Method for post-forming a reinforcement part in a housing of a battery

Abstract

A housing body and a method for manufacturing a housing including one of extruding a housing body and deep-punching the housing body, the housing including a plurality of sidewalls defining a first cavity. The plurality of side walls are formed without reinforcing portions. After extrusion and deep punching of the housing, a plurality of stiffened portions are formed on the housing using an expandable punch, a hydraulic punch, and / or hydraulic forming.

Description

Technical Field

[0001] introduction

[0002] The information provided in this section is for the purpose of generally presenting the context of the present disclosure. The work of the presently named inventors, to the extent it is described in this section and in all aspects of this description that may not otherwise be considered prior art at the time of filing, is neither explicitly nor implicitly admitted to be prior art against the present disclosure.

[0003] The present disclosure relates to housings, and more particularly to housings including post-formed reinforcement portions. Background Art

[0004] Electric vehicles (EVs) (such as battery electric vehicles (BEVs), hybrid vehicles) and / or fuel cell vehicles include one or more motors and a battery system, which includes one or more battery cells, modules and / or battery packs. A power control system is used to control the charging and / or discharging of the battery system during charging and / or driving. Summary of the invention

[0005] A method for manufacturing a shell body includes performing one of "extruding the shell body" and "deep drawing the shell body", the shell body including a plurality of side walls defining a first cavity, wherein the plurality of side walls are formed without reinforcement portions; and after performing one of extruding the shell body and deep drawing the shell body, forming a plurality of reinforcement portions on the shell body.

[0006] In other features, forming the plurality of reinforcement portions includes: using a die to surround the plurality of side walls of the shell body; and inserting an outer punch of an expandable physical punch into a first cavity of the shell body. The outer punch includes a plurality of punches and a plurality of side walls, the plurality of side walls defining a second cavity and a plurality of side wall cavities, the plurality of side wall cavities being configured to receive the plurality of punches. The method includes: inserting an inner punch into the second cavity to bias the plurality of punches from a withdrawn position to a punching position, thereby punching a plurality of reinforcement portions in at least one of the plurality of side walls of the shell body.

[0007] In other features, the plurality of reinforcement portions include at least one of dimples and reinforcement beads, and the housing body is made of one of stainless steel, aluminum, and alloys thereof.

[0008] In other features, the plurality of reinforcement portions extend outwardly from an outer side surface of the housing body. The plurality of punches include a body and a protrusion extending laterally from the body. The method includes: using a spring to bias the protrusion of the plurality of punches toward a withdrawn position of the plurality of punches. The plurality of sidewall cavities include a first inclined surface, and the plurality of punches include a body having a second inclined surface.

[0009] In other features, the plurality of punches are inclined at an acute angle relative to the direction in which the inner punch moves. The plurality of punches move in a direction transverse to the direction in which the inner punch moves. The edges of the inner ends of the plurality of punches are inclined at an acute angle relative to the direction in which the inner punch moves.

[0010] In other features, a first pattern of reinforcement portions on one of the plurality of side walls of the shell body is complementary to a second pattern of reinforcement portions on another of the plurality of side walls of the shell body to allow adjacent reinforcement portions of the shell bodies to nest.

[0011] In other features, forming the plurality of reinforcement portions includes: using a die to surround the plurality of side walls of the shell body; and inserting an outer punch of an expandable physical punch into a first cavity of the shell body. The outer punch includes a plurality of punches and a plurality of side walls, the plurality of side walls defining a second cavity and a plurality of side wall cavities, the plurality of side wall cavities being configured to receive the plurality of punches. The method includes: sealing the second cavity; supplying a liquid to the second cavity; and using the liquid to bias the plurality of punches into the plurality of side walls of the shell body to punch out a plurality of reinforcement portions in the plurality of side walls of the shell body.

[0012] In other features, the method includes sealing the plurality of punches relative to the sidewall cavities. Sealing the plurality of punches relative to the plurality of sidewall cavities includes disposing an "O" ring between the plurality of punches and the plurality of sidewall cavities.

[0013] In other features, forming the multiple reinforcement portions includes: using a mold to surround the multiple side walls of the shell body, the mold including multiple second cavities; and using a liquid in a first cavity of the shell body to drive the side walls into the multiple second cavities to produce multiple reinforcement portions on the side walls of the shell body.

[0014] A battery case includes a case body formed by one of extrusion and deep drawing and including a plurality of side walls defining a first cavity. A plurality of reinforcement portions are formed in at least one of the plurality of side walls of the case body.

[0015] In other features, the plurality of reinforcement portions include at least one of a dimple and a reinforcement bead. The housing body is made of one of stainless steel, aluminum, and alloys thereof. The plurality of reinforcement portions extend outwardly from an outer side surface of the housing body. A first pattern of reinforcement portions on one of the plurality of side walls of the housing body is complementary to a second pattern of reinforcement portions on another of the plurality of side walls of the housing body to allow adjacent reinforcement portions of the housing body to be nested.

[0016] The present disclosure also relates to the following technical solutions:

[0017] 1. A method for manufacturing a housing, the method comprising:

[0018] performing one of extruding a housing body and deep drawing the housing body, wherein the housing body includes a plurality of side walls defining a first cavity, and wherein the plurality of side walls are formed without a reinforcement portion; and

[0019] After one of extruding the housing body and deep drawing the housing body is performed, a plurality of reinforcement portions are formed on the housing body.

[0020] 2. The method according to technical solution 1, wherein forming the plurality of reinforcement portions comprises:

[0021] Using a mold to surround a plurality of side walls of the housing body;

[0022] inserting an outer punch of an expandable physical punch into the first cavity of the housing body,

[0023] wherein the outer punch comprises a plurality of punches and a plurality of side walls, the plurality of side walls defining a second cavity and a plurality of side wall cavities, the plurality of side wall cavities being configured to receive the plurality of punches; and

[0024] An inner punch is inserted into the second cavity to bias the plurality of punches from a withdrawn position to a punching position, thereby punching a plurality of reinforcement portions in at least one of the plurality of side walls of the housing body.

[0025] 3. The method according to technical solution 1, wherein:

[0026] The plurality of reinforcement portions include at least one of a recess and a reinforcement bead, and

[0027] The housing body is made of one of stainless steel, aluminum and alloys thereof.

[0028] 4. The method according to technical solution 1, wherein the plurality of reinforcement portions extend outward from an outer side surface of the housing body.

[0029] 5. The method according to technical solution 2, wherein the plurality of punches include a body and a protrusion extending laterally from the body.

[0030] 6. The method according to technical solution 5 further comprises: using a spring to bias the protrusions of the plurality of punches toward a withdrawn position of the plurality of punches.

[0031] 7. The method according to technical solution 2, wherein the plurality of side wall cavities include a first inclined surface, and the plurality of punches include a body having a second inclined surface.

[0032] 8. The method according to Technical Solution 2, wherein the multiple punches are inclined at an acute angle relative to the direction in which the inner punch moves.

[0033] 9. The method according to technical solution 2, wherein the plurality of punches move in a direction transverse to the direction in which the inner punch moves.

[0034] 10. The method according to technical solution 2, wherein the edges of the inner ends of the plurality of punches are inclined at an acute angle relative to the direction in which the inner punch moves.

[0035] 11. A method according to technical solution 1, wherein a first pattern of a reinforcing portion on one of the multiple side walls of the shell body is complementary to a second pattern of a reinforcing portion on another of the multiple side walls of the shell body to allow adjacent reinforcing portions of the shell body to be nested.

[0036] 12. The method according to technical solution 1, wherein forming the plurality of reinforcement portions comprises:

[0037] Using a mold to surround a plurality of side walls of the housing body;

[0038] inserting an outer punch of an expandable physical punch into the first cavity of the housing body,

[0039] wherein the outer punch comprises a plurality of punches and a plurality of side walls, the plurality of side walls defining a second cavity and a plurality of side wall cavities, the plurality of side wall cavities being configured to receive the plurality of punches;

[0040] sealing the second cavity;

[0041] supplying liquid to the second chamber; and

[0042] The plurality of punches are biased into the plurality of side walls of the housing body using the liquid to punch out a plurality of reinforcement portions in the plurality of side walls of the housing body.

[0043] 13. The method according to technical solution 12 further comprises: sealing the plurality of punches relative to the side wall cavity.

[0044] 14. The method according to technical solution 13, wherein sealing the plurality of punches relative to the plurality of side wall cavities comprises: arranging an “O” ring between the plurality of punches and the plurality of side wall cavities.

[0045] 15. The method according to technical solution 2, wherein forming the plurality of reinforcement portions comprises:

[0046] surrounding the plurality of side walls of the housing body using a mold, the mold comprising a plurality of second cavities; and

[0047] A liquid is used in the first cavity of the housing body to drive the sidewall into the plurality of second cavities to create a plurality of reinforcements on the sidewall of the housing body.

[0048] 16. A housing for a battery cell, the housing comprising:

[0049] a housing body formed by one of extrusion and deep drawing and including a plurality of side walls defining a first cavity; and

[0050] A plurality of reinforcement portions are formed in at least one of the plurality of side walls of the housing body after one of extruding and deep drawing.

[0051] 17. The housing according to technical solution 16, wherein the plurality of reinforcement portions include at least one of pits and reinforcement strips.

[0052] 18. The housing according to technical solution 16, wherein the housing body is made of one of stainless steel, aluminum and alloys thereof.

[0053] 19. The housing according to Technical Solution 16, wherein the plurality of reinforcement portions extend outward from an outer side surface of the housing body.

[0054] 20. A housing according to Technical Solution 16, wherein a first pattern of a reinforcing portion on one of the multiple side walls of the housing body is complementary to a second pattern of a reinforcing portion on another of the multiple side walls of the housing body to allow adjacent reinforcing portions of the housing body to be nested.

[0055] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and accompanying drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] The present disclosure will become more fully understood from the detailed description and accompanying drawings, in which:

[0057] Figure 1 is a side cross-sectional view of an example of a battery cell according to the present disclosure, the battery cell including a cathode electrode, an anode electrode, and a separator arranged in a battery cell housing;

[0058] Figure 2A is a perspective view of an example of a battery cell housing;

[0059] Figure 2B is a perspective view of an example of a battery cell housing having a pressure-based vent cap;

[0060] FIG. 3A to FIG. 3C is a perspective view of examples of housings for battery cells according to the present disclosure, the housings having post-formed reinforcement portions;

[0061] FIG. 4A to FIG. 4C are perspective and side views illustrating examples of nesting of battery cells having post-formed reinforcement beads according to the present disclosure;

[0062] FIG. 5A to FIG. 5C are perspective and side views illustrating examples of nesting of battery cells having post-formed reinforcement pockets according to the present disclosure;

[0063] FIG. 6A to FIG. 6C is a perspective view of examples of housings for battery cells according to the present disclosure, the housings having post-formed reinforcement portions;

[0064] FIG. 7A to FIG. 7B is a functional block diagram illustrating a tool for punching a reinforcement portion in a housing using a physical or hydraulic punch or hydroforming according to the present disclosure;

[0065] FIG. 8A to FIG. 8D is a side cross-sectional view of an example of an expandable physical punch according to the present disclosure;

[0066] Figures 9A to 9B is a side cross-sectional view of an example of a hydroform according to the present disclosure;

[0067] FIG. 10A to FIG. 10B is a side cross-sectional view of an example of an expandable hydraulic punch according to the present disclosure; and

[0068] FIG. 11A to FIG. 11C is a side cross-sectional view of an example of an expandable physical punch according to the present disclosure.

[0069] In the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0070] Although housings according to the present disclosure are shown in the context of battery cells for electric vehicles, the housings may be used in stationary applications and / or other applications.

[0071] The battery cells are arranged in housings such as prismatic and cylindrical housings, which are made of metals such as stainless steel, aluminum or other metals. During the cycling of the battery cells, the side walls of the battery cells may bulge due to internal pressure. Conventional prismatic housings are made of aluminum using extrusion or deep drawing methods. However, housings made using this method are not hard enough to prevent bulging due to internal pressure.

[0072] Simple vertical reinforcing bead extending to the open edge of the shell (to allow removal from the mold) has been used to strengthen the flat surface of a metal shell made using extrusion or deep drawing methods. However, more complex reinforcing bead and / or dimples are not possible when using extrusion or deep drawing methods.

[0073] The present disclosure relates to a method for post-forming reinforcements (e.g., beading, dimples, manufacturer logos, and / or other shapes) after the shell body is made (e.g., using an extrusion or deep drawing process). The method uses an expandable physical or hydraulic punch or hydraulic forming to stamp outward-facing reinforcements (e.g., shallow beading, dimples, and / or other shapes) on the sidewalls of the prefabricated shell. In some examples, the shell body (without the reinforcements) is made using a conventional 2-piece or 3-piece process (such as, an extrusion process, a deep drawing process, or other processes).

[0074] After manufacturing the shell, the shell is arranged in a mold that includes cavities corresponding to the locations of the reinforcement bead and / or dimples on the shell body. In some examples, an expandable physical or hydraulic punch is inserted into the shell body, with one or more punches in a withdrawn position. The one or more punches are physically or hydraulically extended into one or more side walls of the shell body to stamp out reinforcement portions on the one or more side walls. In other examples, hydraulic forming is used.

[0075] The reinforcement portion can have a variety of shapes, including reinforcement beading, pits or other geometric shapes (such as, manufacturer logo). The reinforcement portion can be arranged on the wide and / or narrow sidewalls of the shell in any position or in any direction. After formation, the reinforcement portion geometrically strengthens the sidewalls (and / or around the edges) of the shell body. For a given sidewall thickness, the reinforcement portion strengthens the shell body. Alternatively, the reinforcement portion enables a thinner metal material to be used for the sidewalls of the shell body, thereby reducing weight without sacrificing strength and / or rigidity. The reinforcement portion can also be used to define gas flow channels, which are used to guide hot exhaust flow to the vent during a thermal event.

[0076] In some examples, the depth of the reinforcement portion is in the range of 0.2 to 1.0 times the thickness of the shell wall. In some examples, the width of the bead is in the range of from 2 mm to 6 mm. In some examples, the reinforcement portion includes a reinforcement bead extending horizontally, vertically and / or diagonally. In some examples, the first pattern of the reinforcement portion on one side of the shell body is complementary to the second pattern of the reinforcement portion on the other side of the shell body to allow adjacent shells to be nested, thereby saving packaging space.

[0077] Reference now Figure 1The battery cell 10 includes C cathode electrodes 20, A anode electrodes 40, and S separators 32, which are arranged in a predetermined sequence in a stack 12 in a housing 50, wherein A, C, and S are integers greater than one. The C cathode electrodes 20-1, 20-2, ..., and 20-C include a cathode active layer 24 arranged on one or both sides of a cathode current collector 26. The A anode electrodes 40-1, 40-2, ..., and 40-A include an anode active layer 42 arranged on one or both sides of an anode current collector 46.

[0078] In some examples, anode active layer 42 and / or cathode active layer 24 are freestanding electrodes that are disposed adjacent to (or attached to) a current collector. In some examples, anode active layer 42 and / or cathode active layer 24 include coatings that include one or more active materials, one or more conductive fillers / additives, and / or one or more binder materials. In some examples, cathode current collector 26 and / or anode current collector 46 include foil, mesh, and / or expanded metal layers.

[0079] In some examples, the current collector is made of one or more materials selected from the group consisting of: copper, stainless steel, brass, bronze, zinc, aluminum, and / or alloys thereof. In some examples, external tabs 28 and 48 of the current collectors connected to the cathode electrode and the anode electrode are located on opposite sides of the battery stack (e.g., Figure 1 ), on different sides, or on the same side of the battery stack.

[0080] Reference now Figure 2A and Figure 2B , the battery cell 58 includes a housing 60. In some examples, the housing 60 has a prismatic shape having a rectangular cross-section in the x, y, and z axis planes. In some examples, the housing 60 includes a housing body 61 that includes side portions 80 and 82 that define an open rectangular prism. In some examples, the width of the side portion 80 is narrower than the side portion 82. In some examples, the housing 60 includes a bottom portion 86. In other examples, the bottom portion 86 is attached after the housing 60 is formed. In some examples, the housing body is made using an extrusion method, a deep drawing method, or other methods.

[0081] The cover portion 84 and optionally the bottom portion 86 are attached to the housing body 61 to respectively enclose the top opening and the bottom opening of the housing body 61. The battery cell 58 includes external terminals 62 and 64 passing through the cover portion 84. The stack 12 consisting of C cathode electrodes 20, A anode electrodes 40 and S separators 32 is arranged in the housing 60.

[0082] External terminals 62 and 64 are connected to external tabs 28 and 48 of C cathode electrodes 20 and A anode electrodes 40, respectively. Figure 2AIn the embodiment, the cover portion 84 does not include a pressure-based vent cap. Figure 2B , the cover portion 84 (and / or the bottom portion 86) includes a pressure-based vent cap 66. The pressure-based vent cap 66 is configured to release exhaust gas when the pressure within the inner housing is greater than a predetermined pressure.

[0083] Reference now FIG. 3A to FIG. 3C , the battery cell 94 includes a housing 96 having one or more side surfaces 128, wherein the one or more side surfaces include a plurality of reinforcing portions 122. Although the reinforcing portions 122 include dimples, the reinforcing portions 122 can have different shapes, such as beading or other shapes. In some examples, the dimples have a rectangular, hemispherical, and / or arcuate shape. As can be appreciated, the reinforcing portions 122 can be arranged on other side surfaces 129, the cover, and / or the bottom.

[0084] In some examples, the reinforcing portion 122 is arranged on the side surface 128 of the battery cell 94 in a predetermined pattern 120. In some examples, the reinforcing portion 122 is arranged on the surface of the housing 96 with the largest area. In some examples, two or more side surfaces of the battery cell 94 have the same pattern of reinforcing portions 122. In other examples, opposite side surfaces of the battery cell 94 have different patterns of reinforcing portions 122.

[0085] exist Figure 3A In some examples, the reinforcement portion 122 includes a dimple extending outwardly from a side surface 128 of the housing 96. In some examples, when two or more of the battery cells 94 are arranged adjacent to each other, the reinforcement portions 122 of the facing side surfaces of the adjacent battery cells are offset to allow nesting. In some examples, an insulation layer or thermal interface material and a cooling plate are arranged between adjacent battery cells.

[0086] exist Figure 3B and Figure 3C In the embodiment of the present invention, the reinforcing portion 122 includes a reinforcing bead or rib having a rectangular cross-section. The reinforcing portion 122 extends vertically, horizontally and / or diagonally along one or more of the side surfaces. The reinforcing portion 122 is arranged on one side of the battery cell 94 in a first predetermined pattern and on the opposite side surface of the battery cell 94 in a second predetermined pattern.

[0087] In some examples, the first predetermined pattern and the second predetermined pattern are the same. In other examples, the reinforcement portions of the first predetermined pattern and the second predetermined pattern are different. For example, the reinforcement portions on one side are complementary to allow nesting or overlapping to minimize space (e.g., offset relative to the reinforcement portions on the opposite side). In other words, adjacent battery cells in the battery cell can be arranged in close proximity (e.g., where the reinforcement portions are in a nested or staggered pattern when aligned or positioned adjacent to each other).

[0088] In some examples, the backside volume created by the reinforced portion is used to direct exhaust gas within the housing to the vent. In other examples, the backside volume is filled with a material to provide a smooth surface. In other examples, the material includes an insulating material or a thermal interface material. In other examples, the material includes a first inhibitor material, such as sodium bicarbonate.

[0089] Reference now FIG. 4A to FIG. 4C , shows an example of a battery cell 400 having reinforcing bead 416 and 418. Figure 4A and Figure 4B In the embodiment, the reinforcing strips 416 and 418 on the opposite sides 410 and 412 are arranged to be offset from each other to allow Figure 4C The reinforcement beads of adjacent battery cells 400 - 1 , 400 - 2 , . . . , and 400 -C shown in FIG. 4 are nested, thereby reducing space.

[0090] Reference now FIG. 5A to FIG. 5C , shows an example of a battery cell 450 having reinforced dimples 466 and 468. Figure 5A and Figure 5B , the reinforcement dimples 466 and 468 on the opposite sides 460 and 462 are arranged offset from each other to allow Figure 5C The reinforcement recesses of adjacent battery cells 450 - 1 , 450 - 2 , . . . , and 450 -C shown in FIG. 4 are nested, thereby reducing space.

[0091] Reference now Fig. 6A , the battery cell 500 includes a housing 504 having one or more sides 510, the one or more sides including a first or peripheral region 516 and a second or central region 530 (e.g., disposed inside the peripheral region 516). The central region 530 of the side 510 of the battery housing is typically the hottest location when a thermal runaway event occurs. In some examples, reinforcement portions are omitted in areas of the housing that tend to be hotter (such as the central region 530 of the side 510). Reinforcement portions 518 and 520 are disposed in the peripheral region 516 (while the central region 530 does not include reinforcement portions).

[0092] Fig. 6A The battery housing in the embodiment helps limit the heat transfer or propagation between adjacent battery cells. There are no beading or dimples in the central region 530 where one or two of the adjacent battery cells are hottest. In some examples, insulation or thermal interface materials and cooling plates (shown below) are arranged between the central regions 530 of adjacent battery cells.

[0093] exist Figure 6BIn FIG. 5 , a battery cell 540 includes a housing 504 having one or more sides 510 that include a pattern 546 of reinforcing beadings 548 extending in parallel in a horizontal direction. Figure 6C In the embodiment, the battery cell 560 includes a housing 504 having one or more sides 510 that include a pattern 566 of reinforcing beadings 568 extending in parallel in both horizontal and vertical directions. For example, a rectangular pattern with interconnected horizontal and vertical beadings may be used.

[0094] Reference now Fig. 7A , the tool 700 includes one or more dies 710 and an expandable punch 720. In some examples, the one or more dies 710 include split dies 710-1 and 710-2, which are arranged above a lower die surface 710-3 around the shell. A positioning device 712 can be used to arrange a shell body 724 on the lower die surface 710-3 and open and close the dies 710-1 and 710-2 around the side surface of the shell body 724.

[0095] When the housing body 724 is arranged in the tool 700, the expandable punch 720 is inserted into the inner cavity of the housing body 724. The expandable punch 720 includes one or more punches 728, which are physically or hydraulically driven outward or laterally into the inner surface of the housing body 724 by the actuator 730. In some examples, the actuator 730 includes a physical punch that moves in a first direction and contacts and physically biases the one or more punches 728 in a second direction. In some examples, the second direction is transverse to the first direction or at an acute angle relative to the first direction.

[0096] In other examples, the actuator 730 is a hydraulic actuator that supplies or pressurizes high pressure fluid in the expandable punch 720. The high pressure of the hydraulic fluid biases the punch 728 outwardly into the inner surface of the housing body 724. The controller 732 is configured to control the positioning device 712 and / or the actuator 730.

[0097] Reference now Figure 7B , tool 748 is similar to Fig. 7A. The tool 748 includes an actuator 750 and a seal / punch 754. After the housing body 724 is located in the tool 748, the positioning device 712 arranges the seal / punch 754 above the open end of the housing body 724 to provide a liquid seal. Liquid is supplied to the cavity of the housing body 724. The pressure of the liquid is increased by applying pressure to the seal / punch 754. The high-pressure liquid forces the side wall of the housing body 724 outward into the cavity (shown below) defined on the inwardly facing surface of the mold 710 to form a reinforcement portion.

[0098] Reference now FIG. 8A to FIG. 8D , shows an example of an expandable physical punch. Fig. 8A and Figure 8B , the expandable physical punch 800 includes an inner punch 810 and an outer punch 828. The expandable physical punch 800 is inserted into the shell body 724. The shell body 724 is surrounded by a mold (as shown above). The outer punch 828 includes a side wall 829 that defines an inner cavity 830. The outer surface of the side wall 829 is arranged to be adjacent to the inner surface of the side wall of the shell body 724. During the formation of the reinforcement feature, the inner punch 810 is inserted into the inner cavity 830 to bias the punch 834 arranged in the side wall 829 of the outer punch 828 outwardly into the side wall of the shell body 724. The punch 834 is moved from a withdrawn position ( Fig. 8A ) moves to the punching position ( Figure 8B ) to stamp one or more side walls of the housing body 724.

[0099] The sidewall 829 and the removable wall portion 841 define a cavity 842 for receiving the punch 834. In some examples, the removable wall portion 841 can be removed to allow replacement of the punch 834. The punch 834 includes a body 833 having an inner end 835 and an outer end 836. When in the withdrawn position, the inner end 835 extends into the inner cavity 830. During punching, the outer end 836 is biased into the inner surface of the sidewall of the housing body 724. In some examples, the punch 834 includes a body 833 and a protrusion 837 (e.g., an annular protrusion extending transversely relative to the longitudinal length of the body). In some examples, a spring 844 is arranged between the removable wall portion 841 and the protrusion 837 of the punch 834 to bias the punch 834 into the withdrawn position. In some examples, the outer end 836 of the inner punch 810 and the edge 840 of the punch 834 are inclined at an acute angle relative to the direction of reciprocation of the inner punch.

[0100] exist Figure 8C and Fig.8D, another example of an expandable physical punch 900 is shown. The side wall 910 of the outer punch 912 defines an inner cavity 916 for receiving the inner punch 810. The side wall 910 further defines a cavity 920 having an inclined surface 921. The cavity 920 receives punches 924, which include a body 926 having an inclined surface 928. Gravity causes the inclined surface 928 of the punch 924 to move along the inclined surface 921 of the cavity to bias the punch 924 toward the withdrawn position. The inner punch 810 biases the inner end 930 of the punch outward to cause the outer end 932 to stamp a reinforcement portion on the shell body 724, as shown. Fig.8D as shown in .

[0101] Reference now Fig. 9A and Fig. 9B , a hydraulic forming tool 934 may be used to form a reinforcement portion on the shell body 724. Fig. 9A , a hydroforming tool 934 includes dies 935 that include cavities 936 in locations corresponding to the reinforcement portions. The housing body 724 is inserted into the cavity defined between the dies 935. The liquid at least partially fills the cavity of the housing body 724. A seal / punch 939 is inserted into the cavity of the housing body 724 to compress the liquid, thereby increasing the pressure in the cavity. When the liquid pressure increases sufficiently, the liquid forces the sidewalls into the cavity 936 to create the reinforcement portion ( Fig. 9B ).

[0102] exist Fig. 10A and Fig. 10B , an example of an expandable hydraulic punch 950 is shown. The side wall 960 of the outer punch 962 defines an inner cavity 966. The side wall 960 further defines a cavity 968 for reciprocatingly receiving a punch 972. The punch 972 includes an inner end 976 and an outer end 978. The actuator 987 applies pressure to the seal / punch 986, which applies pressure to the liquid in the housing body 724 to increase the pressure and cause the punch 972 to move laterally into the housing body 724, thereby stamping out a reinforcement feature in the housing body 724. The liquid transmits the pressure to the punch 972 without direct contact, thereby reducing wear. After the liquid pressure is released, the punch 972 returns to the withdrawn position.

[0103] In some examples, a pressure in the range of from 50 to 300 MPa is used. In some examples, the reinforcement portion has a width in the range of from 2 to 6 mm and a depth in the range of from 0.2 mm to 0.5 mm. In some examples, the reinforcement portion extends around the corners of the housing.

[0104] The liquid applies sufficient pressure to bias the inner end 976 of the punch 972 outward. The outer end 978 is biased into the inner surface of the side wall of the housing body 724 to form a reinforced portion. In some examples, a seal 983 (e.g., an O-ring) provides a seal between the punch 972 and the cavity 968.

[0105] Reference now FIG. 11A to FIG. 11C , another example of an expandable physical punch 1050 is shown. Fig.11A 1060, the sidewall 1060 of the outer punch 1062 defines a cavity 1067. The cavity 1067 includes one or more inclined surfaces 1068, 1069, etc., which are inclined at an acute angle relative to the direction (e.g., vertical) of the reciprocating movement of the inner punch (not shown). The cavity 1067 receives the punches 1072, which include a protrusion 1078 with an inclined surface 1080. The punches 1072 may also include an inclined surface 1076 at the inner end 1077. The split die 1090 includes cavities 1092, which are aligned with the punches 1072 when the punches 1072 are in the punching position.

[0106] exist Fig.11A In the embodiment, the punch 1072 is biased by gravity along the inclined surface to a retracted position, wherein the inner end 1077 extends into the inner cavity 1094 of the outer punch 1062. The outer end 1079 of the punch is spaced apart from the side wall of the housing body 724. Fig. 11B In the embodiment of the present invention, the inner punch 1098 moves into the inner cavity 1094 and biases the inner end 1077 of the punch 1072 in an outward and upward direction into the inner surface of the side wall of the shell body 724 to create a reinforcement portion in the shell body 724 at 1100. Fig. 11C In the embodiment of the present invention, the inner punch 1098 is removed and the punch 1072 moves to the withdrawn position due to gravity.

[0107] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in various forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because when studying the drawings, the specification and the following claims, other modifications will become apparent. It should be understood that one or more steps in the method can be performed in different orders (or simultaneously) without changing the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented and / or combined with it in the features of any one of the other embodiments, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the arrangement of one or more embodiments to each other is still within the scope of the present disclosure.

[0108] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "immediately adjacent," "on top of," "above," "below," and "disposed." Unless explicitly described as "directly," when describing a relationship between a first element and a second element in the above disclosure, the relationship may be a direct relationship in which no other intervening elements exist between the first element and the second element, but may also be an indirect relationship in which one or more intervening elements exist (either spatially or functionally) between the first element and the second element. As used herein, the phrase at least one of A, B, and C should be interpreted to mean a logical (A OR B OR C) using a non-exclusive logical OR, and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

[0109] In the drawings, the direction of the arrows, as indicated by the arrows, generally demonstrates the flow of information (such as data or instructions) that the illustration is concerned with. For example, when element A and element B exchange various information but the information transmitted from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. Further, for information sent from element A to element B, element B may send a request for the information or a receipt acknowledgment to element A.

Claims

1. A method for manufacturing a housing, the method comprising: performing one of extruding a housing body and deep drawing the housing body, wherein the housing body includes a plurality of side walls defining a first cavity, and wherein the plurality of side walls are formed without a reinforcement portion; and After one of extruding the housing body and deep drawing the housing body is performed, a plurality of reinforcement portions are formed on the housing body.

2. The method according to claim 1, wherein: Forming the plurality of reinforcement portions comprises: Using a mold to surround a plurality of side walls of the housing body; inserting an outer punch of an expandable physical punch into the first cavity of the housing body, wherein the outer punch comprises a plurality of punches and a plurality of side walls, the plurality of side walls defining a second cavity and a plurality of side wall cavities, the plurality of side wall cavities being configured to receive the plurality of punches; and An inner punch is inserted into the second cavity to bias the plurality of punches from a withdrawn position to a punching position, thereby punching a plurality of reinforcement portions in at least one of the plurality of side walls of the housing body.

3. The method according to claim 1, wherein: The plurality of reinforcement portions include at least one of a recess and a reinforcement bead, and The housing body is made of one of stainless steel, aluminum and alloys thereof.

4. The method according to claim 1, wherein: The plurality of reinforcement portions extend outwardly from an outer side surface of the housing body.

5. The method according to claim 2, wherein: The plurality of punches include a body and a protrusion extending laterally from the body.

6. The method according to claim 5, further comprising: A spring is used to bias the protrusions of the plurality of punches toward a withdrawn position of the plurality of punches.

7. The method according to claim 2, wherein: The plurality of sidewall cavities include a first inclined surface, and the plurality of punches include a body having a second inclined surface.

8. The method according to claim 2, wherein: The plurality of punches are inclined at an acute angle relative to a direction in which the inner punch moves.

9. The method according to claim 2, wherein: The plurality of punches move in a direction transverse to a direction in which the inner punch moves.

10. The method according to claim 2, wherein: The edges of the inner ends of the plurality of punches are inclined at an acute angle relative to the direction in which the inner punch moves.

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