Systems and methods of use for a battery pack enclosure
AssigneeBeta Air, LLC
InventorsSean Richard Donovan, Sam Wagner
Life of this patent
Estimating the term…
Abstract
Aspects relate to systems and methods for manufacture of a battery pack including a metal case circumscribing an inner volume circumscribed on all but one open side, where the case additionally includes a sealing rim positioned at least partially about the open side, a first component that includes at least two or more sides of the case, and a second component that includes at least one other side of the case, at least a battery module installed within the inner volume of the case, and an inner panel installed within the inner volume, between the case and the at least a battery module. In some aspects, sealing rim, first component, and second component are all joined together by welding.
Claims21
A battery pack comprising:
- a metal case circumscribing an inner volume on all but one open side, wherein the case additionally comprises:
- a sealing rim positioned at least partially about the open side;
- a first component that comprises at least a first side and a second side of the case;
- and
- a second component that comprises at least a third side of the case, wherein the second component additionally comprises:
- at least an electrical connection;
- and
- at least a mechanical connection comprising a first breakaway mount, wherein the case is connected to an electric aircraft by the at least a mechanical connection;
- wherein the sealing rim, the first component, and the second component are all joined together by welding;
- at least a battery module installed within the inner volume of the case;
- an inner panel installed within the inner volume, between the case and the at least a battery module;
- and
- a crush zone installed within the inner volume of the case, wherein the crush zone contains substantially no battery modules and comprises a compressible material;
- wherein the first breakaway mount comprises a frangible nut attached to the third side of the case, wherein the frangible nut is configured to disconnect the entire battery pack from the electric aircraft under a predetermined load.
A method of manufacture for a battery pack comprising:
- manufacturing a metal case circumscribing an inner volume circumscribed on all but one open side, wherein manufacturing a case further comprises:
- receiving a first component, wherein the first component comprises a first side and a second side of the case;
- receiving a second component, wherein the second component comprises at least a third side of the case, and wherein the second component additionally comprises:
- at least an electrical connection;
- and
- at least a mechanical connection comprising a first breakaway mount, wherein the case is connected to an electric aircraft by the at least a mechanical connection, wherein the first breakaway mount comprises a frangible nut attached to the third side of the case;
- positioning a sealing rim at least partially about the open side;
- and
- joining together at least the first component, the second component, and the sealing rim by welding;
- installing at least a battery module within the inner volume of the case;
- installing an inner panel within the inner volume, between the case and the at least a battery module;
- installing a crush zone within the inner volume of the case, wherein the crush zone contains substantially no battery modules and comprises a compressible material;
- and
- disconnecting, by the frangible nut, the entire battery pack from the electric aircraft under a predetermined load.
Dependencies are inferred from the claim text.