Patent ID: 12233702

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

With reference toFIG.1, a vehicle10such as an electric vehicle is shown. In the example provided, the electric vehicle is a battery electric vehicle (BEV). In other examples, the electric vehicle may be a hybrid electric vehicle (HEV), a plug-in electric vehicle (PHEV), or a fuel cell vehicle, among others. The vehicle10includes a vehicle frame12and a battery structure or battery housing assembly14. The vehicle frame12is the main supporting structure of the vehicle10, to which various components are attached either directly or indirectly. The vehicle frame12includes opposed longitudinal rails28a,28b. The rails28a,28bare spaced apart from each other and may establish a length of the vehicle frame12. In the example illustrated, the vehicle10is a body on frame vehicle architecture, though other configurations can be used, such as a unibody architecture, for example.

The battery housing assembly14powers a rear motor (not shown) to drive rear wheels20a,20bof a set of rear wheels20via a rear axle and/or powers a front motor (not shown) to drive front wheels24a,24bof a set of front wheels24via a front axle.

With reference toFIGS.2and3, the battery housing assembly14includes a battery tray or housing30and one or more battery arrays32(FIG.3). The battery housing30is an enclosure which provides a structural surrounding and sealed compartment for the battery arrays32and other battery components such as cooling lines, support brackets, and wiring disposed therein or extending therethrough. The battery housing30may disposed at various locations of the vehicle10and is mounted to the vehicle frame12. In this way, the battery housing30is supported by the vehicle frame12and is remote from a passenger cabin (not shown) and cargo compartments (not shown) of the vehicle10, therefore, not occupying space that would otherwise be available for passengers or cargo. The battery housing30includes a cover or lid34, a body36, and a seal (not shown). The lid34may optionally be removably coupled to the body36via mechanical fasteners such as bolts or screws (not shown), for example. In this way, the lid34may be removed to service the battery arrays32disposed within the battery housing30.

The body36includes a plurality of side walls or panels36aand a bottom wall or panel36b. The side walls36amay be manufactured via stamping, for example, and extend in a vertical direction Z. The side walls36adefine an outer boundary of the battery housing30and are secured to each other via welding or an adhesive, for example. The bottom wall36bsupports the battery arrays32disposed within the battery housing30and is secured to lower portions of the side walls36a. The seal is disposed around a periphery of the body36and is engaged with the body36and the lid34. In this way, fluids, debris and other materials are inhibited from entering into the battery housing30.

With additional reference toFIG.4, each battery array32may be rechargeable and may include one or more cell stacks39formed by battery cells40(e.g., lithium-ion batteries such as those in which the cell components are enclosed in an aluminum-coated plastic film, or any other suitable electrical power storage units). In the example illustrated, the cell stacks39are formed by battery cells40arranged in a side-by-side configuration. In some forms, the cell stacks may be formed by battery cells stacked on each other in a vertical arrangement. Each battery array32comprises a structural assembly42surrounding and supporting the cell stack39. In some forms, the battery arrays32are in fluid communication with each other via connecting lines (not shown). In this way, fluid such as glycol, for example, is allowed to flow through the structural assembly42of each battery array32, thereby cooling the battery cells40.

Each structural assembly42is in the form of a modular structure that can be installed within and removed from the battery housing30. Each structural assembly42also spans substantially an entire width of the battery housing30and is configured to transfer loads from one side of the battery housing30to an opposite side of the battery housing30, for example, during certain side impacts. Stated differently, each modular structural assembly42is configured to house the battery cells40and transfer loads away from the battery cells40during certain side impacts.

Each structural assembly42may be removably coupled to the battery housing30and includes a cold plate44, a lid48and a pair of cross members50. In the example illustrated, the cold plate44is manufactured via a stamping process, for example, and is made of a metal material. In some forms, the cold plate44may be manufactured via other manufacturing processes such as an extrusion process, for example. In the example illustrated, the cold plate44is a lower wall configured to support the cell stack39and in a heat transfer relationship with the cell stack39. In some forms, the cold plate44may be a wall supporting a respective side of the cell stack39or a wall covering a top of the cell stack39. In one example, an upper surface of the cold plate44contacts a lower end of the cell stack39such that heat generated by the cell stack39is transferred to the cold plate44. As used herein, the term “heat transfer relationship” should be construed to mean an arrangement in which heat from the cell stack39is directly or indirectly transferred to one or more cold plates of the structural assembly42via thermal conduction. In the example illustrated, the cold plate44is also secured to the pair of cross members50. The cold plate44has a uniform thickness and includes a support portion44aand a pair of flanges44b. The support portion44aextends in a horizontal direction and supports the cell stack39. Each flange44bextends downward in a vertical direction from a respective end of the support portion44aand is secured to a respective cross member50of the pair of cross members50(i.e., each flange44bextends perpendicular from the support portion44a). In the example illustrated, each flange44bis secured to the respective cross member50by welding. In some forms, each flange44bmay be secured to the respective cross member50by mechanical fasteners (not shown) such as rivets, screws, or bolts, for example.

The lid48is made of a metal material and covers the cell stack39. The lid48has a solid structure and includes a uniform thickness that is less than a thickness of the cross members50. The lid48is secured to the pair of cross members50and is disposed between the pair cross members50. In the example illustrated, the lid48is welded to the pair of cross members50. In some forms, the lid48may be secured to the pair of cross members50by mechanical fasteners (not shown) such as rivets, screws, or bolts, example. The lid48extends in a horizontal direction and covers a top of the cell stack39. In the example illustrated, the cross members50extend upward past the lid48. Stated differently, the lid48is secured to the cross member50at a location below an uppermost end of the cross members50.

The pair of cross members50are spaced apart from each other in the longitudinal direction of the vehicle10and extends in a transverse direction relative to the longitudinal direction of the vehicle10. Each cross member50supports a respective side of the cell stack39and is made of a metal material such as aluminum, for example. In the example illustrated, each cross member50extends downward past the cold plate44.

Each cross member50includes an outer wall60, an inner wall62, connecting members64a,64b, and a plurality of internal stiffening members66a,66b. The outer wall60extends in a vertical direction and defines an outer boundary of the battery array32. The inner wall62is spaced apart from the outer wall60and extends in a vertical direction. In the example illustrated, the inner walls62of the pair of cross members50are secured to the lid48and the cold plate44to define a container that the cell stack39is disposed in. In the example illustrated, the cold plate44is secured to the inner walls62of the pair of cross members50at a location above the connecting members64band the lid48is secured to the inner walls62of the pair of cross members50at a location below the connecting members64a. In the example illustrated, the inner wall62of each cross member50is a single component that extends substantially an entire width of the battery structure14. In some configurations, the inner wall62of each cross member50is made of two or more adjacent components that together extend substantially an entire width of the battery structure14. In some forms of the above configuration, the two or more adjacent components of the inner wall62of each cross member50may be separate (distinct) from each other. In other forms of the above configuration, the two or more adjacent components of the inner wall62of each cross member50may be joined to each other by welding, adhesives, fasteners, or any other suitable attachment means.

The connecting member64aconnects the upper section of the inner wall62with an upper section of the outer wall60. The connecting member64aincludes a body portion65a, an outer flange portion65b, and an inner flange portion65c. The body portion65aextends in a horizontal from the outer wall60of a respective cross member50past the inner wall62of the respective cross member50. The outer flange portion65bextends downward in a vertical direction from an end of the body portion65a. The outer flange portion65bis also located above and is spaced apart from a respective end of the lid48. The inner flange portion65cextends downward in a vertical direction from the body portion65aand is located between the outer wall60and the outer flange portion65b. In the example illustrated, the inner flange portion65cis adjacent the outer flange portion65b(i.e., the inner flange portion65cis closer toward the outer flange portion65bthan the outer wall60) such that the inner flange portion65cand the outer flange portion65bdefine a channel67that an upper end of the inner wall62is slidably received in. The inner flange portion65calso extends downward past the outer flange portion65b.

The connecting member64bconnects the lower section of the inner wall62with a lower section of the outer wall60. The connecting member64bincludes a body portion69a, an outer flange portion69b, and an inner flange portion69c. The body portion69aextends in a horizontal from the outer wall60of a respective cross member50past the inner wall62of the respective cross member50. The outer flange portion69bextends upward in a vertical direction from an end of the body portion69a. The outer flange portion69bis also located below a respective flange44bof the cold plate44. The outer flange portion69bis spaced apart from the respective flange44bof the cold plate44. The inner flange portion69cextends upward in a vertical direction from the body portion69aand is located between the outer wall60and the outer flange portion69b. In the example illustrated, the inner flange portion69cis adjacent the outer flange portion69bsuch that the inner flange portion69cand the outer flange portion69bdefine a channel71that a lower end of the inner wall62is slidably received in (i.e., the inner flange portion69cis closer toward the outer flange portion69bthan the outer wall60). The inner flange portion69calso extends upward past the outer flange portion69b. The inner walls62of the pair cross members50, the cold plate44, and the lid48are secured to each other to define a container that houses the cell stack39and is slidable relative to the outer walls60of the pair of cross members50.

The outer wall60, the inner wall62and the connecting members64a,64bcooperate to define an internal cavity80. The internal stiffening members66aare disposed within the internal cavity80and extend in a horizontal direction from the outer wall60toward the inner wall62. In the example illustrated, the internal stiffening members66aare spaced apart from each other in a vertical direction and are spaced apart from the inner wall62of the cross member50. The internal stiffening members66bare disposed within the internal cavity80and extend in a horizontal direction from the inner wall62toward the outer wall60. In the example illustrated, the internal stiffening members66bare spaced apart from each other in a vertical direction and are spaced apart from the outer wall60of the cross member50. In this way, sliding of the inner walls62of the cross members50relative to the outer walls60of the cross members50are facilitated. In the example illustrated, the internal stiffening members66aand the internal stiffening members66bare arranged in an alternating configuration.

As shown inFIG.3, a first end wall82is oriented vertically and is secured to the structural assembly42. In one example, the first end wall82is secured to one or both of the pair of cross members50, the lid48and/or the cold plate44. The first end wall82covers and supports a first end of the cell stack39(FIG.4). Similarly, a second end wall84that is opposite the first end wall82is oriented vertically and is secured to the structural assembly42. In one example, the second end wall84is secured to one or both of the pair of cross members50, the lid48and/or the cold plate44. The second end wall84covers and supports a second end of the cell stack39(FIG.4) that is opposite the first end of the cell stack39(FIG.4). The end walls82,84are secured to the structural assembly42such that the end walls82,84and the structural assembly42cooperate to form a structural surrounding and sealed compartment for the cell stack39(FIG.4). In one example, the first and second end walls82,84are secured to gussets (not shown), which are, in turn, secured to the battery housing30.

The structural assembly42of the present disclosure provides multiple functions such as load paths, heat transfer, and fluid flow paths. In one example, the cross members50of each structural assembly42are configured to house the battery cells40and transfer loads across the battery housing30away from the battery cells40during certain side impacts. In some forms, the structural assembly42may be additively manufactured in which one or more walls include an internal lattice structure to provide fluid flow paths for cooling fluid flowing through the structural assembly42.

With reference toFIG.5, a structural assembly142is illustrated. The structural assembly142may be incorporated into the battery housing assembly14described above, instead of, the structural assembly42. The structure and function of the structural assembly142may be similar or identical to the structural assembly42described above, apart for any differences noted below.

The structural assembly142surrounds and supports a plurality cell stacks139. The structural assembly142includes a plurality of cold plates144, a plurality of lids148, and a plurality of cross members150.

The structure and function of the cold plates144and the lids148may be similar or identical to that of the cold plate44and the lid48, respectively, described above, and therefore, will not be described again in detail.

Each cross member150is disposed between two adjacent cell stacks139and supports a respective side of the two cell stacks139. Each cross member150includes a pair of outer walls160, an intermediate wall162, connecting members164a,164b, and a plurality of internal stiffening members166. Each outer wall160is spaced apart from the intermediate wall162and extends in a vertical direction. In the example illustrated, each outer wall160is secured to a respective lid148and a respective cold plate144to define a container that a respective cell stack139is disposed in. Each outer wall160is also slidable relative to the intermediate wall162and the connecting members164a,164b. The intermediate wall162extends in a vertical direction and is disposed between the pair of outer walls160. The intermediate wall162also extends from the connecting member164ato the connecting member164b.

The connecting member164aconnects the upper section of the intermediate wall162with upper sections of the outer walls160. The connecting member164aincludes a body portion165a, a pair of outer flange portions165b, and a pair of inner flange portions165c. Each outer flange portion165bextends downward in a vertical direction from a respective end of the body portion165a. Each outer flange portion165bis also located above and is spaced apart from a respective end of the lid148. Each inner flange portion165cextends downward in a vertical direction from the body portion165aand is located between the intermediate wall162and a respective outer flange portion165b. In the example illustrated, the inner flange portion165cis adjacent the respective outer flange portion165bsuch that the inner flange portion165cand the respective outer flange portion165bdefine a channel167that an upper end of a respective outer wall162is slidably received in. The inner flange portion165calso extends downward past the respective outer flange portion165b.

The connecting member164bconnects the lower section of the intermediate wall162with lower sections of the outer walls160. The connecting member164bincludes a body portion169a, a pair of outer flange portions169b, and a pair of inner flange portions169c. Each outer flange portion169bextends upward in a vertical direction from a respective end of the body portion169a. Each outer flange portion169bis also located below and is spaced apart from a respective end of the cold plate144. Each inner flange portion169cextends upward in a vertical direction from the body portion169aand is located between the intermediate wall162and a respective outer flange portion169b. In the example illustrated, the inner flange portion169cis adjacent the respective outer flange portion169bsuch that the inner flange portion169cand the respective outer flange portion169bdefine a channel171that a lower end of a respective outer wall162is slidably received in. The inner flange portion169calso extends upward past the respective outer flange portion169b.

The outer walls160, the intermediate wall162and the connecting members164a,164bcooperate to define an internal cavity180. The internal stiffening members166are disposed within the internal cavity180and extend in a horizontal direction. That is, a plurality of the internal stiffening members166extend from the intermediate wall162toward one outer wall160of the pair of outer walls160and a plurality of the internal stiffening members166extend from the intermediate wall162toward the other outer wall160of the pair of outer walls160. In the example illustrated, the internal stiffening members166are spaced apart from the outer walls162of the cross member150. In this way, sliding of the outer walls160of the cross members150relative to the intermediate walls162of the cross members150is facilitated.

Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.

As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.