Battery structure of electric vehicle

Abstract

A battery structure for an electric vehicle includes a first battery array and a second battery array. The first battery array includes first walls secured to each other to form a first unitized structure configured to receive a first battery cell. A first wall of the plurality of first walls extends in a transverse direction with respect to a longitudinal direction of the electric vehicle. The second battery array is adjacent to the first battery array and includes second walls secured to each other to form a second unitized structure configured to receive a second battery cell. A second wall of the plurality of second walls is fixed to the first wall of the first battery array and includes a first vertical portion, a second vertical portion spaced apart from the first vertical portion, and a connecting member connecting the first vertical portion and the second vertical portion.

Description

Technical Field

[0001] This invention relates to a battery structure and more specifically to a battery structure for electric vehicles. Background Technology

[0002] The statements in this section are provided only as background information in connection with this disclosure and may not constitute prior art.

[0003] Electric vehicles differ from conventional motor vehicles because they are powered by one or more rechargeable battery packs containing, for example, lithium-ion batteries or any other suitable energy storage units. The battery pack typically uses a battery array to power one or more motors to drive a set of wheels. In some electric vehicles, particularly those capable of long-distance travel (e.g., electric vehicles capable of traveling more than 500 miles), the battery array comprises a structural assembly surrounding the battery pack.

[0004] This disclosure addresses these and other issues related to battery arrays in electric vehicles. Summary of the Invention

[0005] This section provides a general overview of this disclosure and is not a full disclosure of its entire scope or all its features.

[0006] In one embodiment, this disclosure provides a battery structure for an electric vehicle, the battery structure including a first battery array and a second battery array. The first battery array includes a plurality of first walls fixed to each other to form a first unitized structure configured to accommodate a first battery cell. One of the first walls extends laterally relative to the longitudinal direction of the electric vehicle. The second battery array is adjacent to the first battery array and includes a plurality of second walls fixed to each other to form a second unitized structure configured to accommodate a second battery cell. One of the second walls is fixed to the first wall of the first battery array and includes a first vertical portion, a second vertical portion spaced apart from the first vertical portion, and a connecting member connecting the first vertical portion and the second vertical portion.

[0007] In a variation of the battery structure described in the previous paragraph, which can be implemented individually or in any combination: the first wall includes a third vertical portion and a flange portion extending from the third vertical portion toward the second battery array; the second vertical portion of the second wall is spaced apart from the third vertical portion of the first wall; the flange portion is located above the second vertical portion of the second wall and above the connecting member of the second wall; a first fastener extends through the flange portion of the first wall and through one of the connecting members of the second wall to secure the first wall to the second wall; a battery tray is configured to receive the first battery array and the second battery array; a plurality of second fasteners... The device comprises: a first battery array and a second battery array; a plurality of fasteners, each fastener extending through the connecting member of the second wall and at least partially through the bottom wall of the battery tray to secure the second wall to the battery tray; a third battery array adjacent to the first battery array and connected to another first wall of the first battery array; and the height of the first vertical portion of the second wall being greater than the height of the second vertical portion of the second wall.

[0008] In another embodiment, the present invention provides a battery structure for an electric vehicle, the battery structure comprising a battery tray, a plurality of crossbeams, and a plurality of battery arrays. The plurality of crossbeams are fixed to the battery tray and spaced apart from each other along the longitudinal direction of the electric vehicle. Each crossbeam extends in a transverse direction. The plurality of battery arrays are disposed within the battery tray. The plurality of battery arrays include a first battery array and a second battery array. The first battery array includes a plurality of first walls fixed together to form a first unitized structure configured to accommodate a first battery cell. One of the plurality of first walls includes a first vertical portion and a flange portion extending from the first vertical portion. The second battery array is adjacent to the first battery array and includes a plurality of second walls fixed together to form a second unitized structure configured to accommodate a second battery cell. One of the plurality of second walls is supported by a corresponding crossbeam of the plurality of crossbeams and includes a second vertical portion, a third vertical portion spaced apart from the second vertical portion, and a connecting member connecting the second vertical portion and the third vertical portion. The flange portion of the first wall is fixed to the second wall.

[0009] In a variation of the battery structure of the previous paragraph, which can be implemented individually or in any combination: the third vertical portion of the second wall is spaced apart from the first vertical portion of the first wall; the flange portion is located above the third vertical portion of the second wall and above the connecting member of the second wall; a plurality of fasteners, each extending through the connecting member and a corresponding crossbeam to secure the second wall to the battery tray; a plurality of first fasteners extending through the flange portion of the first wall and through one of the connecting members of the second wall to secure the first wall to the second wall; a plurality of second fasteners, each extending through each of the connecting members and a corresponding crossbeam to secure the second wall to the battery tray; the plurality of first fasteners having a first length and the plurality of second fasteners having a second length greater than the first length; the flange portion of the first wall again abuts the second vertical portion of the second wall; and a third battery array is adjacent to and connected to another first wall of the first battery array.

[0010] In another embodiment, a method for assembling a battery structure for an electric vehicle is provided. The method includes: disposing a first battery array within a battery tray; securing the first battery array to the battery tray; disposing a second battery array within the battery tray after the first battery array has been secured to the battery tray; and securing the second battery array to the first battery array. The first battery array includes a first wall comprising a first vertical portion, a second vertical portion spaced apart from the first vertical portion, and a connecting member connecting the first and second vertical portions. The second battery array includes a second wall having a vertical portion and a flange portion extending from the vertical portion.

[0011] In a variation of the battery structure in the previous paragraph, securing the second battery array to the first battery array includes inserting one of a plurality of fasteners through the flange portion of the second wall and through the connecting member of the first wall.

[0012] Further applicability will become apparent from the description provided herein. It should be understood that the descriptions and specific examples are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0013] To better understand this disclosure, various forms of the disclosure will now be described by way of example with reference to the accompanying drawings, in which:

[0014] Figure 1 This is a schematic diagram of a vehicle including a battery housing assembly based on the principles of this disclosure;

[0015] Figure 2 yes Figure 1 A perspective view of the battery housing assembly;

[0016] Figure 3 yes Figure 1 Another perspective view of the battery housing assembly shown, in which the battery array and the cover of the battery housing assembly have been removed for clarity;

[0017] Figure 4 yes Figure 1 Another perspective view of the battery housing assembly, including the battery array disposed therein, with the cover of the battery housing assembly removed for clarity;

[0018] Figure 5 yes Figure 1 A perspective view of a battery array within the battery housing assembly;

[0019] Figure 6 yes Figure 1 Another perspective view of a battery array within the battery housing assembly;

[0020] Figure 7 yes Figure 1 A cross-sectional view of a portion of the battery housing assembly;

[0021] Figure 8 yes Figure 1 Another cross-sectional view of a part of the battery housing assembly;

[0022] Figures 9A to 9D It is to assemble with each other and to assemble into Figure 1 A schematic diagram of the battery array in the battery housing assembly, including the battery tray; and

[0023] Figure 10 This is a flowchart illustrating a method for manufacturing a battery housing assembly according to the principles of this disclosure.

[0024] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way. Detailed Implementation

[0025] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses. It should be understood that throughout the drawings, corresponding reference numerals indicate similar or corresponding parts and features.

[0026] refer to Figure 1The illustration shows a vehicle 10, such as an electric vehicle. In the provided example, the electric vehicle is a battery electric vehicle (BEV). In other examples, the electric vehicle may be a hybrid electric vehicle (HEV), a plug-in electric vehicle (PHEV), or a fuel cell vehicle, etc. Vehicle 10 includes a frame 12 and a battery structure or battery housing assembly 14. The frame 12 is the main support structure of vehicle 10, to which various components are attached directly or indirectly. The frame 12 includes opposing longitudinal beams 28a, 28b. The longitudinal beams 28a, 28b are spaced apart from each other and can define the length of the frame 12. In the example shown, vehicle 10 is a non-load-bearing body vehicle architecture, but other configurations, such as, for example, a unibody architecture, can be used.

[0027] The battery housing assembly 14 supplies power to a rear motor (not shown) to drive the rear wheels 20a, 20b of a set of rear wheels 20 via the rear axle, and / or supplies power to a front motor (not shown) to drive the front wheels 24a, 24b of a set of front wheels 24 via the front axle.

[0028] refer to Figures 2 to 6 The battery housing assembly 14 includes a battery tray or housing 30 and a plurality of battery arrays 32. Figure 2 and Figures 4 to 6 The battery housing 30 is an outer casing that provides a structurally enclosed and sealed compartment for the battery array 32 and other battery components, such as cooling lines, support brackets, and wires disposed therein or extending through them. The battery housing 30 can be positioned at different locations on the vehicle 10 and mounted to the frame 12. In this way, the battery housing 30 is supported by the frame 12 and located away from the passenger compartment (not shown) and cargo compartment (not shown) of the vehicle 10, thus not occupying space that would otherwise be available for passengers or cargo. The battery housing 30 includes a cover or cover 34. Figure 2 ), main body 36 ( Figures 2 to 4 ), multiple crossbeams 37 ( Figure 3 and Figure 4 The cover 34 is removably attached to the body 36 via mechanical fasteners such as bolts or screws (not shown). In this way, the cover 34 can be removed to maintain the battery array 32 disposed within the battery housing 30.

[0029] The main body 36 includes one or more sidewalls or panels 36a and a bottom wall or panel 36b. The sidewalls 36a are manufactured, for example, by stamping and extend in a vertical direction. The sidewalls 36a define the outer boundary of the battery housing 30 and are fixed to each other, for example, by welding or adhesive. The bottom wall 36b supports the battery array 32 disposed within the battery housing 30 and is fixed to the lower portion of the sidewalls 36a.

[0030] For further reference Figure 7 and Figure 8The crossbeams 37 are supported and secured to the bottom wall 36b of the body 36 and are evenly spaced from each other along the longitudinal direction of the vehicle 10. Each crossbeam 37 also extends along the lateral direction of the vehicle 10 and at least partially supports the adjacent battery arrays 32 of the battery housing assembly 14. Each crossbeam 37 includes a pair of end portions 37a and a center portion 37b. The pair of end portions 37a are secured to the upper surface of the bottom wall 36b of the battery housing 30. In one example, the pair of end portions 37a are secured to the upper surface of the bottom wall 36b by welding. In some forms, the pair of end portions 37a are secured to the upper surface of the bottom wall 36b by mechanical fasteners such as, for example, rivets, threaded screws, and / or bolts. The center portion 37b is located above the pair of end portions 37a and has a planar surface. The center portion 37b and the bottom wall 36b of the battery housing 30 cooperate to form a cavity. A seal is disposed around the periphery of the body 36 and engages with the body 36 and the cover 34. In this way, fluids, debris and other materials are prevented from entering the battery casing 30.

[0031] refer to Figure 2 , Figure 5 and Figure 6 Multiple battery arrays 32 are disposed within the battery housing 30. In the example shown, the battery arrays 32 are arranged side-by-side within the battery housing 30 to form a lower battery array. In some forms, the battery arrays are arranged side-by-side within the battery housing 30 and located on top of the battery arrays 32 to form an upper battery array. Each battery array in the upper battery array may be vertically stacked on top of the corresponding battery array 32 in the lower battery array.

[0032] Each battery array 32 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 32 also substantially spans the entire width of the battery housing 30. (Reference) Figures 5 to 7 Each battery array 32 includes a plurality of walls 38, which are fixed together to form a modular structure that houses and supports one or more stacks (not shown) of battery cells (e.g., lithium-ion batteries or any other suitable energy storage units). In some forms, the battery cells may be stacked on top of each other in a vertical arrangement within the modular structure. In some forms, the battery cells may be arranged side-by-side within the modular structure.

[0033] The battery arrays 32 are fixed to each other to form a structural assembly configured to transfer loads from one side of the battery housing 30 to the opposite side of the battery housing 30, for example, during a collision event. In other words, the battery arrays 32 are fixed to each other to transfer loads from the cell stacks (not shown) located within each battery array 32 during a collision event.

[0034] Each battery array 32 has multiple walls 38, including an upper wall 38a, a lower wall 38b, a right side wall 38c, a left side wall 38d, a front wall 38e, and a rear wall 38f. Each of the walls 38a to 38f is fixed to each other to form a compartment for structural surrounding and sealing of the cell stack. In the example shown, the structural surrounding has a box shape. The upper wall 38a defines the uppermost boundary of the battery array 32 and is oriented horizontally. Similarly, the lower wall 38b defines the lowermost boundary of the battery array 32a and is oriented horizontally. The right side wall 38c is oriented vertically and defines the rightmost boundary of the battery array 32. Similarly, the left side wall 38d is oriented vertically and defines the leftmost boundary of the battery array 32.

[0035] refer to Figure 5 , Figure 7 and Figure 8 The front wall 38e of each battery array 32 faces the front end of the vehicle 10 more than the rear wall 38f of the battery array 32a. Figure 4 Arrow F in the diagram indicates the front end of vehicle 10, which is positioned and fixed to the rear wall 32f of the adjacent battery array 32. In this way, the front wall 38e of battery array 32 and the rear wall 38f of the adjacent battery array 32 form a lateral member or structure 33 that substantially spans the entire width of battery housing 30 and is configured to, for example, transfer loads from one side of battery housing 30 to the opposite side of battery housing 30 during a collision event. It should be understood that the foremost battery array 32 in battery housing 30 is fixed to a structure 40 disposed within battery tray 30. In other words, the front wall 38e of the foremost battery array 32 in battery housing 30 is fixed to structure 40.

[0036] The front wall 38e of the battery array 32 includes a vertical portion 42, a first upper portion or flange portion 44, a second upper portion or flange portion 45, and a connecting member 46. The vertical portion 42 extends vertically and faces the rear wall 38f of the adjacent battery array 32. In the example shown, the lower end of the vertical portion 42 is flush with the lower wall 38b of the battery array 32, and the upper end of the vertical portion 42 is below the upper wall 38a of the battery array 32. In some forms, the lower end of the vertical portion 42 may extend downward over the lower wall 38b of the battery array 32, and the upper end of the vertical portion 42 may extend upward over the upper wall 38a of the battery array 32.

[0037] A first upper portion 44 extends vertically from the upper end of the vertical portion 42 toward the rear wall 38f of the adjacent battery array 32. The first upper portion 44 of the foremost battery array 32 in the battery housing 30 extends vertically from the upper end of the vertical portion 42 toward a structure 40 disposed within the battery tray 30. The first upper portion 44 is horizontally oriented and secured to the upper wall 38a of the battery array 32. The first upper portion 44 includes a plurality of openings (not shown) extending therethrough, the plurality of openings receiving fasteners (not shown) to secure the upper wall 38a of the battery array 32 to the front wall 38e of the battery array 32.

[0038] The second upper portion 45 extends vertically from the vertical portion 42 at a position between the upper and lower ends of the vertical portion 42 toward the rear wall 38f of the adjacent battery array 32. The second upper portion 45 is horizontally oriented and spaced apart from the first upper portion 44. In the example shown, the thickness of the first upper portion 44 is greater than the thickness of the second upper portion 45. The second upper portion 45 includes a plurality of openings 51 extending therethrough. Figure 5 The plurality of openings receive fasteners 50 to secure the front wall 38e of the battery array 32 to the rear wall 38f of the adjacent battery array 32. The opening 51 is offset relative to an opening (not shown) formed in the first upper portion 44 (i.e., the opening 51 of the second upper portion 45 is not vertically aligned with the opening in the first upper portion 44).

[0039] The connecting member 46 is oriented vertically and connects the first upper portion 44 and the second upper portion 45 to each other. In the example shown, the connecting member 46 extends from the first upper portion 44 near the middle region of the first upper portion 44 to the second upper portion 45 near the middle region of the second upper portion 45. In this way, the connecting member 46 is spaced apart from the vertical portion 42. In some forms, the connecting member 46 is spaced apart from the ends 48a and 48b of the first upper portion 44 and the second upper portion 45, respectively. In other forms, the connecting member 46 extends from the end 48a of the first upper portion 44 to the end 48b of the second upper portion 45.

[0040] refer to Figures 6 to 8 The rear wall 38f of the battery array 32 is fixed to a corresponding crossbeam 37 disposed within the battery housing 30. The rear wall 38f is also fixed to the front wall 38e, such that a minimum gap 56 is defined between the rear wall 38f and the vertical portion 42 of the front wall 38e of the adjacent battery array 32. Figure 7 and Figure 8The rear wall 38f includes a first vertical portion 52, a second vertical portion 54, and a plurality of connecting members 58a, 58b, and 58c. The first vertical portion 52 extends vertically and is spaced apart from the vertical portion 42 of the front wall 38e of the adjacent battery array 32. In the example shown, the first vertical portion 52 is located below the upper wall 38a of the battery array 32 and above the bottom wall 38b of the battery array 32.

[0041] The second vertical portion 54 extends vertically and is spaced apart from the vertical portion 42 of the front wall 38e of the adjacent battery array 32. In other words, the second vertical portion 54 is positioned closer to the vertical portion 42 of the front wall 38e of the adjacent battery array 32 than the first vertical portion 52, and cooperates with the vertical portion 42 to define a minimum gap 56 therebetween. In the example shown, the first vertical portion 52 extends further along the Z direction than the second vertical portion 54. The second vertical portion 54 also extends below the first upper portion 44 and the second upper portion 45 of the front wall 38e of the adjacent battery array 32.

[0042] Connecting members 58a, 58b, and 58c are spaced apart from each other along the Z-direction and connect the first vertical portion 52 of the rear wall 38f to the second vertical portion 54 of the rear wall 38f. In other words, connecting members 58a, 58b, and 58c extend vertically from the first vertical portion 52 to the second vertical portion 54 and are oriented horizontally, with gaps between them. In the example shown, each of the connecting members 58a, 58b, and 58c may have a different thickness. For example, the thickness of connecting member 58a may be greater than the thickness of connecting members 58b and 58c, and the thickness of connecting member 58c may be greater than the thickness of connecting member 58b. In some forms, the thickness of each of the connecting members 58a, 58b, and 58c may be the same. In the example shown, connecting member 58c is positioned above the center portion 37b of the corresponding crossbeam 37, such that the rear wall 38f is spaced apart from the bottom wall 36b of the battery casing 30.

[0043] In the example shown, fastener 50 extends through a second upper portion 45 of the front wall 38e of the battery array 32 and through a connecting member 58a of the rear wall 38f of the adjacent battery array 32 to secure the battery array 32 and the adjacent battery array 32 to each other. In some forms, fastener 50 may extend through the second upper portion 45 of the front wall 38e of the battery array 32 and through connecting members 58a, 58b, 58c to secure the battery array 32 and the adjacent battery array 32 to each other. Figure 5As shown, a groove or cutout 60 may be formed in portions of the front wall 38e and the upper wall 38a to provide passage to the second upper portion 45 of the front wall 38e. In this way, the fastener 50 does not contact the first upper portion 44 of the front wall 38e and the upper wall 38a of the battery array 32.

[0044] In the example shown, fastener 64 extends through connecting members 58a, 58b, 58c of the rear wall 38f of the battery array 32 and through the central portion 37b of the corresponding crossbeam 37 to secure the battery array 32 to the housing 30. In some forms, fastener 64 may extend through connecting members 58a, 58b, 58c of the rear wall 38f of the battery array 32, through the central portion 37b of the corresponding crossbeam 37, and at least partially through the bottom wall 36b of the battery housing 30 to secure the battery array 32 to the housing 30. The length of each fastener 64 is greater than the length of fastener 50. Figure 5 As shown, a groove or cutout 66 may be formed in a portion of the front wall 38e to occupy or accommodate the head of each fastener 64 extending through the connecting members 58a, 58b, 58c. In this way, the fastener 64 does not contact the front wall 38e and the upper wall 38a of the battery array 32.

[0045] refer to Figures 9A to 9D and Figure 10 The method 100 for assembling a battery structure 14 for an electric vehicle will be described in detail. At 104, a battery array 32a of a plurality of battery arrays 32 is disposed within a battery tray 30. Figure 9A At position 108, the battery array 32a is secured to the battery tray 30. That is, the front wall 38e of the battery array 32a, located at the foremost point in the battery housing 30, is secured to the structure 40 of the battery housing 30 using fasteners 50. Figure 9B And fastener 64 is used to secure the rear wall 38e of the battery array 32a to the battery tray 30.

[0046] At position 112, another battery array 32b of the plurality of battery arrays 32 is placed adjacent to battery array 32a within the battery tray 30. Figure 9C At position 116, battery array 32b is fixed to battery tray 30 and to battery array 32a. Figure 9D That is, by inserting fastener 64 into the opening 70 passing through the connecting members 58a, 58b, 58c ( Figure 6 ) and the opening 72 of the corresponding crossbeam 37 fixed to the battery tray 30. Figure 3 and Figure 4The rear wall 38f of the battery array 32b is secured to the battery tray 30 by inserting each fastener 50 through the corresponding opening 51 in the front wall 38e of the battery array 32b and through the corresponding opening 76 in the connecting member 58a in the rear wall 38f of the battery array 32b. Figure 6 The front wall 38e of the battery array 32b is fixed to the rear wall 38f of the battery array 32a. Similarly, additional battery arrays 32 are placed within the battery tray 30 and fixed one after another to the battery tray 30 until the desired number of battery arrays 32 are placed within the battery tray 30.

[0047] Unless otherwise expressly indicated herein, all numerical values ​​indicating mechanical / thermal properties, percentage of composition, dimensions and / or tolerances or other characteristics should be understood as being modified by the words “about” or “approximately” when describing the scope of this disclosure. Such modification is desired for various reasons, including: industrial practice; material, manufacturing and assembly tolerances; and testing capabilities.

[0048] As used herein, the phrases A, B, and C at least one should be interpreted as using the non-exclusive logic "or" to represent logic (A or B or C), and should not be interpreted as meaning "at least one of A, at least one of B, and at least one of C".

[0049] The description in this disclosure is merely exemplary in nature, and therefore, variations thereof without departing from the spirit and scope of this disclosure are intended to be made within its scope. Such variations should not be considered as departing from the spirit and scope of this disclosure.

[0050] According to the present invention, a battery structure for an electric vehicle is provided, comprising: a battery tray; a plurality of crossbeams fixed to the battery tray and spaced apart from each other along the longitudinal direction of the electric vehicle, each crossbeam extending in a transverse direction; and a plurality of battery arrays disposed within the battery tray, the plurality of battery arrays comprising: a first battery array including a plurality of first walls fixed together to form a first unitized structure configured to accommodate a first battery cell, one of the plurality of first walls including a first vertical portion and a flange portion extending from the first vertical portion; and a second battery array adjacent to the first battery array and including a plurality of second walls fixed together to form a second unitized structure configured to accommodate a second battery cell, one of the plurality of second walls being supported by a corresponding crossbeam of the plurality of crossbeams and including a second vertical portion, a third vertical portion spaced apart from the second vertical portion, and a connecting member connecting the second vertical portion and the third vertical portion, wherein the flange portion of the first wall is fixed to the second wall.

[0051] According to one embodiment, the third vertical portion of the second wall is spaced apart from the first vertical portion of the first wall.

[0052] According to one embodiment, the flange portion is located above the third vertical portion of the second wall and above the connecting member of the second wall.

[0053] According to one embodiment, the invention is further characterized by a plurality of fasteners, each fastener extending through the connecting member and the corresponding crossbeam to secure the second wall to the battery tray.

[0054] According to one embodiment, the invention is further characterized by a plurality of first fasteners extending through the flange portion of the first wall and through one of the connecting members of the second wall to secure the first wall to the second wall.

[0055] According to one embodiment, the invention is further characterized by a plurality of second fasteners, each second fastener extending through each of the connecting members and the corresponding crossbeam to secure the one second wall to the battery tray.

[0056] According to one embodiment, the plurality of first fasteners have a first length, and the plurality of second fasteners have a second length, the second length being greater than the first length.

[0057] According to one embodiment, the flange portion of the first wall is adjacent to the second vertical portion of the second wall.

[0058] According to one embodiment, the invention is further characterized by a third battery array, which is adjacent to the first battery array and connected to another first wall of the first battery array.

Claims

1. A battery structure for an electric vehicle, the battery structure comprising: A first battery array, the first battery array including a plurality of first walls fixed to each other to form a first unitized structure, the first unitized structure being configured to accommodate a first battery cell, one of the plurality of first walls extending in a lateral direction relative to the longitudinal direction of the electric vehicle; as well as A second battery array, adjacent to the first battery array and including a plurality of second walls, the plurality of second walls being fixed to each other to form a second unitized structure configured to accommodate a second battery cell, one of the plurality of second walls being fixed to the first wall of the first battery array, and including a first vertical portion, a second vertical portion spaced apart from the first vertical portion, and a connecting member connecting the first vertical portion and the second vertical portion.

2. The battery structure according to claim 1, wherein one of the first walls includes a third vertical portion and a flange portion extending from the third vertical portion toward the second battery array.

3. The battery structure according to claim 2, wherein the second vertical portion of the second wall is spaced apart from the third vertical portion of the first wall.

4. The battery structure according to claim 2, wherein the flange portion is located above the second vertical portion of the second wall and above the connecting member of the second wall.

5. The battery structure of claim 2, further comprising a first fastener extending through the flange portion of the first wall and through one of the connecting members of the second wall to secure the first wall to the second wall.

6. The battery structure according to claim 5, further comprising: A battery tray configured to accommodate the first battery array and the second battery array; as well as A plurality of second fasteners, each extending through the connecting member and at least partially through the bottom wall of the battery tray, to secure the one second wall to the battery tray.

7. The battery structure according to claim 6, wherein the first fastener has a first length, and the plurality of second fasteners have a second length, the second length being greater than the first length.

8. The battery structure according to claim 1, further comprising: A battery tray configured to accommodate the first battery array and the second battery array; as well as Multiple fasteners, each fastener extending through the connecting member of the second wall and at least partially through the bottom wall of the battery tray, to secure the second wall to the battery tray.

9. The battery structure of claim 1, further comprising a third battery array, the third battery array being adjacent to the first battery array and connected to another first wall of the first battery array.

10. The battery structure according to claim 1, wherein the height of the first vertical portion of the second wall is greater than the height of the second vertical portion of the second wall.

11. The battery structure according to claim 1, further comprising: A battery tray configured to accommodate the first battery array and the second battery array; as well as Multiple crossbeams are fixed to the battery tray and spaced apart from each other along the longitudinal direction of the electric vehicle, with each crossbeam extending in the transverse direction.

12. The battery structure of claim 11, further comprising a plurality of fasteners, each fastener extending through the connecting member and a corresponding crossbeam to secure the second wall to the battery tray.

13. The battery structure of claim 1, wherein one of the plurality of first walls includes a first vertical portion and a flange portion extending from the first vertical portion, wherein the flange portion of the first wall is fixed to the second wall, and wherein the flange portion of the first wall abuts the second vertical portion of the second wall.

14. A method for assembling a battery structure for an electric vehicle, the method comprising: A first battery array is disposed in a battery tray. The first battery array includes a first wall, the first wall including a first vertical portion, a second vertical portion spaced apart from the first vertical portion, and a connecting member connecting the first vertical portion and the second vertical portion. Secure the first battery array to the battery tray; After the first battery array is fixed to the battery tray, a second battery array is disposed within the battery tray. The second battery array includes a second wall, which includes a vertical portion and a flange portion extending from the vertical portion; and The second battery array is fixed to the first battery array.

15. The method of claim 14, wherein securing the second battery array to the first battery array comprises inserting one of a plurality of fasteners through the flange portion of the second wall and through the connecting member of the first wall.

Images