Ford Global Technolgoies, LLC

Shamsuddin A Syed

Ihab Grace

Rajaram Subramanian

James Maurice Boileau

David J Pfeiffer

Dave Moschet

Afif Sabbagh

Mumtaz Hussain

Saravanan Paramasivam

Suriyaprakash Ayyangar Janarthanam

Ahteram Khan

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

Reinforcement assemblies and associated methods are provided for reinforcing a battery pack of an electrified vehicle. An exemplary battery pack may include a battery internal component (e.g., a battery array), an enclosure assembly for housing the battery internal component, and a reinforcement assembly secured to the enclosure assembly. The reinforcement assembly may include a beam and a bracket secured to the beam. The reinforcement assembly may be positioned at expected high impact load locations of the enclosure assembly and is configured for absorbing and transferring energy during vehicle impact loading events, thereby minimizing transfer of the impact loads inside the battery pack where relatively sensitive battery internal components are housed.

Battery pack reinforcement assemblies

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

This disclosure details reinforcement assemblies and associated methods for reinforcing a battery pack of an electrified vehicle. An exemplary battery pack may include a battery internal component (e.g., a battery array), an enclosure assembly for housing the battery internal component, and a reinforcement assembly secured to the enclosure assembly. The reinforcement assembly may include a beam and a bracket secured to the beam. The reinforcement assembly may be positioned at expected high impact load locations of the enclosure assembly and is configured for absorbing and transferring energy during vehicle impact loading events, thereby minimizing transfer of the impact loads inside the battery pack where relatively sensitive battery internal components are housed.

A battery pack mounting system includes, among other things, an outboard bracket connecting a battery pack to a vehicle underbody, a first inboard bracket connecting the battery pack to the vehicle underbody, and a second inboard bracket connecting the battery pack to a tunnel of the vehicle underbody.

Battery pack mounting system and mounting method

An electrified vehicle includes a vehicle frame, a battery pack mounted to the vehicle frame, a primary bracket secured to each of the vehicle frame and the battery pack, and a support bracket secured to the battery pack and the primary bracket. The support bracket increases the stiffness of the primary bracket.

Battery pack mounting assembly

A battery pack retention assembly includes, among other things, a conforming bracket that secures a battery array within a battery pack. The conforming bracket includes platforms that flexes as the conforming bracket is secured. The flexing facilitates aligning an area of the conforming bracket with a thermal exchange plate. A battery pack retention method includes, among other things, flexing a conforming bracket to reduce a gap between the battery array and a thermal exchange plate. The flexing occurs when securing a battery array to within a battery pack.

Battery pack retention assembly and retention method

An exemplary connector assembly includes, among other things, a bottom brace at least partially disposed beneath an enclosure of a battery pack to provide an open area vertically between the enclosure and a floor of the bottom brace. A side brace is disposed alongside the enclosure to provide an open area laterally between the enclosure and a floor of the side brace. A bracket connects the bottom and side braces to a vehicle structure. An exemplary battery pack connection method includes, among other things, supporting an enclosure of a battery pack with a bottom brace at least partially disposed beneath the enclosure. The method includes supporting the enclosure with a side brace that is at least partially disposed alongside the enclosure. The method further includes connecting the bottom and side braces to a vehicle structure through a bracket.

Growing community of inventors

Canton, MI, United States of America

Shamsuddin A Syed