Ford Global Technolgoies, LLC

Eid Farha

Hari Krishna Addanki

Jesus Cardoso

Temam Kedir

Patrick Daniel Maguire

Michael E Reibling

Kevin A Montgomery

Jeffrey A Walesch

Jeffrey Matthew Haag

Mikolaj Tyksinski

Jeffrey Ronald Bohmer

Erik Billimoria

Marcela Arana

Brent Zapczynski

Scott Benedict

Alexander Arena

Mohamed Ridha Baccouche

James Chih Cheng

Mohannad Hakeem

Rahul Arora

Michael William Danyo

Dave Moschet

Masahiro Kimoto

Jingmei Shen

John Sturza

Keith Kearney

Abdul Lateef

Chung-hsing Kuo

James M McManaman

Sukhwinder Singh Dhindsa

Lucas Amber

Rajesh Narayanan

Himanshu Khandelwal

Jeffery Christ

Rohan Gupta

This disclosure details systems and methods for supporting and isolating vehicle body mounted battery packs from various vehicle loads. An exemplary electrified vehicle may include a frame, a battery support structure mounted to the frame, a battery pack, and one or more isolators. The battery pack is supported by the battery support structure but is not mechanically coupled to the frame. The isolator is mounted between the battery pack and the battery pack support structure for isolating the battery pack from loads that may be imparted on the frame and/or the battery support structure.

High voltage battery pack support and isolation for electrified vehicles

A battery pack assembly includes, among other things, a first battery component, a different, second battery component and an enclosure that has a cover secured to a tray to provide an interior. The first and second battery components are disposed within the interior. The cover has a first area that is disposed directly above the first battery component. The cover has a second area that is disposed directly above the second battery component. The battery pack assembly further includes a rib of the cover. The rib extends into the interior from the first area. The rib is configured to contact the first battery component to inhibit relative movement of the second area toward the second battery component.

Traction battery enclosure and load directing method

This disclosure details assemblies for mounting and supporting components within battery packs. Exemplary battery packs may include a first battery array, a second battery array positioned adjacent to the first battery array, a crossmember positioned between the first battery array and the second battery array, and a support bracket connected to the crossmember. Together, the crossmember and the support bracket established an assembly. Both the first battery array and the second battery array may be secured to the crossmember, and the support bracket may support a second tier structure above at least one of the first battery array or the second battery array.

Assemblies for supporting battery arrays and other components within battery packs

This disclosure relates to a battery assembly with a plate having a compression limiting feature, and a corresponding electrified vehicle and method. An example battery assembly includes a wall having an inner surface and an outer surface. The wall also has a central opening. The battery assembly further includes a plate abutting the outer surface of the wall and covering the central opening. The plate also includes a main body and a post projecting from the main body toward the inner surface of the wall. Among other benefits, this arrangement limits compression of the wall and increases the ease of mounting components, such as electrical or fluid connectors, to the battery assembly.

Battery assembly with plate having compression limiting feature

An exemplary battery assembly includes an endwall, an endplate, and a flange secured within a recess to secure the endwall relative to the endplate. One of the endwall or the endplate provides the flange, and the other of the endwall or the endplate provides the recess.

Battery pack array retention

A battery pack according to an exemplary aspect of the present disclosure includes, among other things, an enclosure and a battery assembly retained relative to the enclosure. One of the battery assembly and the enclosure includes a groove configured to receive a flange of the other of the battery assembly and the enclosure as the battery assembly is slid into engagement with the enclosure.

Battery pack with slide-in battery assembly

An exemplary support assembly includes a first housing that supports a first battery structure, a second housing that supports a second battery structure, a cover, and a common attachment that secures together the first housing, the second housing, and the cover. An exemplary support method includes securing together a first housing, a second housing, and a cover with a common attachment. The first housing supports a first battery structure that is enclosed by the second housing. The second housing supports a second battery structure that is enclosed by the cover.

Traction battery support assembly and method

An exemplary busbar forming method includes, among other things, creasing a sheet of material to form a plurality of creases that partition the sheet into a plurality of segments. The method further includes identifying a desired size for a terminal receiving recess in a busbar. In response to the desired size, the method folds at least some of the segments relative to each other about at least some of the creases according to a first process, or a different, second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that partition at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other about at least some of the creases to provide the terminal receiving recess in the busbar.

Busbar forming method and folded busbar

An exemplary battery pack assembly includes an endplate with a first side region and a second side region opposite the first side region, a first connector in the first side region, and a second connector in the second side region. The first and second connectors each provide a connection point to secure the endplate to a support when a respective one of the first or second side regions is positioned proximate the support.

Battery pack endplate

An exemplary battery assembly includes an endplate of a battery array, and an enclosure wall secured directly to the endplate from outside an open area of a battery pack enclosure. An exemplary method of securing a battery array includes positioning a battery array within an open area of an enclosure and, from a position outside the open area, securing an endplate of a battery array directly to a wall of a battery pack enclosure.

A traction battery assembly includes a tray and a pair of adjacent cell arrays disposed on the tray. Each array includes a plurality of stacked cells and a plurality of cell spacers interleaved with the cells. A portion of each of the spacers of one of the arrays is inserted into one of the spacers of the other of the arrays to form a plurality of end-to-end connected spacer pairs configured to secure the arrays together.

Battery assembly with snap-in arrays

A battery pack according to an exemplary aspect of the present disclosure includes, among other things, an electronics module and an electronics umbrella positioned to channel moisture away from the electronics module.

Electronics umbrella for electrified vehicle battery packs

An exemplary method includes, among other things, winding a curable material at least partially about a plurality of battery cells that are compressed by a fixture. An exemplary assembly includes, among other things, a plurality of battery cells compressed by a fixture, and a curable material wound around the plurality of battery cells.

Battery cell compression method and assembly

A battery array according to an exemplary aspect of the present disclosure includes, among other things, a circuit connector assembly and a cover that partially covers the circuit connector assembly. The cover includes a groove. A sense-line wire is received within the groove.

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Ann Arbor, MI, United States of America

Eid Farha