Patent Document

TECHNICAL FIELD 
       [0001]    This disclosure relates to a vehicle assembly for an electrified vehicle. The vehicle assembly includes a blocking member configured to impede access to high voltage components during servicing events. 
       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 internal combustion engines to propel the vehicle. 
         [0003]    Numerous 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 power electric machines and other electric loads of the electrified vehicle. Seals are disposed within the battery assembly to restrict moisture ingress into its interior. The seals may need to be removed from time to time to service the internal components of the battery assembly. Removal is typically achieved by cutting the seal using a cutting tool. 
       SUMMARY 
       [0004]    A vehicle assembly according to an exemplary aspect of the present disclosure includes, among other things, an enclosure, a high voltage component housed inside the enclosure and a blocking member configured to restrict access to the high voltage component along a path that extends through the enclosure. 
         [0005]    In a further non-limiting embodiment of the foregoing assembly, the enclosure includes a tray and a cover secured to the tray. 
         [0006]    In a further non-limiting embodiment of either of the foregoing assemblies, the blocking member is formed in the tray. 
         [0007]    In a further non-limiting embodiment of any of the foregoing assemblies, the blocking member is formed in the cover. 
         [0008]    In a further non-limiting embodiment of any of the foregoing assemblies, the blocking member is formed in both the tray and the cover. 
         [0009]    In a further non-limiting embodiment of any of the foregoing assemblies, the blocking member includes a block body disposed between the cover and the tray. 
         [0010]    In a further non-limiting embodiment of any of the foregoing assemblies, the blocking member includes an interrupted surface formed in at least one of the tray and the cover. 
         [0011]    In a further non-limiting embodiment of any of the foregoing assemblies, the interrupted surface is formed in the tray and extends toward the cover. 
         [0012]    In a further non-limiting embodiment of any of the foregoing assemblies, the interrupted surface is formed in the cover and extends toward the tray. 
         [0013]    In a further non-limiting embodiment of any of the foregoing assemblies, the blocking member is a stamped feature of the enclosure. 
         [0014]    In a further non-limiting embodiment of any of the foregoing assemblies, a seal is disposed between a cover and a tray of the enclosure. 
         [0015]    In a further non-limiting embodiment of any of the foregoing assemblies, the blocking member includes an interrupted surface formed in the enclosure, the interrupted surface blocking the path through the enclosure. 
         [0016]    In a further non-limiting embodiment of any of the foregoing assemblies, the blocking member is formed in a flange of the enclosure. 
         [0017]    In a further non-limiting embodiment of any of the foregoing assemblies, the blocking member establishes either a lip or a groove around a perimeter of the enclosure. 
         [0018]    In a further non-limiting embodiment of any of the foregoing assemblies, the vehicle assembly is a high voltage battery assembly. 
         [0019]    A method according to another exemplary aspect of the present disclosure includes, among other things, incorporating a blocking member into an enclosure of a vehicle assembly and impeding access through the enclosure to an interior of the enclosure via the blocking member. 
         [0020]    In a further non-limiting embodiment of the foregoing methods, the incorporating step includes forming an interrupted surface in the enclosure. 
         [0021]    In a further non-limiting embodiment of either of the foregoing methods, the interrupted surface is a stamped feature of the enclosure. 
         [0022]    In a further non-limiting embodiment of any of the foregoing methods, the impeding step includes preventing insertion of a cutting tool into the interior of the enclosure such that the cutting tool is prevented from contacting a high voltage component housed inside the enclosure. 
         [0023]    In a further non-limiting embodiment of any of the foregoing methods, the incorporating step includes positioning a block body between a cover and a tray of the enclosure. 
         [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 portions of a vehicle assembly. 
           [0028]      FIG. 3  is a cross-sectional view of the vehicle assembly of  FIG. 2 . 
           [0029]      FIG. 4  illustrates a vehicle assembly according to another embodiment of this disclosure. 
           [0030]      FIGS. 5 and 6  illustrate yet another vehicle assembly. 
           [0031]      FIG. 7  illustrates a vehicle assembly according to yet another embodiment of this disclosure. 
           [0032]      FIG. 8  illustrates yet another vehicle assembly. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    This discourse details a vehicle assembly for an electrified vehicle. The vehicle assembly includes an enclosure and one or more high voltage components housed inside the enclosure. The enclosure includes a blocking member configured to impede access to the high voltage components, such as during servicing events that require cutting through a seal to gain access to the enclosure interior. In some embodiments, the blocking member includes an interrupted surface formed in either a tray of the enclosure, a cover of the enclosure, or both. In other embodiments, the blocking member includes a block body disposed between opposing flanges of the tray and the cover. In still other embodiments, the blocking member establishes a clearance between the tray and the cover of the enclosure for receiving a seal. These and other features are discussed in greater detail in the following paragraphs of this detailed description. 
         [0034]      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). 
         [0035]    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. 
         [0036]    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 . 
         [0037]    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 . 
         [0038]    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 . 
         [0039]    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 . 
         [0040]    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 . 
         [0041]    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. 
         [0042]    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. 
         [0043]      FIGS. 2 and 3  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 its interior. In one non-limiting embodiment, the vehicle assembly  54  is a high voltage traction battery pack assembly for an electrified vehicle. 
         [0044]    The vehicle assembly  54  includes an enclosure  60  that defines an interior  62  for housing one or more high voltage components  64  (shown schematically in  FIG. 3 ). In one embodiment, the high voltage components  64  include battery cells. However, other high voltage components  64  may also be housed inside the enclosure  60 . 
         [0045]    The enclosure  60  may include any size, shape or configuration. That is, the enclosure  60  is not limited to the specific configuration shown in  FIGS. 2 and 3 . In one non-limiting embodiment, the enclosure includes a tray  66  and a cover  68 . The cover  68  may be secured to the tray  66  using one or more fasteners  70 . In one non-limiting embodiment, the tray  66  includes a flange  67  and the cover  68  includes an opposing flange  69  that extends in parallel with the flange  67 . The fasteners  70  may be inserted through the opposing flanges  67 ,  69  to secure the cover  68  to the tray  66 . 
         [0046]    A seal  72  (see  FIG. 3 ) may be disposed between the cover  68  and the tray  66  to prevent moisture from entering into the interior  62  between the cover  68  and the tray  66 . In one embodiment, the seal  72  is a liquid seal that is applied between the opposing flanges  67 ,  69 . The liquid sealant cures over time to form the seal  72 . Non-limiting examples of suitable liquid seals include urethane seals and silicone seals. 
         [0047]    The seal  72  may need to be removed to access the high voltage components  64  housed inside the enclosure  60 , such as during servicing events. For example, one or more of the high voltage components  64  may need repaired or replaced over the life of the vehicle assembly  54 . Removal of the seal  72  is typically achieved using a cutting tool that is configured to cut through the seal  72 . The seal  72  is typically cut along an axis A that extends between the tray  66  and the cover  68  (see  FIG. 3 ). It is desirable to avoid inadvertently contacting the high voltage components  64  with the cutting tool during this cutting process. 
         [0048]    Accordingly, the enclosure  60  may include a blocking member  74  configured to impede access to the high voltage components  64  during removal of the seal  72 . In one embodiment, the blocking member  74  includes one or more interrupted surfaces  76  that are formed in the tray  66 , the cover  68 , or both. In the exemplary embodiment of  FIGS. 2 and 3 , the interrupted surfaces  76  are formed in the opposing flanges  67 ,  69  of the tray  66  and the cover  68 . For example, the interrupted surfaces  76  may be bent portions formed in the opposing flanges  67 ,  69  to establish a lip  71  (see  FIG. 2 ) around a perimeter of the vehicle assembly  54 . However, the interrupted surfaces  76  could be formed in other portions of the tray  66  and the cover  68 . In another embodiment, the interrupted surfaces  76  extend in a different plane from the remaining portions of the opposing flanges  67 ,  69 , as best shown in  FIG. 3 . In yet another embodiment, the interrupted surface  76  of the flange  67  extends toward the interrupted surface  76  of the flange  69 , and the interrupted surface  76  of the flange  69  extends in a direction away from the interrupted surface  76  of the flange  67 . 
         [0049]    The interrupted surfaces  76  may be stamped features, cast features, injection molded features, or could be formed into the enclosure using any other known techniques. A cutting tool or other device that is moved along the axis A toward the interior  62  will be impeded from contacting the high voltage components  64  by one or more of the interrupted surfaces  76 . 
         [0050]    In an alternative embodiment, shown in  FIG. 4 , only the tray  66  is equipped with the blocking member  74 . An interrupted surface  76  of the blocking member  74  is offset from an inner surface  99  of the cover  68  in a direction toward the interior  62 , in this non-limiting embodiment. The interrupted surface  76  restricts access to the high voltage components  64  at a location between the cover  68  and the tray  66  of the enclosure  60 . 
         [0051]    In yet another embodiment, shown in  FIGS. 5 and 6 , only the cover  68  is equipped with the blocking member  74 . The blocking member  74  of the embodiment of  FIGS. 5 and 6  includes an interrupted surface  76  formed in the cover  68  which establishes a groove  73  around a perimeter of the vehicle assembly  54 . In one embodiment, the interrupted surface  76  of the blocking member  74  is offset from an inner surface  97  of the tray  66  in a direction toward the interior  62 . The interrupted surface  76  restricts access to the high voltage components  62  at a location between the cover  68  and the tray  66  of the enclosure. 
         [0052]      FIG. 7  illustrates another exemplary vehicle assembly  154 . 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. 
         [0053]    In this embodiment, a blocking member  174  is disposed between a tray  166  and a cover  168  of the vehicle assembly  154 . The blocking member  174  may include a block body  175 , which is configured as a solid mass of material, positioned between a flange  167  of the tray  166  and another flange  169  of the cover  168 . The block body  175  may be welded to the flanges  167 ,  169 . The block body  175  impedes the insertion of cutting tools or other devices between the tray  166  and the cover  168  to prevent contact with high voltage components  164  housed inside the vehicle assembly  154  during the process of cutting the seal  172 . 
         [0054]      FIG. 8  illustrates yet another exemplary vehicle assembly  254 . The vehicle assembly  254  includes a tray  266  and a cover  268  secured to the tray  266  to house one or more high voltage components  264 . In this embodiment, the tray  266  includes a first blocking member  274 A and the cover  268  includes a second blocking member  274 B. The first blocking member  274 A may include a first interrupted surface  276 A of the tray  266  that extends toward the cover  268 . The second blocking member  274 B may include a second interrupted surface  276 B formed in the cover  268  and extending toward the tray  266 . In one embodiment, the interrupted surfaces  276 A,  276 B are curved surfaces of the tray  266  and the cover  268 . 
         [0055]    The interrupted surfaces  276 A,  276 B establish a clearance C between the tray  266  and the cover  268  for receiving a seal  272 . In other words, the interrupted surfaces  276 A,  276 B establish a height of the seal  272 . In addition, the interrupted surfaces  276 A,  276 B may act as stop for the seal  272  and may impede access to the high voltage components  264  during cutting of the seal  272 . 
         [0056]    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. 
         [0057]    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. 
         [0058]    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.

Technology Category: h