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 traction battery pack, comprising:
an electrical subassembly;
a foam shell disposed around the electrical subassembly to establish a foamed electrical subassembly; and
a battery array positioned in contact with the foamed electrical subassembly,
wherein the foam shell substantially fills all gaps between adjacent components of the electrical subassembly to provide a gapless arrangement.
2. The traction battery pack as recited in claim 1 , wherein the foamed electrical subassembly and the battery array are housed within a polymer-based enclosure assembly.
3. The traction battery pack as recited in claim 2 , wherein the polymer-based enclosure assembly includes a tray comprised of an expanded polymer-based material and a cover comprised of a solid polymer-based material that is more rigid than the expanded polymer-based material.
4. The traction battery pack as recited in claim 2 , comprising a connector secured to the polymer-based enclosure assembly, wherein the connector includes a connector body and a weld flange that circumscribes the connector body.
5. The traction battery pack as recited in claim 4 , comprising an electrical line or a coolant line secured to the connector body.
6. The traction battery pack as recited in claim 4 , wherein the connector is comprised of a thermoplastic material that is weldable to the polymer-based enclosure assembly at the weld flange.
7. A traction battery pack, comprising:
an electrical subassembly;
a foam shell disposed around the electrical subassembly to establish a foamed electrical subassembly;
a battery array positioned in contact with the foamed electrical subassembly, wherein the foamed electrical subassembly and the battery array are housed within a polymer-based enclosure assembly; and
a connector secured to the polymer-based enclosure assembly, wherein the connector includes a connector body and a weld flange that circumscribes the connector body,
wherein the connector is comprised of a thermoplastic material that is weldable to the polymer-based enclosure assembly at the weld flange,
wherein an interference contact bead of the weld flange is received within a multi-level groove formed in the polymer-based enclosure assembly.
8. The traction battery pack as recited in claim 4 , wherein the connector includes a gripping flange that extends outwardly from the weld flange and establishes a surface area for holding the connector.
9. The traction battery pack as recited in claim 2 , wherein the polymer-based enclosure assembly includes a slot, and further comprising a heat exchanger plate having a pin that is configured to engage the slot to mechanically lock the heat exchanger plate relative to the polymer-based enclosure assembly.
10. The traction battery pack as recited in claim 1 , wherein the electrical subassembly includes one or more wiring harnesses, one or more wiring looms, and one or more I/O connectors.
11. The traction battery pack as recited in claim 1 , wherein the foamed electrical subassembly is positioned over top of the battery array, over top of a second battery array, and over top of a third battery array.
12. The traction battery pack as recited in claim 1 , wherein the foam shell is comprised of an expandable polymer foam.
13. A traction battery pack, comprising:
a polymer-based enclosure assembly including a tray and a cover;
a battery array assembly positioned within an open area of the tray,
the battery array assembly including a plurality of battery arrays and a foamed electrical subassembly positioned over the plurality of battery arrays; and
the foamed electrical subassembly including an electrical subassembly and a foam shell that substantially encapsulates the electrical subassembly.
14. The traction battery pack as recited in claim 13 , wherein the tray is 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.
15. The traction battery pack as recited in claim 13 , wherein the electrical subassembly includes one or more wiring harnesses, one or more wiring looms, and one or more I/O connectors.
16. The traction battery pack as recited in claim 13 , wherein the foam shell substantially fills all gaps between adjacent components of the electrical subassembly to provide a gapless arrangement.
17. The traction battery pack as recited in claim 13 , wherein the foam shell wherein the foam shell is comprised of an expandable polymer foam.
18. The traction battery pack as recited in claim 13 , comprising a connector that includes a weld flange having an interference contact bead received within a multi- level groove of the polymer-based enclosure assembly.
19. The traction battery pack as recited in claim 2 , comprising a connector that includes a weld flange having an interference contact bead received within a multi- level groove of the polymer-based enclosure assembly.