Ford Global Technolgoies, LLC

Francisco Fernandez-Galindo

Daniel Paul Roberts

Nihar Kotak

Benjamin A Tabatowski-Bush

Liam West

Vedat Haydin

Dominic Mario Bertolini

Saravanan Paramasivam

John Paul Gibeau

Rajaram Subramanian

George Albert Garfinkel

Debbi Callicoat

Baojin Wang

Scott M Rollins

Masahiro Kimoto

Mladen Marjanovic

Abdul Lateef

Jason Luke Sielaff

Steven Droste

Rajesh Narayanan

Kimberley L C King

Aqil Hamid

John Hammack McCormick

David Doman

A traction battery assembly includes, among other things, an array sense lead header of a battery array, a plurality of sense leads extending from the array sense lead header to areas of the battery array, and a battery pack module having a module connector. The battery pack module is configured to move relative to the battery array from a disengaged position where the module connector the array sense lead header are disengaged to an engaged position where the module connector and the array sense lead header are engaged.

Traction battery assembly having battery pack module and sense lead header and connecting method

A battery pack sensing module includes a rigid printed circuit board that is to be carried by and bridge between a pair of battery cell arrays, a plurality of integrated circuits mounted on the rigid printed circuit board, and a pair of sense lead connectors at opposite ends of the rigid printed circuit board. Each of the sense lead connectors is electrically connected with at least one of the integrated circuits and can mate with a receiving connector of one of the battery cell arrays to establish an electrical connection between the receiving connector and the at least one of the integrated circuits.

Bridged battery pack sensing module for multiple arrays

A structural assembly for a battery structure of a vehicle includes a lower wall and a pair of cross members. The lower wall is configured to support a cell stack. The pair of cross members are spaced apart from each other in a longitudinal direction of the vehicle. Each cross member provides lateral support for a respective side of the cell stack and is configured to extend substantially an entire width of a battery enclosure. Each cross member of the pair of cross members includes an outer wall, an inner wall spaced apart from the outer wall, and connecting members. The outer wall, the inner wall, and connecting members cooperate with each other to define an internal cavity. The inner walls of the pair of cross members are secured to the lower wall and slidable relative to the outer walls of the pair of cross members.

Structural assembly for battery structure of electric vehicle

A traction battery assembly includes battery cells of a battery array, and switches of the battery array. The switches are transitionable between a first configuration and a second configuration. When the switches are in the first configuration, the battery cells of the array are partitioned into a first number of groups of battery cells in parallel with each other. When the switches are in the second configuration, the battery cells of the array are partitioned into a different, second number of groups of battery cells in parallel with each other.

Traction battery assembly having battery array that is reconfigurable to have different numbers of battery cells in parallel with each other

A traction battery assembly includes, among other things, a cover of a battery array, a holder attached to the cover, and a circuit board held by the holder in a position where the circuit board is spaced from the cover. The holder is configured to communicate thermal energy between the circuit board and the cover. A method of securing a circuit board of a traction battery pack includes, among other things, holding a circuit board with a holder, and attaching a holder that is holding the circuit board to a cover of a battery array. The circuit board held by the holder is held in a position where the circuit board is spaced from the cover.

Battery pack circuit board holder

A traction battery assembly according to an exemplary aspect of the present disclosure includes a lower tier of battery arrays, an upper tier of battery arrays, and a support structure disposed between the lower tier and the upper tier. The lower tier is suspended from a downwardly facing side of the support structure. The upper tier is disposed atop an upwardly facing side of the support structure.

Multi-tier traction battery array support structure

A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, an array of battery cells, with each cell including a terminal, and a busbar assembly having a first busbar component and a second busbar component. Further, each of the terminals are electrically coupled to both the first busbar component and the second busbar component. A method of forming a busbar assembly is also disclosed.

Busbar assembly for an electrified vehicle and method of forming the same

A traction battery assembly includes, among other things, a battery cell array having a plurality of individual battery cells. The battery cell array usable with a first busbar module having a first arrangement of busbars. The battery cell array is also usable with a second busbar module having a second arrangement of busbars. When the battery cell array is used with the first busbar module, the battery cell array is partitioned into a first number of groups of battery cells in parallel with each other. When the battery cell array is used with the second busbar module, the battery cell array is partitioned into a different, second number of groups of battery cells in parallel with each other.

Traction battery having a battery cell array usable with different busbar modules and method of assembling such a traction battery

This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a sense lead assembly having a circuit board that is centrally mounted between first and second wiring members (e.g., flat flexibles cables or flat printed circuits). The circuit board establishes a suitable mounting surface for incorporating sense lead fuses into the sense lead assembly. The centralized sense lead fuses provide for simple and reliable servicing of the battery array in response to battery overcurrent conditions.

Systems and methods for providing individual battery cell circuit protection

A vehicle assembly includes, among other things, a battery array, and an identifier that is associated with the battery array. The identifier is readable by a control module of an electrified vehicle when the battery array is in an installed position within the electrified vehicle.

Electrified vehicle traction battery component identification assembly and identification method

A battery interconnect assembly includes, among other things, at least one first sense lead operably coupled to a structure on a first side of an array of battery cells, and at least one second sense lead operably coupled to a structure on a different, second side of the array. The assembly further includes a multi-port connector configured to communicate signals from both the at least one first sense lead and the at least one second sense lead. A battery monitoring method includes, among other things, communicating signals from a plurality of sense leads through a multi-port connector. At least one of the sense leads is operably connected to a first structure on a first side of a battery array, and least one of the sense leads is operably connected to a second structure on a different, second side of the battery array.

Battery interconnect assembly and method

A covering assembly for a traction battery includes, among other things, a busbar cover that covers a busbar of a battery array, and a terminal cover connected to the busbar cover and moveable back and forth between a closed position and an open position. The terminal cover and cover at least one terminal of the battery array when in the closed position.

Battery terminal covering assembly and terminal covering method

This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery arrays that may be incorporated into electrified vehicle battery packs may include a grouping of battery cells and a circuit connector module configured for electrically connecting the grouping of battery cells. The circuit connector module may include a first bus bar made of a single material and a second bus bar that is fusible and made of at least two dissimilar materials.

Fusible bimetallic bus bars for battery arrays

An exemplary array activating assembly includes, among other things a disconnect key moveable back and forth between an engaged and a disengaged position relative to a battery array. The disconnect key completes an electrical conductive path of the battery array when in the engaged position. The electrical conductive path is open when the disconnect key is in the disengaged position. An exemplary array activating method includes moving a disconnect key relative to a battery array from a disengaged to an engaged position. The disconnect key completes an electrical conductive path of the battery array when in the engaged position. The disconnect key does not complete the electrical conductive path when in the disengaged position.

Growing community of inventors

Canton, MI, United States of America

Francisco Fernandez-Galindo