Ford Global Technolgoies, LLC

Ford Motor Company Limited

Rajaram Subramanian

Saravanan Paramasivam

Steve Droste

Kimberley King

Dave Moschet

Bhaskara Rao Boddakayala

Stuart Schreiber

Tom M Gunther

John Jardine

Mladen Marjanovic

Tommy M Gunther

Patrick Daniel Maguire

Suriyaprakash Ayyangar Janarthanam

Kanchana Perumalla

Rohit Gunna

Sai K Perumalla

Keith Kearney

Shamsuddin A Syed

Edward Popyk

Brian Utley

James Maurice Boileau

Yongcai Wang

Francisco Fernandez

Yunan Guo

David J Pfeiffer

Daniel Miller

Hyung Min Baek

Ihab Grace

Amar Marpu

Juil Yum

Steve F Chorian

Adam Denlinger

Steven Droste

Ronald D Gilland

Thomas M Gunther

Hari Krishna Addanki

Francisco Fernandez-Galindo

Jason C Marcath

Micah Smith

Mike Popovski

LeeAnn Wang

Brandon Michael Dawson

Anil Reddy Pullalarevu

Samir Subba

James M McManaman

Michael Peter Mongeau

Pax Daniel Maguire

David Moschet

Eric Yoo

Sean Brady

Enrique Rivera

John Marshall

Kimberley L C King

Andrew Elms

Charles Moore

Mallikarjun Veeramurthy

Battery pack designs are provided for use in electrified vehicles. Exemplary battery packs may include a battery array that includes one or more interconnected array frames. A split thermal fin may be held within the one or more array frames. The proposed designs of the split thermal fin enable a reduction of the amount of thermal interface material required between the thermal fin and a support structure (e.g., a heat exchanger plate) of the battery pack.

Battery array frames with split thermal fin designs for reducing thermal interface material usage

Electrified vehicles may be powered by traction battery packs. An exemplary traction battery pack may include an enclosure assembly having a tray and a cover. One or more hinged locking plate assemblies may be utilized to secure the cover to the tray of the enclosure assembly. The hinged locking plate assemblies may be configured to exert a clamping or compression force across an interface between the cover and the tray, thereby enhancing retention and providing a leak-proof joint.

Attachment concepts for traction battery pack enclosure assemblies

This disclosure details battery assemblies for use within electrified vehicle battery packs. An exemplary battery assembly includes a grouping of battery cells and an array plate assembly contacting a portion of the battery assembly. The array plate assembly may embody a split panel design that includes an outer panel and an inner panel that are arranged to nest together. One or both of the outer panel and the inner panel may include an embossing pattern. Among various other advantages, the split panel design increases the stiffness of the array plate assembly without significantly increasing the overall package depth of the array plate assembly or the battery assembly.

Split panel array plate assemblies for electrified vehicle battery packs

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

This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a battery array that includes one or more interconnected array frames. A split thermal fin may be held within the one or more array frames. The proposed designs of the split thermal fin enable a reduction of the amount of thermal interface material required between the thermal fin and a support structure (e.g., a heat exchanger plate) of the battery pack.

A battery assembly includes, among other things, an enclosure having a floor, and battery cell frames disposed along an axis within the enclosure. Each of the battery cell frames includes a frame foot that projects laterally outward. An endplate is at an axial end of the battery cell frames. The endplate includes an endplate retention flange that projects laterally outward to laterally overlap with a portion of the retention member. A retention member extends axially alongside the battery cell frames. The retention member includes a lip that projects laterally inward across the frame feet such that the frame feet are held between the lip and the floor. An axial end portion of the retention member is secured directly to the endplate retention flange.

Lipped retention member for retaining a battery array and retention method using lipped retention member

An electrified vehicle assembly includes, among other things, a traction battery, and at least one shield extending longitudinally and having a portion that is vertically beneath the traction battery. The shield is removably fastened directly to the traction battery.

Traction battery protection assembly and method

A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.

Busbar assembly for vehicle traction battery

An exemplary method of securing a battery array includes attaching a twist-lock to a case, and securing a battery array to the case by rotating the twist-lock from a first position to a second position. Another exemplary method of securing a battery array includes securing a twist-lock to a case, and rotating the twist-lock from a first position to a second position where a portion of a battery array is clamped between the twist-lock and the case.

Twist-lock battery pack attachment device

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

A fastener assembly includes a stud and a nut. The stud has a proximal end and a distal end with a body therebetween. The stud also has a central axis extending from the proximal end to the distal end. The proximal end has a flange for coupling to a surface. The body has a cavity opening to an orifice at the distal end. The nut is retained within the cavity. Rotation of the nut about the central axis is inhibited.

Locator fastener with bolt mis-alignment feature

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

A battery module according to an exemplary aspect of the present disclosure includes, among other things, an array of battery cells, a compression structure including a first wall and a second wall, at least one conduit configured to convey fluid adjacent the array, and a tension member connected to the first wall and the second wall. The tension member is adjacent the at least one conduit. This disclosure also relates to an electrified vehicle and a method.

Battery module with tension member resisting deflection

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 array frame may include a frame body extending along a longitudinal axis and including a top frame rail, a bottom frame rail, and frame arms that connect between the top frame rail and the bottom frame rail. An insert extends inside the frame body for increasing the stiffness of the frame body.

Battery array frame including frame rail insert

Growing community of inventors

Ann Arbor, MI, United States of America

Rajaram Subramanian