Ford Global Technolgoies, LLC

Che-Chun Chang

Patrick Daniel Maguire

Marc Dugas

Mohammadreza Eftekhari

Jason C Marcath

Yongcai Wang

LeeAnn Wang

Chung-hsing Kuo

Nilesh Patil

Karen Siler

A battery pack assembly method includes compressing at least one cell stack, inserting the at least one cell stack into a cell-receiving opening of an enclosure structure, and pushing at least one cell of the at least one cell stack out of the enclosure structure using a pusher. Another traction battery pack assembly method includes moving a cell stack into an enclosure structure from a compression fixture that compresses the cell stack. The cell stack includes a plurality of battery cells. After the moving, the method compresses the cell stack using the enclosure structure. The method then includes establishing electrical connections between the battery cells of the cell stack, and testing the electrical connections prior to securing a busbar to the cell stack.

Traction battery pack assembling method

Traction battery packs are disclosed that include cell-to-pack battery systems. A cell stack/cell matrix of the cell-to-pack battery system may be positioned within an irregularly shaped enclosure tray of the traction battery pack. A block insert may be positioned at an interface between the cell stack/cell matrix and an irregularly shaped interior surface of the enclosure tray. The block insert may be configured to facilitate insertion of the cell stack/cell matrix into the enclosure tray, transfer compression loads from the enclosure tray walls to the cell stack/cell matrix, resist battery cell compression loads, etc.

Traction battery packs with cell-to-pack battery systems housed within irregularly shaped enclosures

Manufacturing processes are disclosed for assembling traction battery packs that include battery systems, such as cell-to-pack battery systems. An exemplary assembly method includes inserting one or more cell stacks of the cell-to-pack battery system into a cell-compressing opening of an enclosure tray. The method may involve the use of slider plates that provide sliding surfaces that facilitate the insertion of the cell stacks into the cell compressing opening.

Methods for assembling traction battery packs

A traction battery pack venting system includes a plurality of battery arrays within a traction battery pack. The battery arrays each have a plurality of individual battery cells. The system further includes a divider system that provides a plurality of vented gas receiving compartments. Each of the vented gas receiving compartments are separate and distinct from the other vented gas receiving compartments within the plurality of vented gas receiving compartments. Each of the vented gas receiving compartments are associated with one of the battery arrays. Each of the vented gas receiving compartments can be associated with a manifold. The vent gas produced from thermal runaway can be discharged to the vented gas receiving compartments, directed to a manifold, and discharge to the external atmosphere.

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Ann Arbor, MI, United States of America

Che-Chun Chang