Battery Enclosure

Battery Box Mount

The battery boxes will be mounted in the chassis just behind the seats. They will slide in and out on aluminum extrusions bolted to the steel frame. When the rear panel is raised a person will be able to walk into the rear of the vehicle and slide the battery boxes out of their mounting fixtures. The size of the battery box is defined by the size of the mounting fixture in CAD. 

Enclosure Material and Structure

The battery box will be made out of Teklam panels bonded with an adhesive and reinforced with 90 degree plastic extrusions (PVC or other). The top panel of the box will be able to slide to allow access to the internals while the box is mounted in the vehicle. This panel should be able to be locked in position once the battery is certified at the race. 

Module Structure

The battery box will be made up of several modules (groups of 36 cells held together between two plastic plates.

Electrical Connections

The screenshot above shows the approximate make up of each module however we will not be using mechanical connections or flexures to make the electrical contact. Instead we will copper tabs bolted to busbars running along the top of the box. 

Cooling

The modules will all be mounted in the same orientation such that all the cooling pass throughs are aligned. Fans will be mounted inside the box and air will flow along the length of the box. 

Fans: Startech 12V 60x60x10 replacement computer case fan

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Additional Components 

The boxes will be come in two configurations: master and slave. The following additional components will also be housed in each configuration

HV Conductors 

The HV conductors will connect to either the front panel or inside panel of the box. 

Handles

Handles will be required on the exterior of the box to slide the box in and out of the vehicle and lift it.