Battery assembly including structural foamed materials

Patent metadata

Field	Value
Publication number	US-9853263-B2
Application number	US-201414537273-A
Country	US
Kind code	B2
Filing date	Nov 10, 2014
Priority date	Nov 10, 2014
Publication date	Dec 26, 2017
Grant date	Dec 26, 2017

Abstract

A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a battery array and a foam shell that surrounds the battery array.

First claim

What is claimed is:

1. A battery assembly, comprising:
a battery array;
an electronic component configured as a control module, a bussed electrical center, or a service disconnect; and
a foam shell that surrounds said battery array and said electronic component, said battery array housed in a first compartment and said electronic component housed in a second compartment of said foam shell, and said first compartment is separated from said second compartment by a wall of said foam shell.

2. The assembly as recited in claim 1 , wherein said foam shell is made of polypropylene or polyethylene.

3. The assembly as recited in claim 1 , comprising a barrier secured to said foam shell.

4. The assembly as recited in claim 3 , wherein said barrier is made of polyamide 6, polyamide 6,6, high density polyethylene, or polypropylene.

5. The assembly as recited in claim 3 , wherein said barrier includes a service cover that is removable from said barrier to access said electronic component of said battery assembly.

6. The assembly as recited in claim 3 , wherein edges of said barrier are curved.

7. The assembly as recited in claim 3 , wherein said barrier includes a plurality of straps that extend around said foam shell to secure said foam shell around said battery array.

8. The assembly as recited in claim 3 , wherein an inner surface of said barrier includes ribbing.

9. The assembly as recited in claim 3 , wherein said barrier includes inwardly protruding walls that establish a vent conduit around a battery cell vent.

10. The assembly as recited in claim 1 , wherein said foam shell includes a first foam section and a second foam section nestled against said first foam section.

11. The assembly as recited in claim 1 , comprising a foam material provided in a space between said battery array and said foam shell.

12. The assembly as recited in claim 1 , comprising a second battery array adjacent to said battery array, and said foam shell houses both said battery array and said second battery array in said first compartment.

13. The assembly as recited in claim 1 , comprising a strap that extends around a barrier and said foam shell.

14. The assembly as recited in claim 13 , wherein said strap includes a closed loop and extensions attached to said closed loop.

Assignees

• Ford Global Tech Llc

Inventors

• Baek Hyung Min
• Maguire Patrick Daniel
• Marpu Amar

Classifications

• B29C44/1228 Primary

  Joining preformed parts by the expanding material · CPC title

• H01M50/209

  adapted for prismatic or rectangular cells (H01M50/216 takes precedence) · CPC title

• H01M50/249 Primary

  specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64) · CPC title

• B29K2623/06

  PE, i.e. polyethylene · CPC title

• H01M2/1077 Primary

  Electricity · mapped topic