The present disclosure relates to a structural assembly for a battery structure of an electric vehicle.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Electric vehicles differ from conventional motor vehicles because they are driven by one or more rechargeable battery packs having lithium-ion batteries, for example, or any other suitable electrical power storage units. The battery pack typically powers one or more motors to drive a set of wheels using battery arrays. In some electric vehicles, the battery arrays include a structural assembly that surrounds battery pouches, especially for vehicles capable of traveling long distances (e.g., electric vehicles capable of traveling more than 500 miles).
The present disclosure addresses these and other issues related to battery arrays in electric vehicles.
This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
In one form, the present disclosure provides a battery structure for an electric vehicle. The battery structure includes a first battery array and a second battery array. The first battery array includes a plurality of first walls that are secured to each other to form a first unitized structure that is configured to house a first cell stack. One first wall of the plurality of first walls includes a first vertical portion, a first upper portion, and a first lower portion. The second battery array includes a plurality of second walls that are secured to each other to form a second unitized structure that is configured to house a second cell stack. One second wall of the plurality of second walls includes a second vertical portion and a second upper portion. The second vertical portion is spaced apart from the first vertical portion. The second upper portion extends toward the first vertical portion from an upper end of the second vertical portion and is secured to the first upper portion of the first battery array. The first upper portion extends toward the second vertical portion from an upper end of the first vertical portion. The first lower portion extends toward the second vertical portion from a lower end of the first vertical portion and is connected to the one second wall.
In variations of the battery structure according to the above paragraph, which may be implemented individually or an any combination: the one first wall further includes a first rib extending from the first vertical portion from a location between the first upper portion and the first lower portion, the one second wall further includes a second rib extending from the second vertical portion and secured to the first rib; an interlock assembly secures the first lower portion of the one first wall to the one second wall; the interlock assembly includes a flange defining a recess and extending from one of a lower end of the second vertical portion and an end of the first lower portion, and a protrusion received in the recess of the flange and projecting from the other one of the lower end of the second vertical position and the end of the first lower portion; the one second wall further includes a pair of flanges extending perpendicular from respective ends of the second vertical portion toward the first vertical portion; a third battery array stacked on the first battery array and including a plurality of third walls secured to each other to form a third unitized structure that is configured to house a third cell stack, one third wall of the plurality of third walls includes a third vertical portion and a second lower portion, the second lower portion extends toward the second vertical portion from a lower end of the third vertical portion and is secured to the first upper portion of the one first wall and secured to the second upper portion of the one second wall; another first wall of the plurality of first walls of the first battery array is opposite the one first wall and includes a third vertical portion, a third upper portion, and a second lower portion, the third upper portion and the second lower portion extend from the third vertical portion in a direction away from the one first wall; a third battery array adjacent to the first battery array and connected to the another first wall of the first battery array; and a plurality of mechanical fasteners extending through the first upper portion and through the second upper portion to secure the first upper portion and the second upper portion to each other.
In another form, the present disclosure provides a battery structure for an electric vehicle. The battery structure includes battery tray, a plurality of cross beams, and a plurality of battery arrays. The cross beams are supported by the battery tray and are spaced apart from each other along a longitudinal direction of the electric vehicle. Each cross beam extends in a transverse direction. The battery arrays are disposed within the battery tray and includes a first battery array and a second battery array. The first battery array includes a plurality of first walls that are secured to each other to form a first unitized structure that is configured to house a first cell stack. One first wall of the plurality of first walls includes a first vertical portion, a first upper portion, and a first lower portion. The second battery array includes a plurality of second walls that are secured to each other to form a second unitized structure that is configured to house a second cell stack. One second wall of the plurality of second walls includes a second vertical portion and a second upper portion. The second vertical portion is spaced apart from the first vertical portion. The second upper portion extends toward the first vertical portion from an upper end of the second vertical portion and is secured to the first upper portion of the first battery array. The first upper portion and the first lower portion extend toward the second vertical portion from the first vertical portion. The first lower portion of the one first wall is connected to the one second wall and connected to one cross beam of the plurality of cross beams.
In variations of the battery structure according to the above paragraph, which may be implemented individually or an any combination: the one first wall and the one second wall are spaced apart from a bottom panel of the battery tray; the one first wall further includes a first rib extending from the first vertical portion from a location between the first upper portion and the first lower portion and the one second wall further includes a second rib extending from the second vertical portion and engaging the first rib; a pair of gussets, each gusset secured to a respective side wall of the battery tray and secured to the first and second ribs; fasteners extending through a respective gusset of the pair of gussets and through the first and second ribs to secure the respective gusset to the first and second ribs; the one second wall further includes a pair of flanges extending perpendicular from respective ends of the second vertical portion toward the first vertical portion; a pair of energy absorbing structures, each energy absorbing structure secured to a respective flange of the pair of flanges and extending outboard toward a respective wall of the battery tray; and the energy absorbing structure is spaced apart from the respective wall of the battery tray.
In yet another form, the present disclosure provides a battery structure for an electric vehicle. The battery structure includes battery tray, a plurality of cross beams, and a plurality of battery arrays. The cross beams are disposed on a bottom panel of the battery tray and are spaced apart from each other along a longitudinal direction of the electric vehicle. Each cross beam extends in a transverse direction. The battery arrays are disposed within the battery tray and includes a first battery array, a second battery array, a third battery array and a pair of energy absorbing structures. The first battery array includes a plurality of first walls that are secured to each other to form a first unitized structure that is configured to house a first cell stack. One first wall of the plurality of first walls includes a first vertical portion, a first upper portion, and a first lower portion. The second battery array includes a plurality of second walls that are secured to each other to form a second unitized structure that is configured to house a second cell stack. One second wall of the plurality of second walls includes a second vertical portion, a second upper portion, and a pair of flanges. The second vertical portion is spaced apart from the first vertical portion. The second upper portion extends toward the first vertical portion from an upper end of the second vertical portion and is secured to the first upper portion of the first battery array. The pair of flanges extend perpendicular from respective ends of the second vertical portion toward the first vertical portion. The third battery array is stacked on the first battery array and includes a plurality of third walls secured to each other to form a third unitized structure that is configured to house a third cell stack. One third wall of the plurality of third walls includes a third vertical portion and a second lower portion. The second lower portion extends toward the second vertical portion from the third vertical portion and is secured to the first upper portion of the one first wall and secured to the second upper portion of the one second wall. Each energy absorbing structure is secured to a respective flange of the pair of flanges and extends outboard toward a respective wall of the battery tray.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
With reference to
The battery housing assembly 14 powers a rear motor (not shown) to drive rear wheels 20a, 20b of a set of rear wheels 20 via a rear axle and/or powers a front motor (not shown) to drive front wheels 24a, 24b of a set of front wheels 24 via a front axle.
With reference to
The body 36 includes a plurality of side walls or panels 36a and a bottom wall or panel 36b. The side walls 36a are manufactured via stamping, for example, and extend in a vertical direction. The side walls 36a define an outer boundary of the battery housing 30 and are secured to each other via welding or an adhesive, for example. The bottom wall 36b supports the battery arrays 32a, 32b disposed within the battery housing 30 and is secured to lower portions of the side walls 36a.
With additional reference to
The seal is disposed around a periphery of the body 36 and is engaged with the body 36 and the lid 34. In this way, fluids, debris and other materials are inhibited from entering into the battery housing 30.
As shown in
Each battery array 32a, 32b may be rechargeable and may be in the form of a modular structure that can be installed within and removed from the battery housing 30. Each battery array 32a, 32b also spans substantially an entire width of the battery housing 30. With reference to
The battery arrays 32a, 32b are secured to each other to form a structural assembly that is configured to transfer loads from one side of the battery housing 30 to an opposite side of the battery housing 30, for example, during a certain impact event. Stated differently, the battery arrays 32a, 32b are secured to each other to transfer loads away from the cell stacks located within each battery array 32a, 32b during a certain impact event.
Referring to
Referring to
With reference to
The upper portion 44 extends perpendicular from an upper end of the vertical portion 42 towards the rear wall 38f of the adjacent battery array 32a, 32b. The upper portion 44 is oriented horizontally and is secured to the rear wall 38f of the adjacent battery array 32a, 32b. The lower portion 45 extends perpendicular from the lower end of the vertical portion 42 towards the rear wall 38f of the adjacent battery array 32a, 32b. The lower portion 45 is oriented horizontally and is secured to the rear wall 38f of the adjacent battery array 32a, 32b. The pair of flanges 46a, 46b extend perpendicular from the vertical portion 42 toward the rear wall 38f of the adjacent battery array 32a, 32b. The flange 46a is proximate the right side wall 38c (
The rear wall 38f of the battery array 32a, 32b includes a vertical portion 52, a plurality of upper portions 54, a lower portion 55, and a pair of ribs or tabs 58a, 58b. The vertical portion 52 extends in a vertical direction and is spaced apart from the vertical portion 42 of the front wall 38e of the adjacent battery array 32a, 32b. In the example illustrated, the vertical portion 52 extends upward past the upper wall 38a of the battery array 32a, 32b (
The upper portions 54 are spaced apart from each other along a length of the vertical portion 52 and extend perpendicular from an upper end of the vertical portion 52 toward the vertical portion 42 of the front wall 38e of the adjacent battery array 32a, 32b. The upper portions 54 are oriented horizontally and are secured to the upper portion 44 of the front wall 38e of the adjacent battery array 32a, 32b by mechanical fasteners (not shown) such as rivets, bolts, or threaded screws, for example. That is, the mechanical fasteners extend through openings 57a (
The lower portion 55 extends perpendicular from a lower end of the vertical portion 52 towards the vertical portion 42 of the front wall 38e of the adjacent battery array 32a, 32b. That is, the lower portion 55 extends further toward the vertical portion 42 of the front wall 38e of the adjacent battery array 32a, 32b than the upper portions 54 of the rear wall 38f. As shown in
Fasteners 61 (only one shown in
As shown in
As shown in
The pair of tabs 58a, 58b extend from the vertical portion 52 toward the front wall 38e of the adjacent battery array 32a, 32b. The tab 58a is proximate the right side wall 38c of the vertical portion 52 and the tab 58b is proximate the left side wall 38d of the vertical portion 52. Each tab 58a, 58b is also secured to a respective tab 48a, 48b of the front wall 38e of the adjacent battery array 32a, 32b (only tab 58a is shown secured to the tab 48a in
It should be understood that the battery array 32a, 32b located furthest rearward in the battery housing 30 is secured to a wall 68. Stated differently, the rear wall 38f of the battery array 32a, 32b located furthest rearward in the battery housing 30 is secured to the wall 68. The wall 68 may have structure that is similar or identical to the front wall 38e of the battery arrays 32a, 32b, except that the wall 68 is not part of an adjacent battery array 32a, 32b, and therefore, will not be described again in detail.
With reference to
Each pair of gussets 70 includes a left gusset 70a and a right gusset 70b. The left gusset 70a secures a respective cross member 33 to a left side wall 36a of the battery housing 30 and the right gusset 70b secures the respective cross member 33 to a right side wall 36a of the battery housing 30. Each gusset 70a, 70b includes a body 72, a pair of vertical flanges or walls 74, a pair of horizontal flanges or walls 76, and a pair of connecting members 78. The body 72 has a U-shape and includes a pair of vertical walls 80 and a connecting wall 82. The pair of vertical walls 80 are spaced apart from each other and extend in a vertical direction. The connecting wall 82 also extends in the vertical direction and connects the pair of vertical walls 80 to each other. Each vertical flange 74 extends perpendicular from a side of a respective vertical wall 80 and is secured to a respective side wall 36a of the battery housing 30. The pair of vertical flanges 74 are oriented in a vertical direction and extend away from each other.
Each horizontal flange 76 extends perpendicular from a lower end of a respective vertical wall 80 and is secured to the bottom wall 36b of the battery housing 30. The pair of horizontal flanges 76 are oriented in a horizontal direction and extend away from each other. The connecting members 78 have arcuate shapes and extend perpendicular from upper ends of respective vertical walls 80 toward each other. In the example illustrated, the connecting members 78 of the gusset 70a are connected to each other and to respective tabs 48a, 58a of the walls 38e, 38f, respectively. That is, a fastener 81 (
With reference to
The battery structure 14 of the present disclosure provides battery arrays 32a, 32b that are secured to each other in a way that form a structural assembly configured to transfer loads from one side of the battery housing 30 to an opposite side of the battery housing 30, for example, during a certain impact event. The battery structure 14 of the present disclosure also provides energy absorbing structures 88 secured the cross members 33 so as to transfer side impact from one side of the battery housing 30 to an opposite side of the battery housing 30, for example, during a certain impact event. The battery structure 14 of the present disclosure also allows the battery arrays 32a, 32b to be stacked on top of each other from the bottom wall 36b of the battery housing 30 to the lid 34. In this way, the battery arrays 32b in the upper row may engage the lid 34.
With reference to
The battery housing assembly 114 includes a battery tray or housing 130 and a plurality battery arrays 132a, 132b. The structure and function of the battery tray 130 is similar or identical to the battery tray 30 described above, and therefore, will not be described again in detail.
Each battery array 132a, 132b includes a plurality of walls 138 that are secured to each other to form a unitized structure that houses and supports one or more cell stacks (not shown) formed by battery cells (e.g., lithium-ion batteries or any other suitable electrical power storage units). The plurality of walls 138 of each battery array 132a, 132b include an upper wall 138a, a lower wall 138b, a right side wall 138c (
The front wall 138e of the battery array 132a, 132b includes a vertical portion 142, an upper portion 144, a pair of flanges 146 (only one shown in the
With reference to
The rear wall 138f of the battery array 132a, 132b includes a vertical portion 152, an upper portion 154, a lower portion 155, a pair of flanges 156 (only one shown in the figures) and a pair of ribs or tabs 158 (only one shown in the figures). The vertical portion 152 extends in a vertical direction and is spaced apart from the vertical portion 142 of the front wall 138e of the adjacent battery array 132a, 132b.
The upper portion 154 extends perpendicular from an upper end of the vertical portion 152 towards the vertical portion 142 of the front wall 138e of the adjacent battery array 132a, 132b. The upper portion 154 is oriented horizontally and is secured to the upper portion 144 of the front wall 138e of the adjacent battery array 132a, 132b by mechanical fasteners (not shown) such as rivets, bolts, or threaded screws, for example. The lower portion 155 extends perpendicular from a lower end of the vertical portion 152 towards the vertical portion 142 of the front wall 138e of the adjacent battery array 132a, 132b. That is, the lower portion 155 extends further toward the vertical portion 142 of the front wall 138e of the adjacent battery array 132a, 132b than the upper portion 154 of the rear wall 138f. The lower portion 155 of the rear wall 138f of a respective battery array 132a is disposed on a respective cross beam 137 such that the respective battery array 132a is spaced apart from a bottom wall 136b of a battery housing 130.
Fasteners 161 (only one shown in the figures) extend through the lower portion 155 of the rear wall 138f of the respective battery array 132a and the respective cross beam 137, thereby securing the respective cross beam 137 and the rear wall 138f to each other.
The lower portion 155 of the rear wall 138f of a respective battery array 132b is disposed on the upper portion 144 of the front wall 138e of the battery array 132a located in the lower row. In this way, fasteners (not shown) extend through the upper portion 154 of the rear wall 138f of the respective battery array 132a of the lower row, the upper portion 144 of the front wall 138e of an adjacent battery array 132a of the lower row, and the lower portion 155 of the rear wall 138f of the respective battery array 132b of the upper row, thereby securing the two adjacent battery arrays 132a of the lower row and the respective battery array 132b of the upper row to each other.
An interlock assembly 164 secures the lower portion 155 of the rear wall 138f of the battery array 132a, 132b to the vertical portion 142 of the front wall 138e of the adjacent battery array 132a, 132b. That is, in the example illustrated, the interlock assembly 164 includes a flange 164a and a protrusion 164b. The flange 164a extends from a lower end of the vertical portion 142 of the front wall 138e and defines a recess 166. The protrusion 164b extends upward from an end of the lower portion 155 of the rear wall 138f and is received in the recess 166 of the flange 164a, thereby interlocking the rear wall 138f of the battery array 132a, 132b and the front wall 138e of the adjacent battery array 132a, 132b to each other. In some forms, the flange 164a may be secured to the lower portion 155 of the rear wall 138f and the protrusion 164b may be secured to the front wall 138e without departing from the scope of the present disclosure.
The structure and function of the pair of tabs 158 (only one shown in the figures) are similar or identical to the pair of tabs 58a, 58b described above, and therefore, will not be described again in detail.
Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.
As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.