Description:IMPACT-RESISTANT ENCLOSURE FOR BATTERY PACK
Field of the Invention
[0001] The present disclosure generally relates to battery enclosures. Further, the present disclosure particularly relates to protective housings for battery packs used in various applications.
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 serve as essential power sources in various applications, including electric vehicles. Protecting battery packs from external forces and environmental conditions is vital for operational safety and longevity. Conventional enclosures, typically composed of top and bottom casings, houses battery packs and provide necessary structural support. However, conventional structures often encounter challenges related to maintaining mechanical integrity during impacts, where insufficient structural reinforcement or inadequate energy absorption may result in damage to battery packs. The construction of enclosures and their components plays a significant role in mitigating these issues, yet many existing structures fall short of effectively addressing such concerns.
[0004] One known approach involves the use of basic mounting points extending from the casing to secure the battery pack. While such mounting points offer basic attachment, conventional structures often lack the additional structural reinforcement needed to withstand mechanical stresses during operation. Without reinforcing elements like ribs or struts, stress concentrations may develop within the enclosure, increasing the likelihood of deformation or failure under impact conditions. Additionally, energy absorption capabilities are often limited, as many conventional enclosures do not integrate crushable zones that effectively mitigate impact forces. As a result, such enclosures may inadequately protect battery packs during collisions or other high-stress scenarios.
[0005] Another approach in enclosure incorporates reinforcing elements, such as ribs or struts, to enhance structural integrity. These elements are typically integrated into the casing to distribute mechanical loads more evenly across the enclosure. However, conventional structures frequently fail to align reinforcing elements with the forces exerted during operation, leading to suboptimal performance. For instance, reinforcing ribs or struts may not extend to areas where force concentrations occur, resulting in uneven load distribution and structural failure. Furthermore, crushable zones, intended to absorb impact energy, are often inadequately implemented in conventional structures. Such crushable zones may be poorly positioned or insufficiently sized, limiting their effectiveness in protecting battery packs from external forces.
[0006] Further issues arise in conventional enclosures due to a lack of integrated design, where structural elements like mounting points, ribs, struts, and crushable zones are not cohesively aligned. Misalignment of these elements during assembly can weaken the overall structure of the enclosure. For example, improper alignment of ribs and struts may prevent uniform force distribution, creating localized stress points that compromise the structural integrity of the enclosure. Moreover, conventional structures that utilize single-shear mounting points often present weaker attachment points that are more prone to failure under high-load conditions. There is a clear need for more robust and integrated enclosure that address these challenges effectively.
[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 constructing 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. A first pair of mounting points extends radially outwardly from a first edge of the top casing, each extending up to a first distance. A first crushable zone is disposed between the first pair of mounting points, extending radially outwardly up to a second distance. A set of ribs is disposed onto the first crushable zone, with each rib extending radially outwardly from the outermost edge of the first crushable zone up to a third distance. A second pair of mounting points extends radially outwardly from a primary edge of the bottom casing, with each mounting point extending up to the first distance. A second crushable zone is disposed between the second pair of mounting points, extending radially outwardly up to the second distance. A set of struts is disposed onto the second crushable zone, with each strut extending radially outwardly from the outermost edge of the second crushable zone up to the third distance. Upon mating the top casing and the bottom casing, the first pair of mounting points mates with the second pair of mounting points to form a pair of double shear mounting points, and the set of ribs and the set of struts form a co-centric relationship.
[00011] Further, each of the first pair of mounting points comprises a first interlocking element, and each of the second pair of mounting points comprises a second interlocking element. Upon mating the top casing and the bottom casing, the second interlocking element interlocks with the first interlocking element, thereby providing structural stability to the enclosure.
[00012] Moreover, the first crushable zone and the second crushable zone comprise a reinforcing rib. Said reinforcing rib increases torsional rigidity of the enclosure by providing additional support across the crushable zones.
[00013] Additionally, the reinforcing rib of the first crushable zone extends orthogonally relative to the set of ribs, and the reinforcing rib of the second crushable zone extends orthogonally relative to the set of struts.
[00014] Furthermore, each rib is associated with a tapered profile that increases in thickness towards the first edge of the top casing. The tapering enhances the mechanical properties of the ribs, providing greater resistance to deformation and enhancing overall stability of the top casing under various load conditions.
[00015] Similarly, each strut is associated with a tapered contour that increases in thickness towards the primary edge of the bottom casing. The tapering of the struts improves the structural performance of the bottom casing, particularly under conditions where mechanical stresses are concentrated.
[00016] Moreover, each crushable zone is associated with a shock-absorbing insert. Said shock-absorbing insert absorbs impact shock waves, thereby protecting the battery pack from damage during collisions or other impact events.
[00017] Further, at least one of the top casing and the bottom casing comprises a pressure relief valve. Said pressure relief valve releases gas or pressure buildup within the enclosure, thereby preventing damage to the battery pack due to overpressure conditions.
[00018] Additionally, the first distance is equal to the sum of the second distance and the third distance. Such a dimensional relationship aligns the various components of the enclosure, contributing to the structural integrity and stability of the enclosure.
[00019] Moreover, each of the first pair of mounting points comprises a through hole. A radial distance between a face of the through hole and the outermost edge of the first pair of mounting points is equal to the third distance. Said specific configuration of the through hole distributes load and maintains structural balance across the top casing.
[00020] Further, the face of the through hole is located opposite to the first edge of the top casing. The positioning of the through hole face contributes to mechanical stability of the top casing by aligning with the forces exerted during operational use.
[00021] Additionally, each of the second pair of mounting points comprises a through bore. A radial distance between a side of the through bore and the outermost edge of the second pair of mounting points is equal to the third distance. The design and placement of the through bore maintain structural symmetry and load distribution within the bottom casing.
[00022] Moreover, the face of the through bore is located opposite to the primary edge of the bottom casing. The positioning of the through bore face is important to maintaining mechanical integrity of the bottom casing, particularly in scenarios where external forces are applied to the enclosure.
Brief Description of the Drawings
[00023] 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:
[00024] FIG. 1 illustrates an enclosure for a battery pack, in accordance with the embodiments of the present disclosure.
[00025] FIG. 2 illustrates an architectural diagram of an enclosure for a battery pack, in accordance with the embodiments of the present disclosure.
[00026] FIG. 3 illustrates a top view of a top casing in accordance with the embodiments of the present disclosure.
[00027] FIG. 4 illustrates a top view of a bottom casing in accordance with the embodiments of the present disclosure.
Detailed Description
[00028] 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.
[00029] 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.
[00030] 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.
[00031] 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.
[00032] 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.
[00033] 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.
[00034] 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.
[00035] 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, which secure the two casings. Mounting points are often placed to optimize the stability and alignment of the connected components.
[00036] 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.
[00037] As used herein, the term "ribs" or “struts” refers to structural elements that reinforce a component by distributing mechanical loads across a larger surface area. Ribs or struts can be arranged in different configurations, such as perpendicular to a mating plane, to provide enhanced strength and stability. In enclosures, ribs or struts often serve as support structures for mounting points and may deform selectively under stress to protect internal components from impact. Ribs or strut 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.
[00038] As used herein, the term "double shear mounting points" is used to refer to the points of connection formed when the first pair of mounting points on the top casing mates with the second pair of mounting points on the bottom casing. The double-shear mounting points provide enhanced structural stability by distributing mechanical loads across multiple planes. The double-shear configuration reduces the likelihood of failure at the mounting points under high load conditions.
[00039] As used herein, the term "distance" refers to the measurable space or gap between two points, components, or surfaces. In the context of the present disclosure, "distance" is often used to describe the length over which a structural element, such as a rib or mounting point, extends from one edge or feature to another. This measurement may include vertical, horizontal, or radial distances depending on the specific structural arrangement.
[00040] As used herein, the term "edge" refers to the boundary or periphery of a component, part, or structure. In the context of the present disclosure, "edge" typically denotes the outer limit of casings, mounting points, or other structural elements within the enclosure. The edge serves as a reference for positioning or measuring how far structural components like ribs or crushable zones extend from the enclosure's body.
[00041] As used herein, the term "radially outwardly" refers to a directional attribute where a component extends from a central point, axis, or surface of a structure in a specific outward direction toward the periphery or edge of that structure. In the context of the present disclosure, "radially outwardly" describes how certain elements, such as ribs, struts, or mounting points, project from outer surface, maintaining a consistent radial path relative to the central axis or reference point.
[00042] 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 comprises a top casing 102 and a bottom casing 104. The top casing 102 serves as the upper structural component of the enclosure 100 to house and protect the battery pack from external forces and environmental factors. The top casing 102 is formed from materials that provide both strength and durability, affirming that the battery pack remains secure during operation. The top casing 102 interfaces with other structural elements within the enclosure 100, such as the first pair of mounting points 106, the first crushable zone 108, and the set of ribs 110, which are disposed onto the first crushable zone 108. The top casing 102 also aligns with the bottom casing 104 to form a complete protective enclosure for the battery pack.
[00043] In an embodiment, the bottom casing 104 forms the lower section of the enclosure 100 and provides a stable foundation for the battery pack. Like the top casing 102, the bottom casing 104 is constructed from durable materials that are selected to withstand various mechanical stresses during operation. The bottom casing 104 incorporates several key structural elements, including a second pair of mounting points 112, a second crushable zone 114, and a set of struts 116 disposed onto the second crushable zone 114. The bottom casing 104 mates securely with the top casing 102, thereby forming the complete enclosure 100 that houses and protects the battery pack. The bottom casing 104 makes sure that the battery pack remains stable and secure within the enclosure 100, providing additional support and protection against impacts and other external forces. The bottom casing 104 facilitates the distribution of mechanical forces across the enclosure 100, contributing to the overall durability of the structure.
[00044] In an embodiment, the first pair of mounting points 106 extends radially outwardly from a first edge of the top casing 102. Each mounting point 106 is positioned to provide a secure attachment for the top casing 102 to the bottom casing 104 or to external structures that may be used to secure the enclosure 100 within a larger system. The first pair of mounting points 106 extends up to a specific distance from the first edge of the top casing 102, providing the necessary structural support to maintain the integrity of the enclosure 100. The mounting points 106 are positioned to align with the second pair of mounting points 112 on the bottom casing 104 when the top casing 102 and the bottom casing 104 are mated together. The alignment allows the first pair of mounting points 106 and the second pair of mounting points 112 to form a pair of double shear mounting points, which enhance the overall structural stability of the enclosure 100. The first pair of mounting points 106 may include additional features such as interlocking elements to further secure the attachment between the top casing 102 and the bottom casing 104.
[00045] Extension of the first pair of mounting points 106 up to the first distance enable enhancement of structural integrity and distribution of stresses across the enclosure 100. And also enable effective management of mechanical loads, especially in scenarios involving impacts, fall down or heavy vibrations. By extending each mounting point up to this first distance, the force exerted on the top casing 102 is distributed more evenly across a broader area, reducing the concentration of stress at any single point and thereby minimizing the risk of structural failure. Optimum the first distance is critical as it directly influences the mechanical stability and the load-bearing capacity of the enclosure 100. If the first distance is too short, the first pair of mounting points 106 may not provide sufficient leverage to distribute stresses effectively, which could lead to a higher likelihood of deformation or damage under external loads. Conversely, if the first distance is excessively long, the first pair of mounting points 106 might introduce unnecessary rigidity that could compromise the ability of the enclosure 100 to absorb and dissipate energy effectively. The optimum distance should be determined based on several factors including the material properties of the casing, the anticipated load conditions, and the overall dimensions of the battery pack. For two wheeled vehicles, which usually have lighter and more compact battery packs, the first distance might range from 20 mm to 40 mm. such range is adequate to provide stability and stress distribution without unnecessarily increasing the footprint of the battery pack within the scooter's chassis. Whereas two wheeled vehicles, which requires higher power output or longer range, which typically have larger and heavier battery packs, the first distance might be increased to between 40 mm and 60 mm. The greater distance helps in managing the increased load and in enhancing the structural rigidity required to handle higher operational demands.
[00046] In an embodiment, the first crushable zone 108 is disposed between the first pair of mounting points 106 on the top casing 102. The first crushable zone 108 extends radially outwardly from the first edge of the top casing 102 up to a second distance, providing a buffer that can absorb impact energy and reduce the transmission of forces to the battery pack during collisions or other stress events. The first crushable zone 108 deforms in a controlled manner, thereby protecting the battery pack from damage. The first crushable zone 108 is constructed from materials that are selected for their ability to absorb energy while maintaining the overall integrity of the enclosure 100. The positioning of the first crushable zone 108 between the first pair of mounting points 106 allows effective absorption and dissipation of energy, preventing the concentration of forces in any one area of the enclosure 100.
[00047] The extension of first crushable zone 108 up to the specified second distance is critical for effective management load/stress during collision or impact for efficient energy dissipation. By optimizing the second distance, the present disclosure optimally balances the need for structural integrity and crashworthiness without compromising the compactness and weight of the enclosure. The second distance provides sufficient space for the crushable zone 108 to deform during an impact, thereby protecting the battery cells within the enclosure 100 from damage due to sudden shocks or crush forces. For optimal impact bearing capacity, the second distance should be configured based on the vehicle type and the expected operating conditions. For example, a two-wheeled vehicle, typically having a smaller and lighter battery pack, might have a second distance in the range of 20-30 mm. This range provides adequate protection in a compact form factor, suitable for the limited space within such vehicles. Conversely, a car, especially one equipped with a heavy battery for extended range, might require a second distance of 50-70 mm to effectively manage the higher impact energy associated with larger vehicles and higher speeds. The second distance can be adjusted based on specific vehicle design requirements, expected load cases, and regulatory safety standards.
[00048] In an embodiment, the set of ribs 110 is disposed onto the first crushable zone 108 and extends radially outwardly from the outermost edge of the first crushable zone 108 up to a third distance. Each rib 110 in the set provides additional structural reinforcement to the top casing 102, making sure that the enclosure 100 remains rigid and resistant to deformation during operation. The ribs 110 are positioned in a manner that allows them to distribute mechanical stresses evenly across the top casing 102, reducing the likelihood of failure due to localized stress concentrations. The ribs 110 may comprise specific profiles, such as a tapered thickness, to enhance their performance in reinforcing the top casing 102. The set of ribs 110 maintains the alignment between the top casing 102 and the bottom casing 104 when the two are mated together.
[00049] The third distance is critical to optimize load distribution, particularly during impact events, stiffness and the load-bearing capacity of the enclosure 100, thereby improving the overall durability and safety of the battery pack. The third distance can be optimized to balance the need for crushability (to absorb impact energy) and the necessity for maintaining structural integrity under normal conditions. Th optimal third distance allows the ribs 110 to effectively distribute the forces exerted during impact, thus minimizing damage to the battery cells housed within the enclosure 100. For a two-wheeled vehicle with a smaller battery pack, exemplary values for the third distance might range from 5 to 15 mm, depending on the specific

design and safety requirements. In this context, fewer ribs 110, perhaps 3 to 5, may suffice due to the smaller size and lower weight of the battery pack. However, for a car with a heavier battery, the third distance could be increased to between 15 to 30 mm to provide adequate support and energy absorption capacity. The number of ribs 110 could also be increased to 8 to 12 to improve sufficient load distribution and to enhance the structural integrity of the larger battery pack. Increasing the number of ribs 110 help in evenly distributing the load across the battery pack and improving the structural redundancy. More ribs 110 mean that the load can be spread over more points, reducing the risk of catastrophic failure at any single point upon impact.
[00050] In an embodiment, the second pair of mounting points 112 extends radially outwardly from a primary edge of the bottom casing 104. Each mounting point of the second pair of mounting points 112 aligns with a corresponding mounting point from the first pair of mounting points 106 on the top casing 102, facilitating the secure mating of the top casing 102 and the bottom casing 104. The second pair of mounting points 112 extends up to the first distance, providing a secure attachment point for the bottom casing 104. The second pair of mounting points 112 forms double-shear mounting points when mated with the first pair of mounting points 106 on the top casing 102. The double-shear configuration enhances the structural stability of the enclosure 100, reducing the likelihood of failure at the mounting points under high load conditions. The second pair of mounting points 112 may also include additional features, such as interlocking elements, to further secure the attachment between the top casing 102 and the bottom casing 104. Extending the second pair of mounting points 112 to the same first distance as the first pair of mounting points 106 enables uniform distribution of mechanical stress across both the top casing 102 and the bottom casing 104 for maintaining the structural integrity of the enclosure 100 under various load conditions, particularly during dynamic impacts or vibrations typical in operational environments.
[00051] In an embodiment, the second crushable zone 114 is disposed between the second pair of mounting points 112 on the bottom casing 104. The second crushable zone 114 extends radially outwardly from the primary edge of the bottom casing 104 up to the second distance. The second crushable zone 114 functions similarly to the first crushable zone 108, absorbing impact energy and protecting the battery pack from external forces. The second crushable zone 114 deforms in a controlled manner, preventing the transmission of forces to the battery pack during collisions or other stress events. The second crushable zone 114 is constructed from materials that are selected for their energy absorption properties, making sure that the enclosure 100 can withstand impacts without compromising the safety of battery pack. Maintaining the same second distance in both the first and the second crushable zones 108 and 114 enable achieving balance and uniformity in impact absorption during an impact, thereby reducing the likelihood of damage to the battery cells and enhancing overall vehicle safety. The optimum second distance allows each of the first and the second crushable zones 108 and 114 enable proper deformation under impact, without compromising the compactness required for efficient vehicle integration. For a two-wheeled vehicle with smaller, lighter battery packs, an exemplary second distance might be around 20-30 mm, providing a balance between space economy and effective impact energy absorption. For cars, which need to manage larger impact energies due to heavier batteries and potentially higher speeds, a second distance of 50-70 mm could be more appropriate.
[00052] In an embodiment, the set of struts 116 is disposed onto the second crushable zone 114 and extends radially outwardly from the outermost edge of the second crushable zone 114 up to the third distance. Each strut from the set of struts 116 provides additional structural reinforcement to the bottom casing 104, assuring that the enclosure 100 remains rigid and resistant to deformation during operation. The set of struts 116 are positioned to distribute mechanical stresses evenly across the bottom casing 104, reducing the likelihood of failure due to localized stress concentrations. The set of struts 116 may comprise specific profiles, such as a tapered contour, to enhance their performance in reinforcing the bottom casing 104. The optimal extension of the set of struts 116 up to the third distance allows the struts 116 to efficiently spread out the stresses incurred during impacts, which helps in preserving the structural integrity and thus safeguarding the battery cells within the enclosure 100.
[00053] For a two-wheeled vehicle featuring a smaller battery, three to five struts 116 would be appropriate, mirroring the number of ribs 110, thus maintaining a harmonious and symmetrical design that promotes consistent load distribution. Conversely, for cars equipped with heavier batteries, extending the third distance to between 50 and 100 mm may be necessary to handle higher impacts due to the increased mass. Consequently, the number of struts 116 would also be higher, ranging from eight to twelve, matching the number of ribs 110 to uphold a uniform strength throughout both the top and bottom halves of the enclosure. The number of struts 116 aligns with the number of ribs 110 is critical for optimizing the structural support and guaranteeing that both elements contribute equally to the overall durability of the enclosure. The distance between each strut 116 and corresponding rib 110 is controlled to absorb impact energy to protect the battery pack.
[00054] In an embodiment, upon mating the top casing 102 and the bottom casing 104, the first pair of mounting points 106 mates with the second pair of mounting points 112 to form a pair of double shear mounting points. The double-shear mounting points provide enhanced structural stability to the enclosure 100, affirming that the top casing 102 and the bottom casing 104 remain securely attached during operation. The double-shear configuration distributes mechanical loads across multiple planes, reducing the likelihood of failure at the first and the second pair of mounting points 106 and 112 under high load conditions.
[00055] In addition, upon mating the top casing 102 and the bottom casing 104, the set of ribs 110 and the set of struts 116 form a co-centric relationship. The co-centric alignment enhances the structural stability of the enclosure 100 by assuring that the mechanical forces are distributed evenly across the entire structure. The co-centric relationship between the ribs 110 and the struts 116 prevents misalignment during operation, reducing the co-centric relationship formed by the set of ribs 110 and the set of struts 116 significantly enhances the overall mechanical performance of the battery pack enclosure 100 by improving its ability to uniformly distribute both static and dynamic loads. The co-centric relationship enables that each rib 110 and a corresponding strut 116 shares the burden of external forces, thereby minimizing the risk of stress concentrations that can lead to structural failures. When the ribs 110 and the struts 116 extend radially outwardly by a typical distance, such as 20 cm, from their respective edges, and are co-centrically aligned, they effectively create a robust, ring-like reinforcement. Such reinforcement acts as a structural buffer, absorbing and redistributing the impact energy across the entire enclosure 100 rather than allowing localization in certain weaker spots. Furthermore, the co-centric configuration facilitates a more efficient design from a manufacturing standpoint. By aligning these structural elements along a common central axis, the design simplifies the assembly process, ensuring that the components fit together seamlessly with less tolerance for error. This precision in assembly enhances the structural integrity but also reduces the likelihood of assembly defects, which can compromise the enclosure’s performance. The non-aligned ribs 110 and the struts 116 could be detrimental to the battery pack’s functionality and safety. Without this co-centric alignment, certain zones of the battery enclosure might experience uneven load distribution. In such cases, these areas could undergo excessive stress, which can lead to potential warping or cracking of the material. Moreover, in the absence of uniform stress distribution, the enclosure 100 might not effectively protect the battery cells within, posing risks of mechanical damage and subsequent battery failure. Consider a scenario where the enclosure 100 of the present disclosure is subjected to an external force of 1000 N. If the ribs 110 and the struts 116 are co-centrically aligned, this force would be evenly distributed across the entire circumference of the enclosure. Assuming the structure has ten ribs 110 and ten struts 116, each rib 110 and each strut 116 would effectively manage a load of approximately 50 N. In contrast, if the ribs 110 and the struts 116 were not co-centrically aligned, some ribs 110 or struts 116 might bear a disproportionate share of the load, say 100 N or more, while others might bear much less. Such imbalance can lead to overstressing certain areas, increasing the risk of material fatigue and failure over time.
[00056] In an embodiment, each of the first pair of mounting points 106 comprises a first interlocking element, and each of the second pair of mounting points 112 comprises a second interlocking element. The first interlocking element engages with the second interlocking element when the top casing 102 is mated with the bottom casing 104. The interlocking elements are positioned on the first pair of mounting points 106 and the second pair of mounting points 112 to secure the connection between the top and the bottom casings 102 and 104 under various conditions. The Interlocking elements, enable secure and firm connection between the top and the bottom casings 102 and 104, reducing any relative movement that might compromise the integrity of the enclosure 100. For instance, a snap-fit mechanism, where a protruding part (first interlocking element) on the top casing (102) fits securely into a corresponding slot (second interlocking element) on the bottom casing (104). Another example could be a dovetail joint, where the two elements slide together and lock, preventing lateral displacement. The interlocking of the first and second elements simplifies the assembly process and also provides a self-aligning feature that ensures the parts are properly positioned with minimal manual effort. The interlocking elements also distribute the forces evenly across the first and the second pair of mounting points (106, 112), minimizing the risk of warping or deformation of the enclosure over time. This secure fit also contributes to the durability and resilience of the product, ensuring that the casing remains closed under various environmental conditions, such as vibrations or external pressure.
[00057] In an embodiment, the second crushable zone 114 and the first crushable zone 108 each comprise a reinforcing rib to increase the torsional rigidity of the enclosure 100. The reinforcing ribs are integrated into the crushable zones to provide additional structural support, particularly when the enclosure 100 is subjected to torsional forces. The ribs enhance the ability of the crushable zones to resist deformation. The reinforcing ribs are positioned and oriented to maximize their effectiveness in countering torsional stresses, allowing the crushable zones to perform their energy-absorbing function without compromising the structural integrity of the enclosure 100. The reinforcing rib within these zones is to provide additional structural strength to the enclosure, allowing it to better withstand twisting forces. This structural improvement increases the durability of the enclosure under mechanical stress, reducing the risk of deformation or failure. The reinforcing rib can be associated with a geometrically designed raised or thickened portion of the material within the second and the first crushable zones 114 and 108. The geometry (i.e., triangular or trapezoidal cross-sections) can vary depending on expected force, material etc. The geometry of reinforcing rib is crucial to distributing load more efficiently and improving the resistance to torsion. In conjunction with each strut 116 and each rib 110, the reinforcing rib creates a framework that maximizes structural integrity. For example, when the enclosure 100 experiences torsional forces, the reinforcing rib in the first and the second crushable zones 108 and 114 prevents excessive twisting by stiffening the enclosure 100. Simultaneously, the strut 116 resists buckling under axial loads, and the rib 110 helps balance the load distribution.
[00058] In an embodiment, the reinforcing rib within the first crushable zone 108 extends orthogonally relative to the set of ribs 110, and the reinforcing rib within the second crushable zone 114 extends orthogonally relative to the set of struts 116. The orthogonal arrangement optimizes the load-bearing capabilities of the enclosure 100 by distributing forces more evenly across the structure. The orthogonal orientation of the reinforcing ribs relative to the ribs 110 and the struts 116 provide a more balanced and stable configuration, reducing the likelihood of deformation under stress. The orthogonal orientation also enhances the rigidity of the enclosure 100, making sure that the enclosure 100 can withstand torsional and other mechanical forces without compromising the safety of the battery pack. The orthogonal arrangement of the reinforcing rib in relation to the set of ribs 110 and the set of struts 116 provides several structural benefits compared to parallel or other configurations. The orthogonal configuration optimizes the distribution of impact forces by enhancing rigidity in multiple directions to enable efficient energy distribution. When a force is applied to the first and the second crushable zones 108 and 114, the stress is more evenly distributed across the ribs 110 and the struts 116 due to the orthogonal orientation of the reinforcing ribs 110. This configuration prevents excessive stress concentration along one axis, which is common in parallel arrangements, thereby reducing the likelihood of localized buckling or structural failure. In contrast, parallel configurations of the ribs 110 and the struts 116 tend to concentrate forces along specific axes, which can lead to weaker performance under multi-directional loads. The orthogonal layout improves the overall structural integrity of the enclosure 100 by providing superior resistance to deformation and greater resilience against multi-directional impacts, ultimately enhancing the energy absorption capacity of both the first crushable zone 108 and the second crushable zone 114.
[00059] In an embodiment, each rib 110 associated with the first crushable zone 108 comprises a tapered profile that increases in thickness towards the first edge of the top casing 102. The tapered profile enhances the mechanical strength of the ribs 110, allowing them to better resist deformation and distribute loads more effectively across the top casing 102. The increasing thickness towards the edge helps to counteract the stresses that are typically concentrated at the edges of the enclosure 100, providing a more robust structural configuration. The tapered profile of the ribs 110 also contributes to the stability of the enclosure 100. The structure of the ribs 110 takes into consideration factors such as material properties, load distribution, and specific stresses that the enclosure 100 may encounter, resulting in a durable structure that protects the battery pack. The tapering design allows a more efficient distribution of stress and forces along the ribs 110. By increasing the thickness near the edge where higher forces are typically concentrated, the rib 110 is better able to withstand external loads without deforming or failing. The tapered profile is particularly beneficial in situations where the enclosure might be subjected to external mechanical forces, such as pressure, impacts, or vibrations. The gradual increase in thickness towards the edge enhances the stiffness of the rib 110 to enable that the enclosure 100 remains stable under varying conditions. Compared to a uniform thickness profile, which might lead to stress concentrations at specific points, the tapered configuration provides a more even distribution of stress by reducing likelihood of weak points forming in the structure, thus enhancing durability and extending the lifespan of the enclosure 100. Additionally, the tapered profile also reduces material usage to optimize weight and material efficiency.
[00060] In an embodiment, each strut 116 associated with the second crushable zone 114 comprises a tapered contour that increases in thickness towards the primary edge of the bottom casing 104. The tapered contour of the struts 116 enhances their load-bearing capacity, allowing them to better support the structural integrity of the bottom casing 104. The increasing thickness towards the edge reinforces the areas of the enclosure 100 that are most susceptible to stress. The struts 116 consider the specific mechanical demands placed on the enclosure 100, providing a configuration capable of withstanding forces encountered during use. By gradually increasing the thickness of each strut 116 towards the primary edge, the ability of the set of struts 116 to handle and transfer mechanical stresses can be increased. Further tapered contour also reduce likelihood of structural failure or deformation under load. The tapered contour provides superior performance compared to a uniform thickness strut, as it offers improved rigidity where the highest stress concentrations typically occur—near the primary edge. In contrast, a strut with a constant cross-sectional profile may be more susceptible to localized stress concentrations, especially at the junction with the primary edge, potentially leading to material fatigue or failure over time.
[00061] In an embodiment, each of the first and the second crushable zones 108 and 114 is associated with a shock-absorbing insert to absorb impact shock waves. The shock-absorbing inserts are integrated into the first and the second crushable zones 108 and 114 to enhance their ability to protect the battery pack from external impacts. The shock-absorbing inserts are made from materials chosen for their energy-absorbing properties, allowing them to dissipate the forces generated by collisions or other impacts. The inclusion of shock-absorbing inserts within the first and the second crushable zones 108 and 114 affirms that the battery pack is shielded from the damaging effects of sudden shocks, reducing the risk of damage to the sensitive components within the battery pack.
[00062] In an embodiment, at least one of the top casing 102 and the bottom casing 104 comprises a pressure relief valve to release gas or pressure buildup within the enclosure 100. The pressure relief valve prevents the enclosure 100 from experiencing overpressure conditions that could lead to structural failure or damage to the battery pack. The valve opens automatically when the internal pressure within the enclosure 100 reaches a certain threshold, allowing excess gas or pressure to escape safely.
[00063] In an embodiment, the first distance, which is the distance that each mounting point of the first pair of mounting points 106 extends radially outwardly from the first edge of the top casing 102, is equal to the sum of the second distance and the third distance. The second distance is the distance that the first crushable zone 108 extends radially outwardly from the first edge, while the third distance is the distance that each rib 110 extends radially outwardly from the outermost edge of the first crushable zone 108. This balanced distance configuration allows forces to be spread more uniformly through the first pair and the second pair of mounting points 106, 112, the first and the second crushable zones 108, 114, and the ribs 110 and the struts 116, reducing the risk of localized stress concentrations and potential failure points. Furthermore, the coordinated extension of the ribs 110 and the struts 116 creates a co-centric arrangement, which enhances the structural performance of the enclosure 100 when the top casing 102 and the bottom casing 104 are mated. The set of ribs 110 and the set of struts 116 align to form a concentric reinforcement, improving the ability of the enclosure 100 to withstand mechanical loads, such as impacts or vibrations, without misalignment. By knowing that the first distance (L1) is sum of the second distance (L2) and the third distance (L3), manufacturing tolerances can be better controlled, reducing the likelihood of assembly errors.

[00064] In an embodiment, each mounting point of the first pair of mounting points 106 comprises a through hole, where a radial distance between a face of the through hole and the outermost edge of the first pair of mounting points 106 is equal to the third distance. The through hole provides a passage for securing hardware, such as bolts or screws, which may be used to attach the top casing 102 to the bottom casing 104 or to other external structures. The specific radial distance between the face of the through hole and the outermost edge of the first pair of mounting points 106 makes sure that the securing hardware is properly positioned to distribute mechanical loads evenly across the enclosure 100.
[00065] In an embodiment, the face of the through hole located within the first pair of mounting points 106 is positioned opposite to the first edge of the top casing 102. Said positioning optimizes the structural integrity of the top casing 102 by making sure that the through hole is aligned with the forces exerted on the enclosure 100 during operation. The placement of the through hole face opposite the first edge allows for a balanced distribution of mechanical stresses, reducing the likelihood of deformation or failure at the first pair of mounting points 106. The through hole considers the specific mechanical demands placed on the enclosure 100, providing a configuration capable of withstanding forces encountered during use while maintaining the stability of the top casing 102.
[00066] In an embodiment, each of the second pair of mounting points 112 comprises a through bore, where a radial distance between a side of the through bore and the outermost edge of the second pair of mounting points 112 is equal to the third distance. The through bore provides a passage for securing hardware, such as bolts or screws, which may be used to attach the bottom casing 104 to the top casing 102 or to other external structures. The specific radial distance between the side of the through bore and the outermost edge of the second pair of mounting points 112 assures that the securing hardware is properly positioned to distribute mechanical loads evenly across the enclosure 100.
[00067] In an embodiment, the face of the through bore located within the second pair of mounting points 112 is positioned opposite to the primary edge of the bottom casing 104. Said placement optimizes the structural integrity of the bottom casing 104 by assuring that the through bore is aligned with the forces exerted on the enclosure 100 during operation. The positioning of the through bore face opposite the primary edge allows for a balanced distribution of mechanical stresses, reducing the likelihood of deformation or failure at the mounting points 112. The through bore considers the specific mechanical demands placed on the enclosure 100, providing a configuration capable of withstanding forces encountered during use while maintaining the stability of the bottom casing 104.
[00068] FIG. 2 illustrates an architectural diagram of the enclosure 100 for the battery pack, in accordance with the embodiments of the present disclosure. The top casing 102 includes the first pair of mounting points 106 extending radially outward from a first edge, and a first crushable zone 108 with a set of ribs 110 disposed between the first pair of mounting points 106. The bottom casing 104 similarly includes a second pair of mounting points 112 extending radially outward from a primary edge, and the second crushable zone 114 with the set of struts 116 disposed between the second pair of mounting points 112. Upon mating the top casing 102 and the bottom casing 104, the first pair of mounting points 106 and the second pair of mounting points 112 align to form a pair of double shear mounting points. Simultaneously, the set of ribs 110 and the set of struts 116 form a co-centric relationship, enhancing the structural integrity of the enclosure 100.
[00069] FIG. 3 illustrates a top view of the top casing 102 in accordance with the embodiments of the present disclosure. The top casing 102 includes the first pair of mounting points 106 positioned along a first edge. The first pair of mounting points 106 extend radially outward to mate with corresponding mounting points on the bottom casing 104, forming a double-shear connection.
[00070] FIG. 4 illustrates a bottom view of the bottom casing 104 in accordance with the embodiments of the present disclosure. The bottom casing 104 comprising second pair of mounting points 112 extending radially outward from the primary edge of the bottom casing 104 up to a length/distance L1. The second pair of mounting points 112 are configured to align and mate with corresponding mounting points from the second pair of mounting points 106 from the top casing 102 to form double-shear mounting points, which help distribute forces and increase stability at the connection point between the top and the bottom casings 102 and 104. Each of the second pair of mounting points 112 comprise a through bore for fastening or securing the bottom casing 104 with the top casing 102 and/or another component of vehicle. The radial distance between a side of the through bore and the outermost edge of the second pair of mounting points 112 is equal to L3. This positioning of the through bore optimizes the force distribution across the second pair of mounting points 112 when the top and the bottom casings 102 and 104 are connected, enhancing stability and reducing stress concentrations that could otherwise lead to failure under load. The second crushable zone 114 extends outwardly from the primary edge up to a distance of L2. Further, the second crushable zone 114 is reinforced with the set of struts 116, which extend outwardly from the outermost edge of the crushable zone up to a length of L3. The set of struts 116 forms a co-centric relationship with the ribs 112 from the top casing 102, upon mating. This relationship enhances the overall rigidity and contributes to maintaining alignment between the top and the bottom casings 102 and 104 during assembly and when subjected to external forces.
[00071] 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, comprising:
a top casing;
a bottom casing;
a first pair of mounting points extending radially outwardly from a first edge of the top casing, wherein each mounting point extends up to a first distance;
a first crushable zone disposed between the first pair of mounting points, wherein the first crushable zone extends radially outwardly from the first edge of the top casing up to a second distance;
a set of ribs disposed onto the first crushable zone, wherein each rib extends radially outwardly from an outermost edge of the first crushable zone up to a third distance;
a second pair of mounting points extending radially outwardly from a primary edge of the bottom casing, wherein each mounting point extends up to the first distance;
a second crushable zone disposed between the second pair of mounting points, wherein the second crushable zone extends radially outwardly from the primary edge of the bottom casing up to the second distance;
a set of struts disposed onto the second crushable zone, wherein each strut extends radially outwardly from an outermost edge of the second crushable zone up to the third distance;
wherein, upon mating the top casing and the bottom casing:
the first pair of mounting points mates with the second pair of mounting points to form a pair of double shear mounting points, and
the set of ribs and the second set of struts form a co-centric relationship.
2. The enclosure of claim 1, wherein each of the first pair of mounting points comprises a first interlocking element and each of the second pair of mounting points comprises a second interlocking element, wherein the second interlocking element interlocks with the first interlocking element upon mating of the top casing and the second casing.
3. The enclosure of claim 1, wherein the second crushable zone and the first crushable zone comprise a reinforcing rib to increase torsional rigidity of the enclosure.
4. The enclosure of claim 3, wherein the reinforcing rib of the first crushable zone extends orthogonally relative to the set of ribs, and wherein the reinforcing rib of the second crushable zone extends orthogonally relative to the set of struts.
5. The enclosure of claim 1, wherein each rib is associated with a tapered profile that increases in thickness towards the first edge.
6. The enclosure of claim 1, wherein each strut is associated with a tapered contour that increases in thickness towards the primary edge.
7. The enclosure of claim 1, wherein each crushable zone is associated with a shock-absorbing insert to absorb an impact shock wave.
8. The enclosure of claim 1, wherein at least one of the top casings and the bottom casing comprises a pressure relief valve to release gas or pressure buildup within enclosure.
9. The enclosure of claim 1, wherein the first distance is equal to the sum of the second distance and the third distance.
10. The enclosure of claim 1, wherein each of the first set of mounting points comprises a through hole, wherein a radial distance between a face of the through hole and the outermost edge of first pair of mounting point is equal to the third distance.
11. The enclosure of claim 10, wherein the face of the through hole is located opposite to the first edge of the top casing.
12. The enclosure of claim 1, wherein each of the second set of mounting points comprises a through bore, wherein a radial distance between a side of the through bore and the outermost edge of the second pair of mounting point is equal to the third distance.
13. The enclosure of claim 12, wherein the face of the through bore is located opposite to the primary edge of the bottom casing.

IMPACT-RESISTANT ENCLOSURE FOR BATTERY PACK
Abstract
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 with ribs extending radially outward. The bottom casing features a second pair of mounting points and a second crushable zone with struts extending radially outward. Upon mating the top and bottom casings, the mounting points from double shear mounting points, and the ribs and struts establish a co-centric relationship.
Fig. 1

Dated 03 October 2024 Kumar Tushar Srivastava , Claims:Claims
I/We Claim:
1. An enclosure for a battery pack, comprising:
a top casing;
a bottom casing;
a first pair of mounting points extending radially outwardly from a first edge of the top casing, wherein each mounting point extends up to a first distance;
a first crushable zone disposed between the first pair of mounting points, wherein the first crushable zone extends radially outwardly from the first edge of the top casing up to a second distance;
a set of ribs disposed onto the first crushable zone, wherein each rib extends radially outwardly from an outermost edge of the first crushable zone up to a third distance;
a second pair of mounting points extending radially outwardly from a primary edge of the bottom casing, wherein each mounting point extends up to the first distance;
a second crushable zone disposed between the second pair of mounting points, wherein the second crushable zone extends radially outwardly from the primary edge of the bottom casing up to the second distance;
a set of struts disposed onto the second crushable zone, wherein each strut extends radially outwardly from an outermost edge of the second crushable zone up to the third distance;
wherein, upon mating the top casing and the bottom casing:
the first pair of mounting points mates with the second pair of mounting points to form a pair of double shear mounting points, and
the set of ribs and the second set of struts form a co-centric relationship.
2. The enclosure of claim 1, wherein each of the first pair of mounting points comprises a first interlocking element and each of the second pair of mounting points comprises a second interlocking element, wherein the second interlocking element interlocks with the first interlocking element upon mating of the top casing and the second casing.
3. The enclosure of claim 1, wherein the second crushable zone and the first crushable zone comprise a reinforcing rib to increase torsional rigidity of the enclosure.
4. The enclosure of claim 3, wherein the reinforcing rib of the first crushable zone extends orthogonally relative to the set of ribs, and wherein the reinforcing rib of the second crushable zone extends orthogonally relative to the set of struts.
5. The enclosure of claim 1, wherein each rib is associated with a tapered profile that increases in thickness towards the first edge.
6. The enclosure of claim 1, wherein each strut is associated with a tapered contour that increases in thickness towards the primary edge.
7. The enclosure of claim 1, wherein each crushable zone is associated with a shock-absorbing insert to absorb an impact shock wave.
8. The enclosure of claim 1, wherein at least one of the top casings and the bottom casing comprises a pressure relief valve to release gas or pressure buildup within enclosure.
9. The enclosure of claim 1, wherein the first distance is equal to the sum of the second distance and the third distance.
10. The enclosure of claim 1, wherein each of the first set of mounting points comprises a through hole, wherein a radial distance between a face of the through hole and the outermost edge of first pair of mounting point is equal to the third distance.
11. The enclosure of claim 10, wherein the face of the through hole is located opposite to the first edge of the top casing.
12. The enclosure of claim 1, wherein each of the second set of mounting points comprises a through bore, wherein a radial distance between a side of the through bore and the outermost edge of the second pair of mounting point is equal to the third distance.
13. The enclosure of claim 12, wherein the face of the through bore is located opposite to the primary edge of the bottom casing.