Ford Global Technolgoies, LLC

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Eid Farha

Hari Krishna Addanki

Debbi Callicoat

Masahiro Kimoto

John Sturza

Abdul Lateef

Steven Droste

Rajesh Narayanan

This disclosure relates to a battery assembly with a plate having a compression limiting feature, and a corresponding electrified vehicle and method. An example battery assembly includes a wall having an inner surface and an outer surface. The wall also has a central opening. The battery assembly further includes a plate abutting the outer surface of the wall and covering the central opening. The plate also includes a main body and a post projecting from the main body toward the inner surface of the wall. Among other benefits, this arrangement limits compression of the wall and increases the ease of mounting components, such as electrical or fluid connectors, to the battery assembly.

Battery assembly with plate having compression limiting feature

An exemplary busbar forming method includes, among other things, creasing a sheet of material to form a plurality of creases that partition the sheet into a plurality of segments. The method further includes identifying a desired size for a terminal receiving recess in a busbar. In response to the desired size, the method folds at least some of the segments relative to each other about at least some of the creases according to a first process, or a different, second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that partition at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other about at least some of the creases to provide the terminal receiving recess in the busbar.

Busbar forming method and folded busbar

A battery array according to an exemplary aspect of the present disclosure includes, among other things, a circuit connector assembly and a cover that partially covers the circuit connector assembly. The cover includes a groove. A sense-line wire is received within the groove.

Grooved cover for battery array

A vehicle including an array of pouch battery cells, a pair of carriers, and a plurality of busbars is provided. The array of pouch battery cells may each have terminal tabs of opposite polarity extending from opposing cell faces. The pair of carriers may extend along the cell faces and each may define a plurality of apertures sized to receive the terminal tabs. The plurality of busbars may be arranged with the carriers and terminal tabs such that an electrical connection across the cells includes parallel and series connections. The pouch battery cells may be arranged in clusters of adjacent cells connected in parallel, and the busbars may be arranged in spaced apart groups on each of the carriers and joined to adjacent terminal tabs to connect the clusters in series.

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Ypsilanti, MI, United States of America

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