Battery pack housing for vehicle

Abstract

A battery pack housing for a vehicle having at least one battery module includes a tray, a cover secured to the tray to provide an enclosure, which has an interior to receive the at least one battery module, at least one inner crossmember disposed within the interior, and at least one midpack mount having a first bushing and a second bushing. The first bushing is entirely disposed within the interior and the second bushing extends through the enclosure in a vertical direction of the vehicle. The second bushing threadably engages the first bushing and also a nut placed on an opening of the cover. The midpack mount further includes a circular bushing extending through the inner crossmember, and a mounting bolt extends through an inner bore of the second bushing to fasten the enclosure to the vehicle body.

Description

Attorney Docket No.: 91602-00364 (ID24016)BATTERY PACK HOUSING FOR VEHICLEFIELD

[0001] The present disclosure relates to a battery pack housing in a vehicle. In particular, the present disclosure relates to a mounting structure for the battery pack housing in the vehicle.BACKGROUND

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] The desire to reduce automotive fuel consumption and emissions has been well documented. Therefore, electrified vehicles are being developed that reduce or completely eliminate reliance on internal combustion engines. In general, electrified vehicles differ from conventional motor vehicles because they are selectively driven by one or more battery powered electric machines. Conventional motor vehicles, by contrast, rely exclusively on the internal combustion engine to propel the vehicle.

[0004] A battery pack is typically mounted to an electric vehicle to supply power required to drive the vehicle. The battery pack accommodates a plurality of battery modules, and each of the battery modules includes a plurality of battery cells. In many cases, the battery pack is mounted to a lower portion of a vehicle body. In this case, the battery pack may be firmly mounted to the vehicle body. In addition, the battery pack requires a sealing function to prevent moisture or foreign matter from entering into the battery pack.

[0005] Further, the way of assembling a battery pack inside an enclosure, which is an important part of an electric vehicle, in a vehicle may greatly influence durability of the vehicle against a collision and reduce noise and vibration generated by parts of the vehicle. For example, a vehicle may receive an unexpected impact from the outside environment. Therefore, it may be advantageous that the enclosure storing the battery pack maintains the stable sealing function even when an external impact occurs.SUMMARY

[0006] According to an aspect of the present disclosure, a battery pack housing for an electrified vehicle having at least one battery module includes a tray, a cover secured to theAttorney Docket No.: 91602-00364 (ID24016)tray to provide an enclosure having an outer periphery defining an interior to receive the at least one battery module, at least one inner crossmember disposed within the interior, and at least one midpack mount spaced inwardly from the outer periphery and having a first bushing and a second bushing. The first bushing is entirely disposed within the interior and the second bushing extends through the enclosure in a vertical direction of the vehicle.

[0007] According to a further aspect of the present disclosure, the first bushing is formed with a cylindrical shape having a passage bore for allowing the second bushing to extend through the passage bore. The first bushing includes a bottom end formed with an inner groove to receive a second O-ring and a top end formed with a topmost surface formed with a circular recess to receive a first O-ring. The first and second O-rings are configured to seal and protect against water and / or dust ingress into the enclosure. Further, the bottom end of the first bushing is secured to the at least one inner crossmember and the top end of the first bushing is secured to an interior surface of the cover.

[0008] According to a further aspect of the present disclosure, the second bushing is formed with an inner bore for allowing a mounting bolt to extend through the inner bore. The second bushing includes an upper end portion extending through an opening of the cover and a lower end portion securely engaging a lower side of a support frame of the vehicle. The second bushing extends through a passage bore of the first bushing and threadably engages the first bushing. Further, the upper end portion of the second bushing threadably engages a nut place on an opening of the cover, and the lower end portion of the second bushing is formed with a rectangular shape engaging the support frame of the vehicle.

[0009] According to a further aspect of the present disclosure, the battery pack housing includes a mounting bolt extending through an inner bore of the second bushing to fasten the enclosure to the vehicle body.

[0010] According to a further aspect of the present disclosure, the tray and the cover are each formed of a plastic material such as a polymer material.

[0011] According to a further aspect of the present disclosure, the battery pack housing includes a circular bushing formed as a cylindrical shape and the circular bushing extends through the inner crossmember along a vertical direction of the vehicle. The circular bushing includes a first end engaging a bottom end of the first bushing and a second end is secured to a support frame of the vehicle. Further, the circular bushing includes a circular bore for allowing the second bushing to extend through the circular bore.Attorney Docket No.: 91602-00364 (ID24016)

[0012] According to another aspect of the present disclosure, a method for assembling a battery pack housing having at least one battery module in a vehicle includes the steps of providing an enclosure formed by a tray and a cover, providing a first bushing entirely disposed within an interior, providing a second bushing extending through a passage bore of the first bushing, engaging an upper end portion of the second bushing threadably with the first bushing and engaging a lower end portion of the second bushing with a support frame of the vehicle, and providing a mounting bolt passing through an inner bore of the second bushing to fasten the enclosure to the vehicle body.

[0013] According to a further aspect of the present disclosure, the method further includes the step of providing at least one inner crossmember disposed within the interior to provide structural integrity of the battery pack housing. Further, the method includes the steps of securing the bottom end of the first bushing to an upper side of the inner crossmember and securing the top end of the first bushing to an interior of the cover.

[0014] According to a further aspect of the present disclosure, the method includes the step of providing a circular bushing extending through an opening of the inner crossmember in a vertical direction of the vehicle such that the second bushing extends through a circular bore of the circular bushing. The method further includes the steps of engaging a first end of the circular bushing with a bottom end of the first bushing and engaging a second end of the circular bushing with an upper side of a support frame.

[0015] According to another aspect of the present disclosure, a battery pack housing for a vehicle having at least one battery module includes a tray, a cover secured to the tray to provide an enclosure, at least one inner crossmember disposed within the interior, and a support frame on an outside of the tray and coupled to the at least one crossmember. The enclosure has an outer periphery defining an interior to receive the at least one battery module. During a mis-use of the vehicle, a load is transmitted to the at least one inner crossmember and the support frame to protect the at least one battery module enclosed in the battery housing.

[0016] According to a further aspect of the present disclosure, the battery pack housing includes at least one midpack mount to connect the at least one inner crossmember to the support frame such that the load is further distributed to both the at least one inner crossmember and the support frame via the midpack mount. The at least one inner crossmember and the support frame are each formed of a metallic material.Attorney Docket No.: 91602-00364 (ID24016)

[0017] According to a further aspect of the present disclosure, when the vehicle is in the mis-use case such as a shock or an impact, the load is also transmitted to vehicle structures such as a seat crossmember and / or a vehicle floor.

[0018] Further details and benefits will become apparent from the following detailed description of the appended drawings. The drawings are provided herewith purely for illustrative purposes and are not intended to limit the scope of the present disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

[0020] FIG. 1A is a bottom perspective view of a vehicle having a battery pack housing in accordance with an exemplary embodiment of the present disclosure, and FIG. 1B is a side view of the vehicle having the battery pack housing of FIG. 1 A;

[0021] FIG. 2A is a perspective view of the battery pack housing with a support frame and an underbody protection panel of FIG. 1A, FIG. 2B is an exploded view of the battery pack housing with the support frame and the underbody protection panel of FIG. 2A, and FIG. 2C is a cross-sectional view of the battery pack housing attached to the vehicle, lined 2C-2C of FIG. 1B;

[0022] FIG. 3 is a cross-sectional view of a midpack mount secured in the battery pack housing of FIG. 2A;

[0023] FIG. 4 is a cross-sectional view of a first bushing of the midpack mount of FIG. 3, FIG. 4A is a detailed view of a circular recess in a topmost surface of the first bushing of FIG. 4, and FIG. 4B is a detailed view of an inner groove in a bottom end of the first bushing of FIG. 4; and

[0024] FIG. 5 is a cross-sectional view of a second bushing of the midpack mount of FIG.3, and FIG. 5A is a top view of the second bushing of FIG. 5.

[0025] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.DETAILED DESCRIPTION

[0026] The following description is merely exemplary in nature and is in no way intended to limit the present disclosure or its application or uses. It should be understood thatAttorney Docket No.: 91602-00364 (ID24016)throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0027] FIGS. 1A and 1 B illustrate a part of an electrified vehicle 10 having a battery pack housing 12 mounted to the under body of a vehicle body 14. The electrified vehicle 10 could be a car, a truck, a van, a sport utility vehicle (SUV), a crossover, or any other type of vehicle that includes an electric powertrain. In an embodiment, the electrified vehicle is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and could extend to other electrified vehicles, including, but not limited to, hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs) fuel cell vehicles, etc. Therefore, although not specifically shown in this embodiment, the electric vehicle could be equipped with an internal combustion engine that can be employed either alone or in combination with other energy sources to propel the electric vehicle.

[0028] In general, the electrified vehicle is propelled solely through electric power, such as via one or more electric machines, which may operate as an electric motor, an electric generator, or both. The electric machine receives electric power from a battery pack housing 12 and provides a rotational output torque to one or more drive wheels of the electrified vehicle. A voltage bus electrically connects the electric machine to the battery pack housing 12. The battery pack housing 12 may be a high voltage traction battery pack that includes a plurality of battery modules 18 (i.e. , battery assemblies or groupings of rechargeable battery cells) capable of outputting electrical power to operate the electric machine and / or other electrical loads of the electrified vehicle.

[0029] The battery pack housing 12 may be mounted at various locations of the electrified vehicle 10. As shown in FIG. 1A of the present disclosure, the battery pack housing 12 is securely mounted to an underbody of the electrified vehicle. In other examples, the battery pack housing 12 could be located elsewhere on the electrified vehicle 10. Referring to FIGS.2A and 2B, the battery pack housing 12 includes an enclosure 16 storing a plurality of battery modules 18. The enclosure 16 includes a tray 20 and a cover 22, which is secured to the tray 20 to provide an interior 24. The battery modules 18 are arranged within the interior 24 along with other components. The cover 22, the tray 20, or both, are formed of a plastic material such as a polymer or polymer-based material.

[0030] Further, as shown in FIGS. 1A and 2A, the cover 22 is securely attached to the tray 20 by applying an adhesive material to the periphery of either the cover 22 or the flange of the tray 20 and the adhesive is allowed to cure. Accordingly, when the cover 22 is securedAttorney Docket No.: 91602-00364 (ID24016)to the tray 20, a circumferentially continuous seal is maintained about the perimeter of the interior 24. In another approach, a plurality of mechanical fasteners may be distributed about a periphery of the battery pack housing 12 such that the mechanical fasteners secure the cover 22 to the flange of the tray 20. Accordingly, a sealing interface can be provided between the fasteners and the interior 24. The mechanical fasteners are disposed outside the sealing interface.

[0031] FIG. 2A shows the battery pack housing 12 with a support frame 32 and FIG. 2B shows an exploded view of the battery pack housing 12 with the support frame 32. As shown in FIGS. 2A and 2B, the battery pack housing 12 further includes a plurality of inner crossmembers 26 disposed within the interior 24 of the enclosure 16. Each of the inner crossmembers 26 extends in a cross-vehicle direction C, which is in a direction perpendicular to a fore / aft direction (i.e., a longitudinal direction L) of the electrified vehicle 10. As shown in FIG. 2B, the inner crossmembers 26 are each spaced a distance from each other along the fore / aft direction of the vehicle. Further, the inner crossmembers 26 are formed of a metallic material such as steel, carbon steel, or an aluminum alloy, as nonlimiting example. The inner crossmembers 26 are configured to enhance the structural integrity of the battery pack housing 12 enclosing the battery modules 18.

[0032] In FIG. 2B, further, the battery pack housing 12 includes a plurality of cooling plates 28, thermal interface materials (TIM) 29 that is on top of the cooling plates 28, and a couple of cooling lines 30 to control heat generated by the battery modules 18 within the interior 24 of the battery pack housing 12. The cooling plates 28 and the TIM 29 are arranged under each of the battery modules 18, and the cooling lines 30 are each arranged along the longitudinal direction of the vehicle 10. The TIM 29 is used to increase the thermal draw from the battery modules 18 to the cooling plates 28. Each of the cooling lines 30 is in communication with each other and is connected to each of the cooling plates 28 such that liquid (e.g., coolant) is transported via the cooling lines 30 between each of the cooling plates 28 to cool down heat generated by the battery modules 18. In another approach, the cooling plates 28 and the cooling lines 30 may be arranged in other ways to control heat generated by the battery modules 18 within the interior 24 of the enclosure 16.

[0033] As shown in FIG. 2B, the battery pack housing 12 is further supported by the support frame 32 to enhance the structural integrity of the battery pack housing 12 in the vehicle 10. For example, the support frame 32 may protect the battery pack housing 12 in the event of a collision by absorbing and distributing impact forces. The support frame 32Attorney Docket No.: 91602-00364 (ID24016)may be formed of a metallic material such as steel, carbon steel, an aluminum alloy, etc. Further, the vehicle 10 includes an underbody (UB) protection panel 34 attached to the support frame 32 to protect vehicle components including the battery pack housing 12 from water, mud, rocks, debris, etc. The UB protection panel 34 may be formed of a polymer material, but it is not limited.

[0034] FIG. 2C shows a half section-cut view, lined in 2C-2C of FIG. 1B. As shown in FIG. 2C, as described above, the battery pack housing 12 incorporated with the vehicle body 14 is also designed to support and protect the battery module 18 by distributing loads in the event of a collision. In FIG. 2C, for example, when the vehicle 10 has a side collision as the mis-use of the vehicle 10, a large impact force F (i.e., an external load) is inputted to a body sill 15 of the vehicle 10. As a result, the load moves to an inner side of the vehicle 10 in a lateral direction C (i.e., a width direction of the vehicle) and is transmitted to the seat crossmember including a vehicle floor (i.e., a vehicle body 14) and the battery pack housing 12. (See arrows of FIG. 2C).

[0035] As shown in FIG. 2C, the battery pack housing 12 comprises at least the inner crossmembers 26, the support frames 32, and the midpack mounts 100. Further, the inner crossmembers 26 and the support frames 32 are securely coupled to each other by the midpack mounts 100 or any other coupling methods. During the mis-use of the vehicle such as the side collision, the inner crossmember 26 and the support frame 32 formed of the metallic material may absorb a portion of the inputted load. Further, the midpack mount 100 connects the inner crossmember 26 to the support frame 32 and is also designed to absorb the portion of the inputted load. Accordingly, as shown in FIG. 2C, the inputted load is distributed through the inner crossmember 26, the support frame 32, and the midpack mount 100 such that the battery module 18 enclosed in the battery pack housing 12 is protected from the impact load during the mis-use of the vehicle 10.

[0036] Referring back to FIG. 2A, in the exemplary embodiment of the present disclosure, the battery cells may be grouped together in one or more battery modules 18. The inner crossmembers 26 may be positioned between each adjacent set of battery modules 18. Further, the inner crossmembers 26 add rigidity to the battery pack housing 12 and establish mounting points for securing the attachment and sealing assemblies to the battery pack housing 12. As shown in FIGS. 2A and 2B, the battery pack housing 12 is a sealed enclosure 16, which includes the tray 20 and the cover 22 cooperating to surround and enclose the battery modules 18. The tray 20 provides the interior 24 for holding the battery modules 18,Attorney Docket No.: 91602-00364 (ID24016)and after positioning the battery modules 18 within the interior 24, the cover 22 may be seated and sealed to the tray 20 to enclose the battery modules 18 therein.

[0037] In FIG. 2A, the battery pack housing 12 includes a plurality of midpack mounts 100 to secure the battery pack housing 12 to the support frame 32. The midpack mounts 100 are each spaced inwardly from an outer periphery of the enclosure 16. FIG. 3 shows a cross-sectional view of one of the midpack mounts 100 arranged in a location of the battery pack housing 12. As shown in FIG. 3, the midpack mount 100 includes a first bushing 102 formed with a passage bore 103, which is disposed between the tray 20 and the cover 22 to secure the space of the interior 24 of the battery pack housing 12 in a vertical direction V of the vehicle 10. The first bushing 102 is entirely disposed within the interior 24 of the enclosure 16. The midpack mount 100 includes a second bushing 104 extending though the passage bore 103 of the first bushing 102. As shown in FIG. 3, the second bushing 104 extends toward an opening 23 of the cover 22 from the support frame 32 of the vehicle 10 such that the second bushing 104 passes through the enclosure 16 formed by the tray 20 and the cover 22. The second bushing 104 threadably engages an inner surface of the first bushing 102 and also a nut 108 placed in the opening 23 of the cover 22. Further, a washer 109 may be optionally arranged between the nut 108 and the cover 22 in the vertical direction of the vehicle 10 to distribute clamping forces over a larger area of the cover 22.

[0038] In FIG. 3, the midpack mount 100 further includes a mounting bolt 106 extending through an inner bore 105 of the second bushing 104. The mounting bolt 106 also extends toward the opening 23 of the cover 22 from the support frame 32 of the vehicle 10 such that the mounting bolt 106 passes through the inner bore 105 of the second bushing 104 to securely engage the nut 108. Accordingly, the mounting bolt 106 passing through the second bushing 104 fastens the enclosure 16 to the vehicle body 14. As shown in FIG. 3, further, the midpack mount 100 includes a circular bushing 110 extending through the opening of the inner crossmember 26 along the vertical direction V of the vehicle 10. The circular bushing 110 is formed as a cylindrical shape having a circular bore 111 and is securely attached to the crossmember 26 around the outside diameter by a bonding method such as a welding, which is part of a weldment assembly with the crossmember 26. Further, the circular bushing 110 includes a first end 112 securely engaging the first bushing 102 and a second end 114 securing to the support frame 32 of the vehicle 10. Accordingly, the second bushing 104 extends through the circular bore 111 of the circular bushing 110 and also the passage bore 103 of the first bushing 102 in a vertical direction of the vehicle 10.Attorney Docket No.: 91602-00364 (ID24016)

[0039] FIG. 4 shows the first bushing 102 formed as a cylindrical shape having the passage bore 103. FIG. 4A shows the first bushing 102 including a top end 116 having a topmost surface 117 formed with a recess 115, and FIG. 4B shows the first bushing 102 including a bottom end 118 having an inner circular surface 119 formed with a groove 120. As shown in FIGS. 3, 4A, and 4B, the recess 115 formed on the topmost surface 117 of the first bushing 102 receives a first O-ring 122 and the groove 120 formed on the inner circular surface 119 of the first bushing 102 also receives a second O-ring 124. When the midpack mount 100 is securely fastened to the battery pack housing 12, each of the first and second O-rings 122 and 124 is compressed and sealed to protect against water and / or dust ingress inside the interior 24 of the enclosure 16.

[0040] FIG. 5 shows the second bushing 104 having an upper end portion 126 and a lower end portion 128, and FIG. 5A shows a top view of the second bushing 104. As shown in FIGS. 5 and 5A, the lower end portion 128 of the second bushing 104 is formed as a rectangular shape, which is substantially fitted in the support frame 32 of the vehicle 10 (i.e. , the lower end portion of the second bushing securely engages a lower side of the support frame in a vertical direction of the vehicle), and the upper end portion 126 of the second bushing 104 extends through and threadably engages the passage bore 103 of the first bushing 102. Referring back to FIG. 3, the upper end portion 126 of the second bushing 104 is also threadably engaged with the nut 108 positioned in the opening 23 of the cover 22 such that the second bushing 104 is secured to the enclosure 16.

[0041] As shown in FIG. 3, further, the first end 112 of the circular bushing 110 is arranged on the inner circular surface 119 of the bottom end 118 of the first bushing 102 such that the second O-ring 124 contacts the outer surface of the circular bushing 110, and the second O-ring 124 is compressed between the first bushing 102 and the circular bushing 110. Therefore, sealing between the first bushing 102 and the circular bushing 110 is achieved by the second O-ring 124. In FIG. 3, the second end 114 of the circular bushing 110 extends through the opening of the inner crossmember 26 and is secured on the support frame 32 of the vehicle 10 such that the first bushing 102 is securely connected to the support frame 32 via the circular bushing 110. As shown in FIG. 3, further, the battery pack housing 12 includes a gasket 36 disposed between the inner crossmember 26 and the tray 20 in a vertical direction of the vehicle 10 to prevent leaks and provide a pressure-tight seal within the interior 24 of the enclosure 16.Attorney Docket No.: 91602-00364 (ID24016)

[0042] Further, in FIG. 3, the first 0-ring 122 is positioned between the interior surface of the cover 22 and the topmost surface 117 of the first bushing 102 in a vertical direction of the vehicle 10. The first O-ring 122 disposed in the recess 115 of the first bushing 102 contacts the inner surface of the cover 22 and the first O-ring 122 is compressed between the first bushing 102 and the cover 22. Therefore, sealing between the first bushing 102 and the cover 22 is achieved by the first O-ring 122. As shown in FIG. 3, the mounting bolt 106 extends toward the opening 23 of the cover 22 from the lower end portion 128 of the second bushing 104 and passes through the inner bore 105 of the second bushing 104 to fasten the enclosure 16 to the vehicle body 14.

[0043] As described above and shown in FIG. 3, the midpack mount 100 is securely mounted to the battery pack housing 12 by assembling the first bushing 102 disposed entirely within the interior 24 of the enclosure 16, the circular bushing 110 connected between the support frame 32 of the vehicle body 10 and the first bushing 102, the second bushing 104 extending through the passage bore 103 of the first bushing 102 and the circular bore 111 of the circular bushing 110 and threadably engaging the first bushing 102 and the nut 108, and the mounting bolt 106 extending through the inner bore 105 of the second bushing 104 to secure the enclosure 16 to the vehicle body 14. Accordingly, the midpack mount 100 is configured to transmit the mechanical load from the mass of the battery modules 18 to vehicle mounting points (i.e., support frames of the vehicle) and structurally support the battery pack housing 12 by protecting against vibration and creep of the battery pack housing 12 while the vehicle 10 is in operation. In addition, the midpack mount 100 is securely fastened to each other to achieve sealing between the midpack mount 100 and the battery pack housing 12. Further, sealing between the midpack mount 100 and the vehicle body 14 is achieved (i.e., protecting against water / dust ingress), thereby improving durability of the battery pack housing 12 and allowing easy and inexpensive maintenance.

[0044] The foregoing description of various forms of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Numerous modifications or variations are possible in light of the above teachings. The forms discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various forms and with various modifications as are suited to the particular use contemplated. All such modifications andAttorney Docket No.: 91602-00364 (ID24016)variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims

Attorney Docket No.: 91602-00364 (ID24016)CLAIMSWhat is claimed is:

1. A battery pack housing for a vehicle having at least one battery module, the battery pack housing comprising:a tray;a cover secured to the tray to provide an enclosure, the enclosure having an outer periphery defining an interior to receive the at least one battery module;at least one inner crossmember disposed within the interior; andat least one midpack mount spaced inwardly from the outer periphery, the at least one midpack mount including a first bushing and a second bushing,wherein the first bushing is entirely disposed within the interior and the second bushing extends through the enclosure in a vertical direction of the vehicle.

2. The battery pack housing of claim 1, wherein the first bushing is formed with a cylindrical shape having a passage bore for allowing the second bushing to extend through the passage bore.

3. The battery pack housing of claim 1 , wherein the first bushing includes a bottom end formed with an inner groove to receive a second O-ring and a top end formed with a topmost surface formed with a circular recess to receive a first O-ring.

4. The battery pack housing of claim 3, wherein the first and second 0-rings are configured to seal and protect against water and / or dust ingress into the enclosure.

5. The battery pack housing of claim 3, wherein the bottom end of the first bushing is secured to the at least one inner crossmember and the top end of the first bushing is secured to an interior surface of the cover.

6. The battery pack housing of claim 1 , wherein the second bushing is formed with an inner bore for allowing a mounting bolt to extend through the inner bore.Attorney Docket No.: 91602-00364 (ID24016)7. The battery pack housing of claim 6, wherein the second bushing includes an upper end portion extending through an opening of the cover and a lower end portion engaging a lower side of a support frame of the vehicle.

8. The battery pack housing of claim 7, wherein the second bushing extends through a passage bore of the first bushing and threadably engages the first bushing.

9. The battery pack housing of claim 7, wherein the upper end portion of the second bushing threadably engages a nut placed on the opening of the cover.

10. The battery pack housing of claim 7, wherein the lower end portion of the second bushing is formed with a rectangular shape engaging the support frame of the vehicle.

11. The battery pack housing of claim 1 , wherein the at least one midpack mount includes a mounting bolt passing through an inner bore of the second bushing to engage a nut such that the mounting bolt secures the enclosure to the vehicle.

12. The battery pack housing of claim 1 , wherein the tray and the cover are each formed of a plastic material.

13. The battery pack housing of claim 1 , wherein the at least one midpack mount includes a circular bushing formed as a cylindrical shape, the circular bushing extending through the inner crossmember in a vertical direction of the vehicle.

14. The battery pack housing of claim 13, wherein the circular bushing includes a first end engaging a bottom end of the first bushing and a second end is secured to a support frame of the vehicle.

15. The battery pack housing of claim 13, wherein the circular bushing includes a circular bore for allowing the second bushing to extend through the circular bore.

16. A method for assembling a battery pack housing having at least one battery module in a vehicle, the method comprising the steps of:Attorney Docket No.: 91602-00364 (ID24016)providing an enclosure formed by a tray and a cover, the enclosure having an interior; providing a first bushing entirely disposed within the interior, the first bushing having a top end and a bottom end;providing a second bushing extending through a passage bore of the first bushing, the second bushing having an upper end portion and a lower end portion;engaging the upper end portion of the second bushing threadably with the first bushing and engaging the lower end portion of the second bushing with a support frame of the vehicle; andproviding a mounting bolt passing through an inner bore of the second bushing to fasten the enclosure to the vehicle.

17. The method of claim 16, further comprising the step of providing at least one inner crossmember disposed within the interior to provide structural integrity of the battery pack housing.

18. The method of claim 17, wherein the step of providing the first bushing entirely disposed within the interior further includes the steps of securing the bottom end of the first bushing to an inner crossmember and securing the top end of the first bushing to the cover.

19. The method of claim 17, further comprising the step of providing a circular bushing extending through an opening of the inner crossmember in a vertical direction of the vehicle such that the second bushing extends through a circular bore of the circular bushing.

20. The method of claim 19, wherein the step of providing the circular bushing extending through the opening of the inner crossmember further includes the steps of engaging a first end of the circular bushing with a bottom end of the first bushing and securing a second end of the circular bushing with a support frame of the vehicle.

21. The method of claim 16, further comprising the step of providing a second O-ring arranged in an inner groove formed in the bottom end of the first bushing and a first O-ring arranged in a circular recess formed on a topmost surface of the first bushing.Attorney Docket No.: 91602-00364 (ID24016)22. The method of claim 15, wherein the cover and the tray are each formed of a plastic material.

23. A battery pack housing for a vehicle having at least one battery module, the battery pack housing comprising:a tray;a cover secured to the tray to provide an enclosure, the enclosure having an outer periphery defining an interior to receive the at least one battery module;at least one inner crossmember disposed within the interior; anda support frame arranged on an outside of the tray and coupled to the at least one crossmember,wherein, during a mis-use of the vehicle, a load is transmitted to the at least one inner crossmember and the support frame to protect the at least one battery module enclosed in the battery housing.

24. The battery pack housing of claim 23, further comprising at least one midpack mount to connect the at least one inner crossmember to the support frame such that the load is distributed to both the at least one inner crossmember and the support frame via the midpack mount.

25. The battery pack housing of claim 23, wherein the at least one inner crossmember and the support frame are each formed of a metallic material.

26. The battery pack housing of claim 23, wherein when the vehicle is in the mis-use case such as a shock or an impact, the load is also transmitted to vehicle structures such as a seat crossmembers and / or a vehicle floor.

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