Abstract:
A battery array according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells, a support structure surrounding the plurality of battery cells and a first lifting feature protruding from a first wall of the support structure.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates to a battery array for an electrified vehicle. The battery array includes one or more lifting features integrated into a support structure of the battery array. The lifting features are configured to receive a lifting tool for lifting, handling and maneuvering the battery array. 
       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 because 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 propel the vehicle. 
         [0003]    The powertrain of an electrified vehicle is typically equipped with a battery assembly including a plurality of battery cells that store electric power for powering the electric machines and other electric loads of the electrified vehicle. A support structure (i.e., end walls, side walls, etc.) generally surrounds the battery cells to build a battery array. Some form of a lifting feature is typically required for handling the battery array during the assembly and packaging portions of the manufacturing process. 
       SUMMARY 
       [0004]    A battery array according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells, a support structure surrounding the plurality of battery cells and a first lifting feature protruding from a first wall of the support structure. 
         [0005]    In a further non-limiting embodiment of the foregoing battery array, the first wall is an end wall of the support structure. 
         [0006]    In a further non-limiting embodiment of either of the foregoing battery arrays, the first wall includes an outer shell and an inner shell, and the first lifting feature includes a tab that protrudes from the outer shell. 
         [0007]    In a further non-limiting embodiment of any of the foregoing battery arrays, a bent portion of the tab extends above the inner shell. 
         [0008]    In a further non-limiting embodiment of any of the foregoing battery arrays, the inner shell includes at least one through-hole extending vertically through the inner shell. 
         [0009]    In a further non-limiting embodiment of any of the foregoing battery arrays, a retention bar extends over top of the plurality of battery cells and connects to the tab. 
         [0010]    In a further non-limiting embodiment of any of the foregoing battery arrays, the tab and the retention bar together establish the first lifting feature. 
         [0011]    In a further non-limiting embodiment of any of the foregoing battery arrays, a slot extends between the tab and the inner shell. 
         [0012]    In a further non-limiting embodiment of any of the foregoing battery arrays, the first lifting feature includes a tab that protrudes outwardly from an outer face of the first wall in a direction opposite from the plurality of battery cells. 
         [0013]    In a further non-limiting embodiment of any of the foregoing battery arrays, the tab includes a slot. 
         [0014]    In a further non-limiting embodiment of any of the foregoing battery arrays, the slot is configured to receive a lifting tool. 
         [0015]    In a further non-limiting embodiment of any of the foregoing battery arrays, an outermost face of the tab is an outermost surface of the first wall. 
         [0016]    In a further non-limiting embodiment of any of the foregoing battery arrays, the lifting feature includes a tab that is integrated as part of the support structure. 
         [0017]    In a further non-limiting embodiment of any of the foregoing battery arrays, a second lifting feature protrudes from a second wall of the support structure, the second wall on an opposite end of the plurality of battery cells from the first wall. 
         [0018]    In a further non-limiting embodiment of any of the foregoing battery arrays, the first lifting feature includes a slot configured to receive a lifting tool. 
         [0019]    A method according to another exemplary aspect of the present disclosure includes, among other things, approaching a battery array from its top side with a lifting tool, engaging a lifting feature of a battery array using the lifting tool and moving the battery array by moving the lifting tool. 
         [0020]    In a further non-limiting embodiment of the foregoing method, the engaging step excludes moving any portion of the lifting tool beyond an outer peripheral envelope of the battery array. 
         [0021]    In a further non-limiting embodiment of either of the foregoing methods, the engaging step includes inserting a stationary leg of the lifting tool into a through-hole of a wall of the battery array and moving a movable leg into engagement with the lifting feature. 
         [0022]    In a further non-limiting embodiment of any of the foregoing methods, the step of moving the movable leg includes one of translating the movable leg relative to a body of the lifting tool or pivoting the movable leg relative to the body. 
         [0023]    In a further non-limiting embodiment of any of the foregoing methods, the lifting feature includes a tab that protrudes outwardly from a wall of the battery array and the engaging step includes inserting the lifting tool through a slot of the tab and engaging a leg of the lifting tool with a portion of the tab that surrounds a periphery of the slot. 
         [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  illustrates a battery array according to a first embodiment of this disclosure. 
           [0028]      FIG. 3  illustrates a portion of the battery array of  FIG. 2 . 
           [0029]      FIG. 4A  illustrates a lifting tool according to a first embodiment of this disclosure. 
           [0030]      FIG. 4B  illustrates a lifting tool according to a second embodiment of this disclosure. 
           [0031]      FIGS. 5A, 5B and 5C  schematically illustrate engagement of a lifting feature with a lifting tool for lifting and moving a battery array. 
           [0032]      FIG. 6  illustrates a battery array according to another embodiment of this disclosure. 
           [0033]      FIG. 7  illustrates a top view of a portion of the battery array of  FIG. 6 . 
           [0034]      FIG. 8  schematically illustrates the use of a lifting tool to engage and move a battery array. 
       
    
    
     DETAILED DESCRIPTION 
       [0035]    This disclosure details a battery array for an electrified vehicle. The battery array may employ one or more lifting features configured to receive a lifting tool. The lifting tool engages the lifting feature to lift, handle and/or maneuver the battery array during assembly and packaging processes. The lifting features are integrated as part of a support structure and therefore require minimal additional materials by utilizing structures that are already part of the battery array. In some embodiments, the lifting feature includes a tab that protrudes from the wall. A portion of the tab may be engaged by the lifting tool for handling the battery array. These and other features are discussed in greater detail in the following paragraphs of this detailed description. 
         [0036]      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), battery electric vehicles (BEV&#39;s) and fuel cell vehicles. 
         [0037]    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. 
         [0038]    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 . 
         [0039]    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 . 
         [0040]    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 . 
         [0041]    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 . 
         [0042]    The battery assembly  24  is an exemplary electrified vehicle battery. The battery assembly  24  may include a high voltage traction battery pack that includes a plurality of battery arrays 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 . 
         [0043]    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. 
         [0044]    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. 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. 
         [0045]      FIGS. 2 and 3  illustrate a battery array  25  that can be incorporated into an electrified vehicle. For example, the battery array  25  could be part of the battery assembly  24  of the electrified vehicle  12  of  FIG. 1 . The battery array  25  includes a plurality of battery cells  58  for supplying electrical power to various components of the electrified vehicle  12 . Although a specific number of battery cells  58  are illustrated in  FIG. 2 , the battery array  25  could include a greater or fewer number of battery cells within the scope of this disclosure. In other words, this disclosure is not limited to the specific configuration shown in these figures. 
         [0046]    The battery cells  58  may be stacked side-by-side to construct a grouping of battery cells, sometimes referred to as a “cell stack.” In one embodiment, the battery cells  58  are prismatic, lithium-ion cells. However, battery cells having other geometries (cylindrical, pouch, etc.) and/or chemistries (nickel-metal hydride, lead-acid, etc.) could alternatively be utilized within the scope of this disclosure. 
         [0047]    A support structure  59 , sometimes referred to as an array structure or array support structure, generally surrounds the battery cells  58 . The support structure  59  may include opposing end walls  60  disposed at the longitudinal extents of the grouping of battery cells  58  and opposing side walls  62  that extend on both sides of the battery array  25  between the opposing end walls  60 . The end walls  60  and the side walls  62  cooperate to hold the battery cells  58  under compression relative to one another. The side walls  62  may be connected to the end walls  60  in any known manner. In one non-limiting embodiment, the side walls  62  and the end walls  60  are welded together. In another non-limiting embodiment, the support structure  59  includes a monoblock design that includes a single, contiguous unit that generally surrounds the battery cells  58 . 
         [0048]    The support structure  59  may additionally include a retention bar  72  and one or more bus bar modules  75 . The retention bar  72  may optionally extend over top of the battery cells  58  of the battery array  25  for retaining the battery cells  58  and to provide rigidity to the battery array  25 . The bus bar modules  75  may rest on top of the battery cells  58  and may receive metallic bus bars (not shown) for electrically connecting the battery cells  58 . 
         [0049]    The battery array  25  may additionally employ one or more lifting features  64  that are integrated as part of the support structure  59 . The lifting features  64  are configured to receive lifting tools, examples of which are discussed below, that engage the lifting features  64  to lift, handle and/or move the battery array  25 . For example, lifting tools may be utilized to engage the lifting features  64  during the array or packaging portions of a battery array manufacturing process. In one non-limiting embodiment, the lifting features  64  protrude from the end walls  60  of the support structure  59 . However, other configurations are also contemplated, including configurations in which the lifting features  64  are integrated into the side walls  62  or any other portion of the support structure  59 . 
         [0050]    In one non-limiting embodiment, each end wall  60  exhibits a two-piece design. For example, each end wall  60  may include an outer shell  66  and an inner shell  68  connected to the outer shell  66 . The inner shell  68  is disposed between the outer shell  66  and the battery cells  58 . The outer shell  66  may be a stamped, metallic portion of the end wall  60 , and the inner shell  68  may be a plastic portion of the end wall  60 . 
         [0051]    In one non-limiting embodiment, the lifting feature  64  of each end wall  60  of the battery array  25  includes a tab  70 . The tab  70  may protrude upwardly from the outer shell  66  such that it extends in an opposite direction from the bottom of the battery array  25 . The tab  70  may include a bent portion  74  that extends in a direction toward the opposite end wall  60 . The retention bar  72  may connect to the tab  70 . In one non-limiting embodiment, a tab  69  of the retention bar  72  is welded to the bent portion  74  of the tab  70 . A slot  76  may extend between an underside  77  of the bent portion  74  of the tab  70  and a top face  79  of the inner shell  68 . Together, the tab  70  and the retention bar  72  establish the lifting feature  64  of each end of the battery array  25 . A lifting tool may be received within the slot  76  and then moved to engage the underside  77  of the bent portion  74  in order to lift and move the battery array  25 , as further discussed below. 
         [0052]    One or more through-holes  78  may be formed through the inner shell  68  of each end wall  60 . In one embodiment, the through-holes  78  extend vertically across the height of the inner shells  68 . The through-holes  78  may be positioned within opposing side portions  81  of the inner shell  68 . The opposing side portions  81  are disposed near the junction between each end wall  60  and the side walls  62 . 
         [0053]      FIGS. 4A and 4B  illustrate an exemplary lifting tool  80 . The lifting tool  80  includes a body  82 , a stationary leg  84  and a movable leg  86 . The stationary leg  84  and the movable leg  86  both extend from the body  82 . The stationary leg  84  is substantially immovable relative to the body  82 , whereas the movable leg  86  may be translated or pivoted relative to the body  82 . In one embodiment, the movable leg  86  may be translated along a length of the body  82  as schematically illustrated by arrow X (see  FIG. 4A ). In another embodiment, the movable leg  86  may be pivoted or swung relative to the body  82  as schematically illustrated by arrow Z (see  FIG. 4B ). An engagement member  88  may extend transversely from the movable leg  86  of the lifting tool  80 . 
         [0054]    Referring now to  FIGS. 5A, 5B and 5C , with continued reference to  FIGS. 1-4B , the lifting tool  80  may be used to lift and move the battery array  25  during portions of the battery array manufacturing process. First, the lifting tool  80  is moved to approach the battery array  25 . The battery array  25  may be approached from its top side  90  so that additional side clearances between the end walls  60  and any surrounding obstructions (e.g., battery enclosures, packaging, internal battery components, etc.) are not necessary. 
         [0055]    Next, the lifting tool  80  is used to engage one of the lifting features  64 . The stationary leg  84  of the lifting tool  80  is first inserted into one of the through-holes  78  of the inner shell  68  of the end wall  60  to properly orient and align the lifting tool  80  relative to the end wall  60 . The movable leg  86  may then be moved into the slot  76  at the same time using the engagement of stationary leg  84  in the through-hole  78  as a reactive force for the movement. For example, the movable leg  86  may be translated in a direction X (see  FIG. 5A ) or pivoted in a direction Z (see  FIG. 5B ) to position the engagement member  88  beneath the bent portion  74  of the tab  70 . In either embodiment, it is not necessary to move any portion of the lifting tool  80  to a position that extends beyond the outer peripheral envelope of the battery array  25  in order to engage the lifting feature  64 . 
         [0056]    Finally, the body  82  of the lifting tool  80  can be moved in an upward direction D 1  to lift and move the battery array  25  (best illustrated in  FIG. 5C ). Movement in the upward direction D 1  causes the engagement member  88  to contact the underside  77  of the bent portion  74  of the tab  70 , thereby creating the interference necessary to lift and move the battery array  25 . 
         [0057]      FIGS. 6 and 7  illustrate another exemplary battery array  125 . 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. 
         [0058]    In this exemplary embodiment, the battery array  125  includes a plurality of battery cells  158 , a support structure  159  that surrounds the plurality of battery cells  158 , and one or more lifting features  164  that can be employed to lift, handle and maneuver the battery array  125 . Each end wall  160  (only one shown) of the support structure  159  may include one of the lifting features  164 . In one non-limiting embodiment, the end walls  160  exhibit a single-piece design and are cast, metallic parts. 
         [0059]    The lifting feature  164  of each end wall  160  may include a tab  170  that is formed integrally with the end wall  160 . The tab  170  may protrude outwardly from an outer face  192  of the end wall  160 . The outer face  192  faces in a direction away from the battery cells  158 . The tab includes a slot  176  that is configured to receive a portion of a lifting tool, as further discussed below. In one non-limiting embodiment, the tab  170  is located near the top of the end wall  160  to facilitate access to the lifting feature  164 . 
         [0060]    The tab  170  includes an outermost face  194 . The outermost face  194  extends to a plane P 1 . The outermost face  194  is the outermost surface of the end wall  160 . In other words, no other portion of the end wall  160  protrudes outwardly beyond the plane P 1 . Some other portions of the end wall  160  may, however, extend up to the plane P 1 . 
         [0061]      FIG. 8 , with continued reference to  FIGS. 6 and 7 , illustrates use of a lifting tool  180  to engage and lift the battery array  125 . First, the lifting tool  180  is moved to approach the battery array  125 . The battery array  125  may be approached from its top side  190  so that additional side clearances between the end walls  160  and any surrounding obstructions (e.g., battery enclosures, packaging, etc.) are not necessary. 
         [0062]    Next, the lifting tool  180  is moved to engage the lifting features  164 . The lifting tool  180  may include a leg  198  that may be moved into the slot  176  and then under a portion of the tab  170  in order to engage the lifting feature  164 . The leg  198  may engage any portion of the tab  170  that extends about the periphery of the slot  176 . In one non-limiting embodiment, the lifting tool  180  engages curved ends  199  of the slot  176 . Once the lifting feature  164  has been sufficiently engaged, the lifting tool  180  may be moved to lift and maneuver the battery array  125 . 
         [0063]    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. 
         [0064]    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. 
         [0065]    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.