Method for producing a battery housing

Abstract

A blow-molded article of manufacture comprises first and second battery cases, each having first and second laterally outwardly extending flanges, and a preform made of a polymeric material. The first and second battery case components are arranged to face one another with their respective first and second laterally outwardly extending flanges aligned and spaced apart by an offset. The preform is disposed between and interconnects the first and second battery case components such that the preform conforms to the interior surfaces of the battery case components and substantially fills the offset.The product may be cut along a cut line through the preform and within the offset around an outer perimeter of the product, thereby separating the product into first and second battery case assemblies. Methods of manufacture are also disclosed.

Description

[0001] This description relates to a process for producing blow-molded articles of manufacture.

[0002] In electric and hybrid vehicles, a plurality of individual battery cells may be enclosed in a battery housing. The battery housing may have a metal base tray in which the battery cells are arranged and a metal cover that fits over the base tray, with the tray and cover enclosing the battery cells.

[0003] Additionally, a polymer lining can be incorporated into the shell and cover. This lining provides electrical insulation between the battery cells and the compartment and cover, as well as protection from external chemicals (e.g., engine oil, road salt, etc.) and impulses. The lining can also include partitions (between the battery cells), cable routing structures (for routing wires and cables), and other structures, or these partitions and structures can be provided as separate elements of the lining. Furthermore, various elastomer or polymer seals can be incorporated into the battery casing to enhance sealing and protection of the battery cells.

[0004] CN 1 06 711 360 A describes a battery housing with a lid. Shielding layers and insulator layers are arranged in the walls of the battery housing.

[0005] KR 10 2019 048 616 A describes a battery housing with electrical connections on the bottom surface of the battery housing. The electrical connections are connected to an external circuit.

[0006] JP 2010-097722 A describes a battery housing which is designed to accommodate similar battery cells.

[0007] JP S59-118436 A describes a method for manufacturing a housing from a synthetic resin material having a surface layer.

[0008] The invention is based on the object of providing a battery housing that improves the sealing and protection of battery cells. This object is achieved by the method according to claim 1. Further design features of the method according to the invention are the subject of subclaims 2 to 4.

[0009] According to the invention, a method of manufacturing a battery case comprises: (i) arranging a first and a second battery case component directly against a first and a second battery case component, respectively.a second platen in a blow molding machine, the first and second plates being separated from each other in an open arrangement; (ii) suspending a preform of polymeric material between the first and second battery case components; (iii) moving at least one of the first and second plates toward the other of the first and second plates to position the first and second plates in a closed arrangement; (iv) injecting a gas into the preform to expand the preform into contact with the first and second battery case components, thereby forming a component / preform / component assembly; (v) moving at least one of the first and second plates away from the other of the first and second plates; and (vi) removing the component / preform / component assembly from the area between the first and second plates.

[0010] In one embodiment, the preform may have a first preform side and a second preform side, and in the suspending step, the preform may be suspended between the first and second battery case components, with the first preform side facing the first battery case component and the second preform side facing the second battery case component. The component / preform / component assembly may include the preform attached to the first and second battery case components via the first and second preform sides, respectively. In the injecting step, expansion of the preform in contact with the first and second battery case components may cause the first and second preform sides to adhere to the first and second battery case components, respectively.

[0011] The component / preform / component assembly may include a circumferential seam along which the first and second preform sides are secured together, thereby enclosing and defining an internal cavity within the component / preform / component assembly, the method further including cutting the component / preform / component assembly along the circumferential seam to separate the preform into a first preform portion and a second preform portion, thereby subdividing the component / preform / component assembly into a first battery case assembly having the first battery case component adhered to the first preform portion, and a second battery case assembly having the second battery case component adhered to the second preform portion. The method may further include joining the first and second battery case assemblies together to form the battery case.

[0012] The first battery case component may have a first bottom surface and a first top surface, and the second battery case component may have a second bottom surface and a second top surface. In the placement step, the first battery case component may be placed so that the first bottom surface faces the first plate and the first top surface faces the second plate, and the second battery case component may be placed so that the second bottom surface faces the second plate and the second top surface faces the first plate. At least one of the first and second battery case components may be shaped as an open cover with five sides or as a sleeve with four panels.

[0013] As an exemplary application, a blow-molded article that can be manufactured using the method of the invention is described. Accordingly, a blow-molded article of manufacture comprises: (i) a first battery casing component having a generally planar first main wall, the first main wall having a first main wall inner surface and a first main wall outer surface, a first sidewall extending orthogonally from and around a first outer perimeter of the first main wall, the first sidewall having a first sidewall inner surface and a first sidewall outer surface, and a first laterally outwardly extending flange extending laterally outwardly from the first sidewall;(ii) a second battery case component having a generally planar second main wall, the second main wall having a second main wall inner surface and a second main wall outer surface, a second sidewall extending orthogonally from and around a second outer perimeter of the second main wall, the second sidewall having a second sidewall inner surface and a second sidewall outer surface, and a second laterally outwardly extending flange extending laterally outwardly from the second sidewall, the first and second battery case components being arranged with their respective first and second main wall inner surfaces facing each other and their respective first and second laterally outwardly extending flanges aligned with each other and spaced apart by an offset;and (iii) a preform of a polymeric material disposed between and interconnecting the first and second battery case components such that the preform conforms to the first and second main wall interior surfaces and to the first and second side wall interior surfaces, the preform substantially filling the offset between the first and second laterally outwardly extending flanges;

[0014] The blow-molded article of manufacture may further comprise a first orthogonally outwardly extending segment extending orthogonally outwardly from the first laterally outwardly extending flange, a first laterally inwardly extending segment extending laterally inwardly from the first orthogonally outwardly extending segment, a second orthogonally outwardly extending segment extending orthogonally outwardly from the second laterally outwardly extending flange, and a second laterally inwardly extending segment extending laterally inwardly from the second orthogonally outwardly extending segment.

[0015] The blow molded article may further include a plurality of dividers sandwiched between the inner surface of the second main wall and the preform to form a plurality of pockets between the plurality of dividers and the second side wall.

[0016] The blow-molded article of manufacture may further comprise one or more cord guide structures, each having a first cord guide structure end and a second cord guide structure end, wherein the respective first and second cord guide structure ends are attached to the second main wall inner surface such that each of the cord guide structures is arranged in an arcuate arrangement, and wherein each of the cord guide structures is enclosed between the second main wall inner surface and the preform with a respective passageway provided between each of the cord guide structures and the second main wall inner surface.

[0017] The blow-molded article of manufacture may be configured to be cut along a cut line through the preform and within the offset around an outer perimeter of the blow-molded article of manufacture, thereby separating the blow-molded article of manufacture into a first battery case assembly and a second battery case assembly.

[0018] The blow-molded article of manufacture may be further configured such that the first and second battery case assemblies may be arranged such that their respective first and second main wall interior surfaces face each other and that their respective first and second laterally outwardly extending flanges are aligned and in contact with each other, and that the first and second laterally outwardly extending flanges may be reattached to each other.

[0019] The above features and advantages, as well as other features and advantages of the present teachings, will be readily apparent from the following detailed description of some of the preferred embodiments and other embodiments for carrying out the present teachings, as defined in the appended claims, taken in conjunction with the accompanying drawings. Fig. 1 is a schematic plan view of a blow molding machine. Fig. 2A-C are schematic cross-sectional views of a first embodiment of a blow-molded product before cutting, after cutting, and after assembly, respectively, and Fig. 2D is a schematic top view of the product. Fig. 3 is a schematic cross-sectional exploded view of the Fig. 2B shown product. Fig. 4A-C are schematic cross-sectional views of a second embodiment of a blow molded product before cutting, after cutting, and after reassembly, respectively. Fig. 5-6 are schematic exploded perspective views of two different embodiments of first and second battery casing components that may be used to make the blow molded article, with no laterally outwardly extending flanges or second side walls shown. Fig. 7-8 are schematic cross-sectional views showing two different processes for producing a blow-molded product. Fig. 9A-D are schematic, partially cross-sectional views of first, second, third, and fourth arrangements for producing a blow-molded product, respectively. Fig. 10 is a schematic cross-sectional view of a blow-molded article having a plurality of dividers embedded therein. Fig. 11 is a schematic cross-sectional view of a selected portion of a blow molded article having a cord management structure embedded therein. Fig. 12-14 are flowcharts illustrating a method according to the invention ( Fig. 12) and two unclaimed processes ( Fig. 13 and Fig. 14) for the production of a blow-molded product.

[0020] Referring now to the figures, wherein like numerals designate like parts throughout the several views, there are shown and described various embodiments of a blow molded article of manufacture / battery case 30 and methods 100, 200, 300 for making the article of manufacture 30.

[0021] Fig. Figure 1 shows a typical blow molding machine 10. The machine 10 includes a frame 11 supporting an extruder 12, which is continuously fed via a hopper 13. Pellets 14 of polymeric material are fed in solid form into the hopper 13, and an extruder drive system 15 rotates the extruder 12 about its axis to convey the pellets 14 into a reservoir 16. The pellets 14 are melted in the reservoir 16 to form a viscous polymer liquid, and the liquid polymer is then forced downward through a circular extrusion die to produce a hollow tubular preform 90 having an internal cavity 91 extending longitudinally through the preform 90.

[0022] As the molten polymer continues to be extruded through the circular die, the preform 90 sinks downward due to gravity and increases in length. The preform 90 continues to descend through a working chamber flanked by first and second platens 17, 18, which are opposite one another and each have first and second platen surfaces 19, 20, which are opposite one another. The first and second mold halves 21, 22 are supported by the first and second platens 17, 18, respectively. The platens 17, 18 can, as in Fig. 1, in an open arrangement 23 in which the mold halves 21, 22 are spaced from the descending preform 90. Once the preform 90 has descended a sufficient length, the platens 17, 18 can be moved towards each other into a closed arrangement 24 (explained further below) so that the mold halves 21, 22 press inwardly toward the preform 90, but only contact the preform 90 at its top and bottom. Meanwhile, a blow mandrel 25 extends into the internal cavity 91 of the preform 90, either from below the preform 90, as in Fig. 1, or from above the preform 90 (e.g., from the direction of the reservoir 16). When the platens 17, 18 and the mold halves 21, 22 are pressed together into the closed assembly 24, the mold halves 21, 22 clamp and seal the preform 90 at the top and bottom of the preform 90, with the blow pin 25 extending into the now sealed interior / internal cavity 91 of the preform 90. A gas 26 (e.g., air, nitrogen) is directed through the blow pin 25 and into the now sealed internal cavity 91, thereby "inflating" the sealed volume within the preform 90 and forcing the walls of the preform 90 against the mold halves 21, 22. As a result, the previously melted preform 90 is cooled on the relatively cooler mold halves 21, 22, whereby the preform 90 solidifies and assumes the shape that is milled into the mold halves 21, 22.

[0023] In contrast to the conventional approach mentioned above, the blow-molded article of manufacture 30 and the methods 100, 200, 300 for manufacturing such an article 30 solve the technical problem of providing a battery enclosure that provides sealing and protection for battery cells. This is achieved through the technical effect of utilizing blow molding technology and specific molded structures as described herein, thereby achieving significant advantages and technical benefits not taught or suggested by other approaches. These advantages include the use of structural elements and features, as well as steps in the blow molding and manufacturing process, that are less complex, less costly, and / or more reliable compared to prior approaches.

[0024] Fig. 2A-C show schematic cross-sectional views of a blow-molded product 30 that can be produced with a blow molding machine 10. More specifically, Fig. 2A the article of manufacture 30 in the formed state and before cutting, Fig. Figure 2B shows the article of manufacture 30 after cutting and separating into a first and a second battery housing assemblies 31, 32, and Fig. Figure 2C shows the article of manufacture 30 after filling with battery cells 27 and after the two battery housing assemblies 31, 32 have been reassembled. Fig. 2D is a schematic plan view of the product 30.

[0025] As in Fig. 2A, this blow-molded product 30 begins with a first battery case component 33 (e.g., a metallic top cover for a battery case), a second battery case component 34 (e.g., a metallic bottom tray for a battery case), and a preform 90 sandwiched between and connecting the first and second battery case components 33, 34. (It should be noted that although the product 30 may be molded (i.e., blow-molded) in a vertical orientation, as shown in Fig. 1, the product 30 in the Fig. 2A-2C and others, however, are shown in horizontal orientation).

[0026] The first battery case component 33 has a generally planar first main wall 35 having a first main wall inner surface 36 (in contact with the preform 90), a first main wall outer surface 37, and a first main wall outer perimeter 38. The first battery case component 33 also has a first sidewall 39 extending orthogonally (e.g., downwardly) from the first main wall outer perimeter 38, with the first sidewall 39 also extending the full extent of the first main wall outer perimeter 38. The first sidewall 39 has a first sidewall inner surface 40 (in contact with the preform 90), a first sidewall outer surface 41, a first sidewall upper edge or end 42 extending around the entire extent of the first main wall outer perimeter 38, and a first sidewall lower edge or end 43.The first battery housing component 33 also has a first laterally outwardly extending flange 44 extending laterally outwardly from the first sidewall 39 (e.g., from the first sidewall bottom edge / end 43) and a first flange top surface 44t, a first flange bottom surface 44. b and a first flange outer circumference 45.

[0027] The second battery case component 34 has a generally planar second main wall 46 having a second main wall inner surface 47 (in contact with the preform 90), a second main wall outer surface 48, and a second main wall outer perimeter 49. The second battery case component 34 also has a second sidewall 50 extending orthogonally (e.g., upwardly) from the second main wall outer perimeter 49, the second sidewall 50 also extending the full extent of the second main wall outer perimeter 49. The second sidewall 50 has a second sidewall inner surface 51 (in contact with the preform 90), a second sidewall outer surface 52, a second sidewall upper edge or end 53 and a second sidewall lower edge or end 54 extending around the entire extent of the second main wall outer perimeter 49.The second battery housing component 34 also has a second laterally outwardly extending flange 55 extending laterally outwardly from the second sidewall 50 (e.g., from the top edge / top end 53 of the second sidewall) and a second upper flange surface 55t, a second lower flange surface 55. b and a second outer flange periphery 56.

[0028] Fig. 3 shows an exploded view of the Fig. 2B. Here, the product 30 is divided into a first and a second battery housing assemblies 31, 32, wherein the first battery housing assembly 31 is further divided into the first battery housing component 33 and a first preform part 92, and the second battery housing assembly 32 is further divided into the second battery housing component 34 and a second preform part 93. As shown, the first preform part 92 fits into the first interior space 33.i the first battery housing component 33, and the second preform part 93 fits into the second interior space 34 i the second battery housing component 34. Note that Fig. 3 shows these elements in an exploded view, but this is for information purposes only, since in reality the first preform part 92 is closely molded to the first inner surface 33 by the blow molding process is the first battery housing component 33 and the second preform part 93 is closely connected to the second inner surface 34 is the second battery housing component 34.

[0029] The first main wall 35 and the first side wall 39 - more precisely, the first main wall inner surface 36 and the first side wall inner surface 40 - define a first interior space 33 iwithin the first battery housing component 33. Similarly, the second main wall 46 and the second side wall 50 - more precisely, the second main wall inner surface 47 and the second side wall inner surface 51 - define a second interior space 34 i within the second battery housing component 34. The first main wall inner surface 36 and the first side wall inner surface 40 together have a first inner surface 33 is within the first battery housing component 33, and the second main wall inner surface 47 and the second side wall inner surface 51 together have a second inner surface 34 is within the second battery housing component 34.

[0030] The first main wall inner surface 36 has a first geometric center 36 gc and the second main wall inner surface 47 has a second geometric center 47 gc. The first main wall inner surface 36 defines a first laterally outward direction 36 1o , which from the first geometric center 36 gc away and runs parallel to the first main wall inner surface 36, a first laterally inward direction 36 li , which leads to the first geometric center 36 gc and runs parallel to the first main wall inner surface 36, and a first orthogonally outwardly directed direction 36 oo , which from the first geometric center 36 gc away and is orthogonal (ie normal) to the first main wall inner surface 36. Similarly, the second main wall inner surface 47 defines a second laterally outward direction 47 1o , which from the second geometric center 47 gc away and runs parallel to the second main wall inner surface 47, a second laterally inward direction 47 li, which leads to the second geometric center 47 gc and runs parallel to the second main wall inner surface 47, and a second orthogonally outwardly directed direction 47 oo , which from the second geometric center 47 gc away and runs orthogonally to the second main wall inner surface 47.

[0031] As in Fig. 2A, the first and second battery case components 33, 34 are arranged such that their respective first and second major wall interior surfaces 36, 47 face each other and such that their respective first and second laterally outwardly extending flanges 44, 55 are aligned with each other and spaced apart by an offset or gap 57. The preform 90 is interposed between the first and second battery case components 33, 34 and interconnects the first and second battery case components 33, 34 such that the blow-molded preform 90 conforms to and encloses the entirety of the first and second major wall interior surfaces 36, 47. It should be noted that the preform 90 substantially fills the offset 57 between the first and second laterally outwardly extending flanges 44, 55.

[0032] In Fig. 2A, a cutting line 58 is shown passing through the portions of the preform 90 that lie between the first and second laterally outwardly extending flanges 44, 55 within the offset 57. The blow-molded product 30 can be cut along this line 58 and around the entire outer perimeter 59 of the product (shown in Fig. 2D) to divide the product 30 into two parts, namely a first battery housing assembly 31 and a second battery housing assembly 32, as shown in Fig. 2B. As shown, the first battery housing assembly 31 includes a first battery housing component 33 (e.g., a metallic top or cover), a first preform portion 92 that adheres to the first inner surface 33 is the first battery housing assembly 33 (as well as the first flange base surface 44 b), a first upper side 60 and a first lower side 61, which form a first internal volume 31 iv is "open" within the first battery housing assembly 31. Similarly, the second battery housing assembly 32 includes a second battery housing component 34 (e.g., a metal base or a metal tray), a second preform portion 93 that adheres to the second inner surface 34 is the second battery housing component 34 (as well as the second flange top 55 t ), a second bottom side 62 and a second top side 63, which form a second internal volume 32 iv is “open” within the second battery housing assembly 32.

[0033] Once the blow-molded product 30 has been cut along the cutting line 58 to separate the product 30 into two parts, one or more battery cells 27 can be inserted into the second (lower) battery housing assembly 32 and the first (upper) battery housing assembly 31 can be placed onto the second battery housing assembly 32, thereby completely enclosing and covering the battery cells 27.

[0034] Fig. Figure 2C shows the product 30 after cutting, separating, inserting the battery cells, and reassembly. Note that the portions of the preform 90 that previously formed the offset 57 between the flanges 44, 55 (see Fig. 2A) and into which was cut to form the first and second battery housing assemblies 31, 32 with their respective first and second preform parts 92, 93 (see Fig. 2B), are now shown aligned and joined together. Such joining of the previously cut portions of the preform 90 can be accomplished in various ways, e.g., by ultrasonic bonding, laser welding, chemical adhesive, mechanical fasteners, and the like.

[0035] Fig. 4A-C show schematic cross-sectional views of a second variant of a blow-molded product 30 that can be produced with a blow-molding machine 10. More specifically, Fig. 4A the article of manufacture 30 in the formed state and before cutting, Fig. Figure 4B shows the article of manufacture 30 after cutting and separating into a first and a second battery housing assemblies 31, 32, and Fig. Figure 4C shows the article of manufacture 30 after filling with battery cells 27 and after the two battery housing assemblies 31, 32 have been reassembled.

[0036] As in Fig. 4A, this second variant of a blow-molded product 30 begins with a first battery housing component 33 (e.g., a metallic top cover for a battery housing), a second battery housing component 34 (e.g., a metallic bottom tray for a battery housing), and a preform 90 that is inserted between the first and second battery housing components 33, 34 and joins them together, similar to the first embodiment in Fig. 2A. In the second embodiment, as shown in Fig. 4A, however, the blow-molded article of manufacture 30 may further comprise a first orthogonally outwardly extending segment 64 extending orthogonally outwardly from the first laterally outwardly extending flange 44, a first laterally inwardly extending segment 65 extending laterally inwardly from the first orthogonally outwardly extending segment 64, a second orthogonally outwardly extending segment 66 extending orthogonally outwardly from the second laterally outwardly extending flange 55, and a second laterally inwardly extending segment 67 extending laterally inwardly from the second orthogonally outwardly extending segment 66. Similar to the embodiment shown in the Fig. 2A-D, the portions of the preform 90 enclosed between the first and second laterally outwardly extending flanges 44, 55 within the offset 57 of the second embodiment may be cut along a cut line 58 to separate the product 30 into first and second battery housing assemblies 31, 32 (see Fig. 4B), then one or more battery cells 27 can be inserted into the second (lower) battery housing assembly 32, and the first (upper) battery housing assembly 31 can be placed on the second battery housing assembly 32, thereby completely containing and covering the battery cells 27, and then the first and second battery housing assemblies 31, 32 can be joined together (see Fig. 4C).

[0037] Fig. 5 and Fig. 6 show schematic perspective exploded views of two different variants of the first and second battery housing components 33, 34 that can be used to manufacture the blow-molded product 30. It should be noted that in the Fig. 5-6 no laterally outwardly extending flanges 44, 55 or second side walls 50 are shown. In the Fig. 5, three separate parts are shown: a generally flat battery case top cover 68, a four-walled sleeve 70, and a generally flat battery case bottom shell 72. Optionally, the battery case top cover 68 and the four-walled sleeve 70 may be manufactured separately and then joined together to form a five-sided open top cover 74, similar to the one shown above in Fig. 6 shown structure. In the Fig. 6, two separate parts are shown: a five-sided open top cover 74 and a generally flat battery case bottom shell 72. In both cases and as shown in the Fig. 5 and Fig. 6, the first battery housing component 31 may be joined to a corresponding second battery housing assembly 32 by blow molding, as described in more detail below.

[0038] As in the Fig. 5 and Fig. 6, the first side wall 39 may consist of a plurality of adjacent straight walls (e.g., four adjacent walls as shown here). Alternatively, the first side wall 39 may consist of a single wall having a circular, ellipsoidal, or other rounded shape in plan view. Similarly, the second side wall 50 (in the Fig. 5 and Fig. 6 not shown) may consist of a plurality of adjacent straight walls or of a single wall. Furthermore, configurations of the first and second side walls 39, 50 consisting of multiple walls may include one or more curved walls in addition to or instead of straight walls.

[0039] Fig. 7-8 show schematic cross-sectional views illustrating two different processes for producing a blow-molded product 30. (Note that the Fig. 7-8 have been rotated ninety degrees from their normal vertical orientation to show a horizontal orientation). In Fig. 7 shows a first battery housing component 33 placed against the first plate 17 of a blow molding machine (not shown). A preform 90 was placed between the first battery housing component 33 and the second plate 18, the first and second plates 17, 18 were pressed together, and a blow mandrel (not shown) inflated the preform 90 so that a first preform part 92 was in close contact with the first inner surface 33. is the first battery housing component 33 and a second preform part 93 is pressed into contact with the second plate surface 20. In Fig. 8 shows a first battery housing component 33 abutting the first plate 17 and a second battery housing component 34 abutting the second plate 18. A preform 90 was placed between the first and second battery housing components 33, 34, the first and second plates 17, 18 were pressed together, and the preform 90 was inflated so that a first preform portion 92 was in close contact with the first inner surface 33 is the first battery housing component 33 and a second preform part 93 in close contact with the second inner surface 34 is the second battery housing component 34 is pressed.

[0040] Fig. 9A-D show a first, second, third, and fourth arrangement, respectively, for producing a blow-molded article 30. In each of these four views, the first and second plates 17, 18 are shown in an open arrangement 23 with a preform 90 disposed between and spaced from the plates 17, 18. In Fig. 9A, a single battery housing component, such as a battery housing top cover 68 or a battery housing bottom shell 72, is arranged on the first plate 17. In Fig. 9B, a battery housing component is placed on each plate 17, 18; for

[0041] For example, a battery housing top cover 68 can be placed on the first plate 17 and a battery housing bottom shell 72 on the second plate 18. In Fig. 9C, a battery housing top cover 68 is attached to the first plate 17 and a four-walled sleeve 70 is attached to the second plate 18. And in Fig. 9D, a battery housing bottom shell 72 is attached to the first plate 17, and a five-sided open top cover 74 is attached to the second plate 18. In addition to these four arrangements, other arrangements are also possible.

[0042] In Fig. 10 again shows a blow-molded article 30, but this time with a plurality of partition walls 76 disposed between the second main wall interior surface 47 and the preform 90. It should be noted that although the article 30 is shown here in the form of the above-mentioned first embodiment, the partition walls 76 may be included in both the first and second embodiments. The partition walls 76 may be disposed within the interior space 34i of the second battery housing component 34 and optionally attached to or held against the second main wall interior surface 47 and / or the second sidewall interior surface 51 prior to blow molding. (For example, the partition walls 76 may be retained by folds in the second main wall interior surface 47 and / or the second sidewall interior surface 51, with the partition walls 76 being fitted into these folds.)With the dividers 76 held or secured in place, the plates 17, 18 can be moved into the closed arrangement 24 and the preform 90 can be expanded into contact with these dividers 76 so that a plurality of pockets 78 are formed between the plurality of dividers 76 and the second side wall 50.

[0043] As in Fig. 11, the blow-molded product 30 may further include one or more cord guide structures 80, each having a first cord guide structure end 82 and a second cord guide structure end 84. The cord guide structures 80 may, for example, take the form of a rope or cable made of aramid fiber, carbon fiber, or other high-strength material. The respective first and second ends of the cord guide structures 82, 84 are attached to the second main wall interior surface 47 such that each of the cord guide structures 80 is arranged in an arcuate arrangement 86, wherein each of the cord guide structures 80 is captured between the second main wall interior surface 47 and the preform 90 with a respective passageway 88 between each of the cord guide structures 80 and the second main wall interior surface 47. Such passageways 88 may be used, for example, for passing wires and cables.

[0044] The blow-molded product 30 may be further configured such that the first and second battery case assemblies 31, 32 may be arranged such that their respective first and second main wall inner surfaces 36, 47 face each other and that their respective first and second laterally outwardly extending flanges 44, 55 are aligned and in contact with each other, and that the first and second laterally outwardly extending flanges 44, 55 may be reconnected to each other.

[0045] Fig. 12-14 show flow diagrams for three related but different methods 100, 200, 300 for manufacturing a product / battery case 30 according to the present description. Note that for selected steps, the inputs are shown on the left and the generated results or outputs are shown on the right.

[0046] Fig. 12 shows a flowchart of the steps for a method 100 according to the invention for producing a battery case 30 in a blow molding machine 10. In step 110, a first and a second battery case component 33, 34 are placed directly against a first and a second platen 17, 18, respectively, in a blow molding machine 10, wherein the first and the second platen 17, 18 are arranged separated from one another in an open arrangement 23. In step 120, a preform 90 is suspended between the first and second battery case component 33, 34. In step 130, at least one of the first and second plates 17, 18 is moved towards the other of the first and second plates 17, 18 such that the first and second plates 17, 18 are arranged in a closed arrangement 24.In step 140, a gas 26 is injected into the preform 90 via a blow mandrel 25 to expand the preform 90 and force it into contact with the first and second battery housing components 33, 34, thereby forming a component / preform / component assembly 97. In step 150, at least one of the first and second plates 17, 18 is moved away from the other of the first and second plates 17, 18, and in step 160, the component / preform / component assembly 97 is removed from the area between the first and second plates 17, 18.

[0047] The preform 90 may have a first preform side 94 and a second preform side 95, and in the hanging step 120, the preform 90 may be suspended between the first and second battery case components 33, 34, with the first preform side 94 facing the first battery case component 33 and the second preform side 95 facing the second battery case component 34. The component / preform / component assembly 97 may include the preform 90 attached to the first and second battery case components 33, 34 via the first and second preform sides 94 and 95, respectively. In the injection step 140, the expansion of the preform 90 in contact with the first and second battery case components 33, 34 may cause the first and second preform sides 94, 95 to adhere to the first and second battery case components 33, 34, respectively.

[0048] The component / preform / component assembly 97 may include a circumferential seam 96 along which the first and second preform sides 94, 95 are secured together, thereby enclosing and defining an internal cavity 91 within the preform 90 and the component / preform / component assembly 97. The circumferential seam 96 may optionally include a series of perforations, recesses, or the like, or it may include one long seam, ridge, or depression; alternatively, the circumferential seam 96 may not include any visible structures, boundaries, or the like and may simply be where the first and second preform sides 94, 95 were fused or welded together during the blow molding process, as in Fig. 2A. The method 100 may further include, in step 170, cutting the component / preform / component assembly 97 along the circumferential seam 96 to separate the preform 90 into a first preform portion 92 and a second preform portion 93, thereby subdividing the component / preform / component assembly 97 into a first battery case assembly 31 in which the first battery case component 33 is adhered to the first preform portion 92, and a second battery case assembly 32 in which the second battery case component 34 is adhered to the second preform portion 93. The method 100 may further include, in step 180, joining the first and second battery case assemblies 31, 32 together to form the battery case 30.

[0049] The first battery case component 33 may have a first bottom surface 61 and a first top surface 60, and the second battery case component 34 may have a second bottom surface 62 and a second top surface 63. In the placement step 110, the first battery case component 33 may be placed so that the first bottom surface 61 faces the first plate 17 and the first top surface 60 faces the second plate 18, and the second battery case component 34 may be placed so that the second bottom surface 62 faces the second plate 18 and the second top surface 63 faces the first plate 17. At least one of the first and second battery case components 33, 34 may be shaped as a five-sided open top cover 74, a four-walled sleeve 70, a generally flat battery case top cover 68, or a generally flat battery case bottom shell 72.

[0050] In some arrangements, a blow mold half (ie, a first or second mold half 21, 22) is not supported by either the first or second platen 17, 18.

[0051] The first battery housing component 33 has a first bottom side 61 and a first top side 60, and in the placement step 120, the first battery housing component 33 is placed such that the first bottom side 61 faces the first plate 17 and the first top side 60 faces the second plate 18.

[0052] Fig. 13 shows a flowchart of the steps for a non-claimed method 200 for manufacturing a battery case 30. In step 210, a first battery case component 33 is placed directly against a first plate 17 in a blow molding machine 10 having the first plate 17 and a second plate 18 opposite the first plate 18, the first and second plates 17, 18 being spaced apart from each other in an open arrangement 23. In step 220, a preform 90 is suspended between the first battery case component 33 and the second plate 18. In step 230, at least one of the first and second plates 17, 18 is moved toward the other of the first and second plates 17, 18 such that the first and second plates 17, 18 are arranged in a closed arrangement 24.In step 240, a gas 26 is injected into the preform 90 to expand the preform 90 to contact the first battery housing component 33 and the second plate 18, thereby forming a component / preform assembly 98. In step 250, at least one of the first and second plates 17, 18 is moved away from the other of the first and second plates 17, 18. In step 260, the component / preform assembly 98 is removed from between the first and second plates 17, 18.

[0053] In this method 200, the preform 90 may have a first preform side 94 and a second preform side 95, and in the hanging step 220, the preform 90 may be suspended between the first battery case component 33 and the second plate 18 with the first preform side 94 facing the first battery case component 33 and the second preform side 95 facing the second plate 18. The component / preform assembly 98 may include the preform 90 attached to the first battery case component 33 via the first preform side 94. Further, in the injection step 240, the expansion of the preform 90 in contact with the first battery case component 33 may cause the first preform side 94 to adhere to the first battery case component 33.

[0054] The method 200 may further comprise, in step 215, positioning a second battery housing component 34 directly against the second plate 18, wherein the first and second plates 17, 18 are arranged separately from each other in the open arrangement 23. The second battery housing component 34 may have a second bottom surface 62 and a second top surface 63, and in the positioning step 215, the second battery housing component 34 may be positioned such that the second bottom surface 62 faces the second plate 18 and the second top surface 63 faces the first plate 17.

[0055] The component / preform assembly 98 may include a circumferential seam 96 along which the first and second preform sides 94, 95 are secured together, thereby enclosing and defining an internal cavity 91 within the preform 90 and the component / preform assembly 98. The method 200 may further include, at step 270, cutting the component / preform assembly 98 along the circumferential seam 96 to separate the preform 90 into a first preform portion 92 and a second preform portion 93, thereby subdividing the component / preform assembly 98 into a first battery case assembly 31 in which the first battery case component 33 is adhered to the first preform portion 92, and a second battery case assembly 32 in which the second battery case component 34 is adhered to the second preform portion 93.The method 200 may further comprise, in step 280, joining the first and second battery housing assemblies 31, 32 to form the battery housing 30.

[0056] Fig.14 shows a flow diagram of the steps for a unclaimed method 300 of blow molding in a blow molding machine 10 having opposing first and second platens 17, 18. In step 310, a generally flat battery tray (i.e., either a battery case top cover 68 or a battery case bottom tray 72) is placed directly against the first platen 17, with the first and second plates 17, 18 separated in an open arrangement 23 and with a blow mold half 21, 22 (i.e., a first or second mold half 21, 22) not supported by the first platen 17. In step 320, a preform 90 is suspended between the battery tray 68, 72 and the second platen 18. In step 330, at least one of the first and second plates 17, 18 is moved toward the other of the first and second plates 17, 18 such that the first and second plates 17, 18 are arranged in a closed arrangement 24.In step 340, a gas 26 is injected into the preform 90 to expand the preform 90 to contact the battery tray 68, 72 and the second plate 18, thereby forming a battery compartment / preform assembly 99. In step 350, at least one of the first and second plates 17, 18 is moved away from the other of the first and second plates 17, 18. And in step 360, the battery compartment / preform assembly 99 is removed from between the first and second plates 17, 18.

[0057] The battery compartment / preform assembly 99 may include a circumferential seam 96 along which the first and second preform sides 94, 95 are secured together, thereby enclosing and defining an internal cavity 91 within the preform 90 and the battery compartment / pre-container assembly 99. The method 300 may further include, in step 370, cutting the battery compartment / preform assembly 99 along the circumferential seam 96 to separate the preform 90 into a first preform portion 92 and a second preform portion 93, thereby subdividing the battery compartment / preform assembly 99 into a first battery housing assembly 31 in which the first battery housing component 33 is bonded to the first preform portion 92, and a second battery housing assembly 32 in which the second battery housing component 34 is bonded to the second preform portion 93.The method 300 may further comprise, in step 380, joining the first and second battery housing assemblies 31, 32 to form the battery housing 30.

[0058] The blow-molded article of manufacture 30 can be used for a variety of different purposes, including, but not limited to, various applications in motor vehicles. For example, the article 30 can be used as a housing or container for one or more battery cells 27 or fuel cells in a hybrid or non-hybrid vehicle, including an electric vehicle. The article 30 can also be used to house or contain other items, components, or subsystems, such as electrical fuse blocks, intake air filtration systems, cabin air filtration systems, etc.

[0059] While various steps of the methods 100, 200, 300 have been described as separate blocks and various parts of the blow-molded article of manufacture 30 as separate elements, it should be noted that two or more steps may be combined into fewer blocks, and two or more parts may be combined into fewer elements. Likewise, some steps described as a single block may be divided into two or more blocks, and some parts described as a single element may be divided into two or more elements. Furthermore, the order of the steps or blocks described herein may be rearranged in one or more different orders, and the arrangement of the parts and elements may be rearranged in one or more different arrangements.

Claims

[1] A method for producing a battery case (30), the method comprising: Arranging (110) a first battery housing component (33) and a second battery housing component (34) directly against a first plate (17) and a second plate (18) respectively in a blow molding machine (10), wherein the first plate (17) and the second plate (18) are arranged in an open arrangement separated from one another; Suspending (120) a preform (90) of polymer material between the first battery housing component (33) and the second battery housing component (34); Moving (130) at least one of the first plate (17) or the second plate (18) towards the other of the first plate (17) or the second plate (18) such that the first plate (17) and the second plate (18) are arranged in a closed arrangement; Injecting (140) a gas into the preform (90) to expand the preform (90) into contact with the first battery case component (33) and the second battery case component (34), thereby forming a component / preform / component assembly (97); Moving (150) at least one of the first plate (17) and the second plate (18) away from the other of the first plate (17) and the second plate (18), respectively; and Removing (160) the component / preform / component assembly (97) between the first plate (17) and the second plate (18). [2] The method of claim 1, wherein the component / preform / component assembly (97) includes a circumferential seam (96) along which a first preform side (94) and a second preform side (95) are secured together, thereby enclosing and defining an internal cavity (91) within the component / preform / component assembly (97), the method further comprising: Cutting the component / preform / component assembly (97) along the circumferential seam (96) to separate the preform (90) into a first preform part (92) and a second preform part (93) and thereby subdividing the component / preform / component assembly (97) into: a first battery housing assembly (31) in which the first battery housing component (33) is bonded to the first preform part (92); and a second battery housing assembly (32) in which the second battery housing component (34) is bonded to the second preform part (93). [3] The method of claim 2, further comprising assembling the first battery case assembly (31) and the second battery case assembly (32) to form the battery case (30). [4] The method according to claim 1, wherein at least one of the first battery housing component (34) and the second battery housing component (34) is designed as a five-sided open lid or as a four-walled sleeve.

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