Ford Global Technolgoies, LLC

Liam West

Kevin Mackenzie

Jonathan Barker

Francisco Fernandez-Galindo

Dominic Mario Bertolini

Patrick Daniel Maguire

Daniel Paul Roberts

Scott M Rollins

Mohammadreza Eftekhari

Kanchana Perumalla

Jason Luke Sielaff

Samir Subba

Wen Dai

Gregory Dean Ognjanovski

Justin Eugene Negrete

Nathan Lee

John Hammack McCormick

David Doman

This disclosure relates generally to battery packs for electrified vehicles, and in particular relates to a volume filler for immersion cooled battery arrays. In some aspects, the techniques described herein relate to a battery pack, including: an enclosure assembly defining a volume; a battery array within the volume, wherein the battery array includes a plurality of battery cells; and a volume filler within the volume, wherein the volume filler is disposed on a side of the battery array.

Volume filler for immersion cooling battery array designs

Battery arrays may be housed within electrified vehicle battery packs. An exemplary battery array may include an array support structure that includes a roll bonded cold plate. The roll bonded cold plate may be integrated into the battery array, as opposed to an outer enclosure assembly of the traction battery pack, and is thus arranged to directly thermally manage one or more battery cells of the battery array. The roll bonded cold plate may be configured to establish a single side or multiple sides of the array support structure.

Battery array designs with integrated roll bonded cold plates

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

This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a polymer-based enclosure assembly having features for thermally managing internal components of the battery pack. In some embodiments, the enclosure assembly may include molded-in fluid channels or molded-in tubing for establishing a cooling circuit of the battery pack. In other embodiments, the enclosure assembly may include molded-in channels that receive tubing for establishing a cooling circuit of the battery pack.

Polymer-based battery pack enclosure assemblies with integrated thermal management features

This disclosure describes electric vehicle supply equipment (EVSE) connectors for synchronizing and controlling charging between multiple electric vehicle supply equipment and an electrified vehicle. An exemplary EVSE connector is connectable to a charge port assembly of an electrified vehicle and includes a first port configured to receive a first charger coupler of a first EVSE and a second port configured to receive a second charger coupler of a second EVSE. The EVSE connector further includes a control system for coordinating charging operations between the first and second EVSE and the electrified vehicle.

Electric vehicle supply equipment synchronization and charging connector devices

An electrified vehicle includes a traction battery and a battery thermal control system. A controller is configured to receive an initial regenerative braking capability and operation the battery thermal control system to precondition the traction battery during a charge event to a temperature that corresponds to the initial regenerative braking capability such that, during a subsequent drive cycle, the regenerative braking capability is at least equal to the initial regenerative braking capability for at least a predetermined duration into the subsequent drive cycle.

System and method for battery preconditioning based on selected regenerative braking amount

A power converter for an electric vehicle include a connection interface for coupling an external battery to a first bus. The power converter includes a first set of switching devices configured to transfer power between a charge port and the first bus, and a second set of switching devices configured to transfer power between the first bus and a second bus coupled to a traction battery. The power converter includes a controller programmed to control a voltage level of the first bus to different nominal operating voltages based in different operating modes.

All electric range extender electrical topology for a battery electric vehicle

A system for a vehicle includes a bidirectional power converter, a vehicle controller configured to, in response to a pilot signal indicating a connection to a charging station, cause the converter to initiate power flow from the station to the vehicle, and an electric vehicle supply equipment (EVSE) controller configured to, in response to detecting a connection to another vehicle, generate the pilot signal to cause the converter to generate power to transfer to the another vehicle.

Growing community of inventors

Southfield, MI, United States of America

Liam West