Modular electric vehicle battery pack frame having extruded aluminum structural members

Abstract

Electric vehicle battery pack frames constructed with extruded aluminum side and cross members. Such frames are significantly stronger than conventional cast aluminum frames, while also being much lighter than steel frames. Cross members may be affixed to side members with extruded aluminum brackets. Side members of differing lengths may be employed, to make battery pack frames of differing sizes in modular manner. Battery pack lids and bottom panels may be removably affixed to the frame such as with bolts, for improved serviceability.

1 - 20 . (canceled) 
     
     
         21 . A battery pack, comprising:
 first and second side members comprised of angled front end portions; and   a plurality of cross members each having opposite ends coupled between the first and the second side members, wherein one cross member of the plurality of cross members is shorter than the other cross members and is fixedly attached to the angled front end portions.   
     
     
         22 . The battery pack of  claim 21 , wherein the first side member, the second side member, and the plurality of cross members are each formed of continuous extruded aluminum. 
     
     
         23 . The battery pack of  claim 21 , wherein the first and second side members define a space between continuous inner surfaces thereof. 
     
     
         24 . The battery pack of  claim 21 , wherein respective pairs of the plurality of cross members define respective spaces between continuous inner surfaces thereof. 
     
     
         25 . The battery pack of  claim 21 , wherein the opposite ends of respective cross members of the plurality of cross members are affixed to inner surfaces of the first and second side members by one or more screws. 
     
     
         26 . The battery pack of  claim 21 , wherein the opposite ends of respective cross members of the plurality of cross members are affixed to inner surfaces of the first and second side members by an adhesive. 
     
     
         27 . The battery pack of  claim 21 , wherein each of the opposite ends of respective cross members of the plurality of cross members is affixed to an inner surface the first and second side members by a respective aluminum structure that at least partially encompasses a respective end of a respective cross member. 
     
     
         28 . The battery pack of  claim 21 , wherein one or more of the cross members, the first side members, or the second side members includes one or more fastener holes formed on an upper surface or an opposing lower surface thereof. 
     
     
         29 . The battery pack of  claim 21 , wherein the cross members and the first and second side members each have a generally rectangular cross-sectional shape. 
     
     
         30 . The battery pack of  claim 21 , further comprising a bottom member having a flat surface that is fixedly attached to bottom interfaces of each of the first and second side members. 
     
     
         31 . Battery pack members, comprising:
 first and second side members comprised of angled front end portions;   a plurality of cross members, wherein one cross member of the plurality of cross members is shorter than the other cross members and is fixedly attached to the angled front end portions; and   a bottom member having a flat surface that is fixedly attached to bottom interfaces of each of the first and second side members.   
     
     
         32 . The battery pack members of  claim 31 , wherein the first side member, the second side member, and the plurality of cross members are each formed of continuous extruded aluminum. 
     
     
         33 . The battery pack members of  claim 31 , wherein the first and second side members define a space between continuous inner surfaces thereof. 
     
     
         34 . The battery pack members of  claim 31 , wherein respective pairs of the plurality of cross members define respective spaces between continuous inner surfaces thereof. 
     
     
         35 . The battery pack members of  claim 31 , wherein the opposite ends of respective cross members of the plurality of cross members are affixed to inner surfaces of the first and second side members by one or more of an adhesive or at least one fastener. 
     
     
         36 . The battery pack members of  claim 31 , wherein each of the opposite ends of respective cross members of the plurality of cross members is affixed to an inner surface the first and second side members by a respective aluminum structure that at least partially encompasses a respective end of a respective cross member. 
     
     
         37 . The battery pack members of  claim 31 , wherein one or more of the cross members, the first side members, or the second side members includes one or more fastener holes formed on an upper surface or an opposing lower surface thereof. 
     
     
         38 . The battery pack members of  claim 31 , wherein one or more of the first side member, the second side member or the cross members have a generally rectangular cross-sectional shape. 
     
     
         39 . The battery pack members of  claim 31 , wherein the first side member, the second side member, and the plurality of cross members each comprise internal structures configured to provide structural support to continuous inner surfaces of each member against physical impacts to one or more outer surfaces of the members. 
     
     
         40 . A battery pack comprising a frame configured to accommodate one or more battery modules, the frame comprising:
 first and second side members comprised of angled front end portions; and   a plurality of cross members each having opposite ends coupled between the first and the second side members, wherein one cross member of the plurality of cross members is shorter than the other cross members and is fixedly attached to the angled front end portions.