Battery lid fastener

Abstract

A fastener (10) for an electric vehicle (EV) battery pack lid is provided. The fastener includes an elongated body having first (14) and second (16) opposite ends, and upper and lower surfaces extending between the first and second ends. A first retaining feature is proximate the first end, and a second retaining feature is proximate the second end. The first retaining feature is insertable through a first opening in a battery pack lid and a corresponding first opening in a battery pack housing. Further, the first retaining feature is engageable with a surface of the housing or the lid. The second retaining feature is engageable with a portion of the battery pack lid and a corresponding portion of the battery pack housing. A battery pack for an electric vehicle including the fastener and a method of securing a lid to an electric vehicle battery pack using the fastener are also provided.

Description

BATTERY LID FASTENERCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application No. 63 / 536,966, filed September 7, 2023, the disclosure of which is incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] The disclosure generally relates to battery packs for electric vehicles (EVs) and, more specifically, to fasteners for securing a lid / cap to a battery pack.BACKGROUND OF THE INVENTION

[0003] An electric vehicle utilizes a battery pack including a plurality of battery cells to store and provide a source of power to drive the vehicle. The battery cells are contained within a housing of the battery pack. EV battery packs typically have a removable lid / cap that covers over and closes an opening to the internal space within the housing of the battery pack. On average, about 80 fasteners are necessary to secure the lid / cap onto the battery pack housing in order to enclose the battery cells of the battery pack within the housing, as shown. At the same time, in conjunction with a seal (gasket or similar), the lid / cap seals the battery pack. In order to provide an adequate leakproof seal from the external environment (including moisture, dust, etc.), the lid / cap should compress the seal against a surface of the battery housing such that the seal is sandwiched between the lid / cap and the housing. Conventionally, the fasteners used to fix the lid / cap to the battery pack and to compress the seal are bolts. However, installation cycle time and cost are both concerns with the use of bolts to mount the lid / cap onto the battery pack housing. Therefore, a need exists for a quicker, easier, and less costly fastener for securing a lid / cap to a battery pack.BRIEF SUMMARY

[0004] An improved fastener for an electric vehicle (EV) battery pack lid is provided. The fastener includes an elongated body having first and second opposite ends, and upper and lower surfaces extending between the first and second ends. A first retaining feature is proximate the first end, and a second retaining feature is proximate the second end. The first retaining feature is configured to be insertable through a first opening in a battery pack lid and a corresponding first opening in a battery pack housing. Further, the first retaining feature is configured to be engageable with one of a surface of the battery pack housing or a surface of the battery pack lid. The second retaining feature is configured to be engageablewith one of an outer portion of the battery pack lid and a corresponding outer portion of the battery pack housing. When the first retaining feature is engaged with the surface of the battery pack housing or the surface of the battery pack lid, the second end is angularly pivotable toward the battery pack lid or the battery pack housing to engage the second retaining feature with the portion of the battery pack or the corresponding portion of the battery pack housing to clamp the battery pack lid to the battery pack housing.

[0005] In specific embodiments, the elongated body is a strip of metal including a plurality of bends in a longitudinal direction.

[0006] In certain embodiments, the elongated body includes four longitudinal bends.

[0007] In particular embodiments, at least one of the four longitudinal bends has an angle of greater than 90 degrees.

[0008] In particular embodiments, each of the four longitudinal bends has an angle of greater than 90 degrees.

[0009] In specific embodiments, the first retaining feature is a portion of the upper surface at a longitudinal bend in the elongated body.

[0010] In specific embodiments, the second retaining feature is a locking tab projecting from the lower surface.

[0011] In specific embodiments, the elongated body, the first retaining feature, and the second retaining features are all part of a one-piece element formed by bending portions of a metal piece.

[0012] In specific embodiments, the fastener further includes a third leg extending from the elongated body, and a third retaining feature on the third leg.

[0013] A battery pack for an electric vehicle (EV) is also provided. The battery pack includes a housing defining an internal chamber and having an opening providing access to the internal chamber. A plurality of battery cells are disposed in the internal chamber. A seal is disposed around the perimeter of the opening. A lid covers over the opening and sandwiches the seal between the housing and the lid. The battery pack further includes a first opening in the lid and a corresponding first opening in the housing. The battery pack further includes a fastener as described in the preceding paragraphs. The fastener is insertable through the first opening in the lid and the corresponding first opening in the housing, and engageable with a portion of the lid and a corresponding portion of the housing to clamp the lid to the housing and to compress the seal between the lid and housing.

[0014] In specific embodiments, the first opening in the lid and the corresponding first opening in the battery pack housing have a complementary polygonal shape.

[0015] In alternative embodiments, the first opening in the lid and the corresponding first opening in the battery pack housing have a complementary circular or oval shape.

[0016] In specific embodiments, the portion of the lid is one of: (i) a cutout in an outer edge of the lid; (ii) the outer edge of the lid; and (iii) a second opening in the lid.

[0017] In certain embodiments, the corresponding portion of the battery pack housing is one of: (i) a corresponding cutout in an outer edge of the battery pack housing; (ii) the outer edge of the battery pack housing; and (iii) a corresponding second opening in the battery pack housing.

[0018] A method of securing a lid to an electric vehicle (EV) battery pack is also provided. The method includes providing a fastener as described in the preceding paragraphs. The method further includes disposing the lid on a housing of the battery pack to cover an opening in the housing. The method further includes inserting the first end of the fastener through a first opening in the lid and a corresponding first opening in the battery pack housing. The method further includes engaging the first retaining feature with an underside surface of the battery pack housing or a surface of the lid. The method further includes rotating the second end of the fastener in a direction toward the lid or toward the battery pack housing such that the second retaining feature engages the outer portion of the lid and the corresponding outer portion of the battery pack housing to clamp the lid to the battery pack housing and to compress the seal between the lid and the battery pack housing.

[0019] In specific embodiments, the method further includes disposing a seal between the battery pack housing and the lid, wherein clamping the lid to the battery pack housing with the fastener compresses the seal between the lid and the battery pack housing.

[0020] In particular embodiments, the fastener further includes a third leg extending from the elongated body, and a third retaining feature on said third leg; and the method further includes compressing the lid against the seal with the third retaining feature.DESCRIPTION OF THE DRAWINGS

[0021] Various advantages and aspects of this disclosure may be understood in view of the following detailed description when considered in connection with the accompanying drawings, wherein:

[0022] Figure 1 is a perspective view of a fastener in accordance with some embodiments of the disclosure, for securing a battery pack lid to a housing of a battery pack;

[0023] Figure 2 is a perspective view of the fastener securing the lid to the battery pack housing and compressing a seal between the lid and the battery pack housing;

[0024] Figure 3 is a schematic illustration of a method of securing a lid to a battery pack, using the fastener;

[0025] Figure 4 is a side sectional view of the battery pack illustrating the direction of movement to engage the fastener with the battery pack;

[0026] Figure 5 is a perspective view of the fastener securing the lid to the battery pack;

[0027] Figure 6 is a perspective view of the fastener securing the lid to the battery pack in accordance with some embodiments of the disclosure;

[0028] Figure 7 is a perspective view of the fastener securing the lid to the battery pack in accordance with other embodiments of the disclosure;

[0029] Figure 8 is a perspective view of the fastener securing the lid to the battery pack in accordance with yet other embodiments of the disclosure;

[0030] Figure 9 is a schematic illustration of a method of releasing the fastener from the lid and battery pack housing;

[0031] Figure 10 is a perspective view of a fastener in accordance with other embodiments of the disclosure;

[0032] Figure 11 is another perspective view of the fastener of Figure 10;

[0033] Figure 12 is a perspective view of the fastener of Figure 10 securing a lid to a battery pack;

[0034] Figure 13 is a perspective view of a fastener in accordance with yet other embodiments of the disclosure;

[0035] Figure 14 is a sectional view of the fastener of Figure 13 securing a lid to a battery pack;

[0036] Figure 15 is a perspective view of a fastener in accordance with yet other embodiments of the disclosure; and

[0037] Figure 16 is a sectional view of the fastener of Figure 15 securing a lid to a battery pack.DETAILED DESCRIPTION OF THE INVENTION

[0038] A fastener for an electric vehicle (EV) battery pack lid is provided. Referring to Figures 1 -16, wherein like numerals indicate corresponding parts throughout the several views, the fastener is illustrated and generally designated at 10, 110, 210, 310. The fastener 10, 110, 210, 310 elastically deforms to provide a clamping force that secures a lid / cap / cover onto a battery pack housing as described in more detail below. The fastener 10, 1 10, 210, 310 is also quickly assembled onto the lid and battery back housing, thereby reducing cycle time for securing the lid on the battery pack. Certain features of the fastener 10, 110, 210, 310 are functional, but can be implemented in different aesthetic configurations.

[0039] With reference to Figures 1 -9, the fastener 10 includes an elongated body 12 having a first end 14, an opposite second end 16, and an upper surface 18 and lower surface 20 extending between the first and second ends. The fastener 10 further includes a first retaining feature 22 that is proximate and adjacent to the first end 14 (and thus distal from the second end 16), and a second retaining feature 24 proximate and adjacent to the second end 16 (and thus distal from the first end 14). In the embodiments shown in Figures 1 -9, theelongated body 12 is a strip of material such as an elongated (greater in length than width) piece of metal that is bent longitudinally at locations along the length of the body to include a plurality of bends. For example, the elongated body may have four bends including a first bend 26, a second bend 28, a third bend 30, and a fourth bend 32. Each of the bends 26, 28, 30, 32 may form an angle in the body 12 that is greater than 90 degrees, although for reasons that will become more apparent below, the first bend 26 forms an angle significantly greater than 90 degrees (closer to 180 degrees than 90 degrees) while the fourth bend 32 forms an angle close to 90 degrees (i.e., not much greater than 90 degrees, for example, 100 degrees). The first retaining feature 22 is located at the first bend 26 and is particularly the portion of the upper surface 18 of the body 12 at the first bend 26. The second bend 28, third bend 30, and fourth bend 32 form the other portions of the body 12, particularly, a first prong 34, an arm / crown 36, and a second prong 38. The second retaining feature 24 is a locking tab located on the second prong 38 and projecting outwardly from the lower surface 20 of the body 12.

[0040] With specific reference now to Figures 2-5, the fastener 10 secures a lid / cap 40 that covers over an opening to an internal chamber within a battery pack housing 42 in which a plurality of battery cells are contained. In order to sufficiently seal the internal chamber of the battery pack, a seal 43 such as a gasket or similar is disposed around the perimeter of the opening that is covered by the lid. The seal 43 is thus sandwiched between the lid 40 and the housing 42 when the lid is placed over the opening in the housing. The lid 40 includes a first opening 44 that is spaced from but proximate to an outer edge 46 of the lid. The housing 42 includes a corresponding first opening 48 that is spaced from but proximate to an outer edge 50 of the housing. By “corresponding” it is meant that these two openings 44, 48 are complementary, i.e. when the lid 40 is properly aligned with the housing 42, the two openings 44, 48 are in alignment and the two openings 44, 48 preferably have the same or nearly the same size and / or shape. In some embodiments, the two first openings 44, 48 have a complementary polygonal shape as shown, such as but not limited to square shape, a rectangular shape, a triangular shape, or other polygon shape. In other embodiments (not shown), the first openings 44, 48 may have a complementary circular or oval shape. To install the fastener 10, the first end 14 of the elongated body 12 is inserted into and through the first opening 44 in the lid 40 and the corresponding first opening 48 in the housing 42. The fastener 10 is inserted through the first openings 44, 48 to a point at which the first retaining feature 22 contacts and is engaged with an underside surface of the housing 42, i.e. a surface that is opposite the surface on which the lid 40 is disposed. In this configuration, the first prong 34 of the body 12 extends through the openings 44, 48, and the second end 16 of the body is disposed adjacent the outer edges 46, 50 of the lid and housing. Further, the arm / crown 36 of the body 12 is spaced from the surface of the lid 40 and disposed at anangle relative to the surface of the lid as shown in Figure 4. Next, the arm / crown 36 and second prong 38 are rotated in a direction toward the lid 40, with the engagement between the first retaining feature 22 and the housing 42 providing a fulcrum and the arm / crown 36 functioning as a lever. This rotation bends the elongated body 12 of the fastener 10, and the second retaining feature 24 is pressed into engagement with a portion of the housing 42 to hold the second prong 38 and arm 36 in a closed position as shown in Figures 2 and 5. In the closed position, the second retaining feature 24 and the third bend 30 contact a portion the lid 40 and housing 42, and these two contact points together with the contact of the first retaining feature 22 (third contact point) hold the fastener 10 in place. The mechanical stress on the fastener 10 in the closed position caused by the torque of the second retaining feature 24 relative to the first retaining feature 22 may be primarily at the second bed 28, the first prong 34, the third bend 30, and a portion of the arm 36 adjacent the third bend 30. Further, the bending of the elongated body 12 between the first and second bends 26, 28 and between the third and fourth bends 30, 32 applies a clamping force on the lid 40 that compresses the seal 43 against the housing 42 and ensures that the seal 43 provides a tight seal that prevents gases, liquids, and debris from entering the internal chamber within the housing 42. Furthermore, the clamping force / stress on the fastener 10 resists other outside forces from loosening the clamp, such as vibration, internal pressure within the battery pack housing, etc.

[0041] In some embodiments shown in Figures 2, 5, and 6, the portion of the lid 40 and housing 42 contacted and engaged by the second prong 38 and second retaining feature 24 is a cutout 52 in the outer edge 46 of the lid 40 and a corresponding cutout 54 in the housing 42, wherein the cutouts 52, 54 provide a point of contact for the fastener 10. In other embodiments shown in Figure 7, the portion of the lid 40 and housing 42 contacted and engaged by the second prong 38 and second retaining feature 24 is simply the outer edge 46 of the lid 40 and the outer edge 50 of the housing 42, i.e. there is no cutout or other feature along the length of the outer edges 46, 50. In yet other embodiments shown in Figure 8, the portion of the lid 40 and housing 42 contacted and engaged by the second prong 38 and second retaining feature 24 is a second opening 56 in the lid 40 and a corresponding second opening 58 in the housing 42, i.e. the fastener 10 extends through two openings in both the lid and the housing. Further, in the embodiments of Figures 6 and 7, the fastener 10 is disposed transverse / perpendicular to the outer edges 46, 50 of the lid 40 and housing 42 and thus also perpendicular to the seal 43. On the other hand, in the embodiments of Figure 8, the fastener 10 is disposed parallel to the outer edges 46, 50 of the lid 40 and housing 42 and thus also parallel to the seal 43.

[0042] In some embodiments as described above, the fastener 10 may be installed from the top in a direction from the lid 40 to the battery pack housing 42. In other embodiments (notshown), the fastener 10 may be installed from the bottom in a direction from the battery pack housing 42 to the lid 40. In these embodiments, the first retaining feature 22 contacts the lid 40 (rather than the battery pack housing 42), the third bend 30 contacts the battery pack housing 42 (rather than the lid 40), and the second retaining feature 24 contacts the lid 40 (rather than the battery pack housing 42).

[0043] Turning to Figure 9, to remove the fastener 10 from the lid 40 and battery pack housing 42, a tool such as a flathead screwdriver or similar can be used. Particularly, the body 12 of the fastener 10 includes an opening 60 in a portion of the arm / crown 36 that is adjacent to the second prong 38. The tool is inserted through the opening 60 and pressed against the second prong 38 to apply a force that moves the second prong 38 outwardly to disengage the second retaining feature 24 from the housing 42 and lid 40. Once the second retaining feature 24 is disengaged, the arm / crown 36 may be rotated away from the lid 40, which releases the tension on the first retaining feature 22 and allows the body 12 of the fastener 10 to be removed from the first openings 44, 48.

[0044] With reference now to Figures 10-12, in other embodiments the fastener 1 10 includes an elongated body 112 having a first end 114, an opposite second end 162, and an upper surface 118 and lower surface 120 extending between the first and second ends. The fastener 110 further includes a first retaining feature 122 that is proximate and adjacent to the first end 114 (and thus distal from the second end 162), and a second retaining feature 164 proximate and adjacent to the second end 162 (and thus distal from the first end 114). The elongated body 1 12 is a strip of material such as an elongated (greater in length than width) piece of metal that is bent longitudinally at locations along the length of the body to include a plurality of bends. In these embodiments, the elongated body 1 12 has five bends including a first bend 166, a second bend 168, a third bend 170, a fourth bend 172, and a fifth bend 174. Similar to the first embodiment, the first bend 166 of the fastener 110 forms an angle significantly greater than 90 degrees (closer to 180 degrees than 90 degrees). The fifth bend 174, which is unique to the fastener 1 10, is a nearly complete turn in the body 112 such that the second end 162 is folded back towards and adjacent the fourth bend 172 and the body 1 12 thereby has a folded portion 176. The fastener 1 10 also differs from the fastener 10 in that in the fastener 110, the distance between the first bend 166 and the second bend 168 in the longitudinal direction is short such that the second bend 168 is adjacent or nearly adjacent to the first bend 166, whereas in the fastener 10 the second bend 28 is spaced a distance from the first bend 26 by an elongated arm portion. The first retaining feature 122 is located at the first bend 166 and is particularly the portion of the upper surface 118 of the body 112 at the first bend 126. The second bend 168, third bend 170, and fourth bend 172 form the other portions of the body 1 12, particularly, a first prong 134, an arm / crown 136, and a second prong 138. In these embodiments of the fastener 110, the second retainingfeature 164 is a locking tab projecting from a side of the folded portion 176 towards the first end 114 of the body 112. As shown, the second retaining feature 164 comprises a pair of these tabs, each projecting from an opposite side of the folded portion 176, although it should be understood that the second retaining feature 164 may comprise only a single locking tab projecting from one of the sides of the folded portion. The locking tab of the second retaining feature 164 includes a contact surface 178 that in use engages the fastener 110 with a surface of a component in a fastened disposition.

[0045] As shown in Figure 12, in a fastened disposition the first prong 134 of the body 112 extends through openings 144, 148 in the lid 140 and housing 142, respectively. In this disposition, the first retaining feature 122 contacts and is engaged with an underside surface of the housing 142, i.e. a surface that is opposite the surface on which the lid 140 is disposed. The second end 162 of the body 112 is disposed adjacent the outer edges 146, 150 of the lid 140 and housing 142. The second retaining feature 164 is pressed into engagement with a portion of the lid 140 and housing 142, for example, a cutout portion 152 of the lid 140 and a cutout portion 154 of the housing 142. Particularly, the contact surface 178 of the second retaining feature 164 contacts an underside surface of the housing 142 that faces away from the lid 140. Further, the second retaining feature 164 may include a sloped surface 180 that aides in sliding the second retaining feature 164 along the outer edges 146, 150 of the lid 140 and housing 142 as the fastener 110 is rotated into the fastened disposition. To release the fastener 110, a tab portion 182 at the second end 162 may be pulled outwardly away from the second prong 138 to move the second retaining feature 164 out of engagement with the housing 142. Alternatively, a tool may be used in between the second prong 138 and the folded portion 176 to bend the body 112 at the fourth bend 172 to move the second retaining feature 164 out of engagement. Once the second retaining feature 164 is disengaged, the fastener 1 10 may be rotated away from the lid 140, which disengages the first retaining feature 122 from the housing 142.

[0046] Turning next to Figures 13 and 14, in other embodiments the fastener 210 includes an elongated body 212 having a first end 214, an opposite second end 263, and an upper surface 218 and lower surface 220 extending between the first and second ends. The fastener 210 further includes a first retaining feature 223 that is proximate and adjacent to the first end 214 (and thus distal from the second end 263), and a second retaining feature 265 proximate and adjacent to the second end 263 (and thus distal from the first end 214). The elongated body 212 is a strip of material such as an elongated (greater in length than width) piece of metal that is bent longitudinally at locations along the length of the body to include a plurality of bends. In these embodiments, the elongated body 212 has six bends including a first bend 267, a second bend 269, a third bend 271 , a fourth bend 273, a fifth bend 275, and a sixth bend 277. The first retaining feature 223 is located between the firstbend 267 and the end 214 of the body 212, and the first retaining feature 223 is particularly the portion of the upper surface 218 of the body 212 between the first bend 267 and the end 214. The second bend 269, third bend 271 , fourth bend 273, and fifth bend 275 form the other portions of the body 212, particularly, a first prong 234, an arm / crown 236, and a second prong 238. In these embodiments of the fastener 210, the second retaining feature 265 is a foot between the sixth bend 277 and the second end 263 of the body 212. The second retaining feature 265 is formed by bending the end 263 of the body 212 at the sixth bend 277, such that the foot defining the second retaining feature 265 is a bent or hooked end. The second retaining feature 265 is also at an end of a leg 279 extending between the fifth bend 275 and the sixth bend 277.

[0047] As shown in Figure 14, in a fastened disposition the first prong 234 of the body 212 extends through openings 244, 248 in the lid 240 and housing 242, respectively. In this disposition, the first retaining feature 223 contacts and is engaged with an underside surface of the housing 242, i.e. a surface that is opposite the surface on which the lid 240 is disposed. The second prong 238 of the body 212 is disposed adjacent the outer edges 246, 250 of the lid 240 and housing 242, and the second end 263 of the body 212 is adjacent an underside surface of the housing 242. The second retaining feature 265 is pressed into engagement with the underside surface of the housing 242 that is adjacent the outer edge 250 and that faces away from the lid 240. To release the fastener 210, the second retaining feature 265 may be pulled outwardly away from the lid 240 and housing 242 to move the second retaining feature 265 out of engagement with the housing 242 underside surface. Once the second retaining feature 265 is disengaged, the fastener 210 may be rotated away from the lid 240, which disengages the first retaining feature 223 from the housing 242. The body 212 may then be pulled out of and removed from the openings 244, 248 in the lid 240 and housing 242.

[0048] With reference next to Figures 15 and 16, in yet other embodiments the fastener 310 includes an elongated body 312 having a first end 314, an opposite second end 363, and an upper surface 318 and lower surface 320 extending between the first and second ends. The fastener 310 further includes a first retaining feature 323 that is proximate and adjacent to the first end 314 (and thus distal from the second end 363), and a second retaining feature 365 proximate and adjacent to the second end 363 (and thus distal from the first end 314). The elongated body 312 is a strip of material such as an elongated (greater in length than width) piece of metal that is bent longitudinally at locations along the length of the body to include a plurality of bends. In these embodiments, the elongated body 312 has six bends including a first bend 383, a second bend 384, a third bend 385, a fourth bend 386, a fifth bend 387, and a sixth bend 388. The first retaining feature 323 is located between the first bend 383 and the second bend 384, and the first retaining feature 323 is particularly theportion of the upper surface 318 of the body 312 between the first bend 383 and the second bend 384. The second bend 384, third bend 385, fourth bend 386, and fifth bend 387 form the other portions of the body 312, particularly, a first prong 334, an arm / crown 336, and a second prong 338. In these embodiments of the fastener 310, the second retaining feature 365 is a foot between the sixth bend 388 and the second end 363 of the body 312. The second retaining feature 365 is also at an end of a foot 379 extending between the fifth bend 387 and the sixth bend 388. The fastener 310 additionally includes a third leg 390 that is connected to and extends from the crown 336 of the body 312. As shown by example, the third leg 390 is connected by bridges that extend between the lateral sides of the crown 336 and lateral sides of the third leg 390, such that the third leg 390 is spaced from the crown 336. However, the third leg 390 may not be spaced from the crown 336. The third leg 390 includes a third retaining feature 392 that is a foot formed by a bend 393 in the third leg 390. The third leg 390 extends in a direction towards the first end 314 and away from the second end 363, and extends outwardly from a boundary of the crown 336 and above the first prong 334. The third retaining feature 392 is generally disposed above the first retaining feature 323. The third retaining feature 392 provides an additional clamping load against the seal between the housing and the lid as described in greater detail below.

[0049] As shown in Figure 16, in a fastened disposition the first prong 334 of the body 312 extends through openings 344, 348 in the lid 340 and housing 342, respectively. In this disposition, the first retaining feature 323 contacts and is engaged with an underside surface of the housing 342, i.e. a surface that is opposite the surface on which the lid 340 is disposed. The second prong 338 of the body 312 is disposed adjacent the outer edges 346, 350 of the lid 340 and housing 342, and the second end 363 of the body 312 is adjacent an underside surface of the housing 342. The second retaining feature 365 is pressed into engagement with the underside surface of the housing 342 that is adjacent the outer edge 350 and that faces away from the lid 340. Further, the third retaining feature 392 is pressed into engagement with the top / outer surface of the lid 340 and provides a downward pressure and clamping load adjacent to the opening 344 in the lid 340 and directly above the seal 394 between the lid 340 and the housing 342. Further, the lid 340 and housing 342 are squeezed between the first retaining feature 323 and the third retaining feature 392. The third retaining feature 392 thereby provides a contact point closer to the openings 344, 348 in the lid 340 and housing 342 and close to the seal 394, and the third retaining feature 392 tightly secures the lid 340 against the seal 394 surface and aides in maintaining the seal between the lid 340 and housing 342. The third retaining feature 392 also advantageously reduces the insertion force when inserting the fastener 310 into the openings 344, 348 and rotating the fastener 310 to bring the second retaining feature 365 into engagement with the housing 342. To release the fastener 310, the second retaining feature 365 may be pulled outwardlyaway from the lid 340 and housing 342 to move the second retaining feature 365 out of engagement with the housing 342 underside surface. Once the second retaining feature 365 is disengaged, the fastener 310 may be rotated away from the lid 340, which disengages the first retaining feature 323 from the housing 342. The body 312 may then be pulled out of and removed from the openings 344, 348 in the lid 340 and housing 342.

[0050] Preferably, the fastener 10, 110, 210, 310 may be formed of a metal or metal alloy as described above. However, it should be understood that the fastener may be formed of other materials such as a plastic or other similarly suitable material. Alternatively, the fastener may be a hybrid formed partially of metal and partially of plastic. Further, in some embodiments, the fastener 10, 110, 210, 310 may be formed as an integral, one-piece construction. Additionally, in particular embodiments, the parts of the fastener 10, 110, 210, 310 may all be part of a one-piece element formed by bending portions of a single metal section.

[0051] Furthermore, while the fastener 10, 110, 210, 310 has been described as fastening / securing a lid to a battery pack, it should be understood that the fastener is not limited to this application and may be applied to other applications, such as fastening one panel to another panel or fastening a panel to an extruded profile, or even other applications requiring one part (not necessarily a panel) to be fastened to another part (not necessarily a panel). Also, the fastener may be applied to applications other than vehicular applications, such as in energy storage applications in which battery packs are utilized but the battery packs are stationary. In addition, the fastener may be used to fasten closed a box which contains electric or electronic components other than a battery pack.

[0052] It is to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments which fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, different, special, and / or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.

[0053] Further, any ranges and subranges relied upon in describing various embodiments of the present invention independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and / or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the present invention, and such ranges and subrangesmay be further delineated into relevant halves, thirds, quarters, fifths, and so on. As just one example, a range “of from 0.1 to 0.9” may be further delineated into a lower third, i.e., from 0.1 to 0.3, a middle third, i.e., from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9, which individually and collectively are within the scope of the appended claims, and may be relied upon individually and / or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language which defines or modifies a range, such as “at least,” “greater than,” “less than,” “no more than,” and the like, it is to be understood that such language includes subranges and / or an upper or lower limit. As another example, a range of “at least 10” inherently includes a subrange of from at least 10 to 35, a subrange of from at least 10 to 25, a subrange of from 25 to 35, and so on, and each subrange may be relied upon individually and / or collectively and provides adequate support for specific embodiments within the scope of the appended claims. Finally, an individual number within a disclosed range may be relied upon and provides adequate support for specific embodiments within the scope of the appended claims. For example, a range “of from 1 to 9” includes various individual integers, such as 3, as well as individual numbers including a decimal point (or fraction), such as 4.1 , which may be relied upon and provide adequate support for specific embodiments within the scope of the appended claims.

Claims

CLAIMS1 . A fastener for an electric vehicle (EV) battery pack lid, the fastener comprising: an elongated body having first and second opposite ends, and upper and lower surfaces extending between said first and second ends; a first retaining feature proximate said first end; and a second retaining feature proximate said second end; wherein said first retaining feature is configured to be insertable through a first opening in a battery pack lid and a corresponding first opening in a battery pack housing and configured to be engageable with one of a surface of the battery pack housing or a surface of the battery pack lid; wherein said second retaining feature is configured to be engageable with one of a portion of the battery pack lid and a corresponding portion of the battery pack housing; wherein when said first retaining feature is engaged with the surface of the battery pack housing or the surface of the battery pack lid, said second end is angularly pivotable toward the battery pack lid or the battery pack housing to engage said second retaining feature with said portion of the battery pack lid or said corresponding portion of the battery pack housing to clamp the battery pack lid to the battery pack housing.

2. The fastener of claim 1 , wherein said elongated body is a strip of metal including a plurality of bends in a longitudinal direction.

3. The fastener of claim 2, wherein said elongated body includes four longitudinal bends.

4. The fastener of claim 3, wherein at least one of said four longitudinal bends has an angle of greater than 90 degrees.

5. The fastener of claim 4, wherein each of said four longitudinal bends has an angle of greater than 90 degrees.

6. The fastener of claim 1 , wherein said first retaining feature is a portion of said upper surface at a longitudinal bend in the elongated body.

7. The fastener of claim 1 , wherein said second retaining feature is a locking tab projecting from said lower surface.

8. The fastener of claim 1 , wherein said elongated body, said first retaining feature, and said second retaining feature are all part of a one-piece element formed by bending portions of a metal piece.

9. The fastener of claim 1 , further comprising a third leg extending from said elongated body, and a third retaining feature on said third leg.

10. A battery pack for an electric vehicle (EV), the battery pack comprising: a housing defining an internal chamber and having an opening providing access to the internal chamber; a plurality of battery cells disposed in the internal chamber; a seal disposed around the perimeter of the opening; a lid that covers over the opening and sandwiches the seal between the housing and the lid; a first opening in the lid and a corresponding first opening in the housing; and the fastener of claim 1 ; wherein the fastener is insertable through said first opening in the lid and said corresponding first opening in the housing, and engageable with a portion of the lid and a corresponding portion of the housing to clamp the lid to the housing and to compress the seal between the lid and housing.

11. The battery pack of claim 10, wherein said first opening in the lid and said corresponding first opening in the battery pack housing have a complementary polygonal shape.

12. The battery pack of claim 10, wherein said first opening in the lid and said corresponding first opening in the battery pack housing have a complementary circular or oval shape.

13. The battery pack of claim 10, wherein said portion of the lid is one of: (i) a cutout in an outer edge of the lid; (ii) the outer edge of the lid; and (iii) a second opening in the lid.

14. The battery pack of claim 13, wherein said corresponding portion of the battery pack housing is one of: (i) a corresponding cutout in an outer edge of the battery pack housing; (ii) the outer edge of the battery pack housing; and (iii) a corresponding second opening in the battery pack housing.

15. A method of securing a lid to an electric vehicle (EV) battery pack, the method comprising: providing the fastener of claim 1 ; disposing the lid on a housing of the battery pack to cover an opening in the housing; inserting said first end of the fastener through a first opening in the lid and a corresponding first opening in the battery pack housing; engaging said first retaining feature with one of an underside surface of the battery pack housing or a surface of the lid; and rotating said second end of the fastener in a direction toward the lid or toward the battery pack housing such that said second retaining feature engages the outer portion of the lid and the corresponding outer portion of the battery pack housing to clamp the lid to the battery pack housing.

16. The method of claim 15, further including the step of disposing a seal between the battery pack housing and the lid, wherein clamping the lid to the battery pack housing with the fastener compresses the seal between the lid and the battery pack housing.

17. The method of claim 16, wherein the fastener further comprises a third leg extending from said elongated body, and a third retaining feature on said third leg; and wherein the method further comprises compressing the lid against the seal with the third retaining feature.

Images