Ford Global Technolgoies, LLC

Samir Subba

Saravanan Paramasivam

Michael E Reibling

Patrick Daniel Maguire

Rajaram Subramanian

Daniel Paul Roberts

Steve Droste

Hari Krishna Addanki

Kimberley King

Dave Moschet

Kevin A Montgomery

Liam West

Brock Dunlap

Brent Zapczynski

Edward Popyk

Matthew Erich Von Der Lippe

Justin Eugene Negrete

Ali Saad

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 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

An exemplary method includes, among other things, providing first and second blanks that are nominally identical and that include an array of raised features. The method further includes removing a first combination of individual raised features from the first blank to provide a first battery component with a first flow path, and removing a different, second combination of individual raised features from the second blank to provide a second battery component with a different, second flow path. An exemplary battery assembly includes, among other things, a blank having a plurality of ribs extending from a floor. The blank is configured such that a first combination of the ribs are removable from the blank to provide a first battery component having first flow path, and a different, second combination of the ribs are removable from the blank to provide a second battery component having a different, second flow path.

Battery component with a flow path

An exemplary battery assembly includes first and second pieces of an enclosure, a flange of the first piece, and a clamping device compressing together the flange and a portion of the second piece to seal an interface. The clamping device has an interior area that receives the flange such that the clamping device extends continuously from a first side, about an outer edge, to an opposite, second side of the flange. An exemplary battery enclosure securing method includes receiving a flange of a first enclosure piece within an open area of a clamping device while the clamping device compresses together the flange and a portion of a second enclosure piece. The clamping device extends continuously from a first side of the flange, about an outer edge of the flange, to an opposite, second side of the flange when the flange is received within the open area.

Traction battery enclosure clamping device and securing method

An exemplary battery thermal transfer assembly includes a thermal interface material having a first side with a plurality of protrusions compressed against a plurality of battery cells, and an opposing, second side interfacing with a thermal exchange plate. Another exemplary battery thermal transfer assembly includes a thermal interface material sheet having a first side with a plurality of protrusions compressed against a plurality of battery cells, and an opposing, second side interfacing with a thermal exchange plate.

Battery thermal energy transfer assembly and method

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Dearborn, MI, United States of America

Samir Subba