BATTERY STRUCTURE OF AN ELECTRIC VEHICLE

Abstract

A battery structure for an electric vehicle comprises a first and a second battery bank. The first battery bank includes first walls that are secured to one another to form a first modular structure configured to house first battery cells. One of the first walls extends in a transverse direction relative to a longitudinal direction of the electric vehicle. The second battery bank is adjacent to the first battery bank and includes second walls that are secured to one another to form a second modular structure configured to house second battery cells.A second wall of the multitude of second walls is secured to the first wall of the first battery bank and includes a first vertical section, a second vertical section spaced apart from the first vertical section, and connecting elements that join the first vertical section and the second vertical section.

Description

AREA OF TECHNOLOGY

[0001] The present disclosure relates to a battery structure and in particular a battery structure for an electric vehicle. GENERAL STATE OF THE ART

[0002] The statements in this section merely provide background information in connection with the present disclosure and may not represent the state of the art.

[0003] Electric vehicles differ from conventional motor vehicles in that they are powered by one or more rechargeable battery packs, which may contain, for example, lithium-ion batteries or any other suitable storage unit for electrical power. The battery pack typically supplies power to one or more motors, using battery banks, to drive a set of wheels. In some electric vehicles, the battery banks include a structural assembly that surrounds battery pouches, particularly for vehicles capable of long-distance travel (e.g., electric vehicles with a range exceeding 500 miles).

[0004] The present disclosure addresses these and other problems related to battery banks in electric vehicles. SUMMARY

[0005] This section provides a general summary of the revelation and is not a comprehensive revelation of its full scope or all of its features.

[0006] In one form, the present disclosure provides a battery structure for an electric vehicle, comprising a first battery bank and a second battery bank. The first battery bank comprises a plurality of first walls secured to one another to form a first modularized structure configured to accommodate first battery cells. One first wall of the plurality of first walls extends in a transverse direction relative to a longitudinal direction of the electric vehicle. The second battery bank is adjacent to the first battery bank and comprises a plurality of second walls secured to one another to form a second modularized structure configured to accommodate second battery cells.A second wall of the multitude of second walls is secured to the first wall of the first battery bank and includes a first vertical section, a second vertical section spaced apart from the first vertical section, and connecting elements that join the first vertical section and the second vertical section.

[0007] In variations of the battery structure described in the preceding paragraph, which may be implemented individually or in any combination: the first wall includes a third vertical section and a flanged section extending from the third vertical section towards the second battery bank; the second vertical section of the second wall is spaced apart from the third vertical section of the first wall; the flanged section is located above the second vertical section of the second wall and above the connecting elements of the second wall; first fastening elements extend through the flanged section of the first wall and through one of the connecting elements of the second wall to secure the first wall to the second wall; a battery support is configured to accommodate the first battery bank and the second battery bank;a plurality of second fasteners, each second fastener extending through the connecting elements and at least partially through a lower wall of the battery support to secure the second wall to the battery support; a battery support configured to accommodate the first battery bank and the second battery bank; a plurality of fasteners, each fastener extending through the connecting elements of the second wall and at least partially through a lower wall of the battery support to secure the second wall to the battery support; a third battery bank adjacent to the first battery bank and connected to the other first wall of the first battery bank; and the height of the first vertical section of the second wall is greater than the height of the second vertical section of the second wall.

[0008] In another form, the present disclosure provides a battery structure for an electric vehicle, comprising a battery carrier, a plurality of crossbeams, and a plurality of battery banks. The plurality of crossbeams is secured to the battery carrier and is spaced apart from one another along a longitudinal direction of the electric vehicle. Each crossbeam extends in a transverse direction. The plurality of battery banks is arranged within the battery carrier. The plurality of battery banks includes a first battery bank and a second battery bank. The first battery bank comprises a plurality of first walls secured to one another to form a first modularized structure configured to accommodate first battery cells. A first wall of the plurality of first walls comprises a first vertical section and a flanged section extending from the first vertical section.The second battery bank is adjacent to the first battery bank and comprises a plurality of second walls secured to one another to form a second modular structure configured to house second battery cells. Each second wall of the plurality of second walls is supported by a corresponding crossbeam of the plurality of crossbeams and includes a second vertical section, a third vertical section spaced apart from the second vertical section, and connecting elements that join the second and third vertical sections. The flanged section of the first wall is secured to the second wall.

[0009] In variations of the battery structure described in the preceding paragraph, which may be implemented individually or in any combination: the third vertical section of the second wall is spaced apart from the first vertical section of the first wall; the flange section is located above the third vertical section of the second wall and above the connecting elements of the second wall; a plurality of fasteners, each fastener extending through the connecting elements and a corresponding cross member to secure the second wall to the battery support; a plurality of first fasteners extending through the flange section of the first wall and through one of the connecting elements of the second wall to secure the first wall to the second wall;a plurality of second fasteners, each second fastener extending through each of the connecting elements and a corresponding crossbeam to secure the second wall to the battery support; the plurality of first fasteners having a first length and the plurality of second fasteners having a second length, the second length being greater than the first length; the flanged section of the first wall being adjacent to the second vertical section of the second wall; and a third battery bank being adjacent to the first battery bank and connected to the other first wall of the first battery bank.

[0010] In yet another form, a method for assembling a battery structure for an electric vehicle is provided. The method involves arranging a first battery bank within a battery carrier, securing the first battery bank to the battery carrier, arranging a second battery bank within the battery carrier after the first battery bank has been secured to the battery carrier, and securing the second battery bank to the first battery bank. The first battery bank comprises a first wall, including a first vertical section, a second vertical section spaced apart from the first vertical section, and connecting elements that join the first vertical section and the second vertical section. The second battery bank comprises a second wall, having a vertical section and a flanged section extending from the vertical section.

[0011] In variations of the battery structure described in the preceding paragraph, securing the second battery bank to the first battery bank involves inserting a variety of fasteners through the flange section of the second wall and through one of the connecting elements of the first wall.

[0012] Further areas of application will become apparent from the description provided in this document. It is understood that the description and specific examples serve only for illustration and are not intended to limit the scope of protection afforded by this disclosure. DRAWINGS

[0013] For a comprehensive understanding of the revelation, various forms of it will now be described by way of example with reference to the accompanying drawings, whereby the following applies: Fig. Figure 1 is a schematic view of a vehicle incorporating a battery housing assembly in accordance with the principles of the present disclosure; Fig. Figure 2 is a perspective view of the battery housing assembly. Fig. 1; Fig. Figure 3 is another perspective view of the battery housing assembly. Fig. 1, which is illustrated in such a way that battery banks and one cover of the battery housing assembly have been removed for clarity; Fig. Figure 4 is another perspective view of the battery housing assembly. Fig. 1, which includes the battery banks arranged therein and in which the cover of the battery housing assembly has been removed for clarity; Fig. Figure 5 is a perspective view of a battery bank of the battery housing assembly made of Fig. 1; Fig. Figure 6 is another perspective view of a battery bank of the battery housing assembly. Fig. 1; Fig. Figure 7 is a cross-sectional view of a section of the battery housing assembly made of Fig. 1; Fig. Figure 8 is another cross-sectional view of a section of the battery housing assembly made of Fig. 1; Fig. 9A-9D are schematic views of battery banks connected to each other and to a battery carrier of the battery housing assembly. Fig. 1 are composed of; and Fig. Figure 10 is a flowchart illustrating a method for manufacturing a battery housing assembly according to the principles of the present disclosure.

[0014] The drawings described in this document serve only for illustration and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0015] The following description is merely exemplary and is not intended to limit the present disclosure, application, or uses. It is understood that across all drawings, corresponding reference numerals denote identical or corresponding parts and features.

[0016] With reference to Fig. Figure 1 is a vehicle 10, such as an electric vehicle. In the example provided, the electric vehicle is a battery electric vehicle (BEV). In other examples, the electric vehicle could be, among others, a hybrid electric vehicle (HEV), a plug-in electric vehicle (PHEV), or a fuel cell vehicle. The vehicle 10 includes a vehicle frame 12 and a battery structure or battery housing assembly 14. The vehicle frame 12 is the main support structure of the vehicle 10, to which various components are attached directly or indirectly. The vehicle frame 12 includes opposing longitudinal beams 28a, 28b. The beams 28a, 28b are spaced apart and can define a length of the vehicle frame 12.In the illustrated example, vehicle 10 is a frame-based vehicle architecture, although other configurations can be used, such as a unibody architecture.

[0017] The battery housing assembly 14 supplies power to a rear motor (not shown) to drive rear wheels 20a, 20b of a set of rear wheels 20 via a rear axle, and / or supplies power to a front motor (not shown) to drive front wheels 24a, 24b of a set of front wheels 24 via a front axle.

[0018] With reference to Fig. 2-6 the battery housing assembly 14 includes a battery carrier or battery housing 30 and a plurality of battery banks 32 ( Fig. 2 and 4-6). The battery housing 30 is an enclosure that provides a structurally surrounding and sealed compartment for the battery banks 32 and other battery components, such as cooling lines, support brackets, and wiring, which are located within or extend through it. The battery housing 30 can be located at various points on the vehicle 10 and is mounted to the vehicle frame 12. In this way, the battery housing 30 is supported by the vehicle frame 12 and is located away from any passenger compartment (not shown) and cargo compartments (not shown) of the vehicle 10, thus not occupying any space that would otherwise be available for passengers or cargo. The battery housing 30 includes a cover or lid 34 ( Fig. 2), a body 36 ( Fig. 2-4), a large number of crossbeams 37 ( Fig. 3 and Fig. 4) and a seal (not shown). The cover 34 is removablely coupled to the body 36 by means of mechanical fasteners, such as bolts or screws (not shown). In this way, the cover 34 can be removed to service the battery banks 32, which are arranged inside the battery housing 30.

[0019] The body 36 comprises one or more side walls or plates 36a and a bottom wall or plate 36b. The side walls 36a are manufactured, for example, by stamping and extend in a vertical direction. The side walls 36a define an outer boundary of the battery housing 30 and are secured to one another, for example, by welding or adhesive. The bottom wall 36b supports the battery banks 32, which are arranged inside the battery housing 30, and is secured to the lower sections of the side walls 36a.

[0020] With further reference to Fig. 7 and Fig. In 8, the crossbeams 37 are supported on and secured to the lower wall 36b of the body 36 and are uniformly spaced apart from one another in a longitudinal direction of the vehicle 10. Each crossbeam 37 also extends in a transverse direction of the vehicle 10 and supports at least partially adjacent battery banks 32 of the battery housing assembly 14. Each crossbeam 37 includes a pair of end sections 37a and a central section 37b. The pair of end sections 37a is secured to an upper surface of the lower wall 36b of the battery housing 30. In one example, the pair of end sections 37a is secured to the upper surface of the lower wall 36b by welding. In some embodiments, the pair of end sections 37a is secured to the upper surface of the lower wall 36b by mechanical fasteners, such as rivets, threaded screws, and / or bolts. The middle section 37b is located above the pair of end sections 37a and has a flat surface.The central section 37b and the lower wall 36b of the battery housing 30 work together to form a cavity. The seal is arranged around the circumference of the body 36 and engages with the body 36 and the cover 34. This prevents fluids, dirt, and other materials from entering the battery housing 30.

[0021] With reference to Fig. 2, Fig. 5 and Fig. Figure 6 shows the plurality of battery banks 32 arranged within the battery housing 30. In the illustrated example, the battery banks 32 are arranged side-by-side within the battery housing 30 to form a bottom row of battery banks. In some forms, battery banks (not shown) can be arranged side-by-side within the battery housing 30 and sit atop the battery banks 32 to form a top row of battery banks. Each battery bank of the top row can be stacked vertically on top of a corresponding battery bank 32 of the bottom row.

[0022] Each battery bank 32 can be rechargeable and can be in the form of a modular structure that can be installed inside and removed from the battery housing 30. Each battery bank 32 also essentially spans the entire width of the battery housing 30. With reference to Fig. 5-7 Each battery bank 32 comprises a plurality of walls 38 secured to one another to form a modular structure that accommodates 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). In some forms, the battery cells may be stacked vertically within the modular structure. In other forms, the battery cells may be arranged side-by-side within the modular structure.

[0023] The battery banks 32 are secured to one another 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 certain impact event. In other words, the battery banks 32 are secured to one another to transfer loads away from the cell stacks (not shown) located within each battery bank 32 during a certain impact event.

[0024] The plurality of walls 38 of each battery bank 32 includes a top wall 38a, a bottom wall 38b, a right side wall 38c, a left side wall 38d, a front wall 38e, and a rear wall 38f. The walls 38a-38f are each secured to one another to form a structural environment and a sealed compartment for the cell stack. In the illustrated example, the structural environment has a box shape. The top wall 38a defines a top boundary of the battery bank 32 and is oriented horizontally. Likewise, the bottom wall 38b defines a bottom boundary of the battery bank 32a and is oriented horizontally. The right side wall 38c is oriented vertically and defines a rightmost boundary of the battery bank 32. Likewise, the left side wall 38d is oriented vertically and defines a leftmost boundary of the battery bank 32.

[0025] With reference to Fig. 5, Fig. 7 and Fig. 8 the front wall 38e of each battery bank 32 is located further towards a front end of the vehicle 10 (arrow F in Fig. 4 indicates the front end of the vehicle 10) as the rear wall 38f of battery bank 32 and is secured to the rear wall 32f of an adjacent battery bank 32. In this way, the front wall 38e of battery bank 32 and the rear wall 38f of the adjacent battery bank 32 form a transverse element or structure 33 that essentially spans the entire width of the battery housing 30 and is 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 certain impact event. It is understood that the battery bank 32 located furthest forward in the battery housing 30 is secured to a structure 40 located within the battery carrier 30. In other words, the front wall 38e of the battery bank 32 located furthest forward in the battery housing 30 is secured to the structure 40.

[0026] The front wall 38e of the battery bank 32 includes a vertical section 42, a first upper section or flange section 44, a second upper section or flange section 45, and a connecting element 46. The vertical section 42 extends vertically and faces the rear wall 38f of an adjacent battery bank 32. In the illustrated example, a lower end of the vertical section 42 is flush with the lower wall 38b of the battery bank 32, and an upper end of the vertical section 42 is located below the upper wall 38a of the battery bank 32. In some forms, the lower end of the vertical section 42 may extend downward past the lower wall 38b of the battery bank 32, and the upper end of the vertical section 42 may extend upward past the upper wall 38a of the battery bank 32.

[0027] The first upper section 44 extends perpendicularly from an upper end of the vertical section 42 toward the rear wall 38f of the adjacent battery bank 32. The first upper section 44 of the battery bank 32, located furthest forward in the battery housing 30, extends perpendicularly from the upper end of the vertical section 42 toward the structure 40 located within the battery support 30. The first upper section 44 is horizontally oriented and secured to the upper wall 38a of the battery bank 32. The first upper section 44 includes a plurality of openings (not shown) extending through it to accommodate fasteners (not shown) for securing the upper wall 38a of the battery bank 32 to the front wall 38e of the battery bank 32.

[0028] The second upper section 45 extends perpendicularly from a point on the vertical section 42 located between its upper and lower ends, toward the rear wall 38f of the adjacent battery bank 32. The second upper section 45 is horizontally oriented and spaced apart from the first upper section 44. In the illustrated example, the first upper section 44 has a thickness greater than the thickness of the second upper section 45. The second upper section 45 incorporates a plurality of openings 51 ( Fig. 5), extending thereby and accommodating fastening elements 50 to secure the front wall 38e of battery bank 32 to the rear wall 38f of the adjacent battery bank 32. The openings 51 are offset from the openings (not shown) formed in the first upper section 44 (i.e., the openings 51 of the second upper section 45 are not vertically aligned with the openings in the first upper section 44).

[0029] The connecting element 46 is oriented vertically and connects the first upper section 44 and the second upper section 45. In the illustrated example, the connecting element 46 extends from the first upper section 44 at a point near a mid-region of the first upper section 44 to the second upper section 45 at a point near a mid-region of the second upper section 45. In this way, the connecting element 46 is spaced from the vertical section 42. In some forms, the connecting element 46 is spaced from ends 48a, 48b of the first and second upper sections 44, 45, respectively. In other forms, the connecting element 46 extends from end 48a of the first upper section 44 to end 48b of the second upper section 45.

[0030] With reference to Fig. 6-8 The rear wall 38f of the battery bank 32 is secured to a corresponding crossbeam 37, which is arranged inside the battery housing 30. The rear wall 38f is also secured to the front wall 38e, so that a minimal gap 56 exists between the rear wall 38f and the vertical section 42 of the front wall 38e ( Fig. 7 and Fig. 8) of the adjacent battery bank 32. The rear wall 38f includes a first vertical section 52, a second vertical section 54, and a plurality of connecting elements 58a, 58b, 58c. The first vertical section 52 extends in a vertical direction and is spaced apart from the vertical section 42 of the front wall 38e of the adjacent battery bank 32. In the illustrated example, the first vertical section 52 is below the upper wall 38a of battery bank 32 and above the lower wall 38b of battery bank 32.

[0031] The second vertical section 54 extends in a vertical direction and is spaced from the vertical section 42 of the front wall 38e of the adjacent battery bank 32. In other words, the second vertical section 54 is closer to the vertical section 42 of the front wall 38e of the adjacent battery bank 32 than the first vertical section 52 and interacts with the vertical section 42 to define the minimum gap 56 between them. In the illustrated example, the first vertical section 52 extends further in a Z-direction than the second vertical section 54. The second vertical section 54 also extends below the first upper section 44 and the second upper section 45 of the front wall 38e of the adjacent battery bank 32.

[0032] The connecting elements 58a, 58b, 58c are spaced apart along the Z-direction and connect the first vertical section 52 of the rear wall 38f to the second vertical section 54 of the rear wall 38f. In other words, the connecting elements 58a, 58b, 58c extend perpendicularly from the first vertical section 52 to the second vertical section 54 and are aligned horizontally with gaps between them. In the illustrated example, each of the connecting elements 58a, 58b, 58c can have a different thickness. For example, connecting element 58a can have a thickness greater than the thicknesses of connecting elements 58b and 58c, and connecting element 58c can have a thickness greater than the thickness of connecting element 58b. In some shapes, the thickness of each of the connecting elements 58a, 58b, 58c can be the same.In the illustrated example, the connecting element 58c is arranged above the central section 37b of the corresponding crossbeam 37, so that the rear wall 38f is spaced away from the lower wall 36b of the battery housing 30.

[0033] In the illustrated example, fastening elements 50 extend through the second upper section 45 of the front wall 38e of battery bank 32 and through the connecting element 58a of the rear wall 38f of the adjacent battery bank 32 to secure battery bank 32 and the adjacent battery bank 32 to each other. In some forms, the fastening elements 50 may extend through the second upper section 45 of the front wall 38e of battery bank 32 and through the connecting elements 58a, 58b, 58c to secure battery bank 32 and the adjacent battery bank 32 to each other. As in Fig. As shown in Figure 5, grooves or cutouts 60 can be formed in sections of the front wall 38e and the upper wall 38a to provide access to the second upper section 45 of the front wall 38e. In this way, the fasteners 50 do not touch the first upper section 44 of the front wall 38e and the upper wall 38a of the battery bank 32.

[0034] In the illustrated example, fasteners 64 extend through the connecting elements 58a, 58b, 58c of the rear wall 38f of the battery bank 32 and through the central section 37b of the corresponding cross member 37 to secure the battery bank 32 to the battery housing 30. In some forms, the fasteners 64 may extend through the connecting elements 58a, 58b, 58c of the rear wall 38f of the battery bank 32, through the central section 37b of the corresponding cross member 37, and at least partially through the lower wall 36b of the battery housing 30 to secure the battery bank 32 to the battery housing 30. Each fastener 64 has a length greater than the length of the fastener 50. As shown in Fig. As shown in Figure 5, grooves or cutouts 66 can be formed in sections of the front wall 38e to receive or accommodate a head of each fastener 64 extending through the connecting elements 58a, 58b, 58c. In this way, the fasteners 64 do not contact the front wall 38e and the upper wall 38a of the battery bank 32.

[0035] With reference to Fig. 9A-9D and Fig. Figure 10 describes in detail a method 100 for assembling a battery structure 14 of an electric vehicle. Figure 104 describes how the battery bank 32a of a plurality of battery banks 32 is arranged within the battery carrier 30 ( Fig. 9A). At 108, the battery bank 32a is secured to the battery support 30. That is, the front wall 38e of the battery bank 32a, which is located furthest forward in the battery housing 30, is attached to the structure 40 using the fasteners 50 ( Fig. 9B) of the battery housing 30 is secured and the rear wall 38e of the battery bank 32a is secured to the battery carrier 30 using the fastening elements 64.

[0036] At 112, another battery bank 32b of a plurality of battery banks 32 is arranged within the battery carrier 30 adjacent to the battery bank 32a ( Fig. 9C). At 116, battery bank 32b is secured to battery carrier 30 and to battery bank 32a ( Fig. 9D). That is, the rear wall 38f of the battery bank 32b is secured to the battery carrier 30 by the fastening elements 64 through openings 70 ( Fig. 6) the connecting elements 58a, 58b, 58c and an opening 72 ( Fig. 3 and Fig. 4) a corresponding crossbeam 37, which is secured to the battery support 30, is inserted. The front wall 38e of the battery bank 32b is secured to the rear wall 38f of the battery bank 32a by inserting each fastening element 50 through a corresponding opening 51 in the front wall 38e of the battery bank 32b and through a corresponding opening 76 ( Fig. 6) the connecting element 58a of the rear wall 38f of the battery bank 32a is inserted. Additional battery banks 32 are arranged within the battery carrier 30 and are successively secured to each other and to the battery carrier 30 in a manner similar to the above-described procedure, until the desired number of battery banks 32 is arranged within the battery carrier 30.

[0037] Unless expressly stated otherwise in this document, all numerical values ​​indicating mechanical / thermal properties, percentages of compositions, dimensions and / or tolerances, or other parameters are to be understood as modified by the word "approximately" or "about" when describing the scope of this disclosure. This modification is desirable for various reasons, including industrial practice, material, manufacturing and assembly tolerances, and testability.

[0038] As used in this document, the phrase "at least one of A, B and C" should be interpreted as meaning a logical (A OR B OR C) using a non-exclusive logical OR, and should not be interpreted as meaning "at least one of A, at least one of B and at least one of C".

[0039] The description of the revelation is merely exemplary, and therefore variations that do not deviate from the core of the revelation should be considered within its scope. Such variations are not to be regarded as a deviation from the nature and scope of the revelation.

[0040] According to the present invention, a battery structure for an electric vehicle is provided, comprising: a battery carrier; a plurality of crossbeams secured to the battery carrier and spaced apart from one another along a longitudinal direction of the electric vehicle, each crossbeam extending in a transverse direction; and a plurality of battery banks arranged within the battery carrier, the plurality of battery banks comprising: a first battery bank comprising a plurality of first walls secured to one another to form a first modularized structure configured to accommodate first battery cells, a first wall of the plurality of first walls comprising a first vertical section and a flange section extending from the first vertical section;and a second battery bank adjacent to the first battery bank and comprising a plurality of second walls secured to one another to form a second modularized structure configured to accommodate second battery cells, wherein a second wall of the plurality of second walls is supported by a corresponding crossbeam of the plurality of crossbeams and includes a second vertical section, a third vertical section spaced apart from the second vertical section, and connecting elements connecting the second vertical section and the third vertical section, wherein the flanged section of one first wall is secured to one second wall.

[0041] According to one embodiment, the third vertical section of the second wall is spaced apart from the first vertical section of the first wall.

[0042] According to one embodiment, the flange section is located above the third vertical section of the second wall and above the connecting elements of the second wall.

[0043] According to one embodiment, the invention is further characterized by a plurality of fastening elements, each fastening element extending through the connecting elements and a corresponding cross member to secure a second wall to the battery carrier.

[0044] According to one embodiment, the invention is further characterized by a plurality of first fastening elements extending through the flange section of a first wall and through one of the connecting elements of a second wall to secure the first wall to the second wall.

[0045] According to one embodiment, the invention is further characterized by a plurality of second fastening elements, wherein each second fastening element extends through each of the connecting elements and a corresponding cross member to secure the second wall to the battery carrier.

[0046] According to one embodiment, the plurality of first fastening elements has a first length and the plurality of second fastening elements has a second length, wherein the second length is greater than the first length.

[0047] According to one embodiment, the flange section of a first wall borders the second vertical section of a second wall.

[0048] According to one embodiment, the invention is further characterized by a third battery bank which is adjacent to the first battery bank and is connected to another first wall of the first battery bank.

Claims

[1] Battery structure for an electric vehicle, wherein the battery structure comprises: a first battery bank comprising a plurality of first walls secured to one another to form a first modularized structure configured to accommodate first battery cells, wherein a first wall of the plurality of first walls extends in a transverse direction relative to a longitudinal direction of the electric vehicle; and a second battery bank adjacent to the first battery bank and comprising a plurality of second walls secured to one another to form a second modularized structure configured to accommodate second battery cells, wherein a second wall of the plurality of second walls is secured to the one first wall of the first battery bank and comprising a first vertical section, a second vertical section spaced apart from the first vertical section, and connecting elements connecting the first vertical section and the second vertical section. [2] Battery structure according to claim 1, wherein the first wall includes a third vertical section and a flange section extending from the third vertical section towards the second battery bank. [3] Battery structure according to claim 2, wherein the second vertical section of the second wall is spaced apart from the third vertical section of the first wall. [4] Battery structure according to claim 2, wherein the flange section is located above the second vertical section of the second wall and above the connecting elements of the second wall. [5] Battery structure according to claim 2, further comprising first fastening elements extending through the flange section of a first wall and through one of the connecting elements of a second wall to secure the first wall to the second wall. [6] Battery structure according to claim 5, further comprising: a battery carrier configured to accommodate the first battery bank and the second battery bank; and a plurality of second fastening elements, each second fastening element extending through the connecting elements and at least partially through a lower wall of the battery carrier to secure the second wall to the battery carrier. [7] Battery structure according to claim 6, wherein the first fastening elements have a first length and the plurality of second fastening elements have a second length, the second length being greater than the first length. [8] Battery structure according to claim 1, further comprising: a battery carrier configured to accommodate the first battery bank and the second battery bank; and a plurality of fastening elements, each fastening element extending through the connecting elements of the second wall and at least partially through a lower wall of the battery carrier to secure the second wall to the battery carrier. [9] Battery structure according to claim 1, further comprising a third battery bank adjacent to the first battery bank and connected to another first wall of the first battery bank. [10] Battery structure according to claim 1, wherein the height of the first vertical section of the second wall is greater than the height of the second vertical section of the second wall. [11] Battery structure according to claim 1, further comprising: a battery carrier configured to accommodate the first battery bank and the second battery bank; and a plurality of crossbeams secured to the battery carrier and spaced apart from each other along a longitudinal direction of the electric vehicle, with each crossbeam extending in a transverse direction. [12] Battery structure according to claim 11, further comprising a plurality of fastening elements, wherein each fastening element extends through the connecting elements and a corresponding cross member to secure a second wall to the battery carrier. [13] Battery structure according to claim 1, wherein a first wall of the plurality of first walls comprises a first vertical section and a flange section extending from the first vertical section, wherein the flange section of the first wall is secured to the second wall and wherein the flange section of the first wall adjoins the second vertical section of the second wall. [14] Method for assembling a battery structure for an electric vehicle, the method comprising: Arranging a first battery bank within a battery carrier, wherein the first battery bank comprises a first wall including a first vertical section, a second vertical section spaced apart from the first vertical section, and connecting elements connecting the first vertical section and the second vertical section; Securing the first battery bank to the battery holder; Arranging a second battery bank within the battery carrier after the first battery bank has been secured to the battery carrier, the second battery bank comprising a second wall which includes a vertical section and a flanged section extending from the vertical section; and Securing the second battery bank to the first battery bank. [15] Method according to claim 14, wherein securing the second battery bank to the first battery bank comprises inserting a plurality of fastening elements through the flange section of the second wall and through one of the connecting elements of the first wall.

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