Battery pack assembly

Abstract

An apparatus may include a plate disposed spaced apart from a housing. The plate is configured to be coupled with the housing via the protrusion. A portion of the protrusion melts to couple the plate with the housing.

Description

[0001] introduction

[0002] A battery pack may be a source of electrical power for an electric vehicle. Summary of the invention

[0003] At least one aspect relates to a device. The device may include a plate. The plate may be disposed separately from a housing. The plate may be configured to be coupled to the housing via a protrusion, and the protrusion may have a first melting point. At least one of the housing or the plate may have a second melting point, and the first melting point may be different from the second melting point.

[0004] At least one aspect relates to a device. The device may include a housing. The device may include a plate spaced apart from the housing. The device may include a protrusion disposed between the housing and the plate. The plate may be coupled to the housing via the protrusion. The protrusion may have a first melting point, and at least one of the housing or the plate may have a second melting point. The first melting point may be lower than the second melting point.

[0005] At least one aspect relates to a method. The method may include positioning a plate remote from a housing. The method may include coupling the plate to the housing via a protrusion. A portion of the protrusion may be melted to couple the housing to the plate.

[0006] At least one aspect relates to a method. The method may include providing a housing. The method may include disposing a plate remote from the housing. The method may include disposing a protrusion between the housing and the plate. A portion of the protrusion may be melted to couple the housing to the plate. The method may include coupling the housing to the plate via the protrusion.

[0007] At least one aspect relates to an electric vehicle. The electric vehicle may include a battery pack having a housing. The electric vehicle may include a plate disposed away from the housing and outside the electric vehicle. The electric vehicle may include a protrusion disposed between the housing and the plate. The plate may be coupled to the housing via the protrusion. The protrusion may have a first melting point, and at least one of the housing or the plate may have a second melting point. The first melting point may be less than the second melting point.

[0008] These and other aspects and implementations are discussed in detail below. The foregoing information and the following detailed description include illustrative examples of various aspects and implementations, and provide an overview or framework for understanding the nature and characteristics of the protected aspects and implementations. The accompanying drawings provide illustration and further understanding of various aspects and implementations, and are incorporated into and constitute a part of this specification. The foregoing information and the following detailed description and the accompanying drawings include illustrative examples and should not be considered limiting. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The drawings are not intended to be drawn to scale. Like reference numbers and names indicate similar elements in the various drawings. For clarity, not every component may be labeled in every drawing. In the drawings:

[0010] Figure 1 A cross-sectional view of an example battery pack assembly according to some aspects is shown.

[0011] Figure 2 A cross-sectional view of an example battery pack assembly according to some aspects is shown.

[0012] Figure 3 A cross-sectional view of an example battery pack assembly according to some aspects is shown.

[0013] Figure 4 A cross-sectional view of an exemplary protrusion according to some aspects is shown.

[0014] Figure 5 A cross-sectional view of an exemplary protrusion according to some aspects is shown.

[0015] Figure 6 A cross-sectional view of an exemplary protrusion according to some aspects is shown.

[0016] Figure 7 A cross-sectional view of an exemplary protrusion according to some aspects is shown.

[0017] Figure 8 is a top view of an exemplary protrusion according to some aspects.

[0018] Fig. 9 A perspective view of a protrusion grid is shown according to some aspects.

[0019] Fig.10 A cutaway perspective view of an exemplary battery pack assembly according to some aspects is shown.

[0020] Fig.11 A cross-sectional view of an electric vehicle is shown according to some aspects.

[0021] Fig.12 A flow chart illustrating an exemplary method of providing a battery pack assembly according to some aspects is shown. DETAILED DESCRIPTION

[0022] The following is a more detailed description of various concepts related to methods, apparatuses, and systems of battery pack assembly and their specific implementations.The various concepts introduced above and discussed in more detail below can be implemented in any of numerous ways.

[0023] The present disclosure relates to a system and method for providing a battery pack assembly. For example, the present disclosure relates to a battery pack assembly, which may include a plate for protecting a battery pack, and contents disposed therein. A protrusion may be disposed between a plate and a battery pack. By being at least partially melted onto at least one of the plate or the housing of the battery pack, the protrusion may couple the housing of the battery pack to the plate, or vice versa. No mechanical fasteners (e.g., screws, bolts, nails, etc.) are required for coupling the protrusion to the plate or housing. For example, the protrusion may be integrated with one of the housing or the plate. For example, the protrusion and the housing may form a single structure, or the protrusion and the plate may form a single structure. The protrusion may have a first melting point. The other of the housing or the plate that is not integrated with the protrusion may have a second melting point. The first melting point may be lower than the second melting point. Heat may be applied to the other of the housing or the plate to a temperature higher than the first melting point or between the first and second melting points to melt the tip of the protrusion when the tip of the protrusion contacts the other of the plates of the housing.

[0024] The disclosed solution uses few or no mechanical fasteners to couple the plates to the housing of the battery pack to provide protection for the battery pack. The components of the battery pack assembly can be melted to form a single assembly. Melting the components together can reduce or eliminate holes and cavities for accommodating mechanical fasteners, which traditionally can lead to leakage paths for contaminants to enter the assembly and damage the internal components of the assembly. The disclosed solution can provide a lightweight, strong and cost-effective solution that is also used to protect the exterior of the battery pack.

[0025] Figure 1 A cross-sectional view of an exemplary battery pack assembly 100 is shown. The battery pack assembly 100 can accommodate and protect a battery pack 105. For example, the battery pack assembly 100 can prevent substances from entering or contacting the battery pack 105. When an object (e.g., an electric vehicle) containing the battery pack 105 is moving, the battery pack assembly 100 can reduce the force applied to the battery pack 105. The battery pack 105 can be or include at least one energy storage device 110. The energy storage device 110 can be or include at least one battery, battery module, or battery cell, etc.

[0026] The battery pack assembly 100 can include a housing 115. The housing 115 can at least partially enclose the battery pack 105. For example, the housing 115 can define at least one cavity 120. The cavity 120 can receive the battery pack 105.

[0027] The housing 115 may include at least one housing coupling surface 125. The housing coupling surface 125 may be an outer surface of the housing 115. The housing coupling surface 125 may face away from the cavity 120. The housing coupling surface 125 may couple with other components of the battery pack assembly 100. The housing coupling surface 125 may have any shape. For example, the housing coupling surface 125 may be flat, wavy, asymmetric, etc.

[0028] The battery pack assembly 100 may include at least one plate 130. The plate 130 may be spaced apart from the housing 115 by at least one protrusion 140. The plate 130 may be disposed opposite to the housing coupling surface 125. The plate 130 may be coupled to the housing 115 using the at least one protrusion 140. For example, the plate 130 may include at least one plate coupling surface 135. The plate 130 may be coupled to the housing 115 via the plate coupling surface 135 and the housing coupling surface 125. The plate coupling surface 135 may have a shape that conforms to the shape of the housing coupling surface 125. For example, the plate coupling surface 135 may have a flat, wavy, asymmetric, etc. shape that is a mirror image or corresponds to the shape of the housing coupling surface 125. At least a portion of the shape of the plate coupling surface 135 may be different from at least a portion of the shape of the housing coupling surface 125. For example, at least a portion of the housing coupling surface 125 may be wavy or have ribs, and a corresponding portion of the plate coupling surface 135 facing the portion of the housing coupling surface 125 may be flat, or vice versa.

[0029] The battery pack assembly 100 may include at least one protrusion 140. The protrusion 140 may be disposed between the housing 115 and the plate 130. For example, the protrusion 140 may be disposed between the housing coupling surface 125 and the plate coupling surface 135. The housing 115 may be coupled to the plate 130 via the protrusion 140. For example, the protrusion 140 may extend between the housing 115 and the plate 130. At least a portion of the protrusion 140 may be configured to melt to couple the plate 130 to the housing 115.

[0030] The battery pack assembly 100 may include at least one protrusion component 145 and at least one heating component 150. The protrusion component 145 may be a component of the battery pack assembly 100 that includes the protrusion 140 or is integrated with the protrusion (e.g., the housing 115 or the plate 130). For example, the protrusion component 145 may include the protrusion 140 and one of the housing 115 or the plate 130. For example, the protrusion component 145 may include the protrusion 140 and the housing 115. The protrusion 140 may be integrated with the housing 115. For example, the protrusion 140 and the housing 115 may form a single unitary structure (e.g., the protrusion 140 may be formed integrally with the housing 115). The protrusion component 145 may include the protrusion 140 and the plate 130. The protrusion 140 may be integrated with the plate 130. For example, the protrusion 140 and the plate 130 may form a single unitary structure (e.g., the protrusion 140 may be formed integrally with the plate 130). The heating member 150 may be the other of the housing 115 or the plate 130 that is not integral with the protrusion 140. The heating member 150 may receive energy to increase the temperature of the heating member 150 to facilitate the connection of the protrusion member 145 with the heating member 150. For example, the protrusion member 145 may be made of a first material. The first material may be, for example, a metal, a polymer (e.g., plastic), or a composite, etc. The first material may include a filler. For example, the filler may be carbon fiber or glass fiber. The amount of filler in the protrusion member 145 may vary. The first material may have a first melting point. The heating member 150 may be made of a second material. The second material may be, for example, a metal, a polymer (e.g., plastic), or a composite, etc. The second material may include a filler. For example, the filler may be carbon fiber or glass fiber. The second material may have a second melting point. The first melting point may be lower than the second melting point. The heating member 150 may receive energy to increase the temperature of the heating member 150 to the first melting point or a temperature higher than the first melting point and lower than the second melting point. The heated heating member 150 may contact the protrusion 140 of the protrusion member 145 to melt at least a portion of the protrusion 140 to couple the heating member 150 with the protrusion member 145 .

[0031] The heating component 150 may include a bonding agent 155. The bonding agent 155 may be any agent capable of coupling the protrusion 140 to the housing 115 or the plate 130. For example, the bonding agent may be a hot melt or an adhesive (e.g., epoxy, polyurethane, cyanoacrylate), or any other substance configured to create a physical or chemical bond between the protrusion 140 and the housing 115 or the plate 130. The bonding agent 155 may be disposed on a surface of the heating component 150. For example, the bonding agent 155 may be disposed on the housing coupling surface 125 or the plate coupling surface 135. The bonding agent 155 may be disposed between the protrusion 140 and the housing 115 or the plate 130 disposed away from the protrusion 140. The bonding agent 155 may be applied to the housing 115 or the plate 130 to align with the protrusion 140. The bonding agent 155 may be randomly applied to the housing 115 or the plate 130. The bonding agent 155 may be applied as a layer to a majority of the housing coupling surface 125 or the board coupling surface 135. The bonding agent 155 may be activated by heat to facilitate coupling of the housing 115 to the board 130. The bonding agent 155 may interface with the protrusions 140 to couple the housing 115 to the board 130 via the protrusions 140.

[0032] like Figure 1 As shown, the protrusion component 145 may include a housing 115 and a protrusion 140. The protrusion 140 may be integral with the housing coupling surface 125. The protrusion 140 may extend away from the housing coupling surface 125. The battery pack assembly 100 may include a plurality of protrusions 140. The plurality of protrusions 140 may be integral with the housing coupling surface 125. Each protrusion 140 may have an initial length 160. The plurality of protrusions 140 may have the same or different initial lengths 160. For example, the first protrusion 140 may have a first initial length 160a, and the second protrusion 140 may have a second initial length 160b. Each of the plurality of protrusions 140 may interface with the plate 130 to couple the housing 115 to the plate 130.

[0033] Figure 2 A cross-sectional view of an example of a battery pack assembly 100 is shown. The protrusion component 145 may include a plate 130 and a protrusion 140. The protrusion 140 may be integral with the plate coupling surface 135. The protrusion 140 may extend away from the plate coupling surface 135. The battery pack assembly 100 may include a plurality of protrusions 140. The plurality of protrusions 140 may be integral with the plate coupling surface 135. For example, the protrusion 140 and the plate coupling surface 135 may be or form a single body structure. The plurality of protrusions 140 may be the same or different lengths. Each of the plurality of protrusions 140 may interface with the housing 115 to couple the housing 115 to the plate 130.

[0034] Figure 3A cross-sectional view of a battery pack assembly 100 is shown. The battery pack assembly 100 may include a plurality of protrusions 140. When the battery pack assembly 100 is assembled, each of the plurality of protrusions 140 may extend between the housing 115 and the plate 130. Each protrusion 140 may have a coupling length 305. The coupling length 305 may be less than the initial length 160. The plurality of protrusions 140 may have the same coupling length 305 or different coupling lengths 305. For example, in the case where the housing coupling surface 125 has a shape that is a mirror image of the shape of the plate coupling surface 135, the distance between the housing coupling surface 125 and the plate coupling surface 135 may remain constant so that the protrusions 140 may have the same length. In the case where the housing coupling surface 125 includes a shape that is not a mirror image of the shape of the plate coupling surface 135, the distance between the housing coupling surface 125 and the plate coupling surface 135 may vary so that the protrusions 140 may have multiple heights to accommodate the varying distances.

[0035] Figures 4 to 7 A cross-sectional view of an exemplary protrusion 140 is shown. Protrusion 140 can be any material. For example, the protrusion can be a metal, a polymer (e.g., plastic), or a composite, etc. Protrusion 140 can include filler. For example, the filler can be carbon fiber or glass fiber. The amount of filler in protrusion 140 can vary. For example, a first portion of protrusion 140 can have a first percentage of filler, and a second portion of protrusion 140 can have a second percentage of filler. Protrusion 140 can include at least one base 405. Base 405 can be coupled or integrated with housing 115 or plate 130. Base 405 can have a base width 410. Base 405 can have a first percentage of filler material. The filler material can be any filler material (e.g., carbon fiber, glass fiber, etc.). The filler material can enhance the strength and / or rigidity of protrusion 140.

[0036] The protrusion 140 may include at least one tip 415. The tip 415 may be disposed away from the housing 115 or the plate 130 that is integral or coupled to the base 405. The tip 415 may have a tip width 420. The tip width 420 may be less than the base width 410. At least a portion of the tip 415 may be tapered so that the tip width 420 varies. For example, the tip 415 may have a first tip end 425 and a second tip end 430. The tip width 420 at the first tip end 425 may be greater than the tip width 420 at the second tip end 430. The tip 415 may have a tip length 435. The tip width 420 at the first tip end 425 may be one-half of the tip length 435 when the protrusion 140 includes the initial length 160. For example, the tip width 420 may be less than 3 mm, and the tip length 435 of the protrusion 140 at the initial length 160 may be greater than 1.5 mm. The tip 415 may have a second percentage of filler material. The second percentage may be less than the first percentage. For example, tip 415 may be less than or equal to 20% filler material and base 405 may be up to 60% filler material. Tip 415 may be more flexible or less rigid than base 405 based on the smaller percentage of filler material.

[0037] The protrusion 140 may include at least one body 440. The body 440 may be disposed between the base 405 and the tip 415. The body 440 may have a body width 445. The body 440 may be tapered such that the body width 445 varies. The body width 445 may be less than the base width 410. At least a portion of the tip 415 may have a tip width 420 that is less than the minimum body width 445. The protrusion 140 may not include the body 440. For example, as Figure 6 As shown, the tip 415 may extend directly from the base 405 .

[0038] The protrusion 140 may include at least one neck 450. The neck 450 may be where the base 405 or the body 440 transitions to the tip 415. The neck 450 may restrict the flow of filler material to the tip 415 to form a tip 415 that is more flexible than the base 405 and the body 440. Greater flexibility may allow the tip 415 to withstand higher strain levels before breaking. The tip width 420 at the neck 450 may be based on at least one of the material of the protrusion 140, the filler material, the percentage of the filler material, and / or the length of the filler material. For example, the tip width 420 at the neck 450 may be less than 3 mm.

[0039] like Figure 7 As shown, the base 405 may include at least one recess 705. The recess 705 may be disposed on one or both sides of the tip 415 or the body 440. The recess 705 may redirect the flow of the filling material from the base 405 into the tip 415 or the body 440.

[0040] Figure 8 A top view of a plurality of protrusions 140 is shown. The protrusions 140 may be elongated structures. The protrusions 140 may be coupled together or formed together (e.g., integral with each other), or the protrusions 140 may be segmented or separated from each other. The protrusions 140 may be arranged to form at least one pit 805. The pit 805 may have any shape. For example, the pit 805 may be hexagonal, square, rectangular, or triangular, etc. The pit 805 may be of any size. For example, the pit 805 may have an area for receiving an object having a diameter of at least 30 mm. The protrusions 140 may intersect or join at a joint 810 to form the pit 805. Any number of protrusions 140 may intersect at a joint 810. For example, two, three, or four protrusions 140 may intersect at a joint.

[0041] The protrusions 140 may form a plurality of pits 805. The pits 805 may all have the same shape or different shapes. The pits 805 may form a grid on the housing connection surface 125 or the plate connection surface 135. For example, the protrusions 140 may form a grid of a plurality of pits 805 having the same shape. The grid may include a plurality of joints 810. Three protrusions may intersect at the joints 810 to form hexagonal pits 805. Four protrusions may intersect at the joints 810 to form square or rectangular pits 805. The grid may be symmetrical or asymmetrical. For example, the protrusion density may be greater at a first position of the grid (e.g., at the center of the grid) than at a second position of the grid (e.g., at the periphery of the grid). The protrusions 140 may be randomly dispersed or patterned. Gaps may be provided between the individual protrusions 140 to provide a path for contaminants or particles to be discharged from the battery pack assembly 100. The protrusion 140 may include an opening extending through the protrusion 140 to provide an exit path for contaminants or particles.

[0042] Fig. 9 An exemplary grid 905 is shown. The grid 905 may include any number of protrusions 140, any number of joints 810, and any number of dimples 805. The grid 905 may be integral with the housing 115 or the plate 130. The grid 905 may include dimples of any shape (e.g., hexagonal, rectangular, square, triangular, circular, asymmetric, etc.). Prior to coupling the housing 115 to the plate 130 via the protrusions 140, the protrusions 140 may have an initial length 160. The initial length 160 may be the same across the grid 905 or may vary across the grid 905.

[0043] Fig.10An exemplary battery pack assembly 100 is shown. The battery pack assembly 100 may include a plurality of protrusions 140. The protrusions 140 may be integral with the plate 130. For example, the protrusions 140 and the plate 130 may be or form a single body structure. The housing 115 may have a non-planar shape. For example, the housing 115 may have at least one protrusion or recess 1005. The plate 130 may have a shape that is different (e.g., not mirrored) from the housing 115. For example, the plate 130 may be planar. The distance between the plate 130 and the housing 115 may vary so that the coupling length 305 of the plurality of protrusions 140 may vary. For example, the first protrusion 140 may have a first coupling length 305a, and the second protrusion 140 may have a second coupling length 305b.

[0044] Fig.11An example cross-sectional view of an electric vehicle 1105 with at least one battery pack assembly 100 installed is shown. The electric vehicle 1105 may include an electric truck, an electric sport utility vehicle (SUV), an electric van, an electric car, an electric car, an electric motorcycle, an electric scooter, an electric passenger car, an electric passenger or commercial truck, a hybrid vehicle or other vehicle, such as a sea or air vehicle, an airplane, a helicopter, a submarine, a ship or a drone, and other possibilities. However, it should also be noted that the battery pack 105 can also be used as an energy storage system to power a building (such as a residential or commercial building). The electric vehicle 1105 can be fully electric or partially electric (e.g., a plug-in hybrid), and further, the electric vehicle 1105 can be fully autonomous, partially autonomous or unmanned. The electric vehicle 1105 can also be manually operated or non-autonomous. The electric vehicle 1105 (such as an electric truck or car) may include an on-board battery pack 105 to power the electric vehicle 1105. The battery pack 105 may be or may include a battery module 1115 or a battery cell 1120. The electric vehicle 1105 may include a chassis 1125 (e.g., a frame, an internal frame, or a support structure). The chassis 1125 may support various components of the electric vehicle 1105. The chassis 1125 may span a front portion 1130 (e.g., a hood or lid portion), a main body portion 1135, and a rear portion 1140 (e.g., a luggage compartment, a payload, or a trunk portion) of the electric vehicle 1105. The battery pack assembly 100 may be at least partially mounted or placed within the electric vehicle 1105. The plate 130 of the battery pack assembly may be disposed within the electric vehicle 1105 or disposed outside the electric vehicle 1105. For example, the battery pack assembly 100 may be supported by the chassis 1125 of the electric vehicle 1105 in one or more of the front portion 1130, the main body portion 1135, or the rear portion 1140. The battery pack 105 of the battery pack assembly 100 may include or be connected to at least one bus bar, such as a current collector element. For example, the first bus bar 1145 and the second bus bar 1150 may include conductive materials to connect or otherwise electrically couple the battery module 1115 or the battery cell 1120 to other electrical components of the electric vehicle 1105 to provide power to various systems or components of the electric vehicle 1105.

[0045] Fig.12 An exemplary method 1200 of providing a battery pack assembly 100 is shown. The method 1200 may include providing a plate 130 and a housing (act 1205). Act 1205 may include disposing the plate 130 remote from the housing 115. The housing 115 may at least partially enclose the battery pack 105. The housing 115 may include at least one housing coupling surface 125. The plate 130 may include a plate coupling surface 135. The plate 130 may be disposed remote from the housing 115.

[0046] Method 1200 may include coupling housing 115 to plate 130 (act 1210). Act 1210 may include disposing at least one protrusion 140 between housing 115 and plate 130. At least a portion of protrusion 140 (e.g., tip 415) may be melted to couple housing 115 to plate 130 (e.g., weld). Protrusion 140 may be integral with one of housing 115 and plate 130. For example, protrusion 140 may be integral with housing 115 and extend away from housing coupling surface 125 toward plate coupling surface 135. Protrusion 140 may be integral with plate 130 and extend away from plate coupling surface 135 toward housing coupling surface 125. Protrusion 140 and housing 115 or plate 130 integral therewith may form protrusion member 145. The other of housing 115 or plate 130 that is not integral with protrusion 140 may be heating member 150.

[0047] Act 1210 may include forming protrusion 140. For example, protrusion 140 may be formed integrally with housing 115 or plate 130. Forming the protrusion at act 1210 may include forming base 405 and tip 415. Base 405 may include a first percentage of filler material, and tip 415 may include a second percentage of filler material. The first percentage may be greater than the second percentage.

[0048] Action 1210 may include coupling housing 115 to plate 130 via protrusion 140. Protrusion 140 may be integral with housing 115 or plate 130. Protrusion 140 may have a first melting point. The other of housing 115 or plate 130 (e.g., the one not integral with protrusion 140) may have a second melting point. The first melting point may be lower than the second melting point. Coupling housing 115 to plate 130 may include heating the other of housing 115 or plate 130 to a temperature between the first melting point and the second melting point. Action 1210 may include melting at least a portion of protrusion 140. For example, at least a portion of tip 415 of protrusion 140 may melt. Housing 115 may be coupled to plate 130 via protrusion 140.

[0049] Action 1210 may include applying a bonding agent 155 to the housing 115 or the plate 130. The bonding agent 155 may be applied, for example, as a layer over a majority of the housing 115 or the plate 130, or may be applied to align with the protrusion 140. Action 1210 may include activating the bonding agent 155 by applying heat to the heating component 150. Activation of the bonding agent 155 may facilitate bonding or coupling between the protrusion 140 and the other of the housing 115 or the plate 130. The housing 115 may be coupled to the plate 130 without the use of mechanical fasteners.

[0050] Although operations are depicted in a particular order in the drawings, these operations need not be performed in the particular order shown or in sequential order, and not all of the operations shown need be performed. The actions described herein may be performed in a different order.

[0051] Now that some exemplary implementations have been described, it is apparent that the foregoing is illustrative rather than restrictive and has been presented by way of example. Specifically, although many of the examples presented herein relate to specific combinations of method actions or system elements, these actions and these elements may be combined in other ways to achieve the same purpose. The actions, elements, and features discussed in conjunction with one implementation are not intended to be excluded from similar roles in other implementations.

[0052] The words and terms used herein are for descriptive purposes and should not be construed as limiting. The use of "including," "comprising," "having," "containing," "involving," "characterized by," and variations thereof herein is intended to encompass the items listed thereafter, their equivalents and additional items, and alternative implementations consisting solely of the items listed thereafter. In one implementation, the systems and methods described herein consist of one, each combination of more than one, or all of the elements, acts, or components described.

[0053] Any specific implementation or element or action of the system and method mentioned in the singular form herein may also include a specific implementation comprising a plurality of these elements, and any plural form of any specific implementation or element or action herein may also include a specific implementation comprising only a single element. Reference in the singular or plural form is not intended to limit the currently disclosed system or method, its parts, actions or elements to a single or multiple configurations. Reference to any action or element based on any information, action or element may include a specific implementation in which the action or element is based at least in part on any information, action or element.

[0054] Any implementation disclosed herein may be combined with any other implementation or embodiment, and references to "an implementation," "some implementations," "an implementation," etc. are not necessarily mutually exclusive, but are intended to indicate that a particular feature, structure, or characteristic described in conjunction with an implementation may be included in at least one implementation or embodiment. Such terms as used herein do not necessarily all refer to the same implementation. Any implementation may be combined, inclusively or exclusively, with any other implementation in any manner consistent with the aspects and implementations disclosed herein.

[0055] References to "or" may be interpreted as inclusive, such that any term described using "or" may indicate any of a single, more than one, and all of the terms. References to at least one of a conjunctive list of terms may be interpreted as inclusive OR to indicate any of a single, more than one, and all of the terms. For example, references to "at least one of 'A' and 'B'" may include only "A," only "B," and both "A" and "B." Such references used in conjunction with "including" or other open-ended terms may include additional items.

[0056] Where a technical feature in the drawings, detailed description or any claims is followed by a reference numeral, the reference numeral is included to enhance the intelligibility of the drawings, detailed description and claims. Therefore, the presence or absence of a reference numeral has no limiting effect on the scope of any claim element.

[0057] Without departing substantially from the teachings and advantages of the subject matter disclosed herein, modifications may be made to the elements and actions, such as changes in size, dimensions, structure, shape and proportion, parameter values, mounting arrangements, use of materials, color, orientation of the various elements. For example, an element shown as being integrally formed may be composed of multiple parts or elements, the position of elements may be reversed or otherwise changed, and the nature or number or position of discrete elements may be changed or varied. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the disclosed elements and operations without departing from the scope of the present disclosure.

[0058] For example, the description of the upper and lower parts or the top and bottom can be reversed. An element described as a negative element can be configured as a positive element, while an element described as a positive element can be configured as a negative element. For example, an element described as having a first polarity can have a second polarity, while an element described as having a second polarity can have a first polarity. Further relative parallel, vertical, vertical or other positioning or orientation descriptions include changes within + / -10% or + / -10 degrees of pure vertical, parallel or vertical positioning. Unless otherwise expressly stated, references to "approximately", "substantially" or other degree terms include changes of + / -10% with a given measurement, unit or range. The connected elements can be electrically connected, mechanically connected or physically connected to each other directly or through an intermediate element. Therefore, the scope of the systems and methods described herein is indicated by the appended claims rather than the foregoing description, and changes falling within the meaning and scope of the equivalents of the claims are included therein.

Claims

1. A device, comprising: a plate spaced apart from the housing; and The plate is configured to be coupled with the housing via a protrusion, a portion of which is melted to couple the plate with the housing.

2. The device according to claim 1, comprising: the portion of the protrusion includes a first melting point, the protrusion being integral with the plate; as well as The housing includes a second melting point, the first melting point is lower than the second melting point, and the housing receives heat to melt the portion of the protrusion to couple the housing with the plate.

3. The device according to claim 1, comprising: the portion of the protrusion includes a first melting point, the protrusion being integral with the housing; as well as The plate includes a second melting point, the first melting point is lower than the second melting point, and the plate receives heat to melt the portion of the protrusion to couple the housing to the plate.

4. The device according to claim 1, comprising: A bonding agent between the protrusion and at least one of the housing or the plate, the bonding agent interfacing with the protrusion to couple the plate to the housing.

5. The device according to claim 1, comprising: The protrusion comprises: a base comprising a first percentage of filler material; and A tip includes a second percentage of the fill material, the first percentage being greater than the second percentage.

6. The device according to claim 1, comprising: The protrusion comprises: an initial length prior to coupling the housing to the plate; and A coupling length after coupling the housing with the plate, the coupling length being smaller than the initial length, the portion of the protrusion being melted to reach the coupling length.

7. The device according to claim 1, comprising: The protrusion comprises an initial length and a tip, the tip comprising: Width; and The tip length, the width is half of the tip length.

8. The device according to claim 1, comprising: A plurality of protrusions comprising the protrusions define a recess including an area for receiving an object having a minimum diameter of 30 mm.

9. The device according to claim 1, comprising: A plurality of protrusions including the protrusions define a plurality of recesses having a plurality of joints, the plurality of joints including three intersecting protrusions of the plurality of protrusions.

10. The device according to claim 1, comprising: The plate is coupled to the housing without any mechanical fasteners.

11. The device according to claim 1, comprising: The housing is a housing of a battery pack, and the battery pack supplies power to the electric vehicle; as well as The plate is disposed outside the electric vehicle.

12. A method comprising: providing a plate and a housing; as well as The plate is coupled to the housing via a protrusion, a portion of which is melted to couple the housing to the plate.

13. The method of claim 12, wherein the protrusion is integral with the housing or the plate, the method comprising: heating the other of the housing or the plate, the protrusion comprising a first melting point and the other of the housing or the plate comprising a second melting point, the first melting point being lower than the second melting point; melting the portion of the protrusion; as well as The housing is coupled to the plate via the protrusion.

14. The method according to claim 12, comprising: applying a bonding agent to the housing or the plate; activating the bonding agent by applying heat; as well as The housing is coupled to the plate via the protrusion.

15. The method according to claim 12, comprising: forming the protrusion, the protrusion comprising: a base comprising a first percentage of filler material; and The tip includes a second percentage of fill material, the first percentage of fill material being greater than the second percentage of fill material.

16. An electric vehicle, comprising: A battery pack including a housing; a plate disposed away from the housing; as well as A protrusion is at least partially disposed between the housing and the plate, the plate being coupled to the housing via the protrusion, the protrusion comprising a first melting point, and at least one of the housing or the plate comprising a second melting point, the first melting point being less than the second melting point.

17. The electric vehicle according to claim 16, comprising: said protrusion being integral with said housing or said plate; and The other of the housing or the plate includes the second melting point, and the other of the housing or the plate receives heat to melt a portion of the protrusion to couple the housing with the plate.

18. The electric vehicle according to claim 16, comprising: A bonding agent is disposed between the protrusion and the at least one of the housing or the plate, the bonding agent interfacing with the protrusion to couple the plate to the housing.

19. The electric vehicle according to claim 16, comprising: The protrusion comprises: a base comprising a first percentage of filler material; and A tip includes a second percentage of the fill material, the first percentage being greater than the second percentage.

20. The electric vehicle according to claim 16, comprising: A plurality of protrusions including the protrusions define a plurality of recesses having a hexagonal shape.

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