公开(公告)号：US20220059892A1

公开(公告)日：2022-02-24

申请号：US17517953

申请日：2021-11-03

Applicant: Shape Corp.

Inventor： Joseph Robert Matecki ,  Mark Charles Stephens ,  Matthew Kuipers ,  Zehua Qin

IPC: H01M50/20 ,  B60K1/04 ,  B60L50/60

Abstract: A battery tray for a vehicle includes a peripheral tubular member that borders at least a lateral side of a battery containment area relative to the vehicle. A crush section is attached along an outboard side of the peripheral tubular member. The crush section includes an outboard wall portion, an upper leg portion integrally extending inboard from an upper end of the outboard wall potion, and a lower leg portion integrally extending inboard from a lower end of the outboard wall potion. The upper and lower leg portions of the crush section each terminate inboard at an end flange of the crush section that is attached to the peripheral tubular member to enclose a hollow interior there between.

公开(公告)号：US11214137B2

公开(公告)日：2022-01-04

申请号：US15862200

申请日：2018-01-04

Applicant: Shape Corp.

Inventor： Mark Charles Stephens ,  Joseph Robert Matecki ,  Ed C. Pendergrass

IPC: B60K1/04 ,  B60L50/60 ,  H01M50/20

Abstract: A battery support structure for a vehicle includes a plurality of side reinforcement members and front and rear reinforcement members. The plurality of side reinforcement members are configured to extend longitudinally relative to an associated vehicle frame, and the front and rear reinforcement members are configured to extend laterally relative to the associated vehicle frame. A plurality of module nodes are attached between adjacent ends of the side reinforcement members and the front and rear members to together form a containment wall that generally surrounds a battery containment area. The plurality of module nodes comprise corner sections of the containment wall, such that a length of the side reinforcement members or the front and rear reinforcement members is selected to provide a desired respective length or width of the battery containment area.

公开(公告)号：US20210309297A1

公开(公告)日：2021-10-07

申请号：US17222326

申请日：2021-04-05

Applicant: Shape Corp.

Inventor： Joseph R. Matecki ,  Brian Oxley ,  Matthew Kuipers ,  Cody Alger ,  Douglas S. Baas

IPC: B62D25/02 ,  B62D21/15

Abstract: A rocker component for a vehicle includes a reinforcement beam having a metal sheet that is shaped with a plurality of elongated bends extending in parallel along a length of the reinforcement beam that together form a cross-sectional shape extending continuously along the length of the reinforcement beam. The cross-sectional shape of reinforcement beam includes a beam portion and a flange portion integrally extending from the beam portion. The beam portion has a multi-hollow shape that encloses a plurality of hollow cavities that extend longitudinally between openings at opposing ends of the reinforcement beam. The flange portion integrally extends from the beam portion and includes an edge of the metal sheet. The flange portion is configured to attach to the vehicle for supporting the rocker component along an outboard side region of the vehicle.

公开(公告)号：US11088412B2

公开(公告)日：2021-08-10

申请号：US16130580

申请日：2018-09-13

Applicant: Shape Corp.

Inventor： Joseph Robert Matecki ,  Mark Charles Stephens

IPC: H01M50/00 ,  H01M50/20 ,  B60K1/04 ,  B60L50/60

Abstract: A battery tray for supporting batteries at a lower portion of a vehicle frame includes a floor plate and a perimeter wall disposed around the of the floor plate to substantially surround a containment area for storing vehicle battery cells. The perimeter wall includes a tubular member that extends along a periphery of the floor plate to form a perimeter wall around a containment area for storing vehicle battery cells. The perimeter wall is attached at an upper surface of the floor plate, such that the containment area may be generally bounded horizontally by the perimeter wall and at the bottom by the floor plate.

公开(公告)号：US11072844B2

公开(公告)日：2021-07-27

申请号：US15791834

申请日：2017-10-24

Applicant: Shape Corp.

Inventor： Helen Weykamp

IPC: C22F1/053 ,  B21B3/00 ,  B23K26/21 ,  B23K103/10 ,  B21B1/22

Abstract: A method of forming and processing a high strength aluminum alloy for the production of a vehicle component includes providing a metal sheet that was rolled from an aluminum alloy. The sheet is heat treated through a first aging step of a set of aging steps that are necessary to achieve a T6 or a T7 temper state. Prior to achieving the T6 or a T7 temper state, the sheet is formed to a desired shape and welded in the desired shape to produce a desired vehicle component. Once formed, the vehicle component is heat treated through a remaining aging step to achieve a T6 or T7 temper state homogeneously throughout the vehicle component.

公开(公告)号：US20210188071A1

公开(公告)日：2021-06-24

申请号：US17192008

申请日：2021-03-04

Applicant: Shape Corp.

Inventor： Joseph Robert Matecki ,  Mark Charles Stephens ,  Helen Weykamp

IPC: B60K1/04 ,  B60L50/60 ,  H01M50/20

Abstract: A vehicle battery tray includes a floor assembly that has elongated tray sections that attach together at lateral edge portions of adjacent tray sections to form a floor structure that supports vehicle batteries contained in the vehicle battery tray. The elongated tray sections each have a substantially consistent cross-sectional shape that extends longitudinally along a length of the respective tray section. A first tray section includes a first attachment feature at the lateral edge portion thereof and a second tray section includes a second attachment feature at the lateral edge portion thereof that corresponds with the first attachment feature. The first and second attachment features engage together at a longitudinal seam between the lateral edge portions of the first and second tray sections, such as to align upper surfaces of the first and second tray sections.

公开(公告)号：US10483510B2

公开(公告)日：2019-11-19

申请号：US15981654

申请日：2018-05-16

Applicant: Shape Corp.

Inventor： Mark Charles Stephens ,  Joseph Robert Matecki

IPC: H01M2/10 ,  B60L50/64 ,  B60L50/60 ,  B60R16/04

Abstract: A battery tray for a vehicle includes two tray components or pieces that attach or mate together, such as with one tray component over or within the other tray component, to form sealed and separate battery containment areas. The lower tray component that has a panel portion and a pair of elongated reinforcement members integrally protruding upward from opposing edges of the panel portion. Also, the upper tray component has a panel portion and a cross members that integrally extend across its panel portion. The upper tray component is disposed at an upper surface of the panel portion of the lower tray component with the cross members extending between the elongated reinforcement members and defining a battery containment area between each of the cross members.

公开(公告)号：US10155493B2

公开(公告)日：2018-12-18

申请号：US15693550

申请日：2017-09-01

Applicant: Shape Corp.

Inventor： Joseph R. Matecki ,  Jonathon J. Pothoven

IPC: B60R19/02 ,  B60R19/18 ,  B60R19/04 ,  E04C3/06 ,  B23K9/02 ,  E04C3/28 ,  E04C3/29 ,  E04C3/04 ,  B23K101/00

Abstract: A beam article for a vehicle includes a plurality of separate elongated metal sheets attached together to form generally planar walls of an elongated tubular structure. At least one of the plurality of separate elongated metal sheets has a shear wall that is disposed along a hollow interior of the elongated tubular structure and is attached at opposing walls of the elongated tubular structure. At least one of the plurality of separate elongated metal sheets comprises an edge that abuts a side surface of an adjacent one of the plurality of separate elongated metal sheets to define a non-radiused perpendicular weld corner along the elongated tubular structure.

公开(公告)号：US20170361793A1

公开(公告)日：2017-12-21

申请号：US15693550

申请日：2017-09-01

Applicant: Shape Corp.

Inventor： Joseph R. Matecki ,  Jonathon J. Pothoven

IPC: B60R19/02 ,  B60R19/04 ,  E04C3/06 ,  B23K9/02 ,  B60R19/18 ,  E04C3/04 ,  B23K101/00

CPC classification number: B60R19/023 ,  B23K9/02 ,  B23K2101/006 ,  B60R19/04 ,  B60R19/18 ,  B60R2019/182 ,  B60R2019/1826 ,  E04C3/06 ,  E04C3/28 ,  E04C3/29 ,  E04C2003/0413 ,  E04C2003/043 ,  E04C2003/0439 ,  E04C2003/0465

Abstract: A beam article for a vehicle includes a plurality of separate elongated metal sheets attached together to form generally planar walls of an elongated tubular structure. At least one of the plurality of separate elongated metal sheets has a shear wall that is disposed along a hollow interior of the elongated tubular structure and is attached at opposing walls of the elongated tubular structure. At least one of the plurality of separate elongated metal sheets comprises an edge that abuts a side surface of an adjacent one of the plurality of separate elongated metal sheets to define a non-radiused perpendicular weld corner along the elongated tubular structure.

公开(公告)号：US09815352B2

公开(公告)日：2017-11-14

申请号：US15099979

申请日：2016-04-15

Applicant: Shape Corp.

Inventor： Paul Michael Roehm ,  Corey J. Hoff

IPC: B60J5/04

CPC classification number: B60J5/0423 ,  B60J5/0425 ,  B60J5/0443 ,  B60J5/0444 ,  B60J5/0461

Abstract: An impact beam for reinforcing a vehicle door includes an elongated beam having a hollow interior spanning a length of the elongated beam. The elongated beam includes an impact portion spanning the length and configured to face an exterior side of the vehicle door. The elongated beam also includes a cross-sectional shape having a top wall section and a bottom wall section that interconnect at a bend section of the cross-sectional shape, which includes the impact portion. The top and bottom wall sections each include an intermediate bend to define a substantially horizontal section and an angled section on opposing sides of the intermediate bend, where the intermediate bends are configured to limit inward displacement of the elongated beam from an impact force at the exterior side of the vehicle door.