Battery pack assembly

Abstract

The invention discloses a battery pack assembly. Also disclosed is an apparatus that may include a unit carrier defining a first engagement feature and a second engagement feature. The first engagement feature and the second engagement feature may be configured to engage with a housing. The unit carrier may be configured to couple with the housing via at least one of the first engagement feature or the second engagement feature.

Description

[0001] introduction

[0002] Battery packs may be used to power electric vehicles. Summary of the invention

[0003] The components coupled to the battery subassembly or battery pack may complicate the construction of the battery subassembly or battery pack by using additional fasteners, coupling multiple components separately, and using insulating materials for all components or fasteners due to the close proximity of the high voltage components of the battery subassembly or battery pack. The technical solution described herein provides a battery voltage and temperature module (BVT) that follows a 2-way and 4-way positioning scheme and a retention scheme, the positioning scheme utilizing two positioning pins in the housing to interface with specific cutouts in the battery box, and the retention scheme utilizing snap-fit ​​clamps or tabs of the housing to interface with different cutouts of the battery box to couple the BVT to the battery subassembly.

[0004] At least one aspect relates to a device. The device may include a unit carrier that defines a first engagement feature and a second engagement feature. The first engagement feature and the second engagement feature may be configured to engage with a housing. The unit carrier may be configured to couple to the housing via at least one of the first engagement feature or the second engagement feature.

[0005] At least one aspect relates to a method. The method may include providing a unit carrier. The unit carrier may include a first engagement feature and a second engagement feature. The method may include engaging a first docking element with the first engagement feature to couple a housing to the unit carrier. The method may include engaging a second docking element with the second engagement feature to prevent at least some lateral movement of the housing relative to the unit carrier.

[0006] At least one aspect relates to a module. The module may include a housing coupled to a unit carrier. The housing may include a first docking element that couples the housing to the unit carrier. The housing may include a second docking element that facilitates proper positioning of the housing relative to the unit carrier.

[0007] At least one aspect relates to an electric vehicle. The electric vehicle may include a unit carrier, the unit carrier including a first engagement feature and a second engagement feature. The electric vehicle may include a module coupled to the unit carrier. The module may include a housing. The housing may include a first docking element and a second docking element. The first docking element may engage with the first engagement feature to couple the module to the unit carrier. The second docking element may engage with the second engagement feature to position the module relative to the unit carrier.

[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 Depicted is a front perspective view of an exemplary battery pack assembly according to some aspects.

[0011] Figure 2 Depicted is a front view of a portion of a unit carrier according to some aspects.

[0012] Figure 3 Depicted is a rear view of an example module according to some aspects.

[0013] Figure 4 Depicted is a front perspective view of an exemplary module according to some aspects.

[0014] Figure 5 Depicted is a partial side perspective view of an exemplary battery pack assembly according to some aspects.

[0015] Figure 6 Depicted is a partial front perspective view of an exemplary battery pack assembly according to some aspects.

[0016] Figure 7 A partial side cross-sectional view of an example battery pack assembly according to some aspects is shown.

[0017] Figure 8 Depicted is a partial side cross-sectional view of an exemplary battery pack assembly according to some aspects.

[0018] Fig. 9 Depicted is a side cutaway view of an exemplary electric vehicle according to some aspects.

[0019] Fig.10 A flow chart of an exemplary method of assembling a battery pack assembly according to some aspects is depicted.

[0020] Fig.11 An exemplary flow chart of an exemplary method of forming a battery subassembly according to some aspects is depicted. DETAILED DESCRIPTION

[0021] 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.

[0022] The present disclosure relates to systems and methods for coupling a battery voltage and temperature module (BVT) to a battery subassembly, a battery module, or a battery pack. The disclosed solution may have the technical advantage of coupling a single modular assembly (e.g., a BVT) to a housing of a battery subassembly (e.g., a cell carrier) without the need for additional fasteners. The BVT may follow two-way and four-way positioning schemes to facilitate proper positioning of the BVT relative to the cell carrier. The BVT may include a retaining feature to quickly snap the BVT into place with the cell carrier. The BVT may be a modular assembly of various electrical components to monitor or control components of a battery subassembly. For example, the BVT may include a circuit board that is heat-riveted to the housing of the BVT. The BVT may have various connectors to couple with, for example, a thermistor that can measure the temperature of a battery subassembly or its battery cells, a voltage sensor or balancer that can sense or control the voltage flowing through the battery subassembly, or a communication device that can receive, transmit, or analyze data associated with the battery subassembly.

[0023] The disclosed solution may include a unit carrier. The unit carrier may carry or accommodate a battery subassembly (e.g., at least one battery cell). The unit carrier may define a first engagement feature and a second engagement feature. The first engagement feature may facilitate coupling the BVT to the unit carrier. The first engagement feature may include a first retaining opening and a second retaining opening. The first retaining opening and the second retaining opening may receive components of the BVT to couple the BVT to the unit carrier. The second engagement feature may facilitate positioning of the BVT relative to the unit carrier. The second engagement feature may include a first positioning opening and a second positioning opening. The first positioning opening may be a two-way positioning feature to prevent lateral movement of the BVT in two directions (e.g., up and down). The second positioning opening may be a four-way positioning feature to prevent lateral movement of the BVT in four directions (e.g., up and down and left and right).

[0024] The disclosed solution may include a BVT. The BVT may include a housing. The housing may include a first docking element and a second docking element. The first docking element may engage with a first engagement feature of a unit carrier to couple the BVT to the unit carrier. The first docking element may include at least one tab. The tab may be disposed in one of the retaining openings to couple the BVT to the unit carrier. The second docking element may engage with a second engagement feature of the unit carrier to position the BVT relative to the unit carrier. The second docking element may include at least one protrusion. The protrusion may be disposed in one of the positioning openings to facilitate proper positioning of the BVT relative to the unit carrier.

[0025] The BVT may include a circuit board (e.g., a printed circuit board). The circuit board may be disposed in a housing. The circuit board may be heat riveted to the housing. In the case where the housing is coupled to the unit carrier, the circuit may be positioned so that it is spaced apart from the unit carrier. The printed circuit board may have electronic components on both sides of the printed circuit board. The housing may include at least one connector. The connector may electrically couple an external component to the circuit board. For example, the housing may have a thermistor connector, a voltage sensor or a balancer connector, or a communication connector. The housing may include at least one lip to prevent matter from entering the connector. The housing may include a post to provide clearance from the busbars of the unit carrier and prevent the BVT from rotating relative to the unit carrier.

[0026] Figure 1 A front perspective view of an exemplary battery pack assembly 100 is shown. The battery pack assembly 100 may include at least one battery pack 105. The battery pack 105 may include at least one battery subassembly 110. For example, the battery pack 105 may have a first (e.g., top) battery subassembly 110 and a second (e.g., bottom) battery subassembly 110. The battery subassembly 110 may house at least one energy storage device, such as a battery cell. For example, the battery subassembly 110 may have a housing, shown as a cell carrier 115. The battery cells may be disposed in the cell carrier 115.

[0027] The battery pack assembly 100 may include at least one electronic module, shown as a battery voltage and temperature module (BVT) 120. The BVT 1410 may be a monitor, module, controller, or other device. The BVT 120 may be coupled to the battery pack 105. For example, the BVT 120 may be coupled to the battery subassembly 110 of the battery pack 105. The BVT 120 may be coupled to the cell carrier 115 of the battery subassembly 110.

[0028] Figure 2A front view of an exemplary unit carrier 115 is depicted. The unit carrier 115 may define at least one engagement feature to engage with a component of the BVT 120. For example, the unit carrier 115 may include: at least one first engagement feature 205 to facilitate coupling of the BVT 120 to the unit carrier 115; and at least one second engagement feature 210 to facilitate proper positioning of the BVT 120 relative to the unit carrier 115. The first engagement feature 205 may include at least one retaining opening 215. The retaining opening 215 may be an opening in the unit carrier 115 to receive a component of the BVT 120 to couple the BVT 120 to the unit carrier 115. The unit carrier 115 may have a plurality of retaining openings 215. For example, the unit carrier 115 may have a first retaining opening 215 and a second retaining opening 215. Each of the plurality of retaining openings 215 may engage with a corresponding component of the BVT 120 to couple the BVT to the unit carrier 115.

[0029] The second engagement feature 210 may include at least one locating opening 220. The locating opening 220 may be an opening in the unit carrier 115 to receive components of the BVT 120 to facilitate proper positioning of the BVT 120 relative to the unit carrier 115. The locating opening 220 may prevent lateral movement of the BVT 120 relative to the unit carrier 115 in at least two directions. For example, the locating opening 220 may prevent the BVT 120 from at least moving up and down or left and right relative to the unit carrier 115.

[0030] The unit carrier 115 may have a plurality of positioning openings 220. For example, the unit carrier 115 may have a first positioning opening 220a and a second positioning opening 220b. The first positioning opening 220a may provide a two-way positioning solution to prevent or reduce movement of the BVT 120 in two lateral directions. For example, the first positioning opening 220a may be a narrow slot that allows horizontal movement (e.g., left and right lateral directions) and prevents vertical movement (e.g., up and down lateral directions). The second positioning opening 220b may provide a four-way positioning solution to prevent or reduce movement of the BVT 120 in four lateral directions. For example, the second positioning opening 220b may be circular to prevent both vertical and horizontal movement. Each positioning opening 220 may engage with a corresponding component of the BVT 120 to facilitate proper positioning of the BVT 120 relative to the unit carrier.

[0031] Figure 3 A rear perspective view of an exemplary BVT 120 is depicted. Figure 4A front perspective view of the BVT 120 is depicted. The BVT 120 may include at least one housing 305. The housing 305 may house or hold various components (e.g., electrical components) associated with the battery pack 105 or the battery 110. For example, the housing 305 may house at least one of a voltage sensor, a temperature sensor, or a communication component. The housing 305 may define a cavity 310 to receive an electrical component or a portion thereof. The housing 305 may be made of any material that is configured to hold a shape to hold such components. The housing 305 may be made of an insulating material to prevent voltage from being transferred from the battery pack 105 to the housing 305. For example, the housing 305 may be made of a plastic material.

[0032] The BVT 120 may include at least one circuit board 315. The circuit board 315 may be electrically coupled to various electrical components within the housing 305 or other electrical components coupled to the BVT 120. The circuit board 315 may be a printed circuit board 315. The circuit board 315 may have a first side and a second side. The circuit board 315 may have electrical components on both the first side and the second side.

[0033] The circuit board 315 may be disposed in the cavity 310 of the housing 305. The circuit board 315 may be coupled to the housing 305. For example, the circuit board 315 may have at least one coupling location 320. The circuit board 315 may be coupled to the housing 305 at each coupling location 320. For example, the circuit board 315 may be heat-riveted to the housing 305. The circuit board 315 may be heat-riveted to the housing 305 at each coupling location 320. The coupling location 320 may be, for example, located at a corner of the circuit board 315. The coupling location 320 may be located at each corner of the circuit board 315. The circuit board 315 may have a coupling location 320 located at the center (or a more central location) of the circuit board 315.

[0034] The housing 305 may position the circuit board 315 at a desired position. For example, when the housing is coupled to the unit carrier 115, the housing 305 may allow the circuit board 315 to be disposed at a predetermined distance away from the unit carrier 115. The housing 305 may protect the circuit board 315 and other components disposed in the housing 305. For example, the housing 305 may transfer a load between the BVT 120 and the battery 110. The housing 305 may transfer a load in a lateral direction.

[0035] The housing 305 may include at least one docking element to engage with an engagement feature of the cell carrier 115. For example, the housing 305 may include at least one first docking element, shown as a tab 325. The tab 325 may couple the housing 305 of the BVT 120 to the cell carrier 115. For example, the tab 325 may engage with the first engagement feature 205 of the cell carrier 115 to couple the housing 305 to the cell carrier 115. The tab 325 may enter or extend through the first engagement feature 205 in a direction perpendicular to the cell carrier 115 (or battery pack 105). The housing 305 may be coupled to the cell carrier 115 so that the battery subassembly 110 can couple the housing 305 to the battery subassembly 110 without requiring an additional bracket or coupling mechanism.

[0036] The first engagement feature 205 may receive at least a portion of the tab 325 to couple the housing 305 to the unit carrier 115. For example, the tab 325 may be flexible and may be at least partially disposed in or extend through the first engagement feature 205. The tab 325 may include an arm 330 and a head 335 disposed at the end of the arm 330. In order to couple the housing 305 to the unit carrier 115, the arm 330 may extend through the retention opening 215 of the first engagement feature 205 so that the head 335 is disposed inside the unit carrier 115. When the head 335 is inserted through the retention opening 215, the arm 330 may move or deform. The arm 330 may be biased back to its initial position so that the tab 325 may snap into the retention opening 215. A portion of the head 335 may dock with the unit carrier 115 to prevent the head 335 from sliding back through the retention opening 215 and preventing the housing 305 from disengaging from the unit carrier 115.

[0037] The housing 305 may include a plurality of tabs 325. For example, the housing 305 may include a first tab 325 and a second tab 325. The first tab 325 may be located on a different side of the housing 305 than the second tab 325. For example, the first tab 325 may be located on a side of the housing 305 opposite to the second tab 325. The tabs 325 may have the same size or different sizes, or may have the same shape or different shapes. For example, the tabs 325 may have the same width or different widths. Each tab 325 may have a corresponding first engagement feature 205 or retention opening 215. The size or shape of the tab 325 may be based on the size and shape of the corresponding first engagement feature or retention opening 215. A plurality of tabs 325 may engage with a plurality of retention openings 215 to couple the housing 305 to the unit carrier 115.

[0038] The housing 305 may include at least one second docking element, shown as a protrusion 340. The protrusion 340 may facilitate proper positioning of the housing 305 relative to the unit carrier 115. For example, the protrusion 340 may engage with the second engagement feature 210 of the unit carrier 115 to facilitate proper positioning of the housing 305 relative to the unit carrier 115. The protrusion 340 may enter or extend through the second engagement feature 210 in a direction perpendicular to the unit carrier 115 (or battery pack 105).

[0039] The second engagement feature 210 may receive at least a portion of the protrusion 340 to facilitate proper positioning of the housing 305 relative to the unit carrier 115. For example, the protrusion 340 may extend from the rear side of the housing 305 and may be at least partially disposed in or extend through the second engagement feature 210. The protrusion 340 may engage with the first positioning opening 220a or the second positioning opening 220b of the second engagement feature 210. When the protrusion 340 is located in the first positioning opening 220a, the protrusion 340 may prevent lateral movement of the housing 305 in two directions (e.g., movement parallel to a side of the unit carrier 115 that includes the second engagement feature 210). When the protrusion 340 is located in the second positioning opening 220b, the protrusion 340 may prevent lateral movement of the housing 305 in four directions.

[0040] The housing 305 may include a plurality of protrusions 340. For example, the housing 305 may include a first protrusion 340 and a second protrusion 340. The protrusions 340 may be located on opposite sides of the housing 305. For example, the first protrusion 340 may be located at the lower right corner of the housing 305, and the second protrusion 340 may be located at the lower left corner of the housing 305. The protrusions 340 may have the same size or different sizes, or may have the same shape or different shapes. Each protrusion 340 may have a corresponding second engagement feature 210 or positioning opening 220. The shape and size of the protrusion 340 may be based on the size and shape of the corresponding second engagement feature 210 or positioning opening 220. A plurality of protrusions 340 may engage with a plurality of positioning openings 220 to position the housing relative to the unit carrier 115.

[0041] The BVT 120 may include at least one connector 345. The connector 345 may electrically couple an external component to the circuit board 315 of the BVT 120. The external component may be, for example, a voltage sensor (e.g., a voltage sensing harness), a temperature sensor, or a communication component, etc. The BVT 120 may have a plurality of connectors 345. The BVT 120 may receive data indicating the characteristics (e.g., temperature, voltage, state of charge, fault state, etc.) of the battery subassembly 110. The BVT 120 may transmit the characteristics or data to a battery management system (BMS). For example, the BVT 120 may communicate with the BMS via a wired or wireless connection. The BMS may include any combination of hardware and software for controlling the power, voltage, current, or energy of the battery pack 105, the battery subassembly 110, or the battery cell 120. The BMS may operate on a computer system of the electric vehicle 905. The BMS may include scripts, controls, computer codes, or instructions for monitoring, controlling, or managing the charging or discharging of the battery pack 105. The BMS may include functionality for routing or distributing power from the battery pack 105 to components of the electric vehicle 905 (e.g., the motor, powertrain, or other electric vehicle 905 components). For example, the BMS may regulate power to the battery pack 105 or battery subassembly 110 when the electric vehicle 905 is charging.

[0042] The housing 305 may include at least one connector opening 350. The connector opening 350 may expose the connector 345 to the outside so that the connector 345 may be accessed and connected to an external component. The connector opening 350 may be provided around one side of the housing 305.

[0043] The housing 305 may include at least one lip 355. The lip 355 may prevent material (e.g., debris, potting material, etc.) from entering the connector opening 350 and thereby the connector 345. For example, the lip 355 may extend from a side of the housing 305 adjacent to the connector opening 350. The lip 355 may extend beyond the edge of the housing 305 so that material will have to go over or around the lip 355 to enter the connector 345 or the connector opening 350. The housing 305 may include a lip 355 for each connector opening 350 or a subset thereof.

[0044] The housing 305 may have a peripheral surface 360. When the BVT 120 is coupled to the unit carrier 115, at least a portion of the peripheral surface 360 ​​may interface with the unit carrier 115.

[0045] like Figure 1As shown, the BVT 120 can be disposed on one side of the battery pack 105. For example, the retaining opening 215 and the positioning opening 220 can be located on one side of the unit carrier 115. For a battery pack 105 having a plurality of unit carriers 115, the retaining opening 215 and the positioning opening 220 can be located on at least one of the unit carriers 115. For example, the retaining opening 215 and the positioning opening 220 can be located on a first (e.g., top) unit carrier 115. The BVT 120 can be coupled to the top unit carrier 115. The BVT 120 can be coupled to the bottom unit carrier 115. The BVT 120 can be easily coupled to and disengaged from the unit carrier 115 by snapping the tab 325 of the housing 305 into the retaining opening 215 and then pinching or otherwise manipulating the tab 325 to pull the tab 325 out of the retaining opening 215.

[0046] Figure 5 A portion of a battery pack assembly 100 is depicted. The housing 305 may include at least one post 405. The post 405 may provide a barrier for a bus bar 410 of the battery subassembly 110 to provide clearance from the bus bar 410. The post 405 may prevent the housing 305 from rotating relative to the unit carrier 115. For example, the post 405 may extend from a side of the housing 305. The post 405 may be disposed adjacent to the tab 325 of the housing 305. The bus bar 410 may be coupled to the unit carrier 115. The post 405 may abut the bus bar 410. The interaction between the post 405 and the bus bar 410 may prevent the housing 305 from rotating relative to the unit carrier 115.

[0047] Figure 6 A partial front perspective view of the battery pack assembly 100 is depicted. The BVT 120 may be coupled to the cell carrier 115. The lip 355 of the housing 305 may extend beyond the edge of the battery subassembly 110 to prevent material (eg, potting material) from entering the connector opening 350 of the housing 305.

[0048] Figure 7 A side cross-sectional view of the battery pack assembly 100 is depicted. With the BVT 120 coupled to the unit carrier 115, a portion of the arm 330 of the tab 325 may extend through the retaining opening 215, and the head 335 of the tab 325 may be disposed inside the unit carrier 115, while the remainder of the housing 305 is located outside the unit carrier 115. With the BVT 120 coupled to the unit carrier 115, a portion of the protrusion 340 may extend through the locating opening 220.

[0049] Figure 8A side cross-sectional view of the battery pack assembly 100 is depicted. With the housing 305 coupled to the unit carrier 115, the circuit board 315 may be spaced apart from the unit carrier 115. With a space between the unit carrier 115 and the circuit board 315, the circuit board 315 may have electrical components on both sides of the circuit board 315.

[0050] Fig. 9 An exemplary cross-sectional view of an electric vehicle 905 with at least one battery pack 105 installed is depicted. The electric vehicle 905 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 marine or air vehicle, an airplane, a helicopter, a submarine, a ship, or a drone, etc. However, it should also be noted that the battery pack 105 can also be used as an energy storage system to power buildings such as residential or commercial buildings. The electric vehicle 905 can be fully electric or partially electric (e.g., a plug-in hybrid), and further, the electric vehicle 905 can be fully autonomous, partially autonomous, or unmanned. The electric vehicle 905 can also be manually operated or non-autonomous. The electric vehicle 905, such as an electric truck or car, may include a battery pack assembly 100, a battery subassembly 110, or a battery cell 910 to power the electric vehicle. The electric vehicle 905 may include a chassis 915 (e.g., a frame, an internal frame, or a support structure). The chassis 915 may support various components of the electric vehicle 905. The chassis 915 may span a front portion 920 (e.g., a hood or lid portion), a body portion 925, and a rear portion 930 (e.g., a luggage compartment, cargo, or trunk portion) of the electric vehicle 905. The battery pack 105 may be mounted or placed within the electric vehicle 905. For example, the battery pack 105 may be mounted within one or more of the front portion 920, the body portion 925, or the rear portion 930 on the chassis 915 of the electric vehicle 905. The battery pack 105 may include or be connected to at least one bus bar 410, such as a collector element. For example, the bus bar 410 may include a conductive material to connect or otherwise electrically couple the battery subassembly 110 or battery cell 910 to other electrical components of the electric vehicle 905 to power various systems or components of the electric vehicle 905.

[0051] The electric vehicle 905 may include at least one battery pack assembly 100. For example, the electric vehicle 905 may include a battery subassembly 110 and a BVT 120 coupled to the battery subassembly 110. Each battery subassembly 110 may have a designated BVT 120, or a single BVT 120 may be coupled to a plurality of battery subassemblies 110.

[0052] Fig.10A flow chart of a method 1000 for assembling a battery pack assembly 100 is depicted. The method 1000 may include providing a unit carrier 115 (act 1005). The unit carrier 115 may include a first engagement feature 205 and a second engagement feature 210.

[0053] Method 1000 may include engaging a first docking element with a first engagement feature 205 (act 1010). Engaging the first docking element with the first engagement feature 205 may include inserting at least a portion of a tab 325 of a housing 305 into a retention opening 215. The housing 305 may be a housing 305 for a BVT 120. Act 1010 may include coupling the housing 305 with a unit carrier 115. For example, the housing 305 may be coupled with the unit carrier 115 via the tab 325. The tab 325 may snap into the retention opening 215 to secure a head 335 of the tab 325 in the unit carrier 115. Act 1010 may include engaging a plurality of tabs 325 of the housing 305 with a plurality of retention openings 215.

[0054] Action 1010 may include placing a circuit board 315 in the housing 305 and coupling the circuit board 315 to the housing 305. The circuit board 315 may be coupled to the housing via heat staking. The circuit board 315 may be placed at a predetermined distance away from the unit carrier 115 so that there is a gap between the circuit board 315 and the unit carrier. In the presence of the gap, the circuit board 315 may have electrical components on both sides of the circuit board.

[0055] Action 1010 can include preventing material from entering the housing 305. For example, the housing 305 can have a lip 355. The lip 355 can extend from the housing 305 at a location adjacent to the connector opening 350 of the housing 305. The lip 355 can form a barrier such that material must bypass or pass over the lip 355 before entering the housing 305 via the connector opening 350.

[0056] Method 1000 may include engaging a second docking element with a second engagement feature 210 (act 1015). Engaging the second docking element with the second engagement feature 210 may include inserting at least a portion of a protrusion 340 into the locating opening 220. Act 1015 may include preventing at least some lateral movement of the housing 305 relative to the unit carrier 115. For example, the housing 305 may have a protrusion 340. The protrusion 340 disposed in the locating opening 220 may prevent at least some lateral movement of the housing 305. For example, the locating opening 220 may be a first locating opening 220a, which may provide a two-way locating solution to prevent or reduce movement of the housing 305 in two lateral directions (e.g., up and down). The locating opening 220 may be a second locating opening 220b, which may provide a four-way locating solution to prevent or reduce movement of the housing 305 in four lateral directions (e.g., up and down and left and right). Act 1015 may include engaging a plurality of protrusions 340 of the housing 305 with a plurality of locating openings 220. For example, the first protrusion 340 may engage with the first positioning opening 220 a , and the second protrusion 340 may engage with the second positioning opening 220 b .

[0057] Action 1015 can include preventing the housing 305 from rotating relative to the unit carrier 115. For example, the housing 305 can have a post 405. The post 405 can interface with a bus bar 410 coupled to the unit carrier 115. The post 405 can prevent the housing 305 from rotating relative to the unit carrier 115. Action 1015 can include providing a gap with the bus bar 410. For example, the post 405 can abut the bus bar 410 to form a barrier between the bus bar 410 and other components of the BVT 120.

[0058] Fig.11A flow chart of a method 1100 for forming a battery subassembly 110 is depicted. The method 1100 may include loading at least one battery cell 910 into a cell carrier 115 (act 1105). The method 1100 may include applying an adhesive (e.g., a wicking adhesive) to the battery cell 910 or the cell carrier 115 to facilitate securing the battery cell 910 to the cell carrier 115 (act 1110). The method 1100 may include coupling a current collector assembly (CCA) to the battery cell 910 (act 1115). The method 1100 may include welding the CCA to at least one cell terminal (e.g., a button) (act 1120). The method 1100 may include coupling a first cell carrier 115, a thermal component, and a second cell carrier 115 together to form the battery subassembly 110 (act 1125). For example, at least a portion of an area between the battery cell 910 and the thermal component may be filled with a thermal adhesive to couple the thermal component to the battery cell 910. The method 1100 may include coupling the terminal busbars and the series busbars to the battery subassembly 110 (act 1130). The method 1100 may include coupling various components such as fuses, switches, current sensors, temperature sensors, voltage sensors, thermistors, contactors, etc. to the battery subassembly 110 (act 1135). For example, a thermistor harness and / or BVT 120 may be coupled to the battery subassembly 110, the thermistor harness and / or BVT being configured to receive electrical signals, data packets, measurements, sensor readings, or other data indicating characteristics of the battery subassembly 110 such as temperature, voltage, state of charge, and / or fault status for transmission to a battery management system (BMS).

[0059] Action 1135 may include aligning at least one protrusion 340 of housing 305 with positioning opening 220. For example, first protrusion 340 may be aligned with first positioning opening 220a, and second protrusion 340 may be aligned with second positioning opening 220b. Protrusion 340 may extend into positioning opening 220. Action 1135 may include aligning at least one tab 325 with retention opening 215. Tab 325 may extend through retention opening 215 and couple BVT 120 with unit carrier 110. For example, tab 325 may bend or deform slightly to enter retention opening 215, and return to its initial position to snap BVT 120 into place, thereby coupling BVT 120 with unit carrier 110.

[0060] With the BVT 120 coupled to the unit carrier 110, at least one lip 355 of the housing 305 may extend beyond an edge or side of the unit carrier 115. The lip 355 may prevent material (e.g., adhesives and potting materials) from contaminating or entering the BVT 120. Such material may block the connector 345 or the connector opening 350 and render the BVT 120 or a portion thereof inoperable. The lip 355 may prevent or reduce such contamination to protect the BVT 120 and the various components disposed therein.

[0061] Method 1100 may include potting (e.g., partially or completely filling the space between the cells with a compound to provide resistance to shock waves or vibrations) after coupling first carrier 110 to second carrier 110 with a thermal component disposed between carriers 110 (act 1140). Lip 355 of housing 305 may be a barrier to prevent potting material (or adhesive) from entering housing 305, connector 345, or connector opening 350. Method 1100 may include coupling the touch cover to the subassembly (act 1145).

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] For example, the description of positive and negative electrical characteristics can be reversed. For example, up and down or left and right can be reversed or interchanged based on the orientation of the system. 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 unit carrier defining a first engagement feature and a second engagement feature; The first engagement feature and the second engagement feature are configured to engage with a housing; and The unit carrier is configured to be coupled to the housing via at least one of the first engagement feature or the second engagement feature.

2. The device according to claim 1, comprising: The housing includes a first docking element and a second docking element; the first engagement feature being for receiving the first docking element to couple the housing to the unit carrier; as well as The second engagement feature is for receiving the second docking element to facilitate proper positioning of the housing relative to the unit carrier.

3. The device according to claim 1, comprising: The second engagement feature includes a first opening that provides a two-way positioning solution for the housing and a second opening that provides a four-way positioning solution for the housing.

4. The device according to claim 1, comprising: A balanced voltage and temperature module (BVT) includes the housing and a circuit board, wherein the circuit board is thermally riveted to the housing.

5. The device according to claim 1, comprising: A circuit board is disposed in the housing, the circuit board comprising a first side and a second side, the circuit board comprising electrical components on the first side and the second side.

6. The device according to claim 1, comprising: A circuit board is coupled to the housing, and when the housing is coupled to the unit carrier, the circuit board is spaced apart from the unit carrier.

7. The device according to claim 1, comprising: The housing includes a plurality of tabs and a plurality of protrusions; the first engagement feature including a plurality of retention openings with which the plurality of tabs engage to couple the housing to the unit carrier; as well as The second engagement feature includes a plurality of locating openings with which the plurality of protrusions engage to locate the housing relative to the unit carrier.

8. The device according to claim 1, comprising: A circuit board, wherein the circuit board is arranged in the housing; as well as The housing includes a connector to electrically couple an external component with the circuit board, the external component including at least one of a voltage sensor, a temperature sensor, or a communication component.

9. The device according to claim 1, comprising: The housing comprises: a connector opening that exposes the connector to the outside for electrical coupling with an external component; and A lip extends from a side of the housing adjacent the connector opening, the lip preventing material from entering the connector opening and the connector.

10. The device according to claim 1, comprising: The housing includes a post that abuts a bus bar coupled to the unit carrier, the post being used to provide clearance from the bus bar and prevent the housing from rotating relative to the unit carrier.

11. A method comprising: providing a unit carrier comprising a first engagement feature and a second engagement feature; engaging a first docking element with the first engagement feature to couple the housing to the unit carrier; as well as A second docking element is engaged with the second engagement feature to prevent at least some lateral movement of the housing relative to the unit carrier.

12. The method according to claim 11, comprising: placing a circuit board in the housing; as well as The circuit board is coupled to the housing via heat staking.

13. The method according to claim 11, comprising: A circuit board is coupled to the housing, the circuit board being arranged away from the unit carrier when the housing is coupled to the unit carrier, the circuit board comprising a first side and a second side, the circuit board comprising electrical components on the first side and the second side.

14. The method of claim 11, wherein the first engagement feature comprises a plurality of retaining openings and the second engagement feature comprises a plurality of locating openings, the method comprising: engaging a plurality of tabs of the housing with the plurality of retaining openings; as well as The plurality of protrusions of the housing are engaged with the plurality of positioning openings.

15. The method according to claim 11, comprising: preventing the housing from rotating relative to the unit carrier via a post of the housing; as well as A clearance to the busbars of the unit carrier is provided via the uprights.

16. The method according to claim 11, comprising: Material is prevented from entering the housing via a lip of the housing that extends from the housing at a location adjacent a connector opening of the housing.

17. A subassembly comprising: A housing is coupled to the unit carrier, and the housing comprises: a first docking element coupling the housing to the unit carrier; and A second docking element, which facilitates proper positioning of the housing relative to the unit carrier.

18. The subassembly of claim 17, comprising: A circuit board is disposed in the housing, the circuit board comprises a first side and a second side, and the circuit board comprises electronic devices located on the first side and the second side.

19. The subassembly of claim 17, comprising: The housing includes posts for providing clearance from busbars of the unit carrier and preventing rotation of the housing relative to the unit carrier.

20. The subassembly of claim 17, comprising: A circuit board, wherein the circuit board is arranged in the housing; as well as The housing comprises: a connector for electrically coupling an external component to the circuit board; and A lip extends from a side of the housing adjacent to the connector, the lip being used to prevent material from entering the connector.

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