Battery pack including an electric harness and method of manufacturing the same
First Claim
1. A method of manufacturing a battery pack including a top housing, a bottom housing, a frame, a cell pad, a plurality of battery cells, a circuit board, and an electric coupler assembly being formed from a single sheet of metal and having a plurality of links, a plurality of cell couplings, and a plurality of circuit board couplings, the plurality of cell couplings electrically connecting the plurality of battery cells, the plurality of links electrically connecting the plurality of cell couplings, the method comprising:
- molding the frame around the electric coupler assembly into the frame;
after molding, severing the plurality of links between the plurality of cell couplings to provide desired electrical connections between the plurality of battery cells;
attaching the battery cells to the plurality of cell couplings after the links have been severed; and
attaching the circuit board to the plurality of circuit board couplings;
wherein the circuit board is electrically connected to each battery cell individually.
1 Assignment
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Accused Products
Abstract
A battery pack including an electric coupling assembly. The battery pack includes a top housing, a bottom housing, a cell pad, a plurality of battery cells, a harness, and a circuit board. The harness includes a frame and electric coupler assembly having a plurality of internal and external electric couplings. The internal and external electric couplings include cell couplings and circuit board couplings. The internal and external couplings are held in place during manufacturing by links which are cut after the electric coupler assembly is molded into the frame.
25 Citations
20 Claims
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1. A method of manufacturing a battery pack including a top housing, a bottom housing, a frame, a cell pad, a plurality of battery cells, a circuit board, and an electric coupler assembly being formed from a single sheet of metal and having a plurality of links, a plurality of cell couplings, and a plurality of circuit board couplings, the plurality of cell couplings electrically connecting the plurality of battery cells, the plurality of links electrically connecting the plurality of cell couplings, the method comprising:
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molding the frame around the electric coupler assembly into the frame; after molding, severing the plurality of links between the plurality of cell couplings to provide desired electrical connections between the plurality of battery cells; attaching the battery cells to the plurality of cell couplings after the links have been severed; and attaching the circuit board to the plurality of circuit board couplings; wherein the circuit board is electrically connected to each battery cell individually. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of manufacturing a battery pack, the method comprising:
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providing an electric coupler assembly being formed from a single sheet of metal and including a plurality of electric couplings and a plurality of links connected between adjacent ones of the plurality of electric couplings, each of the plurality of electric couplings being formed to include at least one cell coupling; fixing the electric coupler assembly to a frame; after fixing, severing the plurality of links between the adjacent ones of the electric couplings; and after severing, attaching a battery cell to each of the plurality of cell couplings with desired electrical connections between the plurality of battery cells provided by severing the plurality of links. - View Dependent Claims (14, 15, 16, 17, 18, 20)
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19. A method of manufacturing a battery pack, the method comprising:
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providing an electric coupler assembly being formed from a single sheet of metal and including a plurality of electric couplings and a plurality of links connected between adjacent ones of the plurality of electric couplings, each of the plurality of electric couplings being formed to include at least one cell coupling; molding a frame around the electric coupler assembly; after molding, severing the plurality of links between the adjacent ones of the electric couplings; after severing, attaching battery cells to the plurality of cell couplings; and supporting the frame, the electric coupler assembly and the plurality of battery cells in a battery pack housing.
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Specification