# US 11,114,721 B2 · Enclosure assembly mid-trays for electrified vehicle battery packs > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,114,721 B2 - Document ID: US11114721B2 - Status: Granted - Kind: B2 - Application number: 15/872,082 - Filed: 2018-01-16 - Published: 2019-07-18 - Granted: 2021-09-07 - Earliest claimed: 2018-01-16 - Assignees: Ford Global Technologies, LLC - Applicants: Ford Global Technologies, LLC - Inventors: Kyle Krueger; Patrick Daniel Maguire; Mohammadreza Eftekhari - Web page: https://patentgrep.com/patent/US11114721B2 ## CPC - H01M 10/425: {Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00)} - H01M 50/209: adapted for prismatic or rectangular cells (H01M50/216 takes precedence) - H01M 50/227: Organic material - H01M 50/24: adapted for protecting batteries from their environment, e.g. from corrosion (thermal insulation H01M10/658) - H01M 50/249: specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64) - H01M 50/276: Inorganic material - H01M 50/298: characterised by the wiring of battery packs - H01M 2010/4271: {Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing} - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract A battery pack includes a battery array and an enclosure assembly housing the battery array. The enclosure assembly includes a tray, a cover, and a mid-tray. A plurality of internal components are secured within the mid-tray to establish an electrical subassembly within the enclosure assembly. ## Claims ### Claim 1 A battery pack, comprising: a battery array; an enclosure assembly housing the battery array and including a tray, a cover, and a mid-tray; and a plurality of internal components secured within the mid-tray to establish an electrical subassembly within the enclosure assembly, wherein the mid-tray is secured and sealed to the tray via a tongue and groove connection, wherein the plurality of internal components includes a bussed electrical center (BEC), a battery electric control module (BECM), a wiring harness, and an I/O connector, wherein at least a portion of the mid-tray is exposed outside of the enclosure assembly, a first pocket formed in the mid-tray and including a first pocket wall and a first protrusion that protrudes inwardly from the first pocket wall, wherein the first protrusion retains the BEC from movement in at least one direction; a second pocket formed in the mid-tray and including a second pocket wall and a second protrusion that protrudes inwardly from the second pocket wall, wherein the second protrusion retains the BECM from movement in at least one direction; a channel formed in the mid-tray and including a channel wall and a third protrusion that protrudes inwardly from the channel wall, wherein the third protrusion retains the wiring harness from movement in at least one direction; and a core hole formed in the mid-tray and configured to receive the I/O connector. ### Claim 2 (depends on 1) The battery pack as recited in claim 1, wherein the tray is an expanded polymer-based tray, the mid-tray is an expanded polymer-based mid-tray, and the cover is a solid polymer-based cover. ### Claim 3 (depends on 2) The battery pack as recited in claim 2, wherein the mid-tray is made of expanded polypropylene. ### Claim 4 (depends on 2) The battery pack as recited in claim 2, wherein the cover is made of a sheet moulding compound. ### Claim 5 (depends on 1) The battery pack as recited in claim 1, wherein the cover is received in nesting fashion with the mid-tray. ### Claim 6 (depends on 1) The battery pack as recited in claim 1, wherein one of the plurality of internal components includes a flange that is seated within a receiving pocket molded into the mid-tray. ### Claim 7 (depends on 1) The battery pack as recited in claim 1, wherein the cover is sized to cover an entire upper surface of the mid-tray. ### Claim 8 (depends on 1) The battery pack as recited in claim 1, wherein a first length and a first width of the mid-tray is substantially equivalent to a second length and a second width, respectively, of the tray, and wherein a third length and a third width of the cover is substantially equivalent to the first length and the first width, respectively, of the mid-tray. ### Claim 9 (depends on 1) The battery pack as recited in claim 1, wherein the electrical subassembly is a fastenerless electrical subassembly that excludes any fasteners separate from integrally molded features of the mid-tray. ### Claim 10 (depends on 1) The battery pack as recited in claim 1, wherein the portion of the mid-tray that is exposed outside of the enclosure assembly is a side wall that includes the core hole. ### Claim 11 (depends on 1) The battery pack as recited in claim 1, comprising a wiring loom that connects the wiring harness to the I/O connector. ### Claim 12 A battery pack, comprising: a first battery array; a second battery array adjacent to the first battery array; an enclosure assembly housing the first and second battery arrays, wherein the enclosure assembly includes a tray, a mid-tray secured to the tray, and a cover secured to the mid-tray, wherein the tray and the mid-tray are constructed of an expanded polymer-based material and the cover is constructed of a solid polymer-based material that is more rigid than the expanded polymer-based material; a first pocket formed in the mid-tray and including a first pocket wall and a first protrusion that protrudes inwardly from the first pocket wall; a bussed electrical center (BEC) snap-fit within the first pocket and retained from movement in at least one direction by the first protrusion; a second pocket formed in the mid-tray and including a second pocket wall and a second protrusion that protrudes inwardly from the second pocket wall; a battery electric control module (BECM) snap-fit within the second pocket and retained from movement in at least one direction by the second protrusion; a channel formed in the mid-tray and including a channel wall and a third protrusion that protrudes inwardly from the channel wall; a wiring harness snap-fit within the channel and retained from movement in the at least one direction by the third protrusion, wherein the wiring harness is connected to either the BEC or the BECM; a core hole formed in the mid-tray; an I/O connector secured within the core hole; and a wiring loom that connects the wiring harness to the I/O connector. ### Claim 13 A method, comprising: securing a mid-tray to a tray of a battery pack enclosure assembly; establishing an electrical subassembly inside the battery pack enclosure assembly, wherein establishing the electrical subassembly includes: positioning a bussed electrical center (BEC) within a first pocket of the mid-tray; routing and securing a first wiring harness within a first channel of the mid-tray; and connecting the first wiring harness to the BEC; and securing a cover over the mid-tray such that at least a portion of the mid-tray is exposed outside of the enclosure assembly, wherein, once secured in place, the cover extends over top of an entire upper surface of the mid-tray to conceal the electrical subassembly inside the battery pack enclosure assembly. ### Claim 14 (depends on 13) The method as recited in claim 13, wherein establishing the electrical subassembly includes positioning a battery electric control module (BECM) within a second pocket of the mid-tray. ### Claim 15 (depends on 13) The method as recited in claim 13, wherein establishing the electrical subassembly includes positioning a wiring loom within a second channel of the mid-tray, snaking the wiring loom through a core opening of the mid-tray, and then connecting an I/O connector to the wiring loom.