MODULAR HOUSING FOR ELECTRONIC COMPONENTS

Abstract

Aspects of the present disclosure relate to a housing for one or more electrical components of a battery pack. The housing may be configured to mechanically and electrically couple to a power volume of the battery pack. The housing may include an access panel. The access panel may be formed from a solid insulating structure configured to at least partially cover the one or more electrical components and a conductive layer on a surface of the solid insulating structure. The housing may be a modular housing that can be used to provide electrical connection to any different power volumes, including batteries or battery cells with different cell chemistries.

Description

INTRODUCTION

[0001] Batteries are widely used as a power source, including as a power source for electric vehicles, which include wheels driven by an electric motor that receives power from the battery.

[0002] Aspects of the subject technology may contribute to improving the efficiency, maintainability, and / or range of electric vehicles, which may contribute to mitigating climate change by reducing greenhouse gas emissions. SUMMARY

[0003] Aspects of the subject technology relate to a modular enclosure for electronic components for a battery pack. For example, the power electronics for a battery pack (e.g., with a pack frame enclosing one or more battery cells) may be housed in a separate enclosure on the rear of the battery pack. The electronic components in the separate enclosure may be serviceable by removing an access panel of the enclosure (e.g., under a rear vehicle seat). The enclosure may be made (e.g., primarily) of plastic or other insulating materials to reduce the mass and weight of the enclosure, and may be lined or coated with a conductive material, such as a film, coating, or resin, to provide electromagnetic interference (EMI) protection and / or electromagnetic compatibility (EMC).The enclosure may also include one or more metal layers and / or features on or at a base plate of the enclosure for grounding purposes. The enclosure may be modular to provide mechanical and / or electrical connection with different energy volumes for different battery packs.

[0004] According to aspects of the subject technology, a device is provided that includes a housing for one or more electrical components for a battery pack. The housing may be configured to mechanically and electrically couple to an energy volume of the battery pack. The housing may include an access panel comprised of a solid insulating structure configured to at least partially cover one or more electrical components; and a conductive layer on a surface of the solid insulating structure. The surface of the solid insulating structure may include an interior surface of the solid insulating structure. The conductive layer may include at least one of the following: a film, a coating, or a resin. The housing may further include a tray configured for mounting the one or more electrical components thereon.The tray and the access door may be configured to at least partially enclose the one or more electrical components.

[0005] The shell may include a rigid insulating shell, and the housing may further include at least one grounding structure coupled to the rigid insulating shell. The at least one grounding structure may include a metal, and the rigid insulating shell may be overmolded onto the metal. The rigid insulating shell may include a plurality of molded features configured to support the one or more electrical components. The housing may further include a rigid insulating tray disposed between the shell and the access panel. The access panel and the shell may be configured to be attached to the rigid insulating tray, and the rigid insulating tray may include an additional conductive layer on a surface of the rigid insulating tray. The rigid insulating tray may include a plurality of ribs configured to provide structural strength to the rigid insulating tray.

[0006] The shell may include an outer surface having a first portion configured to connect to a frame of the energy volume of the battery pack and a second portion configured to extend beyond the frame of the energy volume of the battery pack. The shell may include one or more first openings in the first portion of the outer surface for receiving one or more high-voltage connectors for one or more battery cells within the frame of the energy volume and one or more second openings in the second portion of the outer surface for receiving one or more high-voltage output connectors connected to the one or more electrical components. The shell may include one or more third openings in the second portion, wherein the one or more third openings are configured to receive one or more coolant ports for the enclosure.The fixed insulation tray may include a bar for mounting a flange of one of the one or more electrical components.

[0007] The shell may include a solid insulating shell, a conductive layer on an inner surface of the shell, and molded metal on an outer surface of the shell, and the housing may further include a support structure including a plurality of molded features configured to support the one or more electrical components.

[0008] The shell may include a metal shell, and the housing may further include a support structure including a plurality of shaped features configured to support the one or more electrical components. The housing may further include a shell including a rigid insulating structure configured to mount the one or more electrical components thereto. The access panel may be configured to be directly attached to the shell to at least partially enclose the one or more electrical components. The housing may further include a support structure including a plurality of shaped features configured to support the one or more electrical components within the housing formed by the rigid insulating structure and the access panel.

[0009] According to other aspects of the disclosure, a vehicle including a battery pack may be provided, the battery pack including a housing for one or more electrical components for the battery pack, the housing configured to be mechanically and electrically coupled to a power volume of the battery pack. The housing may include an access panel comprised of a rigid insulating structure configured to at least partially cover one or more electrical components; and a conductive layer on a surface of the rigid insulating structure.

[0010] The enclosure may further include a central structure including a rigid insulating structure, a conductive layer on an inner surface of the rigid insulating structure, and ribbing configured to provide structural shock resistance to the enclosure. The enclosure may further include a bottom plate, wherein the bottom plate and the access plate are configured to be secured to the central structure to form the enclosure. The enclosure may further include a support structure configured to be secured within a frame of the battery pack and to an overhang on the bottom plate to provide structural shock resistance to the vehicle.

[0011] The center structure may further include a sealing feature for tightly securing the housing to a body structure of the vehicle. The base plate may further include a plurality of gaskets for sealing a plurality of high-voltage terminals between the housing and the battery pack.

[0012] According to other aspects of the disclosure, a method of assembling a vehicle may be provided, the method including: attaching one or more electrical components to a rigid insulating shell having at least one grounding structure thereon; mounting a rigid insulating tray having a conductive layer to the rigid insulating shell; attaching one or more additional electrical components to the rigid insulating tray; forming an enclosure for the one or more electrical components and the one or more additional electrical components by attaching an access panel to the rigid insulating tray; attaching the enclosure to a frame for a power volume for a battery pack; and attaching the enclosure and the frame to one or more body structures of the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Certain features of the subject technology are set forth in the appended claims. However, for illustrative purposes, several embodiments of the subject technology are set forth in the following figures. Fig. 1A and Fig. 1B illustrate schematic perspective side views of example implementations of a vehicle with a battery pack according to one or more implementations. Fig. Figure 1C illustrates a schematic perspective view of a building with a battery pack according to one or more implementations. Fig. 2A illustrates an example perspective view of a battery pack according to one or more implementations. Fig. 2B illustrates schematic perspective views of various battery modules that may be included in a battery pack according to one or more implementations. Fig. 2C illustrates a cross-sectional end view of a battery cell according to one or more implementations. Fig. 2D illustrates a perspective cross-sectional view of a cylindrical battery cell according to one or more implementations. Fig. 2E illustrates a perspective cross-sectional view of a prismatic battery cell according to one or more implementations. Fig. 2F illustrates a perspective cross-sectional view of a pouch battery cell according to one or more implementations. Fig. 3 illustrates a schematic cross-sectional side view of a battery pack according to one or more implementations. Fig. 4 illustrates a top perspective view of a portion of a battery pack according to one or more implementations. Fig. 5 illustrates an exploded perspective view of a modular housing for one or more electrical components for a battery pack according to one or more implementations. Fig. 6 illustrates a bottom perspective view of a subassembly of a modular housing for one or more electrical components for a battery pack according to one or more implementations. Fig. 7A illustrates a bottom perspective view of a modular housing for one or more electrical components for a battery pack according to one or more implementations. Fig. 7B illustrates a perspective view of a high and low voltage feedthrough assembly for a modular enclosure according to one or more implementations. Fig. Figure 7C illustrates an exploded perspective view of the assembly of Fig. 7B according to one or more implementations. Fig. Figure 7D illustrates a top view of the assembly of Fig. 7B according to one or more implementations. Fig. 7E illustrates a top perspective view of another implementation of a high and low voltage feedthrough assembly for a modular housing with a top housing removed, according to one or more implementations. Fig. Figure 7F illustrates a top perspective view of a portion of the assembly of Fig. 7E with upper enclosure installed according to one or more implementations. Fig. 8 illustrates a cross-sectional side view of a modular housing for one or more electrical components for a battery pack according to one or more implementations. Fig. 9 illustrates a cross-sectional side view of a tray for a modular housing for one or more electrical components for a battery pack according to one or more implementations. Fig. 10 illustrates a perspective cross-sectional side view of a portion of a battery pack having a modular housing for one or more electrical components for the battery pack, according to one or more implementations. Fig. 11 illustrates a bottom perspective view of a portion of a battery pack having a modular housing for one or more electrical components for the battery pack, according to one or more implementations. Fig. 12 illustrates a top perspective view of a modular housing coupled to a body structure of a vehicle, according to one or more implementations. Fig. 13 illustrates a bottom view of a modular housing coupled to a body structure of a vehicle, according to one or more implementations. Fig. 14 illustrates an exploded perspective view of another example of a modular housing for one or more electrical components for a battery pack according to one or more implementations. Fig. 15 illustrates an exploded perspective view of another example of a modular housing for one or more electrical components for a battery pack according to one or more implementations. Fig. 16 illustrates an exploded perspective view of another example of a modular housing for one or more electrical components for a battery pack according to one or more implementations. Fig. 17 illustrates a flowchart of illustrative operations that may be performed to assemble a vehicle, according to one or more implementations. DETAILED DESCRIPTION

[0014] The following detailed description is intended as a description of various configurations of the present technology and is not intended to represent the only configurations in which the present technology may be practiced. The accompanying drawings are incorporated herein and form a part of the detailed description. The detailed description includes specific details for the purpose of providing a thorough understanding of the subject technology. However, the present technology is not limited to the specific details set forth herein and may be practiced using one or more other implementations. In one or more implementations, structures and components are shown in block diagram form to avoid obscuring the concepts of the present technology.

[0015] Aspects of the subject technology described herein relate to a modular electronic component housing for battery packs. The modular electronic component housing may include a housing body enclosing one or more electrical and / or electronic components for distributing power from a power volume of a battery pack. The modular electronic component housing may be mechanically and electrically coupled to the power volume of various battery packs of different sizes and / or battery cells of different cell chemistries.According to one or more implementations of the subject technology, the modular housing for electronic components may be primarily made of strong, lightweight, and / or insulating materials and may include conductive layers and / or elements for managing electromagnetic interference (EMI), electromagnetic compatibility (EMC), and / or grounding properties.

[0016] Fig. 1A is a diagram illustrating an exemplary implementation of a movable device as described herein. In the example of Fig. 1A, a movable device is implemented as a vehicle 100. As shown, the vehicle 100 may include one or more battery packs, such as the battery pack 110. The battery pack 110 may be coupled to one or more electrical systems of the vehicle 100 to provide power to the electrical systems.

[0017] In one or more implementations, vehicle 100 may be an electric vehicle having one or more electric motors that drive the vehicle's wheels 102 using electrical power from battery pack 110. In one or more implementations, vehicle 100 may also, or alternatively, include one or more chemically powered engines, such as a gas-powered engine or a fuel cell-powered engine. Electric vehicles may, for example, be fully electric or partially electric (e.g., hybrid or plug-in hybrid).

[0018] In the example of Fig. 1A, the vehicle 100 is implemented as a flatbed truck (e.g., a pickup truck) with a battery pack 110. As shown, the battery pack 110 may include one or more battery modules 115, which may include one or more battery cells 120. As shown in Fig. 1A, the battery pack 110 may also include one or more battery cells 120 mounted directly within the battery pack 110 (e.g., in a cell-to-pack configuration). In one or more implementations, the battery pack 110 may be provided without any battery modules 115 and with the battery cells 120 mounted directly within the battery pack 110 (e.g., in a cell-to-pack configuration) and / or in other battery units installed within the battery pack 110. A vehicle battery pack may include multiple energy storage devices, which may be arranged in units such as battery modules or battery units. A battery unit or battery module may include an array of cells that may be combined with other elements (e.g., structural frames, thermal management devices) that may protect the array of cells from heat, impact, and / or vibration.

[0019] For example, battery cell 120 may include a battery, a battery unit, a battery module, and / or a battery pack for power components of vehicle 100. For example, a battery cell housing of battery cell 120 may be disposed in battery module 115, battery pack 110, a battery array, or other battery unit installed in vehicle 100.

[0020] As discussed in more detail below, the battery cells 120 may be provided with a battery cell housing, which may be provided with any of various external shapes. The battery cell housing may be a rigid housing in some implementations (e.g., for cylindrical or prismatic battery cells). The battery cell housing may also, or alternatively, be formed as a pouch or other flexible or moldable housing for the battery cell in some implementations. In various other implementations, the battery cell housing may be provided with any other suitable external shape, such as a triangular external shape, a square external shape, a rectangular external shape, a pentagonal external shape, a hexagonal external shape, or any other suitable external shape. In some implementations, the battery pack 110 may not include any modules (e.g.,the battery pack may be module-free). For example, the battery pack 110 may have a module-free or cell-to-pack configuration in which the battery cells 120 are arranged directly into a battery pack 110 without being arranged into a module 115. In one or more implementations, the vehicle 100 may include one or more bus bars, electrical connectors, or other charge collection, current collection, and / or coupling components to provide electrical power from the battery pack 110 to various systems or components of the vehicle 100. In one or more implementations, the vehicle 100 may include control circuitry, such as a power step-down circuit, which may be used to convert DC power from the battery pack 110 to AC power for one or more components and / or systems of the vehicle (e.g.,including one or more power outlets of the vehicle and / or the motor(s) that drive the vehicle's wheels 102). The power stage circuit may be provided as part of the battery pack 110 or separately from the battery pack 110 within the vehicle 100. The vehicle 100 may have a front end 131 and a rear end 133.

[0021] The example of Fig. 1A, in which the vehicle 100 is implemented as a pickup truck with a flatbed at the rear portion thereof, is merely illustrative. Fig. For example, Figure 1B illustrates another implementation in which the vehicle 100, including the battery pack 110, is implemented as an SUV (Sports Utility Vehicle), such as an electric SUV. In the example of Fig. 1B, the vehicle 100 including the battery pack 110 may include a cargo storage area enclosed within the vehicle 100 (e.g., behind a row of seats within a cab of the vehicle). In other implementations, the vehicle 100 may be implemented as another type of electric pickup truck, electric delivery truck, electric automobile, electric vehicle, electric motorcycle, electric scooter, electric bicycle, electric passenger car, electric travel or utility truck, hybrid vehicle, an aircraft, a watercraft, and / or any other mobile device that includes a battery pack 110 (e.g., a battery pack or other battery unit that powers propulsion or drive components of the mobile device).

[0022] In one or more implementations, a battery pack such as battery pack 110, a battery module 115, a battery cell 120, and / or any other battery unit as described herein may also, or alternatively, be implemented as an electrical power supply and / or energy storage system in a building, such as a residential building or a commercial building. For example, Fig. 1C illustrates an example where a battery pack 110 is implemented in a building 180. For example, the building 180 may be a residential building, a commercial building, or any other building. As shown, in one or more implementations, a battery pack 110 may be mounted on a wall of the building 180.

[0023] As shown, the battery 110A installed in the building 180 may be coupled to the battery pack 110 in the vehicle 100, such as via: a cable / connector 106 that may be connected to the charging port 130 of the vehicle 100, a vehicle electric supply equipment (EVSE) 170, a power stage circuit 172, and / or a cable / connector 174. For example, the cable / connector 106 may be coupled to the EVSE 170, which may be coupled to the battery 110A via the power stage circuit 172 and / or may be coupled to an external power source 190. In this way, either the external power source 190 or the battery 110A installed in the building 180 can be used as an external power source to charge the battery pack 110 in some use cases in the vehicle 100. In some examples, the battery 110A installed in the building 180 can also, or alternatively, (e.g.,The battery pack 110 in the vehicle 100 may be coupled to the external power source 190 (e.g., via a cable / connector 174, the power step-down circuit 172, and the EVSE 170). For example, the external power source 190 may be a solar power source, a wind power source, and / or an electrical grid of a city or other geographic region (e.g., an electrical grid fed by a remote power facility). For example, at times when the battery pack 110 in the vehicle 100 is not coupled to the battery 110A installed in the building 180, the battery 110A installed in the building 180 may be coupled to the external power source 190 (e.g., using the power step-down circuit 172 for the building 180) to charge and store electrical energy.In some use cases, this stored electrical energy in the battery 110A installed in the building 180 may later be used to charge the battery pack 110 in the vehicle 100 (e.g., during times when solar or wind power is unavailable, in the event of a regional or local power outage for the building 180, and / or during a period of high access rates to the power grid).

[0024] In one or more implementations, the power stage circuit 172 may electrically couple the battery 110A installed in the building 180 to an electrical system of the building 180. For example, the power stage circuit 172 may convert direct current from the battery 110A to alternating current for one or more loads in the building 180. For example, the battery 110A installed in the building 180 may be used to power one or more lights, lamps, appliances, fans, heaters, air conditioners, and / or other electrical components or electrical loads in the building 180 (e.g., via one or more electrical outlets coupled to the battery 110A installed in the building 180).For example, the power stage circuit 172 may include control circuitry operable to switchably couple the battery 110A between the external power source 190 and one or more electrical outlets and / or other electrical loads in the electrical system of the building 180. In one or more implementations, the vehicle 100 may include a power stage circuit (in . Fig. 1C not shown) that can be used to convert power received from the vehicle electrical supply equipment 170 into direct current used to power / charge the battery pack 110 of the vehicle 100 and / or to convert direct current from the battery pack 110 into alternating current for one or more electrical systems, components, and / or loads of the vehicle 100.

[0025] In one or more use cases, the battery 110A installed in the building 180 may be used as an electrical power source for the building 180, such as during times when solar or wind power is unavailable, in the event of a regional or local power outage for the building 180, and / or during a period of high access rates to the electrical grid (as examples). In one or more other use cases, the battery pack 110 installed in the vehicle may be used to charge the battery 110A installed in the building 180 and / or to power the electrical system of the building 180 (e.g.,in a use case where the battery 110A installed in the building 180 has little or no energy stored and where solar or wind power is unavailable, a regional or local power outage for the building 180 occurs, and / or a period of high access rates to the power grid (as examples).

[0026] Fig. 2A illustrates an example battery pack 110 according to one or more implementations. As shown, the battery pack 110 may include a battery pack frame 205 (e.g., a battery pack housing or a pack frame). For example, the battery pack frame 205 may house or enclose a power volume 207 for the battery pack 110, where the power volume 207 includes one or more battery modules 115 and / or one or more battery cells 120 and / or other battery pack components. In one or more implementations, the battery pack frame 205 may include or form a shielding structure on an exterior surface thereof (e.g., a bottom thereof and / or beneath one or more battery modules 115, battery units, batteries, and / or battery cells 120) to protect the battery module 115, battery units, batteries, and / or battery cells 120 from external conditions (e.g.,when the battery pack 110 is installed in a vehicle 100 and the vehicle 100 is driven over rough terrain, such as off-road terrain, ditches, rocks, rivers, streams, etc.).

[0027] The battery pack 110 may include, within the energy volume 207 and the battery pack frame 205, a plurality of battery cells 120 (e.g., installed directly within the battery pack 110 or within batteries, battery units, and / or battery modules 115 as described herein) and / or battery modules 115 and one or more conductive coupling elements for coupling a voltage generated by the battery cells 120 to a power-consuming component, such as the vehicle 100 and / or a building electrical system 180. For example, the conductive coupling elements may include internal connectors and / or contactors that couple a plurality of battery cells 120, battery units, batteries, and / or a plurality of battery modules 115 within the battery pack frame 205 to generate a desired output voltage for the battery pack 110.

[0028] As shown, the battery pack 110 may also include a modular housing 290 (e.g., a modular housing for electronic components or a modular housing for electrical components) mounted to the battery pack frame 205. In one or more implementations, the modular housing 290 may include one or more conductive coupling elements for conducting power from the battery cells 120 and / or battery modules 115 within the pack frame 205 (e.g., within the energy volume 207) to one or more external connection terminals, such as an electrical contact 203 (e.g., a high-voltage terminal or connector). For example, an electrical cable or wire harness may be connected between the electrical contact 203 and an electrical system of the vehicle 100 or the building 180 to provide electrical power to the vehicle 100 or the building 180.The battery pack frame 205 may have a front end 267 and a rear end 269. In one or more implementations, when the battery pack 110 is installed in the vehicle 100, the battery pack 110 may be arranged with the front end 267 closer to the front end 131 of the vehicle and the rear end 269 closer to the rear end 133 of the vehicle. As shown, in one or more implementations, the modular housing 290 may be mounted at or near the rear end 269 of the pack frame 205.

[0029] In one or more implementations, the battery pack 110 may include one or more additional features (e.g., cooling lines and / or plates and / or heating lines and / or plates). For example, the thermal control structures may couple thermal control structures and / or fluids to the battery modules 115, battery units, batteries, and / or battery cells 120 within the battery pack frame 205, such as by distributing fluid throughout the battery pack 110.

[0030] For example, the thermal control structures may form part of a thermal / temperature control or heat exchange system that includes one or more thermal components, such as plates or bladders, positioned in thermal contact with one or more battery modules 115 and / or battery cells 120 disposed within the battery pack frame 205. For example, a thermal component may be positioned in contact with one or more battery modules 115, battery units, batteries, and / or battery cells 120 within the battery pack frame 205. In one or more implementations, the battery pack 110 may include one or more thermal control structures and / or other thermal components for each of a plurality of upper and lower battery module pairs. As shown, the battery pack 110 may include an electrical contact 203 (e.g.,a high-voltage connector or terminal) through which an external load (e.g., the vehicle 100 or an electrical system of the building 180) can be electrically coupled to the battery modules and / or battery cells in the battery pack 110.

[0031] Fig. 2B illustrates various examples of battery modules 115 that may be arranged in the battery pack 110 (e.g., within the battery pack frame 205 of Fig. 2A). In the example of Fig. 2B, a battery module 115A is shown including a battery module housing 223 having a rectangular cuboid shape with a length substantially similar to its width. In this example, the battery module 115A includes a plurality of battery cells 120 implemented as cylindrical battery cells. In this example, the battery module 115A includes rows and columns of cylindrical battery cells coupled together by an interconnect structure 200 (e.g., a power connector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together and / or couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115A may include a charge collector or bus bar 202.For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120 to provide a high voltage output from the battery module 115A.

[0032] Fig. 2B also shows a battery module 115B having an elongated shape in which the length of the battery module housing 223 (e.g., extending along a direction from a front end of the battery pack 110 to a rear end of the battery pack 110 when the battery module 115B is installed in the battery pack 110) is substantially greater than a width (e.g., in a direction transverse to the direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115B is installed in the battery pack 110) of the battery module housing 223. For example, one or more battery modules 115B may span the entire length of a battery pack within the battery pack frame 205 from front to rear. As shown, the battery module 115B may also include a bus bar 202 electrically coupled to the interconnect structure 200.For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120 to provide a high voltage output from the battery module 115B.

[0033] In the implementations of battery module 115A and battery module 115B, the battery cells 120 are implemented as cylindrical battery cells. However, in other implementations, a battery module may include battery cells with other form factors, such as battery cells with a right prismatic outer shape (e.g., a prismatic cell) or a pouch cell implementation of a battery cell. As an example, Fig. 2B also illustrates a battery module 115C having a battery module housing 223 with a rectangular cuboid shape having a length substantially similar to its width and enclosing a plurality of battery cells 120 implemented as prismatic battery cells. In this example, the battery module 115C includes rows and columns of prismatic battery cells coupled together by an interconnect structure 200 (e.g., a current collector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together and / or couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115C may include a charge collector or bus bar 202.For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120 to provide a high voltage output from the battery module 115C.

[0034] Fig. 2B also shows a battery module 115D including prismatic battery cells and having an elongated shape in which the length of the battery module housing 223 (e.g., extending along a direction from a front end of the battery pack 110 to a rear end of the battery pack 110 when the battery module 115D is installed in the battery pack 110) is substantially greater than a width (e.g., in a direction transverse to the direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115D is installed in the battery pack 110) of the battery module housing 223. For example, one or more battery modules 115D with prismatic battery cells may span the entire length of a battery pack within the battery pack frame 205 from front to rear. As shown, the battery module 115D may also include a bus bar 202 electrically coupled to the interconnect structure 200.For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120 to provide a high voltage output from the battery module 115D.

[0035] As another example, Fig. 2B also shows a battery module 115E having a battery module housing 223 with a rectangular cuboid shape with a length substantially similar to its width and enclosing a plurality of battery cells 120 implemented as pouch battery cells. In this example, the battery module 115C includes rows and columns of pouch battery cells coupled together by an interconnect structure 200 (e.g., a current collector assembly or CCA). For example, the interconnect structure 200 may couple the positive terminals of the battery cells 120 together and couple the negative battery terminals of the battery cells 120 together. As shown, the battery module 115E may include a charge collector or bus bar 202.For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120 to provide a high voltage output from the battery module 115E.

[0036] Fig. 2B also shows a battery module 115F including pouch battery cells and having an elongated shape in which the length of the battery module housing 223 (e.g., extending along a direction from a front end of the battery pack 110 to a rear end of the battery pack 110 when the battery module 115E is installed in the battery pack 110) is substantially greater than a width (e.g., in a direction transverse to the direction from the front end of the battery pack 110 to the rear end of the battery pack 110 when the battery module 115E is installed in the battery pack 110) of the battery module housing 223. For example, one or more battery modules 115E with pouch battery cells may span the entire length of a battery pack within the battery pack frame 205 from front to rear. As shown, the battery module 115E may also include a bus bar 202 electrically coupled to the interconnect structure 200.For example, the bus bar 202 may be electrically coupled to the interconnect structure 200 to collect the charge generated by the battery cells 120 to provide a high voltage output from the battery module 115E.

[0037] In various implementations, a battery pack 110 may be provided with one or more of the battery modules 115A, 115B, 115C, 115D, 115E, and 115F. In one or more other implementations, a battery pack 110 may be provided without battery modules 115 (e.g., in a cell-to-pack implementation).

[0038] In one or more implementations, multiple battery modules 115 may be used in any of the implementations of Fig. 2B may be coupled to a current collector of the battery pack 110 (e.g., in series). In one or more implementations, the current collector may be coupled to one or more external connectors (e.g., electrical contact 203) on the battery pack 110 via a high-voltage wiring harness. In one or more implementations, the battery pack 110 may be provided without any battery modules 115. For example, the battery pack 110 may have a cell-to-pack configuration in which the battery cells 120 are arranged directly into a battery pack 110 without being arranged into a battery module 115 (e.g., without including a separate battery module housing 223). For example, the battery pack 110 (e.g., the battery pack frame 205) may include or define a variety of structures for positioning the battery cells 120 directly within the battery pack frame 205.

[0039] Fig. 2C illustrates a cross-sectional end view of a portion of a battery cell 120. As in Fig. 2C, a battery cell 120 may include an anode 208, an electrolyte 210, and a cathode 212. As shown, the anode 208 may include or be electrically coupled to a first current collector 206 (e.g., a metal layer such as a layer of copper foil or another metal foil). As shown, the cathode 212 may include or be electrically coupled to a second current collector 214 (e.g., a metal layer such as a layer of aluminum foil or another metal foil). As shown, the battery cell 120 may include a first terminal 216 (e.g., a negative terminal) coupled to the anode 208 (e.g., via the first current collector 206) and a second terminal 218 (e.g., a positive terminal) coupled to the cathode (e.g., via the second current collector 214). In various implementations, the electrolyte 210 may be a liquid electrolyte layer or a solid electrolyte layer.In one or more implementations (e.g., implementations where the electrolyte 210 is a liquid electrolyte layer), the battery cell 120 may include a separator layer 220 separating the anode 208 from the cathode 212. In one or more implementations where the electrolyte 210 is a solid electrolyte layer, the solid electrolyte layer may function as both a separator layer and an electrolyte layer.

[0040] In one or more implementations, the battery cell 120 may be implemented as a lithium-ion battery cell in which the anode 208 is formed from a carbonaceous material (e.g., graphite or silicon-carbon). In these implementations, lithium ions may move from the anode 208 through the electrolyte 210 to the cathode 212 during discharging of the battery cell 120 (and, e.g., through the electrolyte 210 from the cathode 212 to the anode 208 during charging of the battery cell 120). For example, the anode 208 may be formed from a graphite material coated on a copper foil corresponding to the first current collector 206. In these lithium-ion implementations, the cathode 212 may be formed from one or more metal oxides (e.g., a lithium cobalt oxide, a lithium manganese oxide, a lithium nickel manganese cobalt oxide (NMC), or the like) and / or a lithium iron phosphate.As shown, the battery cell 120 may include a separation layer 220 separating the anode 208 from the cathode 212. In an implementation where the battery cell 120 is implemented as a lithium-ion battery cell, the electrolyte 210 may include a lithium salt in an organic solvent. The separation layer 220 may be formed from one or more insulating materials (e.g., a polymer such as polyethylene, polypropylene, polyolefin, and / or polyamide, or other insulating materials such as rubber, glass, cellulose, or the like). The separation layer 220 may prevent contact between the anode 208 and the cathode 212 and may be permeable to the electrolyte 210 and / or ions within the electrolyte 210. In one or more implementations, the battery cell 120 may be implemented as a lithium polymer battery cell with a dry solid polymer electrolyte and / or a gel polymer electrolyte.

[0041] Although some examples are described herein in which the battery cells 120 are implemented as lithium-ion battery cells, some or all of the battery cells 120 in a battery module 115, battery pack 110, or other battery or battery unit may be implemented using other battery cell technologies, such as nickel-metal hydride battery cells, sodium-ion battery cells, lead-acid battery cells, and / or ultracapacitor cells. For example, in a nickel-metal hydride battery cell, the anode 208 may be formed from a hydrogen-absorbing alloy, and the cathode 212 may be formed from a nickel oxide hydroxide. In the example of a nickel-metal hydride battery cell, the electrolyte 210 may be formed from an aqueous potassium hydroxide in one or more examples.

[0042] Battery cell 120 may be implemented as a lithium-sulfur battery cell in one or more other implementations. For example, in a lithium-sulfur battery cell, anode 208 may be formed at least partially from lithium, cathode 212 may be formed at least partially from sulfur, and electrolyte 210 may be formed from a cyclic ether, a short-chain ether, a glycol ether, an ionic fluid, a supersaturated salt-solvent mixture, a polymer-gelled organic medium, a solid polymer, a solid inorganic glass, and / or other suitable electrolyte materials.

[0043] In various implementations, the anode 208, the electrolyte 210 and the cathode 212 of the Fig. 2C, the battery cells 120 may be packaged in a battery cell housing having any of various shapes and / or dimensions and / or formed from any of various suitable materials. For example, the battery cells 120 may have a cylindrical, rectangular, square, cubic, flat, pouch, oblong, or prismatic shape. As shown in Fig. 2D, a battery cell, such as battery cell 120, may be implemented as a cylindrical cell. In the example of Fig. 2D, the battery cell 120 includes a cell casing 215 having a cylindrical outer shape. For example, the anode 208, the electrolyte 210, and the cathode 212 may be rolled into one or more substantially cylindrical windings 221. As shown, one or more windings 221 of the anode 208, the electrolyte 210, and the cathode 212 (and, for example, one or more separator layers, such as the separator layer 220) may be disposed within the cell casing 215. For example, a separator layer may be disposed between adjacent ones of the windings 221. The cylindrical cell implementation of Fig. However, Figure 2D is merely illustrative and other implementations of the battery cells 120 are contemplated.

[0044] For example, Fig. 2E shows an example in which the battery cell 120 is implemented as a prismatic cell. As in Fig. 2E, the battery cell 120 may include a cell casing 215 having a right prismatic outer shape. As shown, one or more layers of the anode 208, the cathode 212, and the electrolyte 210 disposed therebetween (e.g., with separating materials between the layers) may be disposed within the cell casing 215 having the right prismatic shape. As examples, multiple layers of the anode 208, the electrolyte 210, and the cathode 212 may be stacked (e.g., with separating materials between each layer), or a single layer of the anode 208, the electrolyte 210, and the cathode 212 may be formed into a flattened spiral shape and provided within the cell casing 215 having the right prismatic shape. In the implementation of Fig. 2E, the cell housing 215 has a relatively thick cross-sectional width 217 and is formed from a rigid material. For example, in the implementation of Fig. 2E may be formed from a welded, stamped, deep-drawn and / or butt-extruded metal sheet, such as a welded, stamped, deep-drawn and / or butt-extruded aluminum sheet. For example, the cross-sectional width 217 of the cell casing 215 may be Fig. 2E may be equal to or greater than 1 millimeter (mm) to provide a rigid housing for the prismatic battery cell. In one or more implementations, the first terminal 216 and the second terminal 218 in the prismatic cell implementation of Fig. 2E may be formed from a feedthrough insulated from the cell housing 215 (e.g., a glass for metal feedthrough) when the conductor extends to the cell housing 215 to expose the first terminal 216 and the second terminal 218 outside the cell housing 215 (e.g., for contact with a connection structure 200 of Fig. 2B). This implementation of Fig. However, Figure 2E is also illustrative and other implementations of the battery cell 120 are contemplated.

[0045] For example, Fig. 2F shows an example in which the battery cell 120 is implemented as a pouch cell. As in Fig. 2F, one or more layers of the anode 208, the cathode 212, and the electrolyte 210 disposed therebetween (e.g., with separating materials between the layers) may be disposed within the cell casing 215, which forms a flexible or deformable pouch casing. In the implementation of Fig. 2F, the cell housing 215 has a relatively thin cross-sectional width 219. For example, the cell housing 215 may be used in the implementation of Fig. 2F may be formed from a flexible or formable material (e.g., a foil, such as a metal foil, or a film, such as an aluminum-coated plastic film). For example, the cross-sectional width 219 of the cell housing 215 may be Fig. 2F may be as low as or less than 0.1 mm, 0.05 mm, 0.02 mm, or 0.01 mm to provide a flexible or deformable housing for the pouch battery cell. In one or more implementations, the first terminal 216 and the second terminal 218 in the pouch cell implementation of Fig. 2F may be formed from conductive contact points (e.g., foil tabs) that are coupled (e.g., welded) to the anode 208 and the cathode 212, respectively, and sealed to the pouch, which in these implementations forms the cell housing 215. In the examples of Fig. 2C, Fig. 2E and Fig. 2F, the first terminal 216 and the second terminal 218 are formed on the same side (e.g., a top side) of the battery cell 120. However, this is merely illustrative, and in other implementations, the first terminal 216 and the second terminal 218 may be formed on two different sides (e.g., opposite sides, such as a top side and a bottom side) of the battery cell 120. The first terminal 216 and the second terminal 218 may, in different implementations, be on the same side or on different sides of the cylindrical cell of Fig. 2D formed.

[0046] In one or more implementations, a battery module 115, a battery pack 110, a battery unit, or any other battery may include some battery cells 120 implemented as solid-state battery cells and other battery cells 120 implemented with liquid electrolytes for lithium-ion or other liquid electrolyte battery cells. One or more of the battery cells 120 may include a battery module 115 or a battery pack 110, such as to provide an electrical power supply to components of the vehicle 100, the building 180, or another electrically powered component or device. The cell casing 215 of the battery cell 120 may be installed in the battery module 115, the battery pack 110, or any of the vehicle 100, the building 180, or another electrically powered component or device.

[0047] Fig. 3 illustrates a schematic cross-sectional side view of a battery pack according to one or more implementations of the subject technology. As in Fig. 3, the battery pack 110 may include the energy volume 207 and the housing 290. As shown, the energy volume 207 may include the pack frame 205 and one or more battery modules 115 and / or battery cells 120 therein. The housing 290 may enclose or house one or more electrical components 304 for the battery pack 110. For example, the housing 290 may be configured to be mechanically and electrically connected to the energy volume 207 of the battery pack 110. For example, the electrical components 304 (e.g., a high-voltage distribution bus, one or more other electrical and / or electronic components, and / or the like) disposed within the housing 290 may be configured to conduct power (e.g., a high-voltage output) from the battery modules 115 and / or battery cells 120 within the energy volume 207 to one or more terminals on the housing, such as the electrical contact 203.

[0048] In one or more implementations, the housing 290 may include an access panel 300. The access panel 300 may include a solid insulating structure 301 configured to at least partially cover the electrical components 304, as well as a conductive layer 302 on a surface of the solid insulating structure 301. The solid insulating structure 301 may be formed from any solid insulating material, including plastic or reinforced plastic. In some implementations, the solid insulating structure 301 may include or be replaced with one or more conductive materials, such as magnesium.

[0049] In the example of Fig. 3, the surface of the solid insulating structure 301 enclosing the conductive layer 302 is an inner surface of the solid insulating structure 301. However, in one or more other implementations, the conductive layer 302 may be provided on an outer surface of the solid insulating structure 301. In various implementations, the conductive layer 302 may be formed from a foil (e.g., a metal foil, such as aluminum foil, pressed onto the surface), a coating (e.g., a metal coating, such as a coating formed using a vapor deposition process), or a resin (e.g., an EMI-compatible resin). By forming the solid insulating structure from an insulating material with a conductive coating (or from a lighter conductive material, such as magnesium), the mass of the housing 290 may be reduced (e.g.,Compared to providing a full metal enclosure, such as a steel or aluminum enclosure, or compared to increasing the side of the pack frame 205 to enclose the electrical components, while still meeting EMI and EMC specifications. This reduced mass can increase the range of an electric vehicle in which the battery pack 110 is implemented.

[0050] In the example of Fig. 3, an energy volume enclosure for the energy volume 207 includes the pack frame 205 and a lid 307 that enclose the battery modules 115 and / or battery cells 120. As shown, the lid 307 may be attached to the pack frame 205 by one or more fasteners 312, and a seal 316 may be provided between the lid 307 and the pack frame 205 to seal the interior of the energy volume 207 from the external environment (e.g., from liquid ingress).

[0051] As shown, the housing 290 may be removably attached to the energy volume 207 (e.g., to the packing frame 205 and / or the lid 307). In the example of Fig. 3, the housing 290 is attached to the energy volume 207 by fasteners 310 (e.g., bolts) that extend through portions of the access panel 300 into the lid 307 and / or the pack frame 205. A seal 314 may be provided between the housing 290 and the energy volume 207 (e.g., between the housing 290 and the lid 307 and / or the pack frame 205). Because the electrical components 304 are provided in a housing 290 that can be removably attached to the energy volume 207, the housing and its electrical components 304 can be installed, serviced, and / or leak tested separately from the battery modules 115 and / or the battery cell 120 without compromising EMI / EMC, grounding, and structural performance. For example, the housing 290 and its electrical components 304 can be assembled and tested separately to test electrical properties and leak tightness.

[0052] By providing a housing 290 for the electrical components 304 that can be removably attached to the energy volume 207, the housing can be modular and used (e.g., for voltage distribution) with any number of different types of energy volumes, regardless of the cell chemistry of the battery cells 120 contained therein or the size of the battery pack frame 205. The housing 209 can be scaled up or down depending on the power and / or EMI specifications for a particular battery pack. The advantages of providing the housing 290 can include having a single electronics box pre-assembled with different configurations depending on the vehicle type and / or the cell technology used in the battery packs.

[0053] The housing 290 may provide benefits for the serviceability of the battery pack 110 and / or a vehicle in which the battery pack 110 is implemented. For example, as shown in Fig. 3, the access panel 300 may be removed (e.g., by removing the fasteners 310), thereby allowing access to the electrical components 304 without opening the energy volume 207 (e.g., without opening the lid 307 or otherwise exposing the battery modules 115 and / or battery cells 120). In one or more implementations, the battery pack 110 may be installed in the vehicle 100 such that the housing 290 is disposed beneath a seat (e.g., a rear seat) of the vehicle. In this manner, the electrical components 304 may be serviced from the passenger compartment of the vehicle (e.g., by removing or sliding a lower cushion assembly of the rear seat and removing or opening the access panel 300).

[0054] In one or more implementations, the housing 290 provides a single enclosure for the electrical components 304 of the battery pack 110 and acts as an EMI / EMC shield. In one or more implementations, the housing 290 is provided in a modular form that can be connected to power volumes of various sizes and enclose battery cells with different cell chemistries.

[0055] In the example of Fig. 3, a portion of the housing 290 is disposed on the lid 307, and a portion of the housing 290 extends beyond the end of the lid 307. For example, a portion of the housing 290 may be located outside the seal 316 between the lid and the packing frame 205. In this example, the housing 290 may be sealingly attached to the energy volume 207, such as by providing a seal 314 between the access flap 300 and the lid 307 and a seal 315 between the access flap 300 and the packing frame 205. In the example of Fig. 3, the electrical contact 203 (e.g., a high-voltage terminal) is arranged on the portion of the housing 290 that extends beyond the end of the cover 307. As shown, a grounding structure 306 may be attached to the package frame 205 and / or the access panel 300 to provide grounding for the electrical contact 203 and / or the electrical components 304. In the example of Fig. 3, the grounding structure 306 is formed from a metal plate that is attached to the package frame 205 and / or the access panel 300 with one or more fasteners 308. However, this is merely illustrative, and in other implementations, a grounding structure for the housing 290 may be formed in other ways, such as by overmolding a portion of the housing 290, as described in more detail below.

[0056] In the example of Fig. 3, the housing 290 is formed from a single solid insulating structure 301 with a conductive layer 302. However, this arrangement of the housing 290 is merely illustrative, and other implementations of the housing 290 are also contemplated herein. For example, FIG. Fig. 4 shows another exemplary implementation of the housing 290. In the example of Fig. 4, the housing 290 is attached to the pack frame 205. In this example, the access door 300 is not directly attached to the pack frame 205; rather, the access door 300 is attached to a fixed insulation tray 400. As shown, the insulation tray 400 may include a seal 404. The seal 404 may, for example, be configured to couple to a body structure of a vehicle, such as the vehicle 100. In this manner, the seal 404 may sealingly separate the access door 300 from a portion of the vehicle that may be exposed to environmental conditions (e.g., from an underside of the vehicle). In this manner, the access door 300 may be located in a "dry zone" of the vehicle 100.

[0057] In the example of Fig. 4, the access door 300 includes an opening 402. As shown, the opening 402 may provide access to one or more additional connectors or terminals for the battery pack 110, such as one or more connectors 291 (e.g., electrical terminals, terminals, and / or contacts). For example, the connector(s) 291 may be low-voltage connectors to a low-voltage source within the housing 290. The access door 300 may be removed (e.g., by detaching the access door 300 from the fixed insulation tray 400) to provide access (e.g., for maintenance) to one or more other electrical components 304 within the housing 209 that are Fig. 4 are not visible. The access flap 300 can be removed from the housing 290 without removing the fixed insulation tray 400 from the packing frame 205.

[0058] Fig. 5 illustrates an exploded perspective view of the housing 290 according to one or more implementations. As shown in Fig. 5, the access panel 300 may be provided with one or more openings 402 (e.g., to provide access to one or more connectors 291 or other connections to the electrical components 304). As shown, the solid insulating tray 400 may form a peripheral wall 501 for the housing 290. The solid insulating tray 400 may be provided with a conductive layer 508 on a surface thereof. In the example of Fig. 5, the conductive layer 508 is formed on an inner surface of the solid insulating well. However, in one or more other implementations, the conductive layer 508 may be formed on an outer surface of the solid insulating well.

[0059] In various implementations, the conductive layer 508 may be formed from a foil (e.g., a metal foil, such as aluminum foil, pressed onto the surface), a coating (e.g., a metal coating, such as a coating formed using a vapor deposition process), or a resin (e.g., an EMI-compatible resin). By forming the solid insulating tub 400 from an insulating material with a conductive layer 508 (or from a lighter metal, such as magnesium), the mass of the housing 290 may be reduced (e.g., compared to providing an all-metal housing, such as a steel or aluminum housing, or compared to increasing the side of the pack frame 205 to enclose the electrical components) while still meeting EMI and EMC specifications. This reduced mass may increase the range of an electric vehicle in which the battery pack 110 is implemented.The rigid insulation tray 400 may include one or more ribs 504 (e.g., on the peripheral wall 501). The ribs 504 may be configured to provide structural stability to the rigid insulation tray. In this way, the housing 290 may be provided with structural rigidity and may be integrated as a structural component of a vehicle, such as the vehicle 100, in one or more implementations. A groove 511 may be provided on a surface (e.g., a top surface) of the peripheral wall 501 of the rigid insulation tray 400. For example, the groove 511 may be configured to receive a gasket material for forming the seal 404 of. Fig. 4 to be taken up (e.g. to be filled with it).

[0060] As in Fig. 5, the housing 290 may also include a tray 500. The tray 500 may be configured to mount one or more of the electrical components 304 thereto, and the tray 500 and the access panel 300 may be configured to at least partially enclose the electrical components 304. As shown, the rigid insulating tray 400 may be disposed between the tray 500 and the access panel 300. For example, the access panel 300 and the tray 500 may be attached to the rigid insulating tray 400 (e.g., on opposite sides, such as the top and bottom of the rigid insulating tray 400). In one or more implementations, the tray 500 may include one or more features 506 (e.g., molded features such as channels, bottom walls, brackets, etc.). For example, the features 506 may be used to hold, support, secure, or mount one or more of the electrical components 304 (e.g., including cables, bus bars, etc.) must be configured. In the example of . Fig. 5, the shell 500 is a molded structure (e.g., an insulating structure, such as a molded plastic structure) and the features 506 are integrally molded features of the molded structure.

[0061] As in Fig. 5, the access panel 300 may be attached to the fixed insulation tray 400, such as by fasteners 505 (e.g., bolts, screws, or other fasteners) around the perimeter of the access panel 300. The tray 500 may be attached to the fixed insulation tray 400, such as by fasteners 502 (e.g., bolts, screws, or other fasteners) around the perimeter of the tray 500. Providing a separate fixed insulation tray 400 between the tray 500 and the access panel 300 may facilitate the installation of the electrical components 304 into the housing 290 (e.g., by providing additional space and flexibility for installing some of the electrical components 304 on the tray prior to attaching the fixed insulation tray 400 to the tray 500).

[0062] Fig. 6 shows a perspective bottom view of a subassembly of the housing 209 in which the fixed insulation tray 400 is attached to the access door 300. In the bottom view of Fig. 6, the openings 402, as well as the conductive layer 302 on the inner surface of the access panel 300, and the conductive layer 508 on the inner surface of the fixed insulation tray 400 can be seen. The fixed insulation tray 400 can include a bottom surface 600, at least a portion of which is configured to contact the shell 500. The bottom surface 600 of the fixed insulation tray 400 can include one or more features 602 (e.g., protrusions and / or openings) configured for attaching the fixed insulation tray 400 (and thereby the housing 290) to a body structure of a vehicle, such as the vehicle 100.

[0063] Fig. Figure 7A illustrates a bottom perspective view of the housing 290 of Fig. 5 according to one or more implementations. In the example of Fig. 7A shows a bottom surface of the shell 500. As shown, the shell 500 may be formed from a rigid insulating shell 700 overmolded onto a grounding structure 702. For example, the grounding structure 702 may include a metal layer over which a moldable material (e.g., plastic) is overmolded to form the rigid insulating shell 700 with the metal layer molded thereon.

[0064] In one or more implementations, the shell 500 may have an exterior surface (e.g., the floor surface shown in Fig. 7A) having a first portion 704 configured to connect to a frame (e.g., pack frame 205) of the energy volume 207 of the battery pack 110, and a second portion 706 configured to extend beyond the frame of the energy volume 207 of the battery pack. As shown, the shell 500 may include one or more first openings 710 in the first portion 704 of the outer surface. For example, the first openings 710 may be configured to accommodate one or more high-voltage and / or low-voltage feedthroughs between the housing 290 and the energy volume 207. For example, as shown in Fig. 7A, one or more high-voltage terminals, such as a high-voltage terminal 720 (e.g., a negative high-voltage terminal, such as a cylindrical negative high-voltage terminal) and a high-voltage terminal 722 (e.g., a positive high-voltage terminal, such as a cylindrical positive high-voltage terminal) may be provided in each of the openings 710 to couple one or more high-voltage sources within the energy volume 207 to one or more of the electrical components 304 within the housing 290. Although in Fig. 7A, one or more low-voltage connectors may also be provided for passage between the power volume 207 and the housing 290 (as described in more detail below). The shell 500 may include one or more second openings 708 in the second portion 706 of the exterior surface. The second openings 708 may be configured to receive one or more high-voltage output connectors connected to the one or more electrical components 304. The shell 500 may also include one or more third openings 712 in the second portion 706. The one or more third openings 712 may be configured to receive one or more coolant ports for the housing 290.

[0065] Fig. 7B shows an example implementation of an assembly 730 that may be provided within the housing 290 to allow high-voltage (HV) bus lines and low-voltage (LV) signals to pass through a sealed interface between the power volume 207 and the housing 290. As shown, the assembly 730 may include a seal 734 extending around the HV connector 720 and the HV terminal 720. For example, the seal 734 may be pressed against an interior surface of the shell 500 to provide an interior seal around an opening 710 within the housing 290 in which the assembly 730 is mounted (e.g., to position the HV terminals 720 and 722 as HV feedthroughs within the opening 710). As shown, a low-voltage connector 732 may also be provided within the seal 734. For example, the low voltage connector 732 may be configured as a multi-pin (e.g.eight-pin) connector molded into the housing 738 at a location within the seal 734. When the housing 290 is mounted to the pack frame 205, the HV terminals 720 and 722 may be coupled to a high-voltage source within the power volume 207 and configured to conduct power from the high-voltage source within the power volume 207 to high-voltage components within the housing 290. When the housing 290 is mounted to the pack frame 205, the LV connector 732 may be coupled to a cable within the power volume 207 via an opening 710 in the shell 500 and may be configured to conduct low-voltage signals between the housing 290 and the power volume 207.For example, in one or more implementations, a low voltage cable within the housing 290 may be connected to a low voltage connector 736 that includes pins that are electrically coupled to the pins of the low voltage connector 732.

[0066] As shown, the seal 734 may be mounted to and / or protrude from a housing 738 of the assembly 730. As shown, one or more high-voltage contacts 740 may protrude from the housing 738 and be electrically coupled to the HV connector 720. The HV contacts 740 may be coupled to one or more high-voltage electrical components within the housing 290. One or more high-voltage contacts 742 may protrude from the housing 738 and be electrically coupled to the HV connector 722. The HV contacts 742 may be coupled to one or more high-voltage electrical components within the housing 290.

[0067] Fig. Figure 7C illustrates an exploded perspective view of assembly 730 of Fig. 7B. As in Fig. 7B, the housing 738 of the assembly 730 may include an upper housing 738T and a lower housing 738B. The upper housing 738T and the lower housing 738B may cooperate to enclose a bus bar 750 and a bus bar 752 of the assembly 730. HV contacts 740 and / or HV contacts 742 may be formed, for example, from one or more foils or other metal layers welded to the bus bars 750 and 752, respectively. As shown, the bus bar 750 may electrically connect the high-voltage contacts 740 to the high-voltage terminal 720. The bus bar 752 may connect the high-voltage contacts 742 to the high-voltage terminal 722. For example, HV contacts 740 and / or HV contacts 742 may be formed from one or more foils (e.g., 0.6 mm thick welding foils) or other metal layers welded to busbars 750 and 752, respectively.

[0068] In one or more implementations, the electrical connection between the foils and the bus bars may have a resistance of less than 20 μΩ. In one or more implementations, the electrical connection between the cylindrical terminals (e.g., HV terminals 720 and 722) and the bus bars may have a resistance of less than 20 μΩ. In one or more implementations, the foils, the bus bars, and the terminals may support a continuous current of 250-300 A or more. As shown, the upper housing 738T may include the low-voltage connector 732, the low-voltage connector 736, and a feature (e.g., a groove 760) configured to receive the gasket 734. In the example of Fig. 7C shows pins 766 of low voltage connector 736.

[0069] Fig. 7C also shows how the assembly 730 may include one or more sealing features (e.g., O-rings 754) configured to seal the high-voltage terminal 720 and the high-voltage terminal 722 to an interior surface of the upper housing 738T. For example, the upper housing 738T may include an extension 762 and an extension 764 configured to receive the high-voltage terminal 720 (e.g., with an O-ring 754) and the high-voltage terminal 722 (e.g., with an O-ring 754). As shown, the assembly 730 may also include one or more touch guards 758 (e.g., IPXXB touch guards) for the high-voltage terminal 720 and the high-voltage terminal 722. In one or more implementations, a threaded insert 756 may be provided in each of the cylindrical high-voltage terminals to secure a touch guard 758 to that terminal. Fig. Figure 7D shows a top view of assembly 730 of Fig. 7B and Fig. 7C, in which a cable 772 is connected to the low-voltage connector 736 (e.g., via a mating connector 770 for the low-voltage connector). The pins 774 of the low-voltage connector 732 are also shown in Fig. 7D. In this way, the assembly 730 can provide signal paths for multiple (e.g., eight, less than eight, or more than eight) low-voltage communication signals to be passed between the power volume 207 and the housing 290.

[0070] In the examples of Fig. 7B to 7D, the low-voltage connector 732 is implemented using molded-in connector pins (e.g., pins 774) in the upper housing 738T. However, this is merely illustrative, and other implementations of the low-voltage connector are possible. For example, Fig. 7E shows another implementation of the assembly 730 (with the upper housing 738T removed for clarity), in which the low-voltage connector 732 is implemented using connector pins 782 mounted directly on a stiffener with flexible circuitry 780. As in Fig. 7F, when the upper housing 738T is installed, the connector pins 782 and the flexible circuit logic 780 may be mounted between the upper housing 738T and the lower housing 738B, and the connector pins 782 may be accessible via an opening 784 in the upper housing 738T. In this example, the upper housing 738T and the lower housing 738B may provide a support, position, channel, and / or routing path for the flexible circuit logic 780.

[0071] In the examples of Fig. 7B through 7F, the assembly 730 provides three seals, including two O-rings 754 around the ports 720 and 722 and a cover seal (e.g., seal 734). These seals may prevent the ingress of liquid or other foreign matter from the external environment through the openings 710 into the housing 290 or the package frame 205. In one or more implementations, these seals may each meet IP69 sealing standards, may be formed from polyurethane, epoxy, acrylic, and / or silicone adhesives (as examples), may be configured to maintain a seal at temperatures between -40°C and 100°C, and / or have a maximum leak rate of 3 SCCM at -0.5 PSIG under all tolerance conditions.The seal 734 may, in one or more implementations, have a Z-tolerance to the shell 500 of + / - 2 mm, a nominal available Z-spacing of 4 mm, a lid flatness tolerance of 1 mm, and a maximum seal compression force of 12 kgf. In one or more implementations, the assembly 730 may have a width between 200 mm and 400 mm, a length between 50 mm and 170 mm, and / or a height between 25 mm and 50 mm.

[0072] Fig. Figure 8 illustrates a cross-sectional side view of the housing of Fig. 4, with the electrical components 304 installed therein and the access panel 300 removed. As shown, the rigid insulation tray 400 may include a ledge 805. The ledge 805 may be configured to mount a flange 806 of one of the electrical components 304. By mounting the one of the electrical components 304 to the ledge 805, a gap 807 may be provided between the one of the electrical components 304 and the tray 500. One or more additional electrical components 304 (e.g., including cables, bus bars, etc.) and / or one or more thermal features (e.g., cold plates, fluid lines, etc.) may be mounted within the gap 807 (e.g., mounted to the mounting feature 506 on the tray 500). Fig. 8 also shows how the housing 290 may include one or more sealing features 802 configured to provide a seal around the high voltage connectors to the power volume 207. Fig. 8 also shows how the second portion 706 of the tray 500 may have a shape configured to protrude beyond an edge of the pack frame 205 and how the electrical contact 203 (e.g., a high voltage output connector) may be provided on the second portion 706.

[0073] Fig. 9 illustrates a perspective cross-sectional view of a portion of the system 500. In the example of Fig. 9, it can be seen that the grounding structure 702 may be formed from a relatively thin layer of conductive material (e.g., metal) over which the solid insulating shell 700 may be molded. Fig. Figure 10 shows a perspective cross-sectional side view of the battery pack 110 including the housing 290 of Fig. 8. In the example of Fig. 10, the housing 290 is attached to the pack frame 205 of the energy volume 207, and the access panel 300 is installed. In this example, the ribbing 504 can be seen on the rigid insulation tray 400. In this example, the battery pack 110 also includes a support structure 1000. For example, the support structure 1000 may be configured to be attached to the pack frame 205 of the battery pack 110 and to the second portion 706 of the tray that extends beyond the end of the pack frame 205. For example, the support structure 1000 may provide additional structural impact resistance to the battery pack 110 and / or the vehicle 100.

[0074] Fig. Figure 11 illustrates a bottom perspective view of a portion of the battery pack 110 of Fig. 10 and shows the second portion 706 of the shell 500 with various connectors attached thereto. For example, the electrical contact 203 and / or one or more other high-voltage connectors 1100 and / or low-voltage connectors 1104, which provide various voltages from the battery cells 120 within the energy volume 207, may be provided on the second portion 706 of the shell 500 that extends beyond the edge of the pack frame 205. As shown, one or more fluid ports, such as a fluid port 1102 (e.g., a coolant port), may also be provided on the second portion 706 of the shell 500 that extends beyond the edge of the pack frame 205.The fluid port 1102 and / or one or more other fluid ports on portion 706 of the shell 500 may provide coolant inlet ports and / or coolant outlet ports to allow a cooling fluid to flow into and out of the housing 290 to cool one or more of the electrical components 304 disposed therein. Fig. 11 also shows how multiple support structures 1000 may be provided to support the protruding portion of the housing 290 on the pack frame 205 and to reinforce the overall structure of the battery pack 110 and / or the vehicle 100.

[0075] In one or more implementations, the electrical contact(s) 203, the fluid port(s) 1102, the support structure(s) 1000, and the second portion 706 of the shell may be disposed in a “wet zone” of the vehicle 100. For example, the wet zone may be located outside the Fig. 4 shown seal 404.

[0076] As in the Fig. 3 through 11, the enclosure 290 may provide a modular, serviceable, grounded package that enables electrical component testing (e.g., testing and / or testing of electrical components 304, such as the battery management system (BMS), contactors, the high-voltage connectors 720 and 722, the low-voltage connectors 732 and 736, the high-voltage connectors 1100, and / or the low-voltage connectors 1104) and / or thermal testing (e.g., by circulating coolant through the enclosure 290 via one or more liquid connectors 1102) separate from the energy volume 207. For example, coolant cycling, testing of contactors opening and closing, testing of the BMS functioning and / or software updates may be performed on the enclosure 290 separate from the energy volume 207 (e.g.,separated from testing and / or inspection of the energy volume 207 and / or while the housing 290 is physically separated from the energy volume 207, such as prior to attachment of the housing 290 to the packing frame 110). As shown in FIGS. Fig. 3 through 11, the housing 290 may provide a modular, serviceable, grounded package that provides high voltage, low voltage, and thermal feedthroughs to external connectors / terminals.

[0077] In one or more implementations, assembling a vehicle including the battery pack 110 disclosed herein may include attaching the housing 290 to the pack frame 205 (e.g., and thus the energy volume 207) and then installing the battery pack 110 with the housing 290 attached into the vehicle. For example, the housing 290 may be inserted into an opening in a body structure 1200 of the vehicle, as shown in Fig. 12. Inserting the housing 290 into the opening in the body structure 1200 can release the seal 404 from Fig. 4 against a bottom (in Fig. 12 not visible) of the body structure 1200. For example, the body structure 1200 may be a body structure to which one or more seats (e.g., a rear seat) of the vehicle 100 may be mounted. As shown, a portion of the housing 290 extending through the body structure 1200 may enclose the access panel 300 and the connector(s) 291 accessible through the openings 402 in the access panel 300. Due to the seal between the body structure 1200 and the seal 404 on the rigid insulator 400, the portion of the housing 290 extending through the opening in the body structure 1200 may be located in a "dry zone" of the vehicle 100.

[0078] In one or more implementations, a rear seat of the vehicle 100 may be mounted to the body structure 1200. The rear seat of the vehicle may include a removable cushion assembly covering the access panel 300 and the connector 291 of the housing 290. The rear seat cushion assembly may be removed to provide access to the connector 291 and / or the access panel 300 (which may also be removed, for example, for servicing components within the housing 290).

[0079] Fig. Figure 13 shows a bottom view of the housing 290 and the body structure 1200 of Fig. 12. As shown in the bottom view of Fig. 13, the fixed insulation tray 400 may be abutted against the body structure 1200. In this arrangement, the bottom surface of the tray 500, which may include openings 710, 708, and 712, may be formed in a "wet zone" of the vehicle outside of the seal 404 on the fixed insulation tray 400. For example, bolts may be used through features 602 on the fixed insulation tray 400 to attach the fixed insulation tray, and thereby the housing 290, to the body structure 1200.

[0080] Example implementations of a modular housing 290 for a battery pack 110 have been described herein, for example, in connection with Fig. 2A and 3-12. However, these implementations of the housing 290 are merely illustrative, and other implementations of the housing are contemplated herein.

[0081] For example, Fig. 14 illustrates another implementation of the housing 290, in which the shell 500 includes the rigid insulating shell 700 and a conductive layer 1402 (e.g., a conductive foil, a molded metal structure, a conductive plate, a conductive resin, or a conductive coating) on ​​an inner surface of the rigid insulating shell 700. In this implementation, the shell 500 may also include the grounding structure 702 (e.g., a molded metal) on an outer surface of the shell (e.g., as in the examples of Fig. 7, Fig. 9 and Fig. 13). In this example, the housing 290 may also include a support structure 1404. For example, the support structure 1404 may include one or more shaped features 1405 (e.g., similar to the shaped features 506 of Fig. 5, but formed on a support structure separate from the shell 500) for holding, supporting, securing, or otherwise holding or guiding one or more of the electrical components 304 (e.g., electrical components 304 disposed in the gap 807 of Fig. 8 are arranged). The implementation of Fig. 14 may provide additional grounding for the housing 290, but may prevent the molded features 506 from being formed on the shell 500 itself. The molded features 1405 on the support structure 1404 may replace the molded features 506.

[0082] As a further example, Fig. 15 illustrates another implementation of the housing 290 in which the shell 500 is formed from a metal shell 1502. In this example, the housing 290 may also include the support structure 1404 including the molded features 1405 (e.g., configured to support one or more of the electrical components 304). For example, the support structure 1404 may be attached to the metal shell 1502. As another example, Fig. 16 illustrates another implementation of the housing 290 in which one or more features of the solid insulation tray 400 are integrated into the shell 500 (e.g., in a deep shell implementation of the shell 500). For example, as in Fig. 16, in one or more implementations, the tray 500 may include a rigid insulating structure 1600 configured for mounting the one or more electrical components thereto, and the access door 300 may be configured for direct attachment to the tray 500 (e.g., to the rigid insulating structure 1600) to at least partially enclose the electrical components 304.

[0083] For example, the solid insulating structure 1600 may be molded over a grounding structure 702 (e.g., as in the examples of Fig. 7, Fig. 9 and Fig. 13) and may include a bar 1602 for mounting one or more of the electronic components 304. For example, the bar 1602 may be configured to Fig. 8, so that a gap similar to the gap 807 is formed between the electrical component 304 with the flange 806 and a bottom of the fixed insulating shell 1600. In the example of Fig. 16, the housing 290 also includes the support structure 1404 with the shaped features 1405 (e.g., configured to support one or more electrical components 304 within the housing formed by the solid insulating structure 1600 and the access door 300). In the example of Fig. 16, the rigid insulation shell 1600 may include a surface, such as surface 1604, configured to sealingly engage a vehicle structure, such as the body structure 1200 of Fig. 12 and Fig. 13. When one or more electrical components 304 within the housing 290 are to be serviced, the access panel 300 may be removed from the fixed insulating shell 1600 to provide access to the electrical components 304 mounted on the fixed insulating shell 1600.

[0084] As in the Fig. 1A to 16, in one or more implementations, a vehicle 100 may be provided with a battery pack 110 including an enclosure 290 for one or more electrical components 304 for the battery pack 110, the enclosure configured to be mechanically and electrically coupled to a power volume 207 of the battery pack 110. The enclosure 290 may include an access door 300 formed from a solid insulating structure 301 configured to at least partially cover the one or more electrical components, and a conductive layer 302 on a surface of the solid insulating structure. The enclosure may also include a center structure (e.g.,The battery pack 110 and / or the housing 290 may include a rigid insulating tray 400 including a rigid insulating structure 507, a conductive layer 508 on an inner surface of the rigid insulating structure 507, and ribbing 504 configured to provide structural shock resistance to the housing. The housing 290 may also include a bottom plate (e.g., tray 500). The bottom plate and the access plate may be configured to be attached to the center structure to form the housing 290. The battery pack 110 and / or the housing 290 may further include one or more support structures 1000 configured to be attached to a frame (e.g., pack frame 205) of the battery pack 110 and to an overhang (e.g., second portion 706) on the bottom plate to provide structural shock resistance to the vehicle. In one or more implementations, the central structure (e.g., the fixed insulation tray 400) may also include a sealing feature (e.g.,a groove 511 and / or a seal 404) for sealingly securing the housing 290 to a body structure 1200 of the vehicle 100. The bottom plate (e.g., tray 500) may also include a plurality of seals 802 for sealingly protecting a plurality of high-voltage terminals between the housing 290 and the battery pack 110 (e.g., the energy volume of the battery pack 110).

[0085] Fig. 17 illustrates a flowchart of an exemplary process 1700 that may be performed to assemble a vehicle according to implementations of the subject technology. For exemplary explanation, the process 1700 is described herein primarily with reference to the vehicle 100 and the housing 290 of Fig. 1A through 16. However, the process 1700 is not limited to the vehicle 100 and the housing 290, and one or more blocks (or acts) of the process 1700 may be performed by or with one or more other structural components of other suitable movable devices, systems, or movable equipment. Further, for exemplary purposes, some of the blocks of the process 1700 are described herein as occurring serially or linearly. However, multiple blocks of the process 1700 may occur in parallel. In addition, the blocks of the process 1700 need not be performed in the order shown, and / or one or more blocks of the process 1700 need not be performed and / or may be replaced with other acts.

[0086] As in Fig.17, at block 1702, one or more electrical components (e.g., electrical components 304, such as a high-voltage distribution box, cables, bus bars, etc.) may be attached to a fixed insulation tray (e.g., shell 500, fixed insulation tray 700, and / or fixed insulation tray 1600) having at least one grounding structure (e.g., grounding structure 702).

[0087] In block 1704, a fixed insulation tray (e.g., fixed insulation tray 400) having a conductive layer (e.g., conductive layer 508) may be mounted to the fixed insulation shell (e.g., using fasteners 502 or other fasteners).

[0088] In block 1706, one or more additional electrical components (e.g., an electrical component 304 with a flange 806) may be mounted to the fixed insulation tray.

[0089] At block 1708, a housing 290 for the one or more electrical components and the one or more additional electrical components may be formed by attaching an access panel (e.g., access panel 300) to the fixed insulating tray (e.g., using fasteners 505). The access panel may include one or more openings (e.g., openings 402) for accessing one or more terminals (e.g., connectors 291) while the access panel is attached to the fixed insulating tray.

[0090] At block 1710, the housing may be attached to a frame (e.g., pack frame 205) for an energy volume (e.g., energy volume 207) for a battery pack (e.g., battery pack 110). Attaching the housing to the energy volume frame may include mechanically and electrically coupling the housing to the energy volume frame. For example, mechanically coupling the housing to the energy volume frame may include bolting the housing to the frame (e.g., using bolts that pass through the rigid insulation tray and / or the shell) and / or forming one or more seals (e.g., seals 802) between the housing and the frame.For example, electrically coupling the housing to the frame of the energy volume may include electrically coupling the electrical components within the housing to one or more high-voltage contacts on the frame that are electrically coupled to one or more battery cells and / or battery modules within the frame.

[0091] At block 1712, the enclosure and frame may be attached to one or more body structures (e.g., body structure 1200) of the vehicle. Attaching the enclosure and frame to the body structure may include bolting the enclosure to the body structure via the rigid insulation tray. Attaching the enclosure and frame to the body structure may include compressing a seal (e.g., seal 404) on the rigid insulation tray against the body structure. Attaching the enclosure and frame to the body structure may include attaching (e.g., bolting) the frame to the body structure and / or another body structure at one or more locations separate from the enclosure.

[0092] In one or more implementations, a method for servicing a vehicle may also be provided. The method for servicing the vehicle may include removing an access panel (e.g., access panel 300) of a housing (e.g., housing 290) of a battery pack (e.g., battery pack 110) while the battery pack is installed in the vehicle; and servicing (e.g., removing, replacing, and / or repairing) one or more electrical components (e.g., electrical components 304) within the housing via an opening created by removing the access panel while the battery pack is installed in the vehicle. In one or more implementations, a portion (e.g., a cushion or cushion assembly) of a seat (e.g., a rear seat) of the vehicle may be removed to provide access to the access panel and remove the access panel.

[0093] Aspects of the technology in question can contribute to improving the reliability and / or range of electric vehicles. This can help facilitate the operation and / or spread of electric vehicles, which can have a positive impact on the climate by reducing greenhouse gas emissions.

[0094] A reference to an element in the singular shall not mean one and only one, unless expressly stated so, but rather one or more. For example, "a" module may refer to one or more modules. An element preceded by "a," "an," or "the" does not exclude the presence of additional, identical elements, without further limitation.

[0095] Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word "exemplary" is used herein to mean serving as an example or illustration. To the extent the term "including," "comprising," or the like is used in the specification or claims, such term is intended to be included in a manner similar to the term "comprise," as "comprise" is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or act from another without necessarily requiring or implying any actual such relationship or order between such entities or acts.

[0096] Terms such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof, and the like are for convenience and do not imply that a disclosure referring to such term(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology.A disclosure referring to such a term(s) may apply to all configurations or to one or more configurations. A disclosure referring to such a term(s) may provide one or more examples. A term, such as an aspect or some aspects, may refer to one or more aspects, and vice versa, and this applies similarly to other above terms.

[0097] The phrase "at least one of" preceding a list of items with the phrase "and" or "or" separating one of the items modifies the list as a whole, rather than each item of the list. The phrase "at least one of" does not require selection of at least one item; rather, the phrase allows for a meaning that includes at least one of any of the items, and / or at least one of any combination of the items, and / or at least one of each of the items. For example, each of the phrases "at least one of A, B, and C" or "at least one of A, B, or C" refers to only A, only B, or only C; any combination of A, B, and C; and / or at least one each of A, B, and C.

[0098] It is understood that the specific order or hierarchy of disclosed steps, acts, or processes is illustrative of exemplary approaches. Unless expressly stated otherwise, it is understood that the specific order or hierarchy of steps, acts, or processes may be performed in different orders. Some of the steps, acts, or processes may be performed concurrently. The appended method claims, if any, present elements of the various steps, acts, or processes in a sample order and are not intended to be limited to the specific order or hierarchy presented. These may be performed serially, linearly, in parallel, or in different orders.It is understood that the instructions, operations, and systems described may generally be integrated together in a single software / hardware product or may be packaged into multiple software / hardware products.

[0099] In one aspect, a term "coupled" or the like may refer to being directly coupled. In another aspect, a term "coupled" or the like may refer to being indirectly coupled.

[0100] Terms such as top, bottom, front, back, side, horizontal, vertical, and the like refer to any reference frame other than the ordinary gravitational frame. Thus, such a term can extend upward, downward, diagonally, or horizontally in a gravitational frame.

[0101] The disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. In some cases, well-known structures and components are shown in block diagram form to avoid obscuring the concepts of the subject technology. The disclosure provides various examples of the subject technology, and the subject technology is not limited to these examples. Various modifications to these aspects will be readily apparent to those skilled in the art, and the principles described herein may be applied to other aspects.

[0102] All structural and functional equivalents to the elements of the various aspects described in the disclosure that are known or later become known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Furthermore, nothing disclosed herein is intended to be made available to the public, regardless of whether such disclosure is expressly recited in the claims. No claim element is to be understood within the provisions of 35 USC § 112(f) unless the element is expressly recited using the term "means for" or, in the case of a method claim, the element is recited using the term "step for."

[0103] Those skilled in the art would recognize that the various illustrative blocks, modules, elements, components, methods, and algorithms described herein may be implemented in hardware, electronic hardware, computer software, or combinations thereof. To illustrate this interchangeability of hardware and software, various illustrative blocks, modules, elements, components, methods, and algorithms have been described generally in terms of their functionality. Whether such functionality is implemented in hardware or software depends on the particular application and design constraints imposed on the overall system. Those skilled in the art may implement the described functionality in different ways for each particular application. Various components and blocks may be arranged differently (e.g.,arranged in a different order or partitioned in a different way) without departing from the scope of the present technology.

[0104] The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as limiting descriptions. They are submitted with the understanding that they will not be used to limit the scope or meaning of the claims. Additionally, it will be apparent in the detailed description that the description provides illustrative examples and the various features are grouped into various implementations to streamline the disclosure. The method of the disclosure should not be interpreted to reflect an intent that the claimed subject matter requires more features than are expressly recited in each claim.Rather, as the claims reflect, the inventive subject matter lies in less than all features of a single disclosed configuration or process. The claims are hereby incorporated into the Detailed Description, with each claim standing alone as separately claimed subject matter.

[0105] The claims are not intended to be limited to the aspects described herein, but are intended to be accorded the full scope of protection consistent with the language of the claims and to include all legal equivalents. Nevertheless, none of the claims are intended, nor should they be interpreted, to encompass subject matter that does not meet the requirements of applicable patent law.

Claims

[1] Facility comprising: a housing for one or more electrical components for a battery pack, the housing being configured to be mechanically and electrically coupled to an energy volume of the battery pack, and the housing including an access door, comprising: an insulating structure configured to at least partially cover the one or more electrical components; and a conductive layer on a surface of the insulating structure. [2] The device of claim 1, wherein the insulating structure comprises a solid insulating structure, and wherein the surface of the solid insulating structure with the conductive layer comprises an interior surface of the solid insulating structure, and wherein the conductive layer is at least partially configured to reduce electromagnetic interference (EMI) from the one or more electrical components to one or more electronic components external to the housing. [3] The device according to claim 2, wherein the conductive layer comprises at least one of the following elements: a film, a coating, or a resin. [4] The device of claim 1, wherein the housing further comprises a tray configured to mount the one or more electrical components thereon, the tray and the access door configured to at least partially enclose the one or more electrical components. [5] The device of claim 4, wherein the shell comprises a rigid insulating shell, and wherein the housing further comprises at least one grounding structure coupled to the rigid insulating shell. [6] The device of claim 5, wherein the at least one grounding structure comprises a metal and wherein the solid insulating shell is molded onto the metal. [7] The device of claim 6, wherein the rigid insulating shell comprises a plurality of shaped features configured to hold the one or more electrical components. [8] The device of claim 4, wherein the housing further comprises a rigid insulating tray disposed between the shell and the access door, the access door and the shell configured to be attached to the rigid insulating tray, and the rigid insulating tray comprising an additional conductive layer on a surface of the rigid insulating tray. [9] The device of claim 8, wherein the rigid insulation tray comprises a plurality of ribs configured to provide structural strength to the rigid insulation tray. [10] The device of claim 8, wherein the shell comprises an outer surface having a first portion configured to connect to a frame of the energy volume of the battery pack and a second portion configured to protrude beyond the frame of the energy volume of the battery pack. [11] Device according to claim 10, wherein the shell comprises: one or more first openings in the first portion of the outer surface for receiving one or more high-voltage bushings and one or more low-voltage bushings to the energy volume; and one or more second openings in the second portion of the outer surface for receiving one or more high voltage output connectors connected to the one or more electrical components. [12] Device according to claim 11, wherein: the shell further comprises one or more third openings in the second portion, the one or more third openings configured to receive one or more coolant ports for the housing; the one or more electrical components comprise an assembly having first and second high-voltage terminals and at least one low-voltage connector; and the assembly is configured to position the first and second high-voltage terminals as the one or more high-voltage feedthroughs and the at least one low-voltage connector as the one or more low-voltage feedthroughs within one of the one or more first openings. [13] The device of claim 8, wherein the fixed insulating tray comprises a bar for mounting a flange of one of the one or more electrical components. [14] The device of claim 4, wherein the shell comprises a rigid insulating shell, a conductive layer on an inner surface of the shell, and a molded metal on an outer surface of the shell, and wherein the housing further comprises a support structure comprising a plurality of molded features configured to support the one or more electrical components. [15] The device of claim 4, wherein the shell comprises a metal shell, and wherein the housing further comprises a support structure comprising a plurality of shaped features configured to support the one or more electrical components. [16] The device of claim 1, wherein the housing further comprises: a shell comprising a rigid insulating structure configured to mount the one or more electrical components thereon, wherein the access panel is configured to be directly attached to the shell to at least partially enclose the one or more electrical components; and a support structure comprising a plurality of shaped features configured to support the one or more electrical components within the housing formed by the solid insulating structure and the access panel. [17] Vehicle comprising: a battery pack comprising: a housing for one or more electrical components for the battery pack, the housing being configured to be mechanically and electrically coupled to an energy volume of the battery pack, and the housing including an access door comprising: an insulating structure configured to at least partially cover the one or more electrical components; and a conductive layer on a surface of the insulating structure. [18] The vehicle of claim 17, wherein the housing further comprises: a center structure comprising: a solid insulating structure, a conductive layer on an inner surface of the solid insulating structure, and ribbing configured to provide structural shock resistance to the housing; a base plate, wherein the base plate and the access plate are configured to be attached to the central structure to form the housing; and a support structure configured to be attached to a frame of the battery pack and to an overhang on the floor panel to provide structural shock resistance to the vehicle. [19] The vehicle of claim 18, wherein the center structure further comprises a sealing feature for sealingly securing the housing to a body structure of the vehicle, and wherein the bottom plate further comprises a plurality of gaskets for sealing a plurality of high voltage terminals between the housing and the battery pack. [20] A method of assembling a vehicle, the method comprising: Attaching one or more electrical components to an insulating shell having at least one grounding structure; Mounting an insulating tray with a conductive layer on the insulating shell; Attaching one or more additional electrical components to the insulation tray; Forming an enclosure for the one or more electrical components and the one or more additional electrical components by attaching an access panel to the insulation tray; Attaching the housing to a frame for an energy volume for a battery pack; and Attaching the housing and frame to one or more body structures of the vehicle.

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