CROSS MEMBER IN THE FLOOR WITH SPECIAL GEOMETRY FOR MOUNTING THE BATTERY PACK
A mounting system for an electric vehicle includes a floor structure of the electric vehicle and a rear cross beam mounted to the floor structure and extending from a right side of a passenger compartment of the electric vehicle to a left side of the passenger compartment. An underside of the rear cross beam defines a plurality of mounting features configured for mounting a battery assembly to an underside of the electric vehicle. The rear cross beam defines an interior comprising a plurality of ribs extending along a length of the rear cross beam.
1 . A mounting system for an electric vehicle, the mounting system comprising:
a floor structure of the electric vehicle; and
a rear cross beam mounted to the floor structure and extending from a right side of a passenger compartment of the electric vehicle to a left side of the passenger compartment, wherein:
an underside of the rear cross beam defines a plurality of mounting features configured for mounting a battery assembly to an underside of the electric vehicle; and
the rear cross beam defines an interior comprising a plurality of ribs extending along a length of the rear cross beam.
2 . The mounting system for an electric vehicle of claim 1 , wherein:
the rear cross beam comprises extruded aluminum.
3 . The mounting system for an electric vehicle of claim 1 , wherein:
the plurality of mounting features are spaced apart across the length of the rear cross beam.
4 . The mounting system for an electric vehicle of claim 1 , wherein:
the rear cross beam is generally hexagonal in shape.
5 . The mounting system for an electric vehicle of claim 1 , wherein:
the plurality of mounting features are each configured to receive a fastener for securing the battery assembly to the underside of the electric vehicle.
6 . The mounting system for an electric vehicle of claim 1 , wherein:
the rear cross beam comprises:
a top wall, a bottom wall, an intermediate wall, a rear side wall, a front diagonal wall, and a rear diagonal wall, wherein:
the front diagonal wall extends rearward from a front edge of the bottom wall to a front edge of the top wall;
the rear diagonal wall extends rearward from a rear edge of the bottom wall to a front edge of the intermediate wall;
the rear side wall extends downward from a rear edge of the top wall to a rear edge of the intermediate wall; and
the intermediate wall extends between a rear upper edge of the rear diagonal wall and a lower edge of the rear side wall.
7 . The mounting system for an electric vehicle of claim 6 , wherein:
the plurality of ribs comprises:
a first rib extending from and generally planar with the intermediate wall, the first rib extending into a medial portion of the front diagonal wall; and
a second rib extending from and generally planar with the rear diagonal wall, the second rib extending into a medial portion of the top wall.
8 . A mounting system for an electric vehicle, the mounting system comprising:
a floor structure of the electric vehicle; and
a rear cross beam mounted to the floor structure and extending from a right side of a passenger compartment of the electric vehicle to a left side of the passenger compartment, wherein:
an underside of the rear cross beam defines a plurality of mounting features;
the rear cross beam defines an outer periphery comprising a top wall, a bottom wall, an intermediate wall, a rear side wall, a front diagonal wall, and a rear diagonal wall;
the front diagonal wall extends rearward from a front edge of the bottom wall to a front edge of the top wall;
the rear diagonal wall extends rearward from a rear edge of the bottom wall to a front edge of the intermediate wall;
the rear side wall extends downward from a rear edge of the top wall to a rear edge of the intermediate wall;
the intermediate wall extends between a rear upper edge of the rear diagonal wall and a lower edge of the rear side wall; and
the outer periphery defines an interior comprising a plurality of ribs extending along a length of the rear cross beam; and
a battery assembly fastened to the plurality of mounting features on the underside of the rear cross beam.
9 . The mounting system for an electric vehicle of claim 8 , wherein:
the rear cross beam comprises extruded aluminum.
10 . The mounting system for an electric vehicle of claim 8 , wherein:
the plurality of ribs comprises:
a first rib extending from and generally planar with the intermediate wall, the first rib extending into a medial portion of the front diagonal wall; and
a second rib extending from and generally planar with the rear diagonal wall, the second rib extending into a medial portion of the top wall.
11 . The mounting system for an electric vehicle of claim 10 , wherein:
fasteners for securing the battery assembly to the plurality of mounting features are received within a space between the intermediate wall, the rear wall, the top wall, and the second rib.
12 . The mounting system for an electric vehicle of claim 8 , wherein:
the plurality of mounting features are disposed in the intermediate wall.
13 . The mounting system for an electric vehicle of claim 12 , wherein:
a bottom surface of the rear cross beam corresponds to a shape of the floor structure.
14 . The mounting system for an electric vehicle of claim 8 , further comprising:
at least one seat mounted on the rear cross beam.
15 . A method of mounting seats and a battery assembly on an electric vehicle, the method comprising:
positioning a rear cross beam at a base of a passenger compartment of an electric vehicle such that the rear cross beam extends from a left side of the passenger compartment to a right side of a passenger compartment, wherein:
an underside of the rear cross beam defines a plurality of mounting features;
the rear cross beam defines an outer periphery comprising a top wall, a bottom wall, an intermediate wall, a rear side wall, a front diagonal wall, and a rear diagonal wall;
the front diagonal wall extends rearward from a front edge of the bottom wall to a front edge of the top wall;
the rear diagonal wall extends rearward from a rear edge of the bottom wall to a front edge of the intermediate wall;
the rear side wall extends downward from a rear edge of the top wall to a rear edge of the intermediate wall;
the intermediate wall extends between a rear upper edge of the rear diagonal wall and a lower edge of the rear side wall; and
the outer periphery defines an interior comprising a plurality of ribs extending along a length of the rear cross beam;
positioning a battery assembly against an underside of the electric vehicle; and
securing a plurality of fasteners with the plurality of mounting features to secure the battery assembly against the underside of the electric vehicle.
16 . The method of mounting seats and a battery assembly on an electric vehicle of claim 15 , wherein:
the plurality of ribs comprises:
a first rib extending from and generally planar with the intermediate wall, the first rib extending into a medial portion of the front diagonal wall; and
a second rib extending from and generally planar with the rear diagonal wall, the second rib extending into a medial portion of the top wall.
17 . The method of mounting seats and a battery assembly on an electric vehicle of claim 16 , wherein:
Securing the plurality of fasteners comprises tightening the fasteners such that a portion of each fastener extends into a space between the intermediate wall, the rear wall, the top wall, and the second rib.
18 . The method of mounting seats and a battery assembly on an electric vehicle of claim 15 , wherein:
the plurality of fasteners are inserted from the underside of the electric vehicle.
19 . The method of mounting seats and a battery assembly on an electric vehicle of claim 15 , wherein:
the plurality of mounting features are spaced apart across the length of the rear cross beam.
20 . The method of mounting seats and a battery assembly on an electric vehicle of claim 15 , wherein:
the rear cross beam comprises extruded aluminum.