Light battery housing for automotive vehicle and method for manufacturing a light

Abstract

The invention relates to a lightweight battery housing for a motor vehicle and to a method for producing a lightweight battery housing. The lightweight battery case includes: a battery holder formed of a sheet molding compound and having a base portion for placing at least one battery module; the battery holder includes at least one rib extending upwardly from the base to define at least one groove extending along an exterior surface of the battery holder; and an outer frame including at least one beam extending through the at least one groove in a mating relationship.

Description

[0001] This application is a divisional application of an application with an international application date of September 4, 2020, a Chinese national application number of 202080076209.X (international application number PCT / US2020 / 049353), and an invention name of “Lightweight Battery Housing Assembly”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This PCT international patent application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 62 / 896,852, filed on September 6, 2019, and entitled “Lightweight Battery Housing Assembly,” the entire disclosure of which is incorporated herein by reference. Background of the Invention 1. Technical Field

[0004] The present invention relates to a battery housing and a method for assembling the same. More particularly, the present invention relates to a lightweight battery housing for an automobile and a method for assembling the same. 2. Background Technology

[0005] This section provides background information related to the present disclosure which is not necessarily prior art.

[0006] Automobiles are the subject of a continuous effort to reduce weight and improve fuel efficiency without compromising performance. This desire for improved fuel efficiency is driven by both economic and environmental factors, and has driven advancements in automotive components, particularly in electric vehicles, as evidenced by battery development. Unlike conventional vehicles that operate entirely on fossil fuels, electric vehicles incorporate a range of technologies that rely on electrical energy. Some electric vehicles still primarily rely on fossil fuels, using electricity as a supporting energy source to improve fuel efficiency, while others rely primarily or entirely on electricity for vehicle operation. While electrical energy is more economical and environmentally friendly than relying solely on fossil fuels, batteries are heavy, expensive, and relatively fragile compared to adjacent mechanical components. Therefore, battery packaging, particularly within electric vehicles, requires numerous design considerations, including weight distribution, temperature regulation, and maintainability. Regarding maintainability, particularly in electric vehicles, there is a growing demand for batteries that can be stored for charging and maintenance without disassembly.

[0007] To meet the above minimum requirements, batteries have traditionally been packaged in protective casings. These traditional casings have adopted metal-intensive (aluminum and / or steel) designs to meet strength and fire resistance requirements, but at the expense of increased weight, leakage performance and susceptibility to corrosion damage. In addition to the disadvantages during operation, these traditional casings also require a lot of energy, time and money to construct. For example, many traditional casings use aluminum extrusions welded to aluminum sheets, and dimensional tolerances are difficult to meet, and further machining steps are usually required. Once constructed, traditional casings are difficult to integrate into the body-in-white.

[0008] Therefore, there is a continuing desire to further develop and improve housing construction and operation such that the housing does not suffer from conventional drawbacks. Summary of the Invention

[0009] The foregoing has outlined the features and technical advantages of the present invention in a rather broad manner so that the detailed description of the present invention below may be better understood. Additional features and advantages of the present invention that form the subject matter of the claims of the present invention will be described below. It will be understood by those skilled in the art that the disclosed concepts and specific embodiments can be easily used as the basis for modifying or designing other embodiments for achieving the same purpose of the present invention. It will also be appreciated by those skilled in the art that such equivalent embodiments do not depart from the spirit and scope of the present invention as set forth in the appended claims. This section provides an overall overview of the present disclosure and should not be construed as a complete and comprehensive enumeration of all objects, aspects, features and advantages associated with the present disclosure.

[0010] According to one aspect of the present disclosure, a lightweight battery housing for an automobile is provided. The lightweight battery housing includes a battery holder including a battery holder rim extending around a peripheral battery holder edge. The battery holder includes an inner surface for placing at least one battery module and an outer surface defining at least one groove. The lightweight battery housing also includes a frame having an outer frame and at least one beam extending across the outer frame. The battery holder is located within the outer frame, and the battery holder rim sits on and is connected to the top surface of the outer frame, wherein the at least one beam sits within the at least one groove. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The drawings described herein are for illustrative purposes only of selected embodiments and are not intended to limit the scope of the present disclosure. The inventive concepts associated with the present disclosure will be more readily understood by referring to the following description in conjunction with the accompanying drawings, in which:

[0012] Figure 1 is a perspective view of a battery housing assembly for an automobile according to a first embodiment;

[0013] Figure 2 is a perspective view of a battery housing assembly in a disassembled state;

[0014] Figure 3 is an enlarged view of the battery housing assembly including the molded battery attachment;

[0015] Figure 4 is a perspective view of a battery housing assembly including a single sealing surface;

[0016] Figure 5 is a cross-sectional view of a battery housing assembly;

[0017] Figure 6 is a perspective view of a battery housing assembly according to a second embodiment;

[0018] Figure 7 is a perspective view of a battery housing assembly according to a second embodiment in a disassembled state;

[0019] Figure 8 is a cross-sectional view of the battery housing connected to the body-in-white;

[0020] Figure 9 is a perspective view of a battery housing assembly according to a third embodiment in a disassembled state;

[0021] Figure 10A According to the first arrangement Figure 9 A cross-sectional view of the battery housing assembly shown in ;

[0022] Figure 10B According to the second arrangement Figure 9 A cross-sectional view of the battery housing assembly shown in ;

[0023] Figure 10C According to the third arrangement Figure 9 A perspective view of the battery housing assembly shown in ;

[0024] Figure 10D yes Figure 10C Disassembled stereogram;

[0025] Figure 11 is a perspective view of a battery housing assembly according to a third embodiment, wherein the basin is connected to the frame;

[0026] Figure 12 is a perspective exploded view of a battery housing assembly including the external thermal management system of the first embodiment;

[0027] Figure 13 is a perspective view of an external thermal management system including conduits connected to a battery housing assembly for distributing a cooling or heating liquid medium;

[0028] Figure 14 is a cross-sectional view of a conduit connected to a battery housing assembly;

[0029] Figure 15 is a top perspective view of a battery housing assembly with an external thermal management system;

[0030] Figure 16 is a bottom perspective view of a battery housing assembly with an external thermal management system;

[0031] Figure 17 is an enlarged top perspective view of the basin illustrating a connection port for connecting a conduit;

[0032] Figure 18 is a perspective exploded view of a battery housing assembly including an external thermal management system according to a second embodiment;

[0033] Figure 19 is a disassembled perspective view of a battery housing assembly including an external thermal management system according to a third embodiment;

[0034] Figure 20 is a cross-sectional view of a third embodiment of an external thermal management system;

[0035] Figure 21 is a cross-sectional view of the compensation assembly located between the frame and the upper cover;

[0036] Figure 22 is a cross-sectional view of a thermal management layer of a battery housing assembly, the thermal management layer including a laminated thermal control layer; and

[0037] Figure 23 is a method flow chart illustrating a method of constructing a battery housing assembly. DETAILED DESCRIPTION

[0038] Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject embodiments relate to a battery housing assembly for an automobile and a method of assembling the battery housing assembly. However, example embodiments are provided only so that the present disclosure will be thorough and the scope will be fully conveyed to those skilled in the art. Many specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be adopted, that the example embodiments can be implemented in many different forms, and that neither the specific details nor the example embodiments should be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0039] Referring to the drawings, wherein like reference numerals indicate corresponding parts throughout the several views, a battery housing assembly for an automobile and a method of assembling the same are intended to provide a lightweight and relatively simple construction design for protection, weight distribution, and ease of serviceability.

[0040] First refer to Figures 1 to 4 , presents a first embodiment of a battery housing assembly 20 for an automobile. In one example, the battery housing assembly 20 can be used in an electric vehicle. The battery housing assembly 20 includes an upper cover 22, a basin 24, and a protective frame 26. A protective plate 27 formed from steel, aluminum, or a sheet molding compound (SMC) such as glass fiber reinforced plastic or carbon fiber reinforced plastic is positioned below and connected to the frame 26. The protective frame 26 provides a rigid and / or semi-rigid base upon which the upper cover 22 and basin 24 can be stacked. The basin 24 is formed to hold at least one, but preferably multiple, battery modules 28, and the cover 22 is seated on top of the basin 24 and connected via a plurality of connectors 30, such as threaded fasteners. The cover 22 and basin 24 thus surround the battery modules 28 and are connected to the protective frame 26, which is configured to optimize the weight distribution of the battery modules 28. The protective frame 26 also includes at least one bracket 32 ​​that can be connected to the vehicle frame. The bracket 32 ​​includes a plurality of stacked metal plates 34 connected via an intermediate plate 36 and a series of fastener tubes 38 extending through and connected to each of the stacked metal plates 34 for connection to the vehicle frame via fasteners.

[0041] Figure 2 The battery housing assembly 20 is shown in a disassembled state. The cover 22 includes a cover rim 40 around the peripheral edge, and the cover rim 40 is aligned generally along a flat plane. A mating cover aperture 42 is provided around the cover rim 40 for connecting to the basin 24 via the aforementioned connector 30. The cover 22 also includes an exterior surface 43 defining a series of channels 45 for directing water and other debris away from the battery housing assembly 20. The cover 22 also includes a hood portion 44 and a flat portion 46, wherein the hood portion 44 extends outwardly from the exterior surface 43 so that when the cover 22 is placed on the basin 24, the hood portion 44 can be fitted over the stacked battery modules 28 and / or over a battery module 28 that is taller than the battery module 28 aligned below the flat portion 46.

[0042] The basin 24 includes an interior surface 48 and an exterior surface 49, both of which define sidewalls 50 extending around a base 52. The interior surface 48 defines a plurality of recesses 54, each for nesting one or more battery modules 28. The recesses 54 are defined by ribs 56 extending outward from the interior surface 48 of the base 52 and the sidewalls 50. On the exterior surface 49, the ribs 56 are hollow to define recesses 58. A series of spacer members 60 are connected to the top surfaces of the ribs 56 for connecting to the battery modules 28 and for absorbing side-to-side movement during vehicle operation. Structural members 62 are positioned adjacent to the sidewalls 50 between the ribs 56 so that the battery modules 28 can be at least partially placed on the structural members 62. The spacer members 60 and the structural members 62 can be formed integrally with the basin 24 or can be attached as separate pieces. Additionally, the spacing members 60 and the structural members 62 can be formed of a stronger material than the rest of the basin 24. The basin 24 also includes a basin rim 64 having a shape corresponding to the cover rim 40 for being covered during assembly. Similarly, the basin rim 64 can also include mating basin apertures 66 for aligning with the mating cover apertures 42. In addition to the ribs 56, the base 52 and the sidewalls 50 include a matrix of structural webbing 68 (see also Figure 3 ).

[0043] The protective frame 26 includes an outer frame 70 that includes a shape corresponding to the cover rim 40 and the basin rim 64. The outer frame 70 includes a top surface having mating frame apertures 72 that align with the mating cover apertures 42 and the mating basin apertures 66 so that the connector 30 extends through each of the mating apertures 42, 66, and 72. The protective frame 26 also includes a plurality of beams 74 that extend across the outer frame 70. When the basin 24 is placed on the protective frame 26, the beams 74 fit within the grooves 58 so that the pockets 54 are located between and suspended from the beams 74. The spacer members 60 and the structural members 62 can be connected through the basin 24 and directly connected to the protective frame 26. The beams 74 and the grooves 58 can also both have a stepped shape with wide base sections 76A, 76B and narrow top sections 78A, 78B (see also Figure 4 ). Thus, the spacing member 60 may also clamp the top sections 78A, 78B together.

[0044] Figure 3An enlarged view of the basin 24 and more specifically of the structural webbing 68 on the interior surface 48 is shown. A central webbing 80 is positioned between each of the ribs 56 for supporting the structural member 62. The central webbing 80 may also include openings 82, each defined by a raised border for receiving a fastener / pin (not shown) from the structural member 62. The basin rim 64 includes a seal extension channel 84 extending between the sidewall 50 and the mating basin aperture 66 for placement of a seal 86 ( Figure 4 ), the seal 86 is pressed against the cover 22 during tightening of the connector 30. Thus, the seal 86 prevents liquid and other debris from entering the assembled battery housing assembly 20. Figure 4 Basin 24 is illustrated having a seal 86 extending along basin rim 64 . Figure 4 The seal 86 in the lid rim 40 may be located in the channel 84 or the channel 84 may not be present. The seal 86 is shown covering the entire basin rim 64 and having a series of sealing apertures 88 that align with the other mating apertures 42, 66, 72. The basin rim 64 and seal 86 may include a wider portion 90 to increase overlap with the lid rim 40, which may also include a convex portion. The sealing apertures may be located in the convex portion 90.

[0045] Figure 5 8 is a partial cross-sectional view of the battery housing assembly 20 illustrating the connection between the cover 22, the basin 24, and the protective frame 26. The seal 86 is shown as being primarily or completely located within the channel 84. A tolerance compensation assembly 89 connects the cover 22, the basin 24, and the protective frame 26. The tolerance compensation assembly 89 includes a gasket 91 and may also include a grommet 92 that seats in the mating aperture 66 of the basin 24 and passes through one of the corresponding mating apertures 42 of the cover 22 and abuts the gasket 91. The connector 30 extends through the grommet 92 and threadably engages a first bushing 94, which is connected to a second bushing 96. The second bushing 96 is connected to the mating aperture 72 in the protective frame 26. The basin 24 is shown as including chamfered material 98, which increases the structural thickness and strength near the basin edge 64. The tolerance compensation assembly 89 maintains dimensional stability without requiring any machining steps on or around the seal.

[0046] Figure 6 and Figure 7A battery housing assembly 120 according to a second embodiment is illustrated. The battery housing assembly 120 includes a cover 122 and a frame 126, which is an integral structure with the body-in-white 121. The battery housing assembly 120 also includes a tray 125, which can be assembled into the body-in-white 121. The integrated cover 122 and frame 126 can eliminate duplicate components and provide a lightweight alternative to traditional battery housings. The lower tray 125 provides a base on which the battery modules 28 sit. The tray 125 can then be slid into the space defined by the cover 122 and frame 126. A seal 127 is positioned along the edge of the tray 125 and the edge of the cover 122, and the edge of the tray 125 and the edge of the cover 122 can be connected in a manner similar to the previous embodiment. Other features, materials, and construction methods of the battery housing assembly 120 can be similar to those of the first embodiment. Figure 7 is a perspective view of the battery housing assembly 120 in a disassembled state. The cover 122 and frame 126 can be initially integrated into the body-in-white 121 from within the passenger cabin. The cover 122 can be a single-piece or multi-piece component, and the battery modules 28 can be mounted on the tray 125 as individual components or as a stack of pre-connected battery modules 28 before the tray 125 is connected and sealed to the frame 126.

[0047] Figure 8 1 is a cross-sectional view of the battery housing 120 connected to the body-in-white 121. As shown, the cover 122 can be integrated with the body-in-white 121 and can also serve as the body-in-white floor 121 for dual functionality. The cover 122 is integrated with the body-in-white rails or rockers 128. The frame 126 is then connected to the rockers 128 via fasteners 129, welding, or other methods. A first seal 130 is positioned between the top surface of the frame 126 and the rockers 128, and a second seal 132 is positioned between the side surfaces of the frame 126 and the rockers 128. The rockers 128 include stepped surfaces 132 that are used to position the frame 126 so that the first seal 130 is positioned between surfaces perpendicular to the surfaces on either side of the second seal 132. Both seals 130 and 132 are compressed during the connection between the frame 126 and the rockers 128. The frame 126 and the rocker 128 can both define a straight line or other closed shape so that the seals 130, 132 surround the entire battery module 28 when the tray 125 is connected or pre-integrated with the bottom surface of the frame 126. As shown, the tray 125 can include a protrusion 134 to hold the battery module 28 away from the bottom plate 710 of the tray 125.

[0048] Figures 9 to 11 A battery housing assembly 120 according to a third embodiment is illustrated. Figure 9is a perspective view of the battery housing assembly 220 in a disassembled state. The battery housing assembly 220 includes a basin 222, a series of beams 224 similar to the beams 74. The beams 224 can be formed from aluminum extrusion or steel roll forming. The basin 222 can be formed from SMC, such as glass fiber reinforced plastic or carbon fiber reinforced plastic. The basin 222 can be formed via a molding process, wherein the beams 224 are molded into the grooves 223 during the molding process. The beams 224 can be formed from aluminum or steel. The beams 224 are spaced apart so that the beams 224 create a load path from the vehicle side impact load to protect the battery module 28 during a vehicle impact event, and the beams 224 will be directly attached to the frame 226 (see Figure 11 ).

[0049] Figure 10A 2 is a cross-sectional view of a beam 224A molded into the basin 222 according to a first arrangement of overmolded beams 224. The beam 224A includes a base section 228A that narrows to a body section 230A and expands again to a top section 232A. The molded basin 222 is molded over at least a portion of the base section 228A, the body section 230A, and the top section 232A.

[0050] Figure 10B 2 is a cross-sectional view of a beam 224B molded into the basin 222 according to a second arrangement of overmolded beams 224. Each beam 224B includes a first beam portion 250 and a second beam portion 252. The first beam portion 250 is molded into the basin 222 so as to protrude from the interior surface 223. More specifically, the first beam portion 250 includes a base section 228B that narrows into a body section 230B and then expands again into a top section 232B. The molded basin 222 includes a stepped rib 254 molded onto at least a portion of the base section 228B, the body section 230B, and the top section 232B. The stepped rib 254 defines a recess 256 on the opposite side for receiving the second beam portion 252. The second beam portion 252 includes a rectangular cross-section and is connected to the base section 228 via connectors, adhesive, welding, and / or other means. In the illustrated example, the adhesive 258 connects the base section 228 to the second beam portion 252.

[0051] Figure 10C is a cross-sectional view of beams 224C molded into basin 222 according to a third arrangement of overmolded beams 224. Beams 224C each include Figure 10BThe second arrangement of the first beam 250 and the second beam 252 is similar in structure. The first beam 250 is molded into the basin 222 to protrude from the interior surface 223 and includes the same base section 228C, body section 230C and top section 232C. However, the connection between the first beam 250 and the basin 222 is modified. More specifically, the basin 222 includes ribs 254 that define the same Figure 10B The basin 222 includes a second, similarly structured groove 256, and further includes a separator section 260 overmolded around the bottom surface of the base section 228C and separating the base section 228C from the second beam section 252. The basin 222 also includes one or more overmolded strips 262 extending from the ribs 252 and wrapping around the first beam section 250. Thus, the overmolded strips 262 are positioned so as to completely enclose the first beam section 250. The second beam section 252 fits within the groove 256 and is separated from the first beam section 250 by the separator section 260. The second beam section 252 can be connected to the separator section 260 via an adhesive and can also be connected to the first beam section 250 via fasteners 264 extending through the first beam section, the separator section 260, and the second beam section 252. The fasteners 264 can also extend through the overmolded strips 262. Figure 10D yes Figure 10C . The basin 222 may also include a molded bracket 266 that is arranged to connect to the opposite side of the first beam portion 250. The bracket 266 may be integral or added later to the side wall of the basin 222. The bracket 266 includes a protrusion 268 for mating with an aperture 270 in the body segment 230C.

[0052] Figure 11 The diagram shows the disassembled Figure 9 2, and a frame 226. The beams 224 are overmolded into the basin 222 so that the beams 224 protrude outward through the sidewalls 234 of the basin 222, thereby connecting the beams 224 to the frame 226. The frame 226 includes a plurality of clips 236 for connecting to opposite sides of each beam 224. The frame 226 and the clips 236 can be formed of a metal material such as aluminum or steel.

[0053] Figure 12is a perspective view of an external thermal management system 320 that may be used in conjunction with any of the embodiments of the battery housing assembly described herein. The external thermal management system 320 includes a manifold 322 located on the bottom surface of the basin 24, 224 or tray 125 (collectively referred to as a "battery holder") that transports a temperature controlled medium around and near the battery module 28. More specifically, the manifold 322 includes a pair of conduits 324 extending along opposite sides of the frame 26, 126, 226. Each conduit 324 includes an input / output 326 that is connected to the coolant system 328 of the associated vehicle. Each conduit 324 also includes a series of ports 330 that are interconnected or paired with the ports of the opposing conduits 324. A coolant line, such as one or more coolant plates 332 (see Figure 14 and Figure 15 The conduit 324 may also include a series of connection clips 334 for connecting to the support beams 74 , 224 and / or the protective plate 327 .

[0054] Figure 13 329 in the battery holder. Each port 330 includes a tapered section 336 that seals against the lower surface of the battery holder around the fluid port 329. The lower surface of the battery holder includes a flat portion 338 that is devoid of webbing to facilitate a sealed connection. The flat portion 338 includes a series of fastener housings 340 for inserting fasteners from the upper surface of the battery holder. Figure 14 A cross-sectional view of a port 330 connected to a battery holder is illustrated. The conduits 324 are recessed into the respective frames 26, 126, 226 to avoid damage. The coolant plate 332 includes a cylindrical protrusion 342 that is inserted into the associated port 330. The coolant plate 332 also includes a base plate 344 and a series of enclosed channels 346 at least partially defined by the base plate 344. The channels 346 can define walls having a flat rectangular shape that are strong enough to support the weight of the battery module 28. The battery module 28 can include a housing 348 that includes a base portion 350 containing a thermally conductive material and a side portion 352 of an SMC material. Figure 15 is a top side view of an external thermal management system 320 located in the battery holder and frame 26, 126, 226. The external thermal management system 320 includes two vertically stacked channels 346 for vertically stacked battery modules 28. Beams 74, 224 may be located between horizontally adjacent channels 346. Figure 16is a bottom perspective view of the external thermal management system 320 located on the battery holder, wherein the beam 74 , 224 includes a series of grooves 354 for securely positioning the conduit 324 within the frame 26 , 126 , 226 . Figure 17 is an enlarged view of the top surface of the battery holder including the fastener apertures extending into the fastener housing 340 and the fluid apertures 329. A fluid seal 354 extends around the fluid apertures 329 and seals against the coolant plate 332 during connection.

[0055] Figure 18 is a perspective view of an external thermal management system 420 according to a second embodiment, which can be used in conjunction with any of the battery housing assembly embodiments described herein. External thermal management system 420 can include any of the aforementioned components of external thermal management system 320 of the first embodiment, however, external thermal management system 420 is integrated with the battery holder. More specifically, external thermal management system 420 includes a manifold 422, which includes conduits 424 similar to conduits 324, which are connected to coolant plate 432. Manifold 422 is integrated with a protective plate 427, which positions the various components of manifold 422. During assembly of base plate 434, manifold 422 is positioned on base plate 434, making it modular and directly connectable to the underside of the battery holder and / or additional protective plate 27. The connection can be temporary via fasteners or permanent via welding.

[0056] Figure 19 is a perspective view of an external thermal management system 520 according to a third embodiment, which can be used in conjunction with any of the other embodiments described herein. The external thermal management system 520 can include any of the aforementioned components of the external thermal management system 320 of the first embodiment and the external thermal management system 420 of the second embodiment. The external thermal management system 520 includes a bottom plate 522 (similar to the protective plate 27) and a top plate 524, wherein at least one coolant channel 526 is defined by one of the bottom plate 522 and the top plate 524. The bottom plate 522 and the top plate 524 are then connected to each other (see Figure 20 ) and connected to the outer surface of the battery holder, for example, by brazing. The coolant channel 526 includes an input portion 526 and an output portion 528 and may define a serpentine pattern. Figure 20 As best shown in FIG, the cross-sectional shape of the coolant channel 526 may include a flat top surface for placement and support of the battery module 28. The plates 522, 524 may be permanently or temporarily mounted to the protective plate 27 or other features of the battery holder.

[0057] It should be understood that in each embodiment of the external thermal management system, either cold coolant or heated coolant may be provided as provided in a conventional automotive coolant system 328. The external portion improves serviceability and replaceability.

[0058] Figure 21 26, 126, 226 and the battery holder. FIG. 26 is a cross-sectional view of a double-sided insert assembly 620 that can be used to connect the frame 26, 126, 226 to the battery holder and provide a connection from the outside of the frame 26, 126, 226 to the inside of the frame 26, 126, 226 and into the battery holder to minimize loads reaching the battery holder. The frame 26, 126, 226 may include or be further connected to one of the protective plates 27, 327, 427 described previously. The double-sided insert assembly 620 includes a fastener 622 that extends through the bottom surface of the frame 26, 126, 226 and includes a washer 624 that is also located on the bottom surface of the frame 26, 126, 226. The fastener extends through the frame 26, 126, 226 and past the top surface of the frame 26, 126, 226 and into the battery holder, where it connects to a clamping bolt 626, which includes a section for connecting to the fastener 622 and a chamfered section 628 for resting on top of an inner surface, which may include the internal webbing or ribs of the battery holder. An adhesive layer 630 is located between the top surface of the frame 26, 126, 226 and the bottom surface of the battery holder. The double-sided insert assembly 620 can be used in conjunction with any other embodiment described herein.

[0059] Figure 22is a cross-sectional view of a thermal management layer 700, which may include multiple sublayers. The thermal management layer 700 may be present in one or more portions of the battery housing assembly 20, 120, or 220 of various embodiments, including any associated components, such as the lid 22, 122, the basin 24, the tray 125, the pocket 54, the sidewalls 50, the base 52, the ribs 56, the spacer members 60, and the structural members 62. From the outer surface to the inner surface, the thermal management layer 700 includes an impact-resistant sublayer 702, a cooling and / or heating (i.e., thermal control) sublayer 704, a first conductive material sublayer 706, a heat storage sublayer 708, and a second heat-conducting sublayer 710. Individually and / or in combination, the multiple sublayers provide insulation from the environment during cold or hot weather temperatures (e.g., the impact-resistant sublayer 702), remove heat from the battery module during normal and abusive operating conditions (e.g., the cooling and / or heating sublayer 704 and the thermal storage sublayer 708), store heat for use in keeping the battery warm in cold weather temperatures (e.g., the thermal storage sublayer 708), and protect the battery module 28 by absorbing energy in the event of an impact (e.g., the impact-resistant sublayer 702). According to one embodiment, the thermal storage sublayer 708 can be formed of aluminum foam with an integrated phase change material, the thermal control sublayer 704 can include the coolant conduits 346, 432, and / or 526 previously described, the thermally conductive sublayers 706, 710 can be formed of a metallic material such as aluminum, steel, copper, and the impact-resistant sublayer 702 can be formed of polyurethane.

[0060] In addition, the thermal management layer 700 can be formed as a non-integrated thermal management module 700A ( Figure 7 ), the thermal management layer 700 can be located in any of the aforementioned locations, such as between the battery module 28 and the battery holder via fasteners, adhesives and / or welding. The thermal management module 700A can also completely cover the battery module 28, can be located only on a specific side of the battery module 28, or can cover a portion of the interior surface of the battery holder and / or cover 22, 122. The thermal management layer 700 and / or the thermal management module 700A can include all layers or only individual layers. It should be understood that the thermal management layer 700 can be incorporated into any of the aforementioned embodiments. The thermal management layer 700 and / or the thermal management module 700A can be directly attached to one or both of the spacing member 60 and the structural member 62.

[0061] The battery housing assembly 20, 120, 220 can be constructed from a variety of different materials and methods, so that the battery housing assembly 20, 120, 220 is multi-material. For example, the upper cover 22, 122 can be constructed from steel stampings, aluminum stampings, aluminum castings or SMC such as fiber reinforced composite (fire-resistant) sheet molding compound. The battery holder can also be constructed from steel stampings, aluminum stampings, aluminum castings or SMC such as fiber reinforced composite (fire-resistant) sheet molding compound. The protective frame 26, 126, 226 can be constructed from steel stampings, aluminum stampings, aluminum extrusions or aluminum castings. The battery holder and cover 22, 122 can be constructed from any of the aforementioned materials and methods. The battery holder can be a single piece (for improving leak resistance) or can be combined with a separate spacing member 60 and structural member 62. For example, the battery holder can be constructed of aluminum (via any of the aforementioned methods) or a fiber reinforced composite material (fire resistant), and the members 60, 62 and protective frames 26, 126, 226 can be constructed of steel (via any of the aforementioned methods). It should be understood that references to aluminum and steel can also include aluminum alloys and steel alloys.

[0062] The battery housing assembly 20, 120, 220 is designed to accommodate and protect the battery module 28 used in an automobile, such as an electric vehicle. The battery housing assembly 20, 120, 220 also accommodates a thermal management system 320, 420, 520 (e.g., cooling plates, pipes, hoses, and connectors), wires (for connecting the battery module 28 and the electronic module), and electronic control modules among other devices. The battery housing assembly 20, 120, 220 can therefore provide a multi-material solution to optimize mass savings, meet fire resistance standards by incorporating fiber-reinforced composite materials, minimize processing, eliminate welding, and form a single sealing surface. In addition, the battery housing assembly 20, 120, 220 allows for component consolidation, provides an improved sealing method with sealing surface stiffness, and integrates various components and parts to eliminate duplicate structures to save mass.

[0063] According to yet another aspect of the present invention, a method 800 of constructing a battery housing assembly from multiple materials is provided. Figure 23. The method 800 includes forming a cover 802, which may include stamping 804 the cover from steel, stamping 806 the cover from aluminum, casting 807 the cover from aluminum, or molding 808 the cover from a fiber reinforced composite material. The method 800 also includes forming 810 a battery holder, which may include stamping 812 the battery holder from steel, stamping 814 the battery holder from aluminum, casting 815 the battery holder from aluminum, or molding 816 the battery holder from a fiber reinforced composite material. Step 816 may include molding the battery holder around the frame that has been formed by step 818. The method 800 also includes forming 818 a frame, which may include stamping 820 the frame from steel, stamping 822 the frame from aluminum, casting 824 the frame from aluminum, or forming 826 the frame from aluminum extrusion. Method 800 also includes placing 828 the battery module into the battery holder, forming 830 a seal between the battery holder and the cover, and placing 832 the cover on the battery holder. Before (or alternatively after) step 828, the method may also include placing / positioning / connecting 827 a thermal management system. Step 827 may include positioning 829 a layer or module between at least one battery module and the battery holder and / or between at least one battery module and the cover. Step 827 may also include incorporating 831 an external thermal management system. In the case of a basin, method 800 includes placing 834 the basin, cover, and battery module onto the frame and continuing with placing 836 a connector through the basin, cover, and frame and compressing the seal. In the case of using a tray, step 832 is followed by integrating / connecting 838 the cover and / or tray to the body in white and placing 840 the connector through the tray and cover and compressing the seal. Step 838 may include welding the cover and / or tray to the body-in-white and / or otherwise attaching the cover and / or tray with fasteners, adhesives, or other methods.

[0064] It should be understood that the foregoing description of the embodiments has been provided for illustrative purposes. In other words, the present disclosure itself is not intended to be exhaustive or limitative of the present disclosure. The various elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in selected embodiments, even if not specifically shown or described. The various elements or features of a particular embodiment also can be changed in various ways. Such variations should not be considered as departing from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A lightweight battery housing for an automobile, comprising: a battery holder formed of a sheet molding compound and having a base for placing at least one battery module; the battery holder including at least one rib extending upwardly from the base to define at least one groove extending along an exterior surface of the battery holder; as well as An outer frame includes at least one beam extending in mating relationship through the at least one groove.

2. The lightweight battery housing according to claim 1, wherein: The battery holder is made of glass fiber reinforced plastic or carbon fiber reinforced plastic.

3. The lightweight battery housing according to claim 1, wherein: The battery holder is basin-shaped and includes side walls surrounding the base and extending upwardly from the base, and the outer frame is disposed in surrounding relationship with the side walls. 4 . The lightweight battery case according to claim 3 , further comprising a protection plate extending below the battery case and interconnected with the outer frame.

5. The lightweight battery casing according to claim 1, wherein The at least one beam is molded into the at least one groove during formation of the battery holder.

6. The lightweight battery housing according to claim 1, further comprising: the at least one rib comprising a plurality of ribs extending upwardly from the base in spaced relation to one another to define a plurality of pockets, each pocket being disposed between adjacent ones of the plurality of ribs; the at least one groove, the at least one groove comprising a plurality of grooves extending along the exterior surface of the battery holder, each groove of the plurality of grooves being defined by adjacent ribs of the plurality of ribs; the at least one beam, the at least one beam comprising a plurality of beams, each beam extending in mating relationship through a respective one of the plurality of grooves; at least one battery module disposed in each of the plurality of recesses; as well as A spacer member is interconnected to each of the plurality of ribs and a corresponding mating one of the plurality of beams for securing the at least one battery module in a corresponding one of the plurality of recesses and absorbing movement of the at least one battery module from side to side during use of the lightweight battery housing.

7. The lightweight battery casing according to claim 6, wherein: The spacing member is composed of a material that is different from and stronger than the sheet molding compound material of the battery holder.

8. The lightweight battery housing according to claim 4, further comprising: the outer frame, the outer frame having a top surface; as well as The battery holder includes a battery holder rim extending outwardly from the side wall in a resting and overlapping relationship along the top surface of the outer frame. 9 . The lightweight battery case according to claim 8 , further comprising a cover formed of a sheet molding compound and covering the battery holder.

10. The lightweight battery housing according to claim 9, further comprising: the cover, the cover including a cover rim disposed in overlapping relationship with the battery holder rim; the top surface of the outer frame, the top surface of the outer frame defining at least one frame aperture; the battery holder rim, the battery holder rim defining at least one battery holder rim aperture; the cover rim, the cover rim defining at least one cover aperture; the at least one frame aperture and the at least one battery holder edge aperture and the at least one cover aperture, the at least one frame aperture and the at least one battery holder edge aperture and the at least one cover aperture being disposed in aligned relationship with one another; as well as A tolerance compensation assembly is disposed in and extends through the aligned apertures for interconnecting the cover and the battery holder and outer frame to one another.

11. The lightweight battery housing according to claim 10, further comprising: the tolerance compensation assembly comprising a grommet extending through the aligned battery holder rim aperture and cover aperture; the tolerance compensation assembly, the tolerance compensation assembly including a first grommet connected to a second grommet disposed in the at least one cover aperture; as well as The tolerance compensation assembly includes a connector extending through the grommet and configured to threadably engage the first bushing.

12. The lightweight battery housing of claim 10, further comprising a seal extending between the battery holder rim and the cover rim.

13. The lightweight battery housing according to claim 1, further comprising: a clamping bolt disposed within and resting along the at least one rib of the battery housing; and a fastener extending upwardly through the at least one beam of the outer frame and interconnecting with the clamping bolt for securing the at least one beam within the at least one recess.

14. The lightweight battery housing according to claim 6, further comprising: a coolant plate disposed in each of the plurality of pockets in a sandwiched relationship between the base of the battery housing and the at least one battery module; the base of the battery housing, the base of the battery housing defining at least one fluid aperture disposed adjacent the coolant plate; as well as A thermal management system includes at least one conduit extending along the outer frame and having at least one port passing through the at least one fluid aperture and disposed in fluid communication with the coolant plate for managing the temperature of the at least one battery module.

15. The lightweight battery casing according to claim 14, wherein: The at least one conduit comprises an input / output for connection to a cooling system of the vehicle.

16. The lightweight battery casing according to claim 14, wherein: The coolant plate includes a cylindrical protrusion extending downwardly from the coolant plate and inserted into the at least one port.

17. A method for manufacturing a lightweight battery casing, comprising: molding a battery case from sheet molding compound to present a base and at least one rib extending upwardly from the base to define at least one groove extending along an exterior surface of the formed battery case; forming a frame from a steel or aluminum material to define an outer frame and at least one beam extending between opposing sides of the outer frame; as well as The battery housing is placed within the frame to position the at least one beam of the frame in a relationship extending along the at least one groove of the battery housing and to position the at least one beam of the frame within the at least one groove of the battery housing.

18. The method for manufacturing a lightweight battery casing according to claim 17, further comprising: Molding the cover with sheet molding compound; as well as The cover is placed on the battery housing.

19. The method for manufacturing a lightweight battery casing according to claim 18, further comprising: The cover, the battery housing, and the frame are connected to one another via a tolerance compensation assembly.

20. The method for manufacturing a lightweight battery casing according to claim 17, further comprising: placing at least one battery module within the battery housing; as well as A spacing member is commonly connected to the at least one rib and the at least one beam to secure the at least one battery module within the battery case and to absorb side-to-side movement of the at least one battery module during use of the lightweight battery case.

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