BATTERY CONNECTOR PLATE WITH ELECTROMAGNETIC SHIELD

A battery component includes a header body and a frame secured to the header body. The frame includes an electromagnetic shield portion. The electromagnetic shield portion defines at least one electrical connection port. The electrical connection port is configured to receive an electrically conductive object. The electromagnetic shield portion is configured to dissipate electromagnetic radiation from the electrically conductive object.

FIELD

The present disclosure relates to battery assemblies, and more particularly to electrically shielding high voltage from batteries in electric vehicles.

BACKGROUND

The desire to reduce automotive fuel consumption and emissions has been well documented. Thus, electric vehicles (EVs) have been developed to significantly reduce reliance on internal combustion engines. In general, electric vehicles differ from conventional motor vehicles because they are driven by one or more rechargeable battery assemblies having lithium-ion batteries, for example, or any other suitable electrical power storage units. The battery assembly typically powers one or more motors to drive a set of wheels.

The battery assembly further includes one or more shielded connectors that inhibit radio frequency (RF) electromagnetic radiation (EMR) from wires or other electrically conductive components within the battery assembly. Such EMR should be contained or shielded in order to inhibit interference with external devices. Known EMR shields, however, are typically a metal material and thus can add significant weight to an EV and are also prone to corrosion.

The present disclosure addresses these and other issues related to shielding external devices from EMR generated by rechargeable battery assemblies in electric vehicles.

SUMMARY

In one form, a battery component includes a header body and a frame secured to the header body, the frame including an electromagnetic shield portion, the electromagnetic shield portion defining at least one electrical connection port, wherein the electrical connection port is configured to receive an electrically conductive object, and the electromagnetic shield portion is configured to dissipate electromagnetic radiation from the electrically conductive object.

In variations of the battery component, which may be implemented individually or in combination: the battery component further includes a plurality of electrically conductive fasteners securing the frame to the header body; an electrical ground, wherein the electrically conductive fasteners electrically connect the frame to the electrical ground; the frame defines an opening adjacent to the electromagnetic shield portion; further including a seal secured to and extending around a perimeter of the frame; the electromagnetic shield portion is continuous between opposing peripheral edges of the frame; the body is a polymeric material; the body includes an integral electrical connector protruding through the electrical connection port of the frame; the electrical connection port extends through the body; the electromagnetic shield portion defines a second electrical connection port adjacent to the electrical connection port.

In another form, a battery assembly includes a battery tub, an electrically conductive object external to the battery tub, and a battery header secured to the battery tub, the battery header including a body, and a frame secured to the body, the frame including an electromagnetic shield portion, the electromagnetic shield portion defining an electrical connection port, wherein the electromagnetic shield portion is configured to dissipate electromagnetic radiation from the electrically conductive object to the battery tub.

In variations of the battery assembly, which may be implemented individually or in combination: the battery further includes a plurality of electrically conductive fasteners securing the frame to the battery tub; the plurality of electrically conductive fasteners form an electrical connection between the electrically conductive object and the battery tub; the frame defines an opening adjacent to the electromagnetic shield portion; further including a seal secured to and extending around a perimeter of the frame.

In another form, a vehicle subassembly includes a vehicle frame member, a battery tub supported by the vehicle frame member, an electrically conductive object external to the battery tub, and a battery header secured to the battery tub, the battery header including a body and a frame secured to the body, the frame including an electromagnetic shield portion, the electromagnetic shield portion defining an electrical connection port, wherein the electromagnetic shield portion is configured to dissipate electromagnetic radiation from the electrically conductive object to the vehicle frame member via the battery tub.

In variations of the vehicle subassembly, which may be implemented individually or in combination: the vehicle subassembly further includes a plurality of electrically conductive fasteners securing the frame to the battery tub, the plurality of electrically conductive fasteners forming an electrical connection between the electromagnetic shield portion and the frame member; wherein the vehicle frame member forms an electrical ground, and the electromagnetic shield portion dissipates the electromagnetic radiation from the electrically conductive object to the electrical ground; wherein the vehicle frame member is a longitudinal frame rail; further including a seal secured to and extending around a perimeter of the frame.

DETAILED DESCRIPTION

With reference toFIG.1, a vehicle subassembly20for an electric vehicle is shown. The vehicle subassembly20includes opposed frame members22, configured to be mounted to a vehicle chassis (not shown for purposes of clarity), and a battery assembly24supported by the frame members22. In one form, the vehicle is a body-on-frame vehicle architecture and the frame members22are the longitudinal side rails of the structural frame of the vehicle and may extend substantially parallel to each other along opposite lateral sides of the battery assembly24. The battery assembly24includes a battery tub26, a battery header30secured to the battery tub26, and a battery pack (not shown) within the battery tub26. An electrically conductive object28such as a powered wire (as shown) or bus tab (not shown) can be attached or mounted to the battery header30. The battery tub26houses the battery pack (not shown), which may include one or more battery cells (not shown) among other components (e.g., circuitry associated with the battery cells) as described in greater detail below. In the form shown, the electrically conductive object28conducts power from the battery to one or more components of the electric vehicle, such as an electric motor. The header30generally provides (or functions to provide) a mechanical connection for and locates each of the electrically conductive objects28.

Referring now toFIGS.2-6, the battery header30in one form includes a body32and a frame34. The frame34in this form is a separate part or component that is secured to the body32. In this form, the body32is the outermost structure of the battery header30, such that the frame34is between the body32and the battery tub26. The body32includes a wall portion33, a flange portion35, and one or more external electrical connector36.

The flange portion35defines a perimeter of the body32and couples the body32to the battery tub26. In the example provided, the flange portion35is attached to the battery tub26by fasteners37(e.g., bolts or screws), though other configurations can be used, such as interlocking features or clips for example. The wall portion33extends inward, relative to the perimeter defined by the flange portion35, from the flange portion35to the connector36. The wall portion33can support the connector36to space the connector36apart from the flange portion35and the battery tub26.

The connector36provide electrical connection from the battery pack (not shown) to the electrically conductive objects28. The electrical connector36can be shaped to receive mating electrical connectors39(one shown inFIG.6), which can support the electrically conductive object28, such as wires and/or bus tabs.

The body32can be any suitable non-electrically conductive material, such as a polymeric material or a composite material, for example. Specifically, the body32may be formed by injection molding, by way of example, such that the electrical connector36are integrally formed with the wall portion33and the flange portion35. In another form, the body is formed by an additive manufacturing process, such as fused filament fabrication.

The frame34includes a flange portion41, at least one wall portion43, and at least one electromagnetic shield portion38. The flange portion41defines a perimeter of the frame34. The flange portion41couples the frame34to the battery tub26and is disposed between the flange portion35and the battery tub26. In the example provided, the flange portion41is attached to the battery tub26by the fasteners37, though other configurations can be used, such as interlocking features or clips for example.

The wall portion43extends inward, relative to the perimeter defined by the flange portion41, from the flange portion41to the electromagnetic shield portion38. The wall portion43can support the electromagnetic shield portion38to space the electromagnetic shield portion38apart from the flange portion41and the battery tub26.

The electromagnetic shield portion38defines at least one aperture or connection port aligned with a corresponding one of the connector36. In the example provided, the electromagnetic shield portion38defines a first aperture or connection port40aligned with one of the connector36and a second aperture or connection port42aligned with a second one of the connector36, though other configurations can be used. The connection ports (e.g.,40,42) are large enough for electrical conductors (e.g., pin45, shown inFIG.6) to extend through the frame34, into the connector36, where the conductor (e.g., pin45) can electrically couple with the electrically conductive object28(e.g., via a mating pin47of the mating electrical connector39). The conductor (e.g., pin45) is electrically connected to the battery pack (not shown).

The connection ports (e.g.,40,42) defined by the electromagnetic shield portion38are large enough such that the conductor (e.g., pin45) does not contact the frame34and large enough to prevent electrical arcing between the conductor (e.g., pin45) and the frame34. However, the connection ports (e.g.,40,42) are small enough such that the electromagnetic shield portion38still overlaps a rear side (i.e., interior side) of the connector36. In one form, the electromagnetic shield portion38may abut the rear side of the connector36.

In one form, the frame34is metal. The frame34may optionally be formed from sheet metal stamped into a three-dimensional shape. In another form, the frame34may be formed by another method, such as welding, soldering, fastening, adhesive bonding, or additive manufacturing, for example. While the frame34is metal in one form, it should be understood that the frame34can be any electrically conductive material within the scope of the present disclosure, such as an electrically conductive composite material. The electromagnetic shield portion38and the wall portion43provide continuous electrical continuity from opposing peripheral edges of the flange portion41, such as between a top edge46and a bottom edge48of the flange portion41. Because electricity flowing between the battery pack (not shown) and the electrically conductive object28causes electromagnetic radiation (EMR) to be emitted, the metal electromagnetic shield portion38surrounding the conductor (e.g., pin45) is configured to dissipate the EMR to an electrical ground since the frame34provides electrical continuity to the electrical ground, as described in greater detail below.

As further shown, the frame34can define one or more openings44adjacent to the electromagnetic shield portion38. These openings44can be larger than the connection ports (e.g.,40,42) defined by the electromagnetic shield portion38and are configured to reduce the overall weight of the frame34in areas where shielding is not required and/or where structure is required for any other functional purpose. In one form, these openings make up a majority of the geometric area encompassed by the flange portion41.

In one form, the battery header30also includes a seal50, which in one form is a gasket, secured to and extending around the flange portion41of the frame34. The seal50is configured to form a fluid-tight barrier between the flange portion41, the flange portion35, and the battery tub26when the battery header30is secured to the battery tub26. In one form, the seal50is co-molded, or over-molded, to the frame34in an injection molding process. In another form, the seal50is formed separately and then attached to the frame34in a suitable manner, such as with an adhesive, or interlocking geometry. In another form, not specifically shown, one seal is disposed between the flange portion41and the battery tub26, while a separate seal is disposed between the flange portion41and the flange portion35.

In addition to the fasteners37, which can secure the flange portion41to the flange portion35, additional fasteners52may secure the electromagnetic shield portion38to the body32and may secure the connector36to the mating electrical connector39. The fastener52may optionally also be electrically conductive (e.g., metal) to provide grounding electrical continuity between the electromagnetic shield portion38and part of the mating electrical connector39.

In one form, at least one of the fasteners37is electrically conductive and provides electrical continuity between the frame34and the battery tub26, and the battery tub26is electrically connected to an electrical ground (e.g., frame members22, shown inFIG.1). EMR emitted at the connector36is transferred to the electromagnetic shield portion38, through the electrically conductive fasteners37, to the battery tub26, and then to the electrical ground. Thus, the electrically conductive fasteners37provide an electrical grounding path from the electromagnetic shield portion38to an electrical ground.

The battery tub26can also include an internal tray54. The battery header30can be secured to the internal tray54by the fasteners37. The internal tray54generally houses one or more electrically conductive objects (not shown), such as wire bundles and bus tabs/bars, as well as other components of the battery, such as electrical connectors (not shown) or battery cells (not shown). In another form not shown, the battery tub26lacks the internal tray54.

With reference toFIG.6, an internal electrical connector56can be attached to an end of a cable (similar to cable60shown inFIG.7) that extends into the battery tub26and the cable is attached to components of the battery therein. The internal electrical connector56can include the electrical conductor (e.g., pin45) and couples the conductor (e.g., pin45) to the cable. The internal electrical connector56protrudes through the connection port (e.g., connection port42) of the frame34, and is received in the rear side of the connector36to position the conductor (e.g., pin45) therein for connection with the mating pin47. The internal electrical connector56may be removably coupled to the connector36, such as via clips (similar to clips57, shown inFIG.7). The internal electrical connector56can electrically insulate the conductor (e.g., pin45) from the frame34and the fastener52.

Referring toFIG.7, a rear side of the battery header30at the connection port40is shown. The connector36shown inFIG.7can be similar to the connector36shown inFIG.6and described above, except as otherwise shown or described herein. Accordingly, similar features have similar reference numerals and only differences are described in detail herein. Specifically, the connector36shown inFIG.7does not include the fastener52. Instead, the electromagnetic shield portion38includes a tab58that electrically connects to a grounding contact59of the internal electrical connector56. The electrical connection, formed by physical contact between the tab58and the grounding contact59of the internal electrical connector56dissipates EMR to the electrical ground, as described above. That is, the frame34, via the tab58, forms the electrical path from the internal electrical connector56to the electrical ground.

By reducing the amount of material used to form the frame34and incorporating a lighter weight material, such as a polymer into the body32, the overall weight of the battery header30is reduced while providing EMR shielding. Such shielding reduces interference with components that use electromagnetic frequencies to communicate, such as by way of example, a radio or other electronic controls within the vehicle. The battery header30of the present disclosure thus improves operation of the vehicle by reducing the overall weight of the battery assembly, thereby increasing the energy efficiency of the vehicle.