公开(公告)号：US11590911B2

公开(公告)日：2023-02-28

申请号：US16939977

申请日：2020-07-27

Applicant: Shape Corp.

Inventor： Joseph R. Matecki

IPC: B60R19/12 ,  B60R19/03 ,  B60R19/18 ,  B60R19/34 ,  B23K9/007 ,  B23K9/23 ,  B23K101/00 ,  B60R19/24

Abstract: A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.

公开(公告)号：US20220315117A1

公开(公告)日：2022-10-06

申请号：US17657555

申请日：2022-03-31

Applicant: Shape Corp.

Inventor： Tomohisa Honda ,  Kazutoyo Fujikawa

IPC: B62D25/02 ,  B62D29/00 ,  B62D27/02

Abstract: A vehicle floor assembly having a floor panel and a pair of elongated members disposed along opposing sides of the floor panel. A central tunnel extends longitudinally between the pair of elongated members and has an upper surface elevated vertically from a planar extent of the floor panel. A crossmember beam is coupled to and spans between the pair of longitudinal members. The crossmember beam has a cross-sectional shape extending continuously along a length of the crossmember beam. The crossmember beam includes a curved shape along at least a section of the length of the crossmember beam that positions a lower surface of the crossmember beam above the upper surface of the central tunnel.

公开(公告)号：US20220059894A1

公开(公告)日：2022-02-24

申请号：US17519040

申请日：2021-11-04

Applicant: Shape Corp.

Inventor： Mark Charles Stephens ,  Joseph Robert Matecki ,  Bob Brady ,  Matthew Kuipers ,  Paul Michael Roehm

IPC: H01M50/20 ,  B60K1/04 ,  B60L50/60 ,  B60L50/64

Abstract: A battery tray for an electric vehicle includes a tub component that has a floor portion and a perimeter wall portion that integrally extends upward around a peripheral edge of the floor portion to border a battery containment area of the tub component. The tub component may include a plurality of cross member portions that integrally interconnect with the floor portion and the perimeter wall portion so as to span laterally across the battery containment area to divide the battery containment area into separate compartments. A support structure of the battery tray may have an elongated member coupled at an exterior side of each of opposing longitudinal sections of the perimeter wall portion of the tub component.

公开(公告)号：US20210336306A1

公开(公告)日：2021-10-28

申请号：US17366130

申请日：2021-07-02

Applicant: Shape Corp.

Inventor： Joseph Robert Matecki ,  Mark Charles Stephens

IPC: 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：US11155150B2

公开(公告)日：2021-10-26

申请号：US17009237

申请日：2020-09-01

Applicant: Shape Corp.

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

IPC: B60K37/00 ,  B60K1/04 ,  B60L58/26 ,  B60K11/02 ,  B62D25/02 ,  B62D25/20 ,  B60K1/00

Abstract: A battery support tray for an electric vehicle includes a tray floor structure that has an upper surface that is configured to interface with battery modules. The battery support tray also includes a plurality of cooling features that integrally extend along portions of the tray floor structure that are configured to draw heat away from the battery modules supported at the upper surface of the tray floor structure. The tray floor structure may also have a cross-sectional profile that is substantially consistent longitudinally along a length of the tray floor structure or laterally across a width of the tray floor structure, such as formed from extruding a metal, such as an aluminum alloy.

公开(公告)号：US20210111388A1

公开(公告)日：2021-04-15

申请号：US17113968

申请日：2020-12-07

Applicant: Shape Corp.

Inventor： Mark Charles Stephens ,  Joseph Robert Matecki ,  Bob Brady ,  Matthew Kuipers ,  Paul Michael Roehm

IPC: H01M2/10 ,  B60K1/04 ,  B60L50/60 ,  B60L50/64

Abstract: A battery tray for an electric vehicle includes a tub component that has a floor portion and a perimeter wall portion that integrally extends upward around a peripheral edge of the floor portion to border a battery containment area of the tub component. The tub component may include a plurality of cross member portions that integrally interconnect with the floor portion and the perimeter wall portion so as to span laterally across the battery containment area to divide the battery containment area into separate compartments. A support structure of the battery tray may have an elongated member coupled at an exterior side of each of opposing longitudinal sections of the perimeter wall portion of the tub component.

公开(公告)号：US20210024022A1

公开(公告)日：2021-01-28

申请号：US16939977

申请日：2020-07-27

Applicant: Shape Corp.

Inventor： Joseph R. Matecki

IPC: B60R19/12 ,  B60R19/03 ,  B60R19/18 ,  B60R19/34 ,  B23K9/23 ,  B23K9/007

Abstract: A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.

公开(公告)号：US10703312B2

公开(公告)日：2020-07-07

申请号：US15592272

申请日：2017-05-11

Applicant: Shape Corp.

Inventor： Thomas Johnson ,  Doug Witte ,  Daniel Gatti ,  Brian Oxley ,  Brian Malkowski ,  Kannan Ramamoorthy ,  Ed Pendergrass

IPC: B23K26/06 ,  B23K26/24 ,  B23K26/242 ,  B60R19/18 ,  B21D5/08 ,  B21D5/14 ,  B21D53/88 ,  B60R19/02 ,  B23K37/02 ,  B23K37/04 ,  B23K26/08 ,  B23K26/32 ,  B21D51/16 ,  B23K26/20 ,  B23K101/00 ,  B23K101/18 ,  B23K103/04 ,  B23K103/00

Abstract: A vehicle reinforcement beam is roll formed from a metal sheet to provide a multi-tubular reinforcement beam that includes two adjacent tubular sections that share a common center wall. The outer sections the metal sheet extend from opposing ends of the common center wall and are formed to enclose the adjacent tubular sections. An edge portion of the metal sheet that is bent to have a bend radius of about 3-9 mm, where the edge portions attach in abutting and continuous contact with the common center wall to form crevices between the adjacent tubular sections along the first and second faces. A weld is formed in each of the crevices to define crevice ribs in general alignment with and at each of the opposing first and second ends of the common center wall that are configured to improve bending strength and torsional strength of the reinforcement beam.

公开(公告)号：US20180056352A1

公开(公告)日：2018-03-01

申请号：US15686837

申请日：2017-08-25

Applicant: Shape Corp.

Inventor： Helen Weykamp ,  Kenneth E. McKellar ,  David DeVries

IPC: B21C23/08 ,  C22F1/04 ,  B21C23/00

CPC classification number: B21C23/085 ,  B21C23/002 ,  B21D7/06 ,  B21D7/16 ,  B21D53/88 ,  C22F1/04

Abstract: A method for warm forming an aluminum beam, such as an aluminum component for a vehicle, includes providing an extruded aluminum beam with a hollow cross-sectional shape. A portion of a forming die is heated to a desired temperature, so as to heat a portion of the aluminum beam in the die to a temperature below the artificial aging temperature of the aluminum beam. The heated aluminum beam is deformed to a desired shape with the die in a direction transverse to a length of the aluminum beam.

公开(公告)号：US09884597B2

公开(公告)日：2018-02-06

申请号：US15173797

申请日：2016-06-06

Applicant: Shape Corp.

Inventor： Joseph R. Matecki ,  Jonathon J. Pothoven

IPC: B60R19/18 ,  B60R19/04 ,  B60R19/02 ,  B23K9/02 ,  E04C3/06 ,  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 bumper reinforcement beam includes sheets pre-formed to have integral features and to have a final beam shape with non-radiused corners and optimal impact properties, including beams with constant or varied cross-sectional shapes, and beams made of steel, aluminum, or hybrid materials or combinations of material, all of which allow minimization of weight. The non-radiused corners offer excellent impact strength and properties. Beam impact properties can be improved or locally tuned for particular functional requirements by material selection, or by adding an internal reinforcement on an inside center of the front wall, or by localized annealing of the welds to minimize stress risers, or by localized features and shapes. The sheets can be welded using welding processes that provide low heat-affected-zones around the weld or by localized annealing, thus minimizing any adverse effect of welding.