U.S. patent application number 15/076732 was filed with the patent office on 2016-07-14 for battery array rail assembly with tie bracket.
The applicant listed for this patent is FORD GLOBAL TECHNOLOGIES, INC.. Invention is credited to Saravanan PARAMASIVAM, Rajaram SUBRAMANIAN, Yongcai WANG.
Application Number | 20160204403 15/076732 |
Document ID | / |
Family ID | 53275483 |
Filed Date | 2016-07-14 |
United States Patent
Application |
20160204403 |
Kind Code |
A1 |
WANG; Yongcai ; et
al. |
July 14, 2016 |
BATTERY ARRAY RAIL ASSEMBLY WITH TIE BRACKET
Abstract
A battery array according to an exemplary aspect of the present
disclosure includes, among other things, a rail that supports a
battery cell and a tie bracket connected to the rail and configured
to limit travel of the rail.
Inventors: |
WANG; Yongcai; (Troy,
MI) ; SUBRAMANIAN; Rajaram; (Ann Arbor, MI) ;
PARAMASIVAM; Saravanan; (South Lyon, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FORD GLOBAL TECHNOLOGIES, INC. |
Dearborn |
MI |
US |
|
|
Family ID: |
53275483 |
Appl. No.: |
15/076732 |
Filed: |
March 22, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14138632 |
Dec 23, 2013 |
9321337 |
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15076732 |
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Current U.S.
Class: |
429/156 |
Current CPC
Class: |
H01M 2/1077 20130101;
H01M 2220/20 20130101; Y02T 10/70 20130101; B60L 50/66 20190201;
B60L 50/64 20190201; B60K 1/04 20130101; Y10S 903/907 20130101;
Y02E 60/10 20130101; H01M 2/1083 20130101 |
International
Class: |
H01M 2/10 20060101
H01M002/10; B60L 11/18 20060101 B60L011/18; B60K 1/04 20060101
B60K001/04 |
Claims
1. A battery array, comprising: a rail that supports a battery
cell; and a tie bracket connected to said rail and configured to
limit travel of said rail, said tie bracket including a first face,
a second face transverse to said first face, and a stiffener wall
that connects diagonally between said first face and said second
face.
2. The battery array as recited in claim 1, wherein said tie
bracket is welded to said rail.
3. The battery array as recited in claim 1, wherein said tie
bracket resists deflection between transverse portions of said
rail.
4. The battery array as recited in claim 1, wherein said tie
bracket resists deflection of a lower flange toward an upper flange
of said rail.
5. The battery array as recited in claim 1, wherein said tie
bracket resists rotation of said rail.
6. The battery array as recited in claim 1, wherein said tie
bracket resists deformation of said rail.
7. The battery array as recited in claim 1, comprising a plurality
of tie brackets mounted to said rail.
8. The battery array as recited in claim 1, comprising a flange
connected to at least one of said first face and said second
face.
9. The battery array as recited in claim 1, wherein said tie
bracket includes a flange having a mounting portion that mounts to
said rail.
10. The battery array as recited in claim 1, wherein said rail
includes a first wall and a second wall that extends transversely
from said first wall.
11. The battery array as recited in claim 1, wherein said rail
includes a C-shaped body having an upper flange connected to a
lower flange by at least one wall.
12. The battery array as recited in claim 1, comprising a second
rail spaced from said rail and a second tie bracket mounted to said
second rail, wherein a column extends between said rail and said
second rail.
13. The battery array as recited in claim 1, wherein said tie
bracket is L-shaped.
14. The battery array as recited in claim 1, wherein said stiffener
wall is triangular shaped.
15. The battery array as recited in claim 1, wherein said stiffener
wall diagonally extends diagonally from a first edge of said first
face to a second edge of said second face.
16. The battery array as recited in claim 1, comprising a flange
connected to said tie bracket on an open side opposite from said
stiffener wall.
17. A method, comprising: mounting a tie bracket to a rail of a
battery array such that a first face of the tie bracket is secured
to a first portion of the rail and a second face of the tie bracket
is secured to a second, different portion of the rail; and limiting
travel of the rail with the tie bracket.
18. The method as recited in claim 17, wherein the step of limiting
travel includes resisting deflection of a lower flange of the rail
toward an upper flange of the rail.
19. The method as recited in claim 17, wherein the step of limiting
travel includes resisting rotation or deformation of the rail.
20. The method as recited in claim 17, comprising mounting the tie
bracket between walls or flanges of the rail.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/138,632, which was filed on Dec. 23,
2013.
TECHNICAL FIELD
[0002] This disclosure relates to an electrified vehicle, and more
particularly, but not exclusively, to a rail assembly for use with
a battery array.
BACKGROUND
[0003] Electrified vehicles, such as hybrid electric vehicles
(HEV's), plug-in hybrid electric vehicles (PHEV's), battery
electric vehicles (BEV's), or fuel cell vehicles differ from
conventional motor vehicles in that they are powered by electric
machines (i.e., electric motors and/or generators) instead of or in
addition to an internal combustion engine. High voltage current for
powering these types of electric machines is typically supplied by
a high voltage traction battery system.
[0004] Electrified vehicle battery systems may employ one or more
battery modules that include a plurality of battery arrays. Each
battery array includes a plurality of battery cells that are
supported relative to one another. The packaging of these battery
arrays may benefit from structural energy management to maintain
the integrity of the battery cells.
SUMMARY
[0005] A battery array according to an exemplary aspect of the
present disclosure includes, among other things, a rail that
supports a battery cell and a tie bracket connected to the rail and
configured to limit travel of the rail.
[0006] In a further non-limiting embodiment of the foregoing
battery array, the tie bracket is welded to the rail.
[0007] In a further non-limiting embodiment of either of the
forgoing battery arrays, the tie bracket resists deflection between
transverse portions of the rail.
[0008] In a further non-limiting embodiment of any of the foregoing
battery arrays, the tie bracket resists deflection of a lower
flange toward an upper flange of the rail.
[0009] In a further non-limiting embodiment of any of the foregoing
battery arrays, the tie bracket resists rotation of the rail.
[0010] In a further non-limiting embodiment of any of the foregoing
battery arrays, the tie bracket resists deformation of the
rail.
[0011] In a further non-limiting embodiment of any of the foregoing
battery arrays, a plurality of tie brackets are mounted to the
rail.
[0012] In a further non-limiting embodiment of any of the foregoing
battery arrays, the tie bracket includes a first face, a second
face transverse to the first face, and a stiffener wall that
connects between the first face and the second face.
[0013] In a further non-limiting embodiment of any of the foregoing
battery arrays, a flange is connected to at least one of the first
face and the second face.
[0014] In a further non-limiting embodiment of any of the foregoing
battery arrays, the tie bracket includes a flange having a mounting
portion that mounts to the rail.
[0015] In a further non-limiting embodiment of any of the foregoing
battery arrays, the rail includes a first wall and a second wall
that extends transversely from the first wall.
[0016] In a further non-limiting embodiment of any of the foregoing
battery arrays, the rail includes a C-shaped body having an upper
flange connected to a lower flange by at least one wall.
[0017] A battery module according to another exemplary aspect of
the present disclosure includes, among other things, a rail
assembly including an upper rail, a lower rail, a column that
extends between the upper rail and the lower rail and at least one
tie bracket mounted to at least one of the upper rail and the lower
rail.
[0018] In a further non-limiting embodiment of the foregoing
battery module, the rail assembly is part of a battery array that
includes a plurality of battery cells supported by the rail
assembly.
[0019] In a further non-limiting embodiment of either of the
foregoing battery modules, the at least one tie bracket is
configured to limit travel of at least one of the upper rail and
the lower rail.
[0020] In a further non-limiting embodiment of any of the foregoing
battery modules, the at least one tie bracket includes a first tie
bracket mounted to the upper rail and a second tie bracket mounted
to the lower rail.
[0021] A method according to another exemplary aspect of the
present disclosure includes, among other things, limiting travel of
a rail that supports a battery cell with a tie bracket.
[0022] In a further non-limiting embodiment of the foregoing
method, the method of limiting travel includes resisting deflection
of a lower flange of the rail toward an upper flange of the
rail.
[0023] In a further non-limiting embodiment of either of the
foregoing methods, the method of limiting travel includes resisting
rotation or deformation of the rail.
[0024] In a further non-limiting embodiment of any of the foregoing
methods, the method includes mounting the tie bracket between walls
or flanges of the rail.
[0025] The embodiments, examples and alternatives of the preceding
paragraphs, the claims, or the following description and drawings,
including any of their various aspects or respective individual
features, may be taken independently or in any combination.
Features described in connection with one embodiment are applicable
to all embodiments, unless such features are incompatible.
[0026] The various features and advantages of this disclosure will
become apparent to those skilled in the art from the following
detailed description. The drawings that accompany the detailed
description can be briefly described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 schematically illustrates a powertrain of an
electrified vehicle.
[0028] FIG. 2 illustrates a battery module for an electrified
vehicle.
[0029] FIG. 3 illustrates a cross-sectional view of a battery
module.
[0030] FIG. 4 illustrates a rail assembly that can be used to
support battery cells of a battery array.
[0031] FIGS. 5A and 5B illustrate a tie bracket according to a
first embodiment of the present disclosure.
[0032] FIGS. 6A and 6B illustrate a tie bracket according to
another embodiment of the present disclosure.
DETAILED DESCRIPTION
[0033] This disclosure relates to a battery array for use within a
battery module of an electrified vehicle. The battery array
includes a rail assembly that supports and retains one or more
battery cells. The rail assembly includes a tie bracket configured
to act as a travel limiter for cell retention in the battery array.
These and other features are discussed in greater detail
herein.
[0034] FIG. 1 schematically illustrates a powertrain 10 of an
electrified vehicle 12. The electrified vehicle 12 may be a HEV,
PHEV, BEV or any other vehicle type. In other words, this
disclosure is not limited to any particular type of electrified
vehicle.
[0035] The powertrain 10 includes a drive system having at least a
motor 36 (i.e., an electric machine) and a battery system 50. The
battery system 50 may include a high voltage battery that is
capable of outputting stored electrical power to operate the motor
36. Although not shown, the battery system 50 may be made up of
multiple battery modules with each module including a plurality of
battery arrays.
[0036] The drive system generates torque to drive or one more sets
of vehicle drive wheels 30 of the electrified vehicle 12. For
example, in an electric-only mode of operating the electrified
vehicle 12, the motor 36 can be powered by the battery system 50
and employed to electrically drive the vehicle drive wheels 30 by
outputting torque to a shaft 46.
[0037] Of course, this view is highly schematic. It should be
appreciated that other components, including but not limited to an
internal combustion engine, a generator, an engine disconnect
clutch, a gearbox, a power transfer unit, and/or one or more
control systems could be employed by the powertrain 10 for
propelling the electrified vehicle 12 using electric-only power or
with the assistance of engine power.
[0038] FIGS. 2 and 3 illustrate a battery module 60 that may be
part of an electrified vehicle battery system, such as the battery
system 50 of FIG. 1. In one embodiment, the battery module 60 is
made up of a multitude of battery arrays 62. A total of four
battery arrays 62 are depicted in the illustrated embodiment.
However, the specific number of battery arrays 62 that are part of
the battery module 60 is not intended to limit this disclosure.
[0039] Each battery array 62 of the battery module 60 includes a
plurality of battery cells 64 and a rail assembly 66 that supports
and retains the battery cells 64. In one embodiment, the rail
assembly 66 includes upper rails 68 and lower rails 70. One or more
tie brackets 74 (see FIG. 3) may be mounted to the upper rails 68
and the lower rails 70 of each rail assembly 66. As discussed in
greater detail below, the tie brackets 74 act as travel limiters
that resist bending, rotation and/or displacement of the rails 68,
70 in order to substantially reduce the likelihood that the battery
cells 64 become displaced from the rail assembly 66.
[0040] FIG. 4, with continued reference to FIGS. 2 and 3,
illustrates an exemplary rail assembly 66 of a battery array 62.
The battery cells 64 have been removed from FIG. 4 for ease of
reference. The rail assembly 66 includes an upper rail 68, a lower
rail 70 and columns 72 that connect between the upper rail 68 and
the lower rail 70. In one non-limiting embodiment, the columns 72
are fastened to each of the upper rail 68 and the lower rail 70 to
construct the rail assembly 66. The specific number of columns 72
that connect between the upper rail 68 and the lower rail 70 may
vary based on the overall length of the battery array 62, among
other factors.
[0041] In one non-limiting embodiment, the upper rail 68 of the
rail assembly 66 is L-shaped and includes a first wall 80 and a
second wall 82 that extends transversely from the first wall 80.
When mounted as part of the battery array 62, the first wall 80 may
be a vertical wall that extends generally parallel to the battery
cells 64 and the second wall 82 may be a horizontal wall that
extends in a direction away from the battery cells 64 (see FIG. 3).
The first wall 80 may include a flange 84 that can contact the
battery cells 64 to support and retain them in place.
[0042] In another non-limiting embodiment, the lower rail 70 of the
rail assembly 66 includes a C-shaped body 86 that includes an upper
flange 88, a lower flange 90, and a wall 92 that connects the upper
flange 88 to the lower flange 90. Platforms 94 may extend from the
lower flange 90 for supporting tie brackets 74, as is further
discussed below. In addition, the upper flange 88 can include an
extension 89 that can contact the battery cells 64 to support and
retain them in place.
[0043] In one embodiment, as best illustrated in FIG. 4, a
plurality of walls 92 connect the upper flange 88 to the lower
flange 90 of the lower rail 70. A plurality of cooling openings 96
may extend between adjacent walls 92. Airflow F may be freely
communicated through the cooling openings 96 to cool the battery
cells 64 of the battery array 62. For example, the cooling openings
96 may be part of an air cooled thermal management system of the
battery array 62.
[0044] A gusset 76 may be disposed at each opposing end 98A, 98B of
both the upper rail 68 and the lower rail 70 of the rail assembly
66. The gussets 76 can be utilized to retain end plates (not shown)
for packaging the battery array 62. For example, end plates may be
received by the gussets 76 which apply a compressive force against
the battery cells 64 at the opposing ends 98A, 98B.
[0045] One or more tie brackets 74 may be positioned relative to
each of the upper rail 68 and the lower rail 70 of the rail
assembly 66 for supporting and retaining battery cells 64. The
specific placement and number of tie brackets 74 incorporated into
the rail assembly 66 is design dependent and may depend on the
expected locations of deflection or displacement of the rail
assembly 66 and the overall length of the battery array 62, among
other factors. In one non-limiting embodiment, the tie brackets 74
are mounted adjacent to the mounting locations of the columns
72.
[0046] In one embodiment, the tie brackets 74 are welded to the
upper rail 68 and/or the lower rail 70. However, other attachment
methodologies are also contemplated.
[0047] With respect to the upper rail 68, the tie brackets 74 are
mounted to extend between the first wall 80 and a second wall 82.
In other words, the tie brackets 74 may be welded to both the first
wall 80 and the second wall 82.
[0048] Tie brackets 74 may also extend between the upper flange 88
and the lower flange 90 of the lower rail 70. In one non-limiting
embodiment, the tie brackets are mounted to both the platforms 94
and the extensions 89 of the upper flange 88.
[0049] The tie brackets 74 act as travel limiters to limit
displacement of the battery cells 64 in response to an impact event
at the battery module 60. For example, a vehicle impact event can
damage the battery module 60 containing the battery arrays 62. The
tie brackets 74 reduce the likelihood of the battery cells 64
becoming displaced from the rail assembly 66 in the event of a
vehicle crash or other accident.
[0050] In one embodiment, the tie brackets 74 limit deflection of
the upper rail 68 and the lower rail 70 of the rail assembly 66.
For example, by way of a non-limiting embodiment, the tie brackets
74 may limit deflection of the lower flange 90 in a direction
toward the upper flange 88 of the lower rail 70. In another
non-limiting embodiment, the tie brackets 74 resist rotation of the
rail assembly 66 that may be caused by the collapse of one or more
of the columns 72. In yet another embodiment, the tie brackets 74
may resist deformation of the upper and lower rails 68, 70 of the
rail assembly 66 during an impact event.
[0051] It should be understood that the rail assembly 66 is not
limited to the exact configurations shown in FIGS. 2, 3 and 4. For
example, the upper and lower rails 68, 70 of the rail assembly 66
may embody other sizes, shapes, and configurations within the scope
of this disclosure.
[0052] FIGS. 5A and 5B illustrate a tie bracket 74 according to a
first embodiment of the present disclosure. The tie bracket 74 may
be suitable for use with either the upper rail 68 or the lower rail
70 of the rail assembly 66 of FIG. 4. In this embodiment, the tie
bracket 74 includes a first face 100, a second face 102 that is
transverse to the first face 100, and a stiffener wall 104 that
connects between the first face 100 and the second face 102.
Together, the first face 100, the second face 102 and the stiffener
wall 104 establish a monolithic structure.
[0053] In one non-limiting embodiment, the tie bracket 74 is made
of a metallic material. However, other materials are contemplated
as within the scope of this disclosure.
[0054] The stiffener wall 104 may be positioned on one side of the
first and second faces 100, 102. The tie bracket 74 may include an
open side 106 opposite the stiffener wall 104. The stiffener wall
104 is generally triangular shaped, in one non-limiting
embodiment.
[0055] Referring now to FIGS. 4, 5A and 5B, the first face 100 and
the second face 102 of the tie bracket 74 may sit flush against
respective surfaces of the upper and lower rails 68, 70 of the rail
assembly 66. For example, in a first embodiment, the tie bracket 74
is mounted to the upper rail 68. The first face 100 may connect to
the first wall 80 of the upper rail 68 and the second face 102 may
connect to the second wall 82 of the upper rail 68. In a second
embodiment, the first face 100 may connect to the platform 94 of
the lower flange 90 of the lower rail 70 and the second face 102
may connect to the upper flange 88 of the lower rail 70. Of course,
tie brackets 74 may be employed by both the upper rail 68 and the
lower rail 70 of the rail assembly 66 as shown in FIG. 4.
[0056] FIGS. 6A and 6B illustrate a tie bracket 174 according to a
second exemplary embodiment of this disclosure. In this disclosure,
like reference numbers designate like elements where appropriate
and reference numerals with the addition of 100 or multiples
thereof designate modified elements that are understood to
incorporate the same features and benefits of the corresponding
original elements.
[0057] In this embodiment, the tie bracket 174 is similar to the
tie bracket 74 of FIGS. 5A and 5B with the exception that the tie
bracket 174 includes a flange 108 in addition to the first face
100, the second face 102 and the stiffener wall 104. The flange 108
may be connected to the open side 106 of the tie bracket 174. In
one embodiment, the flange 108 is welded to the first face 100. In
another embodiment, the flange 108 is welded to the second face
102. In yet another embodiment, the flange 108 is connected to both
the first face 100 and the second face 102.
[0058] The flange 108 may be generally cradle-shaped and includes a
first mounting portion 110, a second mounting portion 112 and a
connecting portion 114 that connects between the first mounting
portion 110 and the second mounting portion 112. The first and
second mounting portions 110, 112 extend transversely from the
connecting portion 114. The flange 108 may include one or more
openings 116 for mounting the flange 108 to other surfaces.
[0059] In one embodiment, the first mounting portion 110 mounts to
a surface of either the upper rail 68 or the lower rail 70 (see
FIG. 4), and the second mounting surface 112 may mount to a surface
of the battery module 60 to provide additional stability to the
rail assembly 66 during a vehicle impact event. The tie bracket 174
may be particularly suited for use with the upper rail 68 of the
rail assembly 66 of FIG. 4, although it is not limited to such
use.
[0060] Although the different non-limiting embodiments are
illustrated as having specific components or steps, the embodiments
of this disclosure are not limited to those particular
combinations. It is possible to use some of the components or
features from any of the non-limiting embodiments in combination
with features or components from any of the other non-limiting
embodiments.
[0061] It should be understood that like reference numerals
identify corresponding or similar elements throughout the several
drawings. It should be understood that although a particular
component arrangement is disclosed and illustrated in these
exemplary embodiments, other arrangements could also benefit from
the teachings of this disclosure.
[0062] The foregoing description shall be interpreted as
illustrative and not in any limiting sense. A worker of ordinary
skill in the art would understand that certain modifications could
come within the scope of this disclosure. For these reasons, the
following claims should be studied to determine the true scope and
content of this disclosure.
* * * * *