Patent Application
20250055107
The present disclosure relates to modular structural composites for use as battery enclosures and, in particular, to structural composites having an exterior impact component for use as a protection barrier.
Vehicles powered by electric batteries have grown in popularity with users. These vehicles allow a user the ability to charge the batteries at their place of residence or at a charging station and avoid the cost of purchasing gasoline. To supply the power needed to reach long distances, these vehicles need large capacity batteries. However, these large capacity batteries pose an increased risk to occupants and emergency responders if the batteries are damaged during a collision. The batteries need to be protected from the force generated during the collision or alternatively, any force transmitted to the batteries must be low enough so as not to cause significant damage to the batteries.
The present disclosure provides battery enclosures that are strong and light weight, as compared to battery enclosures known previously. The enclosures utilize composite materials, optionally with exterior impact components and features, to protect the batteries from significant damage during a collision and assist in the assembly of the enclosures during manufacturing. The exterior impact components provide an initial deflection or absorption for improved crash performance while also allowing access to the battery enclosure attachments to permit service of the interior batteries and related equipment.
In a first aspect, disclosed is a battery enclosure, for example a composite battery enclosure, that includes an outer surface that forms the perimeter shell of the enclosure, the outer surface is formed, at least in part, of a first cover component and a second cover component that make up an exterior portion of the outer surface of the battery enclosure, and the enclosure further includes an impact barrier positioned on the outer surface of the battery enclosure, the impact barrier having a deflection section arranged away from or spaced apart from the outer surface of the battery enclosure.
In another example of aspect 1, the deflection section of the impact barrier forms an open area between the outer surface of the battery enclosure and the exterior surface of the deflection section such that an attachment point is accessible in the open area to disassemble or gain access to the battery storage area of the battery enclosure, for instance, to perform maintenance.
In a second aspect, there is a battery enclosure that includes a protective shell having an outer exterior surface, the protective shell defining in part a battery storage space inside its outer exterior surface, and a service access component arranged on the outer exterior surface of the protective shell for permitting access to the battery storage space inside the protective shell, and the enclosure further includes an impact barrier secured to the protective shell, the impact barrier having a deflection section spaced apart from the outer surface of the protective shell.
In another example of aspect 2, the service access component is positioned in an open area formed between the outer surface of the protective shell and a surface of the deflection section of the impact barrier such that the service access component is accessible through the open area for entry into the battery storage area or related compartment.
Any one of the above aspects (or examples of those aspects) may be provided alone or in combination with any one or more of the examples of that aspect discussed above; e.g., the first aspect may be provided alone or in combination with any one or more of the examples of the first aspect discussed above; and the second aspect may be provided alone or in combination with any one or more of the examples of the second aspect discussed above; and so-forth.
Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments, and together with the description serve to explain principles and operation of the various embodiments. Directional terms as used herein—for example, up, down, right, left, front, back, top, bottom—are made only with reference to the figures as drawn and are not intended to imply absolute orientation.
The above and other features, examples and advantages of aspects or examples of the present disclosure are better understood when the following detailed description is read with reference to the accompanying drawings, in which:
The terminology as set forth herein is for description of the embodiments only and should not be construed as limiting the invention as a whole. Herein, when a range such as 5-25 (or 5 to 25) is given, this means preferably at least or more than 5 and, separately and independently, preferably less than or not more than 25. In an example, such a range defines independently 5 or more, and separately and independently, 25 or less.
The terms “substantial,” “substantially,” and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. It also is noted that the terms “substantially” and “about” may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
The present disclosure relates to battery enclosures, such as composite battery boxes, that can be used in a variety of applications. For example, the battery enclosures can be used to house battery systems and related accessories for mechanical equipment and in automotive applications (e.g., passenger vehicle, car, truck, bus, tractor, all-terrain vehicle). In some embodiments, the battery enclosure can house in a storage area a battery system for electric and hybrid vehicles. In some examples, the battery enclosure can be modular and be formed from multiple pieces or components connected or attached to one another, at attachment points, to form a complete enclosure, box or shell having an exterior outer surface, for instance, in the form of a protective shell defining an interior battery storage area or plurality of compartments.
The battery enclosures can generally have increased global stiffness that resists bending and torsion of the structure and are relatively lightweight. In one or more embodiments, the composite battery enclosures can have connection or attachment points between the top and bottom covers to secure the covers together and provide crash strength and integrity. Easy access to the connection points is desirable to perform maintenance on the battery enclosure and equipment contained inside, such as batteries and related electronics in the battery storage area. In other embodiments, the covers or the like can be a protective shell that forms an outer surface of the battery enclosure. The protective shell can be a composite material used to house an internal storage area or plurality of compartments for containing batteries and other related components such as wiring, cooling features, sensors, etc. The protective shell, or one or more covers, can have a service access component arranged on the outer surface of the battery enclosure for accessing one or more areas or compartments in the battery enclosure. For example, the service access component can be mechanical fastener or latch for opening a panel or portion of the outer surface to permit entrance into an internal storage area of the battery enclosure.
During the operating life of the battery enclosure and the components that reside inside, maintenance is required that includes working on or checking equipment housed in the enclosure. Design features that are arranged on the outer surface of the battery enclosure, such as connection points or service access components, need to be accessible and the present battery enclosures include one or more impact barriers that accommodate or are capable of providing a user to engage a connection point or service access component. The impact barrier is positioned on an outer surface of the battery enclosure, for example, on a cover or protection shell, to provide improved crash performance and offer protection from an impact or collision. That is, the force from a collision is applied first to the impact barrier that can deflect and/or absorb the force or part of the force before it is potentially transferred to and encountered by the battery enclosure.
The impact barrier has a deflection section that is designed to provide an open entry point for a user to engage a connection point or service access component on the outer surface of the battery enclosure. The deflection section can be designed to cantilever from a base section of the barrier such that the cantilevered section is positioned away from the outer surface of the battery enclosure to form an opening between outer surface of the battery enclosure and the deflection section that is further open to the surrounding environment. The opening provided between the deflection section of the impact barrier and the outer surface of the battery enclosure permits a user to easily contact the connection point or service access component for opening the battery enclosure to perform needed maintenance or inspection tasks. For example, a user can insert a tool or similar device into the open area to interact with the connection point or service access component for opening the battery enclosure.
In one or more embodiments, the impact barrier can be primarily or substantially hollow to minimally contribute to the overall weight of the battery enclosure without reducing the rigidity of the overall structure. The impact barrier, noted above, is further equipped with a deflection section that is spaced apart from the outer surface of a battery cover or shell to provide a section that can more easily bend and deform when encountering a collision force. The deflection section can also be primarily hollow or contain a plurality of open cells or hollow through passages to reduce weight and also promote bending or detachment from the remaining portion of the impact barrier. In one or more embodiments, the deflection section will partially detach from a base portion of the barrier and interface with the outer surface of the battery enclosure to provide distributing impact forces on selective sections of the battery enclosure, for example, an upper or lower section of the enclosure.
In other embodiments, the battery enclosure can have two or more impact barriers arranged on its outer surface to provide additional protection of multiple areas of potential impact with a collision force or related crash contact. For instance, impact barriers can be positioned around the exterior perimeter of the battery enclosure in areas having a high frequency or incidence of impact with a foreign object. Multiple impact barriers can be arranged around a single connection point or service access component to ensure routing access for disassembling the battery enclosure is available.
As described herein, the battery enclosures can be formed from composite materials, however, this is only one example of a material that can be utilized. When using composite materials, the battery enclosures can have a cover with a multi-thickness composite structure attributing to improved assembly of the enclosure and increased lateral stiffness of the enclosure in combination with accommodating the attachment of one or more impact barriers on the outer surface of the enclosure. Other advantages of the composite battery enclosure and impact barriers are the components being easily formable into a desirable shape by conventional methods, such as extrusion, pultrusion, or molding methods, e.g., that preferably use low or moderate pressure and heat, which advantageously lowers time and cost to manufacture the structures.
The individual components, for instance battery enclosure components and impact barriers, even if made from different materials, can be attached to one another by conventional methods, for example, using an adhesive or epoxy, a fastener (e.g., screw, bolt, clip), welding, a sealing material, or a combination thereof. For a chemical bond or attachment means between components of the battery enclosure and/or impact barrier, any suitable adhesive can be used, for example, an epoxy. The adhesive can be applied to an outer surface of a composite cover, such as an exposed surface of fiber layer or an outer perimeter flange section, and an attachment surface of the impact barrier designed to contact or engage with the outer surface of the battery enclosure. It is preferable that the components of the battery enclosure are permanently attached to one another and the impact barrier to ensure structural integrity of the battery enclosure or modular structure during use. Other fasteners or attachment fixtures can be used in place of an adhesive, for example, a screw, snap fitting, rivet, clamp, bolt or clip. Additional local inserts or onserts can be provided at attachment locations to provide increased stiffness beyond that provided by the improved connection points of the top and bottom covers of the battery enclosure, which are also preferably accessible through the open area formed between the deflection section of the impact barrier and the outer surface of the battery enclosure.
The individual composite structures of the battery enclosure, such as a molded bottom and top composite cover, can have similar components that can be made of the same or similar materials. For example, the composite covers can have a fiber-containing layer at least partially adhered to a core structure or material, which can optionally have a select multi-thickness or regions therein, for example, at or near the connection point between the covers. The fiber layers of various individual composite covers can be made of the same or similar materials to reduce material and manufacturing costs. Similarly, when recycled materials can be substituted, for example, for fibers in the fiber layers, such materials can be used to further reduce manufacturing costs and promote sustainability.
The one or more impact barriers can also be made from several methods and be prepared form similar components, or combination of components. For example, the impact barrier can be made from a metal, such as carbon steel, aluminum, an alloy, stainless steel, or carbon fiber, fiber glass, aramid, nylon, polyester, PET, PEN, or any combination thereof. The impact barrier can have any desired shape and includes at least a base portion that has a surface for contacting and/or attaching to the outer surface of the battery enclosure or an attachment device arranged thereon. The impact barrier can also include a deflection section, which, in some examples, can be in contact or extend from the base portion or section of the barrier. The deflection section is designed to cover or surround a portion of the outer surface of the battery enclosure but not be, either entirely or a portion thereof, directly in contact with the outer surface. The portion of the deflection section spaced apart from the outer surface of the battery enclosure permits the deflection section to flex, bend, tear, detach or otherwise deform or be damaged before any impact force is exerted onto and transferred to the outer surface of the battery enclosure.
One or more embodiments further include methods for fabricating and manufacturing individual and modular composite battery enclosures and impact barriers. For example, an impact barrier can be positioned or applied on an outer surface or multiple surfaces of a cover or protective shell (e.g., a first surface) to form a modular structure. Attachment devices or adhesives can optionally be positioned and used to secure the impact barrier to the battery enclosure, for example, a curable material (e.g., resin) can be sprayed, poured, spread, rolled, brushed or calendared onto the outer surface or a surface of the impact barrier to form an attachment means. Under heated conditions, the structure components can be molded (e.g., in a compression or press mold or similar tooling) or pressed together to form a final shape of the battery enclosure or simply curing the one or more adhesives to rigidly secure the impact barrier to the outer surface of the battery enclosure.
Molding or bonding conditions, if used with the impact barrier and/or components of the battery enclosure, such as temperature and pressure, can be adjusted as needed but are preferably low to moderate to reduce time and cost of manufacturing the desired structure. For example, the enclosure can be heated during molding or bonding to a temperature in the range of about 100° to about 200° C., about 110° to about 190° C., about 120° to about 180° C., or about 130° to about 160° C. In another example, the enclosure can be subjected to pressure during molding in a range of about 0.1 megapascal (MPa) to about 1 MPa, about 0.15 to about 0.8 MPa, or about 0.2 to about 0.6 MPa.
Before securing the impact barrier to the outer surface of the battery enclosure, the enclosure surface (e.g., covers, protective shell) can be cleaned to remove debris or any excess material from the surface. Cleaning can be carried out with conventional methods, for example, pressurized gas or air can be blown on the composite covers to dislodge debris, such as dust or particles, that is adhered to the surface. The battery enclosure can also be brushed or wiped to remove unwanted material. In another example, the enclosure can be brought into contact with a cleaning solution, which can dissolve residue (e.g., release agents) from the surface. For instance, an aqueous solution with a cleaning agent (e.g., a surfactant) can be used. A cleaning solution can applied to the surface of the enclosure by any suitable method such as spraying, dipping or brushing before securing the impact barrier. In some embodiments, the battery enclosure can have additional coatings applied to its surface, such as an overcoat or protective coating (a fire, smoke and toxicity (FST) material, fire-retardant material or resin), which can underlie or be applied around an impact barrier. In other embodiments, the composite battery enclosure can be painted for its final application, inclusive of any impact barrier adhered to its surface, for example, for installation in an electric or hybrid vehicle.
In one or more embodiments, assembly of the battery enclosure and related components can be carried out by positioning the bottom cover and then inserting the desired battery system. Battery cells can be mounted over a cooling system, if present, followed by connection of all electrical cables. If desired, a perimeter seal is positioned on the bottom cover before placing the top cover over the bottom cover. Attachment means, for instance adhesive or fixtures (e.g., screws) at a connection point or service access component, are used to secure the top and bottom covers tightly together before attaching the one or more impact barriers, for example along a perimeter edge, and mounting the assembled battery enclosure in the desired application such as an electric vehicle.
Turning to the figures,
A polymer forming material or resin can be applied onto the fibers. The polymer forming material can penetrate and soak into the fibers arranged on the core material, which can embed or partially embed the fibers in the polymer forming material. As described herein, polymer forming material can be pushed and forced into the fiber layer to embed the fibers during a molding step, for example, a press or compression mold can push polymeric resin into the fibers to coat the fibers, fill voids in the fiber layer and contact the core material. A sufficient amount of polymer forming material can be applied to the fibers to form polymer layer that embeds the fibers and contacts the core material 12, 22 to adhere the fibers to one another and to the core. In one or more embodiments, the polymer can be formed from a curable polymer resin or composition. The composition can include a mixture of components, for example, a thermoset material, a thermoplastic material, a hardener, a catalyst, fillers, and any combination thereof. Materials can include epoxy, polyurethane, polyether ether ketone, polyethylene, or combinations thereof.
For the core sections of the covers disclosed herein, for example cores 12, 22 of the individual covers, the core material can be a plurality of open or gas-filled cells defined by cell walls. The cells can have any suitable cross-section shape (e.g., circular, hexagon, square, etc.). For example, the cores can be a honeycomb structure that includes many individual open cells side by side and arranged in the composite structures such that the cell walls are perpendicular to the longitudinal axis of the composite structure or an adjacent fiber layer. Alternatively, the cell walls can be arranged at other angles, for example, parallel or angled relative to the longitudinal axis of the composite structure. The cell walls can be made of plastic, for example, a thermoplastic or thermoset material. In one example, polypropylene or polycarbonate can be used as the material for the core and/or cell walls. The plurality of cells can be molded to form a desired shape wherein a portion of the cells are deformed under pressure, and optionally heat, to reduce the initial thickness of the core material.
The top and bottom covers 10, 20 can also be made of non-composite materials, such as a metal, an in any configuration that forms a protective shell around the battery storage area. As shown, the top or first and bottom or second covers 10, 20 are stacked, the top cover 10 overlying the bottom cover 20, to form a battery enclosure area for storing a plurality of battery units 2. In some embodiments, the top and bottom cover 10, 20 can be identical in dimensions and shape aside from an interface surface where the two covers meet, which can be mirror images of one another for forming an interlocking interface. Thickness of the bottom and top composite covers 10, 20, and those shown in the other figures, can range from about 10 to about 40 mm across the various components and regions in the covers containing a core material.
The top cover 10 includes a top section or portion that forms the central top surface of the battery enclosure. A portion of the sidewalls of the battery enclosure are formed by the sidewall section 14 of the top cover 10. In one or more embodiments, the battery enclosure 30 can be in the shape of a square or rectangular box such that the top cover 10 includes up to four sidewall sections 14 connected together and formed by core material 12 sandwiched by skins 11, 13. The bottom cover 20 includes a bottom section or portion that forms the central bottom surface of the battery enclosure. A portion of the sidewalls of the battery enclosure are formed by the sidewall section 24 of the bottom cover 20. In one or more embodiments, the bottom cover 20 includes up to four sidewall sections 24 connected together and formed by core material 22 sandwiched by skins 21, 23. Together, the sidewall sections 14, 24 of the top and bottom covers 10, 20 form the sidewalls of the battery enclosure.
Along the sidewalls of the battery enclosure, the sidewall sections 14, 24 of the top and bottom covers 10, 20 can meet, as shown, in an interlocking arrangement, in direct contact or close proximity if a seal, e.g., 36, is present therebetween, to form the battery enclosure area for storing battery units 2. The interlocking arrangement forms an interface defined in part by the shape of the perimeter surfaces for the sidewall portions of the top and bottom covers. Sidewall section 14 of the top cover 10 has a perimeter surface 15 and sidewall section 24 of the bottom cover 20 has a perimeter surface 25 that faces perimeter surface 15. The perimeter surfaces 15, 25 of the top and bottom covers 10, 20 are not entirely flat surfaces, but rather have sections that can form angles, interface angles, with respect to one another to form a non-linear interface.
As described herein, the interface can be divided into sections defined by portions of the perimeter surfaces facing or meeting one another. The interface includes at least two sections, wherein each interface section includes an interface angle formed by the facing or meeting of mirroring portions of the perimeter surfaces 15, 25 of the top and bottom covers. The at least two sections of the interface have different interface angles as compared to one another. The difference in interface angles between the first section and the second section can be any suitable degree, for example, in the range of 1° to 90°, 10° to 60°, or 20° to 50°. The interface can include more than two sections, for example, 3, 4, 5 or 6 sections. In one or more embodiments, at least two of the sections of the interface can have the same interface angle wherein the two sections having the same interface angle are not directly next to one another.
By including at least two interface sections that have different interface angles, the interface reduces the chance of material passing into or out of the battery enclosure area. For example, the various interface angles positioned in the interface forms an intricate pathway or barrier that prevents material from flowing into the battery enclosure. Thus, the interface pathway between the perimeter surfaces 15, 25 makes it difficult for debris, moisture, chemicals, liquids and the like to enter into the battery enclosure area. Preventing harmful materials from entering the battery enclosure ensures a more stable operating environment in the battery enclosure area.
As shown in
The top and bottom covers 10, 20 can be secured together by any of the means above, for instance, a fastener, adhesive, rivet, etc. In one or more embodiments, the covers 10, 20 can be secured together at or near the interface 32 area. As shown in
An attachment device, fastener or component 34 thereof can be joined to, or molded into or onto the monolithic sections 16, 26 to accommodate attachment or anchoring to another structure, such as the frame or body of a vehicle or adjacent composite cover in the case of a multi-piece composite battery enclosure. As shown, the monolithic sections can 16, 26 can be riveted together, or alternatively apertures in each section can be aligned to accommodate a fastener for attaching the top and covers 10, 20 together at an attachment point. The use of a fastener attachment component and the like can reduce the need for adhesives for securing the composite covers together or to other parts. In an alternative embodiment, the monolithic sections can be bound together with an adhesive material or an epoxy, which also creates an attachment point that can be used to open the battery enclosure.
The attachment device 34 securing the covers 10, 20 together serves as a connection or attachment point as noted above. Depending on the number and arrangement of cover components, the battery enclosure can have multiple attachment points, for example, 2, 3, 4, 5 or 6 or more, that function to secure parts of the battery enclosure together, and which must be accessible to disassemble the battery enclosure or maintenance, service, inspection or for battery replacement. The battery enclosure can also have a service access component, which can include the one or more attachment points. A service access component can be also be a latch or other fastening device that provides a way to enter the battery enclosure or a portion thereof. For example, the battery enclosure can have an access panel for performing maintenance and the like, wherein the access panel, door, etc. is secured shut during operation. The service access component and attachment points are accessible on the outer surface of the battery enclosure and as shown in
As shown, the impact barrier 40 has base section 43 that represents the portion of the barrier 40 that is secured to the battery enclosure. The base section 43 can be of any suitable size to provide a connection area for being secured to the battery enclosure. The impact barrier 40 includes a deflection section 42 for absorbing an external force that may contact the impact barrier. The deflection section 42 functions to absorb the external force, or a portion thereof, prior to the force being distributed to the battery enclosure to minimize the damage to the enclosure that would otherwise resulting from the external force directly contacting the battery enclosure. In some embodiments, the deflection section 42 can bend, twist, break away, crumple or otherwise deform as it absorbed an external force. To facilitate easier bending and the like, the deflection section can have a hinge point, for example 42a, that accommodates the deflection section 42 bending or deflecting from its position during normal operation of the battery enclosure.
A hinge point can be formed by arranging the deflection section 42 such that it is cantilevered from another portion of section 42, for example, the base section 43 as shown in
In other embodiments, the deflection section 42 can also bend or be deformed in other ways that do not rely on or utilize a hinge point depending on the direction and impact position of an external force on the impact barrier 42.
The bending or deflection direction and degree of force absorption can be affected by the design of the deflection section 42. As shown in
In addition to being arranged on the impact barrier 40 for absorbing an external force, the deflection section 42 as shown in
In one or more embodiments, the impact barrier can have alternate shapes as that shown in
The configuration shown in
The end faces of the deflection sections 62, 72 face one another but do not contact each other. The end faces form an opening 66 that exposes attachment device 34 securing the covers 10, 20 together that serves as a connection or attachment point. The open area 66 is further accessible to a user so an attachment point or service access component can be reached during a maintenance or inspection situation, for example, the open area 66 can be sized and arranged to accommodate a tool or other apparatus that is needed to remove a fastener or the like to disassemble the battery enclosure or a portion thereof. The open area 66 can be sized and configured as needed, for example, by changing the shape and dimensions of sections 62, 72, to facilitate tools or similar components required to detach or unhinge a fastener or the like at an attachment point or service access component.
Surfaces 67 and 77 of the deflection sections 62, 72 of the impact barriers 60, 70 are also respectively spaced apart from surfaces 11 and 21 of the battery enclosure to form additional open area in communication with area 66. These additional openings permit the deflection sections 62, 72 to bend inward when contacted by an external force for absorbing and deflecting the force from the battery enclosure and thereby reducing potential damage. Alternatively, open area 66 could be covered with a thin material to prevent debris, moisture, etc. from collecting around the outer surface of the enclosure and attachment point. Any thin material can be selected to not interfere with the bending and deformation of the deflection sections 62, 72 as they are intended and designed to operate. Material can be removed and replaced or re-attached after any access by use to the battery enclosure during a maintenance or inspection situation.
The first and second impact barriers 60, 70 can have similar design characteristics and components as impact barriers 40, 50 above. For example, impact barriers 60, 70 can also include hollow sections 65, 75 as described for the impact barrier of
While various aspects and embodiments of the compositions and methods have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/081520 | 12/14/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63292550 | Dec 2021 | US |
