Abstract:
A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a tray, a battery pack received within the tray, a cover positioned over the battery pack and a mounting assembly connected to the tray and including at least one bushing configured to establish an interface with a vehicle component.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates to a battery assembly for an electrified vehicle. The battery assembly is suspended from a vehicle frame by a mounting assembly that includes one or more interface devices. The interface devices isolate the battery assembly from energy transmitted from the vehicle frame. 
       BACKGROUND 
       [0002]    The need to reduce automotive fuel consumption and emissions is well known. Therefore, vehicles are being developed that either reduce or completely eliminate reliance on internal combustion engines. Electrified vehicles are one type of vehicle being developed for this purpose. In general, electrified vehicles differ from conventional motor vehicles in that they are selectively driven by one or more battery powered electric machines. Conventional motor vehicles, by contrast, rely exclusively on the internal combustion engine to drive the vehicle. 
         [0003]    A high voltage battery pack is employed to power the electric machines of an electrified vehicle. The high voltage battery pack typically includes multiple battery arrays that included a plurality of interconnected battery cells and various electronic components that are required to interface with the electrified vehicle. Traditionally, the high voltage battery pack is mounted in a passenger compartment or cargo space of the electrified vehicle. The battery pack therefore occupies an amount of space that would otherwise be available for carrying passengers or cargo. 
       SUMMARY 
       [0004]    A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a tray, a battery pack received within the tray, a cover positioned over the battery pack and a mounting assembly connected to the tray and including at least one bushing configured to establish an interface with a vehicle component. 
         [0005]    In a further non-limiting embodiment of the foregoing battery assembly, the mounting assembly includes a first bracket attached near a first end of the tray and a second bracket attached near a second end of the tray, each of the first bracket and the second bracket including multiple bushings. 
         [0006]    In a further non-limiting embodiment of either of the foregoing battery assemblies, the vehicle component is a vehicle frame. 
         [0007]    In a further non-limiting embodiment of any of the foregoing battery assemblies, the battery pack is a high voltage battery pack that includes at least one battery array having a plurality of battery cells. 
         [0008]    In a further non-limiting embodiment of any of the foregoing battery assemblies, a heat shield is mounted to an underside of the tray. 
         [0009]    In a further non-limiting embodiment of any of the foregoing battery assemblies, insulation is between the cover and the battery pack and between the tray and the battery pack. 
         [0010]    In a further non-limiting embodiment of any of the foregoing battery assemblies, a thermal management system includes inlet and outlet tubing disposed between the tray and the battery pack. 
         [0011]    In a further non-limiting embodiment of any of the foregoing battery assemblies, the thermal management system is configured to cool the battery pack from exceeding an upper threshold temperature. 
         [0012]    In a further non-limiting embodiment of any of the foregoing battery assemblies, the battery pack includes a second cover and a battery pack base that are separate from the tray and the cover. 
         [0013]    In a further non-limiting embodiment of any of the foregoing battery assemblies, the bushing includes an inner sleeve, an outer casing, and a flexible member extending radially between the inner sleeve and the outer casing. 
         [0014]    An electrified vehicle according to another exemplary aspect of the present disclosure includes, among other things, a floor pan, an exhaust system that extends under the floor pan and a high voltage battery assembly mounted between the floor pan and the exhaust system. 
         [0015]    In a further non-limiting embodiment of the foregoing electrified vehicle, the high voltage battery assembly is mounted at a location that is remote from a passenger cabin that is located on an opposite side of the floor pan. 
         [0016]    In a further non-limiting embodiment of either of the foregoing electrified vehicles, the high voltage battery assembly is mounted axially between a fuel tank and frame rail of a vehicle frame. 
         [0017]    In a further non-limiting embodiment of any of the foregoing electrified vehicles, the high voltage battery assembly is suspended from a vehicle frame by at least one bushing. 
         [0018]    In a further non-limiting embodiment of any of the foregoing electrified vehicles, a heat shield is mounted between the high voltage battery assembly and the exhaust system. 
         [0019]    An electrified vehicle according to another exemplary aspect of the present disclosure includes, among other things, a vehicle frame, a battery assembly suspended from the vehicle frame and a mounting assembly that includes at least one bushing configured to establish an interface between the battery assembly and the vehicle frame to provide road load isolation to a battery pack of the battery assembly. 
         [0020]    In a further non-limiting embodiment of the foregoing electrified vehicle, the battery assembly is mounted between a floor pan and an exhaust system. 
         [0021]    In a further non-limiting embodiment of either of the foregoing electrified vehicles, a bracket extends from the vehicle frame and receives the bushing to suspend the battery assembly from the vehicle frame, the bushing configured to provide road load isolation at an interface between the battery assembly and the vehicle frame. 
         [0022]    In a further non-limiting embodiment of any of the foregoing electrified vehicles, insulation at least partially surrounds the battery pack. 
         [0023]    In a further non-limiting embodiment of any of the foregoing electrified vehicles, the bushing includes an inner sleeve, an outer casing, and a flexible member extending radially between the inner sleeve and the outer casing. 
         [0024]    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. 
         [0025]    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 
         [0026]      FIG. 1  schematically illustrates an electrified vehicle. 
           [0027]      FIG. 2  is an exploded view of a battery assembly with integral thermal protection that can be incorporated into an electrified vehicle. 
           [0028]      FIG. 3  illustrates a cross-section of a high voltage battery pack of a battery assembly. 
           [0029]      FIG. 4  schematically illustrates the installation of a battery assembly onto a vehicle frame. 
           [0030]      FIG. 5  is a cross-sectional view of a bushing that provides road load isolation at a vehicle frame/battery assembly interface. 
           [0031]      FIG. 6  is a cross-sectional side  9  view of a battery assembly installed onto a vehicle frame. 
           [0032]      FIG. 7  is a rear, cross-sectional view of a battery assembly installed on a vehicle frame. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    This disclosure details an exemplary battery assembly for an electrified vehicle. The battery assembly, which includes a high voltage battery pack, is secured relative to a vehicle frame of the electrified vehicle and therefore does not reduce the available space of the passenger compartment or cargo area of the vehicle. In some embodiments, the battery assembly is mounted between a floor pan and an exhaust system of the electrified vehicle. In other embodiments, the battery assembly is suspended from the vehicle frame by a mounting assembly that includes one or more interface devices that isolate the battery assembly from vibrations or other loads communicated from the vehicle frame. These and other features are discussed in greater detail in the following paragraphs of this disclosure. 
         [0034]      FIG. 1  schematically illustrates an electrified vehicle  10 . In one non-limiting embodiment, the electrified vehicle  10  is a hybrid electric vehicle (HEV). However, this disclosure is not limited to HEV&#39;s and could extend to other types of electrified vehicles, including but not limited to plug-in hybrid electric vehicles (PHEV&#39;s) and battery electric vehicles (BEV&#39;s). The electrified vehicle  10  is also depicted as a pickup truck. However, trucks, cars, vans or any other types of vehicles could benefit from the teachings of this disclosure. In addition, although a specific component relationship is illustrated in  FIG. 1 , this illustration is not intended to limit this disclosure. In other words, the placement and orientation of the various components of the electrified vehicle  10  could vary within the scope of this disclose. 
         [0035]    The exemplary electrified vehicle  10  includes a powertrain that may include an engine  12  and an electric machine  14 . The engine  12 , which may be an internal combustion engine, and the electric machine  14 , which could be a motor, generator or a combined motor/generator, may both be employed as available drive sources for the electrified vehicle  10 . For example, the engine  12  and/or the electric machine  14  can generate torque to drive one or more sets of vehicle drive wheels  15  of the electrified vehicle  10 . A high voltage battery assembly  16  may electrically power the electric machine  14 . 
         [0036]    The electrified vehicle  10  may additionally include a passenger cabin  18  and a cargo area  19  (here, a pick-up bed) to the rear of the passenger cabin  18 . A floor pan  20  separates the passenger cabin  18  from a vehicle frame  22 . The battery assembly  16  may be suspended from the vehicle frame  22  such that it is remote from both the passenger cabin  18  and the cargo area  19 . The battery assembly  16  therefore does not occupy space that would otherwise be available for carrying passengers or cargo. 
         [0037]      FIG. 2  is an exploded view of the battery assembly  16 , which is only schematically depicted in  FIG. 1 . The battery assembly  16  may include a tray  24 , a battery pack  26 , a cover  28 , a heat shield  44  and a thermal management system  46 . The battery pack  26  may be a high voltage battery pack that includes one or more battery arrays that each includes a plurality of battery cells stacked side-by side to build the battery array (see, for example,  FIG. 3 ). 
         [0038]    The battery pack  26  is received within the tray  24 . The cover  28  is received over the tray  24  to house the battery pack  26 . In one embodiment, the cover  28  is positioned over the battery pack  26  and is secured to the tray  24  using one or more fasteners (not shown). The cover  28  may be a stamped part made of steel. Other materials are also contemplated within the scope of this disclosure. 
         [0039]    The tray  24  may also be made from steel or some other suitable material. The tray  24  includes a bottom  30  and sidewalls  32  that extend upwardly from the bottom  30  to form the tray  24 , which in one embodiment is pan shaped. 
         [0040]    Insulation  34  may line the cover and/or one or more of the bottom  30  and the sidewalls  32  of the tray  24 . In a non-limiting embodiment, the insulation  34  is high performance fiber insulation. 
         [0041]    A mounting assembly  36  may be attached to the tray  24 . In one embodiment, the mounting assembly  36  includes a first bracket  38 A and a second bracket  38 B mounted at opposing ends  40  of the tray  24 . The first bracket  38 A and the second bracket  38 B may be attached to one or more of the bottom  30  and the sidewalls  32  of the tray  24 . 
         [0042]    Each of the first bracket  38 A and the second bracket  38 B may receive bushings  42  that establish an interface between the battery assembly  16  and the vehicle frame  22  (see  FIGS. 4-7 ). In the illustrated embodiment, two bushings  42  are mounted within each of the first bracket  38 A and the second bracket  38 B; however, the mounting assembly  36  could include any amount of bushings  42 . In one non-limiting embodiment, the bushings  42  are isolator bushings that isolate the battery assembly  16  from loads that act on the vehicle frame  22 , as is further discussed below. 
         [0043]    The heat shield  44  may be mounted to an underside of the tray  24  (i.e. on an opposite side of the tray  24  from the battery pack  26 ). The heat shield  44  is made of aluminized steel, in one embodiment, although other materials are also contemplated. The heat shield  44  shields the battery assembly  16  from heat generated by surrounding components of the electrified vehicle  10  and may also protect the battery assembly  16  from debris that may ricochet off the vehicle driving surface. 
         [0044]    The battery assembly  16  may additionally include an insulated, liquid cooled thermal management system  46  for the temperature sensitive battery pack  26 . The thermal management system  46  prevents the battery pack  26  from exceeding upper threshold temperatures for proper battery operation/life under all driving/environmental conditions. In one embodiment, the thermal management system  46  includes a fluid source  47 , inlet tubing  48  and outlet tubing  50  for communicating a fluid F to and from the battery pack  26 . The fluid F may remove heat from the battery pack  26 . In one embodiment, the inlet tubing  48  and the outlet tubing  50  of the thermal management system  46  extend between the battery pack  26  and the tray  24 . 
         [0045]      FIG. 3  is a cross-sectional view through the battery pack  26 . The battery pack  26  may include multiple battery arrays  25 . Each battery array  25  includes a plurality of battery cells  27  stacked side-by side (into the page in  FIG. 3 ) to build the battery array  25 . The battery arrays  25  are housed inside a battery pack base  29  and a cover  31 . As shown in  FIG. 2 , the battery pack base  29  and the cover  31  are separate structures from the tray  24  and the cover  28  of the battery assembly  16 . The battery pack base  29  may include a cold plate  35 . 
         [0046]      FIG. 4  schematically illustrates the installation of the battery assembly  16  to the vehicle frame  22  of the electrified vehicle  10 . The vehicle frame  22  may include a first frame rail  52 A, a second frame rail  52 B and cross members  54  that connect between the first frame rail  52 A and the second frame rail  52 B. The first frame rail  52 A is spaced from the second frame rail  52 B. The first and second frame rails  52 A,  52 B extend longitudinally to establish a length of the vehicle frame  22 , and the cross members  54  extend in a direction that is transverse to the first frame rail  52 A and the second frame rail  52 B to establish a width of the vehicle frame  22 . 
         [0047]    Brackets  56  may be mounted to the cross members  54  for accommodating the bushings  42  of the mounting assembly  36 . The bushings  42  are received by the brackets  56  to suspend the battery assembly  16  from the vehicle frame  22 . In this way, the battery assembly  16  is secured relative to the vehicle frame  22  but is not hard mounted to it. In one non-limiting embodiment, the brackets  56  include openings  58  that receive inner sleeves  60  of the bushings  42 . Bolts  61  may be received through the inner sleeves  60  and openings  58  to secure the bushings  42  to the brackets  56 . Of course, other mounting configurations are also contemplated within the scope of this disclosure. 
         [0048]    The bushings  42  establish an interface between the vehicle frame  22  and the battery assembly  16  and will dampen energy that is transmitted from the vehicle frame  22  isolating the battery assembly  16  from vibrations and other high acceleration loads. In some embodiments, the bushings  42  allow some amount of movement to occur between the battery assembly  16  and the vehicle frame  22 . For example, the bushings  42  may allow the battery assembly  16  to slightly move in multiple degrees of freedom relative to the vehicle frame  22  to create a modal misalignment between the battery assembly  16  and the vehicle frame  22 . 
         [0049]    Referring to  FIG. 5 , each bushing  42  may include the inner sleeve  60 , an outer casing  62 , and a flexible member  64  extending radially between the inner sleeve  60  and the outer casing  62 . The flexible member  64  may be made of rubber, polyurethane, or some other flexible material. The flexible member  64  is configured to act as a damper for dampening energy transmitted from the vehicle frame  22  through the brackets  38 A,  38 B in order to isolate the battery assembly  16  from this energy. This disclosure is not limited to the specific bushing configuration shown in  FIG. 5 . Indeed, other bushing type isolation devices are contemplated as within the scope of this disclosure. 
         [0050]      FIGS. 6 and 7 , with continued reference to  FIGS. 1-5 , illustrate an installed position IP of the battery assembly  16  relative to the vehicle frame  22 . The battery assembly  16  is suspended from the vehicle frame  22 . The bushings  42  provide road load dampening at the vehicle frame  22  interface preventing high dynamic loads from entering the battery pack  26 . 
         [0051]    In one embodiment, the battery assembly  16  extends between the floor pan  20  and an exhaust system  66  of the electrified vehicle  10 . The exhaust system  66  may be disposed underneath the floor pan  20  and extends at least partially beneath the vehicle frame  22 . In another embodiment, the battery assembly  16  is secured relative to the vehicle frame  22  at a location between the floor pan  20  and piping  68  of the exhaust system  66 . 
         [0052]    The battery assembly  16  may also be mounted adjacent to a fuel tank  70  of the electrified vehicle  10 . For example, in another non-limiting embodiment, the battery assembly  16  is axially disposed between the fuel tank  70  and one of the frame rails  52 A,  52 B of the vehicle frame  22  (see  FIG. 7 ). 
         [0053]    The heat shield  44  is positioned between the battery assembly  16  and the exhaust system  66  to insulate the battery assembly  16  from any heat that is expelled by the exhaust system  66 . Insulation  34  may be positioned around the battery pack  26  of the battery assembly  16  to provide additional protection against the high heat conditions that may exist near the exhaust system  66 . In one non-limiting embodiment, insulation  34  is provided between the cover  28  and the battery pack  26  and between the tray  24  and the battery pack  26  (see  FIG. 6 ). 
         [0054]    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. 
         [0055]    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. 
         [0056]    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.