Abstract: A molded composite battery enclosure containing top and bottom composite covers having a formed cross member arranged between the top and bottom covers. The cross member is a formed member having a surface portion secured to a reinforcement section in one of the composite covers. The reinforcement section is a buildup of resin and fibers on or near a surface of one of the covers that provides a rigid joining point for securing internal battery enclosure components and vehicle components to the composite covers of the battery enclosure.

Abstract: A molded composite battery enclosure containing top and bottom composite covers attached together. The joined top and bottom composite cover structures form an enclose or open area for housing a battery system of battery cells and cooling devices. The composite battery enclosures are lightweight and made of materials that can function to absorb energy and insulate the battery housing area. The composite structures contain a core material adhered and sandwiched between skin fiber layers and an electromagnetic shielding material or resin incorporated into one of the composite structures.

Abstract: A battery enclosure formed by a protective shell of multiple components secured to one another to house a battery storage area are protected from damage by attachment of an impact barrier to deflect and absorb damaging forces encountered by the enclosure. The impact barrier includes a deflection section spaced apart from the outer surface of the battery enclosure to permit deformation of the deflection section. The deflection section further provides an open space for engaging a service access component of the protective shell for gaining entrance to the battery storage area or disassembling the battery enclosure.

Abstract: A molded composite battery enclosure containing top and bottom composite covers having a formed cross member arranged between the top and bottom covers. The cross member is a formed member having a bottom portion shaped to accommodate interior surface features of the bottom composite cover. The cross member contains a flange portion for attaching to an interior surface of a battery enclosure. The flange portion of the cross member is split into separate sections to adapt to an interior surface contour of the top composite cover and an interior surface contour of the bottom composite cover.

Abstract: A molded composite battery enclosure containing top and bottom composite covers attached together. The joined top and bottom composite cover structures form an enclose or open area for housing a battery system of battery cells and cooling devices. The composite battery enclosures are lightweight and made of materials that can function to absorb energy and insulate the battery housing area. The composite structures contain a core material adhered and sandwiched between fiber layers with monolithic flange sections for improved fitting of the covers.

Abstract: A molded composite battery enclosure containing top and bottom composite covers having a formed cross member arranged between the top and bottom covers. The cross member is a formed member having a surface portion secured to a reinforcement section in one of the composite covers. The reinforcement section is a buildup of resin and fibers on or near a surface of one of the covers that provides a rigid joining point for securing internal battery enclosure components and vehicle components to the composite covers of the battery enclosure.