Description:BATTERY PACK ENCLOSURE
TECHNICAL FIELD
[0001] The present disclosure pertains to a battery pack enclosure, specifically to a robust casing designed to resist crushing and protect internal components from damage under heavy load conditions.
BACKGROUND
[0002] Battery packs are a fundamental component of electric vehicles (EVs) and various portable electronic devices. A battery pack consists of multiple individual cells each having significant energy density. Each cell is a reservoir of stored energy, and its energy density is a measure of how much power the cell can hold relative to its volume or mass. To amplify their power, these individual cells are often combined in both series and parallel configurations. However, given the life-threatening consequences of battery damage related events, ensuring the safety of battery packs is highly desired.
[0003] Battery or EV manufacturers have acknowledged the aforementioned risks and have accordingly addressed them. One of the primary ways by which they have mitigated the risk is through the design of the battery pack casing, which are designed to offer some level of protection against the everyday bumps, vibrations, and minor impacts that a battery pack, might experience. Passing vehicle-level certification often requires these battery packs to withstand low-level mechanical vibrations, shocks, and even specific drop or impact tests. While these tests and standards have undoubtedly made battery packs safer and more robust, they may not fully account for the extreme conditions presented by high-speed or high-force collisions. Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks.
SUMMARY
[0004] The aim of the present disclosure is to provide an enclosure for a battery pack and to prevent the battery pack from crushing as well as to protect the internal components of the battery pack when subjected to heavy loads. The aim of the disclosure is achieved by an enclosure for a battery pack that prevents thermal runaway due to external penetration in case of an accident or impact resulting from extreme driving maneuvers.
[0005] The present disclosure relates to an enclosure for a battery pack, the enclosure comprising: a top casing comprising: a first pair of mounting points, wherein each of the first pair of mounting points is associated with a first set of ribs; and a first crushable zone disposed between the first pair of mounting points, wherein the first crushable zone is associated with a second set of mounting bores, and wherein the extreme ends of each bore of the second set of mounting bores are coplanarly arranged with the outermost ends of each rib of the first set of ribs; and a bottom casing comprising: a second pair of mounting points, wherein each of the second pair of mounting points is associated with a third set of ribs; and a second crushable zone disposed between the second pair of mounting points, wherein the second crushable zone is associated with a fourth set of mounting bores, and wherein the extreme ends of each bore of the fourth set of mounting bores are coplanarly arranged with the outermost ends of each rib of the third set of ribs; wherein the first pair of mounting points mate with the second pair of mounting points to form a pair of double shearing mounting points.
[0006] In an embodiment, the top casing is arranged co-axially onto the bottom casing to mate each mounting point of the first pair to corresponding mounting point of the second pair to form the pair of double shearing mounting points.
[0007] In an embodiment, each rib of the first set of ribs mates with a corresponding rib of the third set of ribs to form a first continuous set of ribs associated with the pair of double shearing mounting points; and each rib of the second set of mounting bores mates with a corresponding rib of the fourth set of mounting bores to form a second continuous set of ribs associated with the crushable zone.
[0008] In another embodiment, the at least one of the first crushable zone and the second crushable zone is associated with at least one gusseting rib, disposed on an external surface.
[0009] In an embodiment, at least one of the top casing and the bottom casing comprises at least one set of internal ribs associated, respectively, with at least one of an internal surface of the top casing and an inner surface of the bottom casing.
[0010] In yet another embodiment, at least one of the internal surface of the top casing, the inner surface of the bottom casing, a side wall of at least one of the top casing, and the bottom casing comprises at least one groove and wherein the at least one groove receives a bolt.
[0011] In an embodiment, at least one of an external surface of the top casing and an outer surface of the bottom casing is associated with a plurality of thermal fins.
[0012] In an embodiment, the enclosure comprises a coolant inlet for allowing flow of a coolant into the enclosure, and a coolant outlet for allowing discharge of the coolant out of the enclosure.
[0013] In an embodiment, the enclosure comprises at least one pressure release vent.
[0014] The present disclosure relates to a method for assembling an enclosure for a battery pack, the method comprising the steps of: providing a top casing having a first pair of mounting points, each of the first pair of mounting points being associated with a first set of ribs; disposing a first crushable zone between the first pair of mounting points, wherein the first crushable zone is associated with a second set of mounting bores, and aligning the extreme ends of each bore of the second set of mounting bores coplanarly with the outermost ends of each rib of the first set of ribs; providing a bottom casing having a second pair of mounting points, each of the second pair of mounting points being associated with a third set of ribs; disposing a second crushable zone between the second pair of mounting points, wherein the second crushable zone is associated with a fourth set of mounting bores, and aligning the extreme ends of each bore of the fourth set of mounting bores coplanarly with the outermost ends of each rib of the third set of ribs; aligning the first pair of mounting points on the top casing with the second pair of mounting points on the bottom casing; and securing the first pair of mounting points to the second pair of mounting points, thereby forming a pair of double shearing mounting points to enhance the mechanical integrity of the assembled enclosure.

BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein.
[0016] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams.
[0017] FIG. 1 showcase an enclosure for housing a battery pack, in accordance with embodiments of the present disclosure.
[0018] FIG. 2 illustrates a method for assembling an enclosure for a battery pack, in accordance with embodiments of the present disclosure.
[0019] FIG. 3A and 3B showcase a sectional view of a signal sheering joint and a double sheering joint, respectively, in accordance with embodiments of the present disclosure.
[0020] In FIG. 4, an isometric view showcases an enclosure securely attached to a chassis of vehicle, , in accordance with embodiments of the present disclosure.
[0021] FIG. 5 showcases a top view of an enclosure, , in accordance with embodiments of the present disclosure.
[0022] FIG. 6 illustrates a top view of top casing and parts thereof, in accordance with embodiments of present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS
[0023] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
[0024] FIG. 1 showcase an enclosure 100 for housing a battery pack, in accordance with an embodiment of the present disclosure. The enclosure 100, includes a top casing 102 and a bottom casing 104, wherein the top casing 102 and bottom casing 104 are designed to enhance the structural integrity and protective capability of the battery pack.
[0025] In an embodiment, the top casing 102 of the enclosure 100 covers the battery pack from the upper side. Top casing 102 may include a first pair of mounting points 106. Each of these mounting points is associated with a first set of ribs 108, which may provide, (a) structural rigidity to the mounting points, ensuring that the mounting points remain steadfast even under duress, and (b) even distribution of any force exerted across the top casing 102. Such distribution minimizes focal stress points, thereby reducing the potential for structural compromise or failure.
[0026] The first pair of mounting points 106 can provide a connection point to connect with the corresponding mounting points of the bottom casing 104 to create the complete enclosure 100. Optionally, the first pair of mounting points 106 in the top casing 102 serve as the areas where the enclosure 100 is anchored or fixed to an adjacent structure, such as a vehicle chassis or an equipment frame. The first pair of mounting points 106 are critical components in ensuring the secure installation and stable positioning of the battery pack. Often reinforced with additional materials or structures like ribs, the first pair of mounting points 106 can bear loads and withstand forces exerted from different directions, such as vertical stress from the weight of the battery pack or lateral forces in the event of sudden movements or impacts. The integrity of the first pair of mounting points 106 is crucial for the mechanical stability of the battery pack and the operational safety. If the first pair of mounting points 106 fail, it could lead to shifting or dislodgement of the battery pack, potentially causing internal damage or even dangerous repercussions.
[0027] In an embodiment, the first set of ribs 108 serve as reinforcing structures to enhance both rigidity and durability of the first pair of mounting points 106. The first set of ribs 108 can be fabricated from the same material as the enclosure 100 or any other high-strength materials. The first set of ribs 108 extends outward from the surface of the first pair of mounting points 106, forming a pattern that increases the overall surface area and, hence, the load-bearing capacity. The first set of ribs 108 improves the first pair of mounting points 106 ability to withstand external stresses, such as those experienced during sudden impacts or heavy loading. When force is applied/received to the first pair of mounting points 106, the first set of ribs 108 enable distribution of the applied force more evenly across the enclosure 100, reducing the risk of focal stress points, which could compromise the integrity of the battery pack. The first set of ribs 108 can distribute the loads more uniformly across the mounting points and minimizes the risk of stress concentration and fatigue. Further, the first set of ribs 108 can enhance the stiffness and overall rigidity of the mounting point. The rigidity is beneficial in applications where dynamic loads or vibrations lead to structural issues over time. Furthermore, the first set of ribs 108 can increase the surface area of the mounting point, which can improve load bearing capacity.
[0028] In an embodiment, a first crushable zone 110 can be disposed between the first pair of mounting points 106, wherein the first crushable zone 110 can provide an area of controlled deformation. In the event of an impact or heavy load, the first crushable zone 110 is primed to absorb and dissipate energy. To enhance the effectiveness and structural conformity, the first crushable zone 110 is associated with a second set of mounting bores 112. The extremities of each rib in the second set of mounting bores 112 are coplanarly aligned with the outermost endpoints of each rib belonging to the first set of ribs 108. Such alignment ensures uniformity in design and promotes consistent energy dispersion throughout the enclosure 100 when faced with external forces. The second set of mounting bores 112 may be disposed discretely (at uniform distance there between or at variable gap there between) along the width of the first crushable zone 110. The discrete second set of mounting bores 112 can be positioned to distribute loads effectively across first crushable zone 110, thereby to protect the battery pack. The discretely disposed second set of mounting bores 112 ensures that no single part of first crushable zone 110 or pack 100 bears excessive stress, which can lead to material fatigue or failure over time. Further, the discretely disposed second set of mounting bores 112 can increase the moment of inertia of the battery pack surface without a significant addition of weight and also enhance its rigidity to improvise impact and vibration handling capacity. Further, the second set of mounting bores 112 can also reduce the weight of the battery pack. As the second set of mounting bores 112 despites external stress, thick body enclosure is not required. The thick body enclosure may add unnecessary weight. The reduced weight is vital for electric vehicle efficiency. In the event of an impact or excessive load, the presence of discrete ribs 112 can help direct the force to specific regions, allowing for predictable and controlled deformation patterns to ensure that failures, if occurring, do not propagate rapidly and unpredictably across the battery pack. In an embodiment of the current disclosure, the first set of double shearing mounting point 106 can extend at the same height as the first crushable zone 110, thus ensuring a uniform load distribution across the critical areas during high-stress or impact conditions. To improvise strength of the first crushable zone 110 external gusseting ribs can be incorporated, wherein the gusseting ribs can serve as structural reinforcement elements to make the first crushable zone 110 more resistant to external impacts and less prone to unwanted deformation or buckling.
[0029] In an aspect, the coplanar arrangement (between extreme ends of each bore of the second set of mounting bores 112 and each outermost endpoint of each rib) ensures that any force or stress applied to the enclosure 100 is uniformly distributed across both sets of ribs. By aligning the respective ends of the ribs 112, the transition of force is smooth, avoids stress concentrations that could lead to premature failure of the battery pack and also prevent or minimize damage to the battery cells, which are often sensitive and can pose safety risks under external force. The coplanar arrangement ensures that the battery pack behaves in a known manner under adverse conditions, safeguarding against catastrophic failures.
[0030] In one embodiment, complementing the top casing 102 is the bottom casing 104. Mirroring the top casing 102, the bottom casing 104 features a second pair of mounting points 114. Every mounting point in the second pair of mounting points 114 is paired with a third set of ribs 116, reflecting the design considerations depicted in the top casing 102. The third set of ribs 116 lends enhanced sturdiness to the second pair of mounting points 114 and enables an even force distribution, once again, acting as a safeguard against concentrated stress points. It would be appreciated that technical benefits offered by the third set of ribs 116 on the bottom casing 104 mirror precisely those of the first set of ribs 108 on the upper or top casing 102. As such, any advantages and/or configuration previously outlined for the first set of ribs 108 can be directly applied to the third set of ribs 116. For an instance, material, form factor, position of the first set of ribs 108 and third set of ribs 116 can be identical to ensure symmetrical protection and performance. In an exemplary aspect, the third set of ribs 116 can be oriented at 90 degrees to the Y-plane (of enclosure 100), facilitating better load distribution and greater resilience against forces over 100 KN.
[0031] In an embodiment, the bottom casing 104 also houses a second crushable zone 118 nestled between the second pair of mounting points 114. The second crushable zone 118 is primed for controlled deformation to absorb the brunt of any impact or load. The second crushable zone 118 too is paired with a fourth set of mounting bores 120. The far ends of each rib from the fourth set of mounting bores 120 align coplanarly with the external ends of each rib from the third set of ribs 116. Such alignment again underscores the importance of uniform energy distribution and the principle of consistent design. In the framework of present application, a person ordinarily skilled in the art can seamlessly extrapolate the technical features (e.g., material, form factor, number of ribs, distance between two adjacent rib, height of each rib etc.) and advantages (e.g., uniform load distribution), as delineated for crushable zone 110, to the design of the second crushable zone 118, ensuring consistent performance across both zones.
[0032] In an embodiment, the first pair of mounting points 106 on the top casing 102 aligns with the second pair of mounting points 114 on the bottom casing 104. Such alignment causes formation of a pair of double shearing mounting points. The concept of 'double shearing' in the aforementioned context refers to the mounting points' enhanced capability to withstand loads from two opposing directions without buckling or shearing. In essence, such a feature greatly amplifies the overall resilience of the enclosure 100 against both vertical and lateral forces. The double shearing mounting point can distribute loads more uniformly across two shear planes, mitigating the chances of localized stress concentrations which could lead to premature failure. Further, the additional ribs (i.e., first set of rib 108 and third set of ribs 116) can provide an extra layer of support and also enhance the structural integrity of the mounting points even further. Thus, rib strengthened double sheering mounting points of present disclosure ensures that the battery pack remains stable and secure, even under challenging conditions. The ribs can act as conduits for stress flow, directing stresses away from weak points and distributing them more evenly across the housing. As the third set of ribs 116 and fourth set of mounting bores 120 are arranged coplanarly, the height difference between the mounting point edge and crushable zone is eliminated, enabling an even load distribution.
[0033] In an exemplary embodiment, the structural strength of the second crushable zone 118 can be enhanced through gusseting ribs (disposed on an external surface), which enable the second crushable zone 118 to withstand impacts greater than 100 KN without deformation. The gusseting ribs distribute stress evenly across the battery enclosure 100, ensuring that localized stress, which might otherwise compromise the enclosure 100, are minimized. During accidental impacts or collisions, the gusseting ribs act as a buffer, and absorb and/or dissipate the impact energy to prevent damage to the battery cells or reduce risks of cell rupture or leakage. Furthermore, in case of an external force, the gusseting ribs ensure that the second crushable zone 118 compresses uniformly, thereby preventing uneven deformation. It would be appreciated that, number of the gusseting ribs can be dependent on material and form factor (e.g., shape, dimension etc.) of gusseting ribs, length and width of the second crushable zone 118, overall dimension of battery enclosure 100, application of the battery pack, and the like. The gusseting ribs can be seamlessly integrated into the second crushable zone 118 to eliminate weak junctions or points of detachment. Furthermore, the gusseting ribs can be equidistantly spaced, ensuring uniform stress distribution and consistent performance throughout the second crushable zone 118. In an alternative implementation, multiple internal ribs can be disposed on an internal surface of the second crushable zone 118 to further increase load bearing capacity of enclosure 100.
[0034] Similar to the second crushable zone 118, first crushable zone 110 can also integrate various optional structural elements, to enhance performance. The gusseting rib (disposed on an external surface) can be associated with the first crushable zone 110 to enhance rigidity, efficient distribution of stresses and increased resistance to deformation. Furthermore, the incorporation of internal ribs (which can be in the form of a gusseting rib) at an internal surface (for the first crushable zone 110) further supplements strength and aids in uniform stress absorption. Beyond these, the crushable zone 110 can also be equipped with other recognized structural or mechanical property enhancement features to augment the overall safety and durability of the battery pack.
[0035] In a use-case scenario, consider an electric vehicle equipped with a battery housed within the enclosure 100. While navigating city streets, the vehicle inadvertently collides with a heavy object, perhaps a fallen lamppost. The impact's force is directed towards the battery compartment. In traditional setups, the collision could lead to catastrophic outcomes like battery puncture or explosion. However, with the present disclosure, several protective mechanisms can provide protection. The mounting points, with their associated ribs, distribute the collision's force across the entire enclosure 100, preventing focal damage. The crushable zones then come into action, deforming in a controlled manner, thereby absorbing a significant chunk of the impact energy. And finally, the double shearing mounting points ensure that the entire assembly remains integrated, preventing any separation between the top 102 and bottom casing 104 even under extreme duress.
[0036] In an embodiment, the enclosure 100 may exhibit a refined assembly technique wherein the top casing 102 is arranged co-axially onto the bottom casing 104. Such coaxial arrangement facilitates the precise mating of each mounting point of the first pair of mounting points 106 from the top casing 102 to the corresponding mounting point of the second pair of mounting points 114 in the bottom casing 104. When the mounting points are aligned, they form a pair of double shearing mounting points. Such design improves the mechanical coupling between the top casing 102, the bottom casing 104 and also significantly enhances the enclosure 100’s overall structural integrity. The double shearing effect acts to distribute loads more evenly across the connection points, thereby substantially increasing the enclosure 100’s ability to resist various forms of mechanical stress and failure.
[0037] In an embodiment, each rib of the first set of ribs 108 on the top casing 102 may align with a corresponding rib of the third set of ribs 116 on the bottom casing 104 to form a first continuous set of ribs. Such integrated rib design is associated with the pair of double shearing mounting points, which serves to enhance both the rigidity and mechanical strength of the enclosure 100. By creating a continuous rib structure across both the top casing 102 and bottom casing 104, the design ensures that any loads or forces applied to the enclosure 100 are evenly distributed, further enhancing the resilience and durability of the enclosure 100.
[0038] In an embodiment, the pair of double shearing mounting points may refer to a specialized design feature, where the first pair of mounting points 106 aligns with the second pair of mounting points 114 in such a way that they work in tandem to bear loads and resist forces. The term "double shearing" implies that the first pair of mounting points 106 and the second pair of mounting points 114 are aligned to counteract shear forces from two opposing directions. Such alignment is unlike single shear designs, where the shear force is primarily managed in one plane. The pair of double shearing mounting points are robust and offer enhanced rigidity, distributing mechanical stresses more evenly and improving the structure's resistance to both vertical and lateral forces.
[0039] In an embodiment, each rib of the second set of mounting bores 112 may align with a corresponding rib of the fourth set of mounting bores 120 to form a second continuous set of ribs, associated with the crushable zone. Such design provides an additional layer of protection by absorbing and dissipating impact forces. The unique rib alignment in the first crushable zone 110 and the second crushable zone 118, upon external penetration or high-impact forces, the structure is designed to crumple in a controlled manner, reducing the risk of internal battery damage or thermal runaway.
[0040] In an embodiment, at least one of the first crushable zone 110 and the second crushable zone 118 may incorporate at least one gusseting rib as a specialized structural element. The at least one gusseting rib is implemented with the aim of improving the resistance of the enclosure 100 to deformation or buckling under extreme mechanical loads. Unlike standard ribs, the gusseting rib is designed, often featuring complex geometries that efficiently distribute stresses across multiple directions. The gusseting ribs presence in the crushable zones enhances their structural integrity, making the crushable zones much more resilient under conditions of high impact or external force

penetration. The gusseting ribs ensure that the crushable zones can absorb and dissipate energy more effectively, reducing the likelihood of damaging the internal battery components or inducing hazardous conditions like thermal runaway. The gusseting rib distributes the forces from impact across a larger area of the enclosure, reducing the likelihood of localized damage.
[0041] In an embodiment, at least one of the top casing 102 and the bottom casing 104 may comprise at least one set of internal ribs (which can be gusseting ribs to improve load bearing capacity), which are associated with either the internal surface of the top casing 102 or the inner surface of the bottom casing 104. The at least one set of internal ribs provide additional structural integrity and also contribute to the force distribution within the enclosure 100, further reducing stress concentrations that could compromise the enclosure 100’s mechanical stability. The internal ribs can also create sections or compartments within the battery casing, which can be useful for modular battery designs or to separate other components like BMS (Battery Management System) units. The internal ribs can be disposed parallel to each other, ensuring even stress distribution and uniform protection across the length of casing 100.
[0042] In an embodiment, at least one of the internal surfaces of the top casing 102, the inner surface of the bottom casing 104, a side wall of either the top casing 102 or bottom casing 104, may comprise at least one groove that is designed to receive a bolt. Such design facilitates easy assembly and secure fastening of the enclosure components, ensuring robust attachment and operational integrity under various conditions. The bolt can be any type of fastener, usually made of suitable material such as metal, designed to connect two or more components together. In the context of connecting an upper casing 102 and lower casing 104, a bolt typically works in conjunction with a nut, where the bolt is inserted through aligned holes of (mounting points of upper casing 102 and lower casing 104) and then secured on the other side by tightening the nut. This ensures a strong, reliable, and often semi-permanent bond between the two casings. The bolt's threaded design allows for a tight grip and ensures that the connected components remain firmly attached under various conditions. In an embodiment, at least one of the external surfaces of the top casing 102 and the outer surface of the bottom casing 104 can be associated with a plurality of thermal fins, which can improve thermal management by facilitating heat dissipation away from the battery cells, thereby contributing to the overall safety and longevity of the battery pack. Apart from heat management, the thermal fins can add rigidity and strength to the enclosure 100, helping it in resisting deformation under load. Apart from the first set of mounting points 108 and second set of mounting points 114, each of top casing 102 and bottom casing 104 can comprise multiple mounting holes to enable secure mounting of casings (102 and 104) with each other to form enclosure 100 through fastener.
[0043] In an embodiment, the enclosure 100 may include a coolant inlet. Such features allow for the flow of a coolant into the enclosure 100 and the discharge of the coolant out of the enclosure 100, providing an additional mechanism for temperature regulation and thermal management within the battery pack. The coolant, when circulated, can efficiently absorb and remove excess heat from the enclosure 100 and/or battery pack to enable operation of cell and/or electronic components (housed within enclosure 100) at their optimal temperatures, leading to increased performance, reliability, and longevity. With the distinct inlet and outlet points, the coolant can flow seamlessly through the enclosure 100, ensuring a constant supply of fresh coolant and the expulsion of heated coolant. Non-limiting examples of coolants are Water-Glycol based liquid coolant, refringent (e.g., R-134a and R-1234yf), air and other known examples.
[0044] In an embodiment, the enclosure 100 may comprise at least one pressure release vent that can be designed to release built-up internal pressure within the enclosure 100 in case of events like thermal runaway, providing a safety mechanism that can prevent catastrophic failure and potential harm. Instead of allowing the internal pressure to escalate to dangerous levels, the pressure release vent enables a controlled release of this pressure. By doing so, the pressure release vent mitigates the possibility of the enclosure 100 undergoing catastrophic failure, if internal pressure breaches a threshold that might compromise the integrity of the enclosure 100, the vent ensures that this pressure finds a safe outlet.
[0045] The third set of ribs 116 and fourth set of mounting bores 120, individually, may comprise more than 2 ribs, for instance, 3, 4, 5, 6, 8, 10 and the like.
[0046] FIG. 2 illustrates a method 200 for assembling enclosure 100 for a battery pack, in accordance with an embodiment of the present disclosure. The process initiates at step 202 in which a top casing 102 is provided. The top casing 102 is characterized by a first pair of mounting points 106 and a first set of ribs 108. Each rib associates directly with the mounting points to improvise structural coherence of top casing 102. At step 204, a first crushable zone 110 is disposed between the first pair of mounting points 106 of the top casing 102. Further, the first crushable is characterized by a second set of mounting bores 112, which improvises structural and mechanical properties of the first crushable zone 110. The outermost extremities of each rib from this second set are aligned, on a coplanar level, with the ends of the ribs from the first set. The coplanar alignment is critical for impact distribution or energy absorption. The first crushable zone 110 can undergo deformation in the event of an impact to protect the battery pack from damage. The coplanar alignment ensures that the two sets of ribs work together to provide optimal protection for the battery pack.
[0047] Step 206 involves arrangement of a bottom casing 104, which can be analogous to the top casing 102 and forms a lower half of the battery pack enclosure 100. The bottom casing 104 comprises a second set of mounting points, which can be used to secure the bottom casing 104 with the top casing 102. The second set of mounting points 114 are associated with a third set of ribs 116, which provide additional strength and support to the enclosure 100. The step 208 involves disposal of a second crushable zone 118 between the second pair of mounting points 114, this second crushable zone 118 is associated with a fourth set of mounting bores 120. Similar to step 204, the extreme ends of fourth set of mounting bores 120 are aligned coplanarly with the outermost ends of the third set of ribs 116, emphasizing consistency in design and strength requirement.
[0048] The step 210 involves alignment of top casing 102 and bottom casing 104, through alignment of first pair of mounting points 106 and second pair of mounting points 114. The alignment ensures that the two casings 102 and 104 fit together properly when they are assembled. The step 212 involves formation of double shearing mounting points by securing the first pair of mounting points 106 with the second pair of mounting points 114, through appropriate fasteners (E.g., screw, rivet, bolt etc.). Double shearing mounting points are stronger and more resistant to failure than single shearing mounting points. This also enhances the mechanical integrity of the assembled enclosure 100 and helps to protect the battery pack from damage.
[0049] FIG. 3A and 3B showcase a sectional view of a signal sheering joint and a double sheering joint, respectively, in accordance with an embodiment of the present disclosure. The single shear mount is a simpler design but is less effective in distributing force, which places greater stress on the bolt and can lead to quicker failure under heavy loads. Fig. 3A showcases a singular point or plane where the applied load causes shearing. Single shear mounting point usually involves a single interface between two components, with one component (like a bolt or pin) resisting the force trying to slide or separate the assembly. In contrast, the double shear mounting point in cross-section presents two distinct points or planes where the shearing force is distributed. The double shear mounting point typically involves three components, with the central component (often a bolt or pin) bridging the two outer components, resisting forces trying to displace them. By distributing the load across two interfaces instead of one, the double shear mounting offers enhanced strength and durability compared to the single shear mounting point.
[0050] In addition to the front-side mounts, rear double-sheared mounts are also present, offering an extra layer of mechanical robustness. The crushable zone is reinforced with external gusseting ribs, which are designed to enhance its resistance to deformation and provide controlled crumpling during impacts. To tie all these elements together, horizontal side members fasten the top casing 102 and bottom casing 104 using bolts, thereby providing a fully integrated, resilient structure capable of withstanding loads from multiple directions.
[0051] In FIG. 4, an isometric view showcases an enclosure 100 securely attached to a chassis 402 of vehicle, embodying the principles outlined in the present disclosure. The enclosure 100 serves for vehicular safety, designed to absorb and dissipate the forces exerted during an accident event. Manufactured from materials known for their durability and resilience, such as high-strength steel or composite materials, the enclosure 100 is designed to maintain structural integrity even under extreme conditions. The enclosure 100 form interlocks seamlessly with the existing chassis 400, enhancing the overall stability and safety profile of the vehicle. Through a balance of materials science and engineering ingenuity, the assembly aims to significantly mitigate the risks associated with vehicular accidents. To ensure safety and optimal performance, battery pack enclosure 100 can be securely attached to the frame/chassis 400 through utilization of appropriate fasteners 404, which can withstand the forces. Use of sturdy fasteners 402 like nut-bolt combinations or similar alternatives ensures a robust attachment, reducing the risk of dislodgement of battery pack. By fastening the battery pack enclosure 100 directly to the chassis 400 may maximize stability and safety.
[0052] FIG. 5 showcases a top view of an enclosure 100, in accordance with an embodiment of the present disclosure. From top view, only the top casing 102 and parts thereof are visible. As discussed, the top casing 102 comprises the first pair of mounting points 106, each disposed at a front side. These first pair of mounting points 106 are disposed at extreme ends of a front surface of top casing 102. The disposal of mounting points at extreme ends can improve stability and enable uniform distribution of stresses more evenly along the surface of the enclosure 100. The mounting points 106 can be disposed at equidistant from a midline of top casing 102 to enable symmetric weight and forces distribution and also prevent tilting or misalignment of battery pack. The first crushable zone 110 can extend from the midline towards both the mounting points 106 to enable symmetric arrangement of first crushable zone 110. The symmetric design of the first crushable zone 110 ensures that external load/forces from an impact are distributed evenly across the structure, and also eliminates generation of hotspots that can bear excessive load to reduce risk of localized failure. The symmetric first crushable zone 110 ensures that the center of gravity (of enclosure 100) remains centralized, even when parts of the zone start to deform under impact, and also prevents battery pack from becoming unstable during or after an accident. Furthermore, the symmetric first crushable zone 110 simplifies the manufacturing process, leading to cost savings.
[0053] In another embodiment, the present disclosure provides enclosure 100 for battery pack, the enclosure comprising the top casing 102 and the bottom casing 104, which is coupled with the top casing 102 through a plurality of fasteners (e.g., nut-bolt, screw, rivet etc.) to form enclosure 100 to house various components such as multiple cells, cooling plate, cell separator etc. The top casing 102 comprises a first pair of mounting points 106, wherein each of the first pair of mounting points is associated with a first set of ribs 108. The first crushable zone 110 can be disposed between the first pair of mounting points 106, wherein the extreme ends of each rib of the first set of ribs 106 are coplanarly arranged with an outermost edge 122 (shown in Fig. 6) of the first crushable zone 110. The coplanar arrangement, between outermost egde 122 and each outermost endpoint of each rib 108, ensures that any force or stress applied to the enclosure 100 is uniformly distributed across the first pair of mounting points 106 and first crushable zone 110. The bottom casing 104 comprises a second pair of mounting points 114, wherein each of the second pair of mounting points 114 is associated with a third set of ribs 116. The second crushable zone 118 can be disposed between the second pair of mounting points 114, wherein the outermost ends of each rib of the third set of ribs 116 are coplanarly arranged with an outermost edge of the second crushable zone 118. Similar to the top casing 102, coplanar arrangement between outermost edge of bottom casing 104 and each outermost endpoint of each rib 116 ensures that any force or stress applied to the enclosure 100 is uniformly distributed across the second pair of mounting points 106 and second crushable zone 118. The first pair of mounting points 106 mate with the second pair of mounting points 114 to form a pair of double shearing mounting points.
[0054] FIG. 6 illustrates a top view of top casing 102 and parts thereof, in accordance with embodiments of present disclosure. The top casing 102 comprises the first pair of mounting points 106, each disposed at a front side and at extreme ends of a front surface of top casing 102. The first crushable zone 110 can be disposed in between the first pair of mounting points 106. The extremities of each rib in the first set of ribs 112 are coplanarly aligned with an outermost edge 122. Such alignment ensures uniformity in design and promotes consistent energy dispersion throughout the top casing when external force is applied.
[0055] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
[0056] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C … and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims:
1. An enclosure for a battery pack, the enclosure comprising:
a top casing comprising:
a first pair of mounting points, wherein each of the first pair of mounting points is associated with a first set of ribs; and
a first crushable zone disposed between the first pair of mounting points, wherein the first crushable zone is associated with a second set of mounting bores, and wherein the extreme ends of each bore of the second set of mounting bores are coplanarly arranged with the outermost ends of each rib of the first set of ribs; and
a bottom casing comprising:
a second pair of mounting points, wherein each of the second pair of mounting points is associated with a third set of ribs; and
a second crushable zone disposed between the second pair of mounting points, wherein the second crushable zone is associated with a fourth set of mounting bores, and wherein the extreme ends of each bore of the fourth set of mounting bores are coplanarly arranged with the outermost ends of each rib of the third set of ribs;
wherein the first pair of mounting points mate with the second pair of mounting points to form a pair of double shearing mounting points.
2. The enclosure as claimed in claim 1, wherein the top casing is arranged co-axially onto the bottom casing to mate each mounting point of the first pair to corresponding mounting point of the second pair to form the pair of double shearing mounting points.
3. The enclosure as claimed in claim 1, wherein:
each rib of the first set of ribs mates with a corresponding rib of the third set of ribs to form a first continuous set of ribs associated with the pair of double shearing mounting points; and
each rib of the second set of mounting bores mates with a corresponding rib of the fourth set of mounting bores to form a second continuous set of ribs associated with the crushable zone.
4. The enclosure as claimed in claim 1, wherein the at least one of the first crushable zone and the second crushable zone is associated with at least one gusseting rib disposed on an external surface.
5. The enclosure as claimed in claim 1, wherein at least one of the top casing and the bottom casing comprises at least one set of internal ribs associated, respectively, with at least one of an internal surface of the top casing and an inner surface of the bottom casing.
6. The enclosure as claimed in claim 1, wherein at least one of the internal surface of the top casing, the inner surface of the bottom casing, a side wall of at least one of the top casing, and the bottom casing comprises at least one groove and wherein the at least one groove receives a bolt.
7. The enclosure as claimed in claim 1, wherein at least one of an external surface of the top casing and an outer surface of the bottom casing is associated with a plurality of thermal fins.
8. The enclosure as claimed in claim 1, wherein the enclosure comprises a coolant inlet for allowing flow of a coolant into the enclosure, and a coolant outlet for allowing discharge of the coolant out of the enclosure.
9. The enclosure as claimed in claim 1, wherein the enclosure comprises at least one pressure release vent.
10. A method for assembling an enclosure for a battery pack, the method comprising the steps of:
providing a top casing having a first pair of mounting points, each of the first pair of mounting points being associated with a first set of ribs;
disposing a first crushable zone between the first pair of mounting points, wherein the first crushable zone is associated with a second set of mounting bores, and aligning the extreme ends of each bore of the second set of mounting bores coplanarly with the outermost ends of each rib of the first set of ribs;
providing a bottom casing having a second pair of mounting points, each of the second pair of mounting points being associated with a third set of ribs;
disposing a second crushable zone between the second pair of mounting points, wherein the second crushable zone is associated with a fourth set of mounting bores, and aligning the extreme ends of each bore of the fourth set of mounting bores coplanarly with the outermost ends of each rib of the third set of ribs;
aligning the first pair of mounting points on the top casing with the second pair of mounting points on the bottom casing; and
securing the first pair of mounting points to the second pair of mounting points, thereby forming a pair of double shearing mounting points to enhance the mechanical integrity of the assembled enclosure.
11. An enclosure for a battery pack, the enclosure comprising:
a top casing comprising:
a first pair of mounting points, wherein each of the first pair of mounting points is associated with a first set of ribs; and
a first crushable zone disposed between the first pair of mounting points, wherein the extreme ends of each rib of the first set of ribs are coplanarly arranged with an outermost edge of the first crushable zone; and
a bottom casing comprising:
a second pair of mounting points, wherein each of the second pair of mounting points is associated with a third set of ribs; and
a second crushable zone disposed between the second pair of mounting points, wherein the outermost ends of each rib of the third set of ribs are coplanarly arranged with an outermost edge of the second crushable zone;
wherein the first pair of mounting points mate with the second pair of mounting points to form a pair of double shearing mounting points.

ABSTRACT

The present disclosure provides an enclosure designed for housing a battery pack to enhance mechanical strength and safety. The enclosure comprises a top casing and a bottom casing and mounting points reinforced by sets of ribs. The top casing includes a first pair of mounting points associated with a first set of ribs and a first crushable zone, which is positioned between the mounting points, incorporates a second set of mounting bores with extreme ends that align coplanarly with the outermost ends of the first set of ribs. Similarly, the bottom casing has a second pair of mounting points, each related to a third set of ribs, and a second crushable zone associated with a fourth set of mounting bores. When assembled, the first and second pairs of mounting points engage to form a pair of double shearing mounting points, optimizing load distribution and minimizing the risk of structural failure. Such design ensures enhanced rigidity, even load distribution, and controlled crumpling under high-impact forces.
Fig. 1 , C , Claims:Claims:
1. An enclosure for a battery pack, the enclosure comprising:
a top casing comprising:
a first pair of mounting points, wherein each of the first pair of mounting points is associated with a first set of ribs; and
a first crushable zone disposed between the first pair of mounting points, wherein the first crushable zone is associated with a second set of mounting bores, and wherein the extreme ends of each bore of the second set of mounting bores are coplanarly arranged with the outermost ends of each rib of the first set of ribs; and
a bottom casing comprising:
a second pair of mounting points, wherein each of the second pair of mounting points is associated with a third set of ribs; and
a second crushable zone disposed between the second pair of mounting points, wherein the second crushable zone is associated with a fourth set of mounting bores, and wherein the extreme ends of each bore of the fourth set of mounting bores are coplanarly arranged with the outermost ends of each rib of the third set of ribs;
wherein the first pair of mounting points mate with the second pair of mounting points to form a pair of double shearing mounting points.
2. The enclosure as claimed in claim 1, wherein the top casing is arranged co-axially onto the bottom casing to mate each mounting point of the first pair to corresponding mounting point of the second pair to form the pair of double shearing mounting points.
3. The enclosure as claimed in claim 1, wherein:
each rib of the first set of ribs mates with a corresponding rib of the third set of ribs to form a first continuous set of ribs associated with the pair of double shearing mounting points; and
each rib of the second set of mounting bores mates with a corresponding rib of the fourth set of mounting bores to form a second continuous set of ribs associated with the crushable zone.
4. The enclosure as claimed in claim 1, wherein the at least one of the first crushable zone and the second crushable zone is associated with at least one gusseting rib disposed on an external surface.
5. The enclosure as claimed in claim 1, wherein at least one of the top casing and the bottom casing comprises at least one set of internal ribs associated, respectively, with at least one of an internal surface of the top casing and an inner surface of the bottom casing.
6. The enclosure as claimed in claim 1, wherein at least one of the internal surface of the top casing, the inner surface of the bottom casing, a side wall of at least one of the top casing, and the bottom casing comprises at least one groove and wherein the at least one groove receives a bolt.
7. The enclosure as claimed in claim 1, wherein at least one of an external surface of the top casing and an outer surface of the bottom casing is associated with a plurality of thermal fins.
8. The enclosure as claimed in claim 1, wherein the enclosure comprises a coolant inlet for allowing flow of a coolant into the enclosure, and a coolant outlet for allowing discharge of the coolant out of the enclosure.
9. The enclosure as claimed in claim 1, wherein the enclosure comprises at least one pressure release vent.
10. A method for assembling an enclosure for a battery pack, the method comprising the steps of:
providing a top casing having a first pair of mounting points, each of the first pair of mounting points being associated with a first set of ribs;
disposing a first crushable zone between the first pair of mounting points, wherein the first crushable zone is associated with a second set of mounting bores, and aligning the extreme ends of each bore of the second set of mounting bores coplanarly with the outermost ends of each rib of the first set of ribs;
providing a bottom casing having a second pair of mounting points, each of the second pair of mounting points being associated with a third set of ribs;
disposing a second crushable zone between the second pair of mounting points, wherein the second crushable zone is associated with a fourth set of mounting bores, and aligning the extreme ends of each bore of the fourth set of mounting bores coplanarly with the outermost ends of each rib of the third set of ribs;
aligning the first pair of mounting points on the top casing with the second pair of mounting points on the bottom casing; and
securing the first pair of mounting points to the second pair of mounting points, thereby forming a pair of double shearing mounting points to enhance the mechanical integrity of the assembled enclosure.
11. An enclosure for a battery pack, the enclosure comprising:
a top casing comprising:
a first pair of mounting points, wherein each of the first pair of mounting points is associated with a first set of ribs; and
a first crushable zone disposed between the first pair of mounting points, wherein the extreme ends of each rib of the first set of ribs are coplanarly arranged with an outermost edge of the first crushable zone; and
a bottom casing comprising:
a second pair of mounting points, wherein each of the second pair of mounting points is associated with a third set of ribs; and
a second crushable zone disposed between the second pair of mounting points, wherein the outermost ends of each rib of the third set of ribs are coplanarly arranged with an outermost edge of the second crushable zone;
wherein the first pair of mounting points mate with the second pair of mounting points to form a pair of double shearing mounting points.