invention.

[0019] Figure 2 is a perspective view of one embodiment of a vehicle of modular

construction having a forward, center and rear module, in accordance with the present

invention. [0020] Figures 3 a and 3b are side views depicting the crush performance of one

embodiment of a suspension system and center module, in accordance with the present invention.

[0021] Figure 4 is a perspective view of one embodiment of a longitudinal load bearing beam, in accordance with the present invention.

[0022] Figure 5a is an exploded view of one embodiment of a door assembly

including the longitudinal load bearing beam, in accordance with the present invention.

[0023] Figure 5b is a cross sectional side view of the door assembly depicted in Figure 5a.

[0024] Figure 6a is a perspective view of one embodiment of a load bearing binge, in accordance the the present invention.

[0025] Figure 6b is a top view of one embodiment of a load bearing hinge, in

accordance the the present invention.

[0026] Figure 7a is a perspective view of one embodiment of a load bearing lock, in accordance the the present invention.

[0027] Figure 7b is a side cross sectional view of one embodiment of a load bearing lock and door lock pin assembly, in accordance the the present invention.

[0028] Figure 8 is a perspective view of one embodiment of a vehicle including a

door assembly including a load bearing hinge, in accordance with the present invention.

[0029] Figure 9 is a perspective view of one embodiment of a vehicle including a

floor panel housing a battery module case, in accordance with the present invention. [0030] Figure 10a is a perspective view of one embodiment of the floor panel, in

accordance with the present invention.

[0031] Figure 10b is a side cross section view of one embodiment of a floor panel,

in accordance with the present invention.

[0032] Figures 11a and 1 Ib are perspective views of one embodiment of a battery

module case, in accordance with the present invention.

[0033] Figure 12 is perspective view of one embodiment of battery cells housed in

a battery module case, in accordance with the present invention.

[0034] Figure 13 is perspective view of one embodiment a battery module case, in accordance with the present invention.

Detailed Description of Preferred Embodiments

[0035] Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of

the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention are intended to be illustrative, and not restrictive. Further, the figures are not necessarily to scale, some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to

variously employ the present invention. [0036] Figure 1 is a perspective view of a center module 100 for a vehicle of

modular construction including suspension components 10 in accordance with the

present invention. The term module construction means a vehicle body having

provisions for the mechanical attachment of subassemblies, such as diveline

subassemblies, suspension subassemblies, crash structure subassemblies, and body panel

subassemblies. In one embodiment of the present invention, a modular construction is

provided in which a center module 100 including provisions for direct connectivity of the suspension component's 10 to the center module 100.

[0037] The term center module 100 means a vehicle body structure including a

front bulkhead 11 and rear bulkhead 12 defining a passenger compartment 13 therebetween. Referring to Figure 2, in one embodiment, the center module 100 includes

provisions for the mechanical attachement of a forward module 101 including the forward most subassemblies of the vehicle, including but not being limited to a crashbox 99; and in another embodiment provides provisions for the mechanical attachment to a rear

module 102 including the rear most subassemblies of the vehicle, including but not being limited to a driveline assembly 98; and in yet another embodiment the center module

provides provisions for the mechanical attachment of both a forward module 101 and a rear module 102. Mechanical attachment may be provide by fasteners, including nut and

bolt arrangements, but welding configurations have been also been contemplated. In one

embodiment, the center module 100 further provides provisions for the attachment of

body sheet panels, such as fender, quarter, rocker, floor, hood, etc. Although rear engine configurations are depicted in Figure 2, it is noted that other diveline geometries have

been contemplated, including but not being limited to front engine configurations.

[0038] Referring to Figure 1, in one embodiment the center module 100 includes a

passenger compartment 13 between a forward bulkhead 11 and rear bulkhead 12. The

center module 100 may be composed of a metal, such as an aluminum alloy, but may also

be composed of steel or magnesium. As used herein ther term aluminum alloy means an

aluminum metal with soluble alloying elements either in the aluminum lattice or in a

phase with aluminum. Alloying element include but are not limited to Cu, Fe, Mg, Ni, Si,

Zn, Mn, Ti, Cr, V, Ag, Sn, Sc, and Li. It has also been contemplated that the center module is composed of polymeric and composite materials.

[0039] In one embodiment, the forward bulkhead 11 and rear bulkhead 12 may be

composed of a casting, or of a sheet construction, or of a combination of construction

including sheet and castings. In one embodiment, castings utilized for the forward bulkhead 11 and rear bulkhead 12 may be composed of Aluminum Association (AA) 3xx

series alloy, such as AA 356 or 357, and sheet material may be provided by an Aluminum Association (AA) 6xxx series alloy, such as AA 6022. In one embodiment, the material of which the forward and rear bulkheads 11, 12 are composed may be heat treated to T6 or T5 temper. In one embodiment, aluminum alloy containing consructions of the

forward and rear bulkhead 11 may have a πύnimum thickness of less than 2.0 mm and

greater than 1.2 mm, with reinforced portions being as great as 4.0 mm thick. [0040] Still referring to Figure 1, in one embodiment, the forward and rear

bulkheads 11, 12 provide for attachment of the suspension components 10. The

suspension components may include, but are not limited to, suspension arms 15, such as

lower suspension arms, knuckle assembles 16, and dampening suspension components 17. In one embodiment, the suspension arms 15 may be composed of a metal, such as an

aluminum alloy. In another embodiment, the suspension arms 15 may be composed of

steel or magnesium. In one embodiment, the suspension arms 15 may be composed of

one or more castings, extrusions, or may be composed of a sheet contrustion or may be a combination thereof. In one embodiment, the suspension arms 15 may be cast of

Aluminum Association 356 or 357 alloy, or extruded of Aluminum Association 6061 or

7013, or may be composed of sheet of Aluminum Association 6022. Although, the suspension arm depicted in Figure 1 only include a lower suspension arm 15, upper suspension arms have been contemplated and are within the scope of the present invention.

[0041] The term "pivotably connected" to at least one of the forward bulkhead 11 and a rear bulkhead 12 denotes one end of each suspension arms 15 is connected to its respective bulkhead in a manner that allows for rotation of the suspension arm 15 about at

least one axis. In one embodiment, the suspension arms 15 are pivotably connected to provide for rotation about an axis being substantially parallel to the surface on which the

vehicle is riding. In one embodiment, the hinged engagement of the suspension arm is

provided by a mount 19 to the bulkhead 11, 12, wherein a stud disposed through the end 14 of the suspension arm 15 in closest proxity to the bulkhead 11, 12 and connected to the

mount sets the axis of rotation for the suspension arm. In one embodiment, the

engagement of the suspension arm 15 to the bulkhead 11, 12 further includes a bushing

that may be composed of rubber or polyurethane.

[0042] In one embodiment, the mount 19 may be composed of a metal material including but not limited to an aluminum alloy, steel or magnesium, which may be

manufactured using castings, extrusions, sheets or combinations thereof. In one embodiment, the portion of the bulkhead 11, 12 corresponding to the mount 18 may be

reinforced by sheet material or castings. In one embodiment, the portion of the firewall

19 may be reinforced by increasing the thickness of the firewall corresponding to the mount 19 with additional sheet or castings. In one embodiment, the additional sheet or

castings 7 may be attached to the mount portions 18 of the bulkhead 11, 12 mechanically,

including but not being limited to rivot, nut and bolt arrangements and combinations thereof, or in another embodiment may be attached by fashion technology, including but not being limited gas metal arc welding, laser welding, electron beam welding, resistance welding or combinations thereof.

[0043] In another embodiment, the mount portion 18 of the bulkhead 11, 12 is reinforced by a torque box 9 that corresponds to a driveline tunnel. In one embodiment,

the torque box 9 is a casting of a metal. The torque box 9 may be composed of aluminum

alloys, steel, magnesium or combinations thereof. In another embodiment, the torque box 9 is provided by a polymeric or composite material. The torque box 9 may be connected to the bulkhead 11, 12 by mechanical fasteners, such as rivets or nut and bolt

arrangements, or may be connected by fashion technology including but not limited to

adhesives and welding, such as gas metal are welding, resistance welding, resistitive

welding, electron beam welding, laser weldling or combinatios thereof. In one

embodiment, the additional sheet or castings 7 and the torque box 9 may extend across the

lower portion of the bulkhead 11, 12, wherein the interconnectivity of the additional sheet

or castings 7 and the torque box 9 provides a cross beam that stiffens the center module

100. In another embodiment, a cross beam may be provided in the lower portion of the

bulkhead without a torque box by extending the additional sheet or castings 7 across the entire width of the bulkhead.

[0044] Still referring to Figure 1, in one embodiment, the suspension components 10 include a dampening structure 17 that is also connected to the bulkhead 11, 12. In one

embodiment, the dampening structure 17 may include but is not limted to springs, stuts,

shocks, coil over shock arrangements, McPearson Strut arrangements, and derivatives thereof. In one embodiment, similar to the connectivity of the suspension arms 15 to the bulkhead 11, 12, the portion of the bulkhead at which the dampening member 17 connects may be reinforced. In one embodiment, the mount 19 for the dampening structure 17 may be reinforced by additional sheet or castings forming a cross beam across the width of an upper portion of the bulkhead 11, 12. In another embodiment, the mount for the

dampening member 17 may be reinforced by the A-pillar 21 or node to the A-pillar of the

front bulkhead 11, or may be reinforced by the C-pillar 26 or node to the C-pillar of the rear bulkheat 12. In one embodiment, the node to the A-pillar may be a casting,

extrusion, or sheet metal product that is mechanically connected or fused to the bulkhead

11, 12. In another embodiment, the node to the A-pillar may be formed into the bulkhead 11, 12.

[0045] In one embodiment, the suspension components 10 include a front

suspension arm 15a connected to a lower portion of the front bulkhead 11, and a rear

suspension arm 15b connected to a lower portion of the rear bulkhead 12. The front and

rear suspension arms 15a, 15b correspond to a wheel 5, wherein the connectivity to the

wheel may be provided by a knuckle 16 and wheel bearing structure. In one embodiment,

the front dampening structure 17a extends from the front knuckle 16 and is connected to

an upper portion of the front bulkhead 11; and the rear dampending structure 17b extends

from the rear knuckle and is connected to an upper portion fo the rear bulkead 11.

[0046] In one embodiment, the suspension components 10 are configured to displace the center module 100, including the passenger compartment 13, in a vertical

direction away from a longitudinal force of a forward impact. More specifically, in one

embodiment, the suspension arms 15 are configured for axial collapse in response to the resultant longitudinal force impacted upon the suspension arms in an impact event. Axial collapse denotes crush or buckling of the suspension arm 15 in a direction parallel to the longitudinal length of the suspension arm 15. In one embodiment, axial collapse

of the suspension arm may occur in response to an axial force along the longitudinal

direction of the suspension arm 14 of approximately 30 kn or greater. In one embodiment, the suspension arms 15 may experience an axial collapse of up to about

75% of the suspension arms original length. In one embodiment, the axial collapse of

the suspension arm 15 is controlled by forming an indentation crush initiator in the

sidewall of the suspension arm 15. In one embodiment, the indentiation crush initiator

may be positioned a distance equal to approximately 10% of the overall length of the

suspension arm 15 from the further most point of the suspension arm 15 from the

bulkhead 11, 12. In one embodiment, a plurality of indentation crush initiator may be

employed along the length of the suspension arm 15. In one embodiment, for a

suspension arm 15 having an approximately 3" to 4" diameter may have an indentation crush initiator of approximately a 6 mm depth. In yet another embodiment, the axial

collapse of the suspension arm 15 may be controlled by notching via material removal at

locations similar to the indentations to initiate crush, as discussed above.

[0047] In yet another embodiment, the dampening member 17 is configured to maintain structural integrity in an impact event. More specifically, in one embodiment,

the dampening member 17 maintains structural integrity in response to a force of approximately 30 Kn or less. The term maintains structural integrity denotes that the dampening member 17 substantially maintains it's dimensions.

[0048] Referring to Figures 3a and 3b, in the event of an impact that induces a

sufficient force in the longitudinal direction of the vehicle to axially crush the suspension

arm 15 yet the dampening member 17 maintains it structural integrity the suspension

components 10 rotate in a downward direction, while lifting the passenger compartment 13 of the vehicle in an upward direction. Figure 3 a represents the suspension system 10

prior to a frontal collision, in which the distance of the vehicle floor from the ground is

depicted by Tl . Figure 3b represents the suspension 10 after a collision, in which the

suspension arm 15 has been axially crushed, rotating in the downward direction and lifting the passenger compartment 70 upward, wherein the distance between the ground

and the vehicle floor T2 is after the collision is greater than the distance between the

vehicle floor and the ground Tl before the collision. Therefore, lifting the passenger

compartment 13 in a vertical direction away from the longitudinal force 80 of the collision. Although, the above description refers to the center module 100 depicted in

Figures 1 and 2, the present suspension system may be integrated into other vehicle architectures, including but not being limited to spaceframe, body over frame, and sheet

metal unibody construction.

[0049] Referring to Figure 1, the passenger compartment 13 of the center module 100 is defined between the front bulkhead 11 and the rear bulkhead 12. In one

embodiment, the volume of the passenger compartment is further defined by the roof 24, the sidewalls 23, and the floor 22. In one embodiment, the roof 24 begins with the A- pillar 21 , wherein the A-pillar extends from the front bulkhead 11 towards the rear bulkhead. The A-pillar 21 may be a metal, such as an aluminum alloy, steel or magnesium material; or may be a polymeric or composite material. In one embodiment,

the A-pillar 21 is extruded from an aluminum alloy, including but not limited to Aluminum Association 6xxx series alloy, i.e. 6061, or a 7xxx series alloy, i.e. 7013. The

A-pillar may also be referred to as a front window pillar.

[0050] The C-pillar 26 extends from the rear bulkhead 12 towards the front bulkhead 11. Simliar to the A-pillar, the C-pillar may be extruded from a metal, such as

an aluminum alloy. The C-pillar may also be referred to as the rear window pillar. In one embodiment, roof rails 25 may extend from the A-pillar 21 to the C-pillar 26, which may

also be composed of extrusions, such as extrusions of aluminum alloy. In one

embodiment, a roof panel 24 of a sheet material may extended beween the roof rails 25.

[0051] Referring to Figure 1, in one embodiment, the sidewalls 23 of the center

module 100 include rockers 27, A-post 28, B-pillar 29, B-post 30, C-post 31 and door assemblys 35, 36. The rockers 27 are composed of a metal, such as an aluminum alloy,

steel or magnesium. In another embodiment, the rockers 27 may be composed of a

polymeric or composite material. The rockers 27 may be provided by extrusions, castings, or sheet metal constructions. In one embodiment the rockers 27 may be extruded from

Aluminum Association 6xxx series alloy, i.e. 6061, or a 7xxx series alloy, i.e. 7013. In one embodiment the rockers 27 extend from the front bulkhead 11 to the rear bulkhead 12. In one embodiment, the rockers may be formed as part of the floor panel 105.

[0052] In one embodiment, the A-post 28 provides for the attachment of the front

door assembly 35, wherein a load bearing hinge is mounted to the A-post 28. In one embodiment, the A-post is a 28 extends from the A-pillar 21 to the rocker 27. In one

embodiment, the A-post is positioned on the face of the font bulkead 11 opposite the face to which the suspension arms 15 are mounted. In one embodiment, the A-post 28 is

integrated into the front bulkhead 11, wherein the A-post 28 may be formed into the cast

or sheet during the construction of the front bulkhead 11. In another embodiment, the A-

post is a separate structure that is fastened to the front bulkhead 11. In yet another

embodiment, the A-post in composed of a material having a thickness ranging from

approximately 2.0 mm to approximately 4.0 mm and can be subjected to a load of up to approximately 20 Kn without plastic deformation.

[0053] The rockers 27 are composed of a metal, such as an aluminum alloy, steel or magnesium. In another embodiment, the rockers 27 may be composed of a polymeric or

composite material. The rockers 27 may be provided by extrusions, castings, or sheet

metal constructions. In one embodiment the rockers 27 may be extruded from Aluminum Association 6xxx series alloy, i.e. 6061, or a 7xxx series alloy, i.e. 7013. In one

embodiment the rockers 27 extend from the front bulkhead 11 to the rear bulkhead 12.

[0054] In one embodiment, the A-post 28 provides for the attachment of the front door assembly 35, wherein a load bearing hinge 41 is mounted to the A-post 28. In one

embodiment, the A-post is a 28 extends from the A-pillar 21 to the rocker 27. In one embodiment, the A-post is positioned on the face of the font bulkead 11 opposite the face

to which the suspension arms 15 are mounted. In one embodiment, the A-post 28 is integrated into the front bulkhead 11, wherein the A-post 28 may be formed into the

casting or sheet structure during the construction of the front bulkhead 11. In another

embodiment, the A-post is a separate structure that is fastened to the front bulkhead 11. In yet another embodiment, the A-post in composed of a material having a thickness

ranging from approximately 2.0 mm to approximately 4.0 mm and can be subjected to a load of up to approximately 20 Kn without plastic deformation.

[0055] In one embodiment, the C-post 3 provides for the reversible locking

engagement the front door assembly 35 in a two door car configuration, or as depicted in Figure 1 provides reversible locking engagement to the rear door assembly 36 in a four

door car configuration, wherein a door lock pin is mounted to the C-post to provide for

engagement to a load bearing lock 43 mounted to the longitudinal load bearing beam 40.

In one embodiment, the C-post 3 extends from the C-pillar 26 to the rocker 27. In one

embodiment, the C-post 3 is positioned on the face of the rear bulkead 12 opposite the . face to which the suspension arms 15 are mounted. In one embodiment, the C-post 43 is

integrated into the rear bulkhead 12, wherein the C-post 43 may be formed into the

casting or sheet structure during the construction of the rear bulkhead 12. In another embodiment, the C-post 3 is a separate structure that is fastened to the rear bulkhead 12. In yet another embodiment, the C-post 3 in composed of a material having a thickness ranging from approximately 2.0 mm to approximately 4.0 mm and can be subjected to a load of up to approximately 20 Kn without plastic deformation.

[0056] In one embodiment, in four door configurations, the B-post 30 provides for

the site for mounting a door lock pin to provide reversible engagement to a load bearing

lock 44 mounted in a second end of the longitudinal load beam of the front door assembly

35, and provides for the mounting of a load bearing hinge 45 for the rear door assembly 36. In one embodiment, the B-post 30 extends from the B-pillar 29 to the rocker 27. In

one embodiment, the B-post and B-pillar may be an unitary structure. In one

embodiment, the B-post 30 may be composed of metal, such as aluminum, steel or

magnesium. In one embodiem the B-post in composed of a material having a thickness ranging from approximately 2.0 mm to approximately 4.0 mm and can be subjected to a load of up to approximately 20 Kn without plastic deformation. In yet another

embodiment, the B-post 30 may be cast, extruded or formed of a sheet material.

[0057] Referring to Figures 1 and 4, in another aspect of the present invention, a

door assembly 35 is provided including a longitudinal load bearing beam 40, a load bearing hinge 41 , 44 and a load bearing lock 42, 43. The term load bearing denotes that

the structure can be subjected to a force of about 20 Kn without plastic deformation.

Plastic deformation means a deformation that is permanent after the release of an applied load. The term longitudinal denotes the direction extending parallel to the distance seperating the front bulkhead 11 to the rear bulkhead. In combination, with the door assemblies 35 in the closed position the longitudinal load bearing structures 40, 41, and

42 of the door assemblies 35 provide structural rigidity to the vehicle in front end and/or

rear end collision. The rigidity is provided by the connectivity of the load bearing structures 40, 41, 42, 43, 44 and the post structures, such as the A-post 28, B-post 30, and C-post 31 , to which the load bearing structures are attached.

[0058] In one embodiment, each of the door assemblies 35, 36 includes a door

shell and a longitudinal load bearing beam 40, in which the longitudinal load bearing beam 40 is connected at it's first end to a load bearing hinge 41 and engages a load

bearing lock 42 at it's second end.

[0059] Figure 4 depicts one embodiment of the longitudinal load bearing beam 40.

In one embodiment, the longitudinal load bearing beam 40 includes an inner beam 50 and

an outer beam 51 connected at a first end having provisions for attachment to the load

bearing hinge 41 , 44 and a second end having provisions for reversibly engaging a lock 42, 43, wherein at least a window mechanism 53 is mounted between the first end and

second end and the inner and out beams 51, 52 of the longitudinal load bearing beam 40.

The window mechanism 53 may include a frame having rails 54 for guiding a window (not shown), a motor 55, and a window ribbon 56.

[0060] Although the window mechanism is depicted as being contained within the

inner and outer beams 51 , 52 of the longitudinal load bearing beam 40, other

embodiments of the present invention have been contemplated in which the window mechanisms are mounted to an exterior surface of the load bearing beam 40. In one embodiment, the load bearing beam 40 may have the geometry of a box cross section, C-

channel cross section, or I-beam cross section. In an even further embodiment, the load bearing beam 40 may have round or rectangular tube configuration.

[0061] In one embodiment, the longitudinal load bearing beam 40 includes a metal

selected from the group including but not being limited to aluminum, steel or

combinations thereof. In one embodiment, the longitudinal load bearing beam 40 may be

formed of one or more extrusions of an aluminum alloy, such as an Aluminum Association 7xxx aluminum alloy. In another embodiment, the longitudinal load bearing

beam 40 may be composed of one or more castings of an aluminum alloy, such as an

Aluminum Association (AA) 3xx aluminum alloy, such as AA 356 or 357. In another

embodiment, the longitudinal load bearing beam 40 may be composed of sheet contruction of an aluminum alloy, such as an Aluminum Association (AA) 6xxx aluminum alloy, such as AA 6082. In yet another embodiment, the longitudinal load

bearing beam 40 may be composed of a combination of castings, extrusion, and sheet

components. In one embodiment, the longitudinal load bearing beam 40 may have a wall

thickness of 3.0 mm ot 4.0 mm. In yet another embodiment the longitudinal load bearing

beam 40 may be subjected to at least a 20 kn load in compression and in tension without sufficient plastic deformation.

[0062] Figure 5a depicts and exploded perspective view of one embodiment of a

door assembly 35 including the longitudinal load bearing beam 40. The door assembly 35

including a door shell including an outer door panel 57 and an inner door panel 58. In one embodiment, the longitudinal load bearing beam 40 is positioned between the inner

door panel 58 and the outer door panel 57 of the door shell. In one embodiment, the door assembly 35 further includes an auxiliary panel 59. Figure 5b depicts one embodiment of a side cross-sectional view of the door assembly, in which the window 60 is depicted in

the partially down position. Still referring to Figure 5b, in one embodiment, the inner beam 50 and outer beam 51 are separated between the first and second end of the

longitudinal bearing structure 40, between which the window mechanism 53 is mounted. [0063] Figures 6a and 6b, depict one embodiment of a load bearing hinge 41 , 44, in

accordance with the present invention. The load bearing hinge 41 , 44 includes a body

flange 61 for mounting to the A-post or B-post of the vehicle and and includes a door

flange 62 for mounting to the longitudinal load bearing beam 40 of the door assembly 35, 36. In one embodiment, the load bearing hinge 41, 44 is composed of metal, such as

steel. In one embodiment, the load bearing hinge 44, 41 is structured to have sufficient

rigidity in the fore-aft direction Ll to transfer the majority of the load of an impact from the post 28, 30 to which the load bearing hinge 41, 44 is mounted through the load

bearing hinge 41, 44 to the load bearing beam 40 of the door assembly 35, 36. In one

embodiment, the load bearing hinge 41, 44 can be subject to a force in the longitudinal direction Ll of about 20 Kn without plastic deformation.

[0064] Figures 7a to 7c, depict one embodiment of a load bearing lock 42, 43 and

door lock pin 66 assembly. In one embodiment, the load bearing lock 42, 43 is mounted

in the load bearing beam 40 of the door assembly 35, 36 and the door lock pin 66 is mounted to the B-post or C-post of the vehicle. In one embodiment, the load bearing

lock 42, 43 and door lock pin 66 assembly provides a mechanism that compensates for body build variations while providing a reversible locking engagement. The term

reversible locking engagement denotes that the lock may be reversibly engaged and

disengaged. Body build variations result from the manufacturing processes utilized to

build motor vehicles. In one embodiment, the body build variations may range from approximately 2.0 mm to approximately 4.0 mm in spacing from a first post 28, 30 on

which the door hinge is mounted to a second post 30, 31 to which the door lock engages.

[0065] Figure 7a depicts a prospective view of a load bearing lock assembly 42, 43, in which a plurality of paws 65 are configured to engage the door lock pin 66. In one

embodiment, to engage the lock the paws 65 rotate about an axis 69 until a tapered wedge

engagement 68 surface contacts the door lock pin 66. The load bearing lock assembly 42,

43 further includes a detent to maintain engagement of the paws 65 to the door lock pin

66. In one embodiment, the detent includes a gear assembly 71 connected to the paws 65 and a finger 70 to engage the teeth of the gear assembly 71. In one embodiment, the

finger 70 may ratchet 71 into a locking position to close the door and disengage to open

the door.

[0066] Figure 7b depicts a cross sectional side view of the load bearing lock 42, 43

and door lock pin assembly 66. In one embodiment, the door lock pin 66 includes a tapered shoulder portion 67 positioned to correspond to the paws 65 of the load bearing lock assembly 42, 43. In one embodiment, each of the paws 65 include a surface having a tapered wedge 68 to engaged the tapered should portion 67 of the door lock pin 66. In one embodiment, the tapered wedge 68 is angled to correspond to the taper of the tapered

should portion 67 of the door lock pin 66. In yet another embodiment, the width w3 of

the tapered wedge 68 measured from the exterior surface 72 of the paw 65 increase

toward the shoulder portion 67 of the door lock pin 66 as the paws 65 are rotated about

their axis 69 to engage the tapered shoulder portion 67 of the door lock pin 66. In yet a further embodiment, the dimensions of the tapered wedge 68 are selected to compensate

for body build variations ranging from 2.0 mm to approximately 4.0 mm.

[0067J Referring to Figure 8, in one embodiment of a four door vehicle, in the event of a front end collision, a longitudinal force from the collision is transmitted to the

A-post 28 and then to the front door assembly 35 through the load bearing hinge 41. The

force is then transmitted through the load bearing beam 40 of the front door assembly 35

to the B-post 30 through the load bearing lock 42. In one embodiment, the longitunidal

force is then transmitted to the second door assembly 36 through the second load bearing hinge 44, wherien the load is transmitted by the load bearing beam 40 of the second door

assembly 36 to the C-post 3 through the second load bearing lock assembly 43. In one embodiment, in an impact event with the doors in the closed position, the combination of

the load bearing hinges, locks and longitudinal load bearing beam may provide a longitudinally rigid structure that protects the passengers within the vehicle.

[0068] Still referring to Figure 8, in another embodiment, the center module 100

includes two load bearing binges to each post per door, such as an upper load bearing hinge 41 and a lower load bearing hinge 75a, 75b. In yet another embodiment, the door further includes two locks, such as an upper load bearing lock 42, 43 and a lower load bearing lock 76a, 76b. In another embodiment, the door assembly 35 further comprises an anti-intrusion beam 77 extending from the lower load bearing hinge 76a to the upper

load bearing lock 42. In yet an even further embodiment, the door assembly 36 further includes an anti-intrusion beam 78 extending from the upper load bearing hinge 44 to the

lower load bearing lock 76b.

[0069] Figure 9 depicts a perspective view of a one embodiment of a center

module 100 including a floor panel 105 housing a battery module case 120, in accordance

with the present invention. A battery module is a plurality of battery cells in electrical

communication. In one embodiment, the battery cells include Li ion or Ni metal hydride

chemistries. A It is noted that although the floor panel 105 is depicted as a component of

the center module, the floor panel may be incorporated into any body structure including

body over frame constructions, sheet metal unibody constructions and spaceframe

designs. In one embodiment, the floor panel 105 includes an air intake 102 in communication with a housing 150, in which the housing 150 is configured to secure a

battery module case 120. Although note depicted in the figures, the floor panel may

further include an exhaust to vent the air following cooling of the battery module case 120 and battery cells contained therein.

[0070] Figures 1 Oa and 1 Ob depict the configuration of one embodiment of the floor panel 105 in accordance with the present invention. In a once embodiment, the floor panel 105 includes two housings 150 each configured for containing a battery

module case 120. In one embodiment, the housings 150 are separated by a channel

which may house a driveshaft. In one embodiment, the floor panel 105 is composed of a heat conducting material, including but not limited to metals such as aluminum. In one

embodiment, the floor panel 105 is constructed of extrusions. In one embodiment, the floor panel is composed of multiple constant cross section extrusions that may be joined along their longitudinal direction. In one embodiment the extrusions may be joined by gass metal arc welding, electron beam welding, laser welding, or using MIG or TIG torch welding.

[0071] In one embodiment, the battery module case 120 and the housing 150 are

provided in conductive engagement, wherein the heat generated by the battery cells contained in the battery module case is transmitted by thermal exchange from the battery

module case 120 to the housing 150 of the floor panel 105. In one embodiment, a plurality of inter-engaging fins are positioned at the interface of the module case 120 and

the housing 150, wherein the inter-engaging fins increase the surface area for heat

transfer between the battery module case 120 and the housing 150. In one embodiment, the floor panel 105 includes a plurality of fins 106, wherein the fins 106 increases the floors panel's 105 rigidity and increases the floor's surface area. By increasing the floor

panel's 105 surface area, the heat transfer of heat transmitted from the battery module case 120 to the floor panel 105 is increased, as well as cooling of the battery cells within the battery module case 20.

[0072] Figures 11a and l ib depict one embodiment of the battery module case 120 in accordance with the present invention. In one embodiment, the battery module case 120 is composed of aluminum and comprises a plurality of exterior fins 119. The

battery module case 120 engages the housing 150 in thermally conductive contact to

ensure that the heat generated by the enclosed battery cells is transmitted to the floor

panel 5. Referring to Figure l ib, the battery module case 20 comprises a removable cap 122 which ensures that the battery cells 121 are enclosed within the battery module case

20, while providing access for battery cell 21 maintenance and replacement. To provide a sealed engagement the cap may further include a gasket 123, as depicted in Figure 1 Ib.

In one embodiment, the gasket 123 may provide a substantially hermetic seal. The term substantially hermetic means a seal against the substantial entry or exit of air and moisture from the housing.

[0073 J Referring to Figure 12, in one embodiment the battery module case 120

also includes a plurality of interior channels 122, wherein the interior channels 122 ensure that the battery cells 121 are secured in thermally conductive engagement with the battery

module case 20, and in one embodiment protect the battery cells 121 from damaging

vibrations.

[0074 J In one embodiment, the battery module case 120 is secured within the housing 150 so that the passage of air from the air intake 10 is channeled across the battery module case 20 in a manner that cools the battery module case 20 and the battery

cells 121 contained therein. Referring to Figure 13, the floor panel 105 may further

include at least one fan to draw cooling air through the battery module case 20 and past the battery cells 121 contained therein.

[0075] Having described the presently preferred embodiments, it is to be understood that the invention may be otherwise embodied within the scope of the

appended claims.

Claims

What is claimed is:

1. A vehicle structure comprising:

a door having a longitudinal load bearing beam;

a first frame post having a load bearing hinge connected to a first end of the longitudinal load bearing beam of the door, and

2. The vehicle structure of Claim 1 , wherein the door further an outer door panel and an

inner door panel and the longitudinal load beam structure is positioned between the inner door panel and the an outer door panel of the door.

3. The vehicle structure of Claim 1, wherein the longitudinal load bearing beam comprises a inner beam and a outer beam connected at a first end connected to the load

bearin hinge and a second end having a lock, wherein at least a window mechanism is

mounted between the first end and second end and the inner and outer beams of the longitudinal load bearing beam.

4. The vehicle structure of Claim 1 , wherein said longitudinal load bearing beam

comprises an aluminum alloy.

5. The vehicle structure of Claim 1, comprising two load bearing hinges, wherein the first

hinge of the two load bearing hinges is positioned at an upper portion of the first frame

post and a second hinge is positioned at a lower portion of the first frame post.

6. The vehicle structure of Claim 1, wherein the door further comprises an anti-intrusion

bar extending from the second hinge to the load bearing lock.

7. A vehicle strucure comprising:

a center module comprising a passenger compartment between a forward bulkhead and

rear bulkhead; and at least two suspension arms each pivotably connected to at least one of the forward

bulkhead and a rear bulkhead.

8. The vehicle structure of Claim 7, wherein the at least two suspension arms include a front suspension arm connected to a lower portion of the front bulkhead, and a rear

suspension arm connected to a lower portion of the rear bulkhead.

9. The vehicle structure of Claim 8 further comprising at least two front dampening

structures arm connected to an upper portion of the front bulkhead, and at least two rear

dampening structures connected to an upper portion of the rear bulkhead.

10. The vehicle structure of Claim 8 wherein the front and rear suspension arms comprise an aluminum alloy.

11. The vehicle structure of Claim 8, wherein the dampening structure comprises struts,

springs, shocks, coil over shock, mcpherson struts or a combination thereof.

12. A vehicle structure comprising:

a floor panel including an air intake to a battery module housing;

a battery module case mounted within the housing; and a plurality of battery cells contained within the battery module case.

13. The vehicle structure of Claim 12, wherein said floor panel is comprised of

aluminum.

14. The vehicle structure of Claim 12, wherein the floor panel further comprises a

plurality of fins.

15. The vehicle structure of Claim 12, wherein the battery module case comprises an

aluminum alloy.

16. The vehicle structure of Claim 12, wherein the plurality of battery cells are engaged to channels formed within the battery module case.

17. The vehicle structure of Claim 12, wherein the plurality of battery cells comprise a Li

ion or Ni metal hydride composition.

18. The vehicle structure of Claim 12 further comprising a fan.