BATTERY SYSTEM HOUSING WITH BONDED RIB FIXATION
A battery pack for an electric vehicle is disclosed. The battery pack includes an upper tray, a first busbar attached to the upper tray, a lower tray, and a second busbar attached to the lower tray. The battery pack also includes a plurality of battery cells arranged in the upper and lower trays, and a reinforcement rib mechanically connecting the lower tray to the upper tray.
1 . A battery pack for an electric vehicle, the battery pack comprising:
an upper tray;
a first busbar attached to the upper tray;
a lower tray;
a second busbar attached to the lower tray;
a plurality of battery cells arranged in the upper and lower trays; and
a reinforcement rib mechanically connecting the lower tray to the upper tray, wherein the reinforcement rib extends from the lower tray to the upper tray between adjacent battery cells,
wherein a first pair of adjacent battery cells have the reinforcement rib therebetween, and wherein a second pair of adjacent battery cells do not have a reinforcement rib therebetween.
2 . The battery pack of claim 1 , wherein the reinforcement rib is configured to transfer a vertical force between the upper and lower trays.
3 . The battery pack of claim 2 , wherein while the reinforcement rib transfers the vertical force between the upper and lower trays, the battery cells transfer substantially no force between the upper and lower trays.
4 . The battery pack of claim 1 , wherein the reinforcement rib is at least partly integrated with the lower tray.
5 . The battery pack of claim 1 , wherein the reinforcement rib is at least partly integrated with the upper tray.
6 . The battery pack of claim 1 , wherein the reinforcement rib is separate from the upper and lower trays.
7 . The battery pack of claim 1 , wherein the reinforcement rib extends into a hole through at least one of the upper and lower trays.
8 . A method of manufacturing a battery pack for an electric vehicle, the method comprising:
attaching a busbar to an upper tray;
attaching first sides of a plurality of battery cells to the upper tray;
attaching a busbar to a lower tray;
attaching second sides of the battery cells to the lower tray; and
connecting the lower tray and the upper tray with a reinforcement rib, wherein the reinforcement rib extends from the lower tray to the upper tray between adjacent battery cells,
wherein a first pair of adjacent battery cells have the reinforcement rib therebetween, and wherein a second pair of adjacent battery cells do not have a reinforcement rib therebetween.
9 . The method of claim 8 , wherein the reinforcement rib is configured to transfer a vertical force between the upper and lower trays.
10 . The method of claim 9 , wherein while the reinforcement rib transfers the vertical force between the upper and lower trays, the battery cells transfer substantially no force between the upper and lower trays.
11 . The method of claim 8 , wherein the reinforcement rib is at least partly integrated with the lower tray.
12 . The method of claim 8 , wherein the reinforcement rib is at least partly integrated with the upper tray.
13 . The method of claim 8 , wherein the reinforcement rib is separate from the upper and lower trays.
14 . The method of claim 8 , wherein the reinforcement rib extends into a hole through at least one of the upper and lower trays.
15 . An electric vehicle powered by a battery pack, the battery pack comprising:
an upper tray;
a first busbar attached to the upper tray;
a lower tray;
a second busbar attached to the lower tray;
a plurality of battery cells arranged in the upper and lower trays; and
a reinforcement rib mechanically connecting the lower tray to the upper tray, wherein the reinforcement rib extends from the lower tray to the upper tray between adjacent battery cells,
wherein a first pair of adjacent battery cells have the reinforcement rib therebetween, and wherein a second pair of adjacent battery cells do not have a reinforcement rib therebetween.
16 . The electric vehicle of claim 15 , wherein the reinforcement rib is configured to transfer a vertical force between the upper and lower trays.
17 . The electric vehicle of claim 16 , wherein while the reinforcement rib transfers the vertical force between the upper and lower trays, the battery cells transfer substantially no force between the upper and lower trays.
18 . The electric vehicle of claim 15 , wherein the reinforcement rib is at least partly integrated with the lower tray.
19 . The electric vehicle of claim 15 , wherein the reinforcement rib is at least partly integrated with the upper tray.
20 . The electric vehicle of claim 15 , wherein the reinforcement rib is separate from the upper and lower trays.
21 . The electric vehicle of claim 15 , wherein the reinforcement rib extends into a hole through at least one of the upper and lower trays.