0.05” 0.005”

1. Note holes and wire channel in part 5 for temperature sensors. 1 2 The USUSat battery box assembles in the same manner as the HokieSat battery box. The interior assembly in the Dawgstar box is rotated 90°, see Dawgstar drawings for details. 3 4 5 6 7 7 2 RAYCHEM POLYSWITCH 6 14 CELL INTERCONNECT NICKEL 201 5 1 REAR RETAINER DELRIN 4 1 INTERNAL SHELF ELECTROLESS NICKEL PLATED & URALANE COATED ALUMINUM 6061-T6 AA1302-DWG18 • To assemble the pack: • Insert cells into part 5 • Mark thermocouple location on appropriate cells • Remove cells; bond thermocouples; let cure as needed • Reinsert cells, threading thermocouple wires through holes • Insert alignment pins into part 5 • Install part 4 onto alignment pins and flush with part 5; apply epoxy in gaps between cells and holes in part 4 • Install part 2 onto alignment pins and flush with part 4 • Compress pack assembly and let cure as needed; weld cell interconnects and polyswitches • Note that the PigMat pillows will be installed when the pack is inserted into the box. 3 15 SANYO NiCad KR1400-AE 2 1 FRONT RETAINER DELRIN 1 of 1 1 2 ABSORBANT PILLOW PIGMAT 301 2 ITEM QTY NAME MATERIAL Parts List I O N - F Utah State University - University of Washington - Virginia Tech See materials list 0.05” 0.005” 0.01” 0.5° 0.005” Battery Pack Assembly See materials list Schwartz, J. 18/10/01 07/11/01 Bergquist, A. AA21302-DWG18 2 Non-FC 08/11/01 Schwartz, J. 1 of 1

2. Note holes and wire channel in part 5 for temperature sensors. 1 2 3 4 5 6 7 7 19 CELL INTERCONNECT NICKEL 201 6 2 RAYCHEM POLYSWITCH 5 1 REAR RETAINER DELRIN • To assemble the pack: • Insert cells into part 5 • Mark thermocouple location on appropriate cells • Remove cells; bond thermocouples; let cure as needed • Insert cells into part 2 • Insert alignment pins into part 2 • Install part 4 onto alignment pins and flush with part 5; apply epoxy in gaps between cells and holes in part 4 • Thread thermocouple wires through holes in part 5; install part 5 onto alignment pins and flush with part 4 • Compress pack assembly and let cure as needed; weld cell interconnects and polyswitches • Note that the PigMat pillows will be installed when the pack is inserted into the box. 4 1 INTERNAL SHELF ELECTROLESS NICKEL PLATED & URALANE COATED ALUMINUM 6061-T6 3 20 SANYO NiCad KR1400-AE 1 of 1 2 1 FRONT RETAINER DELRIN 2 1 2 ABSORBANT PILLOW PIGMAT 301 ITEM QTY NAME MATERIAL Parts List I O N - F Utah State University - University of Washington - Virginia Tech See materials list 0.05” 0.005” 0.01” 0.5° 0.005” Battery Pack Assembly (internal components) See materials list Schwartz, J. 18/10/01 07/11/01 Bergquist, A. 2 Non-FC 08/11/01 Schwartz, J. 1 of 1