Ford Global Technolgoies, LLC

Debbi Callicoat

Brian Utley

Saravanan Paramasivam

Derek Hartl

Steve Droste

John Peter Bilezikjian

Patrick Daniel Maguire

Philip Michael Gonzales

Hari Krishna Addanki

Masahiro Kimoto

Yunan Guo

Steven F Chorian

Steve F Chorian

Steven Droste

Benjamin A Tabatowski-Bush

Suriyaprakash Ayyangar Janarthanam

Mark J Ferrel

Venkateswa Anand Sankaran

Francisco Fernandez-Galindo

Raymond C Siciak

Jason C Marcath

Francisco Fernandez

Yongcai Wang

Matthew Roger Dedona

Robert Bolduc

Keith Kearney

Ben A Tabatowski-Bush

David James Chesney

Vedat Haydin

Vineeth Seshadri Kallur

Temam Kedir

Rajesh Narayanan

David Wardzala

An example electric vehicle battery current communication device includes a terminal landing and a transition from the terminal landing having an area that is both bent and tapered. The transition can bend toward an interior of a battery cell such that a portion of the transition is closer to the interior than each portion of the terminal landing. The terminal landing can attach to a bus bar. The terminal landing can also weld to a bus bar. The transition can extend from the terminal landing to a current collector extending into an interior of the battery cell.

Electric vehicle battery current communication device

An exemplary electrified vehicle busbar assembly includes a housing, a clamping beam held by the housing, and a plurality of busbars held by the housing.

Electrified vehicle busbar assembly

A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a terminal holder, a terminal at least partially surrounded by the terminal holder, and a bus bar module connectable to the terminal holder. One of the terminal holder and the bus bar module includes at least one locating feature to position the bus bar module in a welding position relative to the terminal.

Bus bar locating feature and method

A vehicle power system may include a battery array having at least one battery with a bus bar connected to an electrical bus. The power system may also include a conductive lead of a sensor welded to the bus bar to form a joint defined by a plurality of stitches, a net cross-sectional area of the plurality being less than a cross-sectional area of the lead such that short-circuit current from the battery array melts the joint to protect the sensor.

Sensor fuse for an electric battery array

A voltage sensing system for a vehicle traction battery having a plurality of cells includes: a battery controller, a plurality of electrical circuits, each being respectively connected to at least one of the cells and including an electrical component for limiting current therethrough, and a plurality of wires, each being respectively connected to one of the electrical circuits in series with a respective one of the electrical components for limiting current and the controller.

Voltage sensing system and method

A vehicle including an array of pouch battery cells, a pair of carriers, and a plurality of busbars is provided. The array of pouch battery cells may each have terminal tabs of opposite polarity extending from opposing cell faces. The pair of carriers may extend along the cell faces and each may define a plurality of apertures sized to receive the terminal tabs. The plurality of busbars may be arranged with the carriers and terminal tabs such that an electrical connection across the cells includes parallel and series connections. The pouch battery cells may be arranged in clusters of adjacent cells connected in parallel, and the busbars may be arranged in spaced apart groups on each of the carriers and joined to adjacent terminal tabs to connect the clusters in series.

Traction battery busbar carriers for pouch battery cells

A vehicle includes a traction battery having a plurality of battery cells positioned in an array with a non-conductive bus bar housing having a plurality of compartments insulated from one another and containing one or more bus bars each having an integrally formed voltage sense connector. Each compartment may accommodate terminals of a pair of adjacent battery cells to be coupled by the associated bus bar. The voltage sense connector may include fingers for crimping and securing a voltage sense wire or a welding pad for welding, soldering, or similar connection. The voltage sense wires connect to a battery control module.

Integrated voltage sense and bus bar system and method for vehicles having a traction battery

A battery system includes a battery cover, a battery access panel removably connected to the battery cover, and a service disconnect switch. The service disconnect switch includes an electrical interlock switch. The service disconnect switch has a first position cooperating with the battery access panel to prevent removal of the access panel from the battery cover. In the first position, the service disconnect connects a traction battery to circuitry. The service disconnect also has a second position, the second position being displaced from the access panel and disconnecting the battery.

Hybrid electric vehicle battery cover with electrical disconnect

An example method of connecting an electric vehicle battery includes welding a landing of a terminal to a bus bar, and pressing a landing of the terminal and the bus bar against one another during the welding. The landing is along a first plane and a base of the terminal is along a second plane that is spaced from the first plane.

Electric vehicle battery attachment assembly and method

A traction battery assembly is provided including a support member, two battery cells, a busbar, and a segmented busbar holder. The battery cells include adjacent terminals at differing heights relative to the support member. The busbar is attached to the terminals. The segmented busbar holder includes adjacent panels configured to cover and orient the busbar relative to the terminals. The panels are also configured to move relative to one another such that the holder accommodates the differing heights of the terminals.

Flexible busbar holder for welded cells

A self-locating bus bar assembly for locating a bus bar on a cell terminal of a battery cell includes a bus bar locating tab adapted for attachment to the bus bar; an assembly bracket; a tab opening in the assembly bracket, the tab opening sized and configured to accommodate the bus bar locating tab; and a bracket terminal opening in the assembly bracket, the bracket terminal opening sized, configured and located to accommodate the cell terminal of the battery cell when the bus bar locating tab is disposed within the tab opening.

Self-locating busbar assembly and alignment method

A bus bar assembly includes a deformable bus bar including a bus bar positive terminal flange, a bus bar negative terminal flange spaced-apart from the bus bar positive terminal flange and a flange connecting portion connecting the bus bar positive terminal flange and the bus bar negative terminal flange. A deformable bus bar frame includes a bus bar frame positive terminal flange carried by the bus bar positive terminal flange of the deformable bus bar and a bus bar frame negative terminal flange carried by the bus bar negative terminal flange of the deformable bus bar. A method of installing a deformable bus bar on positive and negative terminals of a battery cell is also disclosed.

Deformable busbar assembly and bus bar installation method

A low cost charger circuit with pre-charge functionality can include a DC/DC converter arranged in parallel with a charger device. When used for electrified vehicle applications, the DC/DC converter can be configured to operate during vehicle propulsion, restorable energy storage system (RESS) recharging, and while only the DC/DC converter needs to be energized. A DC/DC converter can be coupled to a first high voltage bus on a load side of a primary contactor, and to a second high voltage bus on an energy side of a primary contactor. A pre-charge circuit can controllably charge a voltage bus and protect a DC/DC converter against high inrush current. An auxiliary contactor can controllably couple a DC/DC converter to a load portion of a high voltage bus. It can also couple a charger thereto. A charger contactor can controllably couple a charger device to an energy portion of a high voltage bus.

Low cost charger circuit with precharge

An example contactor weld detection method for an electric vehicle includes detecting that a contactor is welded closed when the contactor is commanded closed.

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Livonia, MI, United States of America

Debbi Callicoat