Traction battery pack module attachment system with splints

Abstract

The present disclosure provides a traction battery pack module attachment system with splints. A battery pack assembly includes a structural member of a battery pack; a module of the battery pack; and an attachment system having a plurality of splints. The cleats can be interlocked to secure the module to the structural member. Mechanical fasteners may also be used to secure the module to the structural member.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to securing modules of a traction battery pack, and more specifically to securing modules with an attachment system having cleats. BACKGROUND

[0002] Electrically powered vehicles include traction battery packs for powering electric motors and other electrical loads of the vehicle. Traction battery packs can include a cell stack having a plurality of battery cells. Traction battery packs can also include various other battery internal components that support the propulsion of electric vehicles. SUMMARY

[0003] In some aspects, the technology described herein relates to a battery pack assembly comprising: a structural member of a battery pack; a module of the battery pack; and an attachment system having a plurality of cleats that interlock to secure the module to the structural member.

[0004] In some aspects, the technology described herein relates to a battery pack assembly wherein the structural member is a cross member within an enclosure of the battery pack.

[0005] In some aspects, the technology described herein relates to a battery pack assembly wherein the structural member is an extruded structural member.

[0006] In some aspects, the technology described herein relates to a battery pack assembly wherein at least one cleat of the plurality of cleats is an extruded cleat.

[0007] In some aspects, the technology described herein relates to a battery pack assembly wherein the attachment system secures the module to a forward-facing side of the structural member within an interior of the battery pack.

[0008] In some aspects, the technology described herein relates to a battery pack assembly wherein the plurality of cleats includes at least one upper cleat of the module and at least one lower cleat of the structural member.

[0009] In some aspects, the technology described herein relates to a battery pack assembly wherein the plurality of cleats includes at least one upper cleat of the module and at least one lower cleat of the structural member.

[0010] In some aspects, the technology described herein relates to a battery pack assembly wherein the attachment system is a French cleat attachment system.

[0011] In some aspects, the technology described herein relates to a battery pack assembly further comprising: at least one mechanical fastener that secures the module to the structural member.

[0012] In some aspects, the technology described herein relates to a battery pack assembly, wherein the at least one mechanical fastener comprises at least one rivet.

[0013] In some aspects, the technology described herein relates to a battery pack assembly, wherein the at least one mechanical fastener comprises at least one rivet nut.

[0014] In some aspects, the technology described herein relates to a battery pack assembly, wherein the plurality of clamping plates comprises a clamping plate on a bottom corner of the module, and the at least one mechanical fastener directly secures an upper region of the module to the structural member.

[0015] In some aspects, the technology described herein relates to a battery pack assembly, wherein the module is a battery energy control module.

[0016] In some aspects, the technology described herein relates to a battery pack assembly, wherein the module is a bus electrical center.

[0017] In some aspects, the technology described herein relates to a battery pack assembly, wherein the module is a DC-DC converter.

[0018] In some aspects, the technology described herein relates to a method of securing a module of a battery pack, comprising: interlocking a first clamping plate of the module with a second clamping plate of a structural member of the battery pack to secure the module to the structural member; and after the interlocking, additionally securing the module to the structural member with at least one mechanical fastener.

[0019] In some aspects, the technology described herein relates to a method of securing a module of a battery pack, further comprising: after securing the module to the structural member, positioning the module and the structural member in an interior of a battery pack enclosure, and then securing the structural member within the battery pack enclosure.

[0020] In some aspects, the technology described herein relates to a method of securing a module of a battery pack, further comprising: rotating the module about the first clamping plate and the second clamping plate after the interlocking and before the securing.

[0021] In some aspects, the technology described herein relates to a method of securing a module of a battery pack, wherein the first clamping plate extends along a bottom corner of the module.

[0022] The embodiments, examples, and alternatives of the preceding paragraphs, claims, or following description and drawings, can be taken independently or in any combination of one another, including any one of their various aspects or respective individual features. Features described in connection with one embodiment are applicable to all embodiments, unless incompatible therewith. Attached Figure Description

[0023] According to the specific embodiments, various features and advantages of the disclosed examples will become apparent to those skilled in the art. The accompanying drawings of the specific embodiments can be briefly described as follows:

[0024] Figure 1 A side view of an electric vehicle with a battery pack is shown.

[0025] Figure 2 Exemplary aspects according to this disclosure are illustrated. Figure 1 A perspective view of the battery pack.

[0026] Figure 3 Examples Figure 2 The battery pack, in which the outer cover is removed to expose the battery pack modules and cell stack inside the battery pack.

[0027] Figure 4 Examples Figure 3 A close-up view of a portion of the battery pack, showing the battery pack module inside the battery pack.

[0028] Figure 5 Examples along Figure 4 The diagram shows a cross-sectional view taken by line 5-5, and illustrates the battery pack module (represented by dashed lines) moved to the installation position and in the installation position, where the clamping plate of the battery pack module is interlocked with the clamping plate of the structural member.

[0029] Figure 6 Example of another exemplary aspect of this disclosure for use in Figure 2 and Figure 3 A perspective view of the structural components used in the battery pack.

[0030] Figure 7 Examples Figure 6 Rear view of the structural components.

[0031] Figure 8 Examples Figure 6 The front view of the structural member, in which multiple modules are fixed to the structural member. Detailed Implementation

[0032] This disclosure details exemplary systems and methods for attaching battery pack modules to structural members of a battery pack. The attachment systems and methods utilize interlocking clamps. These and other features are discussed in more detail in the following paragraphs.

[0033] Figure 1An electrically motorized vehicle 10 is illustratively exemplified. The electrically motorized vehicle 10 can include any type of electrically motorized powertrain. In one embodiment, the electrically motorized vehicle 10 is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and can be extended to other electrically motorized vehicles, including but not limited to hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, etc. Thus, although not specifically shown in the example embodiments, the powertrain of the electrically motorized vehicle 10 can be equipped with an internal combustion engine that can be employed alone or in combination with other power sources to propel the electrically motorized vehicle 10.

[0034] In the exemplified embodiment, the electrically motorized vehicle 10 is depicted as an automobile. However, the electrically motorized vehicle 10 can alternatively be a sport utility vehicle (SUV), a van, a pickup truck, or any other vehicle configuration. Although specific component relationships are exemplified in the drawings of the present disclosure, the drawings are not intended to limit the present disclosure. The placement and orientation of the various components of the electrically motorized vehicle 10 are shown schematically and can vary within the scope of the present disclosure. Additionally, the various drawings attached to the present disclosure are not necessarily drawn to scale, and some features can be exaggerated or minimized to emphasize certain details of the particular component, assembly, or system.

[0035] In the exemplified embodiment, the electrically motorized vehicle 10 is a pure electric vehicle that is propelled solely by electric power, such as by one or more electric machines 12, without the assistance of an internal combustion engine. The electric machine 12 can operate as an electric motor, a generator, or both. The electric machine 12 receives electric power and can convert the electric power to torque for driving one or more wheels 14 of the electrically motorized vehicle 10.

[0036] A voltage bus 16 electrically couples the electric machine 12 to a traction battery pack 18. The traction battery pack 18 is an exemplary electrically motorized vehicle battery. The traction battery pack 18 can be a high-voltage traction battery pack assembly that includes a plurality of battery cells capable of outputting electric power to power the electric machine 12 and / or other electrical loads of the electrically motorized vehicle 10. Other types of energy storage and / or output devices can alternatively or additionally be used to power the electrically motorized vehicle 10.

[0037] The traction battery pack 18 is fixed to a body floor 20 of the electrically motorized vehicle 10. However, in other examples, the traction battery pack 18 can be located elsewhere on the electrically motorized vehicle 10.

[0038] Reference Figures 2 to 5In exemplary embodiments of the present disclosure, the traction battery pack 18 includes a plurality of cell stacks 22 housed within an interior of the housing assembly 26. The cell stacks 22 are arranged on a plurality of tiers within the interior of the housing assembly 26. Three of the cell stacks 22 are arranged on an upper tier within the interior. Three of the cell stacks 22 are arranged on a lower tier within the interior. Each cell stack 22 includes a plurality of individual battery cells 30 stacked side-by-side relative to one another along a cell stack axis. In this example, the cells 30 are lithium-ion prismatic battery cells. However, battery cells having other geometrical shapes (cylindrical, pouch, etc.) and / or chemistries (nickel-metal hydride, lead-acid, etc.) are alternatively utilized within the scope of the present disclosure.

[0039] The housing assembly 26 includes a housing tray 34 and a housing cover 38 that provide the interior. In this example, structural members 42 and various battery pack modules 46 secured to the structural members 42 are disposed within the interior along with the cell stacks 22. Other structural members 48 are also disposed within the interior. The structural members 42 and the structural members 48 can be extruded.

[0040] An attachment system 50 is utilized to secure the battery pack modules 46 to the structural members 42. The attachment system 50 includes a plurality of cleats 54 that interlock to secure the associated battery pack modules 46 to the structural members 42. The plurality of cleats 54 includes at least one upper cleat 58 that is part of one of the battery pack modules 46 and at least one lower cleat 62 that is part of the structural member 42. The lower cleat 62 is a flip-up cleat. The upper cleat 58 is a flip-down cleat. The lower cleat 62 extends along a bottom forward edge of the structural member 42. The lower cleat 62 is on a rear corner of the associated battery pack module 46.

[0041] In this example, the upper cleat 58 and the lower cleat 62 are characterized as a French cleat attachment system. In this example, installing the battery pack module 46 to the structural member 42 includes first inserting the lower cleat 62 into the upper cleat 58 so that the lower cleat 62 and the upper cleat 58 interlock as shown by the dashed lines in Figure 5 .

[0042] Next, the module 46 is rotated about the upper cleat 58 and the lower cleat 62 in the direction R from the dashed line position in Figure 5 to the installed position shown in Figure 5 , where the module 46 is in contact with the structural member 42. Instead of rotating about the upper cleat 58 and the lower cleat 62, the module 46 can be slid vertically downward to interlock the upper cleat 58 with the lower cleat 62.

[0043] Next, a plurality of mechanical fasteners 66 are used to secure the module 46 to the structural member 42. The fasteners 66 prevent the module 46 from rotating away from the structural member 42 in a direction opposite the direction R. The mechanical fasteners 66 can be threaded mechanical fasteners, such as press-in-place rivets, riv-nuts, or the like.

[0044] Interlocking the upper and lower clamping plates 58, 62 secures the lower portion of the module 46 to the structural member 42. As a result, mechanical fasteners 66 are not needed in this area, and instead can be used to secure the upper region of the module 46 to the structural member 42. Thus, interlocking the upper and lower clamping plates 58, 62 to secure the bottom corner of the module 46 to the structural member 42 can reduce the number of mechanical fasteners and labor time required associated with engaging mechanical fasteners to secure the module to the structural member.

[0045] With respect to the general orientation of the vehicle 10 in Figure 1 The battery pack module 46 in the example embodiment is secured to the forward-facing side 68 of the structural member 42. In other examples, the battery pack module 46 can be secured to other sides of the structural member 42.

[0046] In this example, the structural member 42 extends longitudinally in the vehicle transverse direction and serves as a transverse member for the battery pack 18. The structural member 42 can be secured to the housing tray 34, a lower transverse member, or another structure via a plurality of other mechanical fasteners 70, which can be threaded bolts.

[0047] In an example, the battery pack module 46 is secured to the structural member 42 by the mechanical fasteners 66 and interlocking of the upper and lower clamping plates 58, 62 prior to using the mechanical fasteners 70 to install the structural member 42 and battery pack module 46 within the housing tray 34. For example, after the battery pack module 46 is secured to the structural member 42, the battery pack module 46 and structural member 42 can be placed in the housing tray 34. The structural member 42 is then anchored within the housing tray 34 by the mechanical fasteners 70.

[0048] In some examples, one or more thermal interface pads can be attached to the battery pack module 46 and / or the structural member 42 such that the thermal interface pads are sandwiched between the battery pack module 46 and the structural member 42 when the battery pack module 46 is secured to the structural member 42. The thermal interface pads can help transfer thermal energy between the battery pack module 46 and the structural member 42. The structural member 42 may, for example, provide a heat sink for the battery pack module 46.

[0049] Reference is now made to Figures 6 to 8Another example structural member 142 is an extruded structural member. Structural member 142 may be extruded aluminum. Those skilled in the art and those who benefit from this disclosure will be able to distinguish extruded structures from non-extruded structures. Therefore, characterizing structural member 142 as an extruded structural member implies the structure of structural member 42.

[0050] Module 146 is secured to the front side of structural member 142 by, among other things, a plurality of clamps 154. The clamps of battery pack module 146 interlock with the clamps of structural member 142 to secure module 146 to structural member 142. Mechanical fasteners 166 are used to secure module 146 and prevent clamps from unlocking.

[0051] Battery pack module 146 and Figures 2 to 5 The battery pack module 46 of the embodiments includes various types of battery pack modules. In this example, module 146 includes a battery energy control module (BECM), a bus-type electrical center (BEC), and a DC-DC converter. In other examples, other types of modules 146 may be attached to structural member 142.

[0052] Similar to structural member 42 and module 46, module 146 can be attached to structural member 142, and then structural member 142 with module 146 is positioned within the housing tray. After module 146 has been attached, structural member 142 can then be secured to the housing tray by a plurality of mechanical fasteners.

[0053] The disclosed examples feature the use of a clamp-based attachment system to help secure modules to structural members, which helps reduce complexity.

[0054] The foregoing description is exemplary in nature and not restrictive. Variations and modifications made to the disclosed examples will become apparent to those skilled in the art, and such variations and modifications do not necessarily depart from the spirit of this disclosure. Therefore, the scope of protection accorded to this disclosure can only be determined by examining the appended claims.

Claims

1. A battery pack assembly, comprising: Structural components of the battery pack; The modules of the battery pack; as well as An attachment system having multiple clamps that interlock to secure the module to the structural member.

2. The battery pack assembly as claimed in claim 1, wherein the structural member is a transverse member within the outer casing of the battery pack.

3. The battery pack assembly as claimed in claim 1, wherein the structural member is an extruded structural member.

4. The battery pack assembly of claim 1, wherein at least one of the plurality of clamps is an extruded clamp.

5. The battery pack assembly of claim 1, wherein the attachment system secures the module to the forward side of the structural member within the interior of the battery pack.

6. The battery pack assembly of claim 1, wherein the plurality of clamps includes at least one upper clamp of the module and at least one lower clamp of the structural member.

7. The battery pack assembly of claim 1, wherein the plurality of clamps includes at least one upward clamp of the module and at least one downward clamp of the structural member.

8. The battery pack assembly of claim 1, wherein the attachment system is a French clamp attachment system.

9. The battery pack assembly as claimed in claim 1, further comprising: At least one mechanical fastener secures the module to the structural member, and optionally, the at least one mechanical fastener includes at least one press-fit bolt.

10. The battery pack assembly of claim 9, wherein the at least one mechanical fastener comprises at least one rivet nut.

11. The battery pack assembly of claim 9, wherein the plurality of clamps includes a clamp located at the bottom corner of the module, and the at least one mechanical fastener directly secures the upper region of the module to the structural member.

12. The battery pack assembly of claim 1, wherein the module is a battery energy control module, a bus-type electrical center, a DC-DC converter, or some combination thereof.

13. A method for fixing a battery pack module, comprising: The first clamping plate of the battery pack module is interlocked with the second clamping plate of the structural member of the battery pack to fix the module to the structural member; as well as Following the interlock, the module is additionally secured to the structural member using at least one mechanical fastener.

14. The battery pack module fixing method as described in claim 13, further comprising: After the module is secured to the structural member, the module and the structural member are positioned inside the battery pack housing, and then the structural member is secured inside the battery pack housing. Optionally, this also includes rotating the module around the first clamp and the second clamp after the interlocking and before the securing.

15. The battery pack module fixing method of claim 13, wherein the first clamp extends along the bottom corner of the module.

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