Multi-part battery module wall

Abstract

A battery system for providing power to a vehicle includes an assembly having a battery cell. The battery system also includes a shear wall arranged along a side of the assembly to provide structural support. The shear wall is two parts, including a first element and a second element, both of which can be formed from metal sheets and welded together. The first element has a first flange extending away from the side of the assembly, and the second element has a second flange. The first flange and the second flange are stacked together to form an interface. The flanges are welded together at the interface, adjacent to the assembly, to form a resulting flange that is thicker than either individual flange and can be mounted to a frame member. The battery system may also include another shear wall on the opposite side.

Description

Technical Field

[0001] The present disclosure relates to structural walls for battery systems, and more particularly to multi-part shear walls having stacked flange sections. Summary of the invention

[0002] In some embodiments, the present disclosure relates to a battery system configured to provide power to a vehicle. The battery system includes an assembly and at least one shear wall. In some embodiments, the assembly includes a plurality of battery cells. In some embodiments, the plurality of battery cells are arranged in two modules, and the two modules are optionally coupled to a cooling plate to form an assembly. In some embodiments, the battery system includes a plurality of battery cells, which are arranged in a housing and coupled to a cooling plate instead of two separate modules. The shear wall includes a first element and a second element, and is arranged along a side of the assembly. In some embodiments, the first element corresponds to most of the height of the side. The first element includes a first flange extending away from the side of the assembly. The second element includes a second flange. The first flange and the second flange are stacked together to form an interface. A reinforcement may be included to strengthen the flange.

[0003] In some embodiments, the first element comprises a first material thickness and the second element comprises a second material thickness substantially equal to the first material thickness. In some embodiments, the thickness of the resulting flange formed at the interface is equal to the sum of the first material thickness and the second material thickness. In some embodiments, the first element and the second element are welded together at the interface along a path along the side of the assembly adjacent to the side of the assembly. In some embodiments, at least one of the first element or the second element or both include an electrical terminal for electrically grounding the shear wall (e.g., to a cooling plate, frame member, or other electrical reference).

[0004] In some embodiments, the first flange includes a first through feature for mounting to the vehicle, and a first alignment feature for positioning the battery module relative to the vehicle. In some embodiments, the second flange includes a second through feature aligned with the first through feature, and a second alignment feature aligned with the first alignment feature. In some embodiments, the first element includes a third flange disposed at a bottom of the first element, the third flange extending below the assembly.

[0005] In some embodiments, the shear wall is a first shear wall, and the battery system includes a second shear wall disposed along an opposite side of the assembly. In some embodiments, the second shear wall includes a third element and a fourth element. The third element includes a third flange extending away from the opposite side of the assembly, and the fourth element is disposed above the third element. The fourth element includes a fourth flange, and the third flange and the fourth flange are stacked together to form another interface.

[0006] In some embodiments, the first element includes a plurality of through features configured to receive corresponding extensions of the component to constrain relative movement between the shear wall and the component.

[0007] In some embodiments, the present disclosure relates to a shear wall for a vehicle battery system having an assembly including a plurality of battery cells. In some embodiments, the plurality of battery cells are arranged in at least one housing, on the cooling plate. The shear wall comprises a first element and a second element. The first element is configured to be arranged along a side of the assembly. In some embodiments, the first element corresponds to a majority of the height of the side, a majority of the surface area of ​​the side, or both. The first element comprises a first flange, the first flange being configured to extend away from the side of the assembly. The second element is configured to be arranged above the first element along the side of the assembly. The second element comprises a second flange, and the first flange and the second flange are stacked together to form an interface.

[0008] In some embodiments, the present disclosure relates to a method for manufacturing a shear wall for a vehicle battery system having an assembly having a plurality of battery cells. In some embodiments, the plurality of battery cells are arranged in at least one housing on the cooling plate. The method includes: forming a first element, the first element being configured to be arranged along a side of the assembly; forming a second element, the second element being configured to be arranged above the first element along a side of the assembly; and welding the first element and the second element together at the interface along a welding path. For example, a weld, which may include a stitch weld, is arranged adjacent to an inner surface of a shear wall configured to interface with the assembly. In some embodiments, the first element corresponds to a majority of the height of the side, a majority of the surface area of ​​the side, or both. The first element includes a first flange, the first flange being configured to extend away from the side of the assembly. The second element includes a second flange. The first flange and the second flange are stacked together to form an interface. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure according to one or more different embodiments is described in detail with reference to the following drawings. The drawings are provided for illustrative purposes only and depict only typical or exemplary embodiments. These drawings are provided to facilitate understanding of the concepts disclosed herein and should not be considered to limit the breadth, scope or applicability of these concepts. It should be noted that for clarity and ease of illustration, these drawings are not necessarily drawn to scale.

[0010] Figure 1 shows perspective views from above and from the side of an illustrative battery system having shear walls according to some embodiments of the present disclosure;

[0011] Figure 2 According to some embodiments of the present disclosure, Figure 1 illustrative battery system from the front and from above;

[0012] Figure 3 Some embodiments of the present disclosure are shown Figure 1 A bottom view of an illustrative battery system;

[0013] Figure 4 shows cross-sectional views of an illustrative battery system with a multi-part shear wall and an illustrative battery system with a single-part shear wall under loading, according to some embodiments of the present disclosure;

[0014] Figure 5 shows a perspective view of an illustrative multi-part shear wall according to some embodiments of the present disclosure;

[0015] Figure 6 A diagram showing a circuit having a ground terminal according to some embodiments of the present disclosure Figure 5 an enlarged perspective view of a portion of an illustrative multi-part shear wall;

[0016] Figure 7 Some embodiments of the present disclosure are shown Figure 5 A top view of an illustrative multi-part shear wall;

[0017] Figure 8 Some embodiments of the present disclosure are shown Figure 5 A side view of an illustrative multi-part shear wall;

[0018] Fig. 9 shows a side perspective view of an illustrative battery system having a multi-part shear wall with mechanical features according to some embodiments of the present disclosure;

[0019] Fig.10 shows a top view of a portion of an illustrative vehicle with a battery system installed according to some embodiments of the present disclosure;

[0020] Fig.11shows a flow chart of an illustrative process for manufacturing a shear wall according to some embodiments of the present disclosure;

[0021] Fig.12 shows a perspective view from above of a shear wall having different flanges according to some embodiments of the present disclosure;

[0022] Fig.13 shows a perspective view from below of a shear wall having a reinforcing element according to some embodiments of the present disclosure;

[0023] Fig.14 a side cross-sectional view showing the resulting flange of a shear wall according to some embodiments of the present disclosure; and

[0024] Fig.15 A perspective view from above of a portion of a shear wall having a reinforcement element is shown according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0025] The present disclosure relates to a structural wall for a battery system and attaching a flange located near the top of the structural wall to one or more frame members of a vehicle. In some embodiments, the battery system is (e.g., at least partially) suspended from the flange. For example, in some embodiments, the battery system does not need to be supported at the bottom (e.g., due to tolerance and stacking issues). To illustrate, in some cases, such a suspension arrangement can cause the flange and shear wall to experience bending when the vehicle experiences vertical gravity. Therefore, it is desirable to reduce the bending of the battery module shear wall. The multi-part shear wall of the present disclosure can reduce bending by including, for example, a thicker flange area.

[0026] Figure 1 Shown are perspective views from above and from the side of an illustrative battery system 100 having shear walls 120 , according to some embodiments of the present disclosure. Figure 2 According to some embodiments of the present disclosure, Figure 1 2 and 3. Perspective views of an illustrative battery system 100 viewed from the front and above. Figure 3 Some embodiments of the present disclosure are shown Figure 11 is a bottom view of an illustrative battery system 100. As shown, the battery system 100 also includes another shear wall 130 arranged on a side opposite to the shear wall 120. As shown, the battery system 100 includes a first module 101 (e.g., having a plurality of battery cells), a second module 102 (e.g., having a plurality of battery cells, one of which is battery cell 190), and a cooling plate 103, to which the first module 101 and the second module 102 are secured (e.g., using an adhesive). The first module 101, the second module 102, and the cooling plate 103 may be referred to herein as an assembly (e.g., to which the shear wall 120 is secured). As shown, for purposes of illustration, some of the plurality of battery cells (e.g., battery cell 190) at opposite ends of the second module 102 are Figure 3 102, but Figure 3 Only some are shown).

[0027] As shown, the shear wall 120 includes a bottom component (e.g., element 121, which is the main part of the shear wall 120), which includes a flange 125. As shown, the flange 125 includes an extension configured to be attached to a frame member. As shown, the flange 125 includes a mounting feature 171 (e.g., as shown, the flange 125 includes three mounting features) and an alignment feature 172 (e.g., as shown, the flange 125 includes two alignment features). As shown, the element 121 also includes a ground terminal 170 (e.g., as shown, the element 121 includes a ground terminal grounded to the cooling plate 103) and an auxiliary module retention feature 173 (e.g., as shown, the element 121 includes two auxiliary module retention features). As shown, the shear wall 120 also includes a top component (e.g., element 122), which is relatively smaller than the element 121 and includes a flange 126, which has mounting features and alignment features similar to the flange 125 (e.g., the features of the flange 126 are aligned with the corresponding features of the flange 125). Thus, the resulting flange includes stacked flanges 125, 126 with through features (eg, mounting features 171 and alignment features 172). In some embodiments, element 122 includes handling features 127 (eg, for lifting battery module 100).

[0028] Element 121 and element 122 are joined at their respective flanges (flange 125 and flange 126). The resulting flange has a thickness substantially equal to the sum of the thickness of flange 125 and the thickness of flange 126, equal to the stack of the two flanges (e.g., flange 125 and flange 126), which may include material thickness, any thinning (e.g., due to pressing together), or any separation (e.g., due to unevenness of the abutting surfaces). To illustrate, the resulting flange may be within 5% of the sum of the thicknesses of flanges 125, 126. For example, in some embodiments, elements 121, 122 may be joined at (e.g., along Figure 1-2 199 in dashed line 199). For illustration, element 121 and element 122 can be welded together in a linear section (e.g., one, two, three, or more than three sections). For further illustration, in some embodiments, elements 121, 122 are stitch welded together along a suitable path (e.g., to prevent overheating and distortion while still maintaining sufficient weld penetration). For further illustration, in some embodiments, elements 121, 122 are each made of steel such as stainless steel (e.g., 304 or 304L stainless steel or any other suitable grade). In some embodiments, the welding locations are spaced apart along the joint between flanges 125, 126. In some embodiments, the weld is used to attach the back joint between flanges 125 and 126, on the inside of shear wall 120 (e.g., adjacent to the battery cell or the housing of the battery cell). The resulting flanges from stacking flanges 125, 126 have an increased thickness (e.g., double thickness) compared to a configuration that includes only a single flange (e.g., flange 125 or flange 126). In the illustrative example, element 121 and element 122 may be welded together at the interface of flanges 125, 126 along a path adjacent to the side of the first component (dashed line 199) along the side of the first component.

[0029] The two-part construction of shear wall 120 can significantly increase the strength of the mounting flange (e.g., the stacked assembly of flanges 125, 126), significantly reduce bending of the mounting flange, or both. In some embodiments, a weld along the inside (e.g., adjacent the battery) of shear wall 120 (where flange 125 and flange 126 meet at the interface) significantly strengthens the joint where elements 121, 122 come together. For example, the two-layer mounting flange reduces bending of shear wall 120 when the vehicle experiences vertical acceleration and loads.

[0030] For illustration, the battery system 100 may be configured to provide power to a vehicle. In some embodiments, the battery system 100 includes a first plurality of battery cells arranged in a first module 101, a second plurality of battery cells arranged in a second module 102, and a cooling plate 103 coupled between the first module 101 and the second module 102 to form a first assembly. As shown, the battery system 100 includes shear walls 120, 130 attached to the first assembly on the sides of the first assembly. Although in Figure 1-3 Two shear walls are shown in FIG, but according to the present disclosure, the battery system may include one shear wall, two shear walls, or more than two shear walls. Each of the shear walls 120, 130 includes a first element and a second element (e.g., elements 121, 122 for shear wall 120). The first element (e.g., element 121) is arranged along the side of the first component, arranged on most of the height of the side, on most of the surface area of ​​the side, or on both. The first element includes a flange (e.g., flange 125) extending away from the side of the first component (e.g., outward from near a plurality of battery cells). The second element (e.g., element 122) is arranged above the first element along the side of the first component and also includes a flange (e.g., flange 126). The flanges (e.g., flanges 125, 126) are stacked together to form an interface (e.g., where the flanges meet) and a resulting flange (e.g., a stacked composite of two flanges).

[0031] The resulting flange or individual flanges thereof (e.g., flanges 125, 126) may include one or more through features (e.g., mounting feature 171) for mounting to a vehicle, one or more alignment features (e.g., alignment feature 172) for positioning the battery module relative to the vehicle, one or more retaining features (e.g., retaining feature 173, which extends beneath the battery cell), one or more grounding features (e.g., grounding terminal 170), any other suitable features, or any combination thereof.

[0032] Figure 4 A cross-sectional view of an illustrative battery system 450 having a multi-part shear wall 460 and a battery system 400 having a single-part shear wall 410 under load is shown in accordance with some embodiments of the present disclosure. For illustration, shear wall 410 has a flange thickness t1 (e.g., the material thickness of the sheet material used to form shear wall 410), while shear wall 460 has a flange thickness t2 (e.g., the sum of the material thickness of the sheet material used to form the upper and lower elements of shear wall 460).

[0033] In some embodiments, the two-part construction of shear wall 460 produces a flange with double thickness (e.g., t2 is approximately equal to twice t1). The thicker flange of shear wall 460 can reduce flange bending when the vehicle experiences vertical g-forces, increase strength, increase stiffness, reduce shear wall bending when the vehicle experiences vertical g-forces (e.g., reduce stress inside the battery module), or a combination thereof. In some cases, using thicker materials can produce a larger bend radius (e.g., radius of curvature "r") during formation, which can affect the resulting geometry. Additionally, in some cases, the different thicknesses of the materials can be used to reduce the thickness of the flange.

[0034] Figure 5 A perspective view (from the inside) of an illustrative multi-part shear wall 500 is shown, in accordance with some embodiments of the present disclosure. Figure 6 A circuit diagram with a ground terminal 570 according to some embodiments of the present disclosure is shown. Figure 5 An enlarged perspective view (from above) of a portion (eg, generally shown by circle 600) of an illustrative multi-part shear wall 500. Figure 7 Some embodiments of the present disclosure are shown Figure 5 A top view of an illustrative multi-section shear wall 500 is shown. Figure 8 Some embodiments of the present disclosure are shown Figure 5 500. For illustration, the shear wall 500 may be Figure 1-3 The shear wall 500 may be the same, similar, or different than the shear wall 120 of the battery system 100. For example, the shear wall 500 may be included in the battery system 100 as an example of the shear wall 120.

[0035] As shown, the shear wall 500 includes an element 510 (e.g., a lower element) and an element 520 (e.g., an upper element). As shown, the element 510 includes a ground terminal 570 and features 573, 574, all of which are arranged at the bottom of the element 510. For example, the ground terminal 570 may include features such as a protrusion, a hole, a connector (e.g., solderable or welded), or a combination thereof, which is configured to be electrically connected to another part of the battery system, a frame member of the vehicle, or any other suitable ground reference by a cable. In another example, the features 573, 574 may include a protrusion that is bent inwardly and is configured to be assembled under the battery cell of the battery system. In some embodiments, the features 573, 574 can be fixed to the battery cell or a housing surrounding the battery cell. In some embodiments, the features 573, 574 are connected to the frame member of the vehicle and are constrained from displacement in one or more directions. For example, features 573, 574 may include a protrusion with a through hole configured to receive a pin fixed to a frame member of the vehicle, the pin constraining lateral displacement of features 573, 574 (e.g., while optionally allowing vertical displacement), and thus constraining lateral displacement of the battery system. As shown, element 520 includes a lifting feature 557, which can be configured to allow lifting of the battery system (e.g., for handling, maintenance, or installation).

[0036] As shown, shear wall 500 includes feature 590 and feature 591. In some embodiments, feature 590 is included to surround an extension of the battery cell containment housing (e.g., a pin or other boss feature) to prevent relative displacement between shear wall 500 and the rest of the battery system. In some embodiments, shear wall 500 is adhered to the side of the rest of the battery system, where feature 590 provides a mechanical backup or reinforcement for the adhesive. In some embodiments, feature 591 is included to assist in the curing of the adhesive when the shear wall is installed by providing, for example, access to air, humidity, ultraviolet radiation, or a combination thereof from outside the shear wall 500. In some embodiments, feature 590 may be included to reduce the mass of shear wall 500, affect the stiffness of shear wall 500, accommodate other protrusions of the rest of the battery system, or a combination thereof.

[0037] As shown, the elements 510, 520 meet at the interface 599 to form a resulting flange 525, which is oriented substantially at right angles (e.g., 90 degrees or within a few degrees of 90 degrees) to the rest of the elements 510, 520 so as to extend outwardly when the shear wall 500 is installed. The elements 510, 520 can be welded or otherwise secured together. For illustration, both elements 510, 520 can be formed from sheet metal, which can be, but need not be, the same thickness. When assembled, the flange 525 has a thickness equal to the sum of the thicknesses of the elements 510, 520 (e.g., although some thinning or thickening can be attributed to bending, forming, and welding of the components).

[0038] like Figure 7 As shown in , flange 525 includes features 521, 522, 526, 527, and 528. Features 521 and 522 are configured to facilitate alignment of shear wall 500 (e.g., to a frame member of a vehicle). As shown, feature 521 includes a circular hole and feature 522 includes a transverse slot, but either of features 521, 522 may include a circular hole, an elliptical hole, a slot, a polygonal through hole, a square through hole, any other suitable feature for aligning or constraining displacement in at least one degree of freedom, or any combination thereof.

[0039] Fig. 9 A side perspective view of an illustrative battery system 900 having a multi-part shear wall 901 with mechanical features according to some embodiments of the present disclosure is shown. For example, the shear wall 901 may, but need not, be Figure 5-8 The shear wall 901 is the same as the shear wall 500 of the battery system 900. As shown, the shear wall 901 includes an element 910 (e.g., a lower element) and an element 920 (e.g., an upper element). The elements 910, 920 form a resulting flange 925 that is oriented substantially at right angles (e.g., 90 degrees or within a few degrees of 90 degrees) to the rest of the elements 910, 920, thereby extending outward from the battery cell of the battery system 900. As shown, the element 910 includes a feature 990 for interlocking with other parts of the battery system 900, and a feature 991 (e.g., a feature for reducing mass, curing adhesive, or accommodating the battery system 900).

[0040] The battery system 900 may include a first component that includes one or more battery modules (e.g., battery cells, housings, bus bars, current collectors, sensors), a cooling plate (e.g., adhered or otherwise fixed to one or more battery modules), any other suitable components, or any combination thereof. A shear wall 901 is arranged on a side of the first component. An element 910 of the shear wall 901 includes a plurality of through features 990 configured to accommodate corresponding extensions 992 of the first component to constrain relative movement between the shear wall 901 and the first component. For example, the extension 992 includes a pin extending outward from the first component that is aligned with the feature 990 to constrain relative displacement. Although illustrated as a pin arranged in a slot, the feature 990 and the extension 992 may include any suitable geometry and may be engaged in any suitable manner to prevent or otherwise constrain relative displacement. For example, the extension 992 may include a circular pin, a non-circular pin, a cone, a protrusion, any other suitable protrusion, optionally arranged in any suitable array, or any combination thereof.

[0041] Fig.10 A top view of a portion of an illustrative vehicle 1000 with a battery system 1010 installed according to some embodiments of the present disclosure is shown. As shown, the battery system 1010 includes flanges 1025, 1035 that are coupled to respective frame members 1001, 1002 of the vehicle 1000. For example, the battery system 1010 can be lowered into position relative to the frame members 1001, 1002 so that the flanges 1025, 1035 support the weight of the battery system 1010 (e.g., the battery system 1010 is suspended from the frame members 1001, 1002). The flanges 1025, 1035 can be secured to the respective frame members 1001, 1002 using fasteners (e.g., bolts), clamps, mechanical interlocks, press fits, any other suitable engagement, or any combination thereof. In some embodiments, the flanges 1025, 1035 each include one or more alignment features configured to engage with corresponding features of the respective frame members 1001, 1002 to prevent or otherwise constrain relative displacement of the battery system 1010 and the frame members 1001, 1002. For example, the flanges 1025, 1035 may include holes, slots, any other suitable through features, pins, protrusions, lips, any other suitable boss features, or any combination thereof configured to engage with corresponding features of the respective frame members 1001, 1002. In an illustrative example, the flanges 1025, 1035 may each include a circular hole and slot configured to engage with a circular pin of the respective frame members 1001, 1002 to ensure alignment, constrain relative displacement, serve as a hard stop (e.g., if a fastening joint fails), or a combination thereof.

[0042] Fig.11 FIG. 1 is a flow chart showing an illustrative process 1100 for making a shear wall according to some embodiments of the present disclosure. In the illustrative example, the process 1100 may be used to form Figure 1-3 Shear wall 120, Figure 5-8 of shear wall 500 or both.

[0043] Step 1102 includes forming a first element configured to be arranged along a side of the component. In some embodiments, step 1102 includes forming the first element corresponding to a majority of the height of the side. In some embodiments, the first element is formed from a sheet of metal (e.g., a steel sheet such as stainless steel) by cutting a profile of the sheet of metal (e.g., by stamping, shearing, water jet cutting, wire EDM, plasma cutting), punching through features, bending the sheet of metal (e.g., using a breaker or former) to form a flange, drilling a hole feature, coating the metal, treating the surface (e.g., cleaning, etching, grinding, polishing), performing any other suitable process, or any combination thereof.

[0044] Step 1104 includes forming a second element disposed above the first element along a side of the assembly. The second element includes a second flange configured to interface with the first flange. In some embodiments, the second element is formed from a sheet of metal (e.g., a steel sheet such as stainless steel) by cutting a profile of the sheet of metal (e.g., by stamping, shearing, water jet cutting, wire cutting, plasma cutting), punching through features, bending the sheet of metal (e.g., using a breaker or former) to form a flange, drilling hole features, coating the metal, treating the surface (e.g., cleaning, etching, grinding, polishing), performing any other suitable process, or any combination thereof.

[0045] Step 1106 includes welding a first element (e.g., a first metal plate) and a second element (e.g., a second metal plate, which may be, but need not be, the same metal as the first element) together at an interface along a welding path adjacent to an inner surface of a shear wall, the inner surface of the shear wall being configured to interface with the assembly. In some embodiments, the first flange and the second flange are stacked together to form an interface. In some embodiments, step 1106 includes stitch welding the first element and the second element together at the interface along a suitable path to prevent overheating and distortion while still maintaining sufficient weld penetration. Inset 1156 shows an illustrative shear wall with two elements stitch welded together (e.g., as shown by the thicker unbroken lines). As shown, the weld segments are located near the mounting and alignment flange features. For example, the weld segments may each be centered behind the corresponding feature to provide increased strength to the feature. The first element and the second element may be joined together using any suitable welding technique. In some embodiments, the weld does not extend outwardly into the flange portion extending away from the shear wall. For example, this can help prevent or otherwise limit internal stresses in the resulting flange (e.g., avoid over-constraint). Step 1106 can include, for example, laser welding (e.g., laser stitch welding), TIG welding, arc welding, friction welding, any other suitable welding technique, or any combination thereof. In some embodiments, step 1106 need not include welding, and can include, for example, mechanical interlocking elements, adhesive elements, or a combination thereof.

[0046] Step 1108 includes welding or otherwise fixing one or more reinforcement members to the first element, the second element, or both. Step 1108 may be optional and need not be performed in some embodiments. For example, steps 1102-1106 or steps 1102-1108 may be used to create a shear wall. Step 1108 may include, for example, welding (e.g., laser welding) or otherwise fixing one or more additional elements (e.g., reinforcing elements) to an assembly of the first element and the second element. In some embodiments, one or more additional elements are formed by a metal sheet, optionally with the same thickness as the first element or with the second element or with both. In some embodiments, for example, the first element, the second element, and the additional element have the same thickness. In some embodiments, for example, the first element, the second element, and the additional element form a flange with a stacked cross-section. In some such embodiments, the top layer (e.g., the second flange) and the bottom layer (e.g., the additional flange) have the same or similar thickness, and each is thicker than the middle layer (e.g., the first flange).

[0047] Fig.12A perspective view from above of a shear wall 1200 having different flanges according to some embodiments of the present disclosure is shown. As shown, the shear wall 1200 includes an element 1201 and an element 1202. The resulting flange 1210 is formed by a stack of portions (e.g., flange portions) of the elements 1201, 1202, which are stacked in parallel along a portion of the resulting flange 1210. The flange portions of the elements 1201, 1202 that are different from the element 1202 do not include features corresponding to the alignment features 1202, 1203 of the element 1201, but the remaining portions of the flange portions overlap. The resulting flange may include any suitable combination of features according to the present disclosure, wherein the flange portions overlap in any suitable manner.

[0048] Fig.13 A perspective view from below of a shear wall 1300 having reinforcing elements 1303, 1304, and 1305 is shown according to some embodiments of the present disclosure. As shown, the shear wall 1300 includes element 1301, element 1302, and reinforcing elements 1303, 1304, and 1305. The reinforcing elements 1303, 1304, and 1305 may be welded to element 1301 (as shown), element 1302, or both to provide stiffness to the resulting flange formed by elements 1301-1305. Although Fig.13 1301 is shown as having three reinforcing elements, but the shear wall may include any suitable number of elements. For example, in some embodiments, a single reinforcing element may be included that extends the length of the resulting flange. In some embodiments, for example, reinforcing elements 1303-1305 are welded to element 1301 to provide stiffness to the resulting flange.

[0049] Fig.14A side cross-sectional view of the resulting flange 1410 of the shear wall 1400 according to some embodiments of the present disclosure is shown. As shown, the shear wall 1400 includes element 1401, element 1402, and element 1403. The resulting flange 1410 is formed by a stack of portions (e.g., flange portions) of the elements 1401-1403, which are stacked parallel to the mounting surface. One or more features of the flange portions of the elements 1401-1403 can be the same, similar, or different. For example, the flange portion can include a first set of mounting holes and a second set of alignment holes. At least one other flange portion need not include all of the first set of holes and the second set of holes (e.g., at least one flange portion does not need to include alignment features). Each of the elements 1401-1403 includes a material thickness (e.g., resulting from a measurement of the metal sheet used to form the element). In some embodiments, the thickness of each element 1401-1403 is the same, and the resulting flange 1410 is up to 3 times thicker than any of the elements 1401-1403 (e.g., as shown), depending on the overlap of the flange portions. In some embodiments, the thickness of one or both of elements 1402 and 1403 is thicker than element 1401, and the resulting flange is equal to the thickness of the local stack of flange portions (e.g., the flange portions need not have the same shape, nor need to be stacked at all locations). During assembly, elements 1401, 1402 may be overlapped in region 1451 ( Fig.14 ), and element 1403 may be fixed (e.g., welded) in area 1450 ( Fig.14 The device is fixed (e.g., welded) to component 1401 in the dotted area in FIG.

[0050] Fig.15A perspective view from above of a portion of a shear wall 1500 having a reinforcing element 1503 according to some embodiments of the present disclosure is shown. As shown, the shear wall 1500 includes an element 1501, an element 1502, and a reinforcing element 1503. The resulting flange 1510 is formed by a stack of portions (e.g., flange portions) of the elements 1501-1503, which are stacked in parallel to form mounting surfaces at some locations (e.g., at mounting features having through holes). As shown, the flange portions of the elements 1501-1503 are similar, except that the flange portions of the reinforcing element 1503 do not extend the length of the resulting flange 1510, and therefore the resulting flange 1510 has a varying thickness. Each of the elements 1501-1503 includes a similar material thickness (e.g., resulting from the measurement of the metal sheet used to form the element). For example, each element 1501-1503 is the same thickness, and the resulting flange 1510 is up to 3 times thicker than any element 1501-1503 in some locations (e.g., at mounting features). As shown, the reinforcing element 1503 is welded to the element 1501 along a path 1550 (e.g., two sections are shown by the dotted line).

[0051] The foregoing is merely an illustration of the principles of the present disclosure, and various modifications may be made by those skilled in the art without departing from the scope of the present disclosure. The above embodiments are given for illustration and not limitation. The present disclosure may also take many forms other than those explicitly described herein. Therefore, it should be emphasized that the present disclosure is not limited to the methods, systems, and devices explicitly disclosed, but is intended to include variations and modifications of the present invention within the spirit of the following claims.

Claims

1. A battery system configured to provide power to a vehicle, the battery system comprising: an assembly comprising a plurality of battery cells; as well as a shear wall disposed along a side of the assembly, The shear wall comprises: - a first element comprising a first flange extending away from a side of the assembly, and - a second element, said second element comprising a second flange, wherein said first flange and said second flange are laminated together to form an interface, wherein the first element and the second element are welded together, and wherein: a weld path connecting the first element and the second element along a back side of the interface and adjacent an inner surface of the shear wall configured to interface with the assembly, The weld along the weld path faces the side of the component and the weld does not extend outwardly into the first flange and the second flange extending away from the side of the component, and The first flange and the second flange extend laterally away from the weld.

2. The battery system of claim 1 , wherein the first element comprises a first material thickness, wherein the second element comprises a second material thickness, and wherein the resulting flange formed at the interface comprises a thickness equal to the sum of the first material thickness and the second material thickness.

3. The battery system of claim 1, wherein the second component further comprises a lifting feature, the lifting feature comprising a C-shaped structure having a central portion extending vertically away from the interface and two end portions extending laterally away from the central portion.

4. The battery system of claim 3, wherein the lifting feature comprising the C-shaped structure is a first lifting feature, the battery system further comprises a second lifting feature, and the first lifting feature and the second lifting feature are disposed at opposite ends of the second element.

5. The battery system according to claim 1, wherein the first flange comprises: a first pass-through feature, the first pass-through feature being adapted to be mounted to the vehicle; as well as A first alignment feature is provided for positioning the battery system relative to the vehicle.

6. The battery system according to claim 5, wherein the second flange comprises: a second through feature, the second through feature being aligned with the first through feature; as well as A second alignment feature is provided, the second alignment feature being aligned with the first alignment feature. 7 . The battery system of claim 1 , wherein the first element includes a third flange disposed at a bottom of the first element and extending below the assembly.

8. The battery system of claim 1, wherein the first element includes an electrical terminal for electrically grounding the shear wall.

9. The battery system according to claim 1, wherein the component further comprises: at least one module, the at least one module comprising the plurality of battery cells arranged in at least one housing; as well as A cooling plate is coupled to the housing, wherein the shear wall is electrically coupled to the cooling plate.

10. The battery system of claim 1, wherein the shear wall is a first shear wall, and wherein the battery system comprises a second shear wall disposed along an opposite side of the assembly, wherein the second shear wall comprises: a third member including a third flange extending away from an opposite side of the assembly; as well as A fourth element is disposed above the third element, wherein the fourth element includes a fourth flange, and wherein the third flange and the fourth flange are stacked together to form another interface.

11. The battery system of claim 1, wherein the first element includes a plurality of through features configured to receive corresponding extensions of the component to constrain relative movement between the shear wall and the component.

12. A shear wall for a vehicle battery system having an assembly including a plurality of battery cells arranged in at least one housing, the shear wall comprising: a first element configured to be disposed along a side of the assembly, wherein the first element includes a first flange configured to extend away from the side of the assembly; as well as a second element configured to be arranged above the first element along a side of the assembly, wherein: The second element includes a second flange, and The first flange and the second flange are laminated together to form an interface, wherein the first element and the second element are welded together, and wherein: a weld path connecting the first element and the second element along a back side of the interface and adjacent an inner surface of the shear wall configured to interface with the assembly, The weld along the weld path faces the side of the component and the weld does not extend outwardly into the first flange and the second flange extending away from the side of the component, and The first flange and the second flange extend laterally away from the weld.

13. The shear wall of claim 12, wherein the second element further comprises a lifting feature comprising a C-shaped structure having a central portion extending vertically away from the interface and two end portions extending laterally away from the central portion.

14. The shear wall of claim 12, wherein: the first element comprising a first material thickness, The second element comprises a second material thickness, and A resulting flange formed at the interface includes a thickness equal to the sum of the first material thickness and the second material thickness.

15. The shear wall of claim 12, further comprising at least one reinforcing element disposed adjacent to at least one of the first element or the second element, and wherein the at least one reinforcing element is welded to the at least one of the first element or the second element.

16. The shear wall of claim 12, wherein the first flange comprises: a first pass-through feature for mounting to a frame member; as well as A first alignment feature is provided for positioning the battery system relative to the frame member.

17. The shear wall of claim 16, wherein the second flange comprises: a second through feature, the second through feature being aligned with the first through feature; as well as A second alignment feature is provided, the second alignment feature being aligned with the first alignment feature.

18. The shear wall of claim 12, wherein the first element includes a third flange configured to be disposed at a bottom of the first element and to extend below the assembly.

19. The shear wall of claim 12, wherein the first element includes an electrical terminal for electrically grounding the shear wall.

20. The shear wall of claim 12, wherein the first element includes a plurality of through features configured to receive corresponding extensions of the component to constrain relative movement between the shear wall and the component.

21. A method for making a shear wall for a vehicle battery system having an assembly including a plurality of battery cells arranged in at least one housing, the method comprising: forming a first element configured to be disposed along a side of the assembly, wherein the first element includes a first flange extending away from the side of the assembly; forming a second element configured to be arranged above the first element along a side of the assembly, wherein The second element includes a second flange, and The first flange and the second flange are laminated together to form an interface; as well as The first element and the second element are welded together, wherein: a weld path connecting the first element and the second element along a back side of the interface and adjacent an inner surface of the shear wall configured to interface with the assembly, The weld along the weld path faces the side of the component and the weld does not extend outwardly into the first flange and the second flange extending away from the side of the component, and The first flange and the second flange extend laterally away from the weld.

22. The method of claim 21, wherein the second element further comprises a C-shaped lifting feature comprising a central portion extending vertically away from an interface between the first flange and the second flange and two end portions extending laterally away from the central portion.

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