WO2024259255A2

WO2024259255A2 - Single piece sidewall for a battery housing

Info

Publication number: WO2024259255A2
Application number: PCT/US2024/034039
Authority: WO
Inventors: Darren Womack; Gabriel CORDOBA; Thomas Richter
Original assignee: Magna International Inc
Current assignee: Magna International Inc
Priority date: 2023-06-15
Filing date: 2024-06-14
Publication date: 2024-12-19
Anticipated expiration: 2025-12-15
Also published as: WO2024259255A3

Abstract

A battery housing includes a base plate extending to an outer base perimeter, and a top cover is disposed in spaced relationship with the base plate and extends to an outer top perimeter. A peripheral sidewall extends from a bottom peripheral edge secured to the base plate adjacent the outer base perimeter to an upper peripheral edge secured to the top cover adjacent the outer top perimeter. The peripheral sidewall is constructed or formed as a single piece, in contradistinction to the prior art sidewalls which are constructed or formed from multiple pieces. Put another way, the peripheral sidewall for the battery housing is formed from a single, unitary piece of material. The single-piece peripheral sidewall extends integrally and peripherally from a first end, through a plurality of corners and to a second end that is disposed adjacent and interconnected to the first end via a wall joint.

Description

SINGLE PIECE SIDEWALL FOR A BATTERY HOUSING

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 63/521,179, filed June 15, 2023, titled “Single Piece Sidewall For A Battery Housing,” the entire disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention relates to a battery housing for an automobile, and a related method of manufacturing same.

2. Related Art

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

[0004] Automobiles are the subject of a continuing effort to move away from internal combustion engines towards electrified vehicles, to reduce their dependency on fuel, improve emissions and increase fuel efficiency. Thus, this desire to increase fuel efficiency is both economically and environmentally motivated and has led to advanced internal components in automobiles as evidenced by developments in batteries, particularly in electrified automobiles. Unlike traditional automobiles that operate entirely with fossil fuels, electrified automobiles include a range of technologies that rely on electric energy. Even though electric energy is a more economical and environmentally friendly option over relying completely on fossil fuels, batteries are heavy, expensive, and relatively fragile compared to neighboring mechanical components. As such, the packaging of batteries, particularly within electrified automobiles, requires a number of design considerations including weight distribution, temperature regulation, and serviceability. In terms of serviceability, there is a growing need, particularly with electrified automobiles, for the batteries to be stowed in such a manner to be charged and maintained without removal.

[0005] To meet the above minimum requirements, batteries have traditionally been packaged in protective battery housings. In some cases, these traditional battery housings have a lower tray /base plate and a peripheral sidewall to create an internal cavity for housing at least one battery cell/module. However, often this peripheral sidewall is built from multiple individual components that are j oined together via welds, sealers, or the like. Put another way, certain battery housing architectures require that the vertical sidewall structure is constructed of several individually stamped or formed components, which are then collectively joined to form the peripheral sidewall during assembly of the battery housing. Two such examples of this prior art peripheral sidewall component are illustrated in Figures 1-2. For example, Figure 1 illustrates a first prior art arrangement for the peripheral sidewall comprised of eight different parts joined by eight sealed and spot welded joints, and Figure 2 illustrates a second prior art arrangement for the peripheral sidewall comprised of four different parts joined by four welded corner joints and one sealed and bolted joint.

[0006] However, having the peripheral sidewall of the battery housing built from several individual pieces poses a challenge for the leak tightness of the battery housing as each individual piece introduces potential leak paths into the design. In other words, step joints, skive joints and/or component gaps between each of the individual pieces of the peripheral sidewall are all potential spots where a leak could form. Accordingly, to stop the leaks in these joints/gaps, either a sealer must be applied on the joint, or the joint must be continuously welded. Yet, these sealing methods are not fully effective, and can still cause problems for leak sealing, without achieving leak tightness. Furthermore, having the peripheral sidewall built from multiple components introduces challenging joint geometry into the design, especially where the overlapping sidewall components must be bonded to the lower tray/base plate. The multi-piece peripheral sidewall of the prior art designs leads to joint geometries which are very problematic for joint sealing the battery housing from water and environmental intrusion.

[0007] Accordingly, there remains a continuing need for improved battery housing designs, particularly with respect to the design of the peripheral sidewall.

SUMMARY OF THE INVENTION

[0008] The subject disclosure is directed to a battery housing including a peripheral sidewall constructed as a single piece. Put another way, the subject disclosure is directed to a peripheral sidewall for a battery housing which is manufactured or formed from a single, continuous piece of material. The incorporation of the single-piece peripheral sidewall into the battery housing provides a better solution for achieving leak tightness, namely by simplifying the design of the peripheral sidewall, which reduces the number of potential leak paths relative to the prior art designs. Put another way, by simplifying the peripheral sidewall structure from multiple pieces down to a single piece, the need for step or skive joints is eliminated, which reduces the number of potential and common leak paths. The single piece peripheral sidewall also reduces the amount of sealer or continuous welding needed to seal the battery housing, resulting in lower material costs and improved leak performance. The single piece design also reduces a part count for the overall battery housing, further potentially lowering costs and weight of the battery housing. The single piece design also provides potential for improvement or simplification of crash structure for the battery housing. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0010] Figure 1 is a perspective view of a peripheral sidewall constructed in accordance with the prior art design principles;

[0011] Figure 2 is a perspective view of another exemplary peripheral sidewall component constructed in accordance with the prior art design principles;

[0012] Figure 3 is an exploded perspective view of a battery housing including a singlepiece peripheral sidewall constructed in accordance with a first exemplary roll forming manufacturing process and extending from a bottom peripheral edge for connection to a base plate to an upper peripheral edge for connection to a top cover;

[0013] Figure 4 is an exploded perspective view of the battery housing illustrating the single-piece peripheral sidewall constructed in accordance with a second exemplary metal extrusion manufacturing process;

[0014] Figure 5 is a top view of the battery housing of Figure 3 with the top cover removed to more clearly illustrate the single-piece peripheral sidewall extending integrally and peripherally from a first end, through a plurality of corners and to a second end that is connected to the first end via a wall joint, and including an upper seal extending along a top flange;

[0015] Figure 6 is a top view of the battery housing of Figure 4 with the top cover removed to more clearly and similarly illustrate the single-piece peripheral sidewall extending integrally and peripherally from the first end, through the plurality of corners and to the second end that is connected to the first end via a wall joint, and also the upper seal extending along the top flange; [0016] Figure 7 is an end view of the battery housing of Figure 3 to more clearly illustrate the upper peripheral edge of the peripheral sidewall connected to the top cover via an upper connection and the bottom peripheral edge of the peripheral sidewall connected to the base plate via a lower connection;

[0017] Figure 8 is a cross-sectional view of the first embodiment of the single-piece peripheral sidewall taken along 8-8 of Figure 1 to more clearly illustrate the top flange extending radially outward from the upper peripheral edge and the bottom flange extending radially outward from the bottom peripheral edge;

[0018] Figure 9 is an end cross-sectional view of the battery housing of Figure 4 to more clearly illustrate the peripheral sidewall formed as a metal extrusion in accordance with the second embodiment and an internal cavity collectively defined by the base plate, the peripheral sidewall, and the top cover for housing at least one battery module;

[0019] Figure 10 illustrates providing a single, continuous piece of material comprised of a stamped or rolled section of metal that extends from a first end to a second end in accordance with a first exemplary method of manufacturing the peripheral sidewall;

[0020] Figure 11 illustrates a subsequent step of the method of manufacturing the peripheral sidewall in which the single, continuous piece of stamped or rolled metal is passed through a roll forming apparatus to form the top flange in the upper peripheral edge and the bottom flange in the bottom peripheral edge;

[0021] Figures 12-13 illustrate a subsequent step of the method of manufacturing the peripheral sidewall in which the single, continuous piece of stamped or rolled metal is passed through a bending or folding apparatus to form the plurality of corners between the first and second ends; [0022] Figure 14 illustrates a concluding step of the method of manufacturing the peripheral sidewall in which a wall joint is established between the first and second ends to complete formation of the single-piece peripheral sidewall;

[0023] Figure 15 illustrates providing a single, continuous piece of material comprised of a metal extrusion that extends from the first end to the second end and is initially formed to include the top flange and the bottom flange in accordance with a second exemplary method of manufacturing the peripheral sidewall;

[0024] Figures 16-17 illustrate a subsequent step of the second exemplary method of manufacturing the peripheral sidewall in which the single, continuous piece of metal extrusion is passed through a bending or folding apparatus to form the plurality of corners between the first and second ends; and

[0025] Figure 18 illustrates a concluding step of the method of manufacturing the peripheral sidewall in which a wall joint is established between the first and second ends to complete formation of the single-piece peripheral sidewall.

DETAILED DESCRIPTION OF THE ENABLING EMBODIMENTS

[0026] Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject embodiments are directed to a battery housing for an automobile and a method of manufacturing same. However, the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0027] As best illustrated in Figures 3-4, 7 and 9, a battery housing 10 includes a base plate 12 that extends to an outer base perimeter 14. While the base plate 12 is illustrated as being flat and generally planar, the base plate 12 could have other shapes, such as being domed or tubshaped, without departing from the scope of the subject disclosure. The battery housing 10 further includes a peripheral sidewall 16 that is formed as a separate component from the base plate 12 and which extends peripherally adjacent the outer base perimeter 14. The peripheral sidewall 16 extends vertically upward from a bottom peripheral edge 18 that, as best illustrated in Figures 7 and 9, is secured to the base plate 12 adjacent the outer base perimeter 14 via a lower connection 20. For example, the lower connection 20 could be spot welding between the bottom peripheral edge 18 of the sidewall 16 and the base plate 12. However, other means of the first connection 20 can be utilized, such as adhesive joining, mechanical fasteners (e.g., bolts) with or without sealer, or continuous seam welding, for securing the peripheral sidewall 16 to the base plate 12.

[0028] The battery housing 10 further includes a top cover 22 that is disposed in spaced relationship with the base plate 12 and which extends to an outer top perimeter 24. Similar to the base plate 12, while the top cover 22 is illustrated as being flat and generally planar, the top cover 22 could also have other shapes without departing from the scope of the subject disclosure. The peripheral sidewall 16 extends upwardly from the bottom peripheral edge 18 to a top peripheral edge 26 that, as best illustrated in Figures 7 and 9, is secured to the top cover 22 adjacent the outer top perimeter 24 via an upper connection 28 to collectively define an internal cavity 30 by the base plate 12, the peripheral sidewall 16 and the top cover 22 for housing at least one battery module 32. (See Figures 3-4 and 9). Similar to the lower connection 20, the upper connection 28 could be established by spot welding between the top peripheral edge 26 of the peripheral sidewall 16 and the top cover 22. However, other means of the second connection 28, such as adhesive joining, mechanical fasteners (e.g., bolts) with or without sealer, or continuous seam welding, could be utilized without departing from the scope of the subject disclosure.

[0029] As best illustrated in Figures 3-4, the peripheral sidewall 16 is constructed or formed as a single piece, in contradistinction to the prior art sidewalls which, as shown in Figures 1-2, are constructed or formed from multiple pieces. Put another way, as best illustrated in Figures 3-6, the peripheral sidewall 16 for the battery housing 10 is formed from a single, unitary piece of material, preferably steel or aluminum. As described in more detail in the previous sections, use of a single-piece peripheral sidewall 14 reduces the presence of leak paths in the peripheral sidewall 14, and thus provides an improved seal design over the prior art designs which require multiple pieces and thus multiple seals to form the sidewall component.

[0030] As best illustrated in Figures 3-6, the single-piece peripheral sidewall 14 extends integrally and peripherally adjacent the outer base and top perimeters 14, 24 from a first end 34 and through a plurality of comers 36 formed in the sidewall 14 to a second end 38. For example, the single-piece peripheral sidewall 14 can extend between the first and second ends 34, 38 through four corners 36 to establish a generally rectangular box-like shape for the peripheral sidewall 14, when viewed from atop perspective. (See Figures 5-6). However, the peripheral sidewall 14 could have more or less comers 36 and have different shapes without departing from the scope of the subject disclosure. As best illustrated in Figures 5-6, a wall joint 40 extends between the first and second ends 34, 38 to establish an interconnection there between for completing formation of the single-piece peripheral sidewall 16. In a preferred arrangement, the wall joint 40 is comprised of seam welding or adhesively sealing the first and second ends 34, 38 of the peripheral sidewall 14 to one another. However, other means of establishing the wall joint 40 could be utilized without departing from the scope of the subject disclosure.

[0031] As will be described in more detail below, and as best illustrated in Figures 3, 5, 7- 8 and 10-14, in accordance with a first exemplary arrangement, the single-piece peripheral sidewall 16 is formed via a roll forming manufacturing process. Alternatively, as best illustrated in Figures 4, 6, 9 and 15-18 in accordance with a second exemplary arrangement, the single-piece peripheral sidewall 16 can be formed via a metal (e.g., aluminum) extrusion manufacturing process. In either manufacturing process, the single-piece peripheral sidewall 16 is preferably constructed to include a top flange 42 extending radially outwardly from the upper peripheral edge 26 and a bottom flange 44 extending radially outwardly from the lower peripheral edge 18. The top flange 42 can be used for placement of the upper connection 28 to facilitate connection of the perimeter sidewall 16 to the top cover 16. As best illustrated in Figures 5-7 and 9, an upper seal 46 can also be disposed along the top flange 42 for sealing the upper peripheral edge 26 of the perimeter sidewall 16 to the top cover 22. Similarly, the bottom flange 44 can be used for placement of the lower connection 20 to facilitate connection of the perimeter sidewall 14 to the base plate 12. A lower seal 48 can also be disposed along the bottom flange 44 for sealing the lower peripheral edge 18 of the peripheral sidewall 16 to the base plate 12. Each of the upper and lower seals 46, 48 preferably extend around the entire perimeter of their respective upper and lower peripheral edges 18, 26 to establish a sealed relationship between the peripheral sidewall 16 and the top cover 22 and base plate 12 when these components are interconnected together for preventing the passing of contaminants from the environment and into the internal cavity 30 of the battery housing 10.

[0032] As best illustrated in Figures 10-13 and 15-17, a method of manufacturing the single-piece peripheral sidewall 16 begins by providing a single, continuous piece of material 50’, 50” which extends between the first end 34 and the second end 36. For example, in accordance with the first arrangement of the manufacturing process, the single, continuous piece of material 50’ can be a stamped or rolled section of metal, preferably steel or aluminum. Alternatively, in accordance with a second arrangement of the manufacturing process, the single, continuous piece of material 50” can be a section of metal extrusion, again preferably steel or aluminum.

[0033] As best illustrated in Figures 11-12, in accordance with the first arrangement of the manufacturing process, the single, continuous piece of stamped or rolled metal 50’ can first be passed through a roll forming apparatus 52 having a pair of spaced apart rollers 54 to roll form the top flange 42 in the upper peripheral edge 26 and the bottom flange 44 in the bottom peripheral edge 18. As best illustrated in Figures 15-17, in accordance with the second arrangement of the manufacturing process, the single, continuous piece of metal extrusion 50” can be initially extruded to already include the top and bottom flanges 42, 44.

[0034] As best illustrated in Figures 12-13 and 16-17, in both arrangements of the manufacturing process, the single piece of continuous material 50’, 50” is then passed through a bending or folding apparatus 56 to form the plurality of corners 36 in the single piece of continuous material 50’, 50” between the first and second ends 34, 38. In a preferred arrangement, the bending or folding apparatus 56 forms four corners 36 to establish a generally rectangular box shape for the single piece of continuous material 50’, 50”. However, more or less corners and different shapes could be formed without departing from the scope of the subject disclosure.

[0035] As best illustrated in Figures 14 and 18, the method of manufacturing concludes by establishing a wall joint 40 between the first and second ends 34, 38 to complete formation of the single-piece peripheral sidewall 16. The wall joint 40 is preferably established by seam welding or adhesively sealing the first and second ends 34, 38 to one another. However, other means of establishing the wall joint 40 could be utilized without departing from the scope of the subject disclosure.

[0036] Although the method of manufacturing the single-piece peripheral sidewall 16 is preferably via a roll forming or metal extrusion process, the single-piece peripheral sidewall 16 can be constructed as a single unitary piece using other manufacturing processes, without departing from the scope of the subject disclosure. Obviously, many other modifications and variations of the present disclosure are possible in light of the above teachings and may be practiced otherwise than as specifically described.

Claims

CLAIMS What is claimed is:

1. A battery housing comprising: a base plate extending to an outer base perimeter; a top cover disposed in spaced relationship with the base plate and extending to an outer top perimeter; and a peripheral sidewall being comprised of a single-piece and extending from a bottom peripheral edge secured to said base plate adjacent said outer base perimeter to an upper peripheral edge secured to said top cover adjacent said outer top perimeter.

2. The battery housing as set forth in Claim 1, wherein said single-piece peripheral sidewall extends integrally and peripherally from a first end, through a plurality of corners and to a second end disposed adjacent said first end.

3. The battery housing as set forth in Claim 2, wherein said single-piece peripheral sidewall includes four comers to establish a generally rectangular box-like shape for the singlepiece peripheral sidewall.

4. The battery housing as set forth in Claim 2, wherein said single-piece peripheral sidewall includes a wall joint extending between and interconnecting said first and second ends.

5. The battery housing as set forth in Claim 2, wherein said wall joint is comprised of a seam weld.

6. The battery housing as set forth in Claim 1, wherein said single-piece peripheral sidewall is manufactured via a roll forming process.

7. The battery housing as set forth in Claim 1, wherein said single-piece peripheral sidewall is manufactured via a metal extrusion process.

8. The battery housing as set forth in Claim 1, wherein said single-piece peripheral sidewall includes a top flange extending radially outwardly from said upper peripheral edge and a bottom flange extending radially outwardly from said lower peripheral edge.

9. The battery housing as set forth in Claim 8, further comprising an upper connection extending between said top cover and said top flange for establishing the secured relationship between said top cover and said peripheral sidewall, and a lower connection extending between said base plate and said bottom flange for establishing the secured relationship between said base plate and said peripheral sidewall.

10. The battery housing as set forth in Claim 9, further comprising an upper seal disposed along said top flange for sealing said upper peripheral edge of said peripheral sidewall to said top cover, and a lower seal disposed along said bottom flange for sealing said bottom peripheral edge of said peripheral sidewall to said base plate.

11. A peripheral sidewall for a battery housing, comprising: a single piece of material extending integrally and peripherally from a first end, through a plurality of corners and to a second end disposed adjacent said first end.

12. The peripheral sidewall as set forth in Claim 11, wherein said single piece of materially extends vertically upward from a bottom peripheral edge for being secured to a base plate of the battery housing to a top peripheral edge for being secured to a top cover of the battery housing.

13. The peripheral sidewall as set forth in Claim 12, further comprising a wall joint extending between and interconnecting said first and second ends.

14. The peripheral sidewall as set forth in Claim 13, wherein said single piece of material is formed to include four corners and establish a generally rectangular box-like shape for the peripheral sidewall.

15. The peripheral sidewall as set forth in Claim 13, wherein said single-piece of material includes a top flange extending radially outwardly from said upper peripheral edge and a bottom flange extending radially outwardly from said lower peripheral edge.