# US 11,440,391 B2 · Battery assembly having a cross-member and method of managing loads utilizing a cross-member > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,440,391 B2 - Document ID: US11440391B2 - Status: Granted - Kind: B2 - Application number: 16/774,253 - Filed: 2020-01-28 - Published: 2021-07-29 - Granted: 2022-09-13 - Earliest claimed: 2020-01-28 - Assignees: Ford Global Technologies, LLC - Applicants: Ford Global Technologies, LLC - Inventors: Micah Smith; Ihab Grace - Web page: https://patentgrep.com/patent/US11440391B2 ## CPC - B60K 1/04: of the electric storage means for propulsion - H01M 50/20: Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders (structural combination of accumulators with charging apparatus H01M10/46) - H01M 50/209: adapted for prismatic or rectangular cells (H01M50/216 takes precedence) - H01M 50/233: characterised by physical properties of casings or racks, e.g. dimensions - H01M 50/244: Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method - H01M 50/249: specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64) - H01M 50/271: Lids or covers for the racks or secondary casings - B60K 2001/0438: {Arrangement under the floor} - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY ## Abstract A battery assembly includes, among other things, a tray having a floor, a lid secured to the tray to provide an enclosure having an interior, and a battery module disposed within the interior. The battery module has a plurality of battery cell frames disposed along a battery module axis. The battery cell frames each include a frame toe that projects horizontally. The battery assembly further includes a cross-member disposed within the interior adjacent to the battery module. The cross-member includes a vertically extending wall having a protrusion that is vertically aligned with the frame toes of the plurality of battery cell frames. ## Claims ### Claim 1 A battery assembly, comprising: a tray having a floor; a lid secured to the tray to provide an enclosure having an interior; a battery module disposed within the interior, the battery module having a plurality of battery cell frames disposed along a battery module axis, the plurality of battery cell frames each including a frame toe that projects horizontally; and a cross-member disposed within the interior adjacent to the battery module, the cross-member including a vertically extending wall having a protrusion that is vertically aligned with the frame toes of the plurality of battery cell frames, the vertically extending wall of the cross-member extending longitudinally from a first end portion of the cross-member to an opposite, second end portion of the cross-member. ### Claim 2 (depends on 1) The battery assembly of claim 1, wherein the tray further includes a forward wall, an aft wall, and opposing side walls extending horizontally from the forward wall to the aft wall, wherein the cross-member and the vertically extending wall extend along a cross-member axis between the opposing side walls of the tray. ### Claim 3 (depends on 1) The battery assembly of claim 1, wherein the frame toes are lower frame toes, wherein the frame toes each provides an aperture that receives a tensioning member, the tensioning member configured to compress the plurality of battery cell frames along the battery module axis. ### Claim 4 (depends on 3) The battery assembly of claim 3, wherein the battery module includes an interconnect board that is directly vertically above the lower frame toes of the plurality of battery cell frames. ### Claim 5 (depends on 4) The battery assembly of claim 4, wherein the plurality of battery cell frames each include an upper frame toe providing an aperture that receives another tensioning member configured to compress the plurality of battery cell frames along the battery module axis, the interconnect board directly vertically beneath the upper frame toes. ### Claim 6 (depends on 1) The battery assembly of claim 1, wherein interconnect board is vertically above all portions of the protrusion. ### Claim 7 (depends on 1) The battery assembly of claim 1, wherein, when the battery assembly is loaded such that the battery module and the cross-member are moved relatively closer to each other horizontally, the protrusion is configured to contact the frame toes prior to other portions of the vertically extending wall. ### Claim 8 (depends on 1) The battery assembly of claim 1, wherein the cross-member includes a platform, the vertically extending wall extending vertically upward from the platform, the platform extending horizontally to a position vertically beneath the frame toes, the platform of the cross-member extending longitudinally from a first end portion of the cross-member to an opposite, second end portion of the cross-member. ### Claim 9 A battery assembly, comprising: a tray having a floor; a lid secured to the tray to provide an enclosure having an interior; a battery module disposed within the interior, the battery module having a plurality of battery cell frames disposed along a battery module axis, the plurality of battery cell frames each including a frame toe that projects horizontally; and a cross-member disposed within the interior adjacent to the battery module, the cross-member including a vertically extending wall having a protrusion that is vertically aligned with the frame toes of the plurality of battery cell frames, wherein the cross-member includes a platform, the vertically extending wall extending vertically upward from the platform, the platform extending horizontally to a position vertically beneath the frame toes, wherein the platform of the cross-member extends aft to the position vertically beneath the frame toes. ### Claim 10 (depends on 8) The battery assembly of claim 8, further comprising a thermal exchange device, wherein a lip of the thermal exchange device is sandwiched vertically between the platform and the frame toes. ### Claim 11 (depends on 1) The battery assembly of claim 1, wherein the cross-member is secured to the floor of the tray with mechanical fasteners. ### Claim 12 (depends on 1) The battery assembly of claim 1, wherein the cross-member is an extruded cross-member. ### Claim 13 (depends on 1) The battery assembly of claim 1, wherein the cross-member has reflectional symmetry. ### Claim 14 (depends on 1) The battery assembly of claim 1, wherein the protrusion and the remaining portions of the cross-member are different parts of a single, continuous structure. ### Claim 15 (depends on 1) The battery assembly of claim 1, wherein the protrusion is at a vertically lower portion of the vertically extending wall, wherein the vertically extending wall tapers from the protrusion to a primary portion of the vertically extending wall. ### Claim 16 A method of managing loads within a battery pack, comprising: providing a battery module within a battery pack, the battery module having a plurality of battery cell frames disposed along a battery module axis, the plurality of battery cell frames each including a frame toe that projects horizontally; providing a cross-member within the battery pack, the cross-member having a vertically extending wall with a protrusion that is vertically aligned with, and spaced a distance from, the frame toes of the plurality of battery cell frames; and when a load is applied to the battery pack that causes the plurality of battery cell frames to move horizontally relative to the cross-member such that the vertically extending wall contacts the battery cell frames, contacting the frame toes with the protrusion prior to the battery module contacting other portions of the vertically extending wall. ### Claim 17 (depends on 16) The method of claim 16, further comprising supporting the battery module on a platform of the cross-member, the vertically extending wall extending vertically upward from the platform. ### Claim 18 (depends on 16) The method of claim 16, further comprising compressing the battery cell frames along the battery module axis using a tensioning member that is received within apertures provided by the frame toes, wherein the tensioning member extends longitudinally in a direction that is perpendicular to the battery module axis. ### Claim 19 (depends on 16) The method of claim 16, wherein the cross-member extends longitudinally along a cross-member axis that, prior to the loading being applied, is perpendicular to the battery module axis. ### Claim 20 (depends on 1) The battery assembly of claim 1, wherein the cross-member has a consistent cross-section along a length of the cross-member.