US Patent 11951847 Lightweight battery box for electric vehicles

A battery box for an electric vehicle includes an Al casting that extends between and joins to a BIW or chassis rails of the electric vehicle. The Al casting includes a bottom wall, a side wall with a pair of rails that are securely attached to the BIW or chassis rails of the vehicle, and a plurality of cross members. The bottom wall, the side wall, and the plurality of cross members define a structural enclosure with a plurality of battery compartments and at least one crush zone, and the structural enclosure is load bearing member of the electric vehicle.