Mounting hole seal for vehicle battery pack

Abstract

According to a non-limiting example, a battery pack for a vehicle includes a housing including a base, a plurality of sidewalls, and a cover extending across the plurality of sidewalls. The cover includes an outer surface portion and an inner surface portion, and an aperture extending through the outer surface portion and the inner surface portion. A grommet having a central opening is disposed in the bore. The grommet includes a first portion engaging the outer surface portion, a second portion engaging the inner surface portion, and a connecting portion connecting the first portion and the second portion. A compression limiter having a channel is mounted in the central opening of the grommet. The compression limiter includes a flange surrounded by a first portion of the grommet and a support portion extending through a connecting portion to a second portion of the grommet.

Description

Technical Field

[0001] The present invention relates to the field of vehicle battery packs, and more particularly, to a mounting hole seal for a vehicle battery pack. Background Art

[0002] The vehicle battery pack includes a housing surrounding a plurality of battery modules that encapsulate battery cells. The housing includes a sealed cover. The battery pack is mounted in the vehicle via the cover. Typically, the battery pack is located below the vehicle and against a lower surface. Fasteners pass from the interior space of the vehicle through the floor of the vehicle, through the cover, and engage the battery pack. Once tightened, the battery pack is secured to the vehicle.

[0003] After manufacturing, and prior to shipping to the assembly facility, a vacuum is created in the housing. The vacuum is part of the end-of-line vacuum test for the housing, ensuring that the battery pack is properly sealed for shipping. The holes in the cover that receive the fasteners present an obstacle to creating the shipping vacuum. Therefore, it is desirable to provide a seal that will close the holes to allow a vacuum to be drawn in the housing and still provide access for the mechanical fasteners used to mount the battery pack to the vehicle. Summary of the invention

[0004] According to a non-limiting example, a battery pack for a vehicle includes a housing including a base, a plurality of side walls, and a cover extending across the plurality of side walls. The cover includes an outer surface portion and an inner surface portion and a hole extending through the outer surface portion and the inner surface portion. A grommet having a central opening is arranged in the hole. The grommet includes a first portion engaging the outer surface portion, a second portion engaging the inner surface portion, and a connecting portion connecting the first portion and the second portion. A compression limiter having a channel is installed in the central opening of the grommet. The compression limiter includes a flange surrounded by a first portion of the grommet and a support portion extending through the connecting portion to the second portion of the grommet. A plug is arranged in the channel.

[0005] In addition to one or more features described herein, a connecting member is disposed between the housing and the cover, the connecting member including a threaded channel aligned with the hole in the cover.

[0006] In addition to one or more features described herein, the support portion of the compression member abuts the connecting member.

[0007] In addition to one or more features described herein, the first portion of the grommet includes a first thickness and the flange includes a second thickness different than the first thickness.

[0008] In addition to one or more features described herein, the first thickness is greater than the second thickness.

[0009] In addition to one or more features described herein, the flange of the compression limiter includes an annular groove, and the first portion of the grommet overlaps the annular groove.

[0010] In addition to one or more features described herein, the grommet is formed from a resilient material.

[0011] In addition to one or more features described herein, the compression limiter is formed from a non-elastic material.

[0012] In addition to one or more features described herein, the non-elastic material includes one of a metal and a metal alloy.

[0013] In addition to one or more features described herein, the plug is formed of a self-healing pierceable resilient material.

[0014] According to a non-limiting example, a vehicle includes a body defining a passenger compartment, the passenger compartment having a floor including an inner surface and an outer surface. A battery pack is mounted to the outer surface of the floor. The battery pack includes a housing including a base, a plurality of side walls, and a cover extending across the plurality of side walls. The cover includes an outer surface portion and an inner surface portion and a hole extending through the outer surface portion and the inner surface portion. A grommet having a central opening is arranged in the hole. The grommet includes a first portion engaging the outer surface portion, a second portion engaging the inner surface portion, and a connecting portion connecting the first portion and the second portion. A compression limiter having a channel is installed in the central opening of the grommet. The compression limiter includes a flange surrounded by a first portion of the grommet and a support portion extending through the connecting portion to the second portion of the grommet. A plug is arranged in the channel. A fastener extends through the floor into the plug. The fastener secures the battery pack to the outer surface of the floor.

[0015] In addition to one or more features described herein, a connecting member is disposed between the housing and the cover. The connecting member includes a threaded channel aligned with the hole in the cover. A fastener extends through the plug and engages with the threaded channel.

[0016] In addition to one or more features described herein, the support portion of the compression member abuts the connecting member.

[0017] In addition to one or more features described herein, the first portion of the grommet includes a first thickness and the flange includes a second thickness different than the first thickness.

[0018] In addition to one or more features described herein, the first thickness is greater than the second thickness.

[0019] In addition to one or more features described herein, the flange of the compression limiter includes an annular groove, and the first portion of the grommet overlaps the annular groove.

[0020] In addition to one or more features described herein, the grommet is formed from a resilient material.

[0021] In addition to one or more features described herein, the compression limiter is formed from a non-elastic material.

[0022] In addition to one or more features described herein, the non-elastic material includes one of a metal and a metal alloy.

[0023] In addition to one or more features described herein, the plug is formed of a self-healing pierceable resilient material.

[0024] The above features and advantages and other features and advantages of the present disclosure will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, advantages and details appear, by way of example only, in the following detailed description, which refers to the accompanying drawings, in which:

[0026] Figure 1 is a left side view of a vehicle including a battery pack having a mounting hole seal according to a non-limiting example;

[0027] Figure 2 According to a non-limiting example, a plurality of mounting hole seals are included. Figure 1 A partial perspective view of a battery pack;

[0028] Figure 3 is a cross-sectional side view of a portion of a battery pack connected to a vehicle according to a non-limiting example;

[0029] Figure 4 is a perspective view of a mounting hole seal according to a non-limiting example;

[0030] Figure 5 Is installed in Figure 2 A cross-sectional view of a mounting hole seal in a cover of a battery pack; and

[0031] Figure 6 According to non-limiting examples Figure 4 Exploded view of the mounting hole seal. DETAILED DESCRIPTION

[0032] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0033] According to a non-limiting example, the vehicle Figure 11. The vehicle 10 is generally indicated at 10. The vehicle 10 includes a body 12 supported on a plurality of wheels 16. The body 12 partially defines a passenger compartment 20 having a seat 23 located behind an instrument panel 26. A steering controller 30 is disposed between the seat 23 and the instrument panel 26. The steering controller 30 is operated to control the orientation of the steering wheel. The vehicle 10 includes an electric drive motor 34 that provides power to one or more of the plurality of wheels 16.

[0034] A rechargeable energy storage system (RESS) or battery pack 38 is mounted to the vehicle body 12. The battery pack 38 provides power to the electric drive motor 34. At this point, it should be understood that the location of the electric drive motor 34 and the battery pack 38 in the vehicle 10 may vary. In a non-limiting example, the passenger compartment 20 includes a floor 40 ( Figure 3 As will be described in detail herein, the battery pack 38 is mounted to an outer surface 44 of the floor pan 40 beneath the vehicle 10. In a non-limiting example, Figure 2 The support member 48 may provide additional support and protection for the battery pack 38 .

[0035] exist Figure 2 In the non-limiting example shown, the battery pack 38 includes a housing 50 having a base 54 and a plurality of side walls 56 connected to and extending from the base 54. A cover 58 is positioned across the plurality of side walls 56. The housing 50 contains a plurality of battery cells (not shown) that can receive, store, and release electrical energy. Figure 5 As shown, the cover 58 includes an outer surface portion 60 and an inner surface portion 62. A plurality of holes 64 extend through the cover 58. The holes 64 provide passage for mechanical fasteners 66 to pass through the cover 58 and into the battery pack 38.

[0036] like Figure 3 As shown, a plurality of mechanical fasteners 66 pass through the floor 40 in the passenger compartment 20 and are connected to the battery pack 38, as will be described in detail herein. Each of the plurality of mechanical fasteners 66 passes through the floor 40 into a corresponding one of the plurality of holes 64 in the cover 58 of the battery pack 38. In a non-limiting example, the battery pack 38 includes a connection member 74 disposed below the cover 58. The connection member 74 includes a surface 77, and the surface 77 includes a plurality of threaded channels 79. Each of the plurality of mechanical fasteners 66 is connected to a corresponding one of the threaded channels 79 to secure the battery pack 38 to the vehicle body 12.

[0037] exist Figure 3 and Figure 5In the non-limiting example shown, a seal assembly 82 is secured in each of the plurality of apertures 64 in the cover 58. The seal assembly 82 has multiple functions. First, the seal assembly 82 closes the aperture 64 so that the battery pack 38 can undergo a post-manufacturing vacuum inspection to ensure that the housing 50 is properly sealed. The seal assembly 82 also closes the aperture 64 to prevent contamination during transportation from the manufacturing facility to the installation facility. The seal assembly 82 also provides a sealed passage for the mechanical fastener 66. Figure 4 As shown, the sealing assembly 82 includes a grommet 84, a compression limiter 86, and a plug 88. The grommet 84 may be formed from a variety of materials, including elastomeric materials, non-elastomeric materials, metallic materials, and materials formed from various mixtures or alloys, including metal alloys.

[0038] Will refer to Figure 5 and 6 , and continue to refer to Figure 4 The seal assembly 82 is described. In a non-limiting example, the grommet 84 includes a first portion 92, a second portion 94, and a connecting portion 96 extending along a sealing axis "S" between the first portion 92 and the second portion 94. The grommet 84 includes a central opening 100 passing through the first portion 92, the second portion 94, and the connecting portion 96. The grommet 84 penetrates into the hole 64. The first portion 92 rests on the outer surface portion 60 of the cover 58 and includes an annular groove 104. The second portion 94 includes a barb portion 106 that engages the inner surface portion 62 of the cover 58. The first portion 92 includes a first thickness along the sealing axis "S".

[0039] In a non-limiting example, the compression limiter 86 is designed to support compressive loads that may be formed when the battery pack 38 is installed to the vehicle body 12 without inhibiting the sealing effect. The compression limiter 86 includes a flange 108 having a second thickness along the sealing axis "S" that is less than the first thickness. As will be described in detail herein, the flange 108 is nested within the first portion 92 of the grommet 84. The compression limiter 86 also includes a support portion 110 having a channel 112. The support portion 110 extends from the flange 108 through the connecting portion 96 of the grommet 84 and abuts the surface 77 of the connecting member 74 when installed in the hole 64.

[0040] In a non-limiting example, the flange 108 includes an annular groove 114 that forms an annular step 116. The annular step 116 is received by the annular groove 104 in the first portion 92 of the grommet 84. The first portion 92 of the grommet 84 overlaps the annular step 116. The plug 88 is installed in the channel 112 of the compression limiter 86. The plug 88 includes a substantially cylindrical cross-section and is formed of a self-healing material. That is, when punctured, the plug 88 surrounds and seals the mechanical fastener 66.

[0041] In operation, the sealing assembly 82 can seal the hole 64 and maintain the vacuum in the housing 50. The sealing assembly 82 can also prevent dust, water and other debris from entering the housing 50 during transportation. When installed, the mechanical fasteners 66 pass through the base plate 40, through the plug 88, and engage the connecting member 74 through the threaded passage 79. As each mechanical fastener 66 is tightened, the inner surface portion 72 of the gasket 68 is pressed against the compression limiter 86. The support portion 110 of the compression limiter 86 engages the connecting member 74, limiting the compressive force applied to the grommet 84. In this way, the grommet 84 continues to seal the hole 64 after the battery pack 38 is installed to the vehicle body 12.

[0042] The terms "one" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced items. The term "or" means "and / or", unless the context clearly indicates otherwise. References to "an aspect" throughout the specification mean that a particular element (e.g., feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in various aspects.

[0043] When an element such as a layer, film, region, or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.

[0044] Unless otherwise indicated herein, all test standards are the most recent standards in effect as of the filing date of the present application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0045] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0046] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from the scope thereof. In addition, many modifications may be made to adapt specific situations or materials to the teachings of the disclosure without departing from the essential scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery pack for a vehicle, comprising: a housing comprising a base, a plurality of side walls, and a cover extending across the plurality of side walls, the cover comprising an outer surface portion and an inner surface portion and an aperture extending through the outer surface portion and the inner surface portion; a grommet having a central opening disposed in the hole, the grommet including a first portion engaging the outer surface portion, a second portion engaging the inner surface portion, and a connecting portion connecting the first portion and the second portion; a compression limiter having a passage mounted in the central opening of the grommet, the compression limiter including a flange surrounded by a first portion of the grommet and a support portion extending through the connecting portion to a second portion of the grommet; as well as A plug is disposed in the channel. 2 . The battery pack of claim 1 , further comprising a connecting member disposed between the housing and the cover, the connecting member comprising a threaded channel aligned with the hole in the cover.

3. The battery pack according to claim 2, wherein: The support portion of the compression limiter abuts the connecting member.

4. The battery pack according to claim 1, wherein: The first portion of the grommet includes a first thickness, and the flange includes a second thickness different than the first thickness.

5. The battery pack according to claim 4, wherein: The first thickness is greater than the second thickness.

6. The battery pack according to claim 1, wherein: The flange of the compression limiter includes an annular groove, and the first portion of the grommet overlaps the annular groove.

7. The battery pack according to claim 1, wherein: The grommet is formed of an elastic material.

8. The battery pack according to claim 7, wherein: The compression limiter is formed of a non-elastic material.

9. The battery pack according to claim 1, wherein: The plug is formed of a self-healing pierceable elastic material.

10. A vehicle comprising: a vehicle body defining a passenger compartment having a floor including an inner surface and an outer surface; as well as The battery pack as claimed in claim 1, mounted to an outer surface of the base plate.

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