Battery component having flow path

Abstract

An exemplary method, among other things, includes providing a first blank and a second blank that are nominally identical and include an array of raised features. The method also includes removing a first combination of individual raised features from the first blank to provide a first battery component having a first flow path, and removing a different second combination of individual raised features from the second blank to provide a second battery component having a different second flow path. An exemplary battery assembly, among other things, includes a blank having a plurality of ribs extending from a base plate. The blank is configured such that a first combination of the ribs can be removed from the blank to provide a first battery component having a first flow path, and a different second combination of the ribs can be removed from the blank to provide a second battery component having a different second flow path.

Description

Technical Field

[0001] The present disclosure relates to battery packs and, more particularly, to battery components having flow paths. Background Art

[0002] Electrified vehicles generally differ from conventional motor vehicles in that they are selectively driven using one or more electric motors powered by a battery pack. In contrast, conventional motor vehicles are driven solely by an internal combustion engine. Electric motors can drive electrified vehicles in place of or in addition to internal combustion engines. Exemplary electrified vehicles include hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles (FCVs), and battery electric vehicles (BEVs).

[0003] A battery pack typically includes at least one group of battery cells held within an open area provided by an enclosure. Fluid may communicate through portions of the enclosure outside the open area. The fluid helps manage thermal energy levels, which improves efficiency and prevents undesirable heat accumulation. Different electrified vehicles may have different packaging environments for housing the battery pack. Summary of the Invention

[0004] A method according to an exemplary aspect of the present disclosure includes, among other things, providing a first blank and a second blank that are nominally identical and include an array of raised features. The method also includes removing a first combination of individual raised features from the first blank to provide a first battery component having a first flow path, and removing a second, different combination of individual raised features from the second blank to provide a second battery component having a different second flow path.

[0005] In another non-limiting embodiment of the foregoing method, the first battery component and the second battery component are housing trays.

[0006] In another non-limiting embodiment of any of the foregoing methods, each of the individual raised features of the first blank and the second blank is a rib extending from a respective bottom plate.

[0007] In another non-limiting embodiment of the foregoing method, the first battery component and the second battery component are fluid jackets.

[0008] In another non-limiting embodiment of any of the foregoing methods, each of the individual raised features of the first blank and the second blank is a rib extending from a respective bottom plate.

[0009] In another non-limiting embodiment of any of the foregoing methods, the first flow path extends from a first flow path inlet to a first flow path outlet, and the second flow path extends from a second flow path inlet to a second flow path outlet, wherein a position of the first flow path inlet within the first battery component is different from a position of the second flow path inlet within the second battery component. Alternatively or additionally, a position of the first flow path outlet within the first battery component is different from a position of the second flow path outlet within the second battery component.

[0010] Another non-limiting embodiment of any of the foregoing methods includes machining openings in corresponding bosses of the first blank to provide the first flow path inlet and the first flow path outlet, and machining openings in corresponding bosses of the second blank to provide the second flow path inlet and the second flow path outlet. Prior to the removing and prior to the machining, the first blank and the second blank are nominally identical.

[0011] In another non-limiting embodiment of any of the foregoing methods, the first flow path has a circumferential perimeter completely defined by the first cell component and the fluid jacket, or completely defined by the first cell component and the housing tray, and the second flow path has a circumferential perimeter completely defined by the second cell component and the fluid jacket, or completely defined by the second cell component and the housing tray.

[0012] In another non-limiting embodiment of any of the foregoing methods, removing the combined raised features from the first and second blanks includes machining material away from the first and second blanks.

[0013] Another non-limiting embodiment of any of the foregoing methods further includes moving fluid through the first flow path to exchange thermal energy with a traction battery cell array having a first configuration, and moving fluid through the second flow path to exchange thermal energy with a traction battery cell array having a second, different configuration.

[0014] In another non-limiting embodiment of any of the foregoing methods, prior to said removing, said array of raised features is a grid of said raised features disposed on bottom panels of said first blank and said second blank.

[0015] A method according to another exemplary aspect of the present disclosure includes, among other things, casting a first battery component in a mold cavity when a plurality of slides are in a first configuration to provide a first flow path to the first battery component, removing the first battery component from the mold cavity, and casting a second battery component in the mold cavity when the plurality of slides are in a different second configuration to provide a different second flow path to the second battery component.

[0016] In another non-limiting embodiment of any of the foregoing methods, the first flow path extends from an opening in a first flow path inlet boss to an opening in a first flow path outlet boss, and the second flow path extends from an opening in a second flow path inlet boss to an opening in a second flow path outlet boss. The first flow path inlet boss is located in a different position within the first battery component than the second flow path inlet boss is located in the second battery component. The first flow path outlet boss is located in a different position within the first battery component than the second flow path outlet boss is located in the second battery component, or both.

[0017] A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a stock having a plurality of ribs extending from a base plate. The stock is configured such that a first combination of the ribs can be removed from the stock to provide a first battery component having a first flow path, and a second, different combination of the ribs can be removed from the stock to provide a second battery component having a second, different flow path.

[0018] In another non-limiting embodiment of the foregoing assembly, the first flow path is configured to convey fluid to exchange thermal energy with a traction battery cell array having a first configuration, and the second flow path is configured to convey fluid to exchange thermal energy with a traction battery cell array having a second, different configuration.

[0019] In a further non-limiting embodiment of any of the foregoing assemblies, the blank is a cover tray blank.

[0020] In a further non-limiting embodiment of any of the foregoing assemblies, the blank is a fluid jacket blank.

[0021] In another non-limiting embodiment of any of the foregoing assemblies, the first flow path has a circumferential perimeter completely defined by the first cell component and the fluid jacket, or completely defined by the first cell component and the housing tray, and the second flow path has a circumferential perimeter completely defined by the second cell component and the fluid jacket, or completely defined by the second cell component and the housing tray.

[0022] In another non-limiting embodiment of any one of the foregoing assemblies, the first flow path extends from a first flow path inlet to a first flow path outlet, and the second flow path extends from a second flow path inlet to a second flow path outlet, and the first flow path inlet and the second flow path inlet are located at different positions within the blank.

[0023] A method according to another exemplary aspect of the present disclosure includes, among other things, placing a seal having a first pattern between a first fluid jacket and a first housing tray to provide a first flow path, and placing a seal having a second, different pattern between a second fluid jacket and a second housing tray to provide a second, different flow path, the first and second housing trays being nominally identical. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The various features and advantages of the disclosed examples will be apparent to those skilled in the art from the detailed description. The drawings accompanying the detailed description can be briefly described as follows:

[0025] Figure 1 A schematic diagram showing a powertrain for an electrified vehicle.

[0026] Figure 2 Show Figure 1 Expanded view of the powertrain battery pack.

[0027] Figure 3 Show Figure 2 Side view of the battery pack during assembly.

[0028] Figure 4 The diagram can be modified to provide Figure 2 A perspective view of a cover tray blank for a battery pack cover tray.

[0029] Figure 5 yes Figure 4 Bottom view of the blank.

[0030] Figure 6 Shown is an exemplary aspect of the present disclosure for Figure 2 The battery pack used is made of Figure 4 The outer cover tray is formed by the blank.

[0031] Figure 6A Show Figure 6 A cross-sectional view at line 6A-6A in FIG.

[0032] Figure 7 Another exemplary aspect of the present disclosure is shown. Figure 2 The battery pack used is made of Figure 4 The outer cover tray is formed by the blank.

[0033] Figure 8 Another exemplary aspect of the present disclosure is shown. Figure 2 The battery pack used is made of Figure 4 The outer cover tray is formed by the blank.

[0034] Figure 9 Another exemplary aspect of the present disclosure is shown. Figure 2 The battery pack used is made of Figure 4 The blank forms the outer cover tray, and the fluid sleeve.

[0035] Figure 10 A flow chart illustrating an exemplary method for providing battery components having different flow paths using a common blank.

[0036] Figure 11A A mold and slide are shown in a first configuration for casting a housing pallet according to yet another exemplary embodiment of the present disclosure.

[0037] Figure 11B A mold and slide are shown in a second, different configuration for casting a housing pallet according to yet another exemplary embodiment of the present disclosure.

[0038] Figure 12 An exemplary embodiment of the present disclosure is shown. Figure 2 Perimeter seals used in battery packs.

[0039] Figure 13A A method for providing a flow path using a seal having a first pattern according to another exemplary aspect of the present disclosure is shown. Figure 2 The cover tray is used in the battery pack.

[0040] Figure 13B A method for providing a flow path using a seal having a second pattern according to another exemplary aspect of the present disclosure is shown. Figure 2 The cover tray is used in the battery pack.

[0041] Figure 13C A method for providing a flow path using a seal having a third pattern according to another exemplary aspect of the present disclosure is shown. Figure 2 The cover tray is used in the battery pack. DETAILED DESCRIPTION

[0042] The present disclosure relates to a housing for a battery pack of an electrified vehicle. The housing includes a portion formed from a blank. Regions of the blank are adjusted to provide the housing with various flow paths for circulating a fluid. The adjustment may include machining away regions of the blank to provide a first flow path, or machining away other regions of the blank to provide a different second flow path.

[0043] Figure 1 A powertrain 10 of an electrified vehicle, in this example a hybrid electric vehicle (HEV), is schematically illustrated. Although depicted as an HEV, it should be understood that the concepts described herein are not limited to HEVs but can be extended to other types of electrified vehicles, including but not limited to plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), fuel cell vehicles, and the like.

[0044] The powertrain 10 includes a battery pack 14, a motor 18, a generator 20, and an internal combustion engine 22. The motor 18 and the generator 20 are types of electric machines. The motor 18 and the generator 20 may be separate or may be in the form of a combined motor-generator.

[0045] In this embodiment, powertrain 10 is a power-split powertrain that utilizes a first drive system and a second drive system. The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels 26 of an electrified vehicle. The first drive system includes a combination of an engine 22 and a generator 20. The second drive system includes at least a motor 18, a generator 20, and a battery pack 14. The motor 18 and generator 20 are part of the electric drive system of powertrain 10.

[0046] The engine 22 (in this example, an internal combustion engine) and the generator 20 can 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, can be used to connect the engine 22 to the generator 20. 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.

[0047] Generator 20 can be driven by engine 22 through power transfer unit 30 to convert kinetic energy into electrical energy. Generator 20 can alternatively be used as a motor to convert electrical energy into kinetic energy, thereby outputting torque to shaft 38 connected to power transfer unit 30. Because generator 20 is operatively connected to engine 22, the speed of engine 22 can be controlled by generator 20.

[0048] The ring gear 32 of the power transfer unit 30 may be connected to a shaft 40, which is connected to the vehicle drive wheels 26 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.

[0049] Gears 46 transfer torque from the engine 22 to a differential 48 to ultimately provide traction to the vehicle drive wheels 26. The differential 48 may include a plurality of gears that enable torque to be transferred to the vehicle drive wheels 26. In this example, 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 26.

[0050] The motor 18 can also be used to drive the vehicle drive wheels 26 by outputting torque to a shaft 52, which is also connected to the second power transfer unit 44. In one embodiment, the motor 18 and the generator 20 cooperate as part of a regenerative braking system, where both the motor 18 and the generator 20 can function as motors that output torque. For example, the motor 18 and the generator 20 can each output power to the battery pack 14. The battery pack 14 can include an array of battery cells 60 within a housing assembly.

[0051] Now refer to Figure 2 and Figure 3 According to an exemplary aspect of the present disclosure, the battery pack 14 includes a housing assembly that includes various battery components, here a housing tray 64 , a cover 68 , and a fluid jacket 72 .

[0052] The battery cell 60 can be placed within the open area 76 of the housing tray 64. The cover 68 can then be secured to the housing tray 64 to enclose the battery cell 60 within the open area 76. When the battery cell 60 is positioned within the open area 76, the battery cell 60 is disposed on a surface 78 of a floor 80 of the housing tray 64. A wall 81 of the housing tray 64 extends from the floor 80 to the cover 68.

[0053] The battery pack 14 circulates a fluid along a surface of the bottom plate 80 opposite the surface 78. The fluid can exchange thermal energy with the battery cells 60 through the bottom plate 80. The fluid is outside the open area 76 and moves along a flow path provided by the outer cover tray 64 and covered by the fluid jacket 72. The fluid can move from the fluid supply source to the battery pack 14 and then circulate through the fluid path to absorb thermal energy. The fluid can move from the fluid path to a heat exchanger, for example, where the fluid releases thermal energy. The fluid can then move back to the fluid supply source. The fluid can be a liquid. In a specific example, the fluid is liquid water.

[0054] The housing tray 64, the fluid jacket 72, or both may be modified to provide different fluid paths. Different fluid paths may be required to accommodate different configurations of battery cells 60, or to facilitate positioning of inlets and outlets to the flow path in certain areas.

[0055] Figure 3 The battery pack 14 is shown in its orientation as installed in a vehicle. Vertical is with reference to the ground and the normal orientation of the vehicle during operation.

[0056] Now refer to Figure 4 and 5 , and continue to refer to Figure 2 and 3 , the outer cover tray 64 is formed from a blank 82. The blank 82 can be a casting or formed by some other manufacturing technology. The blank 82 can be, for example, a polymer-based material, a metal, or a metal alloy. In a specific exemplary embodiment, the blank 82 is aluminum.

[0057] The blank 82 includes an array 84 of raised features 88. In the exemplary embodiment, the raised features 88 are ribs that extend away from a surface 92 of the base plate 80. The raised features 88 are arranged in a grid pattern. The raised features 88 can be connected to each other at interfaces 96. In this example, the interfaces 96 include holes 100. When the blank 82 is modified into the cover tray 64, the holes 100 can each receive a mechanical fastener that secures the fluid jacket 72 to the cover tray 64.

[0058] To provide the cover tray 64 from the blank 82, selected individual raised features 88 can be removed from the blank 82. Removing the selected raised features 88 establishes a desired flow path within the cover tray 64. That is, as will be shown, a first combination of individual raised features 88 can be removed from the blank 82 to provide a first flow path for the cover tray 64, and a second, different combination of individual raised features 88 can be removed from the blank 82 to provide a second, different flow path for the cover tray 64. Unremoved raised features 88 block flow through the flow path. Fluid can flow between the base plate 80 and the fluid jacket 72 in the areas where the raised features 88 have been removed.

[0059] While the raised features 88 are part of the housing tray 64 in this example, another example may include some or all of the raised features extending from the fluid jacket 72 toward the base plate 80 , which is another type of battery component.

[0060] The blank 82 is also formed with a plurality of inlet bosses 104a, 104b, and 104c, and a plurality of outlet bosses 108a, 108b, and 108c. Depending on the desired flow path within the housing tray 64, one or more of the inlet bosses 104a-104c may be machined to provide an inlet to the flow path, and one or more of the outlet bosses 108a-108c may be machined to provide an outlet to the flow path. Couplings and fittings may then be connected to the bosses to deliver coolant, for example, to and from the fluid path of the housing tray 64. Machining the bosses may include tapping the bosses to provide threaded holes for attaching couplings, fittings, etc.

[0061] For example, referring to the outlet boss 108a and Figure 5A drilling operation may be used to form a conduit that initially extends through the outlet boss 108 in a direction D and then extends perpendicular to the outlet boss 108. Figure 5 The opening O in the surface 92 extends in the direction of the plane of the page in FIG. Within the housing tray 64, such a conduit provides a passage through the outlet boss 108 to convey fluid from the flow path.

[0062] Although the inlet bosses 104a-104c are depicted as separate from the outlet bosses 108a-108c, some fluid path configurations may use one of the bosses designated as the inlet boss 104a-104c as the outlet of the fluid path, while one or more of the bosses designated as the outlet bosses 108a-108c serve as the inlet of the fluid path.

[0063] refer to Figure 6 , the blank 82 has been modified to provide a fluid path FP having a first configuration A To provide the cover tray 64a, the raised feature 88 has been removed from the region 112a and a fluid path FP extending through the inlet boss 104a has been established. A hole 114a, and has been established through the outlet boss 108a extending to the fluid path FP A After the fluid jacket 72 is secured to the housing tray 64a, the fluid can flow along the fluid path FP. A The transport is performed, for example, to cool the battery cells and other components.

[0064] like Figure 6A As shown, the fluid path FP within the assembled battery pack incorporated into the housing tray 64a A , having a circumferential perimeter completely established by the outer cover tray 64a and the fluid jacket 72.

[0065] Now refer to Figure 7 , the blank 82 has been modified to provide a fluid path FP having a second configuration B To provide the cover tray 64b, the raised feature 88 has been removed from the region 112b and a fluid path FP extending through the inlet boss 104b has been established. B hole 114b, and has been established through the outlet boss 108b extending to the fluid path FP B After the fluid jacket 72 is secured to the housing tray 64b, the fluid can flow along the fluid path FP. B The transport is performed, for example, to cool the battery cells and other components.

[0066] Now refer to Figure 8 , the blank 82 has been modified to provide a fluid path FP having a third configuration CTo provide the cover tray 64c, the raised feature 88 has been removed from the region 112c and has been established extending through the inlet boss 104c to the fluid path FP. C hole 114c, and has been established through the outlet boss 108c extending to the fluid path FP C After the fluid jacket 72 is secured to the housing tray 64c, the fluid can flow along the fluid path FP. C The transport is performed, for example, to cool the battery cells and other components.

[0067] Now refer to Figure 9 , the blank 82 has been modified to provide a fluid path FP having a fourth configuration D To provide the cover tray 64d, the raised feature 88 has been removed from the region 112d, and the aperture 114d established in the fluid jacket 72 delivers fluid to the fluid path FP. D , and the hole 116d established in the fluid jacket 72 delivers fluid from the fluid path FP D After the fluid jacket 72 is secured to the housing tray 64d, the fluid can flow along the fluid path FP. D The transport is carried out, for example, to cool battery cells and other components. Figure 9 In the exemplary embodiment, the inlet bosses 104a-104c and the outlet bosses 108a-108c remain free of holes.

[0068] like Figures 6 to 9 As shown, the flow path FP A -FP D The battery pack may be provided with different locations for the inlet of the flow path and the outlet of the flow path. Flow path FP A -FP D Established within the housing trays 64a-64d, the trays may all be formed from a common blank. Depending upon, among other things, the desired packaging locations for the inlets and outlets for the flow paths within the vehicle, the blank 82 may be modified to provide the desired inlet and outlet locations and the desired flow paths for the housing trays 64a-64d.

[0069] Remove raised feature 88 to provide Figures 6 to 9 The desired flow path FP within the embodiment A -FP DThis may involve machining away ribs from the blank 82. Prior to modifying the blank 82 to remove the raised features 88 and form the inlet and outlet ports, the blanks 82 used to form the housing trays 64a-64d are nominally identical. For the purposes of this disclosure, nominally identical means that the blanks are dimensionally similar to one another. While surface imperfections may result in slight differences, the blanks may still be nominally identical. Nominally identical blanks may refer to blanks manufactured using common tools and processes.

[0070] Reference again Figure 1 and Figure 4 The blank 82 can be configured to include anchor tabs 128 for connecting with brackets and mechanical fasteners, for example, to attach the housing tray 64 to the vehicle. The anchor tabs 128 used can be selected based on how the battery pack 14 will be packaged within the vehicle. If the anchor tabs 128 are not required, they can be removed by machining. That is, if certain features are not required for the desired application, those features can be machined out of the blank 82.

[0071] The blank 82 can also be configured to include bosses 136 and 136' representing potential electrical connection locations. For example, if electrical connections to the battery pack 14 are required on a downward-facing surface, holes can be machined into boss 136, while boss 136' remains hole-free. Conversely, if electrical connections to the battery pack 14 are required through a lateral surface of the battery pack 14, holes can be machined into boss 136', while boss 136 remains hole-free.

[0072] Now refer to Figure 10 , an exemplary method 200 for providing battery components having different flow paths using a common blank begins at step 210, wherein a first blank and a second blank that are nominally identical are provided. The first blank and the second blank include an array of raised features. At step 220, the method 200 includes removing a first combination of individual raised features from the first blank to provide a first battery component having a first flow path. At step 230, the method 200 includes removing a different second combination of individual raised features from the second blank to provide a second battery component having a different second flow path.

[0073] In other exemplary aspects of the present disclosure, the housing tray 64 may be cast within the mold cavity 120 of the mold 122, wherein the slide 124 is formed as shown in FIG. Figure 11A The first configuration shown is positioned so that the housing tray 64 is cast with raised features 88 in desired locations and with raised features 88 omitted in other locations. If an alternative configuration of flow paths is desired within the housing tray 64, the same mold cavity 120 can be used to provide the housing tray 64, but the slide 124 can be positioned in a different manner. Figure 11B The different configurations shown are positioned so that raised features 88 are formed in desired locations and omitted in other locations.

[0074] Reference again Figures 6 to 9 When the fluid jacket 72 is secured to the respective housing trays 64a-64d, the raised features 88 in the housing trays 64a-64d that have not been removed can directly contact the fluid jacket 72. The direct contact between the raised features 88 and the fluid jacket 72 can prevent fluid from passing through the area between the raised features 88 and the fluid jacket 72. In some examples, the raised features 88 are received within grooves in the fluid jacket 72 to enhance direct contact. While some fluid could potentially leak through these areas, the leakage should be minimal and not significantly affect fluid flow or cooling effectiveness because the fluid will tend to follow the path of least resistance. Similarly, while the raised features 88 are shown as part of the housing trays 64a-64d, other examples may include raised features from the fluid jacket 72 that extend to the respective housing trays 64a-64d and can directly contact them.

[0075] The interface between the fluid jacket 72 and the associated housing tray 64a-64d can be sealed in other ways. For example, the fluid jacket 72 can be welded to the associated housing tray 64a-64d, specifically around the perimeter of the fluid jacket 72. Many welding techniques can be used, including metal inert gas (MIG) welding, tungsten inert gas (TIG) welding, laser welding, friction stir welding, etc. Some welding techniques, such as friction stir welding (FSW), can also be used to weld the raised features 88 located on the corresponding housing tray 64a-64d to the fluid jacket 72.

[0076] refer to Figure 2 and Figure 12 , another technique may include using a fluid flow path around the FP A -FP C A perimeter seal 118 is positioned about the perimeter of the tray 64a-64d where the fluid jacket 72 interfaces with the corresponding tray 64a-64d. The perimeter seal 118 may be a mechanical gasket, a tip seal, a pumpable foam, a sealant, or various other seal types.

[0077] Another technique may include using a curable sealant to bond the fluid jacket 72 to the Figures 6 to 9 6. The embodiment of the present invention further includes respective housing trays 64a-64d, wherein the fluid jacket 72 interfaces with the respective housing trays 64a-64d. As with the exemplary welding technique or perimeter seal, the sealant may extend along the perimeter of the fluid jacket 72. Alternatively or additionally, the sealant may extend along the interface between the raised feature 88 and the fluid jacket 72 or the housing trays 64a-64d.

[0078] It is worth noting that in some exemplary embodiments, seals may be used in place of raised features 88 to establish various flow paths for directing fluid flow. 13A to 13C, the base casting of the tray 64e may omit the raised features 88 ( Figure 5 ) at least some of. Instead of the raised features 88, the seal S may be Figure 13A The first pattern shown is deposited on the tray 64e to provide a flow path FP A The fluid jacket 72 is then at least partially secured to the tray 64e by the seal S. If the seal S is a viscous curable seal, the fluid jacket 72 can be secured relative to the tray 64e as the seal S cures. While the seal S cures, a fixture, clamps, fasteners, or some combination of these can be used to secure the fluid jacket 72 relative to the tray 64e.

[0079] The seal S may alternatively be configured as follows: Figure 13B The second pattern shown is placed to provide flow path FP B '. The seal S may alternatively be formed according to Figure 13C The third pattern shown is placed to provide flow path FP C '. It will be appreciated that various other patterns of seals S may be utilized to provide various other flow path configurations. Moreover, although shown as being deposited on the tray 64e, the seals S may alternatively be deposited on the fluid jacket 72. Additionally, the seals S may be disposed with at least some of the ribs 88 ( Figure 5 ) are used in combination to provide the desired flow path.

[0080] Reference again Figure 13A Embodiments that utilize a seal S to provide a flow path and secure the fluid jacket 72 to the tray 64e may include a number of raised features 88'. The raised features 88' may be located in the tray 64e, the fluid jacket 72 secured to the tray 64e, or both. The raised features 88' may include holes 100' that may each receive a mechanical fastener that helps secure the fluid jacket 72 to the tray 64e. An O-ring seal may extend around the holes 100' to seal the interface between the raised features 88' of the tray 64e and the fluid jacket 72.

[0081] Examples of the disclosed embodiments feature the use of common tooling to provide battery components with different flow paths. A single stock material can be used to provide features to support a wide range of packaging environments. Among other things, this approach reduces engineering time. Specifically, there is no need to substantially re-engineer and design unique battery packs for each packaging environment. This approach also reduces unit cost by sharing the same basic stock material for battery components across multiple vehicles.

[0082] The foregoing description is illustrative rather than restrictive in nature. Variations and modifications to the disclosed examples that do not necessarily depart from the essence of this disclosure may become apparent to those skilled in the art. Therefore, the scope of legal protection afforded this disclosure can only be determined by studying the appended claims.

[0083] According to the present invention, a battery housing is provided having a housing tray and a fluid jacket adjacent the housing tray to provide a coolant path, wherein the coolant path is adjustable by removing selected portions of the housing tray, the fluid jacket, or both.

[0084] According to the present invention, a method includes providing a component of a battery pack enclosure; removing a first rib of the component to provide a first coolant path for a first environment; and removing a different second rib of the component to provide a different second coolant path for a different second environment.

[0085] According to the present invention, a method includes: providing a first blank and a second blank that are nominally identical and include an array of raised features; removing a first combination of individual raised features from the first blank to provide a first battery component having a first flow path; and removing a different second combination of individual raised features from the second blank to provide a second battery component having a different second flow path.

[0086] According to one embodiment, the first battery component and the second battery component are housing trays.

[0087] According to one embodiment, each of the individual raised features of the first and second blanks is a rib extending from the respective base plate.

[0088] According to one embodiment, the first battery component and the second battery component are fluid jackets.

[0089] According to one embodiment, each of the individual raised features of the first and second blanks is a rib extending from the respective base plate.

[0090] According to one embodiment, the first flow path extends from a first flow path inlet to a first flow path outlet, and the second flow path extends from a second flow path inlet to a second flow path outlet, wherein a position of the first flow path inlet within the first battery component is different from a position of the second flow path inlet within the second battery component, wherein a position of the first flow path outlet within the first battery component is different from a position of the second flow path outlet within the second battery component, or both.

[0091] According to one embodiment, the present invention is further characterized in that openings are machined in corresponding bosses of the first blank to provide the first flow path inlet and the first flow path outlet, and openings are machined in corresponding bosses of the second blank to provide the second flow path inlet and the second flow path outlet, and the first blank and the second blank are nominally identical before the removal and before the machining.

[0092] According to one embodiment, the first flow path has a circumferential perimeter completely defined by the first cell component and the fluid jacket, or completely defined by the first cell component and the housing tray, and the second flow path has a circumferential perimeter completely defined by the second cell component and the fluid jacket, or completely defined by the second cell component and the housing tray.

[0093] According to one embodiment, removing the combined raised feature from the first blank and the second blank includes machining away material from the first blank and the second blank.

[0094] According to one embodiment, the invention is further characterized by moving fluid through the first flow path to exchange thermal energy with a traction battery cell array having a first configuration, and moving fluid through the second flow path to exchange thermal energy with a traction battery cell array having a second, different configuration.

[0095] According to one embodiment, prior to said removing, said array of raised features is a grid of said raised features provided on the bottom plates of said first blank and said second blank.

[0096] According to the present invention, a method includes: casting a first battery component in a mold cavity when a plurality of slides are in a first configuration to provide a first flow path to the first battery component; removing the first battery component from the mold cavity; and casting a second battery component in the mold cavity when the plurality of slides are in a different second configuration to provide a different second flow path to the second battery component.

[0097] According to one embodiment, the first flow path extends from an opening in a first flow path inlet boss to an opening in a first flow path outlet boss, and the second flow path extends from an opening in a second flow path inlet boss to an opening in a second flow path outlet boss, wherein the position of the first flow path inlet boss within the first battery component is different from the position of the second flow path inlet boss within the second battery component, wherein the position of the first flow path outlet boss within the first battery component is different from the position of the second flow path outlet boss within the second battery component, or both.

[0098] According to the present invention, a battery assembly is provided having: a blank having a plurality of ribs extending from a base plate, the blank being constructed so that a first combination of the ribs can be removed from the blank to provide a first battery component having a first flow path, and a different second combination of the ribs can be removed from the blank to provide a second battery component having a different second flow path.

[0099] According to one embodiment, the first flow path is configured to convey fluid to exchange thermal energy with a traction battery cell array having a first configuration, and the second flow path is configured to convey fluid to exchange thermal energy with a traction battery cell array having a second, different configuration.

[0100] According to one embodiment, the blank is a cover tray blank.

[0101] According to one embodiment, the blank is a fluid jacket blank.

[0102] According to one embodiment, the first flow path has a circumferential perimeter completely defined by the first cell component and the fluid jacket, or completely defined by the first cell component and the housing tray, and the second flow path has a circumferential perimeter completely defined by the second cell component and the fluid jacket, or completely defined by the second cell component and the housing tray.

[0103] According to one embodiment, the first flow path extends from a first flow path inlet to a first flow path outlet, and the second flow path extends from a second flow path inlet to a second flow path outlet, wherein the first flow path inlet and the second flow path inlet are located at different positions within the blank.

[0104] According to the present invention, a method includes placing a seal having a first pattern between a first fluid jacket and a first housing tray to provide a first flow path; and placing a seal having a second, different pattern between a second fluid jacket and a second housing tray to provide a second, different flow path, wherein the first and second housing trays are nominally identical.

Claims

1. A method comprising: providing a first blank and a second blank that are nominally identical and include an array of raised features; removing a first combination of individual raised features from the first stock to provide a first battery component having a first flow path; as well as A different second combination of individual raised features is removed from the second stock to provide a second cell component having a different second flow path.

2. The method of claim 1, wherein the first and second battery components are housing trays, and optionally, wherein each of the individual raised features of the first and second stock is a rib extending from a respective base plate.

3. The method of claim 1, wherein the first and second battery components are fluid jackets, and optionally, wherein each of the individual raised features of the first and second stock is a rib extending from a respective base plate.

4. The method according to claim 1, wherein the first flow path extends from a first flow path inlet to a first flow path outlet, and the second flow path extends from a second flow path inlet to a second flow path outlet, wherein the position of the first flow path inlet in the first battery component is different from the position of the second flow path inlet in the second battery component, wherein the position of the first flow path outlet in the first battery component is different from the position of the second flow path outlet in the second battery component, or both.

5. The method of claim 4, further comprising machining openings in corresponding bosses of the first blank to provide the first flow path inlet and the first flow path outlet; and machining openings in corresponding bosses of the second blank to provide the second flow path inlet and the second flow path outlet, Prior to said removing and prior to said machining, said first blank and said second blank are nominally identical.

6. The method according to claim 1, wherein the first flow path has a circumferential perimeter established entirely by the first battery component and the fluid jacket, or entirely by the first battery component and the housing tray, Wherein the second flow path has a circumferential perimeter that is completely defined by the second battery component and the fluid jacket, or completely established by the second battery component and the housing tray.

7. The method of claim 1, wherein removing the combined raised features from the first and second stock materials comprises machining away material from the first and second stock materials, and optionally, wherein, Prior to said removing, said array of raised features is a grid of said raised features disposed on the bottom panels of said first blank and said second blank.

8. The method of claim 1 further comprising moving a fluid through the first flow path to exchange thermal energy with an array of traction battery cells having a first configuration, and moving a fluid through the second flow path to exchange thermal energy with an array of traction battery cells having a second, different configuration.

9. A battery assembly comprising: A blank having a plurality of ribs extending from a base plate, the blank being constructed such that a first combination of the ribs can be removed from the blank to provide a first battery component having a first flow path, and a different second combination of the ribs can be removed from the blank to provide a second battery component having a different second flow path.

10. The battery assembly of claim 9, wherein the first flow path is configured to convey a fluid to exchange thermal energy with a traction battery cell array having a first configuration, and the second flow path is configured to convey a fluid to exchange thermal energy with a traction battery cell array having a second, different configuration, and wherein the stock is a cover tray stock or a fluid jacket stock.

11. The battery assembly according to claim 9, wherein the first flow path has a circumferential perimeter established entirely by the first battery component and the fluid jacket, or entirely by the first battery component and the housing tray, Wherein the second flow path has a circumferential perimeter that is completely defined by the second battery component and the fluid jacket, or completely established by the second battery component and the housing tray.

12. The battery assembly according to claim 9, wherein the first flow path extends from a first flow path inlet to a first flow path outlet, and the second flow path extends from a second flow path inlet to a second flow path outlet, The first flow path inlet and the second flow path inlet are located at different positions within the blank.

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