Electrified vehicle battery packs with polymer-based enclosures
Battery pack designs for use in electrified vehicles may include a polymer-based enclosure having features for sealing external joints, retaining components inside the battery pack, securing electrical and coolant lines to the polymer-based enclosure, etc. The proposed designs reduce the number of overall parts in assembly, such as fasteners and brackets, and simplify the overall battery pack manufacturing and assembly processes.
1. A battery pack, comprising:
an enclosure assembly including a tray, a mid-tray, and a cover;
a battery array assembly positioned within an open area of the tray,
wherein the mid-tray is secured to the tray at a tongue and groove connection; and
at least one of a tape seal or a liquid seal applied at an external seam associated with the tongue and groove connection,
wherein the tray and the mid-tray are comprised of an expanded polymer-based material, and the cover is comprised of a solid polymer-based material that is more rigid than the expanded polymer-based material.
2. The battery pack as recited in claim 1 , wherein the tape seal is secured to an exterior surface of the mid-tray and to an exterior surface of the tray and extends across the external seam.
3. The battery pack as recited in claim 2 , wherein the tape seal is secured in place with an adhesive.
4. The battery pack as recited in claim 1 , wherein the liquid seal is positioned between a lip of the tray and a lip of the mid-tray.
5. The battery pack as recited in claim 1 , wherein both the tape seal and the liquid seal are applied at the external seam.
6. The battery pack as recited in claim 1 , wherein the tongue and groove connection includes a tongue that protrudes upwardly from a lip of the tray and a groove formed in a lower surface of the mid-tray, and further wherein the tongue is received within the groove.
7. A battery pack, comprising:
an enclosure assembly including a tray, a mid-tray, and a cover;
a battery array assembly positioned within an open area of the tray,
wherein the mid-tray is secured to the tray at a tongue and groove connection;
at least one of a tape seal or a liquid seal applied at an external seam associated with the tongue and groove connection,
wherein the tongue and groove connection includes a tongue that protrudes upwardly from a lip of the tray and a groove formed in a lower surface of the mid-tray, and further wherein the tongue is received within the groove; and
a slot that extends from each side of the groove, wherein a protrusion of the tongue is received within the slot as the mid-tray is moved against the tray.
8. The battery pack as recited in claim 1 , wherein the battery array assembly includes a first battery array, a second battery array, and a foam spacer disposed between the first battery array and the second battery array.
9. The battery pack as recited in claim 1 , comprising a plurality of internal components secured within the mid-tray to establish an electrical subassembly within the enclosure assembly.
10. A battery pack, comprising:
an enclosure assembly including a tray, a mid-tray, and a cover;
a battery array assembly positioned within an open area of the tray,
wherein the mid-tray is secured to the tray at a tongue and groove connection;
at least one of a tape seal or a liquid seal applied at an external seam associated with the tongue and groove connection; and
a plurality of internal components secured within the mid-tray to establish an electrical subassembly within the enclosure assembly,
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.
11. The battery pack as recited in claim 9 , wherein the mid-tray includes a combination of pockets, channels, and core holes adapted for accommodating the plurality of internal components.
12. The battery pack as recited in claim 1 , wherein the external seam extends between a first lip of the tray and a second lip of the mid-tray and extends about an entire perimeter of both the tray and the mid-tray.
13. The battery pack as recited in claim 1 , wherein the cover includes a groove, and further comprising a strap received within the groove.
14. The battery pack as recited in claim 1 , comprising a pry point formed in a corner of the mid-tray or the tray and configured to establish a pocket for receiving a pry tool for removing the tape seal or the liquid seal.
15. The battery pack as recited in claim 1 , wherein the liquid seal is a urethane seal.
16. The battery pack as recited in claim 1 , wherein the liquid seal is an epoxy seal.
17. The battery pack as recited in claim 1 , wherein the liquid seal is a room temperature vulcanizing (RTV) seal.