TECHNICAL FIELD

This disclosure relates generally to a cross-member utilized within a battery pack of an electrified vehicle and, more particularly, to a cross-member that can help to manage loads applied to the battery pack.

BACKGROUND

Electrified vehicles differ from conventional motor vehicles because electrified vehicles can be driven using one or more electric machines powered by a traction battery. The electric machines can drive the electrified vehicles instead of, or in addition to, an internal combustion engine. Example electrified vehicles include hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles (FCVs), and battery electric vehicles (BEVs).

SUMMARY

A battery assembly, according to an exemplary aspect of the present disclosure includes, among other things, a tray having a floor, a lid secured to the tray to provide an enclosure having an interior, and a battery module disposed within the interior. The battery module has a plurality of battery cell frames disposed along a battery module axis. The battery cell frames each include a frame toe that projects horizontally. The battery assembly further includes a cross-member disposed within the interior adjacent to the battery module. The cross-member includes a vertically extending wall having a protrusion that is vertically aligned with the frame toes of the battery cell frames.

In another example of the foregoing battery assembly, the tray further includes a forward wall, an aft wall, and opposing side walls extending horizontally from the forward wall to the aft wall. The cross-member extends along a cross-member axis between the opposing side walls of the tray.

In another example of the foregoing battery assembly, the frame toes are lower frame toes. The frame toes each provide an aperture that receives a tensioning member. The tensioning member is configured to compress the battery cell frames along the battery module axis.

In another example of the foregoing battery assembly, the battery module includes an interconnect board that is directly vertically above the lower frame toes of the battery cell frames.

In another example of the foregoing battery assembly, the battery cell frames each include an upper frame toe providing an aperture that receives another tensioning member configured to compress the battery cell frames along the battery module axis. The interconnect board is directly vertically beneath the upper frame toes.

In another example of the foregoing battery assembly, the interconnect board is vertically above all portions of the protrusion.

In another example of the foregoing battery assembly, when the battery assembly is loaded such that the battery module and the cross-member are moved relatively closer to each other horizontally, the protrusion is configured to contact the frame toes prior to other portions of the vertically extending wall.

In another example of the foregoing battery assembly, the cross-member includes a platform. The vertically extending wall extends vertically upward from the platform. The platform extends horizontally to a position vertically beneath the frame toes.

In another example of the foregoing battery assembly, the platform of the cross-member extends aft to the position vertically beneath the frame toes.

Another example of the foregoing battery assembly includes a thermal exchange device. A lip of the thermal exchange device is sandwiched vertically between the platform and the frame toes.

In another example of the foregoing battery assembly, the cross-member is secured to the floor of the tray with mechanical fasteners.

In another example of the foregoing battery assembly, the cross-member is an extruded cross-member.

In another example of the foregoing battery assembly, the cross-member has reflectional symmetry.

In another example of the foregoing battery assembly, the protrusion and the remaining portions of the cross-member are different parts of a single, continuous structure.

In another example of the foregoing battery assembly, the protrusion is at a vertically lower portion of the vertically extending wall. The vertically extending wall tapers from the protrusion to a primary portion of the vertically extending wall.

A method of managing loads within a battery pack according to another exemplary aspect of the present disclosure includes, among other things, providing a battery module within a battery pack. The battery module has a plurality of battery cell frames disposed along a battery module axis. The battery cell frames each include a frame toe that projects horizontally. The method further includes providing a cross-member within the battery pack. The cross-member has a vertically extending wall with a protrusion that is vertically aligned with the frame toes of the battery cell frames. When a load is applied to the battery pack that causes the battery cell frames to move horizontally relative to the cross-member such that the vertically extending wall contacts the battery cell frames, the method includes contacting the frame toes with the protrusion prior to the battery module contacting other portions of the vertically extending wall.

A further example of the foregoing method includes supporting the battery module on a platform of the cross-member. The vertically extending wall extends vertically upward from the platform.

A further example of any of the foregoing methods includes compressing the battery cell frames along the battery module axis using a tensioning member that is received within apertures provided by the frame toes.

In a further example of any of the foregoing methods, the cross-member extends longitudinally along a cross-member axis that, prior to the loading being applied, is perpendicular to the battery module axis.

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

