Composite battery casing

Abstract

A battery housing for a vehicle chassis, having: a base member having protruding surface features on an upper surface, the protruding surface features outlining a plurality of independent cells, each cell being configured to receive at least one battery; and a covering member having a plurality of overhanging surface features on a lower surface, the overhanging surface features being aligned with the surface features of the base member. The covering member includes a channel formed in its upper surface, the channel being aligned with the overhanging surface features arranged on the bottom surface and extending along its length. Also included is a lattice support structure having a plurality of axially and laterally extending support members, wherein the lattice support structure is configured to be at least partially arranged within the channel of the covering member and mounted to the vehicle chassis. The lattice support members provide increased rigidity and a load distribution path for externally applied forces (e.g., collision events) to prevent or inhibit rupture or puncture of the housing.

Description

[0001] This application is a divisional application of Chinese invention patent application No. 201880091089.3, which has entered the Chinese national phase of international application PCT / US2018 / 046722 with the invention name “Composite Battery Casing” and the international application date of August 14, 2018.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit under 35 USC 119 of U.S. Provisional Application No. 62 / 624,288, filed on January 31, 2018, the entire contents of which are incorporated herein by reference. Technical Field

[0004] The disclosed subject matter relates to a system for a composite enclosed compartment. In particular, the disclosed subject matter relates to a composite battery enclosure. Background Art

[0005] Various structures are known for battery housings that are self-supporting and structurally separate from the balance of the vehicle system. This results in increased mass of the overall system and thus reduced economy (increased manufacturing costs) and performance (higher weight reduces operating range between charges or reduced fuel economy in hybrids).

[0006] Large mass batteries typically require a large amount of material to provide stiffness and strength to hold the battery or batteries within the vehicle system. Similarly, conventionally designed battery enclosures require a large amount of reinforcement to prevent object intrusion in the event of a vehicle collision. The structural requirements of the vehicle and the structural requirements of the battery enclosure are traditionally separated, whereby the battery enclosure becomes a pure parasitic mass and is redundant to the performance of the vehicle.

[0007] Examples of conventional battery housings are provided in the following publications, each of which is incorporated herein by reference in its entirety: U.S. Patent Nos. 8,286,743, 8,393,427, 8,833,499, 5,620,057, 7,323,272, 8,115,450, 8,210,301, 8,875,828, 9,331,321; and U.S. Patent Application Publication Nos. 20100136402, 20120103714, 2015079454, and 2015318525.

[0008] The subject matter of the present disclosure provides a new innovative solution for storing, protecting and using batteries for hybrid, plug-in hybrid and electric vehicle applications. The present disclosure comprehensively describes the unique and innovative structural solution to integrate the battery housing with the vehicle body-in-white and / or vehicle chassis. The subject matter of the present disclosure solves many packaging challenges associated with separate battery housings that must exist in the available space of traditional vehicle designs, in which the design of collision protection is independent of the connected battery housing. In addition, the system and structure of the battery housing of the present disclosure can be applied to hybrid, plug-in hybrid and plug-in electric passenger cars for transportation and other public transportation systems (e.g., buses, shuttles and rail cars). Summary of the invention

[0009] The objects and advantages of the disclosed subject matter will be set forth in the following description and will be apparent from the description, as well as learned by the practice of the disclosed subject matter. Other advantages of the disclosed subject matter will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof as well as from the accompanying drawings.

[0010] To achieve these and other advantages and in accordance with the purposes of the disclosed subject matter, as implemented and broadly described, the disclosed subject matter includes systems and structures for forming a battery housing for a vehicle chassis, the battery housing comprising: a base member having an upper surface and a lower surface, the base member having a plurality of protruding surface features on the upper surface, the protruding surface features outlining a plurality of independent cells, each cell being configured to receive at least one battery (in embodiments where a plurality of modules are used to form the battery, each cell can be configured as a discrete module); a covering member having an upper surface and a lower surface, the covering member having a plurality of overhanging surface features on the lower surface, the plurality of overhanging surface features outlining a plurality of independent cells, the surface features of the covering member being aligned with the surface features of the base member, the covering member having at least one channel formed in its upper surface, the channel being aligned with the overhanging surface features arranged on the bottom surface and extending along the length of the overhanging surface features; a lattice support structure, the lattice support structure comprising a plurality of axially extending support members and a plurality of transversely extending support members, wherein the lattice support structure is configured to be at least partially arranged within the channel of the covering member and mounted to the vehicle chassis.

[0011] In some embodiments, the support members of the lattice support structure include hollow beams constructed of metal; and / or the support members of the lattice support structure include multiple independent layers of continuous fiber reinforcement, wherein the continuous fiber reinforcement has at least 60% of the reinforcing fibers aligned with the main axis of the support member.

[0012] In some embodiments, an upper surface of the lattice support structure is coupled to a vehicle chassis, a boundary edge of the lattice support structure is disposed between rocker panels of the vehicle chassis, and the independent unit comprises a plurality of symmetrical units.

[0013] In some embodiments, the lattice support structure includes a first axial support member and a second axial support member having a common cross-section and a third axial support member having a different cross-section.

[0014] In some embodiments, at least one depending surface feature of the cover member extends a distance greater than a distance that at least one protruding surface feature of the base member extends.

[0015] In some embodiments, surface features of the covering member are engaged with surface features of the base member to form at least one closed volume unit, and the covering member has a flange extending around the periphery, and the bottom surface of the grid support structure is engaged with the upper surface of the flange of the covering member, so that the covering member and the grid support structure form a load-bearing floor of the vehicle.

[0016] In some embodiments, at least one of the cover member and the base member is formed as an integral moulding from reinforcing fibres arranged within a resin.

[0017] In some embodiments, the fiber includes at least one of carbon fiber, glass fiber, aramid fiber, polyethylene fiber, or polypropylene fiber, and the resin includes a liquid thermosetting resin, wherein the liquid thermosetting resin includes at least one of epoxy resin, unsaturated isophthalic polyester resin, vinyl ester resin, methyl methacrylate resin, or phenolic resin.

[0018] In some embodiments, the resin includes a thermoplastic resin including at least one of polyethylene, polypropylene, polyamide, acrylic, polycarbonate, polybutylene terephthalate (PBT), or polyphenylene sulfide (PPS) resin.

[0019] In some embodiments, at least one of the cover member and the base member comprises a plurality of individual layers of continuous fiber reinforcement arranged in a cross-ply fashion, wherein the angle of the fibers relative to the axial orientation of the vehicle is greater than + / - 20 degrees and less than + / - 70 degrees.

[0020] In some embodiments, at least one of the cover member and the base member includes a plurality of independent layers having randomly oriented discontinuous reinforcement fibers.

[0021] In some embodiments, a battery housing for a vehicle chassis includes: a base member having an upper surface and a lower surface, the base member having a plurality of protruding surface features on the upper surface, which outline the contours of a plurality of independent units, each unit being configured to receive at least one battery; a covering member having an upper surface and a lower surface, the covering member having a plurality of overhanging surface features on the lower surface, which outline the contours of a plurality of independent units, the surface features of the covering member being aligned with the surface features of the base member, and the covering member having at least one channel formed in its upper surface, the channel being aligned with the overhanging surface features arranged on the bottom surface and extending along the length of the overhanging surface features; a lattice support structure, the lattice support structure including a plurality of axially extending support members and a plurality of transversely extending support members to surround each unit housed in the housing, wherein the upper and lower surfaces of the lattice support structure define a thickness, the thickness of the lattice support structure being equal to the depth of the channel in the covering member.

[0022] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the disclosed subject matter as claimed.

[0023] The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to illustrate and provide a further understanding of the methods and systems of the disclosed subject matter. The drawings, together with the description, serve to explain the principles of the disclosed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] A detailed description of various aspects, features, and embodiments of the subject matter described herein is provided with reference to the accompanying drawings briefly described below. The drawings are illustrative and not necessarily drawn to scale, wherein some components and features are exaggerated for clarity. The accompanying drawings illustrate various aspects and features of the subject matter and may illustrate one or more embodiments or examples of the subject matter in whole or in part.

[0025] Figure 1 is an exploded schematic diagram illustrating a perspective view of components of a battery housing according to the disclosed subject matter.

[0026] Figures 2A-2D is a schematic diagram of a base member according to the disclosed subject matter; Figure 2A It is a top perspective view; Figure 2B-2C It is a bottom perspective view; Figure 2D is a cross-sectional view.

[0027] Figures 3A-3D is a schematic diagram of a cover member according to the disclosed subject matter; Figure 3A and 3C It is a top perspective view; Figure 3BIt is a bottom perspective view; Figure 3D is a cross-sectional view.

[0028] Figures 4A-4D is a schematic diagram of a base member with a cover member and a lattice support structure in accordance with the disclosed subject matter; Figure 4A and 4C It is a top perspective view; Figure 4B It is a bottom perspective view;

[0029] Figure 4D is a cross-sectional view. DETAILED DESCRIPTION

[0030] Reference will now be made in detail to exemplary embodiments of the disclosed subject matter, examples of which are illustrated in the accompanying drawings. The methods and corresponding steps of the disclosed subject matter will be described in conjunction with the detailed description of the system.

[0031] The methods and systems presented herein can be used in battery enclosure structures. The disclosed subject matter is particularly suitable for composite battery enclosure structures that can be directly integrated into a vehicle chassis, thereby enhancing structural integrity while protecting the battery module from intrusion and thermal leakage / intrusion. For purposes of explanation and illustration, but not limitation, Figure 1 An exemplary embodiment of a system in accordance with the disclosed subject matter is shown in FIG. 1 and generally indicated by reference numeral 1000. Like reference numerals (distinguished by leading numerals) may be provided in the various views and figures presented herein to indicate functionally corresponding, but not necessarily identical, structures.

[0032] like Figure 1 As shown, the battery enclosure system 1000 generally includes a plurality of components including a base member 100, a cover member 200, and a grid support structure 300, each of which will be described in further detail below.

[0033] Base member

[0034] Figure 1 and Figures 2A-2D An exemplary embodiment of a lower structure of a battery housing is shown.

[0035] In some embodiments, the base member 100 can be formed as a one-piece molded piece having a plurality of axial and lateral surface features 110 that outline and form a "cell" for receiving the individual batteries that make up the vehicle power system. The presence of such surface features 110 facilitates assembly by providing tactile and visual confirmation of the proper installation of the batteries in each cell via proper registration of the mating surfaces. Additionally, the formation of discrete cells is advantageous because it can isolate adverse events (e.g., leaks, thermal variations, etc.) between adjacent batteries within the housing.

[0036] In the exemplary embodiment shown, the surface features are protruding or upwardly extending ribs or channels 110 that outline the outline of a rectangular unit, but it should be understood that the base member 100 can be formed with units of alternative shapes. Similarly, the surface features 110 can be formed as channels having sidewalls 110a, 110b, such as Figure 2D As shown, the side walls protrude upwardly from the bottom surface of the base member 112. In the exemplary embodiment shown, the height of the side walls 110a, 110b is equal to the width of the horizontal top portion 110c. However, it should be understood that various sizes and relative proportions may be provided as desired.

[0037] In such an embodiment, the bottom surface 112 can form a series of breaks or discontinuities in the plane of its lower surface (at a location consistent with the channel top 110c). Additionally or alternatively, the surface feature 110 can be formed as a solid rib member protruding upward from the continuous bottom surface of the base member so that no breaks or discontinuities are formed therein. Thus, when the battery housing is installed, the battery housing unit described herein can form a flat and planar surface to form the bottom side of the vehicle.

[0038] The base member 100 may also include a flange 120 around its periphery or a selected portion thereof (or portions thereof). The flange 120 may be coupled to the cover member 200 as described in further detail below. In some embodiments, the flange 120 may be formed with a width that extends laterally a distance greater than the distance or vertical height of the surface feature 110.

[0039] In addition, the axial and lateral surface features 110 and the flange portions 120 can be positioned to match or align with similar axially and lateral arranged surface features and flange portions in the covering member 200 so as to fully engage / encapsulate and form an enclosed volume to accommodate the individual battery cells assembled therein, as described in more detail below.

[0040] The base member 100 can be formed of various materials including reinforcing fibers. Some illustrative examples of such reinforcing fibers include carbon fibers, glass fibers, Kevlar (aramid) fibers; and combinations thereof. In some embodiments, polyethylene or polypropylene fibers can be used, which are stable in a matrix of a resin selected from any one of the following chemical classes of liquid thermosetting resins: epoxy resins, unsaturated isophthalic polyester resins, vinyl ester resins, methyl methacrylate resins, or phenolic resins, and combinations thereof. In some embodiments, the reinforcing fibers can be stable in thermoplastic resins, including polyethylene, polypropylene, polyamide (nylon), acrylic, polycarbonate, polybutylene terephthalate (PBT) or polyphenylene sulfide (PPS), or combinations thereof.

[0041] According to one aspect of the present disclosure, the construction material may include multiple independent layers of aligned continuous fiber reinforcements made of the above-mentioned fiber material. For example, the base member can be made into a sandwich material in which multiple layers of reinforcement material are laminated into a core of a low-density material selected from the category of core materials including cross-cut balsa wood or the category of resins cast or extruded with internal foaming (foaming agent): polyvinyl chloride (PVC), cross-linked polyvinyl chloride (CPVC), styrene acrylonitrile (SAN), polyurethane or polyethylene terephthalate (PET); and combinations thereof. In such an embodiment, the lower structure obtains resistance to deformation caused by laterally applied loads, which will be applied by the loads applied by the dense battery pack. However, the in-plane (tensile) stiffness of the lower structure can remain very compliant (less stiffness).

[0042] In some embodiments, the base member can be formed from multiple independent layers of aligned continuous fiber reinforcement, the independent layers consisting of two or more layers of fibers arranged in a cross-laminated manner. For example, the angle of the fiber relative to the axial orientation of the vehicle can be greater than + / -20 degrees and less than + / -70 degrees, but alternative angles can be used as desired. Such a configuration can provide increased torsional stiffness to the battery housing structure.

[0043] Additionally or alternatively, the base member may be formed from a plurality of separate layers of reinforcing fibers, the separate layers being comprised of discontinuous randomly oriented fibers selected from the class of reinforcements comprising carbon fibers, glass fibers, and Kevlar (aramid) fibers, polyethylene or polypropylene fibers.

[0044] Covering components

[0045] Figure 1 and Figures 3A-3D An exemplary embodiment of a cover member of a battery housing is shown.

[0046] In some embodiments, the cover member 200 may be formed as a one-piece molding having a plurality of axial and lateral surface features 210 that outline and form a "cell" for receiving the individual batteries that make up the vehicle powertrain. The presence of such surface features 210 facilitates assembly by providing tactile and visual confirmation of proper installation of the batteries in each cell through proper registration of the mating surfaces.

[0047] In the exemplary embodiment shown, the surface features are depending or downwardly extending ribs or channels 210 that outline the outline of a rectangular unit, but it should be understood that the cover member 200 can be formed with units of alternative shapes. Similarly, the surface features 210 can be formed as channels having sidewalls 210a, 210b, such as Figure 3D As shown, the side walls 210a, 210b protrude downward from the bottom surface of the cover member 212. In the exemplary embodiment shown, the height of the side walls 210a, 210b is equal to the width of the horizontal top portion 210c. However, it should be understood that various sizes and relative proportions can be provided as desired.

[0048] In such an embodiment, the top surface 212 can be formed with a series of breaks or discontinuities in the plane of its upper surface (at a position consistent with the channel top 210c). Additionally or alternatively, the surface feature 210 can be formed as a solid rib member protruding downward from the continuous top surface of the covering member so that no breaks or discontinuities are formed therein. Thus, the battery housing unit described herein can form a flat and planar surface on both its upper and lower surfaces. The advantage of such a planar surface is that a larger surface area is provided for engaging with the vehicle chassis.

[0049] The cover member 200 may also include a flange 220 around its periphery or a selected portion thereof (or portions thereof). The flange 220 may be coupled to the corresponding flange 110 of the base member 100 in a variety of ways, including mechanical fastening, chemical (e.g., adhesive) bonding, and / or fusion (e.g., ultrasonic welding). In some embodiments, the flange 220 may be formed with a width that extends laterally a distance greater than the distance or vertical height of the surface feature 210.

[0050] In addition, the axial and lateral surface features 210 and the flange portion 220 of the covering member 200 can be positioned to match or align with the similar axial and lateral surface features 110 and the flange portion 120 in the base member 100 so as to fully engage / enclose and form a closed volume to accommodate the individual battery cells assembled therein. As described above, the formation of the closed volume is advantageous for isolating adverse events within any particular cell (or multiple particular cells). In order to form such a closed cell, the size and shape of the surface features 110, 210 are designed to engage with each other. In some embodiments, the distance that the surface feature 110 extends upward can be equal to the distance that the surface feature 210 extends downward, so that the peaks 110c, 210c abut each other at the position of the approximately midpoint of the battery contained therein. In other embodiments, the side walls 110a, 11b can be formed to have a height equal to or greater than the height of the battery to be positioned in the cell. Additionally or alternatively, the overhanging surface feature 210 of the cover member 200 can extend a distance greater than the distance that the surface feature 110 of the base member 100 extends upward. In some embodiments, the surface features 110, 210 can be formed to have a height that varies along the length. Thus, the size and shape of the sidewalls of the surface features 110, 210 can be designed to increase structural integrity and / or accommodate the design of the vehicle chassis as desired.

[0051] In some embodiments, an additional sealing member may be provided between the cover member 200 and the base member 100. The sealing member may extend only around the periphery, i.e., between the flanges 220, 120. Additionally or alternatively, the sealing member may extend around selected cells (i.e., between the protruding surface features 110c, 210c). The sealing member may be formed as a compressible gasket, e.g., an O-ring, to prevent fluid from entering or leaving the cells.

[0052] The covering member 200 can be formed of various materials including reinforcing fibers. Some illustrative examples of such reinforcing fibers include carbon fibers, glass fibers, Kevlar (aramid) fibers, and combinations thereof. In some embodiments, polyethylene or polypropylene fibers can be used, and polyethylene or polypropylene fibers are stable in a matrix of a resin selected from any one of the following chemical classes of liquid thermosetting resins: epoxy resins, unsaturated isophthalic polyester resins, vinyl ester resins, methyl methacrylate resins or phenolic resins, or combinations thereof. In some embodiments, the reinforcing fibers can be stable in thermoplastic resins, including polyethylene, polypropylene, polyamide (nylon), acrylic acid, polycarbonate, polybutylene terephthalate (PBT) or polyphenylene sulfide (PPS), or combinations thereof.

[0053] According to one aspect of the present disclosure, the construction material may include multiple independent layers of aligned continuous fiber reinforcements made of the above-mentioned fiber material. For example, the base member can be made into a sandwich material in which multiple layers of reinforcement material are laminated into a core of a low-density material, and the low-density material is selected from the category of core materials including cross-cut balsa wood or the category of resins cast or extruded with internal foaming (foaming agent): polyvinyl chloride (PVC), cross-linked polyvinyl chloride (CPVC), styrene acrylonitrile (SAN), polyurethane or polyethylene terephthalate (PET), and combinations thereof. In such an embodiment, the covering member obtains resistance to deformation caused by laterally applied loads, which will be applied by the loads applied by the dense battery pack. However, the in-plane (tensile) stiffness of the lower structure can remain very compliant (less stiffness).

[0054] In some embodiments, the cover member may be formed from multiple independent layers of aligned continuous fiber reinforcement, the independent layers consisting of two or more layers of fibers arranged in a cross-laminated manner. For example, the angle of the fibers relative to the axial orientation of the vehicle may be greater than + / -20 degrees and less than + / -70 degrees, but alternative angles may be employed as desired. Such a configuration may provide increased torsional stiffness to the battery housing structure.

[0055] Additionally or alternatively, the covering member may be formed from a plurality of separate layers of reinforcing fibres, the separate layers being comprised of discontinuous randomly oriented fibres selected from the class of reinforcements comprising carbon fibres, glass fibres and Kevlar (aramid) fibres, polyethylene fibres or polypropylene fibres.

[0056] The covering member 200 and / or the base member 100 can be formed by various manufacturing techniques. For example, the covering member and the base member can be manufactured by a liquid compression molding (LCM) process. In addition, relative to the use of high pressure resin transfer molding (HP-RTM) technology to inject resin into the tool, the resin can be automatically layered on the top of the part before entering the pressing. In some cases, LCM technology can provide advantages (relative to HP-RTM), including: since the resin is applied to the outside of the mold, the cycle time is faster; less complex tooling; no preforming is required, thereby reducing waste. In addition, in order to facilitate the control of adverse events within a given unit, the covering member 200 and / or the base member 100 can be formed of such a material that exhibits heat resistance for one hour at 600°C without compromising the structural integrity of the member (e.g., no warping, no thinning, no holes, etc.).

[0057] Grid support structure

[0058] Figure 1 and Figures 4A-4D An exemplary embodiment of a grid support structure 300 for a battery enclosure is shown.

[0059] In the exemplary embodiment shown, the lattice support structure 300 is sized and shaped to fit within the slots on the upper surface of the cover member 200, ie, to fit within the recesses formed by the surface features 210c. Figures 4A-4D The integration of the grid support structure 300 with the assembled cover member 200 and base member 100 of the housing is depicted. In this exemplary embodiment, the grid support structure 300 includes axially and transversely assembled support members 310, 312 that fully engage the axial and transverse channels molded into the cover member 200 and the upper surface of the cover member flange 220, thereby providing a rigid structure on which the cover member 220 is attached. In this configuration, the grid support structure 300 provides a rigid frame and provides a direct load path in the event of a side impact (along the support member 312) or a frontal / rear impact (along the support member 310). In this way, when the battery housing is assembled and installed on the vehicle chassis, the cover members and the grid support structure form the load-bearing floor of the vehicle.

[0060] like Figure 4C-4D As shown, in some embodiments, the lattice support structure 300 can be formed with hollow beams 310, 312. In addition, the support member surrounds the entire unit. The lattice support structure 300 has a height or thickness equal to the depth of the side walls 210a, 210b of the cover member 200, so that when the lattice support member 300 is attached to the cover member, the upper surface of the lattice support member 300 is flush or in the same plane as the upper surface of the cover member 200, as shown in FIG. Figure 4D As shown. The upper surface of the grid support structure 300 is coupled to the vehicle chassis. In some embodiments, the battery housing unit described herein is sized so that the boundary edge is located between the rocker panels of the vehicle chassis. The grid support structure 300 can be coupled to the cover member (e.g., along the flange 210 and the channel 210c) in a variety of ways, including mechanical fastening, chemical (adhesive) bonding, and / or fusion (e.g., ultrasonic welding).

[0061] In some embodiments, the support members of the lattice support structure 300 are formed to have a uniform cross-sectional shape, while in other embodiments, the support structure is formed to have varying sizes. For example, the axial support members forming the edges of the lattice support structure 300 may have a larger cross-sectional shape than the axial support member (or multiple support members) arranged between the edges (e.g., along the centerline), such as Figure 4D shown.

[0062] The grid support structure 300 may be formed from a variety of materials, such as extruded metals including carbon steel, aluminum, and alloys or combinations thereof. Additionally or alternatively, the grid support member 300 may also be made from a reinforced polymer composite material pultruded with reinforcing fibers that may include any combination of fibers and resins, such as those discussed above with respect to the base member and cover member.

[0063] Moreover, similar to the base and cover members, the lattice support structure can be made of a continuous fiber reinforced polymer composite material. In such an embodiment, at least 60% of the reinforcing fibers are aligned with the major axis of the support member to form a dominantly orthotropic structure with high stiffness along the length of the beam.

[0064] According to aspects of the present disclosure, the lattice support structure provides high stiffness along its length, which provides a rigid in-plane load path for externally applied loads resulting from an impact or collision of the vehicle. In contrast, the cover member and base member fiber arrangements that are not aligned with the axial or lateral orientation of the vehicle have lower in-plane stiffness, thereby avoiding loads carried by the housing that houses the vehicle's battery cells. This further protects the batteries while providing a rigid frame for the vehicle to prevent intrusion into the passenger compartment in the event of a collision.

[0065] exist Figure 1-4D In the illustrated embodiment, the cells are symmetrical (i.e., rectangular), but alternative designs are also within the scope of the present disclosure. For example, the protruding surface features 110, 210 and the support beams of the lattice support structure (or collectively referred to as "cell walls") can be formed to have varying, non-uniform geometries. For example, a gradient design can be employed with a greater number of cell walls (e.g., smaller sized cells, or repeated / parallel reinforcement walls) at the front of the battery housing to increase rigidity for frontal impact situations.

[0066] In addition, in some embodiments, the cell wall may have passage features (e.g., holes, grooves, etc.) formed therein to allow conduits and interconnects between adjacent cells, such as wiring to / from batteries contained in the cells. Similarly, these passage features can be used as ventilation devices between battery cells. In some embodiments, it may be desirable to direct fluid flow through such passage features to provide heating or cooling of the cells. In addition, in some embodiments, the composite housing may include an access point, for example, for technicians to replace equipment with limited service life, such as fuses, printed circuit boards, connectors, control devices, etc. The access point may be formed as a resealable panel that can be opened by sliding along the horizontal axis of the housing, by pivoting around a hinge formed in the housing, or by removing from the rest of the housing. In some embodiments, the access point (and the replaceable device below) is located in a compartment isolated from the cell containing the battery (i.e., not leading to the cell containing the battery or not in fluid communication with it). This configuration ensures that a hermetic seal is maintained between the battery and the ambient air at all times (i.e., even when the access panel is open).

[0067] Furthermore, while the exemplary embodiments shown herein depict a generally rectangular housing having a constant thickness, alternative designs may be provided, such as a battery housing having a varying (tapered or stepped) width and / or height to accommodate both the desired battery capacity and the vehicle chassis design that dictates how and where the battery housing is to be connected.

[0068] In some embodiments, multiple composite battery enclosures as described above can be combined in a modular manner, for example, vertically stacked on top of each other to increase battery capacity. Such stacking increases mass, thereby suppressing any undesirable vibration loads and increasing the stiffness of the collective structure. Moreover, the composite battery enclosures of the present disclosure can be retrofitted to fit a previously formed vehicle chassis.

[0069] According to another aspect of the present disclosure, the composite battery housing described herein may incorporate electromagnetic shielding properties. In some embodiments, electromagnetic shielding may be provided around the exterior of the housing. In some embodiments, electromagnetic shielding may be provided around selected cells (independent or multiple) of the housing. The presence of such EMF / EMC shielding inhibits any undesirable electrical interference between the battery and other components of the vehicle.

[0070] According to another aspect of the present disclosure, the composite housing described herein can be formed from a plurality of "functionally graded" laminates, i.e., each laminate has a specific and discrete function. For example, the composite material can have a first laminate layer, i.e., one or more layers of carbon nanotube-enriched (e.g., graphene) composite material layers, to form a conductive surface that acts as both a ground plane and provides electromagnetic shielding functions. In addition, a layer of phenolic matrix composite material can be formed on the interior of the housing to provide an insulating layer that can prevent thermal runaway of the battery and prevent catastrophic failure. In addition, a protective layer composed of aromatic polyamide, crystalline polyethylene or Dyneema can be combined to provide local impact (penetration) protection, etc.

[0071] Although the disclosed subject matter is described herein according to certain preferred embodiments, those skilled in the art will recognize that various modifications and improvements may be made to the disclosed subject matter without departing from the scope thereof. Furthermore, although various features of one embodiment of the disclosed subject matter may be discussed herein or shown in the drawings of one embodiment but not shown in other embodiments, it should be apparent that various features of one embodiment may be combined with one or more features of another embodiment or features of multiple embodiments.

[0072] In addition to the specific embodiments claimed below, the disclosed subject matter also relates to other embodiments having the dependent features claimed below and any other possible combination of the dependent features disclosed above. Therefore, within the scope of the disclosed subject matter, the specific features given in the dependent claims and disclosed above may be combined with each other in other ways, so that the disclosed subject matter should be understood to also specifically relate to other embodiments having any other possible combination. Therefore, the foregoing description of specific embodiments of the disclosed subject matter is given for the purpose of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed.

[0073] It is obvious to those skilled in the art that various modifications and variations can be made to the methods and systems of the disclosed subject matter without departing from the spirit or scope of the disclosed subject matter. Therefore, it is intended that the disclosed subject matter includes modifications and variations that fall within the scope of the appended claims and their equivalents.

Claims

1. A battery housing for a vehicle chassis, the battery housing comprising: a base member having an upper surface and a lower surface, the base member having a plurality of raised surface features on the upper surface, the raised surface features outlining a plurality of individual cells, each cell being configured to receive at least one battery; wherein the lower surface of the base member is configured as a continuous surface; a cover member having an upper surface and a lower surface, the cover member having a plurality of overhanging surface features on the lower surface of the cover member, the overhanging surface features outlining a plurality of individual cells, the overhanging surface features of the cover member being aligned with the protruding surface features of the base member, and the cover member having at least one channel formed in the upper surface of the cover member, the channel being aligned with and extending along a length of the overhanging surface feature disposed on the lower surface of the cover member; A lattice support structure, the lattice support structure comprising a plurality of axially extending support members and a plurality of transversely extending support members, wherein the lattice support structure is configured to be disposed at least partially within the channel of the cover member and mounted to the vehicle chassis; wherein a bottom surface of the lattice support structure is disposed above the upper surface of the base member; and Wherein, the top surface of the grid support structure is coplanar with the upper surface of the covering member.

2. The battery case according to claim 1, wherein: The base member includes a flange that extends laterally a distance greater than a distance that the raised surface features on the upper surface of the base member extend vertically.

3. The battery housing according to claim 1, wherein: The cover member includes a flange that extends laterally a distance greater than a distance that the raised surface features on the upper surface of the base member extend vertically.

4. The battery case according to claim 3, wherein: The flange of the cover member is coupled to the flange of the base member.

5. The battery housing according to claim 3, wherein: A bottom surface of the lattice support structure engages an upper surface of the flange of the cover member.

6. The battery housing according to claim 1, wherein: The support members of the lattice support structure comprise hollow beams.

7. The battery housing according to claim 1, wherein: The first support member of the lattice support structure has a larger cross-section than the second support member of the lattice support structure.

8. The battery housing according to claim 1, wherein: The lattice support structure is constructed from metal.

9. The battery housing according to claim 1, wherein: An upper surface of the lattice support structure is coupled to the vehicle chassis.

10. The battery housing according to claim 1, wherein: The boundary edges of the lattice support structure are arranged between rocker panels of the vehicle chassis.

11. The battery housing according to claim 1, wherein: The depending surface features of the cover member engage the protruding surface features of the base member to form at least one enclosed volume unit.

12. The battery housing according to claim 1, wherein: The covering member and the lattice support structure form a load floor for the vehicle.

13. The battery housing according to claim 1, wherein: The lattice support structure is constructed from a plurality of individual layers of continuous fiber reinforcement having at least 60% of the reinforcing fibers aligned with a major axis of the support member.

14. The battery housing according to claim 1, wherein: At least one of the cover member and the base member comprises a plurality of individual layers of continuous fiber reinforcement arranged in a cross-ply fashion, wherein the fibers are oriented at an angle greater than + / - 20 degrees and less than + / - 70 degrees relative to an axial direction of the vehicle.

15. The battery housing according to claim 1, wherein: At least one of the cover member and the base member includes a plurality of separate layers of continuous reinforcement fibers.

16. The battery housing according to claim 1, wherein: At least one of the cover member and the base member includes a plurality of individual layers, each individual layer having a functionally graded laminate.

17. The battery housing according to claim 16, wherein: At least one of the individual layers includes graphene.

18. The battery housing according to claim 16, wherein: At least one of the individual layers includes a phenolic matrix composite material.

19. The battery housing according to claim 16, wherein: At least one of the individual layers includes at least one of aramid, crystalline polyethylene, and / or dyneema.

20. A battery housing for a vehicle chassis, the battery housing comprising: a base member having an upper surface and a lower surface, the base member having a plurality of raised surface features on the upper surface, the raised surface features outlining a plurality of individual cells, each cell being configured to receive at least one battery; wherein the lower surface of the base member is configured as a continuous surface; a cover member having an upper surface and a lower surface, the cover member having a plurality of overhanging surface features on the lower surface of the cover member, the overhanging surface features outlining a plurality of individual cells, the overhanging surface features of the cover member being aligned with the protruding surface features of the base member, and the cover member having at least one channel formed in the upper surface of the cover member, the channel being aligned with and extending along a length of the overhanging surface feature disposed on the lower surface of the cover member; a grid support structure comprising a plurality of support members extending axially and a plurality of support members extending laterally to surround each cell contained within the battery housing; wherein the upper and lower surfaces of the lattice support structure define a thickness, the thickness of the lattice support structure being equal to the depth of the channel in the cover member; wherein a bottom surface of the lattice support structure is disposed above the upper surface of the base member; and Wherein, the top surface of the grid support structure is coplanar with the upper surface of the covering member.

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