System for absorbing and distributing side impact energy utilizing an integrated battery pack

1. A side impact system for a vehicle comprising:

first and second side sills, each of the first and second side sills having multiple longitudinal channels, at least an upper longitudinal channel positioned above a vehicle floor panel and at least a lower longitudinal channel positioned below the vehicle floor panel;

a battery enclosure mounted between front and rear suspensions of the vehicle, the battery enclosure having a first side member attached to the first side sill, a second side member attached to the second side sill, a plurality of cross-members integrated into the battery enclosure and extending between the first side member and the second side member, a top panel, and a bottom panel, wherein the battery enclosure encloses a plurality of batteries with all portions of the plurality of batteries residing below the vehicle floor panel; and

at least one mechanical connection securing the plurality of cross-members to the vehicle floor panel.

2. The side impact system of claim 1 , wherein the battery enclosure is an aerodynamic device having a design that improves aerodynamic performance of the vehicle.

3. The side impact system of claim 1 , wherein front wheel arch edges on the battery enclosure are radiused to allow air from a front wheel to transition to an underside of the vehicle.

4. The side impact system of claim 1 , further comprising a gasket material that covers a gap formed between a top of the battery enclosure and an underside of the vehicle floor panel.

5. The side impact system of claim 1 , further comprising a seat mounting structure on an opposite side of the vehicle floor panel from the one of the plurality of cross-members, wherein the seat mounting structure is coupled to the one of the plurality of cross-members by at least one bolt and at least one nut.

6. The side impact system of claim 1 , wherein the battery enclosure is an integral part of a load path for managing loads in frontal impact.

7. The side impact system of claim 6 , configured so that a majority of the loads are fed from rails at a front of the vehicle into a torque box.

8. The side impact system of claim 6 , further comprising a secondary load path that feeds loads from a lower portion of the vehicle along a sub-frame and into a rear mount of the sub-frame coupled to the battery enclosure and to a torque box.

9. The side impact system of claim 6 , wherein the battery enclosure is configured to feed the loads along its members to the first and second side sills.

10. The side impact system of claim 1 , wherein a bottom plate of the battery enclosure is configured to provide shear stiffness to mounting locations of a steering rack.

11. The side impact system of claim 1 , wherein the first side member is attached to the lower longitudinal channel of the first side sill and the second side member is attached to the lower longitudinal channel of the second side sill.

12. The side impact system of claim 1 , wherein the one of the plurality of cross-members comprise an upper portion and a lower portion, wherein a spacing between the upper and lower portions is configured to receive a mounting bracket for at least one battery module in the battery enclosure.

13. The side impact system of claim 1 , wherein the plurality of cross-members segregate the battery enclosure into full-width sections and at least one other section, each of the full-width sections fitting two battery modules side-by-side in a direction of travel, the at least one other section fitting two stacked modules.

14. The side impact system of claim 1 , wherein the battery enclosure is coupled to a torque box.

15. A side impact system for a vehicle comprising:

first and second side sills, each of the first and second side sills having multiple longitudinal channels, at least an upper longitudinal channel positioned above a vehicle floor panel and at least a lower longitudinal channel positioned below the vehicle floor panel;

a battery enclosure mounted between front and rear suspensions of the vehicle, the battery enclosure having a first side member attached to the first side sill, a second side member attached to the second side sill, a plurality of cross-members integrated into the battery enclosure and extending between the first side member and the second side member, a top panel, and a bottom panel, wherein the battery enclosure encloses a plurality of batteries with all portions of the plurality of batteries residing below the vehicle floor panel; and

at least one mechanical connection securing the battery enclosure to the vehicle floor panel.

16. The side impact system of claim 15 , further comprising a seat mounting structure on an opposite side of the vehicle floor panel from the one of the plurality of cross-members, wherein the seat mounting structure is coupled to the one of the plurality of cross-members by at least one bolt and at least one nut.

17. The side impact system of claim 15 , wherein the battery enclosure is an integral part of a load path for managing loads in frontal impact.

18. The side impact system of claim 15 , wherein a bottom plate of the battery enclosure is configured to provide shear stiffness to mounting locations of a steering rack.

19. The side impact system of claim 15 , wherein the first side member is attached to the lower longitudinal channel of the first side sill and the second side member is attached to the lower longitudinal channel of the second side sill.

20. The side impact system of claim 15 , wherein the battery enclosure is coupled to a torque box.