A tray for a battery enclosure of an electric vehicle

Abstract

Described herein is a tray (100) for a battery enclosure of an electric vehicle, comprising: a base plate (112); and two or more side walls (120a, b, c, d) at least partially defined by an overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the base plate forms the base of the tray, the base plate extending between at least two opposing side walls of the two or more side walls.

Description

[0001] A TRAY FOR A BATTERY ENCLOSURE OF AN ELECTRIC VEHICLE

[0002] FIELD OF THE INVENTION

[0003] The invention relates to trays for a battery enclosure of an electric vehicle and methods of manufacture of such.

[0004] BACKGROUND

[0005] Modem electric vehicles typically comprise a plurality of individual battery modules. These battery modules are often contained within a battery enclosure, or case, which is installed within an electric vehicle during its manufacture. A key purpose of a battery enclosure is to house and protect the individual battery modules from damage. Such enclosures normally form the floor of an electric vehicle and are affixed to vehicle’s chassis using mechanical fasteners. Battery enclosures are therefore a key aspect of the structure of electric vehicles.

[0006] In the event of a collision involving an electric vehicle comprising a battery enclosure, it is important that the battery enclosure maintains its structural integrity so as to protect the contents of the battery enclosure and support the chassis of the vehicle. This protects the passengers travelling within the vehicle and prevents damage to the battery modules contained in the enclosure. Battery enclosures must therefore be strong structures.

[0007] Some battery enclosures of electric vehicles known in the art comprise aluminium, as it is a widely available material the automotive industry. However, a number of issues are present with regards to the use of aluminium in battery enclosures for electric vehicles. These include, but are not limited to, weight, electrical insulation behaviour, and flame retardancy. It desirable for battery enclosures to be light in particular, in order to reduce the overall weight of the electric vehicle. Other battery enclosures are known that use reinforced thermoplastic or thermoset materials. However, ensuring a strong battery enclosure formed of these materials is difficult. Furthermore, battery enclosures of electric vehicles known in the art usually comprise of a number of individual components. This adds complexity to the manufacturing processes of such enclosures, as these individual components must be assembled together either manually or using machinery. There is therefore a need to simplify the construction of battery enclosures for electric vehicles.

[0008] In view of the above-mentioned issues, it is desirable to provide a tray for a battery enclosure of an electric vehicle that is strong, lightweight, but is nonetheless convenient to manufacture.

[0009] SUMMARY OF INVENTION

[0010] In an aspect of the invention there is provided a tray for a battery enclosure of an electric vehicle, comprising: a base plate; and two or more side walls at least partially defined by an overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the base plate forms the base of the tray, the base plate extending between at least two opposing side walls of the two or more side walls.

[0011] In this way, the manufacture of trays for battery enclosures of electric vehicles can be simplified, as the tray can be formed in one single overmoulding step onto a base plate. With a tray according to the invention, there is no need to perform post-machining operations or assembly once the base plate is provided, as any desired features (such as the two or more side walls) can be overmoulded onto the base plate. The manufacturing process of the tray of the invention is therefore less complex than those known in the art.

[0012] Furthermore, the presence of the base plate that extends between opposing side walls enables impact forces to be more effectively transmitted across the tray in the event of a collision involving an electric vehicle comprising such a tray. In particular, the base plate is able to transmit forces experienced during a side impact across the tray between the side walls to shield the contents from these forces. This improves the strength of a battery enclosure including the tray of the invention. The tray of the invention is less likely to buckle or collapse under impact forces. The base plate also serves to protect the battery modules contained therein from damage from impacts to the underbody of the electric vehicle.

[0013] The tray comprises side walls at least partially defined by overmoulded material overmoulded onto the base plate. This means that the overmoulded material extends from the base plate in defining the side walls. Generally, the overmoulded material will define side walls extending substantially perpendicularly from the base plate.

[0014] In contrast with wholly moulded battery trays, the base plate of the present invention is a separate component to the two or more side walls, which are overmoulded thereon.

[0015] The base plate could be any material, including, for example, aluminium. However, preferably, the base plate comprises a composite material. Preferably, the composite material is a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm. Preferably, the fibres comprise glass fibres, carbon fibres and / or aramid fibres. In various embodiments, the fibres are continuous fibres that extend along at least 50% of the length or width of the base plate, preferably along 70%, more preferably along 80%, more preferably along 90% of the length or width of the base plate, wherein more preferably the continuous fibres extend along substantially the entire length or width of the base plate. Preferably, the base plate has a thickness of at least 0.25mm, more preferably at least 0.5mm, more preferably at least 0.75mm, most preferably at least 1cm.

[0016] T rays for battery enclosures of electric vehicles known in the art typically comprise aluminium. Advantages associated with the use of such composite materials described above, instead of materials such as aluminium, include a lighter weight composition, improved strength, improved electrical insulation behaviour, improved flame retardancy, decreased likelihood of damage in the event of underbody impacts, increased resistance to fluid and dust ingress, and a lower carbon footprint.

[0017] Long or continuous fibre-reinforced materials for the base plate provide further advantages. While some thermoplastic materials can be injection moulded and may be suited to integrally forming a base and sidewalls in the same moulding process, long and continuous fibres generally cannot be injection moulded and so require forming separately. However, long and continuous fibres increase the strength of the base plate, which is a critical component in shielding the contents of the battery enclosure from damage during impact.

[0018] In various embodiments, the base plate extends between each of two pairs of opposing side walls, the two pairs of opposing side walls preferably being substantially perpendicular to one another. In this way, the base plate can act to transmit forces in the event of a crash between each set of opposing side walls. A symmetrical structure is also provided in the case of perpendicular opposing side walls, which increases the strength of the tray.

[0019] In other terms, in such embodiments, the tray comprises four side walls arranged in pairs, which oppose each other. In various embodiments, the base plate has an elongate rectangular shape. In such various embodiments, the tray may comprise two opposing longitudinal side walls and two opposing transverse side walls. The longitudinal side walls may be greater in length than the transverse side walls and their longitudinal axes are provided in a direction parallel to that of the longitudinal axis of the base plate. Preferably, the longitudinal and transverse side walls are connected to each other at their respective ends to form a continuous side wall of the tray.

[0020] In various embodiments, the side walls have a height of at least 50mm, preferably at least 100mm, more preferably at least 150mm, most preferably at least 180mm. In various embodiments, the longitudinal side walls have a length of at least 500mm, preferably at least 1000mm, more preferably at least 1500mm, more preferably at least 2000mm, most preferably at least 2400mm and the transverse side walls have a length of at least 400mm, preferably at least 800mm, more preferably at least 1200mm, most preferably at least 1600mm. In various embodiments the base plate may have a width and a length similar to that of the longitudinal and transverse side walls, e.g. a length of at least 500mm, preferably at least 1000mm, more preferably at least 1500mm, more preferably at least 2000mm, most preferably at least 2400mm and / or a width of at least 400mm, preferably at least 800mm, more preferably at least 1200mm, most preferably at least 1600mm. The height, i.e. thickness, of the base plate is typically substantially less than that of the side walls.

[0021] In various embodiments, the tray further comprises: one or more side elements at least partially defining one or more of the at least two opposing side walls, the overmoulded material being overmoulded onto the one or more side elements such that the side element and overmoulded material together define the respective side wall. Preferably, the tray comprises one or more side elements at least partially defining each of the opposing side walls defining the perimeter of the tray.

[0022] Side elements, such as these, may be provided in order to reinforce the side walls defined by the overmoulded material. In this way, the overmoulded material may at least partially envelope the respective side element, providing a reinforced side wall. Such a reinforced side wall provides greater resistance to impact forces in the event of a collision. This reinforced side wall therefore improves the strength and the structural integrity of the tray.

[0023] Side elements described herein may preferably be non-planar and, for example, each side element may comprise portions defining at least two non-parallel surfaces. Preferably, the two non-parallel surfaces are major surfaces of the side element. For example, the side elements may have a generally L or U-shaped cross-section, when viewed along the direction of the longitudinal axis. In this way, the side element is reinforced by the non-planar structure, and furthermore an overlapping region between each side element and the base plate can be provided to give additional strength to the structure. For example, each side element may have a substantially vertical portion arranged to extend away from the base plate and a base portion extending away from the vertical portion along a surface of the base plate, e.g. parallel to or otherwise conformal with the base plate, and configured to engage the base plate. Preferably, each side element has a thickness of at least 0.1 mm, more preferably at least 0.25mm, and most preferably at least 0.5mm.

[0024] In embodiments where the tray comprises two longitudinal side walls and two transverse side walls, the tray preferably comprises two longitudinal side elements and two transverse side elements, wherein the two longitudinal side elements and two transverse side elements are provided within the two longitudinal side walls and the two transverse side walls respectively. The lengths of the longitudinal side elements are preferably greater than that of the transverse side elements.

[0025] In various embodiments, the base plate and the one or more side elements are joined together other than by the overmoulded material. For example, the side elements may be joined to the base plate by mechanical fasteners or an adhesive before overmoulding. In this way, a unitary base assembly of the tray can be formed. This base assembly provides a strong substrate to which the two or more side walls can be overmoulded in order to form a strengthened tray.

[0026] In various embodiments, each of the one or more side elements is joined to the base plate by one or more joining elements to form the base assembly. The joining elements may be mechanical fasteners or an adhesive, for example. In this way, the overmoulded material can be overmoulded onto a base assembly in which the one or more side elements are pre-attached to the base plate. Such a base assembly can form a strong sub-structure without discontinuities or gaps between the one or more side elements and the base plate.

[0027] In various embodiments, the base assembly may comprise at least one pair of opposing side elements, e.g. a pair of opposing longitudinal side elements and / or a pair of opposing transverse side elements. These pairs of side elements are preferably provided along or near to the edges of the base plate, thereby defining a perimeter of the base assembly. The base assembly may also comprise one or more central elements extending at least partway between opposing side elements, at least partway along the length of those between opposing side elements. In other words, the central elements do not extend along the edge of the base plate. The central elements are preferably arranged parallel to opposing side elements, and one or more central elements may be halfway between the opposing side elements. Preferably, the one or more central elements are arranged with the direction of their longitudinal axis perpendicular to that of the base plate. In this way, the base assembly forms a more complete substructure, thereby improving the strength of the tray.

[0028] In various embodiments, each side element comprises a composite material, preferably a fibre-reinforced polymer, wherein more preferably the fibres have a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm, and / or wherein each side element comprises continuous fibres extending along at least 50% of the length of the side element along the direction of the continuous fibres, preferably along 70%, more preferably along 80%, more preferably along 90% of the length of the side element along the direction of the continuous fibres, wherein more preferably the continuous fibres extend along substantially the entire length of the side element along the direction of the continuous fibres.

[0029] As described above, trays for battery enclosures of electric vehicles known in the art typically comprise aluminium. Advantages associated with the use of such composite materials described above, instead of materials such as aluminium, include a lighter weight composition, improved strength, improved electrical insulation behaviour, improved flame retardancy, decreased likelihood of damage in the event of underbody impacts, increased resistance to fluid and dust ingress, and a lower carbon footprint.

[0030] In various embodiments, the base plate extends beyond at least one of the two or more side walls in a direction parallel to a direction within a plane of the base plate. In this way, the base plate may form a flange extending outside of the tray. This may serve multiple purposes, including acting as a way to secure the tray to the chassis of an electric vehicle, and as a member for catching a side impactor before it contacts the side walls of the tray. As this flange is integral with the base plate, the floor of the tray is strengthened in comparison to a tray with a flange separate to the base plate and force can be transmitted across the tray between the side walls. The manufacture of the tray is also simplified as the need to additionally incorporate a flange into the tray is obviated. Also, some existing battery enclosure installation include installing separate side impact catchers around the battery enclosure, which may also be obviated.

[0031] In various embodiments, the base plate may extend beyond at least one of the longitudinal side walls or at least one of the transverse side walls. Preferably, the base plate extends beyond each of the two opposing side walls of the two or more side walls in a direction parallel to a direction within the plane of the base plate. In this way, the flange formed by the base plate extends from two opposing sides of the tray. This may provide two regions in which the tray can be secured to the chassis of an electric vehicle, improving the strength of the floor of the vehicle and the chassis. Additionally, this may allow the forces from an impact that is caught by one of the side flanges to be transmitted across the base plate and into the chassis of the vehicle through the opposing flange to better manage impact forces and protect the contents of the tray.

[0032] Preferably, the base plate extends beyond each of the side walls of the two pairs of opposing side walls in a direction parallel to a direction within the plane of the base plate. In this way, the base plate may act as an impactor catcher for each opposing side wall, further improving the strength of the tray.

[0033] In various embodiments, the base plate extends beyond each of the side walls so as to define a peripheral flange of the tray, the peripheral flange preferably substantially surrounding a centre of the tray. In this way, a continuous flange is formed, which enables the tray to be secured to the chassis of an electric vehicle at various points along the perimeter of the base plate. Furthermore, impact forces in a direction parallel to a direction within the plane of the base plate can be effectively transmitted across the base plate.

[0034] In various embodiments, a substantially planar region of the base plate extends between at least the two opposing side walls. Preferably, the planar region extends along at least 10% of the length of the at least the two opposing side walls, preferably along at least 20%, more preferably along at least 40%, more preferably along at least 50% of the length of the at least the two opposing side walls. Preferably, a substantially planar region of the base plate extends between the side walls of the first pair of opposing side walls, and wherein a substantially planar region of the base plate extends between the side walls of the second pair of opposing side walls. Preferably, the whole of the base plate is substantially planar between each of the two or more side walls. A planar region of the base plate will be best suited to transmitting forces across the tray. In this way, the base plate is less likely to buckle or crumple under impact forces. Impact forces can be transmitted between each opposing side wall and preferably over the whole of the floor of the tray, thereby improving its structural integrity.

[0035] In various embodiments, the tray further comprises: one or more ribs defined by the overmoulded material overmoulded onto the base plate, wherein the one or more ribs extend between the two opposing side walls. In this way, further reinforcement can be provided to the structure of the tray. Impact forces in a direction parallel to that of the one or more ribs can be effectively transmitted along the lengths of the one or more ribs. The one or more ribs can also define housing units within the tray for individual battery modules. The one or more ribs can be overmoulded to the base plate at the same time as the two or more side walls. This simplifies the construction of the tray as fewer individual manufacturing steps are required.

[0036] Preferably, the tray comprises two opposing longitudinal side walls, and the one or more ribs extend between the two opposing longitudinal side walls. In other terms, the direction of the longitudinal axis of the one or ribs is perpendicular to that of the longitudinal side walls. In embodiments where the tray comprises two longitudinal side walls and two transverse side walls, the direction of the longitudinal axis of the one or ribs is preferably parallel to that of the two transverse side walls. In this way, impact forces incident on the tray in a transverse direction, perpendicular to the longitudinal side walls, can be effectively transmitted between the side walls by the one or ribs. The tray is therefore more resistant to impact forces of such a direction.

[0037] In various embodiments, the tray further comprises: one or more busbars arranged over the base plate; and a busbar housing arranged to house the one or more busbars, wherein the busbar housing is defined by the overmoulded material overmoulded onto the base plate. The primary purpose of a busbar in a battery enclosure of an electric vehicle is to carry electrical power between the battery modules contained therein and an electric motor of the vehicle. The purpose of the busbar housing may be to electrically insulate the busbars.

[0038] In this way, the need to integrate the busbars and a busbar housing into the tray in an additional post-manufacturing step is obviated. The busbars can be overmoulded to the base plate simultaneously with the two or more side walls and / or the one or more ribs. The tray requires fewer individual components, and its construction is therefore simplified. Furthermore, the busbar housing may contribute to the overall strength of the tray, as they are overmoulded to the base plate, thereby reinforcing the floor of the tray.

[0039] Preferably, the busbar housing is integral with the overmoulded material at least partially defining the two or more side walls, wherein preferably the busbar housing extends between two opposing side walls of the two or more side walls. In various embodiments, the longitudinal axis of busbar housing is orientated in the direction of the longitudinal axis of the tray. In this way, the busbars and the busbar housing form a spine of the tray between two of the side walls, thereby contributing to the strength of the tray.

[0040] In embodiments comprising two longitudinal side walls and two transverse side walls, the busbar housing is preferably spaced approximately equidistant between each of the longitudinal side walls. The busbar housing is preferably integral with both transverse side walls.

[0041] Preferably, the busbar housing passes through and is integral with the one or more ribs. In other terms, the busbar housing passes through the one or ribs with no spacing provided between them. This further increases the strength of the tray as the tray is less likely to crumple or buckle under lateral impact forces. In various existing battery enclosures featuring ribs, a gap may be left for subsequent insertion of a busbar and its insulation. However, such a gap reduces the strength of the ribs and acts as a likely point of failure. By providing the busbar housing integrally with the one or more ribs, this may be prevented.

[0042] Preferably, the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs. In this way, the busbar housing and the ribs provide effective resistance to lateral impact forces in the longitudinal and transverse directions of the tray.

[0043] Preferably, the tray comprises two busbars, the two busbars being electrically separated from one another by overmoulded material of the busbar housing. In this way, the busbar housing may be an integral piece, improving the strength characteristics of the tray. Preferably, the busbar housing comprises vent openings through the busbar housing partially exposing each of the two busbars, wherein the vent openings for each busbar face away from each other. By arranging the vent openings to face away from one another, this prevents the bus bars from contacting one another in the event that a crash would push the bus bars together.

[0044] In various embodiments, the two or more side walls, the one or more ribs and the busbar housing are defined integrally by the overmoulded material. In this way, the various components of the tray can be formed simultaneously and may be stronger as a result. The construction of the tray is therefore simplified as fewer manufacturing steps are required. A strong, unitary component is also provided thereby.

[0045] In various embodiments, the overmoulded material at least partially defining the two or more side walls forms a single continuous upper peripheral edge surrounding a centre of the tray. In such embodiments, the upper peripheral edge may be spaced apart from the base plate. The upper peripheral edge may form a flange that can be used to secure a lid to the tray to fully enclose battery modules from all sides. The lid may be secured to the tray using mechanical fasteners such as nuts and bolts.

[0046] As indicated above, typically the tray is provided with a lid to close the tray and form a battery enclosure. In various embodiments, the lid may comprise a similar composition to that of the base plate. For instance, the lid may comprise a composite material. Preferably, the composite material is a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm. Preferably, the fibres comprise glass fibres, carbon fibres and / or aramid fibres. In various embodiments, the fibres are continuous fibres that extend along at least 50% of the length or width of the lid, preferably along 70%, more preferably along 80%, more preferably along 90% of the length or width of the lid, wherein more preferably the continuous fibres extend along substantially the entire length or width of the lid. Preferably, the lid is arranged to extend between the opposing sidewalls. In some embodiments, the lid may extend beyond at least one of the two or more side walls in a direction parallel to a direction within a plane of the lid. Preferably, the lid extends beyond each of the two opposing side walls of the two or more side walls in a direction parallel to a direction within the plane of the lid. Preferably, the lid extends beyond each of the side walls of two pairs of opposing side walls in a direction parallel to a direction within the plane of the lid. Preferably, the lid extends beyond each of the side walls so as to define a peripheral flange of the tray, the peripheral flange preferably substantially surrounding a centre of the tray. In various embodiments, a substantially planar region of the lid extends between at least the two opposing side walls. Preferably, the planar region extends along at least 10% of the length of the at least the two opposing side walls, preferably along at least 20%, more preferably along at least 40%, more preferably along at least 50% of the length of the at least the two opposing side walls. Preferably, a substantially planar region of the lid extends between the side walls of the first pair of opposing side walls, and wherein a substantially planar region of the lid extends between the side walls of the second pair of opposing side walls. Preferably, the whole of the lid is substantially planar between each of the two or more side walls.

[0047] In embodiments where a lid is secured to the tray to form a battery enclosure, the enclosure may be installed within an electric vehicle in an orientation in which the base plate forms the underside of the vehicle, with the lid facing in an upwards direction. In alternative embodiments, the lid may form the underside of the vehicle, with the base plate facing in an upwards direction.

[0048] In various embodiments the overmoulded material comprises a composite material, wherein preferably the composite material is a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, the fibres preferably being shorter than any fibres of the base plate.

[0049] As described above, trays for battery enclosures of electric vehicles known in the art typically comprise aluminium. Advantages associated with the use of such composite materials described above, instead of materials such as aluminium, include a lighter weight composition, improved strength, improved electrical insulation behaviour, improved flame retardancy, decreased likelihood of damage in the event of underbody impacts, increased resistance to fluid and dust ingress, and a lower carbon footprint. The fibres of the overmoulded material will generally be relatively short to ensure the fibres flow and orient well during overmoulding. As mentioned above, by providing the base plate separately, this is not a limitation that applies to the base plate.

[0050] Described herein is a tray for a battery enclosure of an electric vehicle, comprising: a base plate; and two or more side walls, wherein the base plate forms the base of the tray, the base plate extending between at least two opposing side walls of the two or more side walls. Various features of the embodiments described herein may be included in conjunction with such a tray.

[0051] In another aspect of the invention there is provided a method of manufacture for a tray for a battery enclosure of an electric vehicle, comprising: providing a base plate; and overmoulding two or more side walls so as to be at least partially defined by an overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the base plate forms the base of the tray, the base plate extending between at least two opposing sides of the two or more side walls.

[0052] The method according to this aspect corresponds to a method of manufacturing a tray according to the first aspect and the various advantageous features described above apply equally to the present method.

[0053] In various embodiments, the various overmoulding steps described herein can be carried out using an overmoulding tool. For example, the base plate or the base assembly can be loaded into an overmoulding tool and the various overmoulded features of the embodiments described herein can be overmoulded onto the base plate or the base assembly.

[0054] Preferably, the base plate extends between each of two pairs of opposing side walls, the two pairs of opposing side walls preferably being substantially perpendicular to one another. In various embodiments, the method further comprises providing one or more side elements; and overmoulding one or more side walls such that the side element and overmoulded material together define the respective side wall. Preferably, the method further comprises defining the perimeter of the tray with one or more side elements at least partially defining each of the opposing side walls. In various embodiments, the method comprises joining the base plate and the one or more side elements together other than by the overmoulded material. In various embodiments, the method comprises overmoulding one or more of the two or more side walls such that the base plate extends beyond at least one of the two or more side walls in a direction parallel to a direction within a plane of the base plate. Preferably, the base plate extends beyond each of the two opposing side walls of the two or more side walls in a direction parallel to a direction within the plane of the base plate. Preferably, the base plate extends beyond each of the side walls of the two pairs of opposing side walls in a direction parallel to a direction within the plane of the base plate. Preferably, the base plate extends beyond each of the side walls so as to define a peripheral flange of the tray, the peripheral flange preferably substantially surrounding a centre of the tray. In various embodiments, a substantially planar region of the base plate extends between at least the two opposing side walls. Preferably, the planar region extends along at least 10% of the length of the at least the two opposing side walls, preferably along at least 20%, more preferably along at least 40%, more preferably along at least 50% of the length of the at least the two opposing side walls. Preferably, a substantially planar region of the base plate extends between the side walls of the first pair of opposing side walls, and wherein a substantially planar region of the base plate extends between the side walls of the second pair of opposing side walls. Preferably, the whole of the base plate is substantially planar between each of the two or more side walls.

[0055] In various embodiments, the method further comprises: overmoulding one or ribs so as to be defined by the overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the one or more ribs extend between the two opposing side walls. Preferably, the tray comprises two opposing longitudinal side walls, and the method comprises: overmoulding the one or more ribs such that the one or more ribs extend between the two opposing longitudinal side walls. Preferably, the one or ribs are overmoulded simultaneously with the two or more side walls.

[0056] In various embodiments, the method further comprises arranging one or more busbars over the base plate; and overmoulding a busbar housing so as to be defined by the overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the overmoulded busbar housing is arranged to house the one or more busbars. Preferably, the method comprises: overmoulding the busbar housing such that the busbar housing is integral with the overmoulded material at least partially defining the two or more side walls, and preferably such that the busbar housing extends between two opposing side walls of the two or more side walls. In various embodiments, the method comprises: overmoulding the busbar housing such that the busbar housing passes through and is integral with the one or more ribs. Preferably, the busbar housing is overmoulded such that the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs. Preferably, the busbar housing is overmoulded simultaneously with the two or more side walls and / or the one or more ribs.

[0057] In various embodiments, the two or more side walls, the one or more ribs and the busbar housing are overmoulded so as to be defined integrally by the overmoulded material. In various embodiments, the method comprises: forming a single continuous upper peripheral edge surrounding a centre of the tray with the overmoulded material at least partially defining the two or more side walls.

[0058] In accordance with a third aspect of the invention, there is provided a battery enclosure of an electric vehicle, comprising: one or more busbars arranged over a base of the battery enclosure; and a busbar housing arranged to house the one or more bus bars, wherein the busbar housing is formed of an overmoulded material, the overmoulded material being overmoulded onto the base of the battery enclosure.

[0059] Preferably, the busbar housing is integral with two or more side walls of the battery enclosure, wherein preferably the busbar housing extends between two opposing side walls of the two or more side walls, wherein preferably the two or more side walls are at least partially defined by the overmoulded material. In various embodiments, the direction of the longitudinal axis of the busbar housing is arranged parallel to the direction of the longitudinal axis of the battery enclosure. In various embodiments, the busbar housing passes through and is integral with one or more ribs of the battery enclosure, the one or ribs being overmoulded onto the base of the battery enclosure and defined by the overmoulded material. Preferably, the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs. In various embodiments, the two or more side walls, the one or more ribs and the busbar housing are defined integrally by the overmoulded material. In various embodiments, the overmoulded material comprises a composite material, wherein preferably the composite material is a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, the fibres preferably being shorter than any fibres of the base plate. Preferably, the enclosure comprises two busbars, the two busbars being electrically separated from one another by overmoulded material of the busbar housing. In this way, the busbar housing may be an integral piece, improving the strength characteristics of the tray. Preferably, the busbar housing comprises vent openings through the busbar housing partially exposing each of the two busbars, wherein the vent openings for each busbar face away from each other. By arranging the vent openings to face away from one another, this prevents the bus bars from contacting one another in the event that a crash would push the bus bars together.

[0060] Preferably, the base of the enclosure comprises a composite material, preferably a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm. Indeed, the base of the enclosure preferably corresponds to the base plate of the first aspect of the invention and so any of the features described above may be incorporated into this aspect.

[0061] According to a fourth aspect of the invention, there is provided a method of manufacture for a battery enclosure of an electric vehicle, comprising arranging one or more busbars over a base of the battery enclosure; and overmoulding a busbar housing so as to be formed by an overmoulded material, the overmoulded material being overmoulded onto the base of the battery enclosure, wherein the overmoulded busbar housing is arranged to house the one or more bus bars. This corresponds to a method of manufacturing a battery enclosure according to the third aspect and so the comments above apply equally in this context.

[0062] Preferably, the method comprises: overmoulding the busbar housing such that the busbar housing is integral with two or more side walls of the battery enclosure, wherein preferably the busbar housing is overmoulded such that the busbar housing extends between two opposing side walls of the two or more side walls, wherein preferably the two or more side walls are at least partially defined by the overmoulded material. In various embodiments, the method comprises: overmoulding the busbar housing such that the direction of the longitudinal axis of the busbar housing is arranged parallel to the direction of the longitudinal axis of the battery enclosure. In various embodiments, the method comprises: overmoulding the busbar housing such that the busbar housing passes through and is integral with one or more ribs of the battery enclosure, wherein the one or ribs being overmoulded onto the base of the battery enclosure and defined by the overmoulded material. Preferably, the method comprises: overmoulding the busbar housing such that the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs. In various embodiments, the two or more side walls, the one or more ribs and the busbar housing are defined integrally by the overmoulded material.

[0063] In various embodiments, two busbars are provided, the two busbars being electrically separated from one another by overmoulded material of the busbar housing. Preferably, the busbar housing comprises vent openings through the busbar housing partially exposing each of the two busbars, wherein the vent openings for each busbar face away from each other. In various embodiments, the base comprises a composite material, preferably a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm.

[0064] Various apparatus features described herein may be included as method steps, and vice versa.

[0065] BRIEF DESCRIPTION OF DRAWINGS

[0066] Embodiments of the invention will now be described, by way of example, by reference to the drawings, in which:

[0067] Figure 1A is a perspective view of a tray for a battery enclosure of an electric vehicle in an embodiment of the invention; Figure 1 B is a perspective view of a base assembly of the tray for a battery enclosure of an electric vehicle in the embodiment of the invention according to Figure 1A;

[0068] Figure 1C is a schematic cross-sectional diagram of the tray for a battery enclosure of an electric vehicle in the embodiment of the invention according to Figure 1A;

[0069] Figure 1 D is a schematic perspective diagram of a set of overmoulding tools in an open configuration in an embodiment of the invention;

[0070] Figure 1 E is a schematic perspective diagram of the set of overmoulding tools of the embodiment of the invention according to Figure 1 D in a closed configuration;

[0071] Figure 1 F is a schematic cross-sectional diagram of the set of overmoulding tools of the invention according to Figure 1 D in the closed configuration;

[0072] Figure 2 is a flow diagram of a method of manufacture for a tray for a battery enclosure of an electric vehicle in an embodiment of the invention; and

[0073] Figure 3 is a perspective view of a tray for a battery enclosure of an electric vehicle in an embodiment of the invention.

[0074] DETAILED DESCRIPTION

[0075] Figure 1A is a perspective view of a tray 100 for a battery enclosure of an electric vehicle in an embodiment of the invention. The tray 100 comprises a base assembly 110, shown in Figure 1 B. This base assembly corresponds to a part of the tray prior to overmoulding of certain features of the tray, described in more detail below.

[0076] The base assembly 110 comprises a rectangular base plate 112, a plurality of side elements 114a, 114b, 114c, 114d, and two central transverse elements 116a, 116b. The side elements comprise longitudinal and transverse side elements 114a, 114b and 114c, 114d, arranged along or near to the edges of the rectangular base plate 112, so that they define side walls of the assembly 110. The side elements 114a, 114b are referred to herein as longitudinal side elements as their longitudinal axes are arranged in parallel with the longitudinal axis of the base plate 112 and the tray 100. The longitudinal side elements 114a, 114b are arranged proximal to the longer edges of the base plate 112. The side elements 114c, 114d are referred to herein as transverse side walls as their longitudinal axes are arranged perpendicular the longitudinal axis of the base plate 112 and the tray 100, but in parallel with the plane of the base plate 112. The transverse side elements 114c, 114d are arranged at the shorter edges of the base plate 112. The longitudinal side elements 114a, 114b are greater in length than the transverse side elements 114c, 114d.

[0077] The base assembly 110 also comprises two central traverse elements 116a, 116b, which are arranged parallel to the transverse side elements 114c, 114d, and are each about halfway between the transverse side elements 114c, 114d. The central transverse element 116a is arranged to extend perpendicularly from the longitudinal side element 114a towards the centre of the tray, and the central transverse element 116b is arranged to extend perpendicularly from the longitudinal side element 114b towards the centre of the tray. A small gap is left between the central transverse elements 116a, 116b at the centre of the tray to allow for connections to be made between the front and rear halves of the tray, defined by the central transverse elements 116a, 116b.

[0078] The side elements 114a, 114b, 114c, 114d and the central traverse elements 116a, 116b are each joined to the base plate 112 prior to any overmoulding, for example by an adhesive or by mechanical fasteners.

[0079] Returning to the final tray shown in Figure 1A, the tray 100 generally comprises a base provided by the base plate 112, two pairs of opposing side walls 120a, 120b and 120c, 120d arranged perpendicular to one another, a plurality of ribs 130 and a busbar housing 140. The side walls 120a, 120b, 120c, 120d, the ribs 130 and the busbar housing 140 are defined integrally and are each overmoulded to the base assembly 110 to form the tray 100. Each side wall 120a, 120b, 120c, 120d is defined by overmoulded material that been overmoulded onto each of the respective side elements 114a, 114b, 114c, 114d and onto the base plate 112. The base plate 112 of the base assembly 110 defines a lower flange 150 and the upper sections of the side walls 120a, 120b, 120c, 120d define an upper flange 160.

[0080] The base plate 112 of the base assembly 110 forms the base of the tray 100 and it extends between each of the two pairs of side walls 120a, 120b and 120c, 120d. The e base plate 112 is planar between each of the two pairs of side walls 120a, 120b and 120c, 120d. In this particular embodiment, the base plate 112 extends beyond the side walls 120a and 120b in a direction parallel to a direction of the base plate 112 so as to define a lower flange 150.

[0081] In alternative embodiments, the base plate 112 may only extend beyond one of the side walls 120a, 120b, 120c, 120d to define a lower flange of the tray 100. In other embodiments, the base plate 112 may extend beyond each of the side walls 120a, 120b, 120c and 120d so as to define a continuous lower peripheral flange that surrounds a centre of the tray.

[0082] In further alternative embodiments, only a planar region or portion of the base plate 112 may extend between at least two of the side walls 120a, 120b, 120c, 120d. This planar region or portion may extend along at least 10% of the length of the at least two of the side walls 120a, 120b, 120c, 120d, along at least 20%, along at least 40%, or along at least 50% of the length of the at least the two of the side walls 120a, 120b, 120c, 120d.

[0083] As mentioned above, the side elements 114a, 114b, 114c, 114d of the base assembly 110 partially define the side walls 120a, 120b, 120c, 120d. Material is overmoulded onto the side elements 114a, 114b, 114c, 114d such that the side element 114 and the overmoulded material together define the respective side wall 120. In other terms, the side walls 120a, 120b, 120c and 120d are formed of overmoulded material and a respective side element 114a, 114b, 114c, 114d within the overmoulded material, wherein the respective side element forms a reinforcing internal element of the side wall. It logically follows from the above description that the side walls 120a, 120b are longitudinal side walls, which are greater in length than transverse side walls 120c, 120d. The side walls 120a, 120b, 120c and 120d form a continuous perimeter of the tray which surround its centre. Their upper sections form an upper flange 160. The side walls 120a, 120b define an array of open hexagonal cells having a honeycomb-like structure extending across the upper face the base plate 112. These open hexagonal cells provide a floor of the tray on which battery modules may sit so that they are lifted off the base plate 112.

[0084] The tray 100 further comprises overmoulded central transverse parts 118a, 118b. Material is overmoulded onto central transverse elements 116a, 116b in order to form the central transverse parts 118a, 118b. The central transverse parts 118a, 118b are therefore similar in structure to the side walls 120a, 120b, 120c, 120d. These central transverse parts 118a, 118b meet the overmoulded material forming the sidewalls 120a, 120b and extend toward the centre of the tray 100. Although not shown in Figure 1A, the overmoulded material may additionally extend between the central transverse parts 118a, 118b to form a reinforced central cross member that may effectively transmit impact forces between the sidewalls 120a, 120b to protect the battery modules provided in the tray.

[0085] The ribs 130 are formed of overmoulded material which is overmoulded to base plate 112. Each of the ribs 130 extend between, and are integral with, the two opposing longitudinal side walls 120a, 120b. The longitudinal axes of each of the ribs 130 are parallel to the longitudinal axes of the transverse side walls 120c, 120d. In this embodiment, seven ribs 130 are provided. However, in other embodiments, greater or fewer ribs may be provided. The ribs 130 further help to transmit impact forces between the opposing overmoulded sidewalls 120a, 120b to shield the battery modules within of the tray from damage. The ribs 130 also form individual housing units within the tray 100 to separate individual battery modules from one another.

[0086] The busbar housing 140 is arranged to house two busbars arranged over the base plate 112. The busbar housing 140 is formed of overmoulded material and extends between, and is integral with, the transverse side walls 120c, 120d. The busbar housing 140 also extends through and is integral with each of the ribs 130. The longitudinal axis of the busbar housing 140 is arranged in parallel with that of the base plate 112. The direction of longitudinal axis of the busbar housing 140 is therefore perpendicular to the direction of the longitudinal axes of each of the ribs 130. The busbar housing will be described in more detail later with respect to Figure 1C.

[0087] The tray 100 of Figure 1A will generally be closed by a lid (not shown) provided over the tray 100, which may be secured by nuts and bolts to the upper flange 160 provided by the overmoulded side walls 120a, 120b, 120c, 120d, for example. Generally, attachment devices or “inserts” must be provided in the overmoulded material to prevent the mechanical fasteners from damaging the thermoplastic material. While these inserts could be provided by machine processes performed after removal of the tray from an overmoulding tool, it is preferred that the inserts be incorporated into the overmoulded material as part of an overmoulding process in order to reduce the complexity of manufacture.

[0088] The tray 100 of Figure 1A has dimensions of approximately 2400mm in length, by 1600mm in width, and by 180mm in height.

[0089] Figure 1C is a schematic cross-sectional diagram through part of the tray 100 for a battery enclosure of an electric vehicle in the embodiment of the invention according to Figure 1A. The perspective of the cross-sectional diagram of Figure 1C is that in the direction of the longitudinal axis of the tray 100. In particular, Figure 1C depicts a cross-section of the busbar housing 140.

[0090] The busbar housing 140 houses two busbars 145a, 145b, which extend substantially through the length of the busbar housing 140. The busbar housing 140 is formed of an overmoulded material that extends around and between the two busbars 145a, 145b to prevent them from coming into contact with one another or other objects if the tray is damaged in a collision.

[0091] The busbar housing 140 also comprises openings 142a, 142b that function as vents to enable heat to escape from within the busbar housing 140. The opening 142a is associated with the busbar 145a and the opening 142b is associated with the busbar 145b. The opening 142a faces away from the busbar 145b and the opening 142b faces away from the busbar 142a. A plurality of openings such as the openings 142a, 142b are located along the length of the busbar housing 140 within the tray.

[0092] Figure 1 D is a schematic perspective view of a set of overmoulding tools A, B in an open configuration in an embodiment of the invention. This set of overmoulding tools A, B can be used to produce the tray 100 for a battery enclosure of an electric vehicle in the embodiment of the invention according to Figure 1A. The set of overmoulding tools comprises an upper overmoulding tool A and a lower overmoulding tool B. The upper overmoulding tool A comprises a main body tool part A1 and first and second side tool parts A2, A3. The first and second side tool parts A2, A3 coincide with the longitudinal side elements 114a, 114b respectively.

[0093] In the open configuration, with the first and second side tool parts A2, A3 removed, the base assembly 110 and the busbars can be loaded into the main body tool A1 of the upper overmoulding tool A. The first and second side tool parts A2, A3 can then be closed with the main body tool part A1 to enclose the base assembly 110 and the busbars 145a, 145b within the upper overmoulding tool A. In Figure 1 D, the base plate 112 of the base assembly 110 and the busbars 145a, 145b have been omitted for the purpose of clarity. The upper overmoulding tool A may also include two further side tool parts, i.e. front and rear side tool parts (not shown), which coincide with the transverse side elements 114c, 114d. The two further side tool parts perform a similar function to that of the first and second side tool parts A2, A3. Once the base assembly 110 and the busbars 145a, 145b have been loaded into the upper overmoulding tool A, the lower overmoulding tool B is closed with the upper overmoulding tool A, as shown in Figure 1 E. This is achieved by moving the lower overmoulding tool B along a direction perpendicular to the plane of the base plate 112.

[0094] When the overmoulding tools A, B are in the closed configuration, spaces are defined within and between the tools. Overmoulding material can then be injected into these spaces in order to overmould features onto the base assembly and the busbars. For example, the upper tool A is configured such that spaces are formed between the upper tool A and the base assembly 110 and the busbars when the tools are in the closed configuration. These spaces may correspond to features of the tray 100 shown in Figure 1A. Such features include the side walls 120a, b, c, d, the ribs 130, the busbar housing 140 and the upper flange 160.

[0095] A partial cross-sectional diagram of the overmoulding tools A, B in the closed configuration is depicted in Figure 1 F. In particular, Figure 1 F depicts the spaces provided around the longitudinal side element 114b and the base plate 112 by the main body tool part A1 and the second side tool part A3. Overmoulding material can be injected into these spaces between these components of the base assembly 110 and the upper overmoulding tool A to form the side wall 120b, the lower flange 150 and the hexagonal cells depicted in Figure 1A.

[0096] Figure 2 is a flow diagram of a method 200 of manufacture for a tray for a battery enclosure of an electric vehicle in an embodiment of the invention. In particular, the method 200 can be implemented in order to produce trays such as that of the embodiments of the invention according to Figures 1A and 3. The method 200 may be implemented using a set of overmoulding tools, such as that of the embodiment of the invention according to Figures 1 D and 1 E.

[0097] The method 200 comprises providing a base plate 202; providing two pairs of side elements 204; defining the perimeter of the tray with the two pairs of side elements 206; joining the base plate and the two pairs of side elements together 208; arranging one or more busbars over the base plate 210; overmoulding side walls onto the base plate and the two pairs of side elements 212; overmoulding a busbar housing onto the one or more busbars and the baseplate 214; and overmoulding one or ribs onto the base plate and the busbar housing 216.

[0098] Steps 202, 204, 206 and 208 comprise forming a base assembly such as that described in the embodiments of the invention according to Figures 1A and 1 B. In alternative embodiments, a complete base assembly may be provided instead of carrying out steps 202, 204, 206 and 208. The complete base assembly can be inserted into an upper overmoulding tool such as that described in the embodiment of the invention according to Figure 1 E prior to the overmoulding steps. Alternatively, the base assembly can be assembled within the overmoulding tool by inserting the base plate and the side elements therein individually, in which case the overmoulded material may join the various elements and base plate together.

[0099] Likewise, at step 210, the one or more busbars can be arranged over the base plate prior to inserting the base assembly or components thereof into the over moulding tool, or this can be done once the base assembly is within the overmoulding tool.

[0100] The overmoulding steps 212, 214 and 216 will typically be performed simultaneously after the base assembly and the one or more busbars have been inserted into the upper overmoulding tool. The upper overmoulding tool can then be closed with a lower overmoulding tool comprising impressions defining the side walls, the busbar housing and the one or ribs. Once the overmoulding tool is in a closed configuration the side walls, the busbar housing and the one or ribs can then be overmoulded by injecting an overmoulding material into the overmoulding tool. The overmoulding steps 212, 214 and 216 can therefore be performed simultaneously. The method 200 thus provides a simple approach for manufacturing a tray for a battery enclosure of an electric vehicle.

[0101] Figure 3 is a perspective view of a tray 300 for a battery enclosure of an electric vehicle in an embodiment of the invention. The tray 300 is similar to the tray 100, except in that the base plate 312 extends beyond each of the side walls 320a, 320b, 320c and 320d so as to define a continuous lower peripheral flange 350 that surrounds a centre of the tray 300. The lower flange 350 can be used to secure the base of the tray to the chassis of a vehicle around its perimeter and further improves the strength of the tray.

[0102] In the above-described embodiments, the base plate 112, 312 comprises a continuous glass fibre-reinforced polymer, the fibres extending along substantially the entire the length of the base plate. The side elements 114a, 114b, 114c, 114d, 314a, 314b, 314c, 314d comprise a continuous glass fibre-reinforced polymer, the fibres extending along substantially the entire length of the side elements 114a, 114b, 114c, 114d, 314a, 314b, 314c, 314d. The overmoulded material comprises a fibre-reinforced polymer, the fibres being shorter than any fibres of the base plate 112, 312 and the side elements 114a, 114b, 114c 114d, 314a, 314b, 314c, 314d.

[0103] The invention may be further understood by reference to the following numbered clauses:

[0104] 1 . A tray for a battery enclosure of an electric vehicle, comprising: a base plate; and two or more side walls at least partially defined by an overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the base plate forms the base of the tray, the base plate extending between at least two opposing side walls of the two or more side walls.

[0105] 2. A tray according to clause 1 , wherein the base plate comprises a composite material.

[0106] 3. A tray according to clause 2, wherein the composite material is a fibre- reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm.

[0107] 4. A tray according to clause 3, wherein the fibres comprise glass fibres, carbon fibres and / or aramid fibres.

[0108] 5. A tray according to clause 3 or clause 4, wherein the fibres are continuous fibres that extend along at least 50% of the length or width of the base plate, preferably along 70%, more preferably along 80%, more preferably along 90% of the length or width of the base plate, wherein more preferably the continuous fibres extend along substantially the entire length or width of the base plate. 6. A tray according to any of the preceding clauses, wherein the base plate extends between each of two pairs of opposing side walls, the two pairs of opposing side walls preferably being substantially perpendicular to one another.

[0109] 7. A tray according to any of the preceding clauses, wherein the tray further comprises: one or more side elements at least partially defining one or more of the at least two opposing side walls, the overmoulded material being overmoulded onto the one or more side elements such that the side element and overmoulded material together define the respective side wall.

[0110] 8. A tray according to clause 7 when dependent on clause 6, wherein the tray comprises: one or more side elements at least partially defining each of the side walls defining the perimeter of the tray.

[0111] 9. A tray according to clause 7 or clause 8, wherein the base plate and the one or more side elements are joined together other than by the overmoulded material.

[0112] 10. A tray according to any of clauses 7 to 9, wherein each side element comprises a composite material, preferably a fibre-reinforced polymer, wherein more preferably the fibres have a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm, and / or wherein each side element comprises continuous fibres extending along at least 50% of the length of the side element along the direction of the continuous fibres, preferably along 70%, more preferably along 80%, more preferably along 90% of the length of the side element along the direction of the continuous fibres, wherein more preferably the continuous fibres extend along substantially the entire length of the side element along the direction of the continuous fibres. 11. A tray according to any preceding clause, wherein the base plate extends beyond at least one of the two or more side walls in a direction parallel to a direction within a plane of the base plate.

[0113] 12. A tray according to clause 11 , wherein the base plate extends beyond each of the two opposing side walls of the two or more side walls in a direction parallel to a direction within the plane of the base plate.

[0114] 13. A tray according to clause 11 or clause 12 when dependent on at least clause 6, wherein the base plate extends beyond each of the side walls of the two pairs of opposing side walls in a direction parallel to a direction within the plane of the base plate.

[0115] 14. A tray according to any of the preceding clauses, wherein the base plate extends beyond each of the side walls so as to define a peripheral flange of the tray, the peripheral flange preferably substantially surrounding a centre of the tray.

[0116] 15. A tray according to any preceding clause, wherein a substantially planar region of the base plate extends between at least the two opposing side walls.

[0117] 16. A tray according to clause 15, wherein the planar region extends along at least 10% of the length of the at least the two opposing side walls, preferably along at least 20%, more preferably along at least 40%, more preferably along at least 50% of the length of the at least the two opposing side walls.

[0118] 17. A tray according to clause 15 or clause 16 when dependent on at least clause 6, wherein a substantially planar region of the base plate extends between the side walls of the first pair of opposing side walls, and wherein a substantially planar region of the base plate extends between the side walls of the second pair of opposing side walls.

[0119] 18. A tray according to any of clauses 15 to 17, wherein the whole of the base plate is substantially planar between each of the two or more side walls.

[0120] 19. A tray according to any preceding clause, further comprising: one or more ribs defined by the overmoulded material overmoulded onto the base plate, wherein the one or more ribs extend between the two opposing side walls.

[0121] 20. A tray according to clause 19, wherein the tray comprises two opposing longitudinal side walls, and wherein the one or more ribs extend between the two opposing longitudinal side walls.

[0122] 21 . A tray according to any preceding clause, further comprising: one or more busbars arranged over the base plate; and a busbar housing arranged to house the one or more busbars, wherein the busbar housing is defined by the overmoulded material overmoulded onto the base plate.

[0123] 22. A tray according to clause 21 , wherein the busbar housing is integral with the overmoulded material at least partially defining the two or more side walls, wherein preferably the busbar housing extends between two opposing side walls of the two or more side walls.

[0124] 23. A tray according to clause 21 or clause 22 when dependent on at least clause 19, wherein the busbar housing passes through and is integral with the one or more ribs.

[0125] 24. A tray according to clause 23, wherein the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs.

[0126] 25. A tray according to any of clauses 20 to 23 when dependent on at least clause 19, wherein the two or more side walls, the one or more ribs and the busbar housing are defined integrally by the overmoulded material.

[0127] 26. A tray according to any preceding clause, wherein the overmoulded material at least partially defining the two or more side walls forms a single continuous upper peripheral edge surrounding a centre of the tray. 27. A tray according to any preceding clause, wherein the overmoulded material comprises a composite material, wherein preferably the composite material is a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, the fibres preferably being shorter than any fibres of the base plate.

[0128] 28. A method of manufacture for a tray for a battery enclosure of an electric vehicle, comprising: providing a base plate; and overmoulding two or more side walls so as to be at least partially defined by an overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the base plate forms the base of the tray, the base plate extending between at least two opposing side walls of the two or more side walls.

[0129] 29. A method according to clause 28, wherein the base plate extends between each of two pairs of opposing side walls, the two pairs of opposing side walls preferably being substantially perpendicular to one another.

[0130] 30. A method according to clause 28 or clause 29, further comprising: providing one or more side elements; and overmoulding one or more side walls such that the side element and overmoulded material together define the respective side wall.

[0131] 31. A method according to clause 30 when dependent on clause 29, comprising: defining the perimeter of the tray with one or more side elements at least partially defining each of the opposing side walls.

[0132] 32. A method according to clause 30 or 31 , comprising: joining the base plate and the one or more side elements together other than by the overmoulded material.

[0133] 33. A method according to any of clauses 28 to 32, comprising: overmoulding one or more of the two or more side walls such that the base plate extends beyond at least one of the two or more side walls in a direction parallel to a direction within a plane of the base plate.

[0134] 34. A method according to clause 33, wherein the base plate extends beyond each of the two opposing side walls of the two or more side walls in a direction parallel to a direction within the plane of the base plate.

[0135] 35. A method according to clause 33 or 34 when dependent on at least clause 29, wherein the base plate extends beyond each of the side walls of the two pairs of opposing side walls in a direction parallel to a direction within the plane of the base plate.

[0136] 36. A method according to any of clauses 28 to 35, wherein the base plate extends beyond each of the side walls so as to define a peripheral flange of the tray, the peripheral flange preferably substantially surrounding a centre of the tray.

[0137] 37. A method according to any of clauses 28 to 36, wherein a substantially planar region of the base plate extends between at least the two opposing side walls.

[0138] 38. A method according to clause 37, wherein the planar region extends along at least 10% of the length of the at least the two opposing side walls, preferably along at least 20%, more preferably along at least 40%, more preferably along at least 50% of the length of the at least the two opposing side walls.

[0139] 39. A method according to clause 37 or 38 when dependent on at least clauses 29, wherein a substantially planar region of the base plate extends between the side walls of the first pair of opposing side walls, and wherein a substantially planar region of the base plate extends between the side walls of the second pair of opposing side walls.

[0140] 40. A method according to any of clauses 37 to 39, wherein the whole of the base plate is substantially planar between each of the two or more side walls.

[0141] 41. A method according to any of clauses 28 to 40, further comprising: overmoulding one or ribs so as to be defined by the overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the one or more ribs extend between the two opposing side walls.

[0142] 42. A method according to clause 41 , wherein the tray comprises two opposing longitudinal side walls, and comprising: overmoulding the one or more ribs such that the one or more ribs extend between the two opposing longitudinal side walls.

[0143] 43. A method according to any of clauses 28 to 42, further comprising: arranging one or more busbars over the base plate; and overmoulding a busbar housing so as to be defined by the overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the overmoulded busbar housing is arranged to house the one or more busbars.

[0144] 44. A method according to clause 43, comprising: overmoulding the busbar housing such that the busbar housing is integral with the overmoulded material at least partially defining the two or more side walls, and preferably such that the busbar housing extends between two opposing side walls of the two or more side walls.

[0145] 45. A method according to clause 43 or 44 when dependent on clause 41 , comprising: overmoulding the busbar housing such that the busbar housing passes through and is integral with the one or more ribs.

[0146] 46. A method according to clause 45, wherein the busbar housing is overmoulded such that the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs.

[0147] 47. A method according to any of clauses 43 to 46 when dependent on at least clause 41 , wherein the two or more side walls, the one or more ribs and the busbar housing are overmoulded so as to be defined integrally by the overmoulded material.

[0148] 48. A method according to any of clauses 28 to 47, comprising: forming a single continuous upper peripheral edge surrounding a centre of the tray with the overmoulded material at least partially defining the two or more side walls.

[0149] 49. A battery enclosure of an electric vehicle, comprising: one or more busbars arranged over a base of the battery enclosure; and a busbar housing arranged to house the one or more bus bars, wherein the busbar housing is formed of an overmoulded material, the overmoulded material being overmoulded onto the base of the battery enclosure.

[0150] 50. A battery enclosure according to clause 49, wherein the busbar housing is integral with two or more side walls of the battery enclosure, wherein preferably the busbar housing extends between two opposing side walls of the two or more side walls, wherein preferably the two or more side walls are at least partially defined by the overmoulded material.

[0151] 51. A battery enclosure according to clause 49 or clause 50, wherein the direction of the longitudinal axis of the busbar housing is arranged parallel to the direction of the longitudinal axis of the battery enclosure.

[0152] 52. A battery enclosure according to any of clauses 49 to 51 , wherein the busbar housing passes through and is integral with one or more ribs of the battery enclosure, the one or ribs being overmoulded onto the base of the battery enclosure and defined by the overmoulded material.

[0153] 53. A battery enclosure according to clause 52, wherein the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs.

[0154] 54. A battery enclosure according to any of clauses 49 to 53, wherein the two or more side walls, the one or more ribs and the busbar housing are defined integrally by the overmoulded material. 55. A battery enclosure according to any of clauses 49 to 54, wherein the overmoulded material comprises a composite material, wherein preferably the composite material is a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, the fibres preferably being shorter than any fibres of the base plate.

[0155] 56. A battery enclosure according to any of clauses 49 to 55, comprising two busbars, the two busbars being electrically separated from one another by overmoulded material of the busbar housing.

[0156] 57. A battery enclosure according to clause 56, wherein the busbar housing comprises vent openings through the busbar housing partially exposing each of the two busbars, wherein the vent openings for each busbar face away from each other.

[0157] 58. A battery enclosure according to any of clauses 49 to 57, wherein the base comprises a composite material, preferably a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm.

[0158] 59. A method of manufacture for a battery enclosure of an electric vehicle, comprising: arranging one or more busbars over a base of the battery enclosure; and overmoulding a busbar housing so as to be formed by an overmoulded material, the overmoulded material being overmoulded onto the base of the battery enclosure, wherein the overmoulded busbar housing is arranged to house the one or more bus bars.

[0159] 60. A method according to clause 59, comprising: overmoulding the busbar housing such that the busbar housing is integral with two or more side walls of the battery enclosure, wherein preferably the busbar housing is overmoulded such that the busbar housing extends between two opposing side walls of the two or more side walls, wherein preferably the two or more side walls are at least partially defined by the overmoulded material.

[0160] 61 . A method according to clause 59 or clause 60, comprising: overmoulding the busbar housing such that the direction of the longitudinal axis of the busbar housing is arranged parallel to the direction of the longitudinal axis of the battery enclosure.

[0161] 62. A method according to any of clauses 59 to 61 , comprising: overmoulding the busbar housing such that the busbar housing passes through and is integral with one or more ribs of the battery enclosure, wherein the one or ribs being overmoulded onto the base of the battery enclosure and defined by the overmoulded material.

[0162] 63. A method according to clause 62, comprising: overmoulding the busbar housing such that the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs.

[0163] 64. A method according to any of clauses 59 to 63, wherein the two or more side walls, the one or more ribs and the busbar housing are defined integrally by the overmoulded material.

[0164] 65. A method according to any of clauses 59 to 64, comprising two busbars, the two busbars being electrically separated from one another by overmoulded material of the busbar housing.

[0165] 66. A method according to clause 65, wherein the busbar housing comprises vent openings through the busbar housing partially exposing each of the two busbars, wherein the vent openings for each busbar face away from each other.

[0166] 67. A method according to any of clauses 59 to 66, wherein the base comprises a composite material, preferably a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm.

Claims

CLAIMS1 . A tray for a battery enclosure of an electric vehicle, comprising: a base plate; and two or more side walls at least partially defined by an overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the base plate forms the base of the tray, the base plate extending between at least two opposing side walls of the two or more side walls.

2. A tray according to claim 1 , wherein the base plate comprises a composite material.

3. A tray according to claim 2, wherein the composite material is a fibre- reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm.

4. A tray according to claim 3, wherein the fibres comprise glass fibres, carbon fibres and / or aramid fibres.

5. A tray according to claim 3 or claim 4, wherein the fibres are continuous fibres that extend along at least 50% of the length or width of the base plate, preferably along 70%, more preferably along 80%, more preferably along 90% of the length or width of the base plate, wherein more preferably the continuous fibres extend along substantially the entire length or width of the base plate.

6. A tray according to any of the preceding claims, wherein the base plate extends between each of two pairs of opposing side walls, the two pairs of opposing side walls preferably being substantially perpendicular to one another.

7. A tray according to any of the preceding claims, wherein the tray further comprises: one or more side elements at least partially defining one or more of the at least two side walls, the overmoulded material being overmoulded onto the oneor more side elements such that the side element and overmoulded material together define the respective side wall.

8. A tray according to claim 7 when dependent on claim 6, wherein the tray comprises: one or more side elements at least partially defining each of the side walls defining the perimeter of the tray.

9. A tray according to claim 7 or claim 8, wherein the base plate and the one or more side elements are joined together other than by the overmoulded material.

10. A tray according to any of claims 7 to 9, wherein each side element comprises a composite material, preferably a fibre-reinforced polymer, wherein more preferably the fibres have a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, more preferably at least 50 mm, more preferably at least 100 mm, most preferably at least 200 mm, and / or wherein each side element comprises continuous fibres extending along at least 50% of the length of the side element along the direction of the continuous fibres, preferably along 70%, more preferably along 80%, more preferably along 90% of the length of the side element along the direction of the continuous fibres, wherein more preferably the continuous fibres extend along substantially the entire length of the side element along the direction of the continuous fibres.

11. A tray according to any preceding claim, wherein the base plate extends beyond at least one of the two or more side walls in a direction parallel to a direction within a plane of the base plate.

12. A tray according to claim 11 , wherein the base plate extends beyond each of the two opposing side walls of the two or more side walls in a direction parallel to a direction within the plane of the base plate.

13. A tray according to claim 11 or claim 12 when dependent on at least claim 6, wherein the base plate extends beyond each of the side walls of the two pairsof opposing side walls in a direction parallel to a direction within the plane of the base plate.

14. A tray according to any of the preceding claims, wherein the base plate extends beyond each of the side walls so as to define a peripheral flange of the tray, the peripheral flange preferably substantially surrounding a centre of the tray.

15. A tray according to any preceding claim, wherein a substantially planar region of the base plate extends between at least the two opposing side walls.

16. A tray according to claim 15, wherein the planar region extends along at least 10% of the length of the at least the two opposing side walls, preferably along at least 20%, more preferably along at least 40%, more preferably along at least 50% of the length of the at least the two opposing side walls.

17. A tray according to claim 15 or claim 16 when dependent on at least claim 6, wherein a substantially planar region of the base plate extends between the side walls of the first pair of opposing side walls, and wherein a substantially planar region of the base plate extends between the side walls of the second pair of opposing side walls.

18. A tray according to any of claims 15 to 17, wherein the whole of the base plate is substantially planar between each of the two or more side walls.

19. A tray according to any preceding claim, further comprising: one or more ribs defined by the overmoulded material overmoulded onto the base plate, wherein the one or more ribs extend between the two opposing side walls.

20. A tray according to claim 19, wherein the tray comprises two opposing longitudinal side walls, and wherein the one or more ribs extend between the two opposing longitudinal side walls.

21. A tray according to any preceding claim, further comprising: one or more busbars arranged over the base plate; anda busbar housing arranged to house the one or more busbars, wherein the busbar housing is defined by the overmoulded material overmoulded onto the base plate.

22. A tray according to claim 21 , wherein the busbar housing is integral with the overmoulded material at least partially defining the two or more side walls, wherein preferably the busbar housing extends between two opposing side walls of the two or more side walls.

23. A tray according to claim 21 or claim 22 when dependent on at least claim 19, wherein the busbar housing passes through and is integral with the one or more ribs.

24. A tray according to claim 23, wherein the direction of the longitudinal axis of the busbar housing is substantially perpendicular to the direction of the longitudinal axis of the one or more ribs.

25. A tray according to any of claims 20 to 23 when dependent on at least claim 19, wherein the two or more side walls, the one or more ribs and the busbar housing are defined integrally by the overmoulded material.

26. A tray according to any preceding claim, wherein the overmoulded material at least partially defining the two or more side walls forms a single continuous upper peripheral edge surrounding a centre of the tray.

27. A tray according to any preceding claim, wherein the overmoulded material comprises a composite material, wherein preferably the composite material is a fibre-reinforced polymer, the fibres preferably having a length of at least 1 mm, more preferably at least 5 mm, more preferably at least 10 mm, more preferably at least 20 mm, the fibres preferably being shorter than any fibres of the base plate.

28. A method of manufacture for a tray for a battery enclosure of an electric vehicle, comprising: providing a base plate; andovermoulding two or more side walls so as to be at least partially defined by an overmoulded material, the overmoulded material being overmoulded onto the base plate, wherein the base plate forms the base of the tray, the base plate extending between at least two opposing side walls of the two or more side walls.

29. A battery enclosure of an electric vehicle, comprising: one or more busbars arranged over a base of the battery enclosure; and a busbar housing arranged to house the one or more bus bars, wherein the busbar housing is formed of an overmoulded material, the overmoulded material being overmoulded onto the base of the battery enclosure.

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