Hydroforming of aluminum extrusions for automotive battery tray structures

A method of forming a structural component for a vehicle, the method comprising:

• extruding a material and defining an extrusion in a first state having a cross-section with a plurality of wall portions, internal cells defined by the wall portions, and a plurality of exterior surfaces;
• placing the extrusion within a die, wherein the extrusion has a size and shape that is reduced relative to a shape of the die;
• providing pressurized water to a first set of the internal cells;
• expanding the wall portions surrounding the first set of internal cells into engagement with an internal surface of the die;
• and
• in response to expanding the wall portions, defining a second state of the extrusion, wherein the second state has a larger cross-sectional size and shape than the first state.

A battery frame for a vehicle, the battery frame comprising:

• a first extrusion extending along a length thereof, the first extrusion defining a first cross-sectional shape;
• a second extrusion extending along a length thereof, the second extrusion defining a second cross-sectional shape;
• wherein the first and second extrusions are spaced from each other laterally and define, at least in part, first and second sidewalls of the battery tray;
• wherein the first and second extrusions each respectively include a plurality of intersecting wall portions that define a plurality of cells extending along the first extrusion or second extrusion, respectively;
• wherein the first and second each have a first state having a first cross-sectional size and shape;
• wherein the first and second extrusion each have a second state, wherein the cross-sectional size and shape of the state is expanded relative to the cross-sectional size of the first state.