# US 11,299,205 B2 · Body structures for an automotive vehicle utilizing upper and lower shear structure assemblies

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- Number: US 11,299,205 B2
- Document ID: US11299205B2
- Status: Granted
- Kind: B2
- Application number: 16/788,860
- Filed: 2020-02-12
- Published: 2021-08-12
- Granted: 2022-04-12
- Earliest claimed: 2020-02-12
- Assignees: GM Global Technology Operations LLC
- Applicants: GM Global Technology Operations LLC
- Inventors: Robert N. Saje; Brian V. Castillo; Giles D. Bryer; Warren J. Parsons; Michael T. Chaney; Eric A. Mathieson; James A. Rochon
- Web page: https://patentgrep.com/patent/US11299205B2

## CPC

- B62D 21/03: transverse members providing body support
- B62D 21/10: in which the main member is plate-like
- B60K 1/04: of the electric storage means for propulsion
- B62D 21/07: wide-hipped frame type, i.e. a wide box-shaped mid portion with narrower sections extending from said mid portion in both fore and aft directions
- B62D 21/17: forming fluid or electrical conduit means or having other means to accommodate the transmission of a force or signal
- B62D 25/025: {Side sills thereof}
- B62D 25/08: Front or rear portions {(sub-frames for mounting engine or suspensions B62D21/11)}
- B62D 27/06: readily releasable
- B60K 2001/0438: {Arrangement under the floor}
- B60K 2015/0634: {the fuel tank is arranged below the vehicle floor}
- B60K 2015/0636: {the fuel tank being part of the chassis or frame}
- B60Y 2306/01: Reducing damages in case of crash, e.g. by improving battery protection
- B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M)
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60Y: INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY

## Abstract

A body structure for an automotive vehicle includes an enclosure for a power source, an upper shear structure assembly and a lower shear structure assembly. The enclosure includes a front cross-member, a rear cross-member, a left rocker and a right rocker. The upper and lower shear structure assemblies are disposed across the top and bottom of the enclosure, respectively, and are fastened to respective top and bottom surfaces of the cross-members and rockers. The upper and lower shear structure assemblies may include respective front and rear generally trapezoidal sections configured for attachment to respective front and rear box structures. Each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the enclosure.

## Claims

### Claim 1

A body structure for an automotive vehicle, comprising:
an enclosure for a power source, the enclosure comprising a front cross-member, a rear cross-member disposed generally parallel to and spaced apart the front cross-member, a left rocker connected at opposed first and second ends thereof to respective left ends of the front and rear cross-members, and a right rocker connected at opposed third and fourth ends thereof to respective right ends of the front and rear cross-members;
an upper shear structure assembly disposed across a top of the enclosure and fastened to respective top surfaces of the front and rear cross-members and the left and right rockers, wherein the upper shear structure assembly includes a front upper edge extending along the front cross-member, a rear upper edge extending along the rear cross-member, a generally trapezoidal front upper section extending from the front upper edge and a generally trapezoidal rear upper section extending from the rear upper edge; and
a lower shear structure assembly disposed across a bottom of the enclosure and fastened to respective bottom surfaces of the front and rear cross-members and the left and right rockers, wherein the lower shear structure assembly includes a front lower edge extending along the front cross-member, a rear lower edge extending along the rear cross-member, a generally trapezoidal front lower section extending from the front lower edge and a generally trapezoidal rear lower section extending from the rear lower edge.

### Claim 2 (depends on 1)

A body structure according to claim 1, wherein the generally trapezoidal front upper and lower sections are configured for attachment to a front box top portion and a front box bottom portion, respectively, of a front box structure, and the generally trapezoidal rear upper and lower sections are configured for attachment to a rear box top portion and a rear box bottom portion, respectively, of a rear box structure.

### Claim 3 (depends on 1)

A body structure according to claim 1, wherein each of the upper and lower shear structure assemblies defines a respective plane and wherein each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the enclosure.

### Claim 4 (depends on 1)

A body structure according to claim 1, wherein at least one of the upper and lower shear structure assemblies is constructed as at least one of a metallic foam sandwich and a lattice of interconnected structural members.

### Claim 5 (depends on 1)

A body structure according to claim 1, wherein each of the generally trapezoidal front upper and lower sections is configured for attachment to a front box bottom portion of a front box structure, and each of the generally trapezoidal rear upper and lower sections is configured for attachment to a rear box bottom portion of a rear box structure.

### Claim 6 (depends on 1)

A body structure according to claim 1, further comprising at least one intermediate cross-member, wherein each intermediate cross-member has a respective fifth end attached to the left rocker and a respective sixth end attached to the right rocker.

### Claim 7 (depends on 6)

A body structure according to claim 6, further comprising the power source, and wherein each of the at least one intermediate cross-member extends through the power source.

### Claim 8 (depends on 1)

A body structure according to claim 1, wherein the enclosure is configured for positioning between front and rear axles of the automotive vehicle.

### Claim 9 (depends on 1)

A body structure according to claim 1, wherein the enclosure is generally rectangular or generally trapezoidal.

### Claim 10

A body structure for an automotive vehicle, the automotive vehicle defining front and rear longitudinal directions, left and right transverse directions, and upward and downward vertical directions, comprising:
a quadrilateral-shaped main box structure for a power source, the main box structure comprising a transversely oriented front cross-member having a main box front width WMF, a rear cross-member disposed generally parallel with and to the rear of the front cross-member and having a main box rear width WMR, a left rocker connected at opposed first and second ends thereof to respective left ends of the front and rear cross-members, and a right rocker connected at opposed third and fourth ends thereof to respective right ends of the front and rear cross-members;
a front box structure connected to the front cross-member and having a front box width WF less than the main box front width WMF;
a rear box structure connected to the rear cross-member and having a rear box width WR less than the main box rear width WMR;
an upper shear structure assembly having an upper main portion disposed across a top of the main box structure and fastened to respective top surfaces of the front and rear cross-members and the left and right rockers, a generally trapezoidal front upper section extending forward from a front upper edge of the upper main portion and attached to the front box structure, and a generally trapezoidal rear upper section extending rearward from a rear upper edge of the upper main portion and attached to the rear box structure; and
a lower shear structure assembly having a lower main portion disposed across a bottom of the main box structure and fastened to respective bottom surfaces of the front and rear cross-members and the left and right rockers, a generally trapezoidal front lower section extending forward from a front lower edge of the lower main portion and attached to the front box structure, and a generally trapezoidal rear lower section extending rearward from a rear lower edge of the lower main portion and attached to the rear box structure.

### Claim 11 (depends on 10)

A body structure according to claim 10, wherein each of the upper and lower shear structure assemblies defines a respective plane and wherein each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the main box structure, the front box structure and/or the rear box structure.

### Claim 12 (depends on 10)

A body structure according to claim 10, wherein at least one of the upper and lower shear structure assemblies is constructed as at least one of a metallic foam sandwich and a lattice of interconnected structural members.

### Claim 13 (depends on 10)

A body structure according to claim 10, wherein the front box structure comprises left and right upper longitudinal front rails, left and right lower longitudinal front rails, and a plurality of vertical and transverse front members interconnecting the longitudinal front rails, and wherein the rear box structure comprises left and right upper longitudinal rear rails, left and right lower longitudinal rear rails, and a plurality of vertical and transverse rear members interconnecting the longitudinal rear rails.

### Claim 14 (depends on 10)

A body structure according to claim 10, further comprising at least one intermediate cross-member, wherein each intermediate cross-member has a respective fifth end attached to the left rocker and a respective sixth end attached to the right rocker.

### Claim 15

An automotive vehicle assembly, comprising:
a generally rectangular main box structure comprising a transversely oriented front cross-member having a main box front width WMF, a rear cross-member disposed generally parallel with and to the rear of the front cross-member and having a main box rear width WMR, a left rocker connected at opposed first and second ends thereof to respective left ends of the front and rear cross-members, and a right rocker connected at opposed third and fourth ends thereof to respective right ends of the front and rear cross-members;
a front box structure connected to the front cross-member and having a front box width WF narrower than the main box front width WMF;
a rear box structure connected to the rear cross-member and having a rear box width WR narrower than the main box rear width WMR;
an upper shear structure assembly having an upper main portion disposed across a top of the main box structure and fastened to respective top surfaces of the front and rear cross-members and the left and right rockers, a generally trapezoidal front upper section extending forward from the upper main portion and attached to the front box structure, and a generally trapezoidal rear upper section extending rearward from the upper main portion and attached to the rear box structure;
a lower shear structure assembly having a lower main portion disposed across a bottom of the main box structure and fastened to respective bottom surfaces of the front and rear cross-members and the left and right rockers, a generally trapezoidal front lower section extending forward from the lower main portion and attached to the front box structure, and a generally trapezoidal rear lower section extending rearward from the lower main portion and attached to the rear box structure; and
a power source disposed within the main box structure and between the upper and lower shear structure assemblies.

### Claim 16 (depends on 15)

An automotive vehicle assembly according to claim 15, wherein the lower shear structure assembly is removably fastened to respective lower portions of the left and right rockers.

### Claim 17 (depends on 15)

An automotive vehicle assembly according to claim 15, wherein each of the upper and lower shear structure assemblies defines a respective plane and wherein each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the main box structure, the front box structure and/or the rear box structure.

### Claim 18 (depends on 15)

An automotive vehicle assembly according to claim 15, wherein at least one of the upper and lower shear structure assemblies is constructed as at least one of a metallic foam sandwich and a lattice of interconnected structural members.

### Claim 19 (depends on 15)

An automotive vehicle assembly according to claim 15, further comprising at least one intermediate cross-member, wherein each intermediate cross-member has a respective fifth end attached to the left rocker and a respective sixth end attached to the right rocker.