Battery enclosure and associated means of manufacture

Abstract

A battery enclosure includes a roll-formed tub sidewall and a tub bottom joined to the roll-formed tub sidewall. The roll-formed tub sidewall may form a closed perimeter of the battery enclosure and include a single joint. A sealed joint such as a double seam may join the tub bottom to the roll-formed tub sidewall. A method of forming a battery enclosure includes roll-forming a metal strip, forming the roll-formed metal strip into a halo with a closed perimeter by joining opposing ends of the roll-formed metal strip, and mating a tub bottom with the halo.

Description

BATTERY ENCLOSURE AND ASSOCIATED MEANS OF MANUFACTUREREFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 618,645, filed on January 8, 2024, and entitled BATTERY ENCLOSURE AND ASSOCIATED MEANS OF MANUFACTURE, the content of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] This application generally relates to battery enclosures, and, more particularly, to battery enclosures for a vehicle and associated methods of manufacturing such battery enclosures.BACKGROUND

[0003] Electric vehicles generally include a high voltage battery pack, an electric motor, and a drive train supported on a frame. The battery pack must be protected from damage during events such as severe crashes, and accordingly is often stored in a battery enclosure. Traditionally, battery enclosures include a floor, a frame, and a cover for surrounding and enclosing the electric battery. Such traditional enclosures have been constructed from composites, plastics, or metals, but such enclosures generally lack the stiffness to be a structural component of the vehicle. Traditional enclosures may utilize either a deep drawn tub or a plurality of extruded components and plates with fully welded joints. Deep draw tubs require deep stamping operations and have limited ability to control the geometry actually needed for the battery enclosure. As an example, deep draw tubs limit the ability to have zero draft tub sidewalls and small radius comers, especially in metals such as aluminum or aluminum alloys. Solutions with welded joints are limited because battery enclosures require hermetic sealing, but the plurality of joints may be locations of ingress / egress of fluids, locations of delamination or other mechanical failure, and / or may prevent the enclosure from being sealed, among other issues. Moreover, the extent of welding required is expensive, such traditional welding requires extensive quality checks (and often requires reworking), and such traditional welding often distorts the end product due to the heat added.SUMMARY

[0004] The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0005] According to various examples, a battery enclosure includes a roll-formed tub sidewall and a tub bottom. The roll-formed tub sidewall forms a closed perimeter of the battery enclosure and includes a single joint in the roll-formed tub sidewall. The tub bottom is joined to the roll-formed tub sidewall. In certain embodiments, a sealed joint may join the tub bottom to the roll-formed tub sidewall.

[0006] According to some embodiments, a battery enclosure includes a metal tub sidewall forming a closed perimeter of the battery enclosure. In various embodiments, the tub sidewall includes a single joint such that the tub sidewall forms the closed perimeter. The battery enclosure additionally includes a tub bottom joined to the tub sidewall with a sealed joint. The tub sidewall and the tub bottom together define a receiving area for at least one battery.

[0007] According to certain embodiments, a method of forming a battery enclosure includes roll-forming a metal strip and forming the roll-formed metal strip into a halo with a closed perimeter by joining opposing ends of the roll -formed metal strip. The method includes mating a tub bottom with the halo such that the halo forms a tub sidewall of the battery enclosure and the tub sidewall and the tub bottom together define a receiving area for at least one battery.

[0008] Various implementations described in the present disclosure can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

[0010] FIG. 1 illustrates a battery enclosure system according to embodiments.

[0011] FIG. 2 illustrates a tub of a battery enclosure according to embodiments.

[0012] FIG. 3 illustrates a portion of the tub of FIG. 2.

[0013] FIG. 4 illustrates a portion of another tub of a battery enclosure according to embodiments.

[0014] FIG. 5 illustrates a battery enclosure system according to embodiments.

[0015] FIG. 6 illustrates a process for forming a battery enclosure according to embodiments.

[0016] FIG. 7 illustrates roll forming and halo forming steps of the process of FIG. 6.

[0017] FIG. 8 illustrates halo shaping and halo mating steps of the process of FIG. 6.DETAILED DESCRIPTION

[0018] Described herein are battery enclosures and associated methods of forming such battery enclosures. While the disclosure makes reference to battery enclosures for housing one or more batteries, such as for an electric vehicle, the enclosures described herein may be utilized as other large size containers or tanks such as but not limited to marine gas tanks, environmentally sealed electrical enclosures, and / or other containers or tanks as desired. In certain embodiments, the enclosures described herein may be utilized as non-pressure vessel type tanks or containers. As such, reference to a “battery enclosure” or “battery enclosures” is intended to refer to all such enclosures unless expressly stated otherwise.

[0019] In certain embodiments, the battery enclosures described herein may include a tub with a roll-formed tub sidewall forming a closed perimeter and with a single joint in the tub sidewall. The tub of the battery enclosure further includes a tub bottom joined to the tub sidewall. In certain embodiments, a joint joining the tub bottom to the tub sidewall is a sealed joint. The sealed joint may be various types of sealed joints such as a hemmed or double-seam joint or a weld with a sealant. Compared to traditional approaches using deep drawn tubs or tubs with a plurality of extrusions and plates, the roll-formed tub sidewall may minimize the number of joints or welds needed to form the tub sidewall (e.g., a single joint may be utilized) while also allowing for an improved geometry of the tub sidewall. As an example, the roll-formed tubsidewall may allow for the tub to have zero draft tub sidewalls relative to the tub bottom and tub sidewalls with small radius comers. In certain embodiments, the sealed joint joining the tub bottom with the tub sidewall may allow for hermetic sealing while maintaining a desired end shape of the tub without requiring the cost, processing (and associated distortions in the end product), and labor traditionally required. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0020] FIG. 1 illustrates an example of a battery enclosure system 100 according to embodiments. The battery enclosure system 100 generally includes a battery enclosure 102, a support structure or frame 104, a base shield 106, and an optional base plate 108. One or more battery cells 110 may be provided within the battery enclosure 102.

[0021] As illustrated in FIG. 1, the battery enclosure 102 generally includes a tub 112 and a cover 114, and the tub 112 of the battery enclosure 102 includes a tub bottom 116 and a tub sidewall 118. The tub bottom 116 may be joined to a lower portion of the tub sidewall 118, and the cover 114 may be joined to the tub sidewall 118 opposite from the tub bottom 116. In certain embodiments, and as discussed in detail below, the cover 114 and the tub bottom 116 may be joined to the tub sidewall 118 such that a receiving area 120 of the battery enclosure 102 is hermetically sealed.

[0022] The battery enclosure 102 may be constructed from various materials as desired, and in certain embodiments, the battery enclosure 102 may be constructed from a metal such as aluminum or an aluminum alloy. In certain embodiments, the battery enclosure 102 may include aluminum alloys such as but not limited to a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, and / or a 7xxx series aluminum alloy. In certain embodiments, the cover 114, the tub bottom 116, and the tub sidewall 118 may be the same aluminum alloy, although they need not be in other embodiments.

[0023] Non-limiting exemplary 2xxx series aluminum alloys can include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111 A, AA211 IB, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060,AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, and AA2199.

[0024] Non-limiting exemplary 5xxx series aluminum alloys can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, and AA5088.

[0025] Non-limiting exemplary 6xxx series aluminum alloys can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, and AA6092.

[0026] Non-limiting exemplary 7xxx series aluminum alloys can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029,AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, and AA7099.

[0027] The cover 114, tub bottom 116, and tub sidewall 118 may have various thicknesses or gauges as desired, and the thicknesses may be the same or different as desired. In some nonlimiting examples, the components of the battery enclosure 102 may have a thickness from about 1 mm to about 4 mm, such as about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, about 3.6 mm, about 3.7 mm, about 3.8 mm, about 3.9 mm, and / or about 4.0 mm. In other embodiments, the battery enclosure 102 may have other thicknesses as desired.

[0028] The cover 114 generally includes a body portion 122 and an edge portion 124 and may be constructed or formed using various techniques as desired. In some embodiments, the cover 114 may be a monolithic or integrally formed component such as but not limited to an extrusion or a stamped sheet. In various embodiments, the cover 114 may be a separate flat plate, a drawn cover, and / or a stamped cover. In yet other embodiments, the cover 114 may have a construction similar to that of the tub bottom 116.

[0029] The tub bottom 116 of the tub 112 includes a body portion 126 and an edge portion 128 and may be constructed or formed using various techniques as desired. In some embodiments, the tub bottom 116 is a monolithic or integrally formed component. The tub bottom 116 may be formed using various techniques and such that the tub bottom 116 has a relatively flat profile. In non-limiting examples, the tub bottom 116 may be an extrusion or a stamped assembly, such as but not limited to a stamped sheet. Optionally, the tub bottom 116 may include one or more cooling features integrated into the tub bottom 116 to facilitate cooling of the one or more battery cells 110. Such cooling features may include channels, ridges, cells, corrugations, air gaps, combinations thereof, and / or other features as desired. Optionally, the cooling features may be used to circulate air, gas, cooling liquid, and / or other suitable coolants. As discussed in detail below, in certain embodiments, the tub bottom 116 may have a generally rectangular shape; however, in other embodiments, the tub bottom 116may have other shapes as desired, such as but not limited to trapezoidal shapes, pentagonal shapes, hexagonal shapes, circular or ovoid shapes, and / or as otherwise desired.

[0030] The tub sidewall 118 of the tub 112 generally includes a wall portion 130 and optionally includes a flange portion 132. As discussed in greater detail below, in various embodiments, the tub sidewall 118 is a roll-formed section of material which is shaped into a halo and such that opposing ends of the roll-formed section are joined with a sealed joint, thereby forming a closed perimeter. As used herein, “halo” refers to any shape with a closed perimeter but is not intended to require any particular shape. As non-limiting examples, a halo may be rectangular, square, round, oval, triangular, elongated, hexagonal, and / or other shape as desired. Compared to traditional approaches, and as discussed in greater detail below, a single joint may be utilized within the tub sidewall 118 to form the closed perimeter. In certain embodiments, the single joint used to form the tub sidewall 118 with the closed perimeter may be a sealed joint minimizing and / or preventing material from entering or exiting via the joint. The sealed joint may be formed using various joining processes as desired, and in one nonlimiting example, the sealed joint of the tub sidewall 118 forming the closed perimeter may be formed via welding.

[0031] As illustrated in FIG. 1, a joint 134 joins the tub bottom 116 with the tub sidewall 118. In certain embodiments, the joint 134 is a sealed joint minimizing and / or preventing material from entering or exiting via the joint 134, such as a hermetically sealed joint. Sealed joints 134 may include, but are not limited to, a joint formed by double seaming or a joint formed by welding and including a sealant.

[0032] In some embodiments, the sealed joint 134 is a double seam 136 formed by a double seaming or hemming operation which mechanically interlocks the edge portion 128 of the tub bottom 116 with the tub sidewall 118. In some embodiments, the double seam 136 as the sealed joint 134 may be a structural and sealed joint without requiring additional sealing. In other embodiments, the double seam 136 optionally includes a sealant or adhesive within the double seam 136 to provide additional sealing. In some embodiments, and as illustrated in FIGS. 3 and 5, for example, the double seam 136 may additionally include a reinforcing portion 238. However, in other embodiments, and as illustrated in FIG. 1, the double seam 136 need not include a reinforcing portion.

[0033] In certain embodiments, and as illustrated in FIGS. 1 and 5, the double seam 136 as the sealed joint 134 may allow for improved shaping or forming of the tub 112 and / or the tub sidewall 118 relative to the tub bottom 116. As a non-limiting example, and as illustrated in FIG. 1, the roll -formed tub sidewall 118 joined to the tub bottom 116 with the double seam 136may allow for the tub sidewall 118 to extend substantially vertically relative to the tub bottom 116 and without a draft angle. Such improved shaping of the tub sidewall 118 may maximize a useful space of the receiving area 120 (e.g., space is not lost due to a draft angle) and / or provide improved interlocking or positioning of components of the battery enclosure system 100 (e.g., positioning of the battery enclosure 102 relative to the frame 104). As a further nonlimiting example, and as illustrated in FIGS. 3 and 5, the double seam 136 may further be reinforced with the reinforcing portion 238. Additionally, or alternatively, the roll-formed tub sidewall 118 joined to the tub bottom 116 with the double seam 136 may allow for improved shaping of the tub sidewall 118 to improve positioning or interlocking with other components of the battery enclosure system 100. As a non-limiting example, in FIG. 5, the tub sidewall 118 of a tub 512 includes an offset portion 539 which conforms to a recess 540 in the frame 104. Various other shapes or profiles may be utilized, and the particular shapes or profiles illustrated in FIGS. 1 and 5 should not be considered limiting.

[0034] In various embodiments, the sealed joint 134 may be a weld joining the roll-formed tub sidewall 118 to the tub bottom 116. In such embodiments, the weld may be formed using various suitable welding techniques, such as but not limited to spot welding, laser welding, self-piercing rivet welding, combinations thereof, and / or other welding techniques as desired, joining the edge portion 128 of the tub bottom 116 with the tub sidewall 118. In certain embodiments, the weld as the sealed joint 134 additionally includes a sealant for further sealing the joint 134. Various sealants may be utilized as desired for sealing the weld joint 134, including but not limited to rubber, silicone, polyurethane, adhesives, combinations thereof, and / or other materials as desired. Similar to the double seam 136, the sealed joint 134 formed by the weld may allow for improved shaping or forming of the tub 112 and / or the tub sidewall 118 relative to the tub bottom 116.

[0035] The cover 114 of the battery enclosure 102 may be joined to the tub sidewall 118 using a joint 146 formed from various joining techniques as desired. As a non-limiting example, and as illustrated in FIG. 1, the joint 146 may include one or more mechanical fasteners 142 to join the cover 114 with the tub sidewall 118. Mechanical fasteners may include, but are not limited to, bolts, rivets, combinations thereof, and / or other mechanical fasteners as desired. Optionally, and as illustrated in FIG. 1, the flange portion 132 of the tub sidewall 118 may include a hem 144, and the mechanical fasteners 142 may engage the hem 144 of the flange portion 132. In certain embodiments, the joint 146 with the mechanical fasteners 142 engaging the hem 144 may provide further structural support to the joint 146.

[0036] Additionally, or alternatively, the joint 146 may include one or more sealants or adhesives such as those previously described. In other embodiments, the cover 114 may have a construction similar to that of the tub bottom 116 and / or the cover 114 may be joined to the tub sidewall 118 in a manner similar to that used to join the tub bottom 116 to the tub sidewall 118, such as using a double seam and / or a weld as the joint 146. In certain embodiments, the joint 146 may provide a water-tight interference fit. In certain embodiments, the cover 114 and the tub bottom 116 may be joined to the tub sidewall 118 such that the receiving area 120 of the battery enclosure 102 is hermetically sealed.

[0037] FIGS. 2 and 3 illustrate an example of a tub 212 for a battery enclosure according to embodiments. As best illustrated in FIG. 3, the tub 212 is similar to the tub 112 except that the double seam 136 forming the sealed joint 134 additionally includes the reinforcing portion 238. In addition, and as best illustrated in FIG. 3, the flange portion 132 of the tub sidewall 118 omits the hem 144.

[0038] Referring back to FIG. 2, in some embodiments, the tub 212 (and therefore the tub bottom 116) has a generally rectangular shape. In certain embodiments, the roll-formed tub sidewall 118 may allow for the tub 212 to have comers 240 with a small radius, thereby providing an improved shape for the battery enclosure 102. However, in other embodiments, the tub 212 may have other shapes as desired.

[0039] As best illustrated in FIG. 3, in certain embodiments, the double seam 136 as the sealed joint 134 may allow for the tub sidewall 118 to extend vertically from the tub bottom 116 without requiring a draft angle. While no draft angle is required, in other embodiments, the roll-formed tub sidewall 118 may allow for the tub sidewall 18 to extend vertically with a draft angle if desired.

[0040] As illustrated in FIG. 2, in certain embodiments, the roll-formed tub sidewall 118 may include a single joint 248 within the tub sidewall 118 and to form the closed perimeter. The single joint 248 may be formed using various joining techniques as desired, and in some embodiments the joint 248 is a sealed joint. In one non-limiting example, the joint 248 may be a weld 250. The particular location of the joint 248 on the tub sidewall 118 should not be considered limiting, and in other embodiments, the joint 248 may be arranged in a corner 240, other non-comer portions of the sidewall 118, and / or as otherwise desired. The single joint 248 within the roll-formed tub sidewall 118 may allow for the perimeter of the battery enclosure 102 to be substantially continuous and the tub sidewall 118 to be a single component. The single joint 248 may allow for a faster forming process compared to traditional approaches andmay further minimize locations of potential failure or leakage in the battery enclosure 102 compared to traditional approaches.

[0041] FIG. 4 illustrates a portion of a tub 312 for a battery enclosure according to embodiments. The tub 312 is similar to the tub 212 except that the joint 134 between the tub bottom 116 and the tub sidewall 118 is a weld 452 and includes a sealant 454.

[0042] FIG. 5 illustrates a battery enclosure system 500 that is similar to the battery enclosure system 100 except that the tub sidewall 118 of the tub 512 of the battery enclosure system 500 additionally includes the offset portion 539, and the double seam 136 as the sealed joint 134 additionally includes the reinforcing portion 238.

[0043] FIG. 6 illustrates a method for forming a battery enclosure according to embodiments. While the method is described in the context of the battery enclosure 102, the method may be utilized for forming any battery enclosure consistent with the disclosure.

[0044] In a block 602, and referring to FIG. 7, the method includes roll-forming an input strip 701 to a roll-formed part 703 having a desired shape and with opposing ends 705, 707. As a non-limiting example, block 602 may include roll-forming the input strip 701 such that the roll- formed part 703 includes the flange portion 132. In some embodiments, block 602 optionally includes cutting the roll-formed part 703 to a desired length.

[0045] In a block 604, and referring to FIG. 7, the method includes forming a halo 709, which is the tub sidewall 118 in the assembled battery enclosure 102, from the roll-formed part 703. In various embodiments, forming the halo 709 includes joining the opposing ends 705, 707 of the roll-formed part 703 by forming the joint 248, which forms the halo 709 with a closed perimeter.

[0046] In a block 606, and referring to FIG. 8, the method includes forming or shaping the halo 709 from a first (or initial) shape (represented by solid lines 811 in FIG. 8) to a second shape (represented by dashed lines 813 in FIG. 8). In some embodiments, the second shape may be a desired perimeter shape for the battery enclosure 102, such as but not limited to a rectangular shape. In some embodiments, block 606 may include using a shaping press with actuators 815 applying forces 817 that stretch, bend, and / or otherwise form the halo 709 into the desired shape (e.g., with corners 240 or otherwise desired). In other embodiments, other techniques and / or equipment may be utilized to shape the halo 709. Optionally, after shaping the halo 709 in block 606, block 606 may further include one or more post-forming operations on the halo 709 (e.g., to provide and / or ensure flange angles, flatness, etc.).

[0047] In a block 608, the method includes joining the shaped halo 709 from block 606 with the tub bottom 116 with the joint 134. In one non-limiting example, block 606 includes seamingor hemming the tub bottom 116 with the halo 709, welding the tub bottom 116 with the halo 709, and / or mechanically fastening the halo 709 with the tub bottom 116.

[0048] In one non-limiting example, block 608 includes forming the double seam 136 as the joint 134 joining the tub bottom 116 with the halo 709. In certain embodiments, block 608 may include locating the tub bottom 116 relative to the halo 709, such as but not limited to in a seaming press, and seaming the tub bottom 116 to the halo 709 to form the double seam 136. Optionally, block 608 may include positioning the tub bottom 116 within the halo 709 before seaming and / or during the seaming step. In some embodiments, the form of the tub bottom 116 may be utilized to locate and / or position the halo 709 in place relative to the tub bottom 116 while the seaming step takes place, thereby providing additional support and shaping of the roll-formed halo 709.

[0049] In another non-limiting example, block 608 includes forming the weld 452 as the joint 134 joining the tub bottom 116 with the halo 709 using a welding process. In certain embodiments, block 608 includes forming the weld 452 by spot welding, laser welding, selfpiercing rivet welding, combinations thereof, and / or other welding techniques as desired. In some embodiments, block 606 includes positioning the tub bottom 116 within the halo 709, which may create an interference fit between the halo 709 and the tub bottom 116 and provide additional support and shaping of the roll-formed halo 709 during welding. In various embodiments, block 608 includes providing the sealant 454 to further seal the joint 134.

[0050] In a block 610, the method includes joining the cover 114 with the tub sidewall 118 by forming the joint 146. In various embodiments, the joint 146 joining the cover 114 with the tub sidewall 118 includes one or more of the mechanical fasteners 142, a sealant or adhesive, a double seam, a weld, and / or a water-tight interference fit. In various embodiments, the cover 114 and the tub bottom 116 joined to the tub sidewall 118 may hermetically seal the receiving area 120 of the battery enclosure 102.

[0051] As previously mentioned, the battery enclosures described herein may have an improved geometry which maximizes a usable space of the receiving area and provides improved positioning relative to other components of a battery enclosure system. The battery enclosures described herein may further provide improved sealing, such as hermetic sealing required for certain battery enclosures. In various embodiments, the battery enclosures described herein may provide size and weight savings compared to traditional battery enclosures. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0052] A collection of exemplary embodiments are provided below, including at least some explicitly enumerated as “Illustrations” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0053] Illustration 1. A battery enclosure comprising: a roll-formed tub sidewall forming a closed perimeter of the battery enclosure, wherein the roll-formed tub sidewall comprises a single joint in the roll-formed tub sidewall; and a tub bottom joined to the roll-formed tub sidewall, wherein the roll-formed tub sidewall and the tub bottom together define a receiving area for at least one battery.

[0054] Illustration 2. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein a double seam joins the tub bottom with the roll-formed tub sidewall.

[0055] Illustration 3. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein the double seam further comprises and adhesive.

[0056] Illustration 4. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein a weld joins the tub bottom with the roll-formed tub sidewall.

[0057] Illustration 5. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein the single joint in the roll-formed tub sidewall is a sealed joint.

[0058] Illustration 6. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein a sealed joint joins the tub bottom to the roll-formed tub sidewall.

[0059] Illustration 7. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein the sealed joint comprises at least one of a double seam, a weld and sealant, or a mechanical fastener and sealant.

[0060] Illustration 8. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, further comprising a cover joined to the roll-formed tub sidewall opposite from the tub bottom.

[0061] Illustration 9. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein the cover is joined to the roll-formed tub sidewall via a double seam.

[0062] Illustration 10. A battery enclosure comprising: a metal tub sidewall forming a closed perimeter of the battery enclosure, wherein the tub sidewall comprises a single joint such that the tub sidewall forms the closed perimeter; and a tub bottom joined to the tub sidewall with a sealed joint, wherein the tub sidewall and the tub bottom together define a receiving area for at least one battery.

[0063] Illustration 11. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein the sealed joint is a double seam.

[0064] Illustration 12. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein the metal tub sidewall extends vertically relative to the tub bottom and without a draft angle.

[0065] Illustration 13. The battery enclosure of any preceding or subsequent illustrations or combination of illustrations, wherein the sealed joint is a welded joint with a sealant.

[0066] Illustration 14. A method of forming a battery enclosure, the method comprising: rollforming a metal strip; forming the roll-formed metal strip into a halo with a closed perimeter by joining opposing ends of the roll-formed metal strip; and mating a tub bottom with the halo such that the halo forms a tub sidewall of the battery enclosure and the tub sidewall and the tub bottom together define a receiving area for at least one battery.

[0067] Illustration 15. The method of any preceding or subsequent illustrations or combination of illustrations, wherein mating the tub bottom with the halo comprises seaming the tub bottom with the halo.

[0068] Illustration 16. The method of any preceding or subsequent illustrations or combination of illustrations, wherein forming the roll-formed metal strip into the halo further comprises shaping the halo from a first shape to a second shape after joining the opposing ends and before mating the tub bottom with the halo.

[0069] Illustration 17. The method of any preceding or subsequent illustrations or combination of illustrations, wherein shaping the halo comprises radially pressing and stretching the halo from the first shape to the second shape.

[0070] Illustration 18. The method of any preceding or subsequent illustrations or combination of illustrations, wherein mating the tub bottom with the halo comprises: inserting the tub bottom into the halo; and joining the tub bottom with the halo to form a sealed joint.

[0071] Illustration 19. The method of any preceding or subsequent illustrations or combination of illustrations, wherein joining the tub bottom to the halo comprises joining using at least one of (i) mechanical fasteners and sealant, (ii) double seaming, or (iii) welding and sealant.

[0072] Illustration 20. The method of any preceding or subsequent illustrations or combination of illustrations, mating a tub bottom with the halo comprises joining the tub bottom to the halo such that the halo extends vertically from the tub bottom without a draft angle.

[0073] Illustration 21. A battery enclosure formed by the method of any preceding or subsequent illustrations or combination of illustrations.

[0074] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0075] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “5xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0076] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0077] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

[0078] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, orexemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention, and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0079] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

CLAIMSThat which is claimed:

1. A battery enclosure comprising: a roll-formed tub sidewall forming a closed perimeter of the battery enclosure, wherein the roll-formed tub sidewall comprises a single joint in the roll-formed tub sidewall; and a tub bottom joined to the roll-formed tub sidewall, wherein the roll-formed tub sidewall and the tub bottom together define a receiving area for at least one battery.

2. The battery enclosure of claim 1, wherein a double seam joins the tub bottom with the roll- formed tub sidewall.

3. The battery enclosure of claim 2, wherein the double seam further comprises an adhesive.

4. The battery enclosure of claim 1, wherein a weld joins the tub bottom with the roll-formed tub sidewall.

5. The battery enclosure of claim 1, wherein the single joint in the roll-formed tub sidewall is a sealed joint.

6. The battery enclosure of claim 1, wherein a sealed joint joins the tub bottom to the roll- formed tub sidewall.

7. The battery enclosure of claim 6, wherein the sealed joint comprises at least one of a double seam or a weld and sealant.

8. The battery enclosure of claim 1, further comprising a cover joined to the roll-formed tub sidewall opposite from the tub bottom.

9. The battery enclosure of claim 8, wherein the cover is joined to the roll-formed tub sidewall via a double seam.

10. A battery enclosure comprising: a metal tub sidewall forming a closed perimeter of the battery enclosure, wherein the metal tub sidewall comprises a single joint such that the metal tub sidewall forms the closed perimeter; and a tub bottom joined to the metal tub sidewall with a sealed joint, wherein the metal tub sidewall and the tub bottom together define a receiving area for at least one battery.

11. The battery enclosure of claim 10, wherein the sealed joint comprises a double seam.

12. The battery enclosure of claim 10, wherein the metal tub sidewall extends vertically relative to the tub bottom and without a draft angle.

13. The battery enclosure of claim 10, wherein the sealed joint is a welded joint with a sealant.

14. A method of forming a battery enclosure, the method comprising: roll -forming a metal strip; forming the roll-formed metal strip into a halo with a closed perimeter by joining opposing ends of the roll-formed metal strip; and mating a tub bottom with the halo such that the halo forms a tub sidewall of the battery enclosure and the tub sidewall and the tub bottom together define a receiving area for at least one battery.

15. The method of claim 14, wherein mating the tub bottom with the halo comprises seaming the tub bottom with the halo.

16. The method of claim 14, wherein forming the roll-formed metal strip into the halo further comprises shaping the halo from a first shape to a second shape after joining the opposing ends and before mating the tub bottom with the halo.

17. The method of claim 16, wherein shaping the halo comprises radially pressing and stretching the halo from the first shape to the second shape.

18. The method of claim 14, wherein mating the tub bottom with the halo comprises: inserting the tub bottom into the halo; and joining the tub bottom with the halo to form a sealed joint.

19. The method of claim 18, wherein joining the tub bottom to the halo comprises joining using at least one of double seaming or welding and sealant.

20. The method of claim 14, wherein mating a tub bottom with the halo comprises joining the tub bottom to the halo such that the halo extends vertically from the tub bottom without a draft angle.

21. A battery enclosure formed by the method of claim 14.

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