# US 2022/0285772 A1 · Battery case for electric vehicle, and method for manufacturing same

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- Number: US 2022/0285772 A1
- Document ID: US20220285772A1
- Status: Published application
- Kind: A1
- Application number: 17/631,337
- Filed: 2020-06-23
- Published: 2022-09-08
- Earliest claimed: 2019-07-31
- Assignees: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
- Applicants: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
- Inventors: Hideki ISHITOBI
- Web page: https://patentgrep.com/patent/US20220285772A1

## CPC

- B21D 22/10: Stamping using yieldable or resilient pads
- H01M 50/231: having a layered structure
- B21D 22/02: Stamping using rigid devices or tools
- B21D 26/021: Deforming sheet bodies
- B21D 39/03: of sheet metal otherwise than by folding
- B60K 1/04: of the electric storage means for propulsion
- B62D 21/00: Understructures, i.e. chassis frame on which a vehicle body may be mounted (combined frame and vehicle body B62D23/00 {; characterised by the material thereof B62D29/00})
- H01M 50/204: Racks, modules or packs for multiple batteries or multiple cells
- H01M 50/209: adapted for prismatic or rectangular cells (H01M50/216 takes precedence)
- H01M 50/224: Metals
- H01M 50/244: Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
- H01M 50/249: specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64)
- H01M 50/289: characterised by spacing elements or positioning means within frames, racks or packs (spacing elements inside cells other than separators, membranes or diaphragms H01M50/471)
- H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane
- Y02E 60/10: Energy storage using batteries
- B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F)
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A method for manufacturing a battery case for electric vehicle includes: preparing a frame, and a blank material formed in a flat plate shape; disposing the frame and the blank material to stack the blank material on the frame; and pressurizing the blank material to press the blank material against the frame, so as to mold the blank material into a bathtub shape and joining the blank material to the frame by press-fitting.

## Claims

### Claim 1

A method for manufacturing a battery case for electric vehicle, the method comprising:
preparing a frame, and a blank material formed in a flat plate shape;
disposing the frame and the blank material to stack the blank material on the frame; and
pressurizing the blank material to press the blank material against the frame, so as to mold the blank material into a bathtub shape and joining the blank material to the frame by press-fitting.

### Claim 2 (depends on 1)

The method for manufacturing the battery case for electric vehicle according to claim 1, wherein the blank material is pressurized based on a pressure molding method.

### Claim 3 (depends on 2)

The method for manufacturing the battery case for electric vehicle according to claim 2, further comprising:
further preparing a fluid pressure transmitting elastic body that is elastically deformable under fluid pressure;
disposing the fluid pressure transmitting elastic body to stack it on the blank material that has been stacked on the frame; and
pressurizing the blank material via the fluid pressure transmitting elastic body to press the blank material against the frame.

### Claim 4 (depends on 2)

The method for manufacturing the battery case for electric vehicle according to claim 2, wherein, before the blank material is pressurized based on the pressure molding method, the blank material is pressurized by cold press molding.

### Claim 5 (depends on 4)

The method for manufacturing the battery case for electric vehicle according to claim 4, wherein, between when the blank material is pressurized based on the pressure molding method and when the blank material is pressurized by the cold press molding, the blank material is subjected to softening heat treatment.

### Claim 6 (depends on 2)

The method for manufacturing the battery case for electric vehicle according to claim 2, wherein when the blank material is molded into a tray of a bathtub shape, negative angle molding is conducted to form a negative angle at least partially from a bottom of the tray of the bathtub shape toward an opening of the tray of the bathtub shape.

### Claim 7 (depends on 6)

The method for manufacturing the battery case for electric vehicle according to claim 6, wherein
before the blank material is pressurized, the frame includes a negative angle portion where the negative angle is previously formed, and
in the negative angle molding, the blank material is pressed against the negative angle portion of the frame.

### Claim 8 (depends on 6)

The method for manufacturing the battery case for electric vehicle according to claim 6, wherein, in the negative angle molding, the blank material is pressurized to be integrally deformed with the frame, causing the negative angle to be formed.

### Claim 9 (depends on 1)

The method for manufacturing the battery case for electric vehicle according to claim 1, further comprising:
further preparing a restricting die having a height dimension greater than that of the frame and configured to restrict a movement of the frame;
disposing the restricting die fixedly to an outer side of the frame;
supporting a first outer edge of the blank material by the frame and supporting a second outer edge of the blank material by the restricting die, the second outer edge being at an outer side of the first outer edge, so as to dispose the blank material in a state where the blank material is deflected to be lower in height from an outer side of the blank material toward an inner side of the blank material; and
pressurizing the blank material in the state where the blank material is deflected.

### Claim 10

A battery case for electric vehicle comprising:
a frame; and
a tray having a bathtub shape, disposed inside the frame, and joined to the frame by press-fitting,
wherein
in joining of the tray to the frame by press-fitting, the tray includes a negative angle portion where a negative angle is formed at least partially inward from a bottom of the tray toward an opening of the tray.

### Claim 11 (depends on 10)

The battery case for electric vehicle according to claim 10, wherein
the frame is formed of an aluminum alloy extruded product, an aluminum alloy cast product, a magnesium alloy extruded product, a magnesium alloy cast product, or a combination of any one of the aluminum alloy extruded product, the aluminum alloy cast product, the magnesium alloy extruded product, and the magnesium alloy cast product, and
the tray is formed of an aluminum alloy or a magnesium alloy.

### Claim 12 (depends on 10)

The battery case for electric vehicle according to claim 10, wherein
the frame is formed of a roll formed sheet steel material, a pressed sheet steel product, or a combination of the roll formed sheet steel material and the pressed sheet steel product, and
the tray is formed of a sheet steel.

### Claim 13 (depends on 10)

The battery case for electric vehicle according to claim 10, wherein
the frame is formed of an aluminum alloy extruded product, an aluminum alloy cast product, a magnesium alloy extruded product, a magnesium alloy cast product, or a combination of any one of the aluminum alloy extruded product, the aluminum alloy cast product, the magnesium alloy extruded product, and the magnesium alloy cast product, and
the tray is formed of a coated sheet steel or a laminated sheet steel.

### Claim 14 (depends on 11)

The battery case for electric vehicle according to claim 11, wherein the frame includes a cross member.

### Claim 15 (depends on 3)

The method for manufacturing the battery case for electric vehicle according to claim 3 wherein, before the blank material is pressurized based on the pressure molding method, the blank material is pressurized by cold press molding.

### Claim 16 (depends on 15)

The method for manufacturing the battery case for electric vehicle according to claim 15, wherein, between when the blank material is pressurized based on the pressure molding method and when the blank material is pressurized by the cold press molding, the blank material is subjected to softening heat treatment.

### Claim 17 (depends on 16)

The method for manufacturing the battery case for electric vehicle according to claim 16, wherein
before the blank material is pressurized, the frame includes a negative angle portion where the negative angle is previously formed, and
in the negative angle molding, the blank material is pressed against the negative angle portion of the frame.

### Claim 18 (depends on 16)

The method for manufacturing the battery case for electric vehicle according to claim 16, wherein, in the negative angle molding, the blank material is pressurized to be integrally deformed with the frame, causing the negative angle to be formed.

### Claim 19 (depends on 2)

The method for manufacturing the battery case for electric vehicle according to claim 2, further comprising:
further preparing a restricting die having a height dimension greater than that of the frame and configured to restrict a movement of the frame;
disposing the restricting die fixedly to an outer side of the frame;
supporting a first outer edge of the blank material by the frame and supporting a second outer edge of the blank material by the restricting die, the second outer edge being at an outer side of the first outer edge, so as to dispose the blank material in a state where the blank material is deflected to be lower in height from an outer side of the blank material toward an inner side of the blank material; and
pressurizing the blank material in the state where the blank material is deflected.

### Claim 20 (depends on 3)

The method for manufacturing the battery case for electric vehicle according to claim 3, further comprising:
further preparing a restricting die having a height dimension greater than that of the frame and configured to restrict a movement of the frame;
disposing the restricting die fixedly to an outer side of the frame;
supporting a first outer edge of the blank material by the frame and supporting a second outer edge of the blank material by the restricting die, the second outer edge being at an outer side of the first outer edge, so as to dispose the blank material in a state where the blank material is deflected to be lower in height from an outer side of the blank material toward an inner side of the blank material; and
pressurizing the blank material in the state where the blank material is deflected.