Patent Publication Number: US-2022216560-A1

Title: Battery containment construct

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority of U.S. Provisional Patent Application Ser. No. 62/844,567 filed May 7, 2019, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention in general relates to a high strength, light weight containment construct and in particular to a high strength, light weight containment construct for containing for example, a fuel cell or battery, to provide impact resistance, fire resistance, and fluid penetration prevention. 
     BACKGROUND OF THE INVENTION 
     Weight savings in the automotive, transportation, aerospace, and logistics-based industries has been a major focus in order to make more fuel-efficient vehicles both for ground and air transport. In order to achieve these weight savings, light weight composite materials have been introduced to take the place of metal structural and surface body components and panels. Composite materials are materials made from two or more constituent materials with significantly different physical or chemical properties, that when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure. A composite material may be preferred for reasons that include materials which are stronger, lighter, or less expensive when compared to traditional materials of steel or aluminum. Still another advantage over metals is reduced corrosion, leading to longer operational life and reduced maintenance costs. 
     Composites typically have two constituent materials: matrix and reinforcement. The matrix material surrounds and supports the reinforcement materials by maintaining their relative positions. The reinforcements impart their special mechanical and physical properties to enhance the matrix properties. A synergism produces material properties unavailable from the individual constituent materials, while the wide variety of matrix and strengthening materials allows the designer of the product or structure to choose an optimum combination. 
     The use of fiber inclusions to strengthen a matrix is well known to the art. Well established mechanisms for the strengthening of a matrix include slowing and elongating the path of crack propagation through the matrix, as well as energy distribution associated with pulling a fiber free from the surrounding matrix material. In the context of sheet molding composition (SMC) formulations, bulk molding composition (BMC) formulations, and resin transfer molding (RTM) fiber strengthening has traditionally involved usage of chopped glass fibers, while carbon fibers are known to be high strength and low weight reinforcements. 
     Weight savings are particularly important for electric and hybrid vehicles powered with energy cells employing battery technologies in order to achieve greater vehicle driving range per charge. However, unique problems associated with some components of electric and hybrid vehicles have hindered the ability to use composite materials for some applications on hybrid or electric vehicles. For example, batteries of electric and hybrid vehicles present unique safety considerations owing to the high voltages of the batteries, chemicals employed in the battery technologies, combustion and fire risks associated with the batteries, and potential fume encounters if the batteries are broken or damaged. Therefore, batteries of electric and hybrid vehicles generally require protective containers designed to shield batteries from forces they may otherwise experience during an impact or crash event. Generally, such protective containers are high strength boxes formed of welded metals, which are heavy, prone to corrosion, and have been found to be water penetrable at at least the welds. 
     Thus, there exists a need for a battery containment construct design that utilizes composite materials to lower the weight of the component, while improving the safety performance compared to conventional vehicle components. 
     SUMMARY OF THE INVENTION 
     A battery containment construct is provided that includes a unitary tray having a bottom and a set of walls including a first side wall, a second side wall, a first end wall, and a second end wall. The set of walls extending from the bottom of the tray and defining a cavity within the tray. A cover removably attached to the plurality of walls of said tray opposite the bottom of said tray. Energy absorption components attached to the bottom of the tray external to at least one of the set of walls in some versions to enhance impact resistance. The construct has high strength, is light weight and well suited for containing and protecting energy cells or batteries that adjusted to impact resistance, fire resistance, and fluid penetration prevention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is further detailed with respect to the following drawings that are intended to show certain aspects of the present invention but should not be construed as a limit on the practice of the present invention. 
         FIG. 1  is an exploded perspective view of a battery containment construct according to embodiments of the present invention; 
         FIG. 2  is a perspective view of a tray and energy absorption components of a battery containment construct assembled together according to an embodiment of the present invention; 
         FIG. 3  is a detailed perspective view of a portion of the battery containment construct shown in the dashed oval  2  of  FIG. 2 ; 
         FIGS. 4A-4R  show a side view of various configurations of an energy absorption component of a battery containment construct according to embodiments of the present invention; 
         FIGS. 5A-5R  show an end view of the configurations of an energy absorption component of a battery containment construct of  FIGS. 4A-4R , respectively; 
         FIGS. 6A and 6B  show a side view of energy absorption components of  FIGS. 4A and 4B , respectively, with dimension indicators; 
         FIGS. 7A-7C  show perspective view of various configurations of an energy absorption component of a battery containment construct according to embodiments of the present invention; 
         FIG. 8  is a detailed cross-sectional view of a portion of the battery containment construct of  FIG. 2  along line  8 - 8 ; 
         FIG. 9  is a schematic drawing of a pole test conducted on embodiments of the inventive battery containment construct. 
     
    
    
     DESCRIPTION OF THE INVENTION 
     The present invention has utility as a high strength, light weight containment construct for containing and protecting energy cells or batteries that provides impact resistance, fire resistance, and fluid penetration prevention. 
     The present invention will now be described with reference to the following embodiments. As is apparent by these descriptions, this invention can be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. For example, features illustrated with respect to one embodiment can be incorporated into other embodiments, and features illustrated with respect to a particular embodiment may be deleted from the embodiment. In addition, numerous variations and additions to the embodiments suggested herein will be apparent to those skilled in the art in light of the instant disclosure, which do not depart from the instant invention. Hence, the following specification is intended to illustrate some particular embodiments of the invention, and not to exhaustively specify all permutations, combinations, and variations thereof. 
     It is to be understood that in instances where a range of values are provided that the range is intended to encompass not only the end point values of the range but also intermediate values of the range as explicitly being included within the range and varying by the last significant figure of the range. By way of example, a recited range of from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4. 
     Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. 
     Unless indicated otherwise, explicitly or by context, the following terms are used herein as set forth below. As used in the description of the invention and the appended claims, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Also as used herein, “and/or” refers to and encompasses any and all possible combinations of one or more of the associated listed items, as well as the lack of combinations when interpreted in the alternative (“or”). 
     As used herein “fluid penetration” refers to a single piece or joined piece construction that prevents unintended transit of gaseous or liquid coolants through a construct component in general, and a tray in particular. 
     Referring now to the figures, a battery containment construct  10  according to embodiments of the present invention includes a tray  20 , and a cover  40 . In some inventive embodiments, as shown in the figures, a pair of energy absorption components  30 ,  30 ′ are provided to impart impact resistance to the construct  10 . It is appreciated that the relative placement of an inventive construct  10  largely dictates the need for additional impact resistance. By way of example, a construct  10  surrounded by a vehicle chassis has reduced or no need for energy absorption components, while in contrast, placement under a vehicle side door has a consider need to inhibit impact induced intrusion into the contained volume of a construct  10 . 
     The tray  20 , the pair of energy absorption components  30 ,  30 ′, if present, and the cover  40  are configured to be assembled in such a way as to form a high strength, light weight containment construct  10  that provides impact resistance, fire resistance, and fluid penetration prevention to contents contained within the construct  10 , which according to embodiments is a plurality of batteries  50 . The containment construct  10  is particularly suitable for containing batteries of a hybrid or electric vehicle. The battery containment construct  10  absorbs and dissipates kinetic energy experienced during a crash or impact event. In particular, the battery containment construct  10  according to embodiments of the present invention exhibits minimal (less than 40%) intrusion into the enclosure and high resistance (at least 80 kN) to the impact when subjected to a quasi-static load by a 10 inch (25 cm) diameter rigid column located at the center of the battery and traveling perpendicular into a predominate longitudinal or lateral edge of the battery containment construct  10 . Additionally, during such crash event or impacts, the content of the construct  10 , such as batteries contained experience limited deformation of the cell perimeter and the high voltage wiring connecting the batteries to other systems of the electric or hybrid vehicle experiences little to no loading. 
     The tray  20  of an inventive battery containment construct  10  includes a bottom  22  and walls including a first and second side wall  24 ,  24 ′ and a first and second end wall  26 ,  26 ′. The walls extend from one side of the bottom  22  of the tray  20 . The walls and the bottom  22  define a cavity  28  within the tray  10 . The first and second energy absorption components  30 ,  30 ′ are attached to the bottom  22  of the tray  20  external to the cavity  28 . That is, a first of the energy absorption components  30  is attached to the bottom  22  of the tray  20  external to the first side wall  24  while the second energy absorption component  30 ′ is attached to the bottom  22  of the tray  20  external to the second side wall  24 ′. The cover  40  is removably attachable to the walls  24 ,  24 ′,  26 ,  26 ′ of the tray  20  opposite the bottom  22  of the tray  20 . 
     As shown in  FIG. 2 , when the first and second energy absorption components  30 ,  30 ′ are present and attached to the bottom  22  of the tray  20 , a plurality of voids  34  are defined between the bottom  22  of the tray  20  and each of the first and second energy absorption components  30 ,  30 ′. According to certain inventive embodiments, the voids  34  are packed with a fire-retardant material or a fire-resistant material. In addition to providing fire resistance and extinguishing capabilities, the fire-retardant material or fire-resistant material packed in the voids  34  provides additional impact resistance. According to other inventive embodiments, any of the components of an inventive battery containment construct  10  may have one or more coatings, shown generically at  35 . The coating  35  illustratively includes materials that impart fire resistance, are phenolic in nature, electromagnetic interference-radiofrequency interference (EMI-RFI) resistance, or a combination of such coatings. It is appreciated that coating as used in this context is intended to include separate layers of material that are applied as a sheet material to a substrate of the construct  10 . 
     That is, according to embodiments, the tray  20 , the energy absorption components  30 ,  30 ′, the cover  40 , or a combination thereof are coated in a fire resistant, or a fire-retardant material. A fire-resistant material is one that is designed to resist burning and withstand heat and provide insulation to the substrate, while a fire-retardant material is designed to burn slowly and reduce the rate of flame spread. Intumescent fire-resistant materials work by expanding their volume from 15 to 30 times and generating an ash-like char layer that erodes as fire exposure continues. Expansion then occurs again with the number of times the process repeats itself dependent upon the thickness of the coating. For example, such fire resistant or fire retardant materials for packing in voids  34  or coating any of the tray  20 , the energy absorption components  30 ,  30 ′, the cover  40  include any of the following: silicone, casein or vinyl resins, aluminum trihydrate or antimony oxide, ammonium polyphosphate, pentaerythritol, melamine derivatives, boric acid (H 3 BO 3 ) and borax (Na 2 B 4 O 7 .10H 2 O), disodium octaborate tetrahydrate (Na 2 B 8 O 13 .4H 2 O), dicyandiamide-formaldehyde-phosphoric acid, melamine-dicyandiamide-formaldehyde-phosphoric acid, poly(n-vinylpyrolidone), colloidal silica, magnesium hydroxide (MDH), monoammonium phosphate (MAP), aluminum hydroxide (ATH), carbonates and hydrogen carbonates, potassium carbonate, Na 2 WO 4 , Na 2 SnO 3 , Na 2 MoO 4 , ammonium polyphosphate, pentaerythritol, melamine, expandable graphite, or combinations thereof. Phenolic resins operative herein illustratively includes epoxy phenolic resins, and phenol formaldehyde resins that impart corrosion resistance and a mar resistance surface relative to the underlying substrate of the construct  10 . EMI-RFI shielding coatings operative herein illustratively include nickel coated glass mat; carbon fiber matting; copper or nickel paint; various metal foils, such as aluminum, nickel, iron, copper, and alloys thereof; and or combinations thereof with the proviso that the EMI-RFI shielding is grounded so as to function as a Faraday cage. It is further appreciated that coatings  35  in the form of sheets are readily applied as an underlying sheet below an inventive construct  10 . 
     According to certain inventive embodiments, the cover  40  is formed of reinforced sheet molding compound (SMC), a phenolic-SMC, epoxy, acrylonitrile butadiene styrene (ABS), polycarbonate, random-oriented fiber reinforced thermoplastic resin (FRTP), steel, or aluminum. Sheet molding compound (SMC) or sheet molding composite is a ready to mold fiber-reinforced polyester material primarily used in compression molding. SMC is a reinforced composite material that is manufactured by dispersing long strands (20-60 mm) of chopped glass fibers in a matrix of polyester resin. It is appreciated that fibers with long range order are also operative herein and include woven mats, continuous fibers, or sheet forms. Thermoplastic materials operative herein amenable to functioning as a fiber matrix illustratively include: poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamides, polylactides, polybenzimidazoles, polycarbonates, polyether sulfones, polyethylene, polypropylene, polystyrene, polyvinyl chloride, or block copolymers of any one of the aforementioned constituting the majority by monomer number. Reinforcing fibers and fillers operative herein illustratively include carbon fibers, glass fibers, aramid fibers, cellulosic fibers, or a combination thereof. In some inventive embodiments, the chopped fiber is glass fiber, alone or in combination with other types of fiber or reinforcing fillers. According to embodiments, the cover  40  is formed of glass fiber reinforced SMC. As noted above, a coating  35  is readily applied to a cover  40  in some inventive embodiments. 
     According to certain inventive embodiments, the battery containment construct further includes a seal  42  positioned between the cover  40  and the plurality of walls  24 ,  24 ′,  26 ,  26 ′ of the tray  20 . The seal  42  may be provided on either of the cover  40  or the plurality of wall. The seal  24  is formed of an elastomeric material. The seal  42  ensures water tight engagement between the tray  20  and the cover  40 . 
     According to certain inventive embodiments, the tray  20  further includes internal divider walls  29 , which divide the cavity  28  into sections of sub-cavities. The internal divider walls  29  extend from the bottom  22  of the tray  20  between the first side wall  24  and the second side wall  24 ′. It will be appreciated that the internal divider walls  29  could alternatively or additionally span between the first end wall  26  and the second end wall  26 ′. The internal divider walls  29  provide additional structural rigidity to the battery containment construct  10  and provide support to batteries  50  positioned within the containment construct  10  to limit shifting of the batteries  50  within the containment construct. According to embodiments, the tray  20  also includes a through hole  27  defined in at least one of the walls  24 ,  24 ′,  26 ,  26 ′. The through hole  27  allows a wire or cable  52  to be passed therethrough, such as a high voltage wire  52  for connecting the batteries  50  contained within the battery containment construct  10  to the other systems of the hybrid or electric vehicle systems. In  FIG. 1 , the through hole  27  is defined in the first end wall  26 ; however it will be understood that a through hole  27  may be provided in any of the plurality of walls  24 ,  24 ′,  26 ,  26 ′, the cover  40 , or the bottom  22  of the tray  20  based on design requirements and routing of a high voltage wire  52  for connecting the batteries  50  to other systems of the hybrid or electric vehicle. 
     According to embodiments, the tray  20  is formed of a reinforced sheet molding compound (SMC), epoxy, acrylonitrile butadiene styrene (ABS), polycarbonate, or random-oriented fiber reinforced thermoplastic resin (FRTP). Thermoplastic materials referred to herein include but are not limited to poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamides, polylactides, polybenzimidazoles, polycarbonates, polyether sulfones, polyethylene, polypropylene, polystyrene, polyvinyl chloride, or block copolymers of any one of the aforementioned constituting the majority by monomer number. Reinforcing fibers and fillers operative herein illustratively include carbon fibers, glass fibers, aramid fibers, cellulosic fibers, or a combination thereof. In some inventive embodiments, the chopped fiber is glass fiber, alone or in combination with other types of fiber or reinforcing fillers. According to embodiments, the tray  20  is formed of glass fiber reinforced SMC or carbon fiber reinforced SMC. 
     According to embodiments, a battery containment construct  10  further includes a frame  60  for reinforcing the tray  20 . The reinforcing frame  60  includes members including any of a first and a second side member  62 ,  62 ′, a first and a second end member  64 ,  64 ′, and cross members  66 . As shown in  FIG. 1 , the members  62 ,  62 ′,  64 ,  64 ′,  66  of the reinforcing frame  60  are any of T-shaped or L-shaped members or a combination thereof. In other words, the members  62 ,  62 ′,  64 ,  64 ′,  66  of the reinforcing frame  60  include upwardly extending portions and outwardly extending portions. The upwardly extending portions of the members  62 ,  62 ′,  64 ,  64 ′,  66  are configured to engage with the protrusions of the walls  24 ,  24 ′,  26 ,  26 ′,  29  that extend from the bottom  22  of the tray  20 , while the outwardly extending or flange portions  68  of the members  62 ,  62 ′,  64 ,  64 ′,  66  are configured to engage with the bottom  22  of the tray  20  on a side of the bottom  22  opposite one of the walls  24 ,  24 ′,  26 ,  26 ′ of the tray  20 , as shown in the detailed perspective view of  FIG. 3 . The reinforcing frame  60  is formed of any of reinforced polymer, such as those reinforced with glass fibers or carbon fibers, aluminum, or steel. According to embodiments, the members of the frame  60  are discrete, individual sections that remain as such until joined with the tray  20 . According to other inventive embodiments, the members of the frame  60  are discrete, individually formed sections that are joined together prior to being joined with the tray  20 . In yet another inventive embodiment, the reinforcing frame  60  is formed as a single frame comprising to joined members that is then joined to the tray  20 . 
     According to certain inventive embodiments, the energy absorption components  30 ,  30 ′ are formed of any of carbon fiber reinforced thermoplastic (CFRTP), aluminum, or steel. According to certain inventive embodiments, the energy absorption components  30 ,  30 ′ are formed of a carbon fiber reinforced thermoplastic known as SEREEBO(R)™, having composition including Carbon fibers “Tenax” (registered trademark) STS40-24KS (average fiber diameter: 7.mu.m, single yarn number: 24,000) manufactured by Teijin., Ltd., which had been cut to an average fiber length of 20 mm were used as carbon fibers. Nylon-6 resin A1030 manufactured by Unichika, Ltd. was used. In accordance with the method described in U.S. Pat. No. 8,946,342, there was manufactured a molding material precursor of the carbon fibers and the Nylon-6 resin, in which the carbon fibers had been randomly oriented in two-dimensions. The obtained molding material precursor was heated at 2.0 MPa for 5 minutes with a pressing device heated to 260.degree. C. to obtain a CFRTP material. 
     As shown in  FIG. 1 , the first and second energy absorption components  30 ,  30 ′ each have a repeating shape of a predetermined geometry. As shown in  FIGS. 4A-4R , the repeating shape of the first and second energy absorption components  30 ,  30 ′ is any of a closed hexagon ( FIG. 4A ), a closed circle ( FIG. 4E ), a closed triangle ( FIG. 4L ), a closed oval ( FIG. 4P ), a closed square ( FIG. 4N ), a closed rectangle ( FIG. 4Q ), an open semi hexagon ( FIGS. 4B, 4C, and 4D ), an open semi-circle ( FIG. 4F ), and open semi oval ( FIG. 4G ), an open triangle ( FIG. 4K ), an open semi square ( FIG. 4M ), and open semi rectangle ( FIG. 4R ), and a sine wave ( FIG. 4O ). As shown in  FIGS. 4H, 4I, and 4J , the first and second energy absorption components  30 ,  30 ′ are extruded or roll formed elongated forms with a continuous cross section. As shown in  FIG. 4A  the first and second energy absorption components  30 ,  30 ′ have a length L measured from a first end to a second end. It will be readily under stood that the various configurations of the first and second energy absorption components  30 ,  30 ′ shown in  FIGS. 4A-4R  also have a length L measured from a first end to a second end, however the length L is not shown in all of the figures for clarity.  FIGS. 5A-5R  show end view of each of the first and second energy absorption components  30 ,  30 ′ show in  FIGS. 4A-4R , respectively. As shown in  FIG. 5A  the first and second energy absorption components  30 ,  30 ′ have a width W and a height H. As with the length L, it will be understood that the width W and height H have not been shown in all of the figures for clarity. According to certain inventive embodiments, the length L of each energy absorption component  30 ,  30 ′ is 5 to 5000 mm, the width W is 5 to 100 mm, and the height H is 5 to 100 mm. The length, L, width W, and height H of each energy absorption component  30 ,  30 ′ generally corresponds to the overall length of the tray  20 , height of the side walls  24 ,  24 ′, and the width of a lip of the bottom  22  that extends beyond the walls  24 ,  24 ′,  26 ,  26 ′ of the tray  20  onto which the energy absorption components  30 ,  30 ′ are attached. 
     The geometry, including the length L, width W, and height H, along with internal dimensions including the length of each individual shape  1 , distance between each shape d, pitch p, wall thickness T 1 , T 2 , and wall angle α, of each of the energy absorption components  30 ,  30 ′ may be tuned to achieve various characteristics depending on design considerations and requirements of a particular containment construct  10 . The length of each individual shape  1 , distance between each shape d, pitch p, and wall thickness T 1 , T 2  are shown in  FIGS. 6A and 6B , which are detailed views of  FIGS. 4A and 4B . Wall angle α is shown in  FIGS. 7A-7C . Notable. The component shown in  FIG. 7A  is the same as the component shown in  FIG. 4B . It will be understood that these dimensions are applicable to the various shapes of the first and second energy absorption components  30 ,  30 ′ shown throughout  FIGS. 4A-4R , but are not labeled in each figure for clarity. For example, as best shown in the exemplary shapes of  FIGS. 4B, 4C, and 4D , the length  1  of each repeated shape and the distance d between each repeated shape can be increased or decreased to vary the strength characteristics of the first and second energy absorption components  30 ,  30 ′. According to certain inventive embodiments, the distance d between the repeated shapes is 0 to 300 mm. According to certain inventive embodiments, the length of each repeated shape is 20 to 300 mm. According to certain inventive embodiments, the pitch is 45 to 120 degrees. According to certain inventive embodiments, the thickness T 1  is 0.25 to 5 mm and the thickness T 2  is 0.25 to 10 mm. According to certain inventive embodiments, the thickness T 2  is two times the thickness to T 1 . According to certain inventive embodiments, the wall angle α or tilt inward toward the voids  34  of the upward extensions of the repeated shapes is 0 to 25 degrees. For example, in  FIG. 7A  the wall angle α is 0 degrees, in  FIG. 7B  the wall angle α is 5 degrees, and in  FIG. 7C  the wall angle α is 12.5 degrees. 
     Further details of an inventive containment construct according to embodiments of the present invention are now described with reference to  FIG. 8  which are detailed cross-sectional view of the construct of  FIGS. 1 and 2  along cut lines  8 - 8  of  FIG. 2 , respectively; and references numerals detailed with respect to these figures have the aforementioned meanings associated therewith. 
     In the cross-sectional view of  FIG. 8 , an end member  64  of frame  60  is shown positioned within the protrusion of end wall  26  of the tray  20 . According to certain inventive embodiments, an adhesive  67  is applied between the frame  60  and the second side of the tray  20 . In  FIG. 8 , the temperature regulation system  70  is shown positioned under the battery  50 . As shown in  FIG. 8 , the battery  50  is not secured by a bracket and fastener to the end wall  26  of the tray, however, according to still other inventive embodiments, the battery  50  may be secured to the end wall  26  using a bracket and fasted. In  FIG. 8 , the cover  40  is attached to the end wall  26  of the tray  20  by a fastener  46 . A seal  42  is positioned between the cover  40  and the walls  26  of the tray  20  to provide a water tight enclosure within the containment construct  10 . According to embodiments, the cover  40  includes a lip  48  that extends from the generally planar cover  40  to cover the seal  42  in order to provide further resistance to water penetration. According to embodiments, a cushioning or shock absorbing material  44  such as foam is provided between the cover  40  and the batteries  50 . 
     A side member  62  and a cross member  66  of frame  60  are shown in  FIG. 2  engaged with an interior divider wall  29  and side wall  24  of the tray  20 . The cover  40  is shown engaged with the seal  42  along the side wall  24  of the tray  20 . The lip  48  of the cover  40  is shown to extend the length of the side wall  24 . Energy absorbing component  30  is shown positioned on an exterior side of the side wall  24 . According to embodiments, the energy absorption components  30 ,  30 ′ are attached to the bottom  22  of the tray  20  with an adhesive  67 , alternatively or additionally the energy absorption components  30 ,  30 ′ are attached to the bottom  22  of the tray  20  with a fastener  32 , which may engage with a through hole defined in the bottom  22  of the tray and/or defined in a flange  68  of the side member  62  of the frame  60 . 
     According to certain inventive embodiments, a containment construct  10  has dimensions suitable to contain batteries  50  of an electric or hybrid vehicle. For example, embodiments of the inventive battery containment construct have a length X measured from the first end wall  26  to the second end wall  26 ′ of the tray  20 , a width Z measured from the first side wall  24  to the second side wall  24 ′ of the tray  20 , and a height Y measured from the second side of the bottom  22  of the tray  20  to the exterior side of the cover  40 . According to embodiments, the overall dimensions of the assembled battery containment construct  10  are a height Y of 100 to 500 mm, a length X of 100 to 5000 mm, and a width Z of 100 to 3000 mm. According to embodiments, multiple layers of batteries  50  are stacked within the containment construct  10 , resulting in taller containment constructs. According to embodiments, multiple layers of containment constructs  10  are stacked. 
     The present invention is further detailed with respect to the following non-limiting examples. These examples are exemplary of specific embodiments of the present invention and not intended to limit the scope of the appended claims. 
     EXAMPLES 
     Embodiments of the inventive battery containment construct  10  were constructed having various forms of the first and second energy absorption components  30 ,  30 ′. These battery containment constructs  10  were subjected to impact testing using a quasi-static load by a 10 inch (25 cm) diameter rigid column located at the center of the construct and traveling perpendicular into a predominate longitudinal or lateral edge of the battery containment construct  10  as shown in the schematic in  FIG. 9 . 
     In a first example, battery containment constructs  10  including energy absorption components  30 ,  30 ′ formed of steel (SPFC590) having various geometries are tested for comparison. In this example, the containment constructs are subjected to 250 J impacts at an impact angle of 90 degrees. As shown in Table 1, different repeating shapes are tested as well as different thicknesses T 1  and T 2  and pitches p. The mass of each component and the deformation results of the impact testing are reported in Table 1. 
     
       
         
           
               
               
               
               
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                   
                 Shape/ 
                   
                   
                   
                   
                   
               
               
                 Analysis 
                 Reference 
                 T1 
                 T2 
                 Mass 
                 pitch 
                 Deformation 
               
               
                 File 
                 FIG. 
                 mm 
                 mm 
                 kg 
                 mm 
                 mm 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 EA-1 
                 FIG. 4A 
                 0.73 
                 1.46 
                 1.33 
                 104.5 
                 11.9 
               
               
                 EA-2 
                 FIG. 4B 
                 0.93 
                 — 
                 1.33 
                 207.8 
                 18.3 
               
               
                 EA-3 
                 FIG. 4C 
                 1.01 
                 — 
                 1.33 
                 323.3 
                 28.4 
               
               
                 EA-4 
                 FIG. 4D 
                 1.11 
                 — 
                 1.33 
                 577.3 
                 49.6 
               
               
                 EA-5 
                 FIG. 4E 
                 0.71 
                 1.41 
                 1.33 
                 90 
                 8.1 
               
               
                 EA-7 
                 FIG. 4F 
                 0.89 
                 — 
                 1.33 
                 180 
                 16.3 
               
               
                 EA-12 
                 FIG. 4G 
                 1.08 
                 — 
                 1.32 
                 360 
                 44 
               
               
                 EA-9 
                 FIG. 4H 
                 0.22 
                 — 
                 1.33 
                 — 
                 &gt;70 
               
               
                 EA-10 
                 FIG. 4I 
                 0.26 
                 — 
                 1.33 
                 — 
                 &gt;70 
               
               
                 EA-11 
                 FIG. 4J 
                 0.23 
                 — 
                 1.33 
                 — 
                 &gt;70 
               
               
                 EA-2 
                 FIG. 4B 
                 0.930 
                 — 
                 1.33 
                 207.8 
                 18.3 
               
               
                 EA-9-2 
                 FIG. 4H 
                 0.620 
                 — 
                 3.77 
                 — 
                 18.4 
               
               
                 EA-10-2 
                 FIG. 4I 
                 0.690 
                 — 
                 3.55 
                 — 
                 18.4 
               
               
                 EA-11-2 
                 FIG. 4J 
                 0.790 
                 — 
                 4.68 
                 — 
                 18.2 
               
               
                   
               
            
           
         
       
     
     In a second example, battery containment constructs  10  including energy absorption components  30 ,  30 ′ formed of steel (SPFC590) having an open hexagon repeating shape are tested to compare the effects of varying the wall angle α. In this example, the containment constructs are subjected to 250 J impacts at an impact angles of 90 and 75 degrees. As shown in Table 2, in this example the thicknesses T 1  and T 2 , pitch p, and mass are generally unchanged. The deformation results of the impact testing are reported in Table 2. 
     
       
         
           
               
               
               
               
               
               
               
               
             
               
                 TABLE 2 
               
               
                   
               
               
                   
                 Shape/ 
                   
                   
                   
                   
                   
                   
               
               
                 Analysis 
                 Reference 
                 t1 
                 Mass 
                 pitch 
                 Deformation 
                 wall 
                 Impact 
               
               
                 file 
                 FIG. 
                 mm 
                 kg 
                 mm 
                 mm 
                 angle 
                 angle 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 EA-2 
                 FIG. 7A 
                 0.93 
                 1.33 
                 207.8 
                 18.3 
                 0 
                 90 
               
               
                   
                 (FIG. 4B) 
                   
                   
                   
                   
                   
                   
               
               
                 EA-13 
                 FIG. 7B 
                 0.93 
                 1.33 
                 207.8 
                 19.5 
                 5 
                 90 
               
               
                 EA-14 
                 FIG. 7C 
                 0.92 
                 1.33 
                 207.8 
                 19.7 
                 12.5 
                 90 
               
               
                 EA-2- 
                 FIG. 7A 
                 0.93 
                 1.33 
                 207.8 
                 19.8 
                 0 
                 75 
               
               
                 obli 
                 (FIG. 4B) 
                   
                   
                   
                   
                   
                   
               
               
                 EA-13- 
                 FIG. 7B 
                 0.93 
                 1.33 
                 207.8 
                 19.4 
                 5 
                 75 
               
               
                 obli 
                   
                   
                   
                   
                   
                   
                   
               
               
                 EA-14- 
                 FIG. 7C 
                 0.92 
                 1.33 
                 207.8 
                 19.9 
                 12.5 
                 75 
               
               
                 obli 
               
               
                   
               
            
           
         
       
     
     In a third example, battery containment constructs  10  including energy absorption components  30 ,  30 ′ formed of steel (SPFC590), aluminum (A5052), and CFRTP (Teijin-SEREEBO®) having various geometries are tested for comparison. In this example, the containment constructs are subjected to 250 J impacts at an impact angle of 90 degrees. Table 3 reports the details of the different geometries tested and resulting impact deformations for each material. 
     
       
         
           
               
               
               
               
               
               
               
               
             
               
                 TABLE 3 
               
               
                   
               
               
                   
                 Shape/ 
                   
                   
                   
                   
                   
                 Defor- 
               
               
                 Analysis 
                 Reference 
                   
                 t1 
                 t2 
                 Mass 
                 pitch 
                 mation 
               
               
                 file 
                 FIG. 
                 Material 
                 mm 
                 mm 
                 kg 
                 mm 
                 mm 
               
               
                   
               
             
            
               
                 EA-1-2 
                 FIG. 4A 
                 Steel 
                 0.33 
                 0.66 
                 0.60 
                 104.5 
                 18.2 
               
               
                   
                   
                 (SPFC590) 
                   
                   
                   
                   
                   
               
               
                 EA-2 
                 FIG. 4B 
                 Steel 
                 0.93 
                 — 
                 1.33 
                 207.8 
                 18.3 
               
               
                   
                   
                 (SPFC590) 
                   
                   
                   
                   
                   
               
               
                 EA-11-2 
                 FIG. 4J 
                 Steel 
                 0.79 
                 — 
                 4.68 
                 — 
                 18.2 
               
               
                   
                   
                 (SPFC590) 
                   
                   
                   
                   
                   
               
               
                 EA-1-Al 
                 FIG. 4A 
                 Aluminum 
                 0.82 
                 1.64 
                 0.52 
                 104.5 
                 18.6 
               
               
                   
                   
                 (A5052) 
                   
                   
                   
                   
                   
               
               
                 EA-2-Al 
                 FIG. 4B 
                 Aluminum 
                 1.90 
                 — 
                 0.94 
                 207.8 
                 18.7 
               
               
                   
                   
                 (A5052) 
                   
                   
                   
                   
                   
               
               
                 EA-9-Al 
                 FIG. 4H 
                 Aluminum 
                 0.95 
                 — 
                 2.00 
                 — 
                 18.8 
               
               
                   
                   
                 (A5052) 
                   
                   
                   
                   
                   
               
               
                 EA-1-Se 
                 FIG. 4A 
                 CFRTP(Teijin- 
                 1.40 
                 2.80 
                 0.45 
                 104.5 
                 17.9 
               
               
                   
                   
                 SEREEBO ®) 
                   
                   
                   
                   
                   
               
               
                 EA-2-Se 
                 FIG. 4B 
                 CFRTP(Teijin- 
                 3.00 
                 — 
                 0.75 
                 207.8 
                 18.7 
               
               
                   
                   
                 SEREEBO ®) 
               
               
                   
               
            
           
         
       
     
     In a fourth example, like the third example, battery containment constructs  10  including energy absorption components  30 ,  30 ′ formed of steel (SPFC590), aluminum (A5052), and CFRTP (Teijin-SEREEBO®) having various geometries are tested for comparison. In this example, the containment constructs are subjected to 250 J impacts at an impact angle of 90 degrees. Table 4 reports the details of the different geometries tested and resulting impact deformations for each material. 
     
       
         
           
               
               
               
               
               
               
               
               
               
             
               
                 TABLE 4 
               
               
                   
               
               
                   
                 Shape/ 
                   
                   
                 Percent 
                   
                   
                   
                   
               
               
                 Analysis 
                 Reference 
                   
                   
                 of 
                 t1 
                 Mass 
                 pitch 
                 Deformation 
               
               
                 file 
                 FIG. 
                 Material 
                 Ply 
                 0° ply 
                 mm 
                 kg 
                 mm 
                 mm 
               
               
                   
               
             
            
               
                 EA-2 
                 FIG. 4B 
                 Steel 
                 — 
                 — 
                 0.93 
                 1.33 
                 207.8 
                 18.3 
               
               
                   
                   
                 (SPFC590) 
                   
                   
                   
                   
                   
                   
               
               
                 EA-11-2 
                 FIG. 4J 
                 Steel 
                 — 
                 — 
                 0.79 
                 4.68 
                 — 
                 18.2 
               
               
                   
                   
                 (SPFC590) 
                   
                   
                   
                   
                   
                   
               
               
                 EA-2-Al 
                 FIG. 4B 
                 aluminum 
                 — 
                 — 
                 1.90 
                 0.94 
                 207.8 
                 18.7 
               
               
                   
                   
                 (A5052) 
                   
                   
                   
                   
                   
                   
               
               
                 EA-9-Al 
                 FIG. 4H 
                 aluminum 
                 — 
                 — 
                 0.95 
                 2.00 
                 — 
                 18.8 
               
               
                   
                   
                 (A5052) 
                   
                   
                   
                   
                   
                   
               
               
                 EA-2-Se 
                 FIG. 4B 
                 CFRTP 
                 — 
                 — 
                 3.00 
                 0.75 
                 207.8 
                 18.7 
               
               
                   
                   
                 (Teijin- 
                   
                   
                   
                   
                   
                   
               
               
                   
                   
                 SEREEBO(R)) 
                   
                   
                   
                   
                   
                   
               
               
                 EA-2- 
                 FIG. 4B 
                 CFRP(DSM, 
                 [0/45/ 
                 50 
                 1.92 
                 0.51 
                 207.8 
                 17.7 
               
               
                 CFRP 
                   
                 PA410) 
                 −45]s 
                   
                   
                   
                   
                   
               
               
                 EA-9- 
                 FIG. 4H 
                 CFRP(DSM, 
                 [0/90]s 
                 25 
                 0.80 
                 0.90 
                 — 
                 17.6 
               
               
                 CFRP 
                   
                 PA410) 
                   
                   
                   
                   
                   
                   
               
               
                 EA-2- 
                 FIG. 4B 
                 GFRP(DSM, 
                 [0/45/ 
                 50 
                 2.72 
                 0.85 
                 207.8 
                 17.9 
               
               
                 GFRP 
                   
                 PA410) 
                 −45]s 
                   
                   
                   
                   
                   
               
               
                 EA-9- 
                 FIG. 4H 
                 GFRP(DSM, 
                 [0/90]s 
                 25 
                 1.12 
                 1.49 
                 — 
                 18.5 
               
               
                 GFRP 
                   
                 PA410) 
               
               
                   
               
            
           
         
       
     
     In a fifth example, battery containment constructs  10  including energy absorption components  30 ,  30 ′ formed of CFRP (DSM, PA410) having a repeating open hexagon shape and an extruded rectangular shape of various geometries are tested for comparison of ply. In this example, the containment constructs are subjected to 250 J impacts at an impact angle of 90 degrees. The results of these tests are shown in Table 5. 
     
       
         
           
               
               
               
               
               
               
               
               
               
             
               
                 TABLE 5 
               
               
                   
               
               
                   
                 Shape/ 
                   
                   
                 Per- 
                   
                   
                   
                   
               
               
                   
                 Refer- 
                   
                   
                 cent 
                   
                   
                   
                 Defor- 
               
               
                 Analysis 
                 ence 
                   
                   
                 of 0° 
                 t1 
                 Mass 
                 pitch 
                 mation 
               
               
                 file 
                 FIG. 
                 Material 
                 Ply 
                 ply 
                 mm 
                 kg 
                 mm 
                 mm 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 EA-2- 
                 FIG. 4B 
                 CFRP 
                 0 
                 100 
                 5.000 
                 1.33 
                 207.8 
                 33.6 
               
               
                 CFRP-1 
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 EA-2- 
                 FIG. 4B 
                 CFRP 
                 [0/90]s 
                 50 
                 5.000 
                 1.33 
                 207.8 
                 5.7 
               
               
                 CFRP-2 
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 EA-2- 
                 FIG. 4B 
                 CFRP 
                 [0/45/ 
                 50 
                 5.000 
                 1.33 
                 207.8 
                 5.1 
               
               
                 CFRP-3 
                   
                   
                 −45]s 
                   
                   
                   
                   
                   
               
               
                 EA-2- 
                 FIG. 4B 
                 CFRP 
                 [0/45/ 
                 75 
                 5.000 
                 1.33 
                 207.8 
                 5.6 
               
               
                 CFRP-4 
                   
                   
                 −45]s 
                   
                   
                   
                   
                   
               
               
                 EA-2- 
                 FIG. 4B 
                 CFRP 
                 [0/45/ 
                 25 
                 5.000 
                 1.33 
                 207.8 
                 5.2 
               
               
                 CFRP-5 
                   
                   
                 −45]s 
                   
                   
                   
                   
                   
               
               
                 EA-2- 
                 FIG. 4B 
                 CFRP 
                 [45/ 
                 0 
                 5.000 
                 1.33 
                 207.8 
                 6.4 
               
               
                 CFRP-6 
                   
                   
                 −45]s 
                   
                   
                   
                   
                   
               
               
                 EA-9- 
                 FIG. 4H 
                 CFRP 
                 0 
                 100 
                 1.180 
                 1.33 
                 — 
                 &gt;70 
               
               
                 CFRP-1 
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 EA-9- 
                 FIG. 4H 
                 CFRP 
                 [0/90]s 
                 50 
                 1.180 
                 1.33 
                 — 
                 15.8 
               
               
                 CFRP-2 
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 EA-9- 
                 FIG. 4H 
                 CFRP 
                 [0/45/ 
                 50 
                 1.180 
                 1.33 
                 — 
                 19.7 
               
               
                 CFRP-3 
                   
                   
                 −45]s 
                   
                   
                   
                   
                   
               
               
                 EA-9- 
                 FIG. 4H 
                 CFRP 
                 [0/90]s 
                 75 
                 1.180 
                 1.33 
                 — 
                 22.6 
               
               
                 CFRP-4 
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 EA-9- 
                 FIG. 4H 
                 CFRP 
                 [0/90]s 
                 25 
                 1.180 
                 1.33 
                 — 
                 9.9 
               
               
                 CFRP-5 
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 EA-9- 
                 FIG. 4H 
                 CFRP 
                 90 
                 0 
                 1.180 
                 1.33 
                 — 
                 &gt;70 
               
               
                 CFRP-6 
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                   
               
            
           
         
       
     
     Patent documents and publications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These documents and publications are incorporated herein by reference to the same extent as if each individual document or publication was specifically and individually incorporated herein by reference. 
     The foregoing description is illustrative of particular embodiments of the invention but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention.