Description:ENCLOSURE FOR BATTERY PACK
Field of the Invention
[0001] The present disclosure generally relates to battery enclosures. Further, the present disclosure particularly relates to an enclosure for a battery pack with specific structural features for enhanced mechanical stability.
Background
[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Battery packs are commonly utilized in electric vehicles to store and provide electrical energy necessary for propulsion. Battery packs are generally enclosed within protective casings to safeguard against external elements, mechanical impacts, and thermal variations. The structural integrity of the enclosure is vital to maintaining the safety and durability of the battery pack. Typically, battery enclosures are composed of top and bottom casings that combine to form a sealed unit. The demand for mechanical stability in various operating conditions has necessitated the development of enclosures with specific design elements intended to counteract external forces.
[0004] Various designs of battery enclosures are known. A commonly implemented design features mounting points that secure the top and bottom casings. Said mounting points are often reinforced with ribs to increase structural rigidity. Certain designs also include crushable zones that serve to absorb impact energy during collisions, thereby protecting the internal battery cells. However, conventional designs often present limitations such as misalignment of ribs and crushable zones, resulting in inadequate energy absorption and structural failure under extreme conditions.
[0005] Another existing structure incorporates co-planar arrangements of ribs and crushable zones. Such arrangements aim to distribute impact forces evenly across the enclosure, reducing the risk of localized failure. Nevertheless, the alignment and interaction of mounting points between the top and bottom casings frequently pose difficulties in achieving a secure and reliable connection. Misalignment can lead to uneven stress distribution, compromising the structural integrity of the battery pack enclosure during regular use or in the event of a collision.
[0006] Moreover, conventional structures incorporating double shearing mounting points are also prevalent. Double shearing mounting points are intended to provide increased resistance to shear forces by engaging pairs of mounting points to create a more robust connection. Despite this, challenges remain regarding the alignment of ribs and the co-planar arrangement of structural components. Such challenges may result in inefficient force transfer, diminishing the protective capabilities of the enclosure.
[0007] In light of the above discussion, there exists an urgent need for solutions that overcome the problems associated with conventional systems and/or techniques for designing and implementing enclosures for battery packs.
Summary
[0008] The following presents a simplified summary of various aspects of this disclosure in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects and is intended to neither identify key or critical elements nor delineate the scope of such aspects. Its purpose is to present some concepts of this disclosure in a simplified form as a prelude to the more detailed description that is presented later.
[0009] The following paragraphs provide additional support for the claims of the subject application.
[00010] In an aspect, the present disclosure provides an enclosure for a battery pack comprising a top casing and a bottom casing. The top casing includes a first pair of mounting points, and a first crushable zone disposed between said mounting points. The bottom casing includes a second pair of mounting points, and a second crushable zone disposed between said mounting points. Each mounting point of the first pair is associated with a first set of ribs, and each mounting point of the second pair is associated with a second set of ribs. The outermost ends of each rib of the second set form a co-planar arrangement with the outermost ends of each rib of the first set, the first edge of the first crushable zone, and the second edge of the second crushable zone. The co-planar alignment contributes to the formation of a pair of double shearing mounting points when the first and second pairs of mounting points are mated, enhancing the structural stability of the enclosure.
[00011] In another aspect, each mounting point of the first and second pairs includes a threaded surface to receive a fastener, securing the top casing to the bottom casing. The threaded engagement provides a reliable attachment method that maintains the integrity of the enclosure under various conditions, preventing unintentional disassembly or separation during use.
[00012] Further, the first set of ribs and the second set of ribs are oriented in a direction perpendicular to the mating plane of the first and second pairs of mounting points. The perpendicular orientation of the ribs distributes forces evenly across the enclosure, reducing stress concentrations at the mounting points and contributing to the durability of the enclosure.
[00013] Moreover, the first crushable zone and the second crushable zone are associated with a plurality of grooves. Said grooves facilitate controlled deformation of the crushable zones under impact, allowing the zones to absorb and dissipate energy.
[00014] In a further aspect, the first crushable zone includes a recess to receive a stiffener, with the end of the stiffener forming a co-planar arrangement with the outermost ends of each rib of the first set of ribs. The integration of the stiffener within the first crushable zone provides additional structural support. The co-planar alignment allows the stiffener and the ribs to respond uniformly to external stresses, improving the overall strength and resilience of the enclosure.
[00015] Additionally, each rib of the first set of ribs and the second set of ribs includes alternating solid and perforated segments. The segments allow for selective deformation and effective force distribution across the ribs. The solid segments provide structural support, while the perforated segments enable the ribs to flex and absorb energy.
[00016] Furthermore, the first crushable zone and the second crushable zone are formed of a lattice structure. The lattice structure allows for progressive deformation, gradually absorbing energy as the load increases. The gradual energy absorption prevents sudden failure of the crushable zones.
[00017] In another aspect, the first set of ribs and the second set of ribs are made from a damping material that selectively stiffens under stress. The damping material allows the ribs to remain flexible under normal conditions, reducing the transmission of vibrations to the battery pack. However, when subjected to higher stress, the material stiffens, providing additional support and protection.
[00018] Moreover, the first set of ribs and the second set of ribs include spaced-apart surfaces that define an internal cavity. The spacing between said surfaces allows controlled deformation, enabling the ribs to absorb and redistribute forces effectively. The controlled deformation capability enhances the structural integrity of enclosure by preventing the direct transmission of impact forces to the battery pack, reducing the likelihood of damage.
[00019] Additionally, the top casing of the enclosure includes a series of tabs positioned equidistantly along the perimeter, each tab associated with a tapered geometry that widens towards the base. The tapered geometry facilitates a secure and stable connection between the top casing and the bottom casing. The widening at the base of each tab provides a broader surface for engagement, enhancing the stability of the enclosure and making sure that the connection remains strong under operational stresses.
[00020] In a further aspect, the bottom casing includes a series of slots positioned equidistantly along the perimeter, each slot featuring a recessed channel to receive the tapered tabs of the top casing. The recessed channels in the slots accommodate the tapered tabs. The configuration maintains the alignment of the top casing and bottom casing, preventing unintended separation and assuring that the enclosure remains intact during use.
[00021] Finally, the first set of ribs and the second set of ribs are associated with a curved profile. The curved profile of the ribs distributes impact forces evenly across the surface, reducing localized stress concentrations that could lead to structural failure. The curvature allows the ribs to absorb and dissipate energy effectively, enhancing the overall resilience of the enclosure and providing protection for the battery pack.
Brief Description of the Drawings
[00022] The features and advantages of the present disclosure would be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
[00023] FIG. 1 illustrates enclosure for a battery pack, in accordance with the embodiments of the present disclosure.
[00024] FIG. 2 illustrates a flow diagram of an enclosure for a battery pack in accordance with the embodiments of the present disclosure.
[00025] FIG. 3 illustrates a top view of the top casing of battery enclosure, in accordance with the embodiments of the present disclosure.
Detailed Description
[00026] In the following detailed description of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to claim those skilled in the art to practice the invention. Other embodiments may be utilized, and structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims and equivalents thereof.
[00027] The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[00028] Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
[00029] As used herein, the term “enclosure for a battery pack” refers to a protective structure housing and securing a battery pack, typically used in electric vehicles or other electronic devices. The enclosure protects the battery pack from external physical impacts, environmental factors such as moisture and dust, and provides structural integrity to the battery pack. The enclosure is made up of multiple parts, including a top casing and a bottom casing, which are connected to form a sealed unit. The enclosure typically facilitates both ease of assembly and maintenance by providing mounting points for connecting different sections together. Additionally, the enclosure may be made of materials offering strength and lightweight properties, such as aluminium or reinforced polymers.
[00030] As used herein, the term "battery pack" refers to an assembly of one or more batteries arranged to provide power for a system or device. A battery pack may include rechargeable or non-rechargeable cells and could be used to power a variety of electronic devices or vehicles. The battery pack is typically housed within an enclosure to get protection from external environmental factors such as moisture, dust, or physical impact. Battery packs often incorporate connections to facilitate the flow of electrical energy from the batteries to the external components of a system, and may include integrated features like cooling systems, electrical connectors, or monitoring electronics for performance management.
[00031] As used herein, the term “top casing” refers to the upper portion of the enclosure for a battery pack, which covers and protects the upper side of the battery cells contained within the enclosure. The top casing typically includes structural features, such as mounting points, ribs, and crushable zones, to enhance the mechanical stability of the battery pack. The top casing works in conjunction with the bottom casing to form a sealed enclosure that provides a protective barrier against environmental factors like dust, moisture, and mechanical impacts. The top casing may also serve as a mounting platform for additional components or provide openings for electrical connections. The top casing is usually made from materials offering a balance between strength, durability, and weight, such as aluminium alloys or high-strength plastics.
[00032] As used herein, the term “bottom casing” refers to the lower portion of the enclosure for a battery pack, which supports and protects the lower side of the battery cells housed within the enclosure. The bottom casing typically includes structural features such as mounting points, ribs, and crushable zones, similar to those found in the top casing. The bottom casing works in tandem with the top casing to form a sealed and protective enclosure that safeguards the battery pack from external elements and mechanical damage. The bottom casing may also include mounting points or interfaces for securing the entire enclosure within a larger system, such as a vehicle chassis. The bottom casing is generally constructed from materials offering both durability and lightness, such as metals like aluminium or reinforced plastics.
[00033] As used herein, the term “mounting points” refers to specific locations on the top and bottom casings of the enclosure for a battery pack, where the casings are secured together. The mounting points aligns the top and bottom casings accurately and may include features such as threaded surfaces to receive fasteners, such as bolts or screws, that secure the two casings. Mounting points are often placed to optimize the stability and alignment of the connected components.
[00034] As used herein, the term "crushable zone" refers to a region within battery pack enclosure that absorbs and dissipates energy during impact. This area typically undergoes controlled deformation to protect more rigid components, such as a battery pack, from damage. Crushable zones may include features such as grooves, recesses, and lattice structures that enable progressive deformation, distributing forces in a way that minimizes harm to the surrounding components. These zones are often positioned between key structural elements, such as mounting points, and can be arranged to collapse predictably under stress to mitigate the effect of external forces like collisions or falls.
[00035] As used herein, the term "crushable zone" refers to a region within a structure that absorb and dissipate energy during impact. This area typically undergoes controlled deformation to protect more rigid components, such as a battery pack, from damage. Crushable zones may include features such as grooves, recesses, and lattice structures that enable progressive deformation, distributing forces in a way that minimizes harm to the surrounding components. These zones are often positioned between key structural elements, such as mounting points, and can be collapsed predictably under stress to mitigate the effect of external forces like collisions or falls.
[00036] As used herein, the term "ribs" refers to structural elements that reinforce a component by distributing mechanical loads across a larger surface area. Ribs can be arranged in different configurations, such as perpendicular to a mating plane, to provide enhanced strength and stability. In enclosures, ribs often serve as support structures for mounting points and may deform selectively under stress to protect internal components from impact. Ribs can have additional features like solid or perforated segments that allow for controlled deformation and force distribution. Ribs are integral to maintaining the overall strength and durability of the system.
[00037] As used herein, the term “threaded surface” refers to a surface feature within the mounting points of the top and bottom casings of the enclosure for a battery pack that receives a fastener, such as a screw or bolt. The threaded surface allows the top and bottom casings to be securely fastened together, assuring a stable and durable connection. The presence of threaded surfaces in the mounting points provides the necessary grip and alignment for the fasteners, preventing them from loosening under vibration or other mechanical stresses.
[00038] FIG. 1 illustrates an enclosure 100 for a battery pack, in accordance with the embodiments of the present disclosure. The enclosure 100 for the battery pack includes a top casing 102 and a bottom casing 108. The top casing 102 incorporates a first pair of mounting points 104, each associated with a first set of ribs 114. The first pair of mounting points 104 facilitates the secure attachment of the top casing 102 to corresponding elements of the battery pack. The first set of ribs 114 provides structural reinforcement around the mounting points 104, distributing mechanical loads across the top casing 102. The ribs 114 are aligned with anticipated forces during operation, reducing stress concentrations at the mounting points 104 and enhancing the overall durability of the top casing 102. The specific positioning and configuration of the first set of ribs 114 provides stability under various conditions, preventing deformation or damage during use. The ribs in the top casing are manufactured with a specific form factor to optimize load distribution and structural reinforcement. Geometrically, the ribs are typically elongated, with a rectangular or trapezoidal cross-section, providing both stiffness and material efficiency. These ribs extend radially or longitudinally outward from the mounting points toward the outer edges of the casing. The ribs are positioned in alignment with the expected direction of forces during operation, which may include vertical, lateral, or torsional forces depending on the application. The ribs can extend in parallel or slightly angled configurations, following the contours of the casing to maximize support in areas where mechanical stress is anticipated. Such rib configuration enables that forces applied to the mounting points are distributed over a wider area of the casing, minimizing localized stress and reducing the risk of material fatigue or failure. The person ordinarily skill in the art can optimize depth and thickness of the ribs to balance the need for reinforcement with material constraints, providing adequate rigidity without adding unnecessary weight
[00039] In an embodiment, a first crushable zone 106 is located between the first pair of mounting points 104 within the top casing 102. The first crushable zone 106 absorbs impact energy, acting as a buffer to protect the battery pack in the event of an external force, such as a collision. The material composition and structure of the first crushable zone 106 are selected to balance toughness with the ability to undergo controlled deformation. The controlled deformation allows the first crushable zone 106 to absorb energy effectively, thereby preventing the transmission of impact forces directly to the battery pack. The placement of the first crushable zone 106 maximizes protection for the battery pack, particularly in high-stress scenarios. The first crushable zone 106 is integral to the top casing 102, working in conjunction with the mounting points 104 and the first set of ribs 114 to maintain the structural integrity of the enclosure 100 while providing necessary protection against impact-related damage. The first crushable zone 106 can be in associated with honeycomb, ribbed, or corrugated pattern, to deform along a specific axis aligned with the direction of expected external forces, such as frontal or side impacts. The controlled deformation helps to manage the energy dissipation effectively, allowing for efficient absorption of forces. The first crushable zone 106 may be made of materials like aluminium foam, thermoplastics, or other energy-absorbing composites that enables balance between rigidity and ductility.
[00040] In an embodiment, the bottom casing 108 of the enclosure 100 features a second pair of mounting points 110, each associated with a second set of ribs 116. The second pair of mounting points 110 serves as the primary attachment interface for the bottom casing 108, enabling secure connection to the battery pack or associated components. The second set of ribs 116 provides additional structural support, making sure that the bottom casing 108 can withstand the mechanical stresses encountered during operation. These ribs 116 are positioned and oriented to distribute loads evenly across the bottom casing 108, minimizing the risk of localized stress concentrations that could lead to structural failure. The second set of ribs 116 contributes to the rigidity of the bottom casing 108, enhancing the ability to protect the battery pack during use.
[00041] In an embodiment, a second crushable zone 112 is positioned between the second pair of mounting points 110 within the bottom casing 108. The second crushable zone 112 functions similarly to the first crushable zone 106, providing a means of energy absorption to protect the battery pack from impact forces. The material and structure of the second crushable zone 112 complement the overall structure of the bottom casing 108. The second crushable zone 112 is placed to align with the first crushable zone 106 when the top casing 102 and the bottom casing 108 are mated. Said alignment provides continuous protection across the entire enclosure 100, with the first crushable zone 106 and the second crushable zone 112 working together to absorb impact energy and safeguard the battery pack. The second crushable zone 112 provide protection by absorbing energy from external forces, complementing the function of the first crushable zone 106. The second crushable zone 112 can be associated with would take the form of a deformable structure such as a honeycomb or accordion pattern, oriented along the vertical axis of the battery pack, for optimum deformation in the direction of the expected impact. Such structure allows for a progressive collapse that manages the energy transfer during a collision. The second crushable zone 112 enables selective deformation under load conditions by varying material thickness or incorporating specific weakening features, such as perforations or notches, which trigger controlled deformation upon impact. By tailoring the structural response, the second crushable zone 112 can absorb different magnitudes of impact, enabling that the load is effectively managed, and that the battery pack remains protected across a range of crash scenarios.
[00042] In an embodiment, the outermost ends of each rib in the second set of ribs 116 form a co-planar arrangement with the outermost ends of each rib in the first set of ribs 114. The co-planar alignment makes sure that the top casing 102 and the bottom casing 108, when mated, create a unified structure. The co-planar arrangement enhances the rigidity of the enclosure 100, allowing for uniform force distribution across the enclosure 100. By aligning the ribs in said manner, the arrangement reduces the potential for stress concentrations and allows the enclosure 100 to withstand external forces without compromising the integrity of the battery pack. The co-planar arrangement of the ribs also simplifies the assembly process, providing a clear and consistent alignment point for the top casing 102 and the bottom casing 108.
[00043] In an embodiment, the outermost ends of the ribs are also aligned with the edges of the first crushable zone 106 and the second crushable zone 112. The alignment assures that the second crushable zone 112 and the first crushable zone 106 are effectively integrated into the overall structure of the enclosure 100, providing continuous protection across the mating interface of the top casing 102 and the bottom casing 108. The alignment of the ribs with the first and the second crushable zones 106, 112 allows for a seamless transfer of forces from the ribs to the first and the second crushable zones 106, 112 in the event of an impact, assuring that the energy absorption is distributed evenly across the enclosure 100.
[00044] In an embodiment, upon mating the first pair of mounting points 104 with the second pair of mounting points 110, a pair of double shearing mounting points is formed. These double shearing mounting points provide enhanced mechanical stability to the enclosure 100, affirming that the top casing 102 and the bottom casing 108 remain securely attached during operation. The double shearing distributes forces across multiple planes, reducing the likelihood of failure at the first and the second pair of mounting points 104, 110 under high load conditions. The geometry and positioning of the double shearing mounting points balance the need for secure attachment with the requirement for ease of assembly and disassembly of the enclosure 100.
[00045] In a collision scenario, such as one involving an impact force of 1000 N, the co-planar arrangement allows for an efficient distribution of the force. The 1000 N impact force would be shared between the first set of ribs 114 and the second set of ribs 116, as well as between the first crushable zone 106 and the second crushable zone 112. For instance, 500 N might be absorbed by the combined ribs, with each rib in both the first set 114 and the second set 116 bearing 125 N if there are four ribs in each set. The remaining 500 N would be managed by the crushable zones, with the first crushable zone 106 and the second crushable zone 112 each absorbing 250 N. The co-planar alignment ensures that the load is evenly distributed, preventing stress concentrations that could lead to localized failures. By directing the force uniformly across the outermost ends of each rib in both the first set 114 and the second set 116 and the first crushable zone 106 and the second crushable zone 112, the enclosure 100 able to absorb impact forces effectively, protecting the battery pack from damage while maintaining the integrity of the double shearing mounting points formed by the mating of the first pair of mounting points 104 and the second pair of mounting points 110.
[00046] In an embodiment, each mounting point of the first pair of mounting points 104 and the second pair of mounting points 110 includes a threaded surface to receive a fastener. The threaded surface provides an interface for securing the top casing 102 to the bottom casing 108, through the fastener. The threaded surface allows the fastener to engage

securely with each mounting point of the first pair of mounting points 104 and the second pair of mounting points 110, thereby making sure stable and firm connection between the top casing 102 to the bottom casing 108. The connection maintains the integrity of the enclosure 100 during various operational conditions, including mechanical stress, vibration, and impact. The threaded surfaces may accommodate different types of fasteners, such as screws, bolts, or other mechanical fasteners, depending on the specific requirements of the battery pack and the intended application. The threaded surfaces may also comprise specific threading patterns or pitches to optimize the strength and durability of the connection.
[00047] In an embodiment, the first set of ribs 114 associated with the first pair of mounting points 104 and the second set of ribs 116 associated with the second pair of mounting points 110 are oriented in a direction perpendicular to the mating plane of the first pair of mounting points 104 and the second pair of mounting points 110. The perpendicular orientation of the first set of ribs 114 and the second set of ribs 116 optimizes the distribution of mechanical loads across the enclosure 100, particularly at the junction where the top casing 102 meets the bottom casing 108. The perpendicular orientation helps in channelling forces away from the mating plane and into the surrounding structure, thereby reducing the likelihood of localized stress concentrations that could lead to deformation or failure. The first and the second set of ribs 114, 116 act as reinforcing elements that enhance the overall rigidity and stability of the enclosure 100 by providing additional support to the first and the second pair of mounting points 104, 110. The perpendicular alignment of the first and the second set of ribs 114, 116 also contributes to the effective transfer of loads between the top and the bottom casings 102, 108, affirming that the enclosure 100 can withstand various mechanical stresses encountered during operation. The placement of the first and the second set of ribs 114, 116 are carefully considered to maximize the strength of the enclosure 100 without adding unnecessary weight or complexity.
[00048] In an embodiment, the first crushable zone 106 associated with the top casing 102 and the second crushable zone 106 associated with the bottom casing 108 including a plurality of grooves. The grooves are incorporated into the first and the second crushable zones 106, 112 to facilitate controlled deformation under impact or mechanical stress. The primary function of the grooves is to direct and manage the way the first and the second crushable zones 106, 112 collapse when subjected to external forces, such as during a collision or other impact events. The grooves act as predetermined weak points that allow the material in the first and the second crushable zones 106, 112 to fold or crumple in a controlled manner, thereby absorbing and dissipating the energy from the impact. The controlled deformation helps to protect the battery pack housed within the enclosure 100 by minimizing the transmission of shock and vibration to the internal components. The number, size, and orientation of the grooves within the first and the second crushable zones 106, 112 can be varied depending on the specific structural requirements and the expected operational conditions of the enclosure 100. The grooves may be arranged in parallel, perpendicular, or diagonal patterns, each offering different deformation characteristics.
[00049] In an embodiment, the first crushable zone 106 within the top casing 102 comprises a recess to receive a stiffener. The stiffener provides enhanced support and rigidity to the first crushable zone 106. The stiffener reinforces the first crushable zone 106 while still allowing for controlled deformation in the event of an impact. The inclusion of a stiffener within the first crushable zone 106 adds an extra layer of protection to the battery pack by affirming that the first crushable zone 106 can absorb and dissipate energy more effectively. The stiffener forms a co-planar arrangement with the outermost ends of each rib of the first set of ribs 114. The co-planar arrangement assures that the stiffener is properly aligned with the surrounding structural elements, thereby enhancing the overall stability and integrity of the enclosure 100.
[00050] In an embodiment, each rib of the first set of ribs 114 associated with the top casing 102 and the second set of ribs 116 associated with the bottom casing 108 comprises alternating solid and perforated segments. The aforesaid arrangement allows for selective deformation and controlled force distribution across the enclosure 100. The solid segments of the first and the second set of ribs 114, 116 provide the necessary rigidity and structural support to the first and the second pair of mounting points 104, 110, such that the enclosure 100 can withstand various mechanical loads and stresses during operation. The perforated segments, on the other hand, introduce controlled flexibility into the first and the second set of ribs 114, 116, allowing them to deform selectively under specific conditions. The perforations act as predetermined weak points that enable the first and the second set of ribs 114, 116 to bend or flex in a controlled manner, thereby absorbing and distributing forces more effectively. The selective deformation capability is particularly important in scenarios where the enclosure 100 is subjected to sudden impacts or mechanical shocks, as the selective deformation capability helps to prevent localized stress concentrations that could lead to structural failure. The alternating pattern of solid and perforated segments within the ribs 114, balances the need for strength and flexibility.
[00051] In an embodiment, the first crushable zone 106 associated with the top casing 102 and the first crushable zone 106 associated with the bottom casing 108 are formed of a lattice structure. The lattice structure enables progressive deformation under impact or mechanical stress. The lattice structure consists of a network of interconnected beams or struts that create a pattern of open spaces within the first and the second crushable zones 106, 112. The lattice structure allows the first and the second crushable zones 106, 112 to deform gradually, absorbing and dissipating energy over a larger area. The progressive deformation provided by the lattice structure helps to prevent sudden or catastrophic failure of the enclosure 100 by distributing the impact forces more evenly across the first and the second crushable zones 106, 112. The lattice structure is particularly effective in managing high-energy impacts, such as those encountered during collisions or other severe mechanical events. The lattice structure can be customized to meet specific requirements, with variations in the size, shape, and orientation of the beams or struts to achieve the desired deformation characteristics.
[00052] In an embodiment, the top casing 102 includes the first pair of mounting points 104, while the bottom casing 108 includes the second pair of mounting points 110. Each mounting point is associated with a set of ribs, where the first set of ribs 114 corresponds to the first pair of mounting points 104, and the second set of ribs 116 corresponds to the second pair of mounting points 110. The ribs are positioned to enhance the structural integrity of the enclosure 100 by distributing mechanical loads away from the first and the second pair of mounting points 104, 110 and reducing deformation. The co-planar arrangement of the outermost ends of the ribs and the edges of the first and the second crushable zones 106, 112 stabilizes the enclosure 100, providing even load distribution and improving durability. The mating of the first and the second pairs of mounting points 104, 110 forms double shearing mounting points, which provide additional resistance to shear forces, resulting in a reliable and robust connection that can withstand various operational stresses.
[00053] In an embodiment, the first and the second pairs of mounting points 104, 110 in the enclosure 100 include threaded surfaces to receive fasteners. The inclusion of threaded surfaces in the first and the second pair of mounting points 104, 110 allows for secure attachment of the top casing 102 to the bottom casing 108 using appropriate fasteners such as bolts or screws. The threaded surfaces create a tight fit between the top and the bottom casings 102, 108, which is important for maintaining the structural integrity of the enclosure 100 under conditions involving vibration or mechanical shocks. The threaded surface also facilitates assembly and disassembly of the enclosure 100, allowing for maintenance or replacement of components. By providing a reliable and repeatable connection mechanism, the threaded surfaces contribute to the stability of the enclosure 100.
[00054] In an embodiment, the first set of ribs 114 associated with the top casing 102 and the second set of ribs 116 associated with the bottom casing 108 are oriented perpendicularly to the mating plane of the first and the second pairs of mounting points 104, 110. The perpendicular orientation of the ribs optimizes the distribution of mechanical loads across the enclosure 100. The perpendicular alignment enhances the ability of the first and the second set of ribs 114, 116 to resist bending and torsional forces, which are encountered during collision. By directing the forces away from the mounting points and into the surrounding structure, the ribs help prevent localized stress concentrations that could lead to structural failure. The perpendicular orientation also aids in maintaining the stability of the enclosure 100 by keeping the top and the bottom casings 102, 108 securely aligned, even under dynamic loading conditions.
[00055] In an embodiment, the first crushable zone 106 in the top casing 102 and the second crushable zone 112 in the bottom casing 108 are associated with a plurality of grooves to facilitate controlled deformation under impact. The grooves act as predetermined paths of least resistance within the first and the second crushable zones 106, 112, directing the way said zones deform when subjected to external forces. By channelling the deformation energy in a controlled manner, the grooves help absorb and dissipate impact energy, thereby reducing the risk of damage to the battery pack housed within the enclosure 100.
[00056] In an embodiment, the first crushable zone 106 in the top casing 102 includes a recess to accommodate a stiffener. The stiffener, when inserted into the recess, provides additional structural support to the first crushable zone 106 without compromising the ability to deform under impact. The stiffener aligns co-planarly with the outermost ends of the first set of ribs 114, creating a continuous and stable structural interface within the enclosure 100. The co-planar arrangement distributes mechanical loads evenly across the first crushable zone 106 and the associated ribs, improving the overall stability of the enclosure 100. The stiffener allows the first crushable zone 106 to absorb and dissipate energy more effectively, providing protection for the battery pack during impact events.
[00057] In an embodiment, each rib within the first set of ribs 114 and the second set of ribs 116 comprises with alternating solid and perforated segments. The alternating segments allow the first and the second set of ribs 114 and 116 to achieve selective deformation and optimized force distribution across the enclosure 100. The solid segments provide the necessary rigidity to the first and the second pair of mounting points 104, 110 and maintain the structural integrity of the enclosure 100 under normal operating conditions. The perforated segments introduce controlled flexibility into the ribs, enabling them to deform in response to specific mechanical stresses. The selective deformation capability is particularly beneficial in managing impact forces, as the perforated segments allow the ribs to bend or flex without compromising the overall structure of the enclosure 100. The alternating segments is calibrated to provide that the first and the second set of ribs 114, 116 can withstand both static and dynamic loads.
[00058] In an embodiment, the first crushable zone 106 in the top casing 102 and the second crushable zone 112 in the bottom casing 108 are formed of a lattice structure. The lattice structure enables progressive deformation under mechanical stress, providing a controlled and gradual collapse of the first and the second crushable zones 106, 112 during impact. The interconnected beams or struts within the lattice structure create a network of open spaces that allow the first and the second crushable zones 106, 112 to deform in a predictable and controlled manner. The progressive deformation capability helps absorb and dissipate impact energy over a larger area, reducing the force transmitted to the battery pack housed within the enclosure 100.
[00059] In an embodiment, the first set of ribs 114 and the second set of ribs 116 within the enclosure 100 include a damping material that selectively stiffens under specific conditions. The damping material adjusts stiffness in response or influence of to external forces such as impact or vibration. Said damping material allows the first and the second set of ribs 114, 116 to remain flexible under normal operating conditions, thereby reducing the transmission of vibrations to the battery pack. Upon experiencing a significant impact or load, the damping material within the first and the second set of ribs 114, 116 stiffens, thereby providing additional support and protection to the enclosure 100.
[00060] In an embodiment, the first set of ribs 114 and the second set of ribs 116 within the enclosure 100 include spaced-apart surfaces that define an internal cavity. The spacing between said surfaces is configured to allow controlled deformation under external forces such as impact or compression. The internal cavity within the first and the second set of ribs 114, 116 acts as a buffer zone, absorbing and redistributing energy that might otherwise be transmitted directly to the battery pack. The controlled deformation enabled by the spacing between the surfaces of the first and the second set of ribs 114, 116 helps in minimizing damage to the battery pack by managing the forces experienced during operation. The first and the second set of ribs 114, 116 bend or flex in a controlled manner, preventing sudden or catastrophic failure of the enclosure 100.
[00061] In an embodiment, the top casing 102 of the enclosure 100 includes a series of tabs positioned equidistantly along the perimeter of the top casing 102. Each tab comprises a tapered geometry, which widens towards the base. The tapered geometry of said tabs facilitates assembly and secure attachment of the top casing 102 to the bottom casing 108. The equidistant placement of said tabs provides uniform distribution of stress along the perimeter of the top casing 102, contributing to the overall structural integrity of the enclosure 100. The widening taper at the base of each tab provides a broader surface area for engagement with the bottom casing 108, thereby enhancing the stability of the connection. Said tabs interlock with corresponding features on the bottom casing 108, creating a secure and reliable connection that prevents unintentional disassembly or separation during operation.
[00062] In an embodiment, the bottom casing 108 of the enclosure 100 includes a series of slots positioned equidistantly along the perimeter of the bottom casing 108. Each slot features a recessed channel receives the tapered tabs of the top casing 102. The recessed channel within each slot is dimensioned to accommodate the taper of said tabs. The equidistant placement of said slots along the perimeter of the bottom casing 108 mirrors the positioning of the tabs on the top casing 102, allowing for a precise and uniform connection. The engagement between the tabs and the slots, facilitated by the recessed channels, helps maintain alignment of the top casing 102 and the bottom casing 108 during assembly and operation.
[00063] In an embodiment, the first set of ribs 114 and the second set of ribs 116 within the enclosure 100 include a curved profile. Said curved profile distributes impact forces more effectively across the surface of the first and the second set of ribs 114, 116, reducing the likelihood of localized stress concentrations that could lead to structural failure. The curvature of the first and the second set of ribs 114, 116 allows absorption and dissipation of energy more efficiently, thereby protecting the battery pack housed within the enclosure 100. The curved profile of the first and the second set of ribs 114, 116 also enhances the overall rigidity and strength of the enclosure 100 by providing additional support where needed most. Said curvature is tailored to the specific requirements of the enclosure 100, considering factors such as the expected load conditions and the material properties of the first and the second set of ribs 114, 116.
[00064] In an embodiment, the enclosure 100 for a battery pack enhances structural integrity and impact resistance through the integration of specific features. The first crushable zone 106 and the second crushable zone 112, disposed between the first and the second pairs of mounting points 104, 110, absorbs energy during impact, thereby reducing the transmission of forces to the battery pack.
[00065] FIG. 3 illustrates a top view of the top casing 102, in accordance with the embodiments of the present disclosure. The top view clearly illustrates that the extreme ends of the first crushable zone 106 and each rib of the first set of ribs 114 are in a co-planar relationship, with the plane being orthogonal to the mating point where the top casing 102 connects with the bottom casing 108. The co-planarity improves load bearing capacity of the enclosure 100, which can efficiently manage impact. Similarly, the bottom casing 108 (not shown) also includes the second pair of mounting points 110 and the second crushable zone 112 positioned between the second pair of mounting points 110. The extreme ends of the second crushable zone 112 and each rib of the second set of ribs 116 are also in a co-planar relationship, maintaining the same orthogonal alignment to ensure consistent structural integrity and alignment between the top and bottom casings.
[00066] While several implementations have been described and illustrated herein, a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein may be utilized, and each of such variations and/or modifications is deemed to be within the scope of the implementations described herein. More generally, all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific implementations described herein. It is, therefore, to be understood that the foregoing implementations are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, implementations may be practiced otherwise than as specifically described and claimed. Implementations of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.
 

Claims
I/We Claim:
1. An enclosure for a battery pack, the enclosure comprising:
a top casing comprising:
a first pair of mounting points; and
a first crushable zone disposed between the first pair of mounting points; and
a bottom casing comprising:
a second pair of mounting points; and
a second crushable zone disposed between the second pair of mounting points;
characterized in that:
each of the first pair of mounting points is associated with a first set of ribs; and
each of the second pair of mounting points is associated with a second set of ribs wherein the outermost ends of each rib of the second set of ribs form a co-planar arrangement with each of:
the outermost ends of each rib of the first set of ribs;
a first edge of the first crushable zone; and
a second edge of the second crushable zone;
upon mating the first pair of mounting points with the second pair of mounting points to form a pair of double shearing mounting points.
2. The enclosure of claim 1, wherein each mounting point of the first pair and the second pair of mounting points comprises a threaded surface to receive a fastener to secure the top casing to the bottom casing.
3. The enclosure of claim 1, wherein the first set of ribs and the second set of ribs are oriented in a direction perpendicular to the mating plane of the first and second pairs of mounting points.
4. The enclosure of claim 1, wherein the first crushable zone and the second crushable zone are associated with a plurality of grooves to facilitate controlled deformation under impact.
5. The enclosure of claim 1, wherein the first crushable zone comprises a recess to receive a stiffener, wherein an end of the stiffener forms a co-planar arrangement with outermost ends of each rib of the first set of ribs.
6. The enclosure of claim 1, wherein each rib of the first set of ribs and the second set of ribs comprises alternating solid and perforated segments to allow for selective deformation and force distribution.
7. The enclosure of claim 1, wherein the first crushable zone and the second crushable zone is formed of a lattice structure to enable progressive deformation.
8. The enclosure of claim 1, wherein the first set of ribs and the second set of ribs comprise a damping material that selectively stiffens under influence of an external force.
9. The enclosure of claim 1, wherein the first set of ribs and the second set of ribs comprise the spaced-apart surfaces defining an internal cavity, wherein the internal cavity is configured to enable controlled deformation.
10. The enclosure of claim 1, wherein the top casing comprises a series of tabs located equidistantly along the perimeter of the top casing, wherein each tab is associated with a tapered geometry, widening towards base thereof.
11. The enclosure of claim 10, wherein the bottom casing comprises a series of slots located equidistantly along the perimeter of the bottom casing, wherein each slot comprises a recessed channel to receive the tapered tabs.
12. The enclosure of claim 1, wherein the first set of ribs and the second set of ribs are associated with a curved profile to distribute the impact forces across the surface thereof.

ENCLOSURE FOR BATTERY PACK
Abstract
The present disclosure provides a battery pack enclosure featuring a top and bottom casing. Each of top casing and bottom comprises a pair of mounting points with a crushable zone in between. Each mounting point is associated with a set of ribs, with the outermost ends of the ribs aligning co-planarly between the top and bottom casings. When the top and bottom casings are joined, pair of mounting points form a pair of double-shearing mounting points for enhanced structural integrity.
Fig. 1 , Claims:Claims
I/We Claim:
1. An enclosure for a battery pack, the enclosure comprising:
a top casing comprising:
a first pair of mounting points; and
a first crushable zone disposed between the first pair of mounting points; and
a bottom casing comprising:
a second pair of mounting points; and
a second crushable zone disposed between the second pair of mounting points;
characterized in that:
each of the first pair of mounting points is associated with a first set of ribs; and
each of the second pair of mounting points is associated with a second set of ribs wherein the outermost ends of each rib of the second set of ribs form a co-planar arrangement with each of:
the outermost ends of each rib of the first set of ribs;
a first edge of the first crushable zone; and
a second edge of the second crushable zone;
upon mating the first pair of mounting points with the second pair of mounting points to form a pair of double shearing mounting points.
2. The enclosure of claim 1, wherein each mounting point of the first pair and the second pair of mounting points comprises a threaded surface to receive a fastener to secure the top casing to the bottom casing.
3. The enclosure of claim 1, wherein the first set of ribs and the second set of ribs are oriented in a direction perpendicular to the mating plane of the first and second pairs of mounting points.
4. The enclosure of claim 1, wherein the first crushable zone and the second crushable zone are associated with a plurality of grooves to facilitate controlled deformation under impact.
5. The enclosure of claim 1, wherein the first crushable zone comprises a recess to receive a stiffener, wherein an end of the stiffener forms a co-planar arrangement with outermost ends of each rib of the first set of ribs.
6. The enclosure of claim 1, wherein each rib of the first set of ribs and the second set of ribs comprises alternating solid and perforated segments to allow for selective deformation and force distribution.
7. The enclosure of claim 1, wherein the first crushable zone and the second crushable zone is formed of a lattice structure to enable progressive deformation.
8. The enclosure of claim 1, wherein the first set of ribs and the second set of ribs comprise a damping material that selectively stiffens under influence of an external force.
9. The enclosure of claim 1, wherein the first set of ribs and the second set of ribs comprise the spaced-apart surfaces defining an internal cavity, wherein the internal cavity is configured to enable controlled deformation.
10. The enclosure of claim 1, wherein the top casing comprises a series of tabs located equidistantly along the perimeter of the top casing, wherein each tab is associated with a tapered geometry, widening towards base thereof.
11. The enclosure of claim 10, wherein the bottom casing comprises a series of slots located equidistantly along the perimeter of the bottom casing, wherein each slot comprises a recessed channel to receive the tapered tabs.
12. The enclosure of claim 1, wherein the first set of ribs and the second set of ribs are associated with a curved profile to distribute the impact forces across the surface thereof.