Battery pack connector assembly and connection method

Abstract

The present disclosure provides a "battery pack connector assembly and connection method". An exemplary connector assembly includes a bottom bracket, etc., wherein the bottom bracket is at least partially arranged below the housing of the battery pack to provide an open area located between the housing and the bottom plate of the bottom bracket in the vertical direction. Side brackets are arranged on the side of the housing to provide an open area located between the housing and the bottom plate of the side bracket in the lateral direction. A bracket connects the bottom bracket and the side bracket to the vehicle structure. An exemplary battery pack connection method includes the steps of supporting the housing of the battery pack by a bottom bracket, etc., wherein the bottom bracket is at least partially arranged below the housing. The method includes supporting the housing by a side bracket, and the side bracket is at least partially arranged on the side of the housing. The method also includes connecting the bottom bracket and the side bracket to the vehicle structure by a bracket.

Description

Technical Field

[0001] The present disclosure relates generally to connector assemblies, and more particularly to connector assemblies that secure a battery pack to the floor of an electrified vehicle. Background Art

[0002] Generally speaking, electrified vehicles differ from conventional motor vehicles in that they selectively utilize one or more electric motors powered by batteries for propulsion. In contrast, conventional motor vehicles are powered solely by an internal combustion engine. Electrified vehicles may utilize electric motors in place of or in addition to the internal combustion engine.

[0003] Example electrified vehicles include hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, and battery electric vehicles (BEVs). A powertrain system for an electrified vehicle may include a high-voltage battery pack having cells that store electricity to power an electric motor and other electrical loads of the electrified vehicle.

[0004] The battery pack may be secured to the floor or another area of ​​the electric vehicle. Different electric vehicles may have different packaging envelopes that may be used to house the battery pack. Summary of the Invention

[0005] According to an exemplary aspect of the present disclosure, a connector assembly includes, among other things, a bottom bracket disposed at least partially below a battery pack housing to provide an open area vertically between the housing and a bottom plate of the bottom bracket. Side brackets are disposed on sides of the housing to provide an open area laterally between the housing and the bottom plates of the side brackets. Brackets connect the bottom bracket and the side brackets to a vehicle structure.

[0006] In another non-limiting embodiment of the foregoing assembly, the bottom bracket is a tubular member having a circumferentially continuous cross-section.

[0007] Another non-limiting embodiment of any of the foregoing assemblies includes the bottom bracket as a first bottom bracket. The assembly further includes a second bottom bracket at least partially disposed below the housing to provide an open area vertically between the housing and the second bottom bracket. The first and second bottom brackets are laterally spaced apart from each other.

[0008] Another non-limiting embodiment of any of the foregoing assemblies includes a third bottom bracket at least partially disposed below the housing to provide an open area vertically between the housing and a bottom plate of the third bottom bracket, the third bottom bracket extending longitudinally from a position adjacent the first bottom bracket to a position adjacent the second bottom bracket.

[0009] In a further non-limiting embodiment of any of the foregoing assemblies, the first, second, and third bottom brackets are each tubular members having a circumferentially continuous cross-section.

[0010] In another non-limiting embodiment of any of the foregoing assemblies, the side bracket is directly connected to a side of the housing, and where the side bracket is directly connected to the side, the side bracket has a circumferentially continuous cross-section.

[0011] In another non-limiting embodiment of any of the foregoing assemblies, the side bracket is directly connected to a side of the housing, and where the side bracket is directly connected to the side, the side bracket has a cup-shaped and circumferentially discontinuous cross-section.

[0012] In another non-limiting embodiment of any of the foregoing assemblies, the side brackets extend from the sides of the housing to a vertical bottom of the housing where they directly interface with the bottom bracket.

[0013] In another non-limiting embodiment of any of the foregoing assemblies, where the side bracket directly interfaces with the bottom bracket, the side bracket has a circumferentially continuous cross-section.

[0014] In another non-limiting embodiment of any of the foregoing assemblies, the side bracket is disposed entirely above the bottom of the housing such that no portion of the side bracket extends vertically below the bottom.

[0015] In a further non-limiting embodiment of any of the foregoing assemblies, the bottom bracket and the side bracket are each directly secured to the housing.

[0016] In a further non-limiting embodiment of any of the foregoing assemblies, the bracket is directly connected to both the bottom bracket and the side bracket.

[0017] In a further non-limiting embodiment of any of the foregoing assemblies, the bracket is a single continuous bracket.

[0018] In another non-limiting embodiment of any of the foregoing assemblies, the assembly includes the housing of the battery pack, the housing being disposed outside the vehicle and connected to the underbody of the vehicle via the bottom bracket, the side bracket, and the bracket.

[0019] A battery pack connection method according to an exemplary aspect of the present disclosure includes the steps of supporting a battery pack housing via a bottom bracket, the bottom bracket being at least partially disposed below the housing. The method also includes supporting the housing via side brackets, the side brackets being at least partially disposed to the sides of the housing. The method also includes connecting the bottom bracket and the side brackets to a vehicle structure via brackets.

[0020] In another non-limiting embodiment of the foregoing method, the bottom plate of the bottom bracket is spaced apart from the housing to provide an open area vertically between the housing and the bottom plate of the bottom bracket. The bottom plates of the side brackets are spaced apart from the housing to provide an open area laterally between the housing and the bottom plates of the side brackets.

[0021] In another non-limiting embodiment of any of the foregoing methods, the side brackets extend continuously from the sides of the housing to the bottom of the housing. The method includes directly docking the side brackets with the bottom bracket below the bottom of the housing.

[0022] In another non-limiting embodiment of any of the foregoing methods, the bracket is a single continuous bracket directly connected to both the bottom bracket and the side bracket.

[0023] Another non-limiting embodiment of any of the foregoing methods includes supporting the housing via the bottom bracket and the side bracket such that the housing is positioned beneath a floor of the vehicle.

[0024] Another non-limiting embodiment of any of the foregoing methods includes directly connecting the bottom bracket to the floor of the housing and directly connecting the side brackets to the sides of the housing. The method also includes directly connecting the bracket to the bottom bracket, the side brackets, and the vehicle structure.

[0025] The embodiments, examples and alternatives of the preceding paragraphs, claims or the following detailed description and drawings, including any of their aspects or corresponding features, may be taken independently or in any combination. Features described in conjunction with one embodiment apply to all embodiments, unless such features are incompatible.

[0026] Description of the drawings

[0027] According to the detailed description, various features and advantages of the disclosed examples will become apparent to those skilled in the art. The drawings accompanying the detailed description can be briefly described as follows:

[0028] Figure 1 A schematic diagram of a powertrain system for an electrified vehicle is shown.

[0029] Figure 2 Shows the Figure 1 A side view of the multiple connector assemblies that secure the powertrain battery pack to the underbody of the vehicle.

[0030] 3 illustrates a perspective view of a connector assembly securing a battery pack to the floor of a vehicle according to another exemplary embodiment.

[0031] 4 shows a perspective view of the embodiment of FIG. 3 with the bracket removed to reveal the bottom bracket and side brackets of the connector assembly.

[0032] Figure 5 A cross-sectional perspective view taken along line 5 - 5 in FIG. 4 is shown.

[0033] Figure 6 A portion of a connector assembly is shown according to another exemplary embodiment, wherein the bottom bracket and the side bracket are provided by a single continuous structure.

[0034] Figure 7 A perspective view of a battery pack secured to the floor of a vehicle via a connector assembly is shown according to yet another exemplary embodiment.

[0035] Figure 8 Shown Figure 7 End view of the connector assembly and battery pack.

[0036] Figure 9 Shown Figure 7 Side view of the connector assembly and battery pack.

[0037] Figure 10 Shown are a bottom bracket and a side bracket from a connector assembly according to yet another exemplary embodiment.

[0038] Figure 11 A perspective view of a connector assembly according to yet another exemplary embodiment is shown.

[0039] Figure 12 A perspective view of a connector assembly according to yet another exemplary embodiment is shown. DETAILED DESCRIPTION

[0040] The present disclosure details a connector assembly for securing a battery pack to an area of ​​an electrified vehicle, such as the underbody of the electrified vehicle.

[0041] The exemplary connector assembly provides open areas vertically below the battery pack and on the sides of the battery pack. The open areas can facilitate load absorption during a crash, among other things. The connector assembly can adapt the battery pack to various packaging environments.

[0042] Figure 1 A powertrain system 10 for an electrified vehicle, in this example a hybrid electric vehicle (HEV), is schematically illustrated. Although depicted as an HEV, it should be understood that the concepts described herein are not limited to HEVs and can be extended to other types of electrified vehicles, including but not limited to plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), fuel cell vehicles, and the like.

[0043] The powertrain 10 includes a battery pack 14, a motor 18, a generator 20, and an internal combustion engine 22. The motor 18 and the generator 20 are different types of electric machines. The motor 18 and the generator 20 may be separate or may be in the form of a combined motor-generator.

[0044] In this embodiment, powertrain 10 is a power-split powertrain system that utilizes a first drive system and a second drive system. The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels 26 of an electrified vehicle. The first drive system includes a combination of an engine 22 and a generator 20. The second drive system includes at least a motor 18, a generator 20, and a battery pack 14. The motor 18 and generator 20 are part of the electric drive system of powertrain 10.

[0045] The engine 22 (which in this example is an internal combustion engine) and the generator 20 can be connected by a power transfer unit 30, such as a planetary gear set. Of course, other types of power transfer units, including other gear sets and transmissions, can be used to connect the engine 22 to the generator 20. In one non-limiting embodiment, the power transfer unit 30 is a planetary gear set that includes a ring gear 32, a sun gear 34, and a carrier assembly 36.

[0046] Generator 20 can be driven by engine 22 through power transfer unit 30 to convert kinetic energy into electrical energy. Generator 20 can alternatively be used as a motor to convert electrical energy into kinetic energy, thereby outputting torque to shaft 38 connected to power transfer unit 30. Because generator 20 is operatively connected to engine 22, the speed of engine 22 can be controlled by generator 20.

[0047] The ring gear 32 of the power transfer unit 30 may be connected to a shaft 40, which is connected to the vehicle drive wheels 26 through a second power transfer unit 44. The second power transfer unit 44 may include a gear set having a plurality of gears 46. Other power transfer units may also be suitable.

[0048] Gears 46 transfer torque from the engine 22 to a differential 48 to ultimately provide traction to the vehicle drive wheels 26. The differential 48 may include a plurality of gears capable of transferring torque to the vehicle drive wheels 26. In this example, the second power transfer unit 44 is mechanically coupled to an axle 50 through the differential 48 to distribute torque to the vehicle drive wheels 26.

[0049] The motor 18 can also be used to drive the vehicle drive wheels 26 by outputting torque to a shaft 52 that is also connected to the second power transfer unit 44. In one embodiment, the motor 18 and the generator 20 cooperate as part of a regenerative braking system in which both the motor 18 and the generator 20 can function as motors to output torque. For example, the motor 18 and the generator 20 can each output power to the battery pack 14.

[0050] Now refer to Figure 2 , the battery pack 14 may include a housing 56 that holds the plurality of arrays 60. The housing 56 may be, for example, sheet metal, a casting, an extruded housing, polymer-based, metal, a metal alloy, or some other material combination.

[0051] Each of the arrays 60 may include a plurality of individual battery cells that may store generated electricity and may output electricity to operate the motor 18 , the generator 20 , or both.

[0052] In this example, a plurality of connector assemblies 64 secure the battery pack 14 to the vehicle floor 68. The battery pack 14 is located vertically below the vehicle floor 68. For the purposes of this disclosure, the vertical direction is referenced to the ground surface G and the normal orientation of the vehicle during operation or when parked. The longitudinal direction is transverse to the vertical direction.

[0053] The housing 56 provides an open area that receives the battery array 60. When secured to the vehicle, the vehicle floor 68 interfaces with the housing 56 to enclose the battery array 60 within the open area.

[0054] The connector assemblies 64 secure the battery pack 14 to the vehicle floor 68 by connecting the housing 56 to the vehicle floor 68. In this example, one of the connector assemblies 64 is disposed on a first side of the battery pack 14 and another of the connector assemblies 64 is disposed on an opposing second side of the battery pack 14.

[0055] If desired, additional connector assemblies 64 may be used to secure the battery pack 14 to the vehicle floor 68. The additional connector assemblies may be located along the first or second side, the side of the battery pack 14 facing the front of the vehicle, the side of the battery pack 14 facing the rear of the vehicle, or at another location depending on the geometry of the battery pack 14.

[0056] The exemplary connector assemblies 64 each include a bottom bracket 72, a side bracket 76, and a bracket 80. The bracket 80 is secured to the bottom bracket 72, the side bracket 76, and the vehicle floor 68. Figure 2 In the embodiment of the present invention, the bottom bracket 72 and the side bracket 76 are shown as separate and different structures. In other exemplary embodiments, the bottom bracket 72 and the side bracket 76 are different parts of the same continuous structure.

[0057] The bottom bracket 72 is at least partially vertically disposed below the vertical bottom 84 of the housing 56. The bottom bracket 72 provides an open area 88 that is located vertically below the bottom 84 of the housing 56.

[0058] The side brackets 76 are disposed to the sides of the housing 56 and laterally outwardly of a laterally facing wall 92 of the housing 56. The side brackets 76 provide an open area 94 that is laterally outwardly of the housing 56.

[0059] A collision event can direct forces into the vehicle. Due to the open areas 88 and 94, the side supports 76 and the bottom support 72 can collapse or otherwise deform to absorb at least a portion of the forces generated by the collision event. Absorbing at least a portion of the forces can reduce the likelihood of battery pack 14 being intruded.

[0060] In some examples, it may be desirable to mount a battery pack having similar geometric dimensions to battery pack 14 to a vehicle that is wider than the vehicle in the transverse or longitudinal directions. Figure 2 The illustrated vehicle is within another vehicle that is smaller than the one shown. In such an example, the side brackets of the connector assembly can be eliminated, and the brackets secured directly to the side-facing walls. Removing the side brackets allows the brackets to be moved laterally inward toward the center of the vehicle. In other examples, the lateral dimensions of the side brackets are reduced rather than eliminated.

[0061] The connection strategy utilizing the connector assembly 64 can therefore facilitate connection of the battery pack 14 to various types of vehicles, even those with different packaging envelopes. No significant changes need to be made to the battery pack 14 to incorporate the battery pack 14 into the vehicle. Figure 2 In the vehicle of, or in another vehicle with less automobile transverse width.On the contrary, can adapt to the change of automobile transverse width by changing connector assembly 64.

[0062] Similarly, if the vertical height for mounting the battery pack is different from Figure 2 , the bottom bracket 72 may be omitted or redesigned to accommodate a different vertical height, rather than substantially redesigning the battery pack 14 for other packaging environments.

[0063] Thus, the connector assembly 64 allows the battery pack 14 to be used across various vehicle platforms, which can reduce build complexity. In some examples, the connector assembly 64 can be used to retrofit a vehicle to include the battery pack 14 .

[0064] In this disclosure, like reference numerals denote like elements where appropriate, and reference numerals one hundred or multiples of one hundred denote modified elements. Modified elements include the same features and benefits of the corresponding modified elements unless otherwise noted.

[0065] Now refer to Figures 3 to Figure 5 A connector assembly 164 according to another exemplary embodiment of the present disclosure includes a bottom bracket 172 , a side bracket 176 , and a bracket 180 .

[0066] The bottom bracket 172 has a bottom plate 104 that is spaced apart from the bottom 84 of the housing 56. Spacing the bottom plate 104 apart from the bottom 84 of the housing 56 provides an open area 188 vertically between the housing 56 and the bottom plate 104.

[0067] The side bracket 176 includes a base plate 108 that is laterally spaced apart from the laterally facing wall 92 of the shell 56. Spacing the base plate 108 of the side bracket 176 from the laterally facing wall 92 provides an open area 194 on the side of the shell 56. With the side bracket 176 attached to the laterally facing wall 92 of the shell 56, the side bracket 176 has a circumferentially discontinuous and generally cup-shaped or C-shaped cross-section. Generally, the cross-section is taken perpendicular to the longitudinal axis of the side bracket 176. In some examples, the cup-shaped profile can help reduce NVH issues by strengthening the connection between the shell 56 and the vehicle floor 68 and increasing modal frequencies.

[0068] In the exemplary embodiment, bottom bracket 172 and side bracket 176 are spot welded to housing 56 to secure bottom bracket 172 and side bracket 176 to housing 56. In other examples, other types of attachment strategies may be utilized, including, for example, utilizing mechanical fasteners or other types of welds to attach bottom bracket 172 and side bracket 176 to housing 56.

[0069] The bottom bracket 172 includes a flange 112 that extends beside and is secured to the laterally facing walls 92 of the housing 56. Securing the flange 112 to the laterally facing walls 92 may be useful if the bottom 84 of the housing 56 lacks available area to properly weld or otherwise attach the bottom bracket 172 to the housing 56.

[0070] Bracket 180 is secured directly to base bracket 172, side bracket 176, and vehicle floor 68 via mechanical fasteners 116. Other attachment strategies may be used in other examples, including, for example, weldably securing bracket 180 to base bracket 172, side bracket 176, and vehicle floor 68.

[0071] Now refer to Figure 6 , a connector assembly according to another exemplary embodiment includes a bottom bracket 272 and a side bracket 276. The bottom bracket 272 provides an open area 288 vertically below the bottom 84 of the housing 56. The side bracket 276 provides an open area 294 laterally outwardly of the laterally facing wall 92 of the housing 56. Brackets (not shown) may be used to secure the bottom bracket 272 and the side bracket 276 to the vehicle floor 68.

[0072] It is worth noting that in Figure 6 In the exemplary embodiment of the present invention, the bottom bracket 272 and the side bracket 276 are different parts of the same continuous support structure. That is, the bottom bracket 272 and the side bracket 276 are different areas of a single integral structure and are not as shown in Figures 3 to 4. Figure 5 A separate and distinct bracket as in the embodiment of FIG.

[0073] Now refer to Figures 7 to 9 According to another exemplary aspect of the present disclosure, a connector assembly 364 includes a bottom bracket 372, a side bracket 376, and a bracket 380. The exemplary bottom bracket 372 is a tubular member having a circumferentially continuous cross-section. The bottom bracket 372 can be an extruded member, a stamped member, or the like.

[0074] With the side bracket 376 attached to the laterally facing wall 92 of the housing 56, the side bracket 376 has a circumferentially discontinuous and generally cup-shaped or C-shaped cross-section. Generally, the cross-section is a section taken perpendicular to the longitudinal axis of the side bracket 376.

[0075] The side brackets 376 extend from the laterally facing wall 92 of the housing 56 to a location vertically below the bottom 84 of the housing 56, and more specifically, to a location where the side brackets 376 directly interface with the bottom bracket 372. Below the bottom 84 of the housing 56, the side brackets 376 may be mechanically fastened to the bottom bracket 372.

[0076] In some examples, extending the side brackets 376 so that they directly interface with the bottom bracket 372 can enhance load absorption by redirecting at least a portion of the side impact load into the bottom bracket 372 and away from the laterally facing wall 92. In some examples, the bottom bracket 372 and the bottom portion 84 can withstand greater loads than the laterally facing wall 92.

[0077] Now refer to Figure 10 According to another exemplary embodiment, the connector assembly includes a side bracket 476, which is as shown in FIG. Figures 7 to 9 Like the side bracket 376 of the side bracket 476, it extends from the cup-shaped area to a position below the bottom of the housing where it directly interfaces with the bottom bracket 472. Specifically, where the side bracket 476 is directly connected to the laterally facing wall 92, the side bracket 476 has a circumferentially continuous cross-section.

[0078] The side bracket 476 includes a plurality of shear notches 120 that facilitate desired deformation of the side bracket 476 when the vehicle is subjected to a collision load. Figure 10 The embodiment shown, however, the shear notch 120 may be incorporated into any of the side brackets of the present disclosure.

[0079] Bottom bracket 472 with Figures 7 to 9 The bottom bracket 372 of the embodiment differs in that, among other things, the bottom bracket 472 has a cross-section that is circumferentially discontinuous and, in particular, has a cup-shaped or C-shaped configuration. The bottom bracket 472 may be an extrusion, stamping, or the like.

[0080] The choice between a bottom bracket 472 having a circumferentially discontinuous cross section and a bottom bracket having a circumferentially continuous cross section is particularly influenced by packaging and assembly constraints. For example, if metal inert gas (MIG) welding of the bottom bracket to the side bracket and the housing is desired, a bottom bracket having a circumferentially continuous cross section may be selected. However, if spot welding of the bottom bracket is desired, a circumferentially discontinuous cross section may be selected. A circumferentially discontinuous cross section may improve accessibility during spot welding, thereby facilitating spot welding of the bottom bracket to the side bracket and the housing.

[0081] Now refer to Figure 11 Another exemplary connector assembly 564 includes a bottom bracket 572, a side bracket 576, and a bracket 580. The bottom bracket 572 is a tubular member having a circumferentially continuous cross-section. The bottom bracket 572 is the first bottom bracket disposed adjacent to the bottom 84 of the housing 56.

[0082] The second bottom bracket 572a is located on the opposite side of the bottom 84 relative to the bottom bracket 572. The bottom bracket 572a is directly connected to the bottom bracket 572 located on the opposite side of the housing 56. Figure 11 The brackets are on opposite sides of the bracket 580 shown in FIG.

[0083] Third bottom bracket 572b extends longitudinally from a position adjacent to bottom bracket 572 to a position adjacent to bottom bracket 572a. Third bottom bracket 572b is generally aligned with one of brackets 580 and the other bracket on the opposite side of housing 56. Third bottom bracket 572b can facilitate distributing a load applied to bottom bracket 572 via bracket 580.

[0084] In this example, the second bottom bracket 572a and the third bottom bracket 572b are both tubular and have a circumferentially continuous cross-section. Other exemplary bottom brackets may have a circumferentially discontinuous cross-section. The first bottom bracket 572, the second bottom bracket 572a, and the third bottom bracket 572b may be extruded parts, stamped parts, etc.

[0085] Now refer to Figure 12Another exemplary connector assembly 664 includes a side bracket 676, a first bottom bracket 672, a second bottom bracket 672a, and a third bottom bracket 672b. The side bracket 676 extends from the side-facing wall 92 of the housing 56 to directly interface with the first bottom bracket 672. The side bracket 676 is a tubular member having a circumferentially continuous cross-section. Specifically, when the side bracket 676 is directly connected to the side-facing wall 92, the side bracket 676 has a circumferentially continuous cross-section. Furthermore, when the side bracket 676 interfaces with the first bottom bracket 672, the side bracket 676 has a circumferentially continuous cross-section.

[0086] In other examples, other cross sections of the side brackets 676 may be used. Extending the side brackets 676 to the first bottom bracket 672 may facilitate directing the crash load into the first bottom bracket 672 and then further distributing the crash load via the third bottom bracket 672b and the second bottom bracket 672a.

[0087] Features of the disclosed examples include a connector assembly that facilitates load absorption. The connector assembly can be modified to allow battery packs to be installed in various packaging envelopes and can be retrofitted to existing vehicles. The connector assembly can, among other things, improve structural performance, provide cost savings, and facilitate repairs.

[0088] The foregoing description is illustrative rather than restrictive in nature. Variations and modifications to the disclosed examples that do not necessarily depart from the essence of this disclosure may become apparent to those skilled in the art. Therefore, the scope of legal protection afforded to this disclosure can only be determined by studying the appended claims.

[0089] According to the present invention, a connector assembly is provided, comprising: a bottom bracket at least partially disposed below a battery pack housing to provide an open area vertically between the housing and a floor of the bottom bracket; a side bracket at least partially disposed on a side of the housing to provide an open area laterally between the housing and a floor of the side bracket; and a bracket connecting the bottom bracket and the side bracket to a vehicle structure.

[0090] According to one embodiment, the bottom bracket is a tubular member with a circumferentially continuous cross section.

[0091] According to one embodiment, the bottom bracket is a first bottom bracket, and the connector assembly further comprises a second bottom bracket, the second bottom bracket being at least partially disposed below the housing to provide an open area vertically between the housing and the second bottom bracket, the first and second bottom brackets being laterally spaced a distance apart from each other.

[0092] According to one embodiment, the above invention is further characterized by a third bottom bracket, which is at least partially disposed below the housing to provide an open area located vertically between the housing and the bottom plate of the third bottom bracket, and the third bottom bracket extends longitudinally from a position adjacent to the first bottom bracket to a position adjacent to the second bottom bracket.

[0093] According to one embodiment, the first, second and third base brackets are each a tubular member having a circumferentially continuous cross section.

[0094] According to one embodiment, the side bracket is directly connected to a side surface of the housing, and in the case where the side bracket is directly connected to the side surface, the side bracket has a circumferentially continuous cross section.

[0095] According to one embodiment, the side bracket is directly connected to a side surface of the housing, and in the case where the side bracket is directly connected to the side surface, the side bracket has a cup-shaped and circumferentially discontinuous cross section.

[0096] According to one embodiment, the side brackets extend from the sides of the housing to the vertical bottom of the housing, where the side brackets directly interface with the bottom bracket.

[0097] According to one embodiment, when the side bracket is directly docked with the bottom bracket, the side bracket has a circumferentially continuous cross section.

[0098] According to one embodiment, the side bracket is entirely disposed above the bottom of the housing, such that no portion of the side bracket extends vertically below the bottom.

[0099] According to one embodiment, the bottom bracket and the side bracket are each fixed directly to the housing.

[0100] According to one embodiment, the bracket is directly connected to both the bottom bracket and the side bracket.

[0101] According to one embodiment, the bracket is a single continuous bracket.

[0102] According to one embodiment, the above invention is further characterized in that the housing of the battery pack is disposed outside the vehicle, and the housing is connected to the underbody of the vehicle through the bottom bracket, the side bracket, and the bracket.

[0103] According to the present invention, a battery pack connection method includes: supporting a battery pack housing by a bottom bracket, the bottom bracket being at least partially disposed below the housing; supporting the housing by side brackets, the side brackets being at least partially disposed on sides of the housing; and connecting the bottom bracket and the side brackets to a vehicle structure by a bracket.

[0104] According to one embodiment, the bottom plate of the bottom bracket is spaced apart from the housing to provide an open area located between the housing and the bottom plate of the bottom bracket in a vertical direction, wherein the bottom plate of the side bracket is spaced apart from the housing to provide an open area located between the housing and the bottom plate of the side bracket in a lateral direction.

[0105] According to one embodiment, the side brackets extend continuously from the sides of the housing to the bottom of the housing, and the method includes directly docking the side brackets with the bottom bracket below the bottom of the housing.

[0106] According to one embodiment, the bracket is a single continuous bracket directly connected to both the bottom bracket and the side bracket.

[0107] According to one embodiment, the above invention is further characterized in that the housing is supported by the bottom bracket and the side bracket so that the housing is located under the vehicle floor.

[0108] According to one embodiment, the above invention is further characterized by directly connecting the bottom bracket to the floor of the shell, directly connecting the side brackets to the sides of the shell, and directly connecting the bracket to the bottom bracket, the side brackets and the vehicle structure.

Claims

1. A connector assembly comprising: a bottom bracket at least partially disposed below the battery pack housing to provide an open area vertically between the battery pack housing and a bottom plate of the bottom bracket; a side bracket at least partially disposed on a side of the battery pack housing to provide an open area between the battery pack housing and a bottom plate of the side bracket in a lateral direction; and a bracket connecting the bottom bracket and the side bracket to a vehicle structure; The bottom bracket and the side bracket are each directly fixed to the housing of the battery pack. 2 . The connector assembly of claim 1 , wherein the bottom bracket is a tubular member having a circumferentially continuous cross-section.

3. The connector assembly of claim 1 , wherein the bottom bracket is a first bottom bracket, and the connector assembly further comprises a second bottom bracket, the second bottom bracket being at least partially disposed below the battery pack housing to provide an open area vertically between the battery pack housing and the second bottom bracket, the first and second bottom brackets being laterally spaced apart from each other by a distance.

4. The connector assembly of claim 3 , wherein the connector assembly further comprises a third bottom bracket, the third bottom bracket being at least partially disposed below the battery pack housing to provide an open area vertically between the battery pack housing and a bottom plate of the third bottom bracket, the third bottom bracket extending longitudinally from a position adjacent to the first bottom bracket to a position adjacent to the second bottom bracket.

5. The connector assembly of claim 4, wherein the first, second, and third base brackets are each a tubular member having a circumferentially continuous cross-section.

6. The connector assembly of claim 1, wherein the side bracket is directly connected to a side of the battery pack housing, and wherein the side bracket has a circumferentially continuous cross-section when the side bracket is directly connected to the side.

7. The connector assembly of claim 1 , wherein the side bracket is directly connected to a side of the battery pack housing, and wherein the side bracket has a cup-shaped and circumferentially discontinuous cross-section when the side bracket is directly connected to the side.

8. The connector assembly of claim 1, wherein the side brackets extend from a side of the battery pack housing to a vertical bottom of the battery pack housing where the side brackets directly interface with the bottom bracket.

9. The connector assembly of claim 1, wherein the side bracket has a circumferentially continuous cross-section when the side bracket is directly mated with the bottom bracket.

10. The connector assembly of claim 1, wherein the side bracket is disposed entirely above a bottom portion of the battery pack housing such that no portion of the side bracket extends vertically below the bottom portion.

11. The connector assembly of claim 1 , wherein the bracket is directly connected to both the bottom bracket and the side bracket.

12. The connector assembly of claim 11, wherein the bracket is a single continuous bracket.

13. The connector assembly of claim 1, further comprising the housing of the battery pack disposed outside a vehicle, the housing of the battery pack being connected to a floor of the vehicle through the bottom bracket, the side bracket, and the bracket.

14. A battery pack connection method, comprising: supporting a battery pack housing via a bottom bracket, the bottom bracket being at least partially disposed below the battery pack housing to provide an open area vertically between the battery pack housing and a bottom plate of the bottom bracket; supporting the battery pack housing by a side bracket, the side bracket being at least partially disposed on a side edge of the battery pack housing to provide an open area between the battery pack housing and a bottom plate of the side bracket in a lateral direction; as well as connecting the bottom bracket and the side bracket to a vehicle structure via brackets; The bottom bracket and the side bracket are each directly fixed to the housing of the battery pack.

15. The battery pack connection method of claim 14 , wherein the bottom plate of the bottom bracket is spaced apart from the battery pack housing to provide an open area between the battery pack housing and the bottom plate of the bottom bracket in a vertical direction, and wherein the bottom plate of the side bracket is spaced apart from the battery pack housing to provide an open area between the battery pack housing and the bottom plate of the side bracket in a lateral direction.

16. A battery pack connection method as described in claim 14, wherein the side bracket extends continuously from the side of the battery pack shell to the bottom of the battery pack shell, and the method includes directly docking the side bracket with the bottom bracket below the bottom of the battery pack shell.

17. The battery pack connection method of claim 14, wherein the bracket is a single continuous bracket directly connected to both the bottom bracket and the side bracket. 18 . The battery pack connection method according to claim 14 , further comprising supporting a housing of the battery pack by the bottom bracket and the side bracket such that the housing of the battery pack is located under a floor of the vehicle.

19. The battery pack connection method of claim 18, further comprising directly connecting the bottom bracket to a bottom plate of the battery pack housing, directly connecting the side bracket to a side of the battery pack housing, and directly connecting the bracket to the bottom bracket, the side bracket, and the vehicle bottom.

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