SEALED ARRAY-TO-ARRAY COLLECTION RAIL ASSEMBLIES

Abstract

Sealed busbar assemblies are provided for use within traction battery packs. An example sealed busbar assembly can be configured to electrically connect a first and second battery array of the traction battery pack. Primary and secondary seals of the sealed busbar assembly can work together to seal high-voltage connections relative to both the first and second battery arrays. The high-voltage connections can be made through the busbar, a pair of fasteners, and the high-voltage array busbars of both the first and second battery arrays.

Description

AREA OF TECHNOLOGY

[0001] This disclosure generally relates to traction battery packs for electrified vehicles and, in particular, to sealed array-to-array busbar assemblies for use within traction battery packs. GENERAL STATE OF THE ART

[0002] An electrified vehicle includes a traction battery pack to supply power to electric motors and other electrical components. The traction battery pack contains numerous battery cells and various other internal components that support the electric vehicle's propulsion system. The battery cells must be reliably connected to achieve the voltage and power levels necessary for electrically powering the vehicle. SUMMARY

[0003] A traction battery pack according to an exemplary aspect of this disclosure includes, among other things, a first battery array, a second battery array, and a sealed busbar assembly configured to electrically connect the first battery array and the second battery array. The sealed busbar assembly includes a busbar, a busbar frame, a pair of fasteners, a pair of primary seals, and a pair of secondary seals.

[0004] In a further non-restrictive embodiment of the aforementioned traction battery pack, a first primary seal of the pair of primary seals and a first secondary seal of the pair of secondary seals work together to seal an interface between the sealed busbar assembly and a first array outer casing of the first battery array.

[0005] In a further non-restrictive embodiment of one of the aforementioned traction battery packs, a second primary seal of the pair of primary seals and a second secondary seal of the pair of secondary seals work together to seal an interface between the sealed busbar assembly and a second array outer casing of the second battery array.

[0006] In a further non-restrictive embodiment of any of the foregoing traction battery packs, a first fastening element of the pair of fastening elements is received through the busbar and a first high-voltage array busbar of the first battery array to establish a first high-voltage connection, and a second fastening element of the pair of fastening elements is received through the busbar and a second high-voltage array busbar of the second battery array to establish a second high-voltage connection.

[0007] In a further non-restrictive embodiment of any of the foregoing traction battery packs, the first fastening element is received by a first fastening element housing of a first internal component of the first battery array, and the second fastening element is received by a second fastening element housing of a second internal component of the second battery array.

[0008] In a further non-restrictive embodiment of any of the foregoing traction battery packs, the first internal component is a first array bus frame of the first battery array and the second internal component is a second array bus frame of the second battery array.

[0009] In another non-restrictive embodiment of any of the above traction battery packs, the busbar frame is formed around the busbar.

[0010] In a further non-restrictive embodiment of any of the foregoing traction battery packs, each primary seal of the pair of primary seals is positioned within a groove of the busbar frame.

[0011] In a further non-restrictive embodiment of any of the foregoing traction battery packs, each secondary seal of the pair of secondary seals is accommodated within a groove of a head section of a respective fastening element of the pair of fastening elements.

[0012] In a further non-restrictive embodiment of any of the foregoing traction battery packs, the busbar frame includes a first cover movable to enclose a first tab section of the busbar and a second cover movable to enclose a second tab section of the busbar.

[0013] A traction battery pack according to another exemplary aspect of this disclosure includes, among other things, a first battery array comprising a first high-voltage array busbar, a sealed busbar assembly comprising a busbar positioned on the first high-voltage array busbar, a first fastener received by the busbar and the first high-voltage array busbar, a first primary seal, and a first secondary seal. The first primary seal and the first secondary seal work together to seal a first high-voltage connection formed by the first fastener, the busbar, and the first high-voltage array busbar.

[0014] In a further non-restrictive embodiment of the aforementioned traction battery pack, the first primary seal is arranged to seal an interface between the sealed busbar assembly and a first array outer casing of the first battery array.

[0015] In a further non-restrictive embodiment of one of the aforementioned traction battery packs, the first primary seal is positioned within a groove of the busbar frame of the sealed busbar assembly.

[0016] In another non-restrictive embodiment of any of the above traction battery packs, the busbar frame is formed around the busbar.

[0017] In a further non-restrictive embodiment of the aforementioned traction battery pack, the first secondary seal is arranged to seal an interface between the first fastening element and the busbar.

[0018] In a further non-restrictive embodiment of any of the aforementioned traction battery packs, the first secondary seal is accommodated within a groove of a head section of the first fastening element.

[0019] In a further non-restrictive embodiment of any of the foregoing traction battery packs, the first fastening element is received by a fastening element housing of an internal component of the first battery array.

[0020] In a further non-restrictive embodiment of any of the foregoing traction battery packs, the internal component is an array busbar frame of the first battery array.

[0021] In a further non-restrictive embodiment of any of the foregoing traction battery packs, the sealed busbar assembly includes a second primary seal, a second secondary seal and a second fastening element that is received by the busbar and a second high-voltage array busbar of a second battery array.

[0022] In a further non-restrictive embodiment of any of the foregoing traction battery packs, the second primary seal and the second secondary seal work together to seal a second high-voltage connection formed by the second fastening element, the busbar, and the second high-voltage array busbar.

[0023] The embodiments, examples, and alternatives described in the preceding paragraphs, the claims, or the following descriptions and drawings, including any of their various aspects or individual features, may be considered independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, provided such features are not incompatible.

[0024] The various features and advantages of this disclosure will become apparent to the person skilled in the art from the following detailed description. The drawings accompanying the detailed description can be summarized as follows. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 schematically illustrates an electrified vehicle. Fig. Figure 2 illustrates a busbar assembly for electrically connecting adjacent battery arrays of a traction battery pack. Fig. Figure 3 illustrates the busbar assembly made of Fig. 2, wherein busbar covers of the busbar assembly are moved into an open position. Fig. 4 is a cross-sectional view along a section line 4-4 from Fig. 2. Fig. Figure 5 is a partially separated perspective view of a busbar assembly. DETAILED DESCRIPTION

[0025] This disclosure describes in detail sealed busbar assemblies for use within traction battery packs. An exemplary sealed busbar assembly can be configured to electrically connect a first battery array and a second battery array of the traction battery pack. Primary and secondary seals of the sealed busbar assembly can work together to seal high-voltage connections relative to both the first and second battery arrays. The high-voltage connections can be made through the busbar, a pair of fasteners, and high-voltage array busbars of both the first and second battery arrays. These and other features are discussed in more detail in the following paragraphs of this detailed description.

[0026] Fig. Figure 1 schematically illustrates an electrified vehicle 10. The electrified vehicle 10 can include any type of electrified powertrain. In one embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and could extend to other electrified vehicles, including, but not limited to, hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, etc. Therefore, although not specifically shown in the exemplary embodiment, the powertrain of the electrified vehicle 10 could be equipped with an internal combustion engine, which can be used either alone or in combination with other power sources to propel the electrified vehicle 10.

[0027] In the illustrated embodiment, the electrified vehicle 10 is depicted as an automobile. However, the electrified vehicle 10 could alternatively be a sport utility vehicle (SUV), a van, a pickup truck, or any other vehicle configuration. Although the figures in this disclosure illustrate a specific relationship between the components, these illustrations are not intended to limit this disclosure. The placement and orientation of the various components of the electrified vehicle 10 are shown schematically and could vary within the scope of this disclosure. Furthermore, the various figures accompanying this disclosure are not necessarily drawn to scale, and some features may be enlarged or reduced to highlight certain details of a specific component or system.

[0028] In the illustrated embodiment, the electrified vehicle 10 is a fully electric vehicle powered exclusively by electrical power, such as from one or more electric machines 12, without assistance from an internal combustion engine. The electric machine 12 can operate as an electric motor, an electric generator, or both. The electric machine 12 receives electrical power and can convert this power into torque to drive one or more wheels 14 of the electrified vehicle 10.

[0029] A voltage bus 16 can electrically couple the electric machine 12 to a traction battery pack 18. The traction battery pack 18 is an exemplary battery of an electrified vehicle. The traction battery pack 18 can be a high-voltage traction battery pack assembly comprising a variety of battery cells capable of outputting electrical power to supply the electric machine 12 and / or other electrical consumers of the electrified vehicle 10. Alternatively or additionally, other types of energy storage devices and / or output devices could also be used to supply the electrified vehicle 10 with electrical power.

[0030] The traction battery pack 18 can be secured to an underbody 20 of the electrified vehicle 10. However, the traction battery pack 18 could be located elsewhere on the electrified vehicle 10 within the scope of protection of this disclosure.

[0031] The traction battery pack 18 can include one or more battery arrays 22 (e.g., battery modules, assemblies, or groups of rechargeable battery cells 24) capable of outputting electrical power to supply the electric machine 12 and / or other electrical consumers of the electrified vehicle 10. The one or more battery arrays 22 of the traction battery pack 18 can each include a plurality of battery cells 24 that store energy to supply various electrical consumers of the electrified vehicle 10. The traction battery pack 18 could employ any number of battery arrays 22 and battery cells 24 within the scope of this disclosure. Accordingly, this disclosure is not intended to limit the use of the battery arrays 22 and battery cells 24 to those described in the following documents. Fig. The highly schematic configuration shown in 1 may be limited.

[0032] In one embodiment, the battery cells 24 of each battery array 22 are lithium-ion pouch cells. Alternatively, however, battery cells having other geometries (cylindrical, prismatic, etc.), other chemical compositions (nickel-metal hydride, lead-acid, etc.), or both, could be used within the scope of protection of this disclosure.

[0033] The battery arrays 22 and various other battery-internal components (e.g., an electrical distribution bus, an electrical battery control module, wiring, connectors, etc.) can be housed within an interior compartment 26 of an enclosure assembly 28. The enclosure assembly 28 can, for example, include an enclosure cover and an enclosure shell. The enclosure cover can be secured to the enclosure shell (e.g., screwed, welded, glued, etc.) to provide the interior compartment 26. The size, shape, and overall configuration of the enclosure assembly 28 are not intended to limit this disclosure.

[0034] The thermal energy levels of the battery cells 24 of each battery array 22 can increase while the electrified vehicle 10 is in operation. A thermal management system can be used to manage the thermal energy levels of the battery cells 24 of the battery arrays 22. The thermal management system can be configured to circulate a coolant C through each battery array 22 to manage the thermal energy within the battery arrays 22, for example, by using the coolant C to absorb heat from the battery cells 24.

[0035] In one embodiment, the thermal management system is an immersion thermal management system in which battery cells 24 and / or other components of the battery arrays 22 can be immersed in the coolant C. Thermal energy can be transferred between the coolant C and the battery cells 24 when the coolant C flows over and / or around the battery cells 24 within the battery arrays 22. The coolant C can help manage the thermal energy levels of the battery cells 24 as well as other components of the battery arrays 22, such as busbars.

[0036] The thermal management system can supply the coolant C to the interior of the battery arrays 22 through one or more inlets of each battery array 22. The coolant C can fill one or more open areas within the battery arrays 22, so that the battery cells 24 are immersed in the coolant C and in direct contact with it. The coolant C can absorb thermal energy from the battery cells 24 to manage the thermal energy levels. The coolant C can then exit the battery arrays 22 through one or more outlets of each battery array 22.

[0037] The coolant C, exiting through the outlets of the battery arrays 22, can move to a heat exchange device (not shown), such as a heat exchanger, where thermal energy can be transferred from the coolant C to the atmosphere. A pump (not shown) can be operated to selectively circulate the coolant C as part of a closed loop between the battery arrays 22 and the heat exchange device, and then back to the battery arrays 22.

[0038] The coolant C circulating in the immersion heat management system can be a dielectric fluid or another type of non-conductive fluid (e.g., oil) designed for immersion cooling of the battery cells 24. However, other non-conductive fluids may also be suitable, and the actual chemical composition and design properties (e.g., dielectric constant, maximum dielectric strength, boiling point, etc.) may vary depending on the environment in which the traction battery pack 18 is to be used.

[0039] The use of immersion cooling may necessitate the development of additional sealing solutions, such as for sealing high-voltage connections between adjacent battery arrays 22 of the traction battery pack 18. This disclosure is therefore directed to sealed busbar assemblies for electrically connecting battery arrays of traction battery packs.

[0040] The Fig. Figures 2-5 illustrate features associated with a sealed busbar assembly 30, which can be used to electrically connect adjacent battery arrays of a battery system. For example, the sealed busbar assembly 30 could be used to connect adjacent battery arrays 22 of the traction battery pack 18 of the electrified vehicle 10. Fig. 1. To connect electrically.

[0041] In the illustrated embodiment, the sealed busbar assembly 30 is used to electrically connect a first battery array 22A and a second battery array 22B. In other embodiments, however, the sealed busbar assembly 30 could be used to provide other high-voltage connections, such as those between a battery array and a bused electrical center (BEC).

[0042] The first battery array 22A and the second battery array 22B could be part of a series of battery arrays of the traction battery pack 18. Depending on the general design requirements of the traction battery pack 18, additional battery arrays could be added to the series by using an additional number of sealed busbar assemblies 30.

[0043] The sealed busbar assembly 30 can be part of an electrical distribution system (EDS) designed for electrically distributing power to / from the traction battery pack 18. The sealed busbar assembly 30 can electrically connect a first high-voltage array busbar 32A of the first battery array 22A to a second high-voltage array busbar 32B of the second battery array 22B (see Fig. 4) The sealed busbar assembly 30 can be used to electrically connect the first battery array 22A and the second battery array 22B either in a parallel configuration or a series configuration.

[0044] Each high-voltage array busbar 32A, 32B can be mounted relative to a surface of a mounting element housing 52 of either the first battery array 22A or the second battery array 22B. In one embodiment, the high-voltage array busbars 32A, 32B are at least partially exposed within openings 37 (see Figure 1). Fig. 4), which are formed in the outer array enclosures 35.

[0045] The sealed busbar assembly 30 can include a busbar 34, a busbar frame 36, a pair of primary seals 38, a pair of fasteners 40, and a pair of secondary seals 42. Each of these substituent parts of the sealed busbar assembly 30 is described in more detail below.

[0046] The busbar 34 can, for example, be made of a metallic material such as copper. However, other conductive materials may also be used within the scope of this disclosure. The busbar 34 can include a first lug section 44, a second lug section 46, and a bridging section 48 that extends between and connects the first lug section 44 and the second lug section 46. Together, the first lug section 44, the second lug section 46, and the bridging section 48 form a single-piece body of the busbar 34.

[0047] The first tab section 44 and the second tab section 46 can be bent relative to the bridging section 48 to form a "hat"-like shape for the busbar 34. The bridging section 48 can thus extend in a plane that is vertically offset from (e.g., vertically above) a plane extending through the first and second tab sections 44, 46. For the purposes of this disclosure, "vertical" refers to the ground in a normal orientation of the traction battery pack 18 when mounted on the electrified vehicle 10.

[0048] The first tab section 44 and the second tab section 46 can each be configured in the form of a loop incorporating an opening 50. The opening 50 can be a hole dimensioned to receive one of the fasteners 40 of the sealed busbar assembly 30. A fastener 40 can be inserted through the first tab section 44, through the first high-voltage array busbar 32A, and then into a mounting housing 52 of an internal component 54 of the first battery array 22A for mounting the sealed busbar assembly 30 to the first battery array 22A (see Fig. 4), and the other fastening element 40 can be inserted through the second tab section 46, through the second high-voltage array busbar 32B and then into a mounting housing 52 of an internal component 54 of the second battery array 22B for mounting the sealed busbar assembly 30 on the second battery array 22B (see Fig. 4).

[0049] In one embodiment, the fastening elements 40 are bolts or screws. In another embodiment, the fastening elements 40 are M6 bolts. Other fastening element configurations could be used within the scope of this disclosure.

[0050] In one embodiment, the internal components 54 are array busbar frames that can position and hold additional busbars (not shown) configured to electrically connect the battery cells 24 of each battery array 22A, 22B. However, other configurations within the scope of this disclosure are considered. The internal components 54 can be firmly secured to the outer array enclosures 35, for example, by the use of mechanical fasteners and / or adhesives.

[0051] The busbar frame 36 can be arranged to substantially surround the busbar 34. For example, the busbar frame 36 can be formed around the busbar 34. The busbar frame 36 can be made of an insulating plastic material, such as a suitable thermoplastic or thermoset. However, other insulating materials could also be used within the scope of this disclosure.

[0052] The busbar frame 36 can include a first platform section 56, a second platform section 58, and a central section 60 that connects and extends between the first platform section 56 and the second platform section 58. The first platform section 56 can be formed around the first lug section 44 of the busbar 34, the second platform section 58 can be formed around the second lug section 46 of the busbar 34, and the central section 60 can be formed around the bridging section 48 of the busbar 34.

[0053] Each of the first platform section 56 and the second platform section 58 can contain a cover 62. Each cover 62 can independently be in a closed position (see Fig. 2 and Fig. 4) and an open position (see Fig. 3 and Fig. 5) be moved relative to the first platform section 56 or the second platform section 58.

[0054] In the closed position, the cover 62 encloses the first tab section 44 or the second tab section 46 and prevents finger access to the busbar 34. The covers 62 can therefore provide “finger-safe” features to prevent unintentional exposure to high-voltage areas of the traction battery pack 18.

[0055] In the open position, the cover 62 is displaced from the first platform section 56 or the second platform section 58 to provide access to the first tab section 44 or the second tab section 46 of the busbar 34. The openings 50 of the first and second tab sections 44, 46 of the busbar 34 are therefore easily accessible for mounting or dismounting the sealed busbar assembly 30 relative to the first and second battery arrays 22A, 22B.

[0056] Each cover 62 can be movably connected to the first platform section 56 or the second platform section 58 by a film hinge 64. The covers 62 can be manually rotated around the film hinge 64 to achieve a rotational movement between the closed and open positions.

[0057] A primary seal 38 can be connected to each of the first platform section 56 and the second platform section 58 of the busbar frame 36. Each primary seal 38 can be accommodated within a groove 66 provided on an inward-facing side 68 of the first platform section 56 or the second platform section 58 (see Fig. 4) The inward-facing sides 68 face the outer array housings 35 of the first and second battery arrays 22A, 22B.

[0058] The primary seals 38 can be configured to seal an interface between the sealed busbar assembly 30 and the outer array housing 35, thereby essentially sealing the high-voltage connections. In one embodiment, the primary seals 38 are flat gaskets. However, other configurations within the scope of this disclosure are considered.

[0059] The secondary seals 42 can each be positioned to seal an interface between one of the fasteners 40 and the busbar 34, thereby further contributing to the sealing of the high-voltage connections. Each secondary seal 42 can be accommodated within a groove 70 formed in a head section 72 of one of the fasteners 40. In one embodiment, the secondary seals 42 are O-ring seals. However, other configurations within the scope of this disclosure are considered.

[0060] The primary seals 38 and the secondary seals 42 can be configured to seal the interface between the sealed busbar assembly 30 and the high-voltage connections simultaneously with the insertion of the fasteners 40. For example, the primary seals 38 and the secondary seals 42 can be compressed to create the sealed interfaces at the same time as the fasteners 40 are tightened to make the high-voltage electrical connections, thus simplifying assembly and increasing installation efficiency.

[0061] The exemplary sealed busbar assemblies disclosed in this disclosure include a double-seal arrangement for sealing high-voltage connections within a traction battery pack. The double-seal arrangement can accommodate required assembly tolerances and increase installation efficiency while maintaining the sealed interface around high-voltage connection areas.

[0062] Although the different non-restrictive embodiments are illustrated by showing specific components or steps, the embodiments of this disclosure are not limited to these specific combinations. It is possible to use some of the components or features from any of the non-restrictive embodiments in combination with features or components from any of the other non-restrictive embodiments.

[0063] It is understood that identical reference numerals denote corresponding or similar elements in the multiple views. It is understood that although a specific component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the lessons of this disclosure.

[0064] The foregoing description is to be interpreted as illustrative and not as limiting. A person skilled in the art understands that certain modifications might be covered by the scope of protection of this disclosure. For these reasons, the following patent claims should be read carefully to determine the true scope of protection and content of this disclosure.

Claims

[1] Traction battery pack, comprising: a first battery array; a second battery array; and a sealed busbar assembly configured to electrically connect the first battery array and the second battery array, wherein the sealed busbar assembly comprises a busbar, a busbar frame, a pair of fasteners, a pair of primary seals and a pair of secondary seals. [2] Traction battery pack according to claim 1, wherein a first primary seal of the pair of primary seals and a first secondary seal of the pair of secondary seals cooperate to seal an interface between the sealed busbar assembly and a first array outer casing of the first battery array. [3] Traction battery pack according to claim 2, wherein a second primary seal of the pair of primary seals and a second secondary seal of the pair of secondary seals cooperate to seal an interface between the sealed busbar assembly and a second array outer casing of the second battery array. [4] Traction battery pack according to claim 3, wherein a first fastening element of the pair of fastening elements is received through the busbar and a first high-voltage array busbar of the first battery array to establish a first high-voltage connection, and a second fastening element of the pair of fastening elements is received through the busbar and a second high-voltage array busbar of the second battery array to establish a second high-voltage connection. [5] Traction battery pack according to claim 4, wherein the first fastening element is received by a first fastening element housing of a first internal component of the first battery array and the second fastening element is received by a second fastening element housing of a second internal component of the second battery array, and wherein optionally the first internal component is a first array busbar frame of the first battery array and the second internal component is a second array busbar frame of the second battery array. [6] Traction battery pack according to one of the preceding claims, wherein the busbar frame is formed around the busbar. [7] Traction battery pack according to one of the preceding claims, wherein each primary seal of the pair of primary seals is positioned within a groove of the busbar frame. [8] Traction battery pack according to one of the preceding claims, wherein each secondary seal of the pair of secondary seals is accommodated within a groove of a head section of a respective fastening element of the pair of fastening elements. [9] Traction battery pack according to any of the preceding claims, wherein the busbar frame includes a first cover movable to enclose a first tab section of the busbar and a second cover movable to enclose a second tab section of the busbar. [10] Traction battery pack, comprising: a first battery array incorporating a first high-voltage array busbar; and a sealed busbar assembly comprising a busbar positioned on the first high-voltage array busbar, a first fastening element received through the busbar and the first high-voltage array busbar, a first primary seal and a first secondary seal, wherein the first primary seal and the first secondary seal work together to seal a first high-voltage connection made by the first fastener, busbar and first high-voltage array busbar. [11] Traction battery pack according to claim 10, wherein the first primary seal is arranged to seal an interface between the sealed busbar assembly and a first array outer casing of the first battery array. [12] Traction battery pack according to claim 11, wherein the first primary seal is positioned within a groove of a busbar frame of the sealed busbar assembly and wherein optionally the busbar frame is formed around the busbar. [13] Traction battery pack according to one of claims 10 to 12, wherein the first secondary seal is arranged to seal an interface between the first fastening element and the busbar, and wherein optionally the first secondary seal is accommodated within a groove of a head section of the first fastening element. [14] Traction battery pack according to one of claims 10 to 13, wherein the first fastening element is received by a fastening housing of an internal component of the first battery array and wherein optionally the internal component is an array busbar frame of the first battery array. [15] Traction battery pack according to any one of claims 10 to 14, wherein the sealed busbar assembly includes a second primary seal, a second secondary seal and a second fastening element which is received by the busbar and a second high-voltage array busbar of a second battery array and wherein optionally the second primary seal and the second secondary seal cooperate to seal a second high-voltage connection which is made by the second fastening element, the busbar and the second high-voltage array busbar.

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