Structural composites for battery enclosure

A composite battery enclosure comprising:

• a. a molded bottom composite cover comprising
• i. a second core sandwiched between a first bottom composite cover skin and a second bottom composite cover skin;
• ii. the second core forming a sidewall of the enclosure, the sidewall comprising an interior sidewall surface, a top sidewall surface, and an outer sidewall surface
• b. a molded top composite cover comprising
• i. a first core sandwiched between a first top composite cover skin and a second top composite cover skin, the first core comprising a reinforced area of increased thickness positioned adjacent sidewall formed by the second core of the molded bottom composite cover such that the reinforced area of increased thickness abuts against a portion of interior sidewall surface of the molded bottom composite cover and along the interface of the interior sidewall surface and top sidewall surface.

A composite battery enclosure comprising:

• a. a molded top composite cover comprising
• i. a first core sandwiched between a first top composite cover skin and a second top composite cover skin, the first core comprising a top portion and a sidewall portion, the sidewall portion of the molded top composite cover comprising a top composite cover perimeter surface;
• b. a molded bottom composite cover comprising
• i. a second core sandwiched between a first bottom composite cover skin and a second bottom composite cover skin, the second core comprising a top portion and a sidewall portion, the sidewall portion of the molded bottom composite cover comprising a bottom composite cover perimeter surface, the bottom composite cover perimeter surface facing the top composite cover perimeter surface;
• c. an interface in the sidewall of the composite battery enclosure, the interface formed by the sidewall portion of the top composite cover meeting the sidewall portion of the bottom composite cover, wherein the interface comprises a first section and a second section, the first section comprising an interface angle different than an interface angle of the second section.