阅读说明：本技术 用于电动化车辆电池组的密封结构穿通总成 (Seal structure feedthrough assembly for an electric vehicle battery pack ) 是由 迈卡·史密斯 于 2019-06-06 设计创作，主要内容包括：本公开提供了“用于电动化车辆电池组的密封结构穿通总成”。本公开详述了电动化车辆,所述电动化车辆配备有用于在结构上加强和密封电池组的穿通总成。示例性穿通总成包括清洁侧部件和脏侧部件。所述清洁侧部件主要定位在所述电池组内部,而所述脏侧部件与所述清洁侧部件接合并延伸到所述电池组外部的位置以用于与车身底部的部件对接。所述穿通总成的密封件被定位在所述清洁侧部件与所述脏侧部件之间,并且被配置为阻止水、污垢和其他潜在污染物进入。(The present disclosure provides a "seal structure feedthrough assembly for an electrified vehicle battery pack. The present disclosure details an electrically powered vehicle equipped with a feedthrough assembly for structurally reinforcing and sealing a battery pack. An exemplary pass-through assembly includes a clean side component and a dirty side component. The clean-side member is positioned primarily inside the battery pack, while the dirty-side member engages the clean-side member and extends to a position outside the battery pack for interfacing with a member of the underbody. The seal of the pass-through assembly is positioned between the clean side component and the dirty side component and is configured to inhibit the ingress of water, dirt, and other potential contaminants.)

1. A feedthrough assembly for a battery pack, comprising:

A cleaning-side member including a pipe and a first flange protruding from the pipe;

A dirty-side component comprising a stud and a second flange protruding from the stud, wherein the stud engages a portion of the pipe; and

a seal disposed between the clean side member and the dirty side member.

2. The feedthrough assembly of claim 1, wherein the conduit extends between a first end and a second end, and the first flange is positioned closer to the first end.

3. The feedthrough assembly of claim 1 or 2, wherein the clean side component comprises a shoulder extending above the first flange, and optionally wherein the second flange of the dirty side component abuts against the shoulder.

4. The feedthrough assembly of any preceding claim, wherein the conduit comprises a threaded passage and the threads of the stud engage with the threaded passage.

5. A feedthrough assembly as claimed in any preceding claim, wherein the stud comprises a drive feature adapted to torque the stud into the conduit.

6. The feedthrough assembly of any preceding claim, wherein the seal comprises an annular body received within a groove formed in a lid of the battery or the second flange, or the seal is established by an inverted flange protruding from a bottom surface of the second flange.

7. The feedthrough assembly of any preceding claim, wherein the seal is embedded within the second flange and the seal is one-sided to seal against one structure or two-sided to seal against two structures.

8. The feedthrough assembly of any preceding claim, wherein a first segment of the stud extending below the second flange engages the portion of the pipe, and the feedthrough assembly comprises a nut received over a second segment of the stud extending above the second flange.

9. An electrified vehicle, comprising:

an underbody including a floor;

A battery pack mounted below the bottom plate;

A pass-through assembly including a clean side component and a dirty side component;

The cleaning side member extends from a location inside the battery pack and includes a portion that is at least partially exposed within a first aperture formed in a lid of the battery pack; and is

The dirty-side member is connected to the clean-side member and extends through a second aperture formed in the base plate.

10. The electrified vehicle of claim 9, wherein the duct of the clean side component is secured to a battery inner structure by a weld bead, and optionally wherein the battery inner structure is a cross member positioned between a first battery array and a second battery array of the battery pack.

11. The electrified vehicle of claim 9 or 10, wherein the flange of the cleaning side member is received against an inner surface of the cover.

12. the electrified vehicle of any of claims 9-11, wherein a shoulder of the clean side member is the portion exposed within the first aperture and the shoulder abuts against a flange of the dirty side member.

13. The electrified vehicle of any of claims 9-12, wherein a flange of the dirty-side component is positioned between an underside of the floor and an outer surface of the cover, and optionally wherein a threaded stud of the dirty-side component engages a threaded channel of a conduit of the clean-side component at a location inside the battery pack.

14. The electrified vehicle of any of claims 9-13, comprising a seal positioned between a flange of the dirty-side component and an outer surface of the cover, and optionally wherein the seal is received within a groove formed in the outer surface of the cover or the flange of the dirty-side component.

15. The electrified vehicle of any of claims 9-14, comprising a nut positioned over a stud of the dirty-side component and received against the floor.

Technical Field

The present disclosure relates to feedthrough assemblies for structurally reinforcing and sealing electrified vehicle battery packs.

Background

The need to reduce fuel consumption and emissions from automobiles has been well documented in the literature. Accordingly, electrified vehicles have been developed that reduce or eliminate the reliance on internal combustion engines altogether. Generally, electrified vehicles differ from conventional motor vehicles in that electrified vehicles are selectively driven by one or more battery-powered electric machines. In contrast, conventional motor vehicles rely entirely on internal combustion engines to propel the vehicle.

High voltage traction battery packs typically power the electric motors and other electrical loads of the electrified vehicle. The battery pack includes a plurality of energy storage devices, such as battery cells, that store energy used to power these electrical loads. The battery cell and various other battery components are typically packaged together inside a housing assembly. Depending on the mounting location relative to the vehicle, the battery pack may be susceptible to noise, vibration, and harshness, as well as vehicle impact events.

Disclosure of Invention

A feedthrough assembly for a battery pack according to an exemplary aspect of the present disclosure includes, inter alia: a cleaning-side member including a pipe and a first flange protruding from the pipe; and a dirty-side component including a stud and a second flange protruding from the stud. The stud engages a portion of the pipe. A seal is disposed between the clean side member and the dirty side member.

In another non-limiting embodiment of the foregoing feedthrough assembly, the conduit extends between a first end and a second end, and the first flange is positioned closer to the first end.

In another non-limiting embodiment of any of the foregoing feedthrough assemblies, the cleaning side member includes a shoulder extending above the first flange.

In another non-limiting embodiment of any of the foregoing feedthrough assemblies, the second flange of the dirty-side component abuts against the shoulder.

In another non-limiting embodiment of any of the foregoing feedthrough assemblies, the tube includes a threaded passage and the threads of the stud engage the threaded passage.

In another non-limiting embodiment of any of the foregoing feedthrough assemblies, the stud comprises a drive feature adapted to torque the stud into the conduit.

In another non-limiting embodiment of any of the assemblies, the seal comprises an annular body received within a groove formed in a lid or the second flange of the battery pack.

in another non-limiting embodiment of any of the foregoing feedthrough assemblies, the seal is established by an inverted flange projecting from a bottom surface of the second flange.

In another non-limiting embodiment of any of the foregoing feedthrough assemblies, the seal is embedded within the second flange and the seal is one-sided for sealing against one structure or two-sided for sealing against two structures.

In another non-limiting embodiment of any of the foregoing feedthrough assemblies, a first segment of the stud extending below the second flange engages the portion of the conduit and a nut is received over a second segment of the stud extending above the second flange.

An electrified vehicle according to another exemplary aspect of the present disclosure includes, inter alia: an underbody including a floor; a battery pack mounted below the bottom plate; and a pass-through assembly including a clean side component and a dirty side component. The cleaning side member extends from a location inside the battery pack and includes a portion that is at least partially exposed within a first aperture formed in a lid of the battery pack. The dirty-side member is connected to the clean-side member and extends through a second aperture formed in the base plate.

In another non-limiting embodiment of the foregoing electrified vehicle, the duct of the clean side member is secured to the battery inner structure by a weld bead.

In another non-limiting embodiment of any of the foregoing electrified vehicles, the battery internal structure is a cross member positioned between a first battery array and a second battery array of the battery pack.

In another non-limiting embodiment of any of the foregoing electrified vehicles, the flange of the cleaning side member is received against an inner surface of the cover.

In another non-limiting embodiment of any of the foregoing electrified vehicles, the shoulder of the clean side member is the portion exposed within the first aperture, and the shoulder abuts against the flange of the dirty side member.

In another non-limiting embodiment of any of the foregoing electrified vehicles, the dirty-side component includes a flange that is positioned between an underside of the floor and an outer surface of the cover.

In another non-limiting embodiment of any of the foregoing electrified vehicles, the threaded stud of the dirty-side component engages the threaded passage of the conduit of the clean-side component at a location inside the battery pack.

In another non-limiting embodiment of any of the foregoing electrified vehicles, a seal is positioned between a flange of the dirty-side component and an outer surface of the cover.

In another non-limiting embodiment of any of the foregoing electrified vehicles, the seal is received within a groove formed in the outer surface of the cover or the flange of the dirty-side component.

In another non-limiting embodiment of any of the foregoing electrified vehicles, a nut is positioned over the stud of the dirty-side component and received against the floor.

The embodiments, examples and alternatives of the preceding paragraphs, claims or the following description and drawings, including any of their various aspects or respective individual features, may be made independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless the features are incompatible.

Various features and advantages of the disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.

Drawings

FIG. 1 schematically illustrates a drivetrain of an electrified vehicle.

FIG. 2 illustrates an electrified vehicle that may employ the powertrain of FIG. 1.

FIG. 3 illustrates an exemplary battery pack of an electrified vehicle.

FIG. 4 illustrates an exemplary feedthrough assembly for structurally reinforcing and sealing a battery pack of an electrified vehicle.

Fig. 5 is an exploded view of the feedthrough assembly of fig. 4.

Fig. 6 shows the seal of the feedthrough assembly of fig. 4 and 5.

Figure 7 shows a recess formed on the dirty side member of the feedthrough assembly of figures 4 and 5.

FIG. 8 illustrates an exemplary cleaning side member of a feedthrough assembly.

fig. 9 illustrates an exemplary dirty side component of the feedthrough assembly.

Fig. 10 illustrates another exemplary dirty-side component of the feedthrough assembly.

Fig. 11 illustrates yet another exemplary dirty-side component of a feedthrough assembly.

Detailed Description

The present disclosure details an electrically powered vehicle equipped with a feedthrough assembly for structurally reinforcing and sealing a battery pack. An exemplary pass-through assembly includes a clean side component and a dirty side component. The clean-side member is positioned inside the battery pack, while the dirty-side member is engaged with the clean-side member and extends to a position outside the battery pack for interfacing with a member of the underbody. The seal of the pass-through assembly is positioned between the clean side component and the dirty side component and is configured to inhibit the ingress of water, dirt, and other potential contaminants. These and other features are discussed in more detail in the following paragraphs of this detailed description.

FIG. 1 schematically illustrates a powertrain 10 of an electrified vehicle 12. In one embodiment, the electrified vehicle 12 is a Battery Electric Vehicle (BEV). In another embodiment, the electrified vehicle 12 is a Hybrid Electric Vehicle (HEV) or a plug-in hybrid electric vehicle (PHEV). Thus, although not shown in this embodiment, the electrified vehicle 12 may be equipped with an internal combustion engine that may be used alone or in combination with other energy sources to propel the electrified vehicle 12.

In the illustrated embodiment, the electrified vehicle 12 is an all-electric vehicle that is propelled solely by electric power (such as by the electric machine 14) without any assistance from an internal combustion engine. The electric machine 14 may function as an electric motor, a generator, or both. The electric machine 14 receives electrical power and provides rotational output torque. The electric machine 14 may be connected to a gearbox 16 to adjust the output torque and rotational speed of the electric machine 14 at a predetermined gear ratio. The gearbox 16 is connected to a set of drive wheels 18 by an output shaft 20. The voltage bus 22 electrically connects the electric machine 14 to the battery pack 24 through the inverter 26. The electric machine 14, the transmission 16, and the inverter 26 may be collectively referred to as a transmission 28.

The battery pack 24 is an exemplary electrified vehicle battery. The battery pack 24 may be a high-voltage traction battery pack that includes a plurality of battery arrays 25 (i.e., battery assemblies or cell stacks) that are capable of outputting electrical power to operate the electric machine 14 and/or other electrical loads of the electrified vehicle 12. Other types of energy storage devices and/or output devices may also be used to power the electrified vehicle 12.

The electrified vehicle 12 is also equipped with a charging system 30 to charge an energy storage device (e.g., battery cell) of the battery pack 24. The charging system 30 may include charging components located on the electrified vehicle 12 and external to the electrified vehicle 12. The charging system 30 can be connected to an external power source (e.g., a wall outlet, a charging station, etc.) to receive and distribute power received from the external power source throughout the electrified vehicle 12.

The powertrain 10 of fig. 1 is highly schematic and is not intended to limit the present disclosure. Powertrain system 10 may alternatively or additionally employ various additional components within the scope of the present disclosure.

FIG. 2 illustrates an electrified vehicle 12 that may employ the powertrain 10 of FIG. 1 or any other electrified or hybrid powertrain. In one embodiment, the electrified vehicle 12 is an automobile. However, the electrified vehicle 12 may be an automobile, truck, van, sport utility vehicle, or any other vehicle type. Although particular component relationships are shown in the drawings of the present disclosure, these illustrations are not intended to limit the present disclosure. The placement and orientation of the various components of the electrified vehicle 12 are schematically illustrated and may vary within the scope of the present disclosure. Additionally, the various drawings that accompany the present disclosure can not be drawn to scale, and some features can be exaggerated or minimized to show certain details of particular components.

The electrified vehicle 12 may include a passenger compartment 32 and a cargo compartment 34 (e.g., a trunk compartment) located rearward of the passenger compartment 32. The floor 36 separates the passenger compartment 32 from the underbody 38. The battery pack 24 may be suspended from the underbody 38 such that it is remote from both the passenger compartment 32 and the cargo compartment 34. Thus, the battery pack 24 does not occupy space that would otherwise be available for carrying passengers or cargo. The battery pack 24 may be secured relative to the underbody 38 using any fastening method, including but not limited to bolting, strapping, welding, etc.

Referring now to fig. 2 and 3, the battery pack 24 may house a plurality of battery cells 40 that store energy for powering various electrical loads of the electrified vehicle 12, such as, for example, the electric machine 14 of fig. 1. In one embodiment, the battery pack 24 houses a prismatic lithium ion battery. However, battery cells having other geometries (cylindrical, pouch, etc.), other chemistries (nickel-metal hydride, lead acid, etc.), or both, may alternatively be utilized within the scope of the present disclosure. The battery pack 24 may additionally house various other components, including but not limited to a Bus Electrical Center (BEC), a Battery Electronic Control Module (BECM), a wire harness, wiring, I/O connectors, and the like.

The battery cells 40 may be grouped together in one or more battery arrays 25. In one embodiment, the battery pack 24 includes two battery arrays 25. However, the total number of battery cells 40 and battery arrays 25 employed within the battery pack 24 is not intended to limit the present disclosure.

A cell internal structure 42, such as a relatively rigid cross-member, may be positioned between adjacent cell arrays 25. The battery internal structure 42 increases the rigidity of the battery pack 24.

The housing assembly 44 houses each battery array 25 of the battery pack 24. In one embodiment, the housing assembly 44 is a sealed housing. The housing assembly 44 may include any size, shape, and configuration within the scope of the present disclosure.

In one embodiment, the housing assembly 44 includes a tray 46 and a cover 48. Tray 46 and cover 48 cooperate to surround and enclose battery array 25. The tray 46 may provide an open area 50 for holding the battery array 25. After positioning the battery array 25 within the open area 50, a cover 48 may be placed and sealed to the tray 46 to enclose the battery array 25.

Portions of the housing assembly 44 may be made of a polymer-based material. In one embodiment, the cover 48 is constructed (e.g., molded) from a solid polymer-based material. Exemplary solid polymer-based materials can include, but are not limited to, sheet molding compounds (e.g., glass fiber reinforced polyesters), polypropylene, and polyamines. The tray 46 or cover 48 may be made of other polymer-based materials within the scope of the present disclosure.

Because the mounting location of the battery pack 24 is below the floor 36 of the underbody 38, the battery pack 24 may be susceptible to noise, vibration, and harshness, as well as vehicle impact events. Additionally, the use of polymer-based materials within the housing assembly 44 of the battery pack 24 may result in a structure that is not rigid or strong enough to adequately mount the battery pack 24 to the underbody 38. Accordingly, the present disclosure presents a novel feedthrough assembly 52. The feedthrough assembly 52 is configured to both structurally reinforce the battery pack 24 and seal a hole or opening formed through the housing assembly 44 of the battery pack 24 to receive the feedthrough assembly 52.

Fig. 4 and 5 illustrate an exemplary feedthrough assembly 52 in more detail. Portions of the battery pack 24 and electrified vehicle 12 have been removed from fig. 4-5 to better illustrate various features and functions of the feedthrough assembly 52.

The pass-through assembly 52 may include a clean side component 54, a dirty side component 56, and a seal 58 positioned to seal a space between the clean side component 54 and the dirty side component 56. These components and their corresponding functions are described in detail below.

The cleaning side member 54 is "clean" in that it is primarily located inside the battery pack 24. The cleaning side member 54 may include a duct 60 and a flange 62 projecting radially outward from the duct 60. The conduit 60 may include a threaded passage 64 extending from a first end 66 of the conduit 60, located adjacent the flange 62, to a second end 68 of the conduit 60, located opposite the first end 66. In one embodiment, the threaded passage 64 is coated with a fluoropolymer (e.g., Polytetrafluoroethylene (PTFE)).

In the mounted position of the cleaning side member 54, the flange 62 may abut against an inner surface 70 of the lid 48 of the battery pack 24, and the second end 68 of the duct 60 may be secured to the cell internal structure 42 inside the battery pack 24. In one embodiment, the second end 68 of the conduit 60 is secured to the cell inner structure 42 by a weld bead 72. The weld bead 72 may be formed using a Metal Inert Gas (MIG) welding technique or any other welding technique and may extend around the entire circumference of the tube 60 at the interface between the second end 68 of the tube 60 and the cell inner structure 42.

Additionally, the cleaning side member 54 may include a shoulder 74 at the first end 66 of the conduit 60. In one embodiment, the shoulder 74 extends in a direction from the flange 62 toward the lid 48 of the battery pack 24. The shoulder 74 of the cleaning side member 54 may be at least partially exposed and, thus, visible from within a hole 76 formed in the lid 48 of the battery pack 24. The shoulder 74 may act as a compression limiter relative to the dirty side member 56 of the feedthrough assembly 52 and generally protects the cap 48 from over-compression.

In one embodiment, the cleaning side member 54 is a cold-formed member. However, cleaning side member 54 may be made of any material using any manufacturing process.

The dirty side component 56 is "dirty" because it is located primarily outside of the battery pack 24. The dirty-side component 56 may include a stud 78 extending between a first end 80 and a second end 82, and a flange 84 projecting radially outward from the stud 78 at a location between the first end 80 and the second end 82. The second end 82 of the stud 78 may include threads 83 that may be inserted into the threaded passage 64 of the conduit 60 of the clean side member 54 until the flange 84 of the dirty side member 56 abuts against the shoulder 74 of the clean side member 54. In one embodiment, the first end 80 of the dirty-side component 56 includes a recess 86 (e.g., a drive feature) for torquing the stud 78 into the pipe 60.

When the battery pack 24 is mounted to the electrified vehicle 12, the first end 80 of the stud 78 extends through an aperture 88 formed in the floor 36, and the flange 84 is positioned between an underside 90 of the floor 36 and an outer surface 92 of the cover 48 of the battery pack 24. A nut 94 may be positioned over the first end 80 of the stud 78 and tightened down against the floor 36 to secure the feedthrough assembly 52 relative to the underbody 38.

In one embodiment, the dirty side component 56 is also a cold-formed component. However, the dirty-side component 56 may be made of any material using any manufacturing process.

In one embodiment, the seal 58 is a self-lubricating silicone o-ring seal (see perspective view of fig. 6). However, other types of seals may also be suitable for sealing between the dirty side member 56 and the clean side member 54.

The seal 58 may include an annular body 59 that may be seated within a groove 96 formed in the outer surface 92 of the cap 48. Alternatively, the groove 96 may be formed in the flange 84 of the dirty-side component 56 (see fig. 7). In either embodiment, the groove 96 is substantially concentric with the aperture 76 formed in the cover 48. Seal 58 prevents water, dirt, or other undesirable debris from entering battery pack 24 through aperture 76. In another embodiment, the diameter D1 of the flange 84 of the dirty-side component 56 is greater than the diameter D2 of the seal 58 (see FIGS. 5 and 6).

fig. 8 illustrates another exemplary cleaning side member 154 of the feedthrough assembly. In this embodiment, instead of a threaded passage extending completely through the conduit, the cleaning side member 154 may include a conduit 160 having a threaded opening 198 formed in each of the first and second ends 166, 168 of the conduit 160. Thus, in this embodiment, the conduit 160 is a solid cylinder rather than a hollow cylinder.

Fig. 9 illustrates another exemplary dirty side member 156 of the feedthrough assembly. In this embodiment, the flange 184 of the dirty side member 156 may comprise an inverted flange 199 that establishes a seal through the assembly rather than using a separate seal. An inverted flange 199 projects from the bottom surface 197 of the flange 184, and the flange 184 faces the outer surface 92 of the lid 48 of the battery pack 24 when the dirty-side piece 156 is mounted to the clean-side piece. Once the feedthrough assembly is assembled and positioned relative to the battery pack 24 and underbody 38, the inverted flange 199 may be partially pressed against the cover 48 to prevent water, dirt, or other undesirable debris from entering the battery pack 24.

Fig. 10 and 11 show an additional dirty side member 256 for the feedthrough assembly. In these embodiments, the seal 258 may be molded or otherwise embedded within the flange 284 of the dirty-side component 256. The seal 258 may be one-sided (see fig. 10) for sealing against the lid 48 of the battery pack 24, or may be two-sided (see fig. 11) for sealing against both the lid 48 of the battery pack 24 and the floor 36 of the underbody 38.

The feedthrough assembly of the present disclosure provides a simple, cost-effective solution to structurally strengthen the battery pack and seal any holes formed in the battery pack in order to accommodate the cleaning side components of the feedthrough assembly. The components used within the feedthrough assembly are relatively low cost and easy to manufacture, thereby facilitating a simple and elegant feedthrough solution.

Although different non-limiting embodiments are shown with specific components or steps, embodiments of the disclosure are not limited to those specific combinations. It is possible to use some of the features or characteristics from any of the non-limiting embodiments in combination with features or characteristics from any of the other non-limiting embodiments.

It should be understood that the same reference numerals indicate corresponding or similar elements throughout the several views. It should be understood that although a particular component arrangement is disclosed and shown in these exemplary embodiments, other arrangements may benefit from the teachings of this disclosure.

The foregoing description is to be construed in an illustrative and not a restrictive sense. Those of ordinary skill in the art will appreciate that certain modifications may fall within the scope of the present disclosure. For that reason, the following claims should be studied to determine the true scope and content of this disclosure.