System and method for making a battery tray assembly

Abstract

A method for making a tray assembly includes providing a first component and a second component. The second component has a lower portion and an upper portion spaced from the first component. A top surface of the lower portion is positioned below a top surface of the first component. A top surface of the upper portion is substantially coplanar with the top surface of the first component such that a gap is defined along the lower portion of the second component. The method also includes filling the gap with an adhesive, and compressing a pad toward the adhesive such that the adhesive becomes substantially coplanar with the top surface of the first component and the upper portion of the second component.

Description

SYSTEM AND METHOD FOR MAKING A BATTERY TRAY ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of, and priority to U.S. Provisional Patent Application Serial No. 63 / 603,893 filed on November 29, 2023, and titled “Battery Tray Assembly And Method For Making A Battery Tray Assembly,” the entire disclosure of which is hereby incorporated by reference.BACKGROUND OF THE DISCLOSURE1. Field of the Disclosure

[0002] The present disclosure relates to battery trays for holding and protecting batteries of electric vehicles.2. Related Art

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] It is known for electric vehicles to include tray assemblies for holding and protecting batteries. Tray assemblies typically have a flat base surrounded by upwardly projecting walls and rounded corner segments. It is known to fdl and seal a gap between upper flanges of the walls and corner segments via an adhesive by way of a manual skiving process. More particularly, the manual skiving process typically entails positioning the adhesive in the gap, then applying pressure to the adhesive in a sweeping motion with a tongue depressor, or similar tool to fill the gap. Edges of the adhesive are then feathered with the tongue depressor to provide a smooth transition to the metal surfaces on sides of the gap.

[0005] Issues with such adhesive connections include a lack of material flushness, sagging of the adhesive, leaking through the gap, and complexities for operators to perform themanual skiving operation. Accordingly, there remains a need for improvements to tray assemblies and methods for making the same.SUMMARY OF THE DISCLOSURE

[0006] A method for making a tray assembly includes providing a first component and a second component. The first component is positioned adjacent to the second component. The second component has a lower portion positioned adjacent to the first component and an upper portion spaced from the first component. A top surface of the lower portion is positioned below a top surface of the first component. A top surface of the upper portion is substantially coplanar with the top surface of the first component such that a gap is defined along the lower portion of the second component beneath the top surfaces of the first component and the upper portion of the second component. The method also includes filling the gap with an adhesive. The method also includes compressing a pad toward the adhesive such that the adhesive becomes substantially planar with the top surfaces of the first component and the upper portion of the second component.

[0007] A system for forming a tray assembly for holding batteries for a vehicle. The system includes a first component and a second component positioned adjacent to the second component. The second component has a lower portion positioned adjacent to the first component and an upper portion spaced from the first component. A top surface of the lower portion is positioned below a top surface of the first component. A top surface of the upper portion is substantially coplanar with the top surface of the first component such that a gap is defined along the lower portion of the second component beneath the top surfaces of the first component and the upper portion of the second component. An adhesive is located in the gap. A pad is configured to be compressed toward the adhesive such that the adhesive becomessubstantially planar with the top surfaces of the first component and the upper portion of the second component.

[0008] According to the above, the resulting seal in the gap between battery tray components is smooth, leak tight, simple and inexpensive to make.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other advantages of the present disclosure will be more readily understood by reference to the following description in combination with the accompanying drawings wherein:

[0010] FIG. 1 is a perspective view of an embodiment of a battery tray assembly, according to an aspect of the disclosure;

[0011] FIG. 1A is a magnified view of a corner of the battery tray assembly of FIG. 1;

[0012] FIG. 2A is a side, cross-sectional view of a meeting of a first component and a second component of the battery tray assembly;

[0013] FIG. 2B is a side, cross-sectional view of a meeting of the first and second components of the battery tray assembly, and including an adhesive in a gap between the first and second components;

[0014] FIG. 3 is a perspective view of a clamping machine used for applying a pad against a fabric overlying an adhesive in the gap between the first and second components of the battery tray assembly;

[0015] FIG. 3A is a magnified view of the clamping machine of FIG. 3;

[0016] FIG. 4 is a schematic diagram of stations used for assembling a battery tray assembly, according to an aspect of the disclosure;

[0017] FIGS. 5A-5C are perspective views of steps of a method of sealing a gap between first and second components of a battery tray assembly, according to an aspect of the disclosure;

[0018] FIGS. 6A-6D are side, cross-sectional views illustrating steps of a method of sealing a gap between first and second components of a battery tray assembly, according to an aspect of the disclosure;

[0019] FIG. 6E is a front, cross-sectional view taken from 7E-7E of FIG. 6D;

[0020] FIG. 6F is a further side, cross-sectional view of another step of the method of sealing a gap of FIGS. 6A-6D;

[0021] FIG. 6G is a perspective view of another step of the method of sealing a gap of FIGS. 6A-6F; and

[0022] FIG. 7 is a flow diagram of a method for making a tray assembly, according to an aspect of the disclosure.DETAILED DESCRIPTION OF THE ENABLING EMBODIMENTS

[0023] Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject embodiments are directed to a system and method for making battery tray assemblies. However, the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0024] Referring to the figures, wherein like numerals indicate corresponding parts throughout the several views, embodiments of a tray assembly 20 for holding batteries, and systems and methods for making the tray assembly 20 are shown. According to the preferred embodiment, the tray assembly 20 is used for holding and protecting batteries in electric vehicles like automobiles, but could be used for holding batteries in other applications. Furthermore, the systems and methods could be used to form trays or similar structures used for other purposes.

[0025] With reference to FIGS. 1 and 1A, the tray assembly 20 includes a base 22 that is substantially planar and generally has a rectangular shape with four corners. A front wall 24 and a rear wall 26 each extend upwardly from opposing edges of the base 22 in spaced and parallel relationship with one another. A pair of side walls 28 extend upwardly from opposing edges of the base 22 in spaced and parallel relationship with one another. The side walls 28 span substantially an entire distance between the front and rear walls 24, 26. A flange 30A, 30B, 30C, 30D extends outwardly from a top of each of the front, rear and side walls 24, 26, 28. According to embodiments, the tray assembly 20 could have other shapes, e.g., an oval or circle.

[0026] Four corner segments 32 each extend upwardly from one of the corners of the base 22. The comer segments 32 each span a distance between one of the side walls 28 and one of the front and rear walls 24, 26. As best shown in FIGS. 1A, both ends of the flange 30A of each of the comer segments 32 may be positioned vertically beneath one of the flanges 30B, 30C of the front, rear and side walls 24, 26, 28. More particularly, FIGS. 2A and 2B illustrate a schematic example of a union between the flange 30A of one of the corner segments 32 and the flange 30D of one of the side wall segments 32. Although the flanges 30B, 30A of a front wallsegment 24 and a corner segment 32 are shown in these figures, the same teachings may be applied for the overlapping flanges 30 of any portions. Furthermore, the same teachings may be applied to other overlapping components. As will be discussed in further detail below, FIG. 2A presents a union between the two flanges 30B, 30C prior to execution of the subject method, and FIG. 2B illustrates the same union after the method has been carried out.

[0027] With reference to FIGS. 2A and 2B, the flange 30A of the comer segment 32 has a lower portion 38 positioned adjacent to the side wall 28, and an upper portion 40 that is laterally spaced from the side wall 28. A top surface of the lower portion 38 is positioned below a top surface of the side wall 28, and a top surface of the upper portion 40 is substantially coplanar with the top surface of the side wall 40. The flange 30A of the corner segment 32 slopes upwardly between the lower and upper portions 38, 40 along a ramp 44. A gap 42 is defined vertically above the lower portion 40 of the comer segment 32 and laterally between an edge of the side wall 28 and the ramp 44. FIG. 2B illustrates the flanges 30D, 30A after the subject method has been carried out. At this point, the gap 42 is filled with an adhesive 46, and a top surface of the adhesive 46 is substantially flush with tops of the flanges 30D, 30A.

[0028] FIG. 7 schematically presents a method 200 of making a battery tray assembly 20 according to embodiments. Furthermore, FIG. 4 presents a schematic diagram of work stations 203, 205, 207, 217 that may be used in association with the subject method. As shown in FIG. 6A, the method includes 202 assembling a tray 20 into an initial position in which a first component 30D (e.g., a front, rear or side wall 24, 26, 28) is positioned adjacent to a second component 32 (e.g., a comer segment 32) as described above. Once the tray assembly 20 is in the initial position, the method may include the step of 204 electro coating (E-coating) the tray assembly 20 at an e-coating station 203 (shown in step 1 of FIG. 4), which may serve as aprotective coating. As shown in step 2 of FIG. 4, the method continues with 206 removing the tray assembly 20 from the e-coating station 203 and moving it to an adhesive application station205.

[0029] As shown in FIG. 5A and 6B, the method continues with 208 fdling the gap 42 with an adhesive 46 at the adhesive application station 205. As shown in step 3 of FIG.4, the method continues with moving the tray assembly 20 to a flattening station 207. As shown in FIGS. 5B and 6C, the method continues with 212 positioning a fdm 48 over the top surfaces of the first component 28, the adhesive 46 and the top surface of the upper portion 40 of the second component 32. According to the preferred embodiment, the film 48 is polytetrafluoroethylene (PTFE) coated fiberglass, but other types of films fall within the scope of the present disclosure.

[0030] As shown in FIGS. 5C and 6D, the method continues with 214 compressing the film 48 downwardly against the adhesive 46 and top surfaces of the first component 28 and upper portion 40 of the second component 32 with a pad 50 that has a planar bottom surface such that a top of the adhesive 46 is substantially flush with the top surfaces of the side wall 28 and the upper portion 40 of the corner segment 32 to fill the gap 42 and secure the side wall 28 and corner segment 32 (e.g., FIGS. 5C and 6D). According to the preferred embodiment, the pad 50 is a 70A durometer pad, but other types of pads fall within the scope of the present disclosure. As shown in FIGS. 2A and 3C, a clamping machine 52 like a robotic arm may be configured to position and press the pad 50 against the film 48 and remove the pad 50.

[0031] As shown in FIG. 6F, the method continues with 216 moving the tray assembly 20 to a final station 217, and 218 removing the pad 50 from the film 48 and curing the adhesive 46. As shown in FIG. 6G, the method continues with 220 removing the film 48. Once the film 48 is removed, a substantially planar and continuous top surface is provided along the firstcomponent 28, the adhesive 46 and the second component 32 with the first and second components 28, 32 securely connected to one another. This method may be used simultaneously, or separately, at any number of comers or other features on the battery tray assembly 20.

[0032] According to the above, the subject system and method provide a seal between battery tray 20 components that is smooth and leak tight, and simple and inexpensive to make. The subject system allows the adhesive 46 to cure to a desired profile, prevents adhesive sag, and the film 48 can cleanly and easily be removed once the adhesive 46 is cured. Furthermore, the entire process may be fully or partially automated, including using the clamping machine 52 to automatically press the pad 50 against the film 48.

[0033] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in that particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0034] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or later, or intervening element or layers may be present. Incontrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0035] Although the terms first, second, third, etc. may be used herein to described various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0036] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0037] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in any embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

CLAIMSWhat is claimed is:

1. A method for making a tray assembly, comprising: providing a first component and a second component, with the first component positioned adjacent to the second component, wherein the second component has a lower portion positioned adjacent to the first component and an upper portion spaced from the first component, wherein a top surface of the lower portion is positioned below a top surface of the first component, and wherein a top surface of the upper portion is substantially coplanar with the top surface of the first component such that a gap is defined along the lower portion of the second component beneath the top surfaces of the first component and the upper portion of the second component; filling the gap with an adhesive; and compressing a pad toward the adhesive such that the adhesive becomes substantially planar with the top surfaces of the first component and the upper portion of the second component.

2. The method as set forth in claim 1, further including positioning a film over the top surface of the first component, the adhesive and the top surface of the upper portion of the second component prior to compressing the pad against the adhesive, such that the pad is compressed against the film to flatten the adhesive.

3. The method as set forth in claim 2, further including removing the film after compressing the pad against the film.

4. The method as set forth in claim 2, wherein the film is a polytetrafluoroethylene coated fiberglass.

5. The method as set forth in claim 1, wherein the battery tray assembly includes a plurality of walls, and a plurality of corner segments each positioned between two of the walls, and wherein the first component is a flange located at a top of one of the walls, and wherein the second component is a flange located at a top of one of the corner segments.

6. The method as set forth in claim 5, wherein the tray assembly further includes a base along a plane in a horizontal direction, wherein each of the walls and corner segments extend in a vertical direction being generally perpendicular to the base, and wherein the flanges of the walls and comer segments extend substantially parallel to the base.

7. The method as set forth in claim 6, wherein the walls are comprised of a front wall, a rear wall parallel to the front wall, and a pair of side walls extending between the front and side walls to constitute a square or rectangular shape, and wherein the corner segments are each located between two of the walls.

8. The method as set forth in claim 1, wherein the second component is sloped between the lower portion and the upper portion.

9. The method as set forth in claim 1, wherein the pad is a 70A durometer pad.

10. A system for forming a tray assembly for holding batteries for a vehicle, comprising: a first component and a second component positioned adjacent to the second component; the second component having a lower portion positioned adjacent to the first component and an upper portion spaced from the first component, wherein a top surface of the lower portion is positioned below a top surface of the first component, and wherein a top surface of the upper portion is substantially coplanar with the top surface of the first component such that a gap is defined along the lower portion of the second component beneath the top surfaces of the first component and the upper portion of the second component; an adhesive located in the gap; and a pad configured to be compressed toward the adhesive such that the adhesive becomes substantially planar with the top surfaces of the first component and the upper portion of the second component.

11. The system as set forth in claim 10, further including a film positioned over the top surface of the first component, the adhesive and the top surface of the upper portion of the second component for being compressed by the pad against the adhesive to flatten the adhesive12. The system as set forth in claim 10, further including a plurality of walls, and a plurality of comer segments each positioned between two of the walls, wherein the first component is a flange located at a top of one of the walls, and wherein the second component is a flange located at a top of one of the comer segments.

13. The system as set forth in claim 12, further including a base along a plane in a horizontal direction, wherein each of the walls and comer segments extend in a vertical direction being generally perpendicular to the base, and wherein the flanges of the walls and comer segments extend substantially parallel to the base.

14. The system as set forth in claim 13, wherein the walls are comprised of a front wall, a rear wall parallel to the front wall, and a pair of side walls extending between the front and side walls to constitute a square or rectangular shape, and wherein the corner segments are each located between two of the walls.

15. The system as set forth in claim 10, wherein the film is a polytetrafluoroethylene coated fiberglass.

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