Battery frame for an electric vehicle and manufacturing method thereof

Abstract

A battery frame for a vehicle has a plurality of frame sections 305 forming an outer perimeter (201, Figure 2) of the battery frame, wherein an end portion 307a of a first frame section 305a is connec

Description

TECHNICAL FIELD The present disclosure relates to a battery frame for an electric vehicle and a manufacturing method thereof. Aspects of the invention relate to a method for manufacturing a battery frame, a battery frame, a battery assembly comprising a battery frame, and a vehicle comprising a battery frame or a battery assembly. BACKGROUND A battery for an electric vehicle is typically supported in a battery frame structure provided in the vehicle. It is known to provide a battery frame comprising a plurality of frame sections forming an outer perimeter of the battery frame and a number of crossmember rails. The frame sections are typically joined by welding. During manufacture, the heated material around the weld pool tends to deform, increasing manufacturing difficulty. If a weld fails during use of the vehicle then the structural integrity of the battery frame is compromised. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a method for manufacturing a battery frame, a battery frame, a battery assembly comprising a battery frame, and a vehicle comprising a battery frame or battery assembly as claimed in the appended claims. According to an aspect of the present invention there is provided a method for manufacturing a battery frame for a vehicle, the battery frame comprising a plurality of frame sections, the method comprising: connecting a first frame section to a second frame section by mating one or more connection support members provided on the first frame section with the second frame section for supporting the connection between the first and second frame sections; and welding the first frame section to the second frame section. Accordingly, during the manufacturing process, the physical structure of the battery frame sections are supported against sagging caused by heating during welding by the connection support member(s). According to an aspect of the present invention there is provided a method for manufacturing a battery frame fora vehicle, the battery frame comprising a plurality of frame sections forming an outer perimeter of the battery frame, the method comprising: connecting a first frame section to a second frame section by mating one or more protruding connection support members provided at an end portion of the first frame section with an adjoining end portion of the second frame section for supporting the connection between the first and second frame sections; and welding the end portion of the first frame section to the adjoining end portion of the second frame section. Accordingly, during the manufacturing process, the physical structure of the battery frame sections are supported against sagging caused by heating during welding. According to another aspect of the invention, there is provided a battery frame for a vehicle, the battery frame comprising a plurality of frame sections, wherein the first frame section is connected to a second frame section by welding, and wherein the first frame section comprises one or more connection support members configured to mate with the second frame section for supporting the connection between the first and second frame sections. Accordingly, if a weld weakens or fails, the structural integrity of the battery frame is maintained. According to another aspect of the invention, there is provided a battery frame for a vehicle, the battery frame comprising a plurality of frame sections forming an outer perimeter of the battery frame, wherein an end portion of a first frame section is connected to an adjoining end portion of a second frame section by welding, and wherein the end portion of the first frame section comprises one or more protruding connection support members configured to mate with the adjoining end portion of the second frame section for supporting the connection between the first and second frame sections. Accordingly, if a weld fails during use, the structural integrity of the battery frame is maintained. According to another aspect of the invention, there is provided a battery assembly comprising: a battery frame according to the preceding aspect; and one or more battery cells. Accordingly, if a weld fails during use, the battery cells are held in place due to the structural integrity of the battery frame being maintained. According to another aspect of the invention, there is provided a vehicle comprising a battery frame, or a battery assembly, according to the above aspects. Accordingly, the vehicle can continue to operate if a weld fails due to the structural integrity of the battery frame being maintained. In an embodiment, the method for manufacturing may further comprise: forming a first part of the battery frame comprising a first side wall and first and second side wall connector members; forming a second part of the battery frame comprising second, third and fourth side walls and third and fourth side wall connector members; and joining the first and second parts of the battery frame. Accordingly, by manufacturing the frame in two parts the assembly of the overall battery frame is facilitated. In an embodiment, one of the first and second frame sections may comprise a first side wall of the battery frame, and the other one of the first and second frame sections may comprise a side wall connector member of the battery frame connected between the first side wall and a second side wall. Accordingly, providing frame sections in the forms of side walls and side wall connector members allows greater flexibility in the battery frame design. In an embodiment, the side wall connector member may be configured to form a corner portion of the battery frame. Accordingly, the side walls may be formed as relatively flat components, with the side wall connector members accommodating bends at the corners of the battery frame. In an embodiment, the one or more connection support members may comprise one or more of: a collar; a flange; a rim; a lip; a pin; a tongue member; a rib; a plug; a clip; and a fastener. Accordingly, the form of the connection support members provide greater support of the connection between frame sections. In an embodiment, one or more of the one or more connection support members may have a tapered shape. Accordingly, mating of the connection support members with an adjoining end portion of a frame section is facilitated. In an embodiment, the one or more connection support members may be arranged around a periphery of the end portion of the first frame section. Accordingly, the frame section provided with the connection support members does not require internal material for attaching the connection support members, minimising overall weight. In an embodiment, the one or more connection support members may be configured to protrude inside the adjoining end portion of the second frame section. Accordingly, a more robust and direct connection between frame sections is achieved. In an embodiment, one or more of the one or more connection support members may be configured to abut one or more inner surfaces of the end portion of the second frame section. Accordingly, the physical structure of the battery frame sections are supported against sagging caused by heat. In an embodiment, one or more of the one or more connection support members may be configured to mate with one or more corresponding recesses, grooves, openings and / or sockets provided in the adjoining end portion of a second frame section. Accordingly, a more secure connection between frame sections is achieved. In an embodiment, the adjoining end portion of the second frame section may comprise one or more protruding connection support members configured to mate with the end portion of the first frame section for supporting the connection between the first and second frame sections. Accordingly, by providing connection support members at both sides of a connection between frame sections the connection is more robust. In an embodiment, each frame section may be connected to adjacent frame sections by a weld and one or more connection support members. According, by connecting all frame sections with both welds and connection support members, the overall structural robustness of the battery frame is improved. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in anyway and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a battery frame for a vehicle in accordance with embodiments of the invention; Figure 2 shows an outer perimeter of the battery frame of Figure 1; Figure 3 shows a structure for supporting a connection between a first frame section and an adjoining second frame section of the battery fame of Figure 1; Figure 4 shows a flow chart of a method for manufacturing a battery frame in accordance with embodiments of the invention; Figure 5 shows a flow chart of another method for manufacturing a battery frame in accordance with embodiments of the invention; and Figure 6 shows a vehicle in accordance with embodiments of the invention. DETAILED DESCRIPTION Figure 1 shows a battery frame for a vehicle in accordance with an embodiment of the invention. The battery frame 100 comprises an outer perimeter 101 and a number of crossmember rails 103 connected at each of their ends to the outer perimeter 101. The crossmember rails 103 are configured to support one or more battery cells (not shown). The battery frame 100 and one or more battery cells together form a battery assembly. Figure 2 shows the outer perimeter 101 of the battery frame 100 of Figure 1, referred to in Figure 2 using numeral 201. The outer perimeter 201 comprises a plurality of frame sections (or segments) 205a-205h. In the example shown in Figure 2 eight frame sections 205 are provided. However, more or fewer frame sections 205 may be provided in other embodiments. Some of the frame sections 205 (for example frame sections 205a, 205c, 205e and 205g) are provided in the form of side walls of the battery frame 201, while other frame sections 205 (for example frame sections 205b, 205d, 205f, and 205h) are provided in the form of side wall connector members that are configured to connect the side walls together. The frame sections 205 may be provided in any suitable form(s). In some embodiments, such as the embodiment shown in Figure 2, the frame sections 205 may be provided with different forms having different structural functions, for example side walls and side wall connectors. In other embodiments, all frame sections 205 may each be provided in a form having the same structural function, for example side walls. In the latter case, the side walls may be connected together directly without using side wall connector members. In the structure shown in Figure 2, the side wall connector members 205b, 205d, 205f, 205h form corner portions of the outer perimeter 201 of the battery frame. However, a side wall connector member may be provided at any suitable location. For example, an overall side wall may be formed from two or more separate sub-side walls, and one or more side wall connector members may be used to connect the sub-side walls together. The frame sections 205 are connected together by welds. For example, an end portion of a first frame section (for example, frame section 205a) is connected to an adjoining end portion of a second frame section (for example, frame section 205b) by welding. As will be discussed in more detail below, the frame sections 205 comprise a structure for supporting the connections between the frame sections 205. Figure 3 shows a structure for supporting a connection between a first frame section 305a (for example corresponding to frame section 205a shown in Figure 2) and an adjoining second frame section 305b (for example corresponding to frame section 205b shown in Figure 2) of the outer perimeter 201 of the battery frame 100 shown in Figures 1 and 2. In the embodiments shown in Figures 1 and 2, all of the connections between the frame sections 205 are supported with a supporting structure, for example as shown in Figure 3. However, in other embodiments only some of the connections between frame sections 205 are supported with a supporting structure. Referring to Figure 3, an end portion 307a of the first frame section 305a is configured to connect with the adjoining end portion 307b of the second frame section 305b. In order to clearly show the supporting structure, Figure 3 shows the first and second frame sections 305a, 305b in an unconnected state. However, when the battery frame 100 is fully assembled, the ends 307a, 307b of the first and second frame sections 305a, 305b abut each other and are further joined by a weld. As shown in Figure 3, the end portion 307a of the first frame section 305a comprises one or more protruding connection support members 309 configured to mate with the adjoining end portion 307b of the second frame section 305b for supporting the connection between the first 305a and second 305b frame sections. The connection support members 309 may comprise any suitable type of structure, for example one or more of a collar, a flange, a rim, a lip, a pin, a tongue member, a rib, a plug, a clip, and a fastener. One or more of the connection support members 309 may have a tapered shape. The connection support members 309 may be arranged around a periphery of the end portion 307a of the first frame section 305a. Any suitable number of connection support members 309 may be provided. Furthermore, the connection support members 309 may be provided at any suitable location(s) on the first frame section 305a. In some embodiments, one or more relatively discrete connection support members 309 and / or one or more relatively continuous or elongate connection support members 309 may be provided, for example around a part (for example upper and lower sides) or all of the periphery of the end portion 307a of the first frame section 305a. The connection support members 309 may be configured to protrude inside the adjoining end portion 307b of the second frame section 305b. For example, one or more of the connection support members 309 may be configured to mate with one or more corresponding recesses, grooves, openings and / or sockets 311 b provided in the adjoining end portion 307b of a second frame section 305b. This arrangement helps to support the connection between the first 305a and second 305b frame sections, particularly in case of failure of the weld joining the first 305a and second 305b frame sections, in which case the connection support members 309 help to maintain structural integrity of the frame 100. One or more of the connection support members 309 may be configured to abut one or more inner surfaces of the end portion 307a of the first frame section 305a. This arrangement helps to support the structural integrity of the frame sections 305b during the welding process at the time of manufacture. In the embodiment shown in Figure 3, with respect to the connection between the first frame section 305a and the second frame section 305b, the first frame section 305a comprises connection support members 309b, but the adjoining end portion 307b of the second frame section 305b does not comprise any connection support members. In other embodiments, the adjoining end portion 307b of the second frame section 305b may also comprise one or more protruding connection support members 309b configured to mate with the adjoining end portion 307a of the first frame section 305a for supporting the connection between the first 305a and second 305b frame sections. With this arrangement, the connection between the first 305a and second 305b frame sections may be more robustly supported by means of connection support members 309, 309b on both sides of the connection. In the embodiment shown in Figure 3, each frame section 305 is connected to adjacent frame sections 305 by both a weld and connection support members as described above. Accordingly, the connection support members 309 provide structural support, in addition to the welds, for each connection between frame sections 305. Furthermore, if a weld fails for any reason then the connection support members 309 help to maintain some structural support for the corresponding connection, thereby helping to maintain the overall structural integrity of the outer perimeter 201 of the frame 100, and hence the frame 100 itself. Figure 4 shows a flow chart of a method for manufacturing a battery frame in accordance with an embodiment of the invention. For example, the battery frame may comprise a battery frame 100 as shown in Figure 1. The battery frame 100 comprises a plurality of frame sections 205, 305 forming an outer perimeter 201 of the battery frame 100 as shown in Figures 2 and 3. The method shown in Figure 4 relates to forming a connection between a first frame section (for example frame section 205a, 305a) and a second frame section (for example frame section 205b, 305b). The method of Figure 4 may be repeated to connect other pairs of frame sections 205, 305. Referring to Figure 4, in a first step 401, the first frame section 205a, 305a is connected to the second frame section 205b, 305b. An end portion 307a of the first frame section 205a, 305a comprises one or more protruding connection support members 309 configured to mate with an adjoining end portion 307b of the second frame section 205b, 305b for supporting the connection between the first 205a, 305a and second 205b, 305b frame sections. In step 401, the connection is made by mating the protruding connection support members 309 with the adjoining end portion 307b of the second frame section 205b, 305b. In a second step 402, the end portion 307a of the first frame section 205a, 305a is welded to the adjoining end portion 307b of the second frame section 205b, 305b. Figure 5 shows a flow chart of another method for manufacturing a battery frame in accordance with an embodiment of the invention. The method shown in Figure 5 relates to forming an entire outer perimeter 101 of the battery frame 100. Referring to Figure 5, in a first step 501, a first part of the battery frame 100 is formed. For example, the first part may comprise a first side wall 205a, and first 205b and second 205h side wall connector members. The first part is formed by connecting the first side wall 205a, and the first 205b and second 205h side wall connector members, for example according to the method shown in Figure 4. In a second step 502, a second part of the battery frame 100 is formed. For example, the second part may comprise second 205c, third 205e and fourth 205g side walls, and third 205d and fourth 205f side wall connector members. The second part is formed by connecting the second 205c, third 205e and fourth 205g side walls, and the third 205d and fourth 205f side wall connector members, for example according to the method shown in Figure 4. In a third step 503, the first and second parts of the battery frame 100 are joined. For example, the first 205b and second 205h side wall connector members of the first part may be connected to the second 205c and fourth 205g side walls, respectively, for example according to the method shown in Figure 4. Figure 6 shows a vehicle in accordance with an embodiment of the invention. The vehicle 600 comprises a battery frame, for example the battery frame 100 shown in Figure 1. The battery frame comprises an outer perimeter, for example the outer perimeter 201 shown in Figure 2. The outer perimeter 201 comprises a plurality of frame sections 205 joined together by means of welds and connection support members 209, for 5 example as shown in Figure 3. The battery frame 100 has been manufactured according to methods as shown in Figures 4 and 5. The vehicle 600 also comprises a number of battery cells supported by the battery frame 100. The battery frame 100 and battery cells together form a battery assembly of the vehicle 600. It will be appreciated that various changes and modifications can be made to the present invention without 10 departing from the scope of the present application.

Claims

1. A method for manufacturing a battery frame for a vehicle, the battery frame comprising a plurality of frame sections forming an outer perimeter of the battery frame, the method comprising:connecting a first frame section to a second frame section by mating one or more protruding connection support members provided at an end portion of the first frame section with an adjoining end portion of the second frame section for supporting the connection between the first and second frame sections; andwelding the end portion of the first frame section to the adjoining end portion of the second frame section.

2. A method according to claim 1, further comprising:forming a first part of the battery frame comprising a first side wall and first and second side wall connector members;forming a second part of the battery frame comprising second, third and fourth side walls and third and fourth side wall connector members; andjoining the first and second parts of the battery frame.

3. A battery frame for a vehicle, the battery frame comprising a plurality of frame sections forming an outer perimeter of the battery frame,wherein an end portion of a first frame section is connected to an adjoining end portion of a second frame section by welding, andwherein the end portion of the first frame section comprises one or more protruding connection support members configured to mate with the adjoining end portion of the second frame section for supporting the connection between the first and second frame sections.

4. A battery frame according to claim 3,wherein one of the first and second frame sections comprises a first side wall of the battery frame, and wherein the other one of the first and second frame sections comprises a side wall connector member of the battery frame connected between the first side wall and a second side wall.

5. A battery frame according to claim 4, wherein the side wall connector member is configured to form a corner portion of the battery frame.

6. A battery frame according to claim 3, 4 or 5, wherein the one or more connection support members comprise one or more of:a collar;a flange;a rim;a lip;a pin;a tongue member;a rib;a plug;a clip; and a fastener.

7. A battery frame according to any of claims 3 to 6, wherein one or more of the connection support members has a tapered shape.

8. A battery frame according to any of claims 3 to 7, wherein the one or more connection support members are arranged around a periphery of the end portion of the first frame section.

9. A battery frame according to any of claims 3 to 8, wherein the one or more connection support members are configured to protrude inside the adjoining end portion of the second frame section.

10. A battery frame according to any of claims 3 to 9, wherein one or more of the connection support members are configured to abut one or more inner surfaces of the end portion of the second frame section.

11. A battery frame according to any of claims 3 to 10, wherein one or more of the connection support members are configured to mate with one or more corresponding recesses, grooves, openings and / or sockets provided in the adjoining end portion of a second frame section.

12. A battery frame according to any of claims 3 to 11, wherein the adjoining end portion of the second frame section comprises one or more protruding connection support members configured to mate with the end portion of the first frame section for supporting the connection between the first and second frame sections.

13. A battery frame according to any of claims 3 to 12, wherein each frame section is connected to adjacent frame sections by a weld and one or more connection support members.

14. A battery assembly comprising:a battery frame according to any of claims 3 to 13; and one or more battery cells.

15. A vehicle comprising a battery frame according to any of claims 3 to 13, or a battery assembly according to claim 14.

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