Abstract:
A sealing system according to an exemplary aspect of the present disclosure includes, among other things, an exterior plate, an interior plate, a first seal received against the exterior plate and configured to restrict moisture ingress through the exterior plate and a second seal received against the interior plate and configured to restrict moisture ingress through the interior plate.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates to a vehicle assembly for an electrified vehicle. The vehicle assembly includes a sealing system configured to restrict moisture ingress through a wall of the assembly. 
       BACKGROUND 
       [0002]    The need to reduce automotive fuel consumption and emissions is well known. Therefore, vehicles are being developed that 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 because they are selectively driven by battery powered electric machines. Conventional motor vehicles, by contrast, rely exclusively on the internal combustion engine to propel the vehicle. 
         [0003]    Numerous vehicle assemblies are employed to house components of electrified vehicles. One example of such an assembly is the battery assembly, which houses a plurality of battery cells that are employed to power electric machines and other electric loads of the electrified vehicle. It may be desirable to restrict moisture ingress into an interior of the vehicle assembly. 
       SUMMARY 
       [0004]    A sealing system according to an exemplary aspect of the present disclosure includes, among other things, an exterior plate, an interior plate, a first seal received against the exterior plate and configured to restrict moisture ingress through the exterior plate and a second seal received against the interior plate and configured to restrict moisture ingress through the interior plate. 
         [0005]    In a further non-limiting embodiment of the foregoing system, tubing is received through the exterior plate and the interior plate. 
         [0006]    In a further non-limiting embodiment of either of the foregoing systems, the tubing is received through openings that extend through each of the exterior plate and the interior plate, the first seal and the second seal both positioned about the tubing. 
         [0007]    In a further non-limiting embodiment of any of the foregoing systems, the system includes fasteners that secure the exterior plate relative to the interior plate. 
         [0008]    In a further non-limiting embodiment of any of the foregoing systems, the fasteners are received through peripheral openings formed in both the exterior plate and the interior plate. 
         [0009]    In a further non-limiting embodiment of any of the foregoing systems, the peripheral openings of the exterior plate open into caps, the caps having internal threads for engaging the fasteners. 
         [0010]    In a further non-limiting embodiment of any of the foregoing systems, the first seal is a peripheral seal and the second seal is an O-ring seal. 
         [0011]    In a further non-limiting embodiment of any of the foregoing systems, the first seal is a polymer infiltration and pyrolysis (PIP) seal and the second seal is a rubber seal. 
         [0012]    In a further non-limiting embodiment of any of the foregoing systems, the exterior plate includes a recessed surface, and the first seal is received within the recessed surface. 
         [0013]    In a further non-limiting embodiment of any of the foregoing systems, the interior plate includes a recessed surface, and the second seal is received within the recessed surface. 
         [0014]    A vehicle assembly according to another exemplary aspect of the present disclosure includes, among other things, an enclosure including a wall, a sealing system mounted to the wall and including an exterior plate contiguous with an exterior surface of the wall, an interior plate contiguous with an interior surface of the wall, and a seal disposed between the exterior plate and the interior plate. Tubing extends through the interior plate, the wall and the exterior plate. 
         [0015]    In a further non-limiting embodiment of the foregoing assembly, the seal is a peripheral seal. 
         [0016]    In a further non-limiting embodiment of either the foregoing assemblies, the seal is an O-ring seal. 
         [0017]    In a further non-limiting embodiment of any of the foregoing assemblies, the seal is a peripheral seal and comprising a second seal that is an O-ring seal. 
         [0018]    In a further non-limiting embodiment of any of the foregoing assemblies, the seal is disposed about the tubing and is configured to restrict moisture ingress through an opening of the wall. 
         [0019]    A vehicle according to another exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells, an enclosure that houses the plurality of battery cells, a cold plate in contact with the plurality of battery cells and a sealing system mounted to a wall of the enclosure and configured to seal around tubing that extends from the cold plate, through the sealing system and the wall, to an exterior of the enclosure. 
         [0020]    In a further non-limiting embodiment of the foregoing vehicle, the tubing extends along a linear axis that excludes any bends. 
         [0021]    In a further non-limiting embodiment of either of the foregoing vehicles, the sealing system includes an exterior plate, an interior plate, O-ring seals, and a peripheral seal. 
         [0022]    In a further non-limiting embodiment of any of the foregoing vehicles, the exterior plate is received against an exterior surface of the wall and the interior plate is received against an interior surface of the wall. 
         [0023]    In a further non-limiting embodiment of any of the foregoing vehicles, the O-ring seals are positioned around the tubing between the interior plate and the wall and the peripheral seal is positioned around the tubing between the exterior plate and the wall. 
         [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 a powertrain of an electrified vehicle. 
           [0027]      FIG. 2  is an outside view of a vehicle assembly. 
           [0028]      FIG. 3  is an inside view of the vehicle assembly of  FIG. 2 . 
           [0029]      FIG. 4  illustrates a top view of the vehicle assembly of  FIG. 2 . 
           [0030]      FIG. 5  illustrates an exploded view of a sealing system of a vehicle assembly. 
           [0031]      FIGS. 6A, 6B and 6C  illustrate an exterior plate of the sealing system of  FIG. 5 . 
           [0032]      FIG. 7  illustrates an interior plate of the sealing system of  FIG. 5 . 
           [0033]      FIG. 8  illustrates a seal of the sealing system of  FIG. 5 . 
           [0034]      FIG. 9  illustrates a battery assembly that employs a plated sealing system. 
           [0035]      FIG. 10  is a cross-sectional view of the battery assembly of  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    This disclosure details a plated sealing system for a vehicle assembly. The sealing system may include an exterior plate, an interior plate and one or more seals positioned between the exterior plate and the interior plate. In some embodiments, the sealing system is part of a vehicle assembly that includes an enclosure having a wall and tubing extending through the interior plate, the wall, and the exterior plate. The sealing system restricts moisture ingress through the plates and the wall into an interior of the enclosure. In other embodiments, the vehicle assembly is a battery assembly that includes a plurality of battery cells and a cold plate in contact with the battery cells. The sealing system seals the tubing-to-wall interface of the assembly to restrict moisture ingress inside the battery assembly. These and other features are discussed in greater detail in the following paragraphs of this detailed description. 
         [0037]      FIG. 1  schematically illustrates a powertrain  10  for an electrified vehicle  12 . Although depicted as a hybrid electric vehicle (HEV), it should be understood that the concepts described herein are not limited to HEV&#39;s and could extend to other electrified vehicles, including, but not limited to, plug-in hybrid electric vehicles (PHEV&#39;s) and battery electric vehicles (BEV&#39;s). 
         [0038]    In one embodiment, the powertrain  10  is a power-split powertrain system that employs a first drive system and a second drive system. The first drive system includes a combination of an engine  14  and a generator  18  (i.e., a first electric machine). The second drive system includes at least a motor  22  (i.e., a second electric machine), the generator  18 , and a battery assembly  24 . In this example, the second drive system is considered an electric drive system of the powertrain  10 . The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels  28  of the electrified vehicle  12 . Although a power-split configuration is shown, this disclosure extends to any hybrid or electric vehicle including full hybrids, parallel hybrids, series hybrids, mild hybrids or micro hybrids. 
         [0039]    The engine  14 , which in one embodiment is an internal combustion engine, and the generator  18  may be connected through a power transfer unit  30 , such as a planetary gear set. Of course, other types of power transfer units, including other gear sets and transmissions, may be used to connect the engine  14  to the generator  18 . In one non-limiting embodiment, the power transfer unit  30  is a planetary gear set that includes a ring gear  32 , a sun gear  34 , and a carrier assembly  36 . 
         [0040]    The generator  18  can be driven by the engine  14  through the power transfer unit  30  to convert kinetic energy to electrical energy. The generator  18  can alternatively function as a motor to convert electrical energy into kinetic energy, thereby outputting torque to a shaft  38  connected to the power transfer unit  30 . Because the generator  18  is operatively connected to the engine  14 , the speed of the engine  14  can be controlled by the generator  18 . 
         [0041]    The ring gear  32  of the power transfer unit  30  may be connected to a shaft  40 , which is connected to vehicle drive wheels  28  through a second power transfer unit  44 . The second power transfer unit  44  may include a gear set having a plurality of gears  46 . Other power transfer units may also be suitable. The gears  46  transfer torque from the engine  14  to a differential  48  to ultimately provide traction to the vehicle drive wheels  28 . The differential  48  may include a plurality of gears that enable the transfer of torque to the vehicle drive wheels  28 . In one embodiment, the second power transfer unit  44  is mechanically coupled to an axle  50  through the differential  48  to distribute torque to the vehicle drive wheels  28 . 
         [0042]    The motor  22  can also be employed to drive the vehicle drive wheels  28  by outputting torque to a shaft  52  that is also connected to the second power transfer unit  44 . In one embodiment, the motor  22  and the generator  18  cooperate as part of a regenerative braking system in which both the motor  22  and the generator  18  can be employed as motors to output torque. For example, the motor  22  and the generator  18  can each output electrical power to the battery assembly  24 . 
         [0043]    The battery assembly  24  is an example type of electrified vehicle battery. The battery assembly  24  may include a high voltage traction battery pack that includes a plurality of battery arrays, or groupings of battery cells, capable of outputting electrical power to operate the motor  22  and the generator  18 . Other types of energy storage devices and/or output devices can also be used to electrically power the electrified vehicle  12 . 
         [0044]    In one non-limiting embodiment, the electrified vehicle  12  has two basic operating modes. The electrified vehicle  12  may operate in an Electric Vehicle (EV) mode where the motor  22  is used (generally without assistance from the engine  14 ) for vehicle propulsion, thereby depleting the battery assembly  24  state of charge up to its maximum allowable discharging rate under certain driving patterns/cycles. The EV mode is an example of a charge depleting mode of operation for the electrified vehicle  12 . During EV mode, the state of charge of the battery assembly  24  may increase in some circumstances, for example due to a period of regenerative braking. The engine  14  is generally OFF under a default EV mode but could be operated as necessary based on a vehicle system state or as permitted by the operator. 
         [0045]    The electrified vehicle  12  may additionally operate in a Hybrid (HEV) mode in which the engine  14  and the motor  22  are both used for vehicle propulsion. The HEV mode is an example of a charge sustaining mode of operation for the electrified vehicle  12 . During the HEV mode, the electrified vehicle  12  may reduce the motor  22  propulsion usage in order to maintain the state of charge of the battery assembly  24  at a constant or approximately constant level by increasing the engine  14  propulsion usage. The electrified vehicle  12  may be operated in other operating modes in addition to the EV and HEV modes within the scope of this disclosure. 
         [0046]      FIGS. 2, 3 and 4  illustrate portions of a vehicle assembly  54  that can be incorporated into an electrified vehicle. For example, the vehicle assembly  54  could be employed within the electrified vehicle  12  of  FIG. 1 . The vehicle assembly  54  could be any assembly that requires sealing to restrict moisture ingress into the vehicle assembly  54 . In one non-limiting embodiment, the vehicle assembly  54  is a high voltage traction battery assembly for an electrified vehicle (see, for example, the embodiment of  FIG. 9 ). 
         [0047]    The vehicle assembly  54  includes an enclosure  60  that defines an interior  66  for housing one or more vehicle components. The enclosure  60  includes a plurality of walls  65  that surround the interior  66 . The enclosure  60  may encompass any size, shape or configuration. That is, the enclosure  60  is not limited to the specific configuration shown in  FIGS. 2 and 3 . For example, although shown with an open top in  FIGS. 2 and 3 , another wall  65  could extend along the top of the enclosure  60  to cover the vehicle components housed in the interior  66 . 
         [0048]    Tubing  70  may extend through one of the walls  65  of the enclosure  60 . The tubing  70  may extend within openings  72  formed through the wall  65 . The tubing  70  may connect between components inside the enclosure  60  and components exterior from the enclosure  60 , such as to communicate fluids between the interior  66  and the exterior. The openings  72  are holes formed through the wall  65  and therefore must be sealed to prevent moisture from entering the interior  66  of the enclosure  60 . A sealing system  74  may therefore be mounted to the wall  65  to seal any leakage paths created by the openings  72 . 
         [0049]    In one embodiment, the sealing system  74  includes an exterior plate  76  and an interior plate  78 . The exterior plate  76  is contiguous with an exterior surface  80  of the wall  65  (see  FIG. 2 ), and the interior plate  78  is contiguous with an interior surface  82  of the wall  65  (see  FIG. 3 ). A portion of the wall  65  is sandwiched between the exterior plate  76  and the interior plate  78 . The tubing  70  extends through the interior plate  78 , then through the wall  65 , and then through the exterior plate  76  to communicate between the interior  66  and the exterior of the enclosure  60  (best illustrated in  FIG. 4 ). As further discussed below, the sealing system  74  may include numerous mechanisms for sealing any leakage paths that exist through the wall  65 . 
         [0050]      FIG. 5 , with continued reference to  FIGS. 2, 3 and 4 , further illustrates the sealing system  74 . The sealing system  74  may include the exterior plate  76 , the interior plate  78 , fasteners  84  (two shown), O-ring seals  86  (two shown) and a peripheral seal  88 . As stated above, the exterior plate  76  is configured for attachment to an exterior surface  80  of the wall  65  and the interior plate  78  is configured for attachment to an interior surface  82  of the wall  65 . In one non-limiting embodiment, the exterior plate  76  and the interior plate  78  are cast, aluminum plates and may take any size or shape. 
         [0051]    The fasteners  84  secure the interior plate  78  relative to the exterior plate  76 . For example, the fasteners  84  may be tightened to secure the exterior plate  76  and the interior plate  78  together on opposing sides of the wall  65  (see  FIG. 4 ). In one embodiment, the fasteners  84  may be received in a direction from the interior surface  82  toward the exterior surface  80  of the wall  65 . The fasteners  84  are received through peripheral openings  90  of the interior plate  78  and peripheral openings  92  of the exterior plate  76 . In one non-limiting embodiment, the fasteners  84  are bolts, although other types of fasteners are also contemplated. The sealing system  74  may utilize any amount of fasteners  84  to secure the interior plate  78  relative to the exterior plate  76 . 
         [0052]    In one embodiment, the O-ring seals  86  are rubber seals. One suitable rubber material includes ethylene propylene diene monomer. However, other materials are also contemplated. The sealing system  74  may utilize any amount of O-ring seals  86  and not necessarily just the two that are shown in  FIG. 5 . The peripheral seal  88  may be a polymer infiltration and pyrolysis (PIP) seal that is fabricated using ceramic matrix composites that include a low viscosity polymer infiltrated into a ceramic structure. The O-ring seals  86  are received over the tubing  70  (e.g., one seal per tube) and abut against the interior plate  78  (i.e., the O-ring seals  86  are positioned on a first side of wall  65 ), whereas the peripheral seal  88  is received against the exterior plate  76  (i.e., the peripheral seal  88  is positioned on a second, opposite side of the wall  65  from the O-ring seals  86 , as shown in  FIG. 4 ). In another embodiment, the O-ring seals  86  could be replaced by a one-piece rubber seal or another PIP seal. 
         [0053]    The tubing  70  is sized to extend through openings  94  of the interior plate  78  and openings  96  of the exterior plate  76 . In one non-limiting embodiment, the tubing  70  may be fixedly secured to the exterior plate  76  and the interior plate  78 . Suitable attachment methodologies include, but are not limited to, brazing, welding, gluing and soldering. 
         [0054]      FIGS. 6A, 6B and 6C  illustrate additional features of the exterior plate  76 . The exterior plate  76  includes a first face  77  and an opposing second face  79 . Once installed, the first face  77  of the exterior plate  76  abuts the exterior surface  80  of the wall  65  and the second face  79  faces away from the wall  65  (see  FIG. 4 ). 
         [0055]    The first face  77  may include a recessed surface  81 . The recessed surface  81  is sized and shaped to receive the peripheral seal  88 . In one embodiment, the shape of the recessed surface  81  matches the shape of the peripheral seal  88 . As best shown in  FIG. 6B , the peripheral seal  88  protrudes slightly outwardly from the recessed surface  81  such that a portion of the peripheral seal  88  extends above the first face  77 . The peripheral seal  88  seals around a periphery of the exterior plate  76 , including around both the peripheral openings  92  and the openings  96 . 
         [0056]    The peripheral openings  92  and the openings  96  extend through the exterior plate  76 . In one embodiment, the peripheral openings  92  and the openings  96  extend through the first face  77  and the second face  79 . The peripheral openings  92  open into caps  83  that protrude from the second face  79 . In one embodiment, the caps  83  are closed-ended and include internal threading for engaging the fasteners  84  (see  FIG. 5 ) of the sealing system  74 . 
         [0057]      FIG. 7  further illustrates the peripheral seal  88  of the sealing system  74  of  FIG. 5 . The peripheral seal  88  includes a plurality of rings  85  and arms  87  that connect between adjacent rings  85 . The rings  85  seal around the peripheral openings  92  and the openings  96  of the exterior plate  76 , which is shown in  FIGS. 6A, 6B and 6C , to restrict moisture ingress. That is, the rings  85  of the peripheral seal  88  seal any leakage path that may exist through the peripheral openings  92  and the openings  96 . 
         [0058]      FIG. 8  further illustrates the interior plate  78  of the sealing system  74  of  FIG. 5 . The interior plate  78  includes a first face  91  and an opposing second face  93 . Once installed, the first face  91  of the interior plate  78  abuts the interior surface  82  of the wall  65 , whereas the second face  93  faces toward the interior  66  of the enclosure  60  (see  FIG. 4 ). The first face  91  may include a recessed surface  95 . The recessed surface  95  is sized and shaped to receive one or more O-ring seals  86 . The O-ring seals  86  seal around the openings  94  which receive the tubing  70 . Both the peripheral openings  90  and the openings  94  extend through the interior plate  78  (i.e., extend through the first face  91  and the second face  93 ). 
         [0059]      FIGS. 9 and 10  illustrate a battery assembly  154  for use in an electrified vehicle. The battery assembly  154  is one non-limiting example of a vehicle assembly that may benefit from the teachings of this disclosure. The exemplary battery assembly  154  includes battery arrays  156 , which can be described as groupings of battery cells  158 , for supplying electrical power to various vehicle components. Although two battery arrays  156  are illustrated in  FIG. 9 , the battery assembly  154  could include a single battery array or multiple battery arrays within the scope of this disclosure. In other words, this disclosure is not limited to the specific configuration shown in  FIG. 9 . 
         [0060]    Each battery array  156  includes a plurality of battery cells  158  that may be stacked side-by-side along a span length of each battery array  156 . Although not shown in the highly schematic depictions of  FIGS. 9-10 , the battery cells  158  may be electrically connected to one another using busbar assemblies. In one embodiment, the battery cells  158  are prismatic, lithium-ion cells. However, battery cells having other geometries (cylindrical, pouch, etc.) and/or other chemistries (nickel-metal hydride, lead-acid, etc.) could alternatively be utilized within the scope of the disclosure. 
         [0061]    An enclosure  160  (shown in phantom in  FIG. 9 ) surrounds the battery arrays  156 ). The enclosure  160  defines an interior  166  for housing the battery arrays  156  and, potentially, other components of the battery assembly  154 . In one non-limiting embodiment, the enclosure  160  includes a tray  162  and a cover  164  which establish a plurality of walls  165  that surround the interior  166 . 
         [0062]    During some conditions, heat may be generated by the battery cells  158  of the battery arrays  156  during charging and discharging operations. Heat may also be transferred into the battery cells  158  during vehicle key-off conditions as a result of relatively hot ambient conditions. During other conditions, such as relatively cold ambient conditions, the battery cells  158  may need heated. A cold plate  199  may therefore be utilized as part of a thermal management system for thermally conditioning (i.e., heating or cooling) the battery cells  158 . 
         [0063]    In one non-limiting embodiment, the battery arrays  156  of the battery assembly  154  are positioned atop the cold plate  199  so that the cold plate  199  is in contact with the bottom surface of each battery cell  158 . A fluid may be circulated through the cold plate  199  to either add or remove heat to/from the battery assembly  154 . Tubing  170  provides a conduit for communicating the fluid into and out of the cold plate  199 . In one embodiment, the tubing  170  protrudes through one of the walls  165  of the enclosure  160  for connection to other thermal management components. 
         [0064]    In one non-limiting embodiment, the tubing  170  extends laterally away from an edge of the cold plate  199  and extends along a completely linear axis (i.e., excludes any bends). The tubing  170  extends through one of the walls  165 , which in this example is a side wall of the enclosure  160 . The battery assembly  154  may include a sealing system  174  that seals around the tubing  170  at locations where the tubing  170  protrudes through the wall  165 . 
         [0065]    Referring now primarily to  FIG. 10 , the sealing system  174  may include an exterior plate  176 , an interior plate  178 , a first seal  186  and a second seal  188 . The exterior plate  176  is secured at an exterior surface  180  of the wall  165  and the interior plate  178  is secured at an interior surface  182  of the wall  165 . Both the first seal  186  and the second seal  188  may be positioned between the exterior plate  176  and the interior plate  178 . In one embodiment, the first seal  186  is positioned around the tubing  170  and is positioned axially between the interior surface  182  of the wall  165  and the interior plate  178  and the second seal  188  is positioned axially between the exterior surface  180  of the wall  165  and the exterior plate  176 . 
         [0066]    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. 
         [0067]    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. 
         [0068]    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.