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US 11,114,721 B2Granted
Enclosure assembly mid-trays for electrified vehicle battery packs
AssigneeFord Global Technologies, LLC
InventorsKyle Krueger, Patrick Daniel Maguire, Mohammadreza Eftekhari
Life of this patent
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Abstract
A battery pack includes a battery array and an enclosure assembly housing the battery array. The enclosure assembly includes a tray, a cover, and a mid-tray. A plurality of internal components are secured within the mid-tray to establish an electrical subassembly within the enclosure assembly.
Claims15
A battery pack, comprising:
- a battery array;
- an enclosure assembly housing the battery array and including a tray, a cover, and a mid-tray;
- and
- a plurality of internal components secured within the mid-tray to establish an electrical subassembly within the enclosure assembly,
- wherein the mid-tray is secured and sealed to the tray via a tongue and groove connection,
- wherein the plurality of internal components includes a bussed electrical center (BEC), a battery electric control module (BECM), a wiring harness, and an I/O connector,
- wherein at least a portion of the mid-tray is exposed outside of the enclosure assembly,
- a first pocket formed in the mid-tray and including a first pocket wall and a first protrusion that protrudes inwardly from the first pocket wall, wherein the first protrusion retains the BEC from movement in at least one direction;
- a second pocket formed in the mid-tray and including a second pocket wall and a second protrusion that protrudes inwardly from the second pocket wall, wherein the second protrusion retains the BECM from movement in at least one direction;
- a channel formed in the mid-tray and including a channel wall and a third protrusion that protrudes inwardly from the channel wall, wherein the third protrusion retains the wiring harness from movement in at least one direction;
- and
- a core hole formed in the mid-tray and configured to receive the I/O connector.
9 more elements
A battery pack, comprising:
- a first battery array;
- a second battery array adjacent to the first battery array;
- an enclosure assembly housing the first and second battery arrays,
- wherein the enclosure assembly includes a tray, a mid-tray secured to the tray, and a cover secured to the mid-tray,
- wherein the tray and the mid-tray are constructed of an expanded polymer-based material and the cover is constructed of a solid polymer-based material that is more rigid than the expanded polymer-based material;
- a first pocket formed in the mid-tray and including a first pocket wall and a first protrusion that protrudes inwardly from the first pocket wall;
- a bussed electrical center (BEC) snap-fit within the first pocket and retained from movement in at least one direction by the first protrusion;
- a second pocket formed in the mid-tray and including a second pocket wall and a second protrusion that protrudes inwardly from the second pocket wall;
- a battery electric control module (BECM) snap-fit within the second pocket and retained from movement in at least one direction by the second protrusion;
- a channel formed in the mid-tray and including a channel wall and a third protrusion that protrudes inwardly from the channel wall;
- a wiring harness snap-fit within the channel and retained from movement in the at least one direction by the third protrusion, wherein the wiring harness is connected to either the BEC or the BECM;
- a core hole formed in the mid-tray;
- an I/O connector secured within the core hole;
- and
- a wiring loom that connects the wiring harness to the I/O connector.
12 more elements
A method, comprising:
- securing a mid-tray to a tray of a battery pack enclosure assembly;
- establishing an electrical subassembly inside the battery pack enclosure assembly,
- wherein establishing the electrical subassembly includes:
- positioning a bussed electrical center (BEC) within a first pocket of the mid-tray;
- routing and securing a first wiring harness within a first channel of the mid-tray;
- and
- connecting the first wiring harness to the BEC;
- and
- securing a cover over the mid-tray such that at least a portion of the mid-tray is exposed outside of the enclosure assembly,
- wherein, once secured in place, the cover extends over top of an entire upper surface of the mid-tray to conceal the electrical subassembly inside the battery pack enclosure assembly.
7 more elements
Dependencies are inferred from the claim text.