Ford Global Technolgoies, LLC

Kimberley King

Saravanan Paramasivam

Rajaram Subramanian

Steve Droste

Dave Moschet

Mladen Marjanovic

John Paul Gibeau

Bhaskara Rao Boddakayala

Neil Robert Burrows

Daniel Miller

James Lawrence Swoish

Amar Marpu

Steve F Chorian

Patrick Daniel Maguire

Benjamin A Tabatowski-Bush

Daniel Paul Roberts

Hari Krishna Addanki

Aaron Walker

Jeffery R Grimes

Baojin Wang

Kanchana Perumalla

Evan Mascianica

LeeAnn Wang

Juil Yum

Sai K Perumalla

David J Pfeiffer

Brian Gillespey

Ai Keramidas

Samir Subba

Edward Popyk

David Moschet

Eric Yoo

Scott David Wojtkowicz

Jeffrey R Grimes

Andy Kummer

A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, an array of battery cells, and a thermal exchange plate assembly adjacent the array. The thermal exchange plate assembly includes an inlet, an outlet, a main channel, and a bypass channel configured to direct fluid from the inlet to the outlet while substantially bypassing the main channel.

Thermal exchange plate assembly for vehicle battery

A vehicle has a battery including a plurality of cells connected in series, and a battery management integrated circuit including a plurality of inputs each being directly electrically connected to a terminal of one of the cells via an electrical path that includes a fuse and a resistor connected in series. The battery management integrated circuit further includes a top input directly electrically connected to a positive output of the battery and configured to receive power from the battery that is defined by a current having a magnitude that is at least an order of magnitude greater than current received by the inputs and a voltage equal to a sum of voltages of all the cells. The battery management integrated circuit is configured to calculate a voltage difference between one of the inputs and an adjacent one of the inputs to determine a voltage of a top cell of the battery cells and to correct the voltage of the top cell to form a corrected voltage as a sum of the voltage of the top cell and a calculated voltage drop across the fuse in the electrical path between the top cell and the one of the inputs. The vehicle further has a controller programmed to balance the cells according to the corrected voltage of the top cell.

Automotive battery system control according to corrected top cell voltage

A battery pack includes a support structure, an array frame including a fastener housing, and a fastener received through the fastener housing for mounting the array frame to the support structure. The array frame may be mounted to the support structure using a top-down approach that includes inserting a fastener through a fastener housing of the array frame.

Battery pack array frames with integrated fastener housings

An exemplary support assembly for a battery array includes a spacer axially separating a first battery cell from a second battery cell, a frame that holds the spacer, and an insert secured to the frame. The insert is compressed against the first battery cell. An exemplary method of supporting a battery cell includes compressing an insert against a corner region of a battery cell. The insert is secured to a frame made of a first material. The insert is made of a second material that is softer than the first material.

Battery cell support assembly

An exemplary battery assembly includes, among other things, battery cells distributed along an axis and disposed on a base. A bracket extends axially along a side of the battery cells. A plate extends from a first side to an opposing, second side of the battery cells. A retention flange of the plate is held between the bracket and the base. An exemplary method of retaining includes holding battery cells relative to a base using a bracket extending along a side of the array, and positioning a retention flange of a plate between the bracket and the base. A primary portion of the plate is disposed along an axial end of the array.

Traction battery pack plate with retention flange

A battery pack includes a heat dissipating structure, an array frame positioned against the heat dissipating structure, and a battery cell retained by the array frame and arranged so at least one surface of the battery cell is exposed by the array frame and is contiguous with the heat dissipating structure. The heat dissipating structure may be a heat exchanger plate or a thermal interface material (TIM).

Battery pack array frame designs that exclude thermal fins

A battery pack includes a grouping of battery cells and a plurality of array frames for retaining the grouping of battery cells. Each of the plurality of array frames includes a ratchet feature. A column bolt includes a raised surface configured to mate with the ratchet feature of each of the plurality of array frames to secure the plurality of array frames together.

Battery pack array frame designs with ratcheting retention features

An exemplary battery assembly includes, among other things, a frame, and a thermal fin extending through an aperture in the frame. The thermal fin is configured to transfer thermal energy between a battery cell and a thermal exchange plate. An exemplary method of thermal energy transfer within a battery pack includes, among other things, transferring thermal energy between at least one battery cell and a thermal exchange plate using a thermal fin that extends through an aperture in a frame.

Battery thermal fin and method of thermal energy transfer using a thermal fin

An exemplary support assembly includes, among other things, a hoop bracket coupling a battery pack to a vehicle body structure, and a tuned bracket within an open area of the hoop bracket. The tuned bracket is configured to control a collapse of the hoop bracket in response to a load above a threshold level to reduce a transfer of the load to the battery pack. An exemplary supporting method includes coupling a battery pack to a vehicle body structure using a hoop bracket disposed alongside the battery pack. The hoop bracket includes an open area that receives a tuned bracket. The tuned bracket is configured to control a deformation of the hoop bracket in response to a load above a threshold level to reduce a transfer of the load to the battery pack.

Collapsible battery pack support assembly and supporting method

A battery pack includes a support structure, an array frame mounted relative to the support structure, and a thermal fin held within the array frame and grounded to the support structure. The thermal fin may include a grounding extension that is grounded to the support structure.

Battery pack array frames with grounded thermal fins

A battery assembly includes a grouping of battery cells and an array plate assembly contacting at least one cell of the grouping of battery cells. The array plate assembly including a spring plate adapted to exert a compressive spring force against the at least one cell. The compressive spring force may be based on a dimensional profile of the grouping of battery cells.

Array plate assemblies for applying compressive spring forces against battery cell stacks

A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, a housing, an array of battery cells provided within the housing, and a thermal exchange assembly adjacent the array and including an inlet, an outlet, and a tube configured to direct fluid from the inlet to the outlet. Further, the tube is overmolded with the housing. This disclosure also relates to a method of forming a battery assembly.

Thermal exchange assembly for vehicle battery

An example battery pack spacer includes a base and at least one rib extending laterally from the base. The rib is configured to turn flow of a coolant through a battery pack.

Electric vehicle battery pack spacer

A vehicle includes a body structure and a traction battery for providing power to a powertrain. The vehicle also includes a bracket connecting the traction battery to the body structure. The bracket defines a frangible element configured to substantially restrict movement of the traction battery and sever in response to force upon the battery greater than a first threshold. The bracket also defines an extensible portion adapted to unfurl after the frangible element is severed allowing tethered displacement of the traction battery.

Growing community of inventors

Northville, MI, United States of America

Kimberley King