BATTERY ARRAY FRAME INCLUDING FRAME RAIL INSERT

• US 20160218332A1
• Filed: 01/28/2015
• Published: 07/28/2016
• Est. Priority Date: 01/28/2015
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: BAEK, Hyung Min, SUBRAMANIAN, Rajaram
• Granted Patent: US 10,319,964 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/224 Metals
• CPC Class Codes: H01M 50/227 Organic material
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery array frame according to an exemplary aspect of the present disclosure includes, among other things, a frame body extending along a longitudinal axis and including a top frame rail, a bottom frame rail and frame arms that connect between the top frame rail and the bottom frame rail. An insert extends inside the frame body.

Claims

1. A battery array frame, comprising:

a frame body extending along a longitudinal axis and including a top frame rail, a bottom frame rail and frame arms that connect between said top frame rail and said bottom frame rail; and

an insert extending inside said frame body.

2. The battery array frame as recited in claim 1, wherein said top frame rail includes at top surface having a first side and a second side that each include an alternating pattern of rigid snap arms and flexible snaps arms.

3. The battery array frame as recited in claim 1, wherein said insert is a metallic insert.

4. The battery array frame as recited in claim 3, wherein said metallic insert is made of steel, copper or brass.

5. The battery array frame as recited in claim 1, wherein said insert is made of a different material from said frame body.

6. The battery array frame as recited in claim 1, wherein said bottom frame rail includes a foot, and said insert extends into said foot.

7. The battery array frame as recited in claim 1, wherein said bottom frame rail includes a first foot at a first end and a second foot at a second end, said insert extending through said bottom frame rail between said first foot and said second foot.

8. The battery array frame as recited in claim 1, wherein said bottom frame rail includes a first foot that includes said insert and a second foot that includes a second insert.

9. The battery array frame as recited in claim 1, wherein said insert includes a bent portion inside a foot of said bottom frame rail.

10. The battery array frame as recited in claim 1, wherein said insert includes a plurality of threads.

11. A battery assembly, comprising:

a tray;

a battery array positioned relative to said tray, said battery array including a plurality of array frames, wherein each of said plurality of array frames include feet having an imbedded metallic insert; and

a bracket secured over said feet and mounted to said tray.

12. The assembly as recited in claim 11, comprising a heat exchanger disposed between said tray and said battery array.

13. The assembly as recited in claim 11, wherein said metallic insert is made of steel, brass or copper.

14. The assembly as recited in claim 11, wherein said feet include a nub, and bent portions of said metallic insert extend inwardly from said nubs.

15. The assembly as recited in claim 11, wherein said feet protrude outwardly from a frame body of each of said plurality of array frames near an intersection between a bottom frame rail and a frame arm.

16. A method, comprising:

positioning a battery array relative to a tray, the battery array including an array frame having a foot and an insert disposed inside the foot, the insert configured to increase the stiffness of the foot;

positioning a bracket over the foot; and

securing the bracket to the tray.

17. The method as recited in claim 16, wherein the step of positioning the battery array relative to the tray includes positioning a heat exchanger between the battery array and the tray.

18. The method as recited in claim 16, wherein the step of securing the bracket to the tray includes fastening the bracket to the tray using a fastener.

19. The method as recited in claim 16, wherein the insert is a metallic insert embedded inside a bottom frame rail of the array frame.

20. The method as recited in claim 16, wherein the insert includes a bent portion extending inside the foot.