Battery pack

Abstract

A battery pack includes a housing defining an internal cavity, a first cell module assembly (CMA) arranged within the internal cavity and including a first plurality of battery cells coupled to a first frame, the first frame including a first notch, and a second CMA arranged side-by-side with the first CMA within the internal cavity, the second CMA including a second plurality of battery cells coupled to a second frame, the second frame including a first protrusion extending into the first notch.

Description

Atty. Dkt. No.: 016831-1993BATTERY PACKCROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Patent Application No.63 / 745,570, filed on January 15, 2025, which is incorporated by reference herein in its entirety.BACKGROUND

[0002] Battery packs typically provide electrical power to various forms of equipment.SUMMARY

[0003] One aspect of the present disclosure relates to a battery pack including a housing defining an internal cavity, a first cell module assembly (CMA) arranged within the internal cavity and including a first plurality of battery cells coupled to a first frame, the first frame including a first notch, and a second CMA arranged side-by-side with the first CMA within the internal cavity, the second CMA including a second plurality of battery cells coupled to a second frame, the second frame including a first protrusion extending into the first notch.

[0004] In some embodiments, the first notch includes a first flange and a second flange, the first flange and the second flange configured to contain the first protrusion therebetween. In some embodiments, the first frame includes a second notch, and the second frame includes a second protrusion extending into the second notch. In some embodiments, the first CMA includes a third frame including a second notch, and the second CMA includes a fourth frame including a second protrusion extending into the second notch. In some embodiments, the second frame includes a second notch, the battery pack further includes a third CMA arranged side-by-side with the second CMA within the internal cavity, the third CMA including a third plurality of battery cells coupled to a third frame, the third frame including a second protrusion extending into the second notch.

[0005] In some embodiments, the first CMA includes a plurality of battery cells, a collector plate electrically coupled to the plurality of battery cells, and a voltage tab directly coupled to the -1- 4937-7944-8709Atty. Dkt. No.: 016831-1993collector plate without the use of a fastener, the voltage tab extending away from the collector plate and configured to be coupled to an electrical connector. In some embodiments, the voltage tab includes a base flange coupled to the collector plate, the base flange including a flange cavity, wherein the collector plate includes a protrusion extending into the flange cavity. In some embodiments, a width of the flange cavity increases with a depth of the flange cavity, and a width of the protrusion increases with the depth of the flange cavity. In some embodiments, an outer surface of the protrusion is in contact with substantially all of an inner surface of the flange cavity.

[0006] In some embodiments, the housing defines the internal cavity between a base and an upper case, the battery pack further includes a terminal coupled to a terminal plate and configured to be coupled to an electrical connector, the terminal electrically connected to the first CMA, and a bracket coupling the terminal plate to the base. In some embodiments, the upper case includes a first opening configured to receive a portion of the terminal plate and a plurality of second openings configured to receive fasteners for coupling the terminal plate to the upper case. In some embodiments, the first opening and the plurality of second openings are positioned such that the terminal plate is configured to be coupled to the bracket and the upper case substantially simultaneously. In some embodiments, the bracket includes a flat sheet of material including a plurality of bends.

[0007] In some embodiments, the battery pack includes an upper plate positioned above the first CMA in the internal cavity, a battery management system (BMS) positioned on the upper plate in the internal cavity, and a BMS cover coupled to the upper plate and including an upper sheet extending over the BMS. In some embodiments, the upper sheet includes a pair of sloped halves that meet at an apex and slope downward toward edges of the upper sheet. In some embodiments, the battery pack further includes side rails extending along sides of the pair of sloped halves of the upper sheet, the sloped halves of the upper sheet and the side rails configured to direct water droplets toward the edges of the upper sheet.

[0008] In some embodiments, the housing includes a base and a case coupled to the base, the case and the base defining the internal cavity, the case including a protrusion extending from an upper-2- 4937-7944-8709Atty. Dkt. No.: 016831-1993surface of the case and a plurality of holes, the protrusion and the plurality of holes forming a mounting pattern for coupling a vehicle control module or a charger to the case.

[0009] Another aspect of the present disclosure relates to a battery pack including a housing defining an internal cavity between a base and an upper case, a first CMA arranged within the internal cavity and including a first plurality of battery cells, a terminal coupled to a terminal plate and configured to be coupled to an electrical connector, the terminal electrically connected to the first CMA, and a bracket coupling the terminal plate to the base.

[0010] In some embodiments, the upper case includes a first opening configured to receive a portion of the terminal plate and a plurality of second openings configured to receive fasteners for coupling the terminal plate to the upper case. In some embodiments, the first opening and the plurality of second openings are positioned such that the terminal plate is configured to be coupled to the bracket and the upper case substantially simultaneously.

[0011] In some embodiments, the bracket includes a flat sheet of material including a plurality of bends.

[0012] In some embodiments, the upper case includes a protrusion extending from an upper surface of the upper case and a plurality of holes, the protrusion and the plurality of holes form a mounting pattern for coupling a vehicle control module or a charger to the upper case. In some embodiments, the plurality of holes are blind holes that do not extend through the upper case. In some embodiments, the base includes a protruding rib extending around a perimeter of the base, and the upper case includes a trough extending around a perimeter of the upper case and configured to receive the protruding rib. In some embodiments, the protrusion and the plurality of holes are positioned on standoffs protruding from the upper surface of the upper case.

[0013] Another aspect of the present disclosure relates to a battery pack including a housing defining an internal cavity, at least one CMA arranged within the internal cavity, each CMA including a plurality of battery cells, an upper plate positioned above the at least one CMA in the-3- 4937-7944-8709Atty. Dkt. No.: 016831-1993internal cavity, a BMS positioned on the upper plate in the internal cavity, and a BMS cover coupled to the upper plate and including an upper sheet extending over the BMS.

[0014] In some embodiments, the upper sheet includes a pair of sloped halves that meet at an apex and slope downward toward edges of the upper sheet. In some embodiments, the battery pack further includes side rails extending along sides of the pair of sloped halves of the upper sheet, the sloped halves of the upper sheet and the side rails configured to direct water droplets toward the edges of the upper sheet.

[0015] In some embodiments, the BMS cover includes side walls extending to the side rails, the side walls including openings under the side rails configured to allow airflow to the BMS. In some embodiments, each of the at least one CMA includes a mounting sleeve, wherein the upper plate is coupled to each mounting sleeve. In some embodiments, a footprint of the BMS is entirely within a footprint of the BMS cover. In some embodiments, the upper plate includes a plurality of protrusions, and the BMS cover includes a plurality of openings configured to receive the protrusions with an interference fit to couple the BMS cover to the upper plate. In some embodiments, the housing includes a base and a case coupled to the base, the case and the base defining the internal cavity, wherein the BMS and the BMS cover are positioned within the internal cavity.

[0016] Another aspect of the present disclosure relates to a housing of a battery pack including a base and a case coupled to the base, the case and the base defining an internal cavity, the case including a protrusion extending from an upper surface of the case and a plurality of holes, the protrusion and the plurality of holes form a mounting pattern for coupling a vehicle control module or a charger to the case. In some embodiments, the plurality of holes are blind holes that do not extend through the case.

[0017] In some embodiments, the protrusion and the plurality of holes are positioned on standoffs protruding from the upper surface of the case. In some embodiments, the standoffs define an-4- 4937-7944-8709Atty. Dkt. No.: 016831-1993airflow gap between the upper surface of the case and the vehicle control module or charger when mounted to the case.

[0018] In some embodiments, the plurality of holes are sized to receive self-tapping screws. In some embodiments, the plurality of holes and the protrusion form multiple common mounting patterns for different vehicle control modules or chargers.10019] Another aspect of the present disclosure relates to a CMA including a plurality of battery cells, a collector plate electrically coupled to the plurality of battery cells, and a voltage tab directly coupled to the collector plate without the use of a fastener, the voltage tab extending away from the collector plate and configured to be coupled to an electrical connector.

[0020] In some embodiments, the voltage tab includes a base flange coupled to the collector plate, the base flange including a cavity, wherein the collector plate includes a protrusion extending into the cavity. In some embodiments, a width of the cavity increases with a depth of the cavity, and a width of the protrusion increases with the depth of the cavity. In some embodiments, an outer surface of the protrusion is in contact with substantially all of an inner surface of the cavity. In some embodiments, the voltage tab includes a connector flange extending substantially perpendicular to the base flange and configured to receive the electrical connector.

[0021] In some embodiments, the collector plate is coupled to the voltage tab by plastically deforming a portion of the collector plate into a cavity of the voltage tab.

[0022] This summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.-5- 4937-7944-8709Atty. Dkt. No.: 016831-1993BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which.(0024] FIG. 1 is top perspective view of a battery pack, according to an exemplary embodiment.(0025] FIG. 2 is a front view of the battery pack of FIG. 1.(0026] FIG. 3 is a top view of the battery pack of FIG. 1.(0027] FIG. 4 is a perspective view of the battery pack of FIG. 1 with an upper cover of a housing of the battery pack hidden.

[0028] FIG. 5 is a partially exploded top perspective view of the battery pack of FIG. 1.

[0029] FIG. 6 is a partially exploded bottom perspective view of the battery pack of FIG. 1.

[0030] FIG. 7 is a top perspective view of a cell module assembly of the battery pack of FIG. 1.

[0031] FIGS. 8 and 9 are top views of portions of the battery pack of FIG. 1.

[0032] FIG. 10 is a top perspective view of a portion of the battery pack of FIG. 1.

[0033] FIG. 11 is a bottom perspective view of a portion of the battery pack of FIG. 1.

[0034] FIG. 12 is a cross-sectional view of a voltage tab couple to a collector plate of the battery pack of FIG. 1.

[0035] FIG. 13 is top perspective view of a portion of the battery pack of FIG. 1 with the upper cover removed.

[0036] FIG. 14 is top view of a portion of the battery pack of FIG. 1 with the upper cover removed.-6- 4937-7944-8709Atty. Dkt. No.: 016831-1993

[0037] FIG. 15 is top perspective view of a portion of the battery pack of FIG. 1 with the upper cover removed.

[0038] FIG. 16 is a side view of a portion of the battery pack of FIG. 1 with the upper cover removed.

[0039] FIG. 17 is a top view of the battery pack of FIG. 1 with the upper cover removed.

[0040] FIG. 18 is a bottom view of the upper case of the battery pack of FIG. 1.

[0041] FIG. 19 is top perspective views of a portion of the upper cover of the battery pack of FIG. 1.

[0042] FIG. 20 is a top perspective view of a portion of the battery pack of FIG. 1.

[0043] FIG. 21 is a bottom perspective view of a portion of the battery pack of FIG. 1.

[0044] FIG. 22 is a bottom perspective view of a base of a housing of the battery pack of FIG. 1.DETAILED DESCRIPTION

[0045] Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0046] Referring to the figures generally, the motor assembly described herein may be used in chore products, including outdoor power equipment, standby generators, portable jobsite equipment, indoor power equipment, or other appropriate uses. Power equipment may include lawn mowers, riding tractors, snow throwers, pressure washers, portable generators, tillers, log splitters, zero-turn radius mowers, walk-behind mowers, wide-area walk-behind mowers, riding mowers, standing mowers, rammers, compactors, concrete trowels, industrial vacuums, concrete -7- 4937-7944-8709Atty. Dkt. No.: 016831-1993saws, grinders, aerators, blowers, edge grinders, turf rakes, golf carts, industrial vehicles such as forklifts, utility vehicles, etc. Outdoor power equipment may, for example, use an internal combustion engine and / or a battery pack to drive an implement, such as a rotary blade of a lawn mower, a pump of a pressure washer, an auger of a snow thrower, the alternator of a generator, and / or a drivetrain of the outdoor power equipment. Portable jobsite equipment may include portable light towers, mobile industrial heaters, and portable light stands.

[0047] A “chore product” as used herein refers to any type of equipment, machine, or vehicle that may be used to perform a chore (e.g., an outdoor chore, an indoor chore, lawn care, etc ). For example, a chore product may include a motor, a pump, an actuator, a compressor, and / or another device that is electrically powered to operate some function of the chore product to facilitate performing a chore. In some embodiments, a chore is a task performed, either by a user or autonomously, at or near a household, a farm, an agricultural facility, a golf course, a building, a sidewalk, a park, a parking lot, a forest, a field, and / or a lawn. In some embodiments, a chore product transports an operator and performs a chore. In some embodiments, a chore product autonomously operates to perform a chore without an operator being present on the chore product or physically / manually manipulating the chore product.

[0048] Referring to FIGS. 1-6, a battery pack 100 is shown according to an exemplary embodiment. In general, the battery pack 100 is configured to supply electrical power to components (e.g., electric motors, user interfaces, controllers, power-take-off (PTO) units, etc.) on a chore product or outdoor power equipment. The battery pack 100 includes a housing assembly 102. In general, the housing assembly 102 is configured to enclose internal components of the battery pack 100. As shown, the housing assembly 102 includes a base or bottom portion, shown as base 104, and an upper portion, shown as case 106. The case 106 is supported on and coupled to the base 104.

[0049] According to an exemplary embodiment, the housing assembly 102 (e.g., the base 104, the case 106) is configured to provide structural support to one or more components of the battery pack 100. For example, the housing assembly 102 (e.g., the base 104, the case 106) may provide-8- 4937-7944-8709Atty. Dkt. No.: 016831-1993structural support to one or more cell module assemblies (CMAs) 149-155 positioned within the housing assembly 102 and each including battery cells 156, as described herein. In general, the housing assembly 102 defines an internal cavity or volume that is enclosed by the base 104 and the case 106. The base 104 includes a mounting flange 105 (which may be referred to as a base flange) with mounting holes extending therethrough. The case 106 includes a mounting flange 107 (which may be referred to as a case flange) that is similar in shape and includes mounting holes in a similar pattern. The mounting flange 105 of the base 104 may be coupled to the mounting flange 107 of the case 106 to couple the base 104 to the case 106 and enclose the CMAs 149-155 in the inner cavity.

[0050] The battery pack 100 includes a negative terminal 114 and a positive terminal 116 each partially covered by a cover 115 and coupled to a terminal plate 181. The battery pack 100 further includes a connector 118 covered by a cover 119 and coupled to the terminal plate 181. The terminal plate 181 may be coupled to the case 106 (e.g., by fasteners 183 inserted into holes 184 in the case 106) such that the negative terminal 114, the positive terminal 116, and / or the connector 118 extend through an opening 185 in the case 106. For example, the opening 185 may be shaped and configured to receive a portion of the terminal plate 181 having substantially the same shape such that the portion of the terminal plate 181 fills and fluidly seals the opening 185. In the illustrated embodiment, the negative terminal 114, the positive terminal 116, and the connector 118 all are supported on and extend through the case 106. In general, the negative terminal 114 and the positive terminal 116 facilitate power output from the battery pack 100. For example, corresponding electrical connectors may be electrically coupled to the negative terminal 114 and the positive terminal 116 to facilitate transferring electrical power from the battery pack 100 to a component on a chore product or outdoor power equipment. In some embodiments, the connector 118 is a data connector that facilitates data communication (e.g., over a controller area network (CAN) communication) between the battery pack 100 and an external controller (e.g., having at least one processor and at least one memory). In some embodiments, the connector 118 is in electrical communication with a battery management system (BMS) of the battery pack 100 and enables data communication between the BMS and the external controller. The BMS may be-9- 4937-7944-8709Atty. Dkt. No.: 016831-1993configured to control the battery pack 100 to ensure that the battery pack 100 and the battery cells 156 operate efficiently and within design limits. For example, the BMS may limit current into and out of the battery pack 100, monitor the voltage of the CMAs 149-155, monitor the state of charge and state of health of the battery cells 156, and balance the power distribution among the battery cells 156.

[0051] As shown in FIGS. 5-6, the battery pack 100 includes seven CMAs 149-155 enclosed within the housing assembly 102, for example, within an internal cavity or volume defined between the base 104 and the case 106. In other embodiments, the battery pack 100 may have more or fewer CMAs. The CMAs 149-155 are supported on the base 104 and arranged in a side-by-side orientation (e.g., supported on the same base platform or surface and not stacked upon one another). As shown in FIGS. 5-6, the CMAs are arranged in a 1 x 7 array. However, in other embodiments, the CMAs may be arranged in other locations (e.g., in a 2 x 3 array, in a 4 x 5 array, etc.).

[0052] Referring now to FIG. 7, a CMA 149 is shown according to an exemplary embodiment. In general, each CMA 149-155 may be designed to include similar components (e.g., a particular number of battery cells held in a support frame, with each battery cell being electrically coupled or bonded to a collector plate), with like features identified using the same reference numerals. In the illustrated embodiment, the CMA 149 includes a plurality of battery cells 156, a plurality of collector plates 157-159, a first or top cell frame 160, and a second or bottom cell frame 162. Each of the plurality of battery cells 156 includes a first end 166, a second end 168, and a body 170 extending between the first end 166 and the second end 168. In some embodiments, each of the battery cells 156 is cylindrical in shape. Each of the battery cells extends between the first cell frame 160 and the second cell frame 162. In some embodiments, each of the battery cells 156 is a lithium-ion battery cell.

[0053] Each of the collector plates 157, 159 is electrically coupled (e g., bonded) to a group of the battery cells 156. For example, each of the collector plates 157, 159 may be electrically coupled to approximately half of the battery cells 156 on the upper portion of the CMA 149. A divider 161-10- 4937-7944-8709Atty. Dkt. No.: 016831-1993may extend longitudinally across the upper portion of the CMA 149 and maintain separation between the collector plates 157, 159. A single collector plate 158 may be electrically coupled to all of the battery cells 156 on the lower portion of the CMA 149 (see, e.g., FIG. 6), thus electrically coupling the two halves of the group of battery cells 156. The first cell frames 160 and the second cell frames 162 each include a plurality of sleeves or apertures 171 and a plurality of first mounting sleeves 172. Each of the apertures 171 receives a respective one of the first end 166 or the second end 168 of the battery cells 156. The apertures 171 provide access through the first cell frame 160 for the electrical coupling between the respective battery cells 156 and the collector plates 157-159. The mounting sleeves 172 are arranged around an outer perimeter of the first cell frame 160 and the second cell frame 162 and extend upwardly past a first or top frame surface 174 of the first cell frame 160. A mounting sleeve 172 of the first cell frames 160 and a mounting sleeve 172 of the second cell frames 162 form an aligned pair. Each pair of mounting sleeves 172 receives a fastener 176 (e.g., a threaded fastener, such as a screw or bolt). Each fastener 176 extends into a mounting aperture 177 formed in the base 104 and is coupled to the first mounting sleeves 172 (see, e.g., FIG. 5), which forms a coupling between the case 106 and the CMA 149. In this way, for example, the base 104 provides structural support to the CMAs 149-155.

[0054] As discussed above, the CMAs 149-155 are arranged in a side-by-side orientation, rather than a stacked orientation, and no additional CMAs are stacked upon the CMAs 149-155, which reduces the number of mounting components required to mount the CMAs 149-155 within the housing assembly 102 and the overall weight of the battery pack 100. Referring now to FIGS. 8 and 9, the interface between the CMA 149 and the CMA 150 is shown in further detail, according to an exemplary embodiment. Each CMA 149-155 may be joined by a similar interface. The collector plates 157 each include a flange 163 with a plurality of openings 165. The collector plates 159 each include openings 167 arranged in substantially the same pattern as the openings 165. The CMAs 149-155 may be electrically coupled to each other by coupling the flange 163 of a CMA 150 to the collector plate 159 of the adjacent CMA 149, for example, using fasteners 169 (e.g., threaded fasteners, bolts, and nuts, etc.) inserted into the openings 165, 167.-11- 4937-7944-8709Atty. Dkt. No.: 016831-1993

[0055] Each of the cell frames 160, 162 includes at least one protrusion 175 extending from a first side of the CMA 149-155 and a corresponding notch 173 defined between two flanges 178 positioned on the opposite side of the CMA 149-155. For example, as shown in FIG. 8, each cell frame 160, 162 includes two protrusions 175 and two notches 173. When the flange 163 of a collector plate 157 of CMA 150 is coupled to the collector plate 159 of the adjacent CMA 149, the protrusions 175 of the CMA 149 extend into the notches 173 of the CMA 150. The notch 173 restricts the movement of the protrusion 175, thereby restricting the relative movement of adjacent CMAs 149, 150. For example, the protrusion 175 will contact one of the flanges 178 of the notch 173 if the CMA 149 moves laterally relative to the CMA 150 (or vice versa). Thus, the protrusion 175 and the corresponding notch 173 may constrain the relative positions of the CMAs 149, 150 to within a tolerance defined by the difference between a width of the protrusion 175 and the gap between the flanges 178. The protrusion 175 will also contact the bottom surface of the corresponding notch 173 if the CMA 149 moves toward the CMA 150 (or vice versa), thus maintaining a gap between other components of adjacent CMAs 149, 150.

[0056] Referring now to FIGS. 11 and 12, voltage tabs 201 of the CMAs 149-155 are shown, according to an exemplary embodiment. As shown in FIG. 10, the voltage tabs 201 are coupled to each collector plate 157, 159 (with the voltage tabs coupled to the collector plates 159 being coupled to the opposite side of the CMA 149-155, not shown). The voltage tab 201 may include a base flange 211 and a connector flange 212, which may extend substantially perpendicular to the base flange 211. An electrical connector 203 may be coupled to the connector flange 212 of the voltage tab 201. The connector 203 may be electrically coupled to the BMS and / or to the connector 118 by one or more wires 205. The voltage tabs 201 may allow for monitoring the voltage of the CMAs 149-155. In typical battery packs, the voltage tabs 201 are connected to a CMA using a fastener, such as a rivet or a bolt. As shown in FIG. 12, the voltage tab 201 is directly coupled to the collector plate 157 without the use of a fastener. Using a specialized punch, a cavity 207 is formed in the base flange 211 of the voltage tab 201 while a portion of the collector plate 157 is deformed into the cavity 207 to form a protrusion 209 having substantially the same shape as the cavity 207 (e.g., such that an outer surface of the protrusion 209 is in contact with substantially all-12- 4937-7944-8709Atty. Dkt. No.: 016831-1993of an inner surface of the cavity 207). In some embodiments, the punch that forms the voltage tab 201 is a TOX lock fitting. The lower portion of the cavity 207 and the corresponding lower portion of the protrusion 209 are wider than the respective upper portions of the cavity 207 and the protrusion 209 (e.g., a width of the cavity 207 and a width of the protrusion 209 both increase with a depth of the cavity). Thus, the voltage tab 201 cannot be easily decoupled from the collector plates 157 by, for example, pulling downward on the voltage tab 201. The voltage tab 201 is thus coupled to the collector plate 157 without the use of a fastener. Further, the tight fit between the outer surface of the protrusion 209 and the inner surface of the cavity 207 provides improved electrical connectivity compared to voltage tabs coupled together by fasteners.

[0057] Referring now to FIGS. 13 and 14, a bracket 301 is shown in the inner cavity of the battery pack 100, according to an exemplary embodiment. The case 106 is not shown. The bracket 301 may be used to hold the terminal plate 181 in place when the case 106 is not present. For example, during initial assembly and testing, the bracket 301 may hold the terminal plate 181 in place to support the terminals 114, 116, and the connector 118. To install the case 106, the case 106 may be lowered onto the base 104 such that the terminals 114, 116, and the connector 118 extend through the opening 185. The fasteners 183 may then be installed to couple the terminal plate 181 to the case 106. The bracket 301 allows the internal components of the battery pack 100 to be fully assembled before the case 106 is attached and thus allows testing of the battery pack 100 without the need to attach the case 106. The bracket 301 may ensure that the terminals 114, 116, and the connector 118 are kept away from other components of the battery pack 100 during initial testing. The terminal plate 181 may be simultaneously coupled to the bracket 301 and the case 106.

[0058] In prior designs without the bracket 301, terminals and a connector may have been set down on the base 104 during assembly while coupled to the CMAs via cables and were thus not tightly held in place. In some cases, the case would have to be installed and the terminals and the connector coupled to the case before testing. Then, if any adjustments were needed, the case could have to be removed, the adjustments made, and the case reinstalled. Further, without the bracket 301, coupling the terminals and connector to the case would be more difficult because the person -13- 4937-7944-8709Atty. Dkt. No.: 016831-1993assembling the battery pack would have to either attach the terminals and connector to the case before attaching the case to the base (which may be difficult considering the wired connections of the terminals and connector and the size of the case) or would have to hold the terminals and connector in place through an opening in the case while also connecting the fasteners to couple the terminals and connector to the case. The bracket 301 thus accelerates the assembly and initial testing process by holding the terminal plate 181 in place. Further, if repairs are made after initial assembly and use of the battery pack 100, the bracket 301 may hold the terminal plate 181 in place while the case 106 is removed to allow access to the internal cavity of the housing assembly 102.

[0059] The bracket 301 includes a lower flange 303 including apertures 305 and apertures 307. The apertures 305 may be configured to receive fasteners 309 that may be coupled to corresponding openings in the base 104. The fasteners 309 may, for example, be threadedly coupled to the openings in the base 104 such that the bracket 301 is coupled to the base 104. The apertures 307 may be configured to receive locating pins or protrusions 311 formed in the base 104. The protrusions 311 may extend upward from the base 104 into the apertures 307 such that the bracket 301 may be more precisely positioned on the base 104. The bracket 301 includes an upper flange 313 at its upper end including apertures 315 and apertures 317. The apertures 315 may be configured to receive fasteners 319 that may be coupled to corresponding openings in a lower flange of the terminal plate 181. Because the terminal plate 181 is coupled to the case 106 during operation of the battery pack 100, the fasteners 319 may be relatively less secure push-in (e g., plastic) rivets. The apertures 317 may be configured to receive locating pins or protrusions 321 formed in a lower flange of the terminal plate 181. The protrusions 321 may extend outward from the terminal plate 181 into the apertures 317 such that the bracket 301 may precisely position the terminal plate 181.

[0060] The bracket 301 may be made, for example, from a flat sheet of material (e.g., sheet metal) and may further include two intermediate flanges 323, forming three bends 325 between the flanges 303, 313, 323. Thus, the bracket 301 may form a spring-like structure with flexibility allowing the upper flange 313 to move relative to the lower flange 303. This may allow for some level of adjustability in the position of the terminal plate 181 during assembly, so that the holes in -14- 4937-7944-8709Atty. Dkt. No.: 016831-1993the terminal plate 181 configured to receive the fasteners 183 may be aligned with the corresponding holes in the case 106.

[0061] Referring now to FIGS. 15-17, a BMS cover 401 is shown according to an exemplary embodiment. As discussed above, the battery pack 100 may include a BMS configured to control the battery pack 100 by, for example, controlling the flow of power to, from, and within the battery pack 100 and monitoring the state of charge and state of health of the battery cells 156. The BMS (not shown) may be positioned on top of an upper plate 403, which may be coupled to the mounting sleeves 172 of the CMAs 149-155 above the battery cells 156. The BMS includes various electrical components that may generate a substantial amount of heat and be sensitive to moisture. As shown in FIGS. 15 and 16, the upper plate 403 includes mounting standoffs 405 that protrude from an upper surface 407 of the upper plate 403. The BMS may be mounted to these mounting standoffs 405 such that a gap is formed between the BMS and the upper surface 407. This may allow cooling air to flow below the BMS. The BMS cover 401 includes openings 425 on each side to allow airflow to reach the BMS.

[0062] The BMS cover 401 may be positioned above the BMS, such that an entire footprint of the BMS is under the footprint of the BMS cover 401. The BMS cover 401 may be mounted to the upper plate 403 using fasteners. Alternatively, as shown in the embodiment of FIGS. 15 and 16, the upper plate 403 may include protrusions 429, and the BMS cover 401 may include corresponding shaped openings 427 that form an interference fit with the protrusions 429. Thus, the BMS cover 401 may be coupled to the upper plate 403 by, for example, pushing the BMS cover 401 downward such that the openings 427 receive and engage the protrusions 429.

[0063] The BMS cover 401 may protect the BMS from condensation formed in the housing assembly 102. For example, when hot air inside the inner cavity of the housing assembly 102 cools down, condensation may form on the inner upper surface of the case 106. The condensation may form water droplets that may drip toward the upper plate 403. The BMS cover 401 includes an upper sheet 409 forming two sloped halves 411, 413 that meet at an apex 415 and slope downward toward edges 417, 419. The BMS cover 401 further includes side rails 421, 423-15- 4937-7944-8709Atty. Dkt. No.: 016831-1993extending along the sides of the halves 411, 413 of the upper sheet 409. The side rails 421, 423 protrude above the halves 411, 413 and ensure that water droplets that fall on the upper sheet 409 do not drip down the sides of the BMS cover 401 where they could pool and reach the BMS via the openings 425. The sloped halves 411, 413 of the upper sheet 409 may ensure that water flows away from the apex 415 to the edges 417, 419 and away from the BMS.

[0064] Referring now to FIG. 17, a top view of the battery pack 100 is shown with the case 106 removed according to an exemplary embodiment. The base 104 of the housing assembly 102 includes a recess, groove, or trough 501 (which may be referred to as a base trough) extending around the entire perimeter of the mounting flange 105 of the base 104. FIG. 18 shows a bottom view of the case 106 according to an exemplary embodiment. The case 106 of the housing assembly 102 includes a protruding rib 503 (which may be referred to as a case rib) extending around the entire perimeter of the mounting flange 107 of the case 106 that matches the trough 501 of the base 104. When the mounting flange 105 of the base 104 is coupled to the mounting flange 107 of the case 106, the base trough 501 may substantially align with the case rib 503, such that the rib 503 protrudes into the trough 501. In order to seal the housing assembly 102, a form-in-place gasket 505 may be formed between the trough 501 and the rib 503. The form-in-place gasket 505 may be formed by spraying an air-cured foam into the trough 501, coupling the case 106 to the base 104, and allowing the foam to expand and cure to fdl any gaps between the trough 501 and the rib 503. This may seal the inner cavity of the housing assembly 102 to an IP67 water resistance rating, indicating that the seal between the base 104 and the case 106 is substantially waterproof. The form-in-place gasket 505 may be made using a two-part air-cured urethane or silicone foam.

[0065] Referring now to FIG. 19, a rear portion of the case 106 is shown, according to an exemplary embodiment. The upper outer surface 108 of the case 106 includes mounting holes 109 and a locating protrusion 110. The rectangular pattern of the mounting holes 109 and locating protrusion 110 corresponds to a matching hole pattern in a vehicle control module (VCM) or a motor controller. When the battery pack 100 is used to power a vehicle, the VCM may be mounted to the battery pack 100. The vehicle control module (VCM) may be positioned on the upper outer -16- 4937-7944-8709Atty. Dkt. No.: 016831-1993surface 108 of the case 106 with the locating protrusion 110 extending through one hole in the VCM Fasteners may then be inserted through the other three holes in the VCM and coupled to the mounting holes 109. The upper outer surface 108 of the case 106 further includes two additional mounting holes 111 to accommodate a VCM or motor controller with a different common mounting pattern. The VCM may be located with the protrusion 110 extending through a first hole in the VCM, and the remaining holes in the VCM may be coupled to the two mounting holes 111 and the mounting hole 109 closest to the locating protrusion 110 to form a second rectangular mounting pattern corresponding to the common mounting pattern of the other VCM. The mounting holes 109, 111 may be self-tapping blind holes, such that a screw may be inserted and threadedly coupled to the case 106 by an interference fit. In other embodiments, the mounting holes 109, 111 may be threaded. The mounting holes 109, 111 may be blind holes to help maintain the waterproofing of the housing assembly 102.

[0066] Referring now to FIG. 20, a front portion of the case 106 is shown, according to an exemplary embodiment. The case 106 includes five standoffs 121 extending from the upper outer surface 108 of the case 106, four of which include mounting holes 123 and one of which includes a protrusion 125. The mounting pattern of the mounting holes 123 and the protrusion 125 correspond to the mounting pattern of a battery charger that may be used to charge the battery cells 156 of the battery pack 100. The battery pack may be mounted on the standoffs 121 with the protrusion 125 extending through one mounting hole of the charger. Because the charger may generate heat, the standoffs 121 ensure that there is a gap between the charger and the upper outer surface 108 of the case 106 to allow cooling air to flow across the underside of the charger. Fasteners may then be inserted through the other four holes in the charger and coupled to the mounting holes 123. The mounting holes 123 may be self-tapping blind holes, such that a screw may be inserted and threadedly coupled to the case 106 by an interference fit. In other embodiments, the mounting holes 123 may be threaded. The mounting holes 123 may be blind holes to help maintain the waterproofing of the housing assembly 102.

[0067] Referring now to FIG. 21, a portion of the bottom of the battery pack 100 is shown, according to an exemplary embodiment. The battery pack 100 includes a vent 511 coupled to a -17- 4937-7944-8709Atty. Dkt. No.: 016831-1993bottom surface of the base 104. FIG. 22 shows the bottom surface of the base 104, which includes a machined surface 513 around an opening 515 shaped to receive the vent 511. The opening 515 includes tabs 517 configured to engage hooks of the vent 511. The machined surface 513 and the opening 515 may be the only machined features of the base 104. The case 106 may not include any machined features aside from a small number of tapped holes. The base 104 and the case 106 may be made, for example, of die cast metal (e.g., die cast aluminum). The holes in the base 104 and / or the case 106 configured to be threadedly coupled to fasteners may be sized to receive selftapping screws.

[0068] As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean + / - 10 percent of the disclosed values, unless specified otherwise. As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms “approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

[0069] It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0070] The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a-18- 4937-7944-8709Atty. Dkt. No.: 016831-1993separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

[0071] References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0072] The hardware and data processing components used to implement the various processes, operations, illustrative logics, logical blocks, modules and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose single- or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, or, any conventional processor, controller, microcontroller, or state machine. A processor also may be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, particular processes and methods may be performed by circuitry that is specific to a given function. The memory (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage) for storing data and / or computer code for completing or facilitating the various processes, layers and modules described in the present disclosure. The memory may be or include volatile memory or non-volatile memory, and may -19- 4937-7944-8709Atty. Dkt. No.: 016831-1993include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. According to an exemplary embodiment, the memory is communicably connected to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or the processor) the one or more processes described herein.

[0073] The present disclosure contemplates methods, systems, and program products on any machine-readable media for accomplishing various operations. The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.

[0074] Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above.-20- 4937-7944-8709Atty. Dkt. No.: 016831-1993

[0075] It is important to note that any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.-21- 4937-7944-8709

Claims

Atty. Dkt. No.: 016831-1993WHAT IS CLAIMED IS:

1. Ab attery pack comprising:a housing defining an internal cavity;a first cell module assembly (CMA) arranged within the internal cavity and comprising a first plurality of battery cells coupled to a first frame, the first frame comprising a first notch; and a second CMA arranged side-by-side with the first CMA within the internal cavity, the second CMA comprising a second plurality of battery cells coupled to a second frame, the second frame comprising a first protrusion extending into the first notch.

2. The battery pack of claim 1, wherein the first notch comprises a first flange and a second flange, the first flange and the second flange configured to contain the first protrusion therebetween.

3. The battery pack of claim 1, wherein the first frame comprises a second notch, and the second frame comprises a second protrusion extending into the second notch.

4. The battery pack of claim 1, wherein the first CMA comprises a third frame comprising a second notch, and the second CMA comprises a fourth frame comprising a second protrusion extending into the second notch.

5. The battery pack of claim 1, wherein the second frame comprises a second notch, the battery pack further comprising a third CMA arranged side-by-side with the second CMA within the internal cavity, the third CMA comprising a third plurality of battery cells coupled to a third frame, the third frame comprising a second protrusion extending into the second notch.-22- 4937-7944-8709Atty. Dkt. No.: 016831-19936. The battery pack of claim 1, wherein the first CMA comprises:a plurality of battery cells;a collector plate electrically coupled to the plurality of battery cells; anda voltage tab directly coupled to the collector plate without the use of a fastener, the voltage tab extending away from the collector plate and configured to be coupled to an electrical connector.

7. The battery pack of claim 6, wherein the voltage tab comprises a base flange coupled to the collector plate, the base flange comprising a flange cavity, wherein the collector plate comprises a protrusion extending into the flange cavity.

8. The battery pack of claim 7, wherein a width of the flange cavity increases with a depth of the flange cavity, and a width of the protrusion increases with the depth of the flange cavity.

9. The battery pack of claim 8, wherein an outer surface of the protrusion is in contact with substantially all of an inner surface of the flange cavity.

10. The battery pack of claim 1, wherein the housing defines the internal cavity between a base and an upper case, the battery pack further comprising:a terminal coupled to a terminal plate and configured to be coupled to an electrical connector, the terminal electrically connected to the first CMA; anda bracket coupling the terminal plate to the base.

11. The battery pack of claim 10, wherein the upper case comprises a first opening configured to receive a portion of the terminal plate and a plurality of second openings configured to receive fasteners for coupling the terminal plate to the upper case.-23- 4937-7944-8709Atty. Dkt. No.: 016831-199312. The battery pack of claim 11, wherein the first opening and the plurality of second openings are positioned such that the terminal plate is configured to be coupled to the bracket and the upper case substantially simultaneously.

13. The battery pack of claim 10, wherein the bracket comprises a flat sheet of material comprising a plurality of bends.

14. The battery pack of claim 1, further comprising:an upper plate positioned above the first CMA in the internal cavity;a battery management system (BMS) positioned on the upper plate in the internal cavity; anda BMS cover coupled to the upper plate and comprising an upper sheet extending over the BMS.

15. The battery pack of claim 14, wherein the upper sheet includes a pair of sloped halves that meet at an apex and slope downward toward edges of the upper sheet.

16. The battery pack of claim 15, further comprising side rails extending along sides of the pair of sloped halves of the upper sheet, the sloped halves of the upper sheet and the side rails configured to direct water droplets toward the edges of the upper sheet.

17. The battery pack of claim 1, wherein the housing comprises:a base; anda case coupled to the base, the case and the base defining the internal cavity, the case comprising:a protrusion extending from an upper surface of the case; anda plurality of holes, the protrusion and the plurality of holes form a mounting pattern for coupling a vehicle control module or a charger to the case.-24- 4937-7944-8709Atty. Dkt. No.: 016831-199318. A battery pack comprising:a housing defining an internal cavity between a base and an upper case;a first cell module assembly (CMA) arranged within the internal cavity and comprising a first plurality of battery cells;a terminal coupled to a terminal plate and configured to be coupled to an electrical connector, the terminal electrically connected to the first CMA; anda bracket coupling the terminal plate to the base.

19. The battery pack of claim 18, wherein the upper case comprises a first opening configured to receive a portion of the terminal plate and a plurality of second openings configured to receive fasteners for coupling the terminal plate to the upper case.

20. The battery pack of claim 19, wherein the first opening and the plurality of second openings are positioned such that the terminal plate is configured to be coupled to the bracket and the upper case substantially simultaneously.

21. The battery pack of claim 18, wherein the bracket comprises a flat sheet of material comprising a plurality of bends.

22. The battery pack of claim 18, wherein the upper case comprises:a protrusion extending from an upper surface of the upper case; and a plurality of holes, the protrusion and the plurality of holes form a mounting pattern for coupling a vehicle control module or a charger to the upper case.

23. The battery pack of claim 22, wherein the plurality of holes are blind holes that do not extend through the upper case.-25- 4937-7944-8709Atty. Dkt. No.: 016831-199324. The battery pack of claim 22, wherein the base comprises a protruding rib extending around a perimeter of the base, and the upper case includes a trough extending around a perimeter of the upper case and configured to receive the protruding rib.

25. The battery pack of claim 22, wherein the protrusion and the plurality of holes are positioned on standoffs protruding from the upper surface of the upper case.

26. A battery pack comprising:a housing defining an internal cavity;at least one cell module assembly (CMA) arranged within the internal cavity, each CMA comprising a plurality of battery cells;an upper plate positioned above the at least one CMA in the internal cavity;a battery management system (BMS) positioned on the upper plate in the internal cavity; anda BMS cover coupled to the upper plate and comprising an upper sheet extending over the BMS.

27. The battery pack of claim 26, wherein the upper sheet includes a pair of sloped halves that meet at an apex and slope downward toward edges of the upper sheet.

28. The battery pack of claim 27, further comprising side rails extending along sides of the pair of sloped halves of the upper sheet, the sloped halves of the upper sheet and the side rails configured to direct water droplets toward the edges of the upper sheet.

29. The battery pack of claim 28, wherein BMS cover includes side walls extending to the side rails, the side walls comprising openings under the side rails configured to allow airflow to the BMS.-26- 4937-7944-8709Atty. Dkt. No.: 016831-199330. The battery pack of claim 26, wherein each of the at least one CMA includes a mounting sleeve, wherein the upper plate is coupled to each mounting sleeve.

31. The battery pack of claim 26, wherein a footprint of the BMS is entirely within a footprint of the BMS cover.

32. The battery pack of claim 26, wherein the upper plate comprises a plurality of protrusions, and the BMS cover comprises a plurality of openings configured to receive the protrusions with an interference fit to couple the BMS cover to the upper plate.

33. The battery pack of claim 26, wherein the housing comprises a base and a case coupled to the base, the case and the base defining the internal cavity, wherein the BMS and the BMS cover are positioned within the internal cavity.

34. A housing of a battery pack, the housing comprising:a base; anda case coupled to the base, the case and the base defining an internal cavity, the case comprising:a protrusion extending from an upper surface of the case; anda plurality of holes, the protrusion and the plurality of holes form a mounting pattern for coupling a vehicle control module or a charger to the case.

35. The housing of claim 34, wherein the plurality of holes are blind holes that do not extend through the case.

36. The housing of claim 34, wherein the protrusion and the plurality of holes are positioned on standoffs protruding from the upper surface of the case.-27- 4937-7944-8709Atty. Dkt. No.: 016831-199337. The housing of claim 36, wherein the standoffs define an airflow gap between the upper surface of the case and the vehicle control module or charger when mounted to the case.

38. The housing of claim 34, wherein the plurality of holes are sized to receive self-tapping screws.

39. The housing of claim 34, wherein the plurality of holes and the protrusion form multiple common mounting patterns for different vehicle control modules or chargers.

40. A cell module assembly (CMA) comprising:a plurality of battery cells;a collector plate electrically coupled to the plurality of battery cells; anda voltage tab directly coupled to the collector plate without the use of a fastener, the voltage tab extending away from the collector plate and configured to be coupled to an electrical connector.

41. The CMA of claim 40, wherein the voltage tab comprises a base flange coupled to the collector plate, the base flange comprising a cavity, wherein the collector plate comprises a protrusion extending into the cavity.

42. The CMA of claim 41, wherein a width of the cavity increases with a depth of the cavity, and a width of the protrusion increases with the depth of the cavity.

43. The CMA of claim 42, wherein an outer surface of the protrusion is in contact with substantially all of an inner surface of the cavity.

44. The CMA of claim 41, wherein the voltage tab comprises a connector flange extending substantially perpendicular to the base flange and configured to receive the electrical connector.-28- 4937-7944-8709Atty. Dkt. No.: 016831-199345. The CMA of claim 40, wherein the collector plate is coupled to the voltage tab by plastically deforming a portion of the collector plate into a cavity of the voltage tab.4937-7944-8709

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