Fusible links

Abstract

A tab configured to connect a printed circuit board with a conductive body, the tab comprising a relaxed state and an elastically deformed state. In the relaxed state, the tab has one or more elastically deformable fusible members spanning between a first end connected with the printed circuit board and a second end attached with the conductive body. In the elastically deformed state, the tab has a first end connected with the printed circuit board and a second end attached to the conductive body.

Description

Technical Field

[0001] This application relates to an electrical connector for coupling between terminals and a printed circuit board, and more specifically, to a connector incorporating a fusible element. Background Technology

[0002] In many applications, printed circuit boards (PCBs) are used to support circuitry that manages power delivery. Circuitry used for power delivery includes inverters and similar devices that switch power to control voltage and current delivery. Battery technology is an example of a power delivery method where battery power is switched by semiconductor devices mounted on a PCB. For any of these devices, a significant amount of current needs to be coupled to or from the PCB. However, there are limitations to the power that wire gauges can reliably solder onto PCBs. To address this, mechanical coupling devices have been used to clamp the PCB and external conductors together, creating a connection sufficient to couple the required high power. However, one problem with these mechanical coupling devices is creep in the PCB; the board material (typically fiberglass) deforms over time, causing increased coupling resistance and potentially leading to failure.

[0003] Therefore, the object of this invention is to mitigate or improve the aforementioned disadvantages of the prior art, or at least to provide the public with a useful alternative. Other objects will be apparent to those skilled in the art. Summary of the Invention

[0004] In one aspect, the present invention relates to a connector tab configured to connect a printed circuit board to a conductor, the tab comprising a relaxed state and an elastically deformable state, wherein, in the relaxed state, the tab comprises one or more elastically deformable fusible members spanning between a first end connected to the printed circuit board and a second end attached to the conductor; and in the elastically deformable state, the tab comprises the first end connected to the printed circuit board and the second end attached to the conductor.

[0005] In some embodiments, one or more elastically deformable fusible components include fuses configured to fail when in an elastically deformable state and when a current threshold is reached.

[0006] In some embodiments, one or more elastically deformable fusible components include an elastically deformable state failure current lower than the relaxation state failure current.

[0007] In some embodiments, the relaxed state includes a first end connected to the printed circuit board and a second end disconnected from the conductor; and

[0008] The first end of the chip includes a solder plate suitable for connection to a printed circuit board.

[0009] In some embodiments, the second end of the sheet includes a plate adapted for welding to a conductor; and one or more fusible components are held in an elastically deformable state by welding.

[0010] In some embodiments, the transition from a relaxed state to an elastically deformed state is caused by the welded component.

[0011] In some embodiments, the connecting piece further includes a sensing member spanning between a sensor end and a second end, the sensor end including a slot, hole, or housing configured to at least partially close one or more temperature sensors.

[0012] In another aspect, the present invention relates to a connector tab configured to couple a printed circuit board to a conductor, the tab comprising: a first end of the tab including a solder plate; a second end of the tab including a hole to allow fasteners to pass through from the first side to the conductor on the second side, wherein the second end of the tab includes a first extending plane when disconnected from a rigid conductive element and a second extending plane when connected to a rigid conductor; one or more fusible members spanning between the first end and the second end; wherein the one or more fusible members are configured to elastically deform upon transition from the first extending plane to the second extending plane, such that the one or more fusible members are held in an elastically deformed state by fasteners.

[0013] In another aspect, the present invention relates to a connector tab configured to span a printed circuit board and a conductor, the tab comprising: a first configuration wherein a first end of a printed circuit board connection portion including the tab is connected to the printed circuit board, and a second end of a conductor connection portion is disconnected from the conductor; a second configuration wherein the conductor connection portion is fastened to the conductor; and one or more elastically deformable fusible members configured to span between the first end printed circuit board connection portion and the second end conductor connection portion; wherein the one or more elastically deformable fusible members in the second configuration include an elastically deformable state.

[0014] In another aspect, the present invention relates to a connector tab configured to connect a printed circuit board to a conductor, the tab comprising a relaxed state and an elastically deformable state, wherein: in the relaxed state, the tab comprises one or more elastically deformable fusible members spanning between a first end connected to the printed circuit board and a second end comprising a second connecting plate adapted to receive fasteners; and in the elastically deformable state, the tab comprises a first plate connected to the printed circuit board and a second plate fastened to the conductor.

[0015] In an embodiment, the conductor includes a battery cell terminal, a bus, a junction, or a ground junction.

[0016] In an embodiment, the sheet is configured to transition from a relaxed state to an elastically deformed state via fasteners connecting the sheet and the conductor.

[0017] In one embodiment, the sheet is configured to transition from a first extension plane to a second extension plane via fasteners connecting the sheet and the conductor.

[0018] In some embodiments, the sheet is configured to transition from a first extension plane to a second extension plane via fasteners connecting the sheet and the conductor.

[0019] In one embodiment, the connecting piece further includes one or more upwardly extending wings.

[0020] In one embodiment, the connecting piece further includes one or more counterweights located within the first end.

[0021] In one embodiment, the first end includes a terminal or pad suitable for soldering a PCB connection.

[0022] In one embodiment, the second end includes a hole adapted to receive a fastener.

[0023] In this embodiment, the hole includes a slotted form.

[0024] In one embodiment, the second end also includes a ridge region.

[0025] In one embodiment, the second end also includes two or more surface regions, one of which is located on top of the other.

[0026] In one embodiment, two or more surface areas are spanned by connectors having both relaxed and compressed states, the compressed state being caused by fasteners connecting the sheet to a conductor or a single cell terminal.

[0027] In one embodiment, the ridge region is adapted to be compressed by a fastener and to apply a laterally outward deformation force to the fusible member.

[0028] In one embodiment, the fusible component includes a fuse configured to fail when under tension and when a current threshold is reached.

[0029] In an embodiment, the fusible member includes a tension failure current that is lower than the relaxation failure current.

[0030] In one embodiment, the fusible component includes a fuse configured to fail at a thermal limit when the melting temperature of the solder used to fuse the first end and the PCB is reached.

[0031] In this embodiment, the fusible component is an elastically deformable structure.

[0032] In one embodiment, the fusible component includes an elastic flexible structure.

[0033] In one embodiment, the fusible component comprises a conductive material under tension.

[0034] In an embodiment, the fusible component includes dimensions corresponding to the fusible current limit.

[0035] In one embodiment, the fusible component includes a leaf spring.

[0036] In another broad aspect, the present invention relates to an electronic component comprising one or more printed circuit boards, a plurality of individual cells, and connecting tabs, wherein the one or more printed circuit boards include a plurality of terminal coupling regions; the plurality of individual cells include individual cell terminals aligned with the terminal coupling regions; and the connecting tabs are disposed in each terminal coupling region according to any of the above embodiments.

[0037] In some embodiments, the component further includes a controller configured to measure the voltage of a single cell near a fusible member.

[0038] In some embodiments, the electronic component further includes a temperature sensor and a controller configured to determine the temperature near the fusible component.

[0039] In some embodiments, the component further includes two or more printed circuit boards, and the connecting piece includes at least two fusible members, wherein: a first fusible member is connected to a first printed circuit board; a second fusible member is connected to a second printed circuit board; and the piece is attached to a conductor.

[0040] In some embodiments, the component further includes: two or more individual cells, each individual cell having an individual cell terminal; two or more connecting pieces, including: a first piece fixed to a first individual cell and soldered to a printed circuit board, and a second piece fixed to a second individual cell and soldered to the printed circuit board; an electronic switching device mounted on the printed circuit board; wherein the printed circuit board and the electronic switching device together form a plurality of circuit paths, the plurality of circuit paths including: a first path in which the individual cell terminals are connected in series, and a second path in which at least one individual cell terminal is bypassed from the series connection.

[0041] In some embodiments, the component further includes a plurality of electronic switching devices and a controller, the plurality of electronic switching devices being configured to guide current through a plurality of circuit paths, the paths including: a first current path including a first current path connected in series with a chip and a second current path arranged to bypass the chip; the controller being configured to: control the operation of the plurality of switching devices to connect the first current path, detect an open-circuit state of a circuit path including a fusible element, and then control the operation of the plurality of switching devices to connect the second current path.

[0042] In another broad aspect, the present invention relates to an electronic component comprising: a printed circuit board including terminal coupling regions; a single battery including individual battery terminals aligned with the terminal coupling regions; a connector tab disposed in each of the above embodiments, the connector tab being connected to the printed circuit board at a first end and attached to the individual battery terminals at a second end; and one or more temperature sensors located in holes or housings at the printed circuit board and at the second end.

[0043] In another broad aspect, the present invention relates to an electronic component including a printed circuit board, a single battery cell, and two or more connecting tabs. The printed circuit board includes: a terminal coupling region connected to a charging or discharging trace, and a controller device connected to a measurement trace. The single battery cell includes a single battery cell terminal aligned with the terminal coupling region. Each connecting tab is disposed within the terminal coupling region according to any of the above embodiments, and each connecting tab includes: a resiliently deformable fusible member having a first end connected to the terminal coupling region, a second end attached to the single battery cell terminal, and a member connected to the measurement trace.

[0044] In another broad aspect, the present invention relates to an electronic component comprising a plurality of individual cells, one or more printed circuit boards, and connecting tabs, each individual cell having one or more individual cell terminals arranged in a substantially predetermined geometrically aligned plane; one or more printed circuit boards aligned with the plane and including a plurality of terminal coupling regions; and connecting tabs disposed in each terminal coupling region as in any other embodiment.

[0045] In one embodiment, the sheet is soldered to a printed circuit board.

[0046] In one embodiment, the sheet is connected to the individual battery terminal by fasteners.

[0047] In one embodiment, the fastener includes a bolt connector.

[0048] In one embodiment, the component also includes a controller configured to monitor the resistance of the fusible component.

[0049] In one embodiment, there is an electronic structure having a controller configured to determine the temperature of the fusible component.

[0050] In one embodiment, the component further includes two or more printed circuit boards, and the connecting piece includes at least two fusible members, wherein: a first fusible member is connected to a first printed circuit board; a second fusible member is connected to a second printed circuit board; and the piece is connected to a conductor.

[0051] In an embodiment, the component further includes: two or more individual battery cells, two or more connecting tabs, and an electronic switching device, each individual battery cell having individual battery terminals; the two or more connecting tabs include: a first tab fixed to a first individual battery cell and soldered to a printed circuit board, and a second tab fixed to a second individual battery cell and soldered to the printed circuit board; the electronic switching device is mounted on the printed circuit board; wherein the printed circuit board and the electronic switching device together form multiple circuit paths, these paths including: a first path in which the individual battery terminals are connected in series, and a second path in which at least one individual battery terminal is bypassed from the series connection.

[0052] In one embodiment, the component further includes a plurality of electronic switching devices and a controller, the plurality of electronic switching devices being configured to guide current through a plurality of circuit paths, the paths including: a first current path including a first current path connected in series with the chip and a second current path arranged to bypass the chip; the controller being configured to: control the operation of the plurality of switching devices to connect the first current path, detect an open-circuit state of the circuit path including a fusible element, and then control the operation of the plurality of switching devices to connect the second current path.

[0053] In another broad aspect, the present invention relates to a reconfigurable battery system comprising: a plurality of individual cells, each individual cell having one or more individual cell terminals arranged in a substantially predetermined geometrically aligned plane; one or more printed circuit boards including a plurality of terminal coupling regions; connecting tabs disposed in each terminal coupling region as in any other embodiment, the connecting tabs being soldered to the circuit board at a first end and connected to the individual cells via fasteners at a second end; wherein the one or more circuit boards include a plurality of circuit paths and a plurality of switching devices arranged to configure the plurality of circuit paths, the paths including at least a first path and a second path, wherein in the first path a first tab is connected in series with two or more individual cells, and in the second path a first connecting tab is bypassed from the first path; wherein the system further includes a controller configured to: control the operation of the plurality of switching devices to connect a first current path, detect an open-circuit state of a circuit path including a fusible element, and then control the operation of the plurality of switching devices to connect a second current path.

[0054] In another broad aspect, the present invention relates to a method for repairing an electronic component comprising a plurality of individual cells, each individual cell having one or more individual cell terminals arranged in a substantially predetermined geometrically aligned plane; one or more printed circuit boards aligned with the plane and including a plurality of terminal coupling regions; and, in any other embodiment, a connecting tab disposed in the terminal coupling regions of the circuit board, the connecting tab having a first end connected to the circuit board and a second end connected to the individual cell via fasteners; wherein the method comprises: identifying a failed tab determined based on the tab's transition from a closed-circuit state to an open-circuit state, desoldering the first end of the tab from the circuit board, loosening the second end from the individual cell terminals, and replacing the tab.

[0055] In another broad aspect, the present invention relates to a method of assembling an electronic structure, comprising: arranging a plurality of individual battery terminals in a geometrically aligned manner; arranging one or more PCBs near one or more individual battery terminals; soldering a first end of a connecting piece, in any other embodiment, to the PCB; and fastening a second end of the connecting piece to an individual battery terminal, thereby transforming the piece from one or more of the following: a first extension plane to a second extension plane, a first configuration to a second configuration, and / or a relaxed state to an elastically deformable state.

[0056] In some embodiments, the invention relates to a combination of any one or more of the foregoing statements with any one or more of the other statements. Other aspects of the invention may become apparent from the following description, given by way of example only and with reference to the accompanying drawings.

[0057] All disclosures of all applications, patents, and publications cited above and below (if any) are incorporated herein by reference. The invention may also be broadly defined as including portions, elements, and features individually or jointly mentioned or indicated in the specification of this application, as well as any or all combinations of any two or more of said portions, elements, or features, and if any particular integer mentioned herein has a known equivalent in the field to which this invention pertains, such known equivalents are deemed to be incorporated herein as if separately stated.

[0058] Many variations in the construction and wide range of embodiments and applications of this invention will become apparent to those skilled in the art without departing from the scope of the invention as defined in the appended claims. The disclosure and description herein are purely illustrative and are not intended to be limiting in any way.

[0059] The term “and / or” as used in the specification and claims means “and” or “or”, or both.

[0060] As used in this specification and claims, the term "comprising" means "consisting of at least a portion of...". When interpreting statements in this specification and claims that contain this term, the feature beginning with that term in each statement must be present, but other features may also be present. Related terms such as "comprising" and "included" should be interpreted in the same manner.

[0061] Unless otherwise expressly stated, the singular forms “a,” “an,” and “the” used herein include the plural forms as well. It should also be understood that the terms “includes,” “comprises,” “including,” and / or “comprising”, when used in this specification, specify the presence of the stated feature, integer, step, operation, element, and / or component, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. It should be understood that when an element is referred to as “connected” or “coupled” to another element, it may be directly connected or coupled to the other element, or there may be intermediate elements. Attached Figure Description

[0062] The invention can be better understood by referring to the following accompanying drawings. The elements in the drawings are not necessarily drawn to scale; the focus is on clearly illustrating the principles of the invention. Furthermore, in the various views, the same reference numerals denote corresponding parts.

[0063] Figure 1 The prior art components are shown, including eight battery modules and electronic components attached to these modules.

[0064] Figure 2 This illustrates a prior art electronic assembly that includes a printed circuit board and electronic components for connecting to a battery module.

[0065] Figure 3 A side view of an electronic assembly including an exemplary connecting piece in a first configuration is shown.

[0066] Figure 4 An exemplary connecting piece in a second configuration is shown. Figure 2 Side view of the electronic components.

[0067] Figure 5 An isometric view of an electronic assembly including an exemplary connecting piece is shown.

[0068] Figure 6 A plan view of an electronic assembly including an exemplary connecting piece is shown.

[0069] Figure 7 An isometric view of an electronic assembly including an exemplary connecting piece is shown.

[0070] Figure 8 A side sectional view of an electronic assembly including an exemplary connecting piece is shown.

[0071] Figure 9 A plan view of an electronic assembly including an exemplary connecting piece is shown.

[0072] Figure 10 An isometric cross-sectional view of an electronic assembly including an exemplary connecting piece is shown.

[0073] Figure 11 A side view of an electronic assembly including an exemplary connecting piece in a first configuration is shown.

[0074] Figure 12 An exemplary connecting piece in a second configuration is shown. Figure 11 Side view of the electronic components.

[0075] Figure 13 An isometric view of an electronic assembly including an exemplary connecting piece is shown.

[0076] Figure 14 An isometric view of an electronic assembly including an exemplary connecting piece is shown.

[0077] Figure 15 A side sectional view of an electronic assembly including an exemplary connecting piece in a first configuration is shown.

[0078] Figure 16 An exemplary connecting piece in a second configuration is shown. Figure 15 A side sectional view of the electronic components.

[0079] Figure 17 A side view of an exemplary connecting piece is shown.

[0080] Figure 18 A plan view of an exemplary connecting piece is shown.

[0081] Figure 19 A schematic diagram showing the exemplary location of the connecting piece in the previously described embodiment is shown.

[0082] Figure 20 Another exemplary circuit is shown, including a location of a fusible link that can be achieved by a fusible member of a connecting piece according to the embodiment described.

[0083] Figure 21 An example of a chip with sensor integration is shown.

[0084] Figure 22 It shows Figure 21 A cross-section of the slice.

[0085] Figure 23 Another example of a chip with sensor integration is shown.

[0086] Figure 24 It shows Figure 23 A cross-section of the slice. Detailed Implementation

[0087] Embodiments of this disclosure are now described. Exemplary methods, devices, components, and systems are described herein. The word “exemplary” is used herein to mean “as an example, instance, or illustration.” Any embodiment or feature described herein as “exemplary” or “illustrative” is not necessarily to be construed as superior to or advantageous to other embodiments or features. More generally, the embodiments described herein are not intended to be limiting. It should be readily understood that certain aspects of the disclosed devices, systems, and methods can be arranged and combined in a variety of different configurations, all of which are contemplated herein.

[0088] This invention includes one or more devices used with an electronic board, and an assembly comprising the devices and the electronic board. In some embodiments, the electronic board is adapted to span the terminals of multiple individual energy storage cells. In such applications, the electronic board is typically subjected to mechanical stress, thermal stress, or heat energy, which are generated in the board itself, in components attached to the board, and / or transferred to the board from the individual energy cells. In some embodiments, the devices of this invention are configured to mitigate the accumulation of these stresses or heat energy.

[0089] The electronic board used in the device of the present invention is typically a printed circuit board. The circuit board is typically composed of a laminate. Any layer in the laminate can be a conductive or non-conductive layer. In some embodiments, the conductive layer may include aluminum or copper. In some embodiments, the non-conductive layer material includes polyimide, KAPTON® tape, polyethylene terephthalate, or polyethylene naphthalate. In some embodiments, one or more support layers may include a glass-reinforced epoxy laminate (e.g., FR4) or aluminum.

[0090] In this specification, the term "cell battery unit" or "cell battery cell" generally refers to a component capable of storing electric charge, and may refer to a single cell battery, a cell battery block connected in parallel, or a combination of single cells, cell battery blocks connected in parallel, or cells battery units connected in series. An energy storage unit may also refer to a cell battery block connected in parallel and / or in series, which also includes circuit components connected in series and / or in parallel with the individual cells battery, such as fuses, resistors, passive control diodes, capacitors, or inductors. The terms "energy storage unit," "storage unit," "cell battery unit," or "cell battery cell" may also refer to non-battery energy storage elements such as fuel cell batteries and supercapacitors. In some embodiments, an energy storage unit may be designed to include one or more energy storage units capable of achieving a charging capacity of at least 10 Ah, 20 Ah, 40 Ah, 60 Ah, 100 Ah, 200 Ah, or 400 Ah ampere-hours. In some embodiments, a plurality of energy storage units may include first and second energy storage units, wherein the charging capacity of the first energy storage unit is substantially greater than the charging capacity of the second energy storage unit.

[0091] In some embodiments, one or more electronic boards are provided, adapted to span three or more terminals of one or more energy storage cells. In industrial applications, due to variations in individual cell size or inconsistencies in individual cell alignment, or for other reasons (e.g., proximity to electrical loads or cooling sources), the terminals of the storage cells will be arranged in a predetermined alignment to best suit the packaging constraints of the application. The predetermined geometric alignment of the conductive terminals is configured as the primary path for current to enter and exit the energy storage cell. The terminals will have a predetermined geometric arrangement, typically determined by the requirements of their application or purpose. For example, to optimize current coupling between cells, the terminals of the cells are typically arranged so that electronic components in a single plane can contact all terminals. However, the terminals may be arranged in such a way that at least one terminal is spatially offset compared to one or more other terminals. For example, physical constraints may exist because one or more other parts of the energy storage module, rack, housing, or other nearby components may collide with the terminal plane, potentially causing terminal misalignment.

[0092] In this specification, the term "primary current path" or similar term refers to the current path between the terminals of individual battery cells connected in series. The term "secondary current path" or similar term refers to the relatively lower current path from the terminals of individual battery cells to a secondary device, such as a voltage monitoring device or a charge balancing device. The primary current path may include conductive portions of electronic components, such as terminal coupling regions and circuit regions. Furthermore, the electronic components may have electronic parts disposed in the primary current path and configured to interrupt the primary current path. For example, the primary current path may be interrupted by disconnecting or bypassing individual battery cells. The primary current path is the circuitry primarily used for charging and discharging as current flows through all battery cells. In some embodiments, the primary current path is selectively operated by selective operation of electronic parts.

[0093] Figure 1 The prior art components are shown, including eight battery modules and electronic components attached to the modules. Figure 2 A prior art electronic assembly is shown, including a printed circuit board (PCB) and electronic components for connection to a battery module. These assemblies include an electronic structure 10, a PCB 11, battery cell units 12, and battery cell terminals 13. The battery cell units are shown in a geometrically aligned manner such that the terminals 13 of each individual cell are also aligned. In this assembly, the PCB is located on top of the battery cells and has PCB terminal coupling regions 15 for connection to each battery cell. The terminal coupling regions 15 of the PCB are typically plated pads with holes that allow fasteners to pass through the PCB and mechanically couple to the terminals 13 of the battery cells. For example, the battery cell terminals typically include threaded bosses, and the PCB is coupled to the terminals by threaded fasteners (e.g., bolts). In this way, the PCB is bolted to the arrangement of the battery cells to secure the assembly and provide an electrical connection between the battery cell terminals 13 and the terminal coupling regions 15 of the PCB.

[0094] Figure 1 The problem with this component is that, over time, the fasteners clamping the PCB tend to lose clamping force. This loss of clamping force can be attributed to creep caused by the slow deformation of the PCB material under clamping loads. During normal operation, the thermal expansion and contraction cycles associated with the electronic components can exacerbate creep. Over time, loosening of the fasteners can lead to increased electrical resistance between the individual battery terminals and the PCB, potentially becoming a localized heating point and ultimately causing PCB failure or coupling failure. Increased temperatures can also lead to faster creep initiation through more rapid deformation.

[0095] Exemplary applications also include those requiring fusible electrical connections between circuit components. The fusible electrical connections of the embodiments discussed in this specification include both current fuses configured to fail at a predetermined current threshold and thermal fuses configured to fail at a predetermined thermal threshold.

[0096] A reconfigurable battery system is an example of a system that may require fusible connections to connect one or more individual cells to other circuit components. Fusible connections provide a safety measure in the event of certain circuit failures that would otherwise result in abnormally high current flow and / or abnormally high temperatures in the area. Reconfigurable battery systems and circuits are well known, and exemplary systems are described in U.S. Patent 1,126,4812 and U.S. Patent Application 20,220,255,194, the entire contents of which are incorporated herein by reference.

[0097] Figure 20 An exemplary circuit with multiple battery cells is shown, wherein the terminals of these battery cells need to be connected, and the connection also requires fuses between circuit components. The exemplary applications discussed in this specification relate to the mechanical and electrical connection between a PCB and battery cells, with fuses between the battery cells in the electrical connection. However, battery cells can also be any other rigid conductor used for conducting current, such as busbars, ground planes, or the like. For the purposes of this specification, rigid conductors should be interpreted as any non-PCB component or material suitable for engagement with fasteners, including conductive material bodies. Applications particularly include those requiring low-resistance electrical and secure mechanical connections to prevent failure. Mechanical failures include connection breakage. Electrical failures include increased connection resistance, causing the connection to overheat or burn out. Therefore, applications are typically found where high currents are encountered, such as battery packs, chassis grounding connections, electric vehicles, welding equipment, motor connections, junctions, grounding junctions, high-current inductors, and other similar devices. However, other low-current applications can also benefit from the advantages discussed herein.

[0098] Figures 3 to 18 Exemplary embodiments and exemplary applications of the connecting piece are shown. In particular, Figure 17 and Figure 18 An exemplary connector 20 is shown. Dimensions are provided for certain contexts; however, these dimensions may vary depending on the intended application of the connector.

[0099] Connector 20 is configured to couple a printed circuit board to a conductor. In some embodiments, the conductor is one or more of a single-cell battery terminal, a bus, a junction, a ground junction, or other fastener-based connection. Therefore, the conductor has at least the same stiffness as the PCB, and preferably higher stiffness. Connector 20 has a first end comprising a plate 24. Plate 24 is adapted to be soldered to the PCB. Similarly, any PCB will have corresponding pads sized to receive plate 24 for a secure solder connection. Connector 20 has a second end comprising a hole 28 to allow a fastener to pass through from the first side to the conductor, such as a single-cell battery terminal on the second opposite side. In some embodiments, the size and / or shape of the hole allows for a degree of misalignment between the fastener and the hole center. In some exemplary embodiments, the hole comprises a slotted form.

[0100] In use, the connector spans between a soldered connection to the PCB at the first end 24 and a fastener-based connection to a rigid conductor at the second end. Therefore, the second end is referred to as terminal coupling regions 26, 31 and can take different forms as discussed with reference to other embodiments herein. The first and second ends of the connector are interconnected by one or more resiliently deformable and fusible members 25. Members 25 can take various forms and typically have dimensions based on the desired fusing current.

[0101] As will be discussed herein, fusible components also remain in a state of elastic deformation during use, thereby altering the fusing current and fusing sensitivity. In some embodiments, the fusible component is a spring (e.g., a leaf spring), or other elastic component, configured to store elastic force through elastic deformation of the material when mounted in an electronic assembly. In some embodiments, elastic deformation is bending moment, tensile stress, compressive stress, or a combination of one or more such factors.

[0102] Specifically, when transitioning from the first extension plane to the second extension plane, member 25 elastically deforms, causing one or more fusible members to maintain tension via fasteners. This means that the second end of the sheet includes a first extension plane when not connected to the rigid conductive element, and a second lower extension plane when connected to the rigid conductive element. The first extension plane is initially controlled by a solder connection to the PCB on the first end. After connection to the PCB, fasteners passing through holes in the terminal coupling area will bend member 25 downwards until mechanical engagement with the rigid conductor occurs. In some embodiments, the fusible member 25 is a leaf spring configured to store bending energy applied by the fasteners upon engagement.

[0103] In some embodiments, the fusible component is pressed into place by the head of a welding machine, or pressed into place to perform a welding process. For example, laser welding or spot welding may include pressing a sheet into a conductor (e.g., a battery terminal) and then welding to fuse the components together. Therefore, fasteners are not required. In the embodiments discussed in this specification, welding attachments can be considered as alternatives to fastener-based attachments.

[0104] Therefore, ideally, the connector tab is used in the assembly where it is soldered to the upper side of the PCB, and the lower side of the tab is deformed to contact a conductor on the lower side of the PCB. In applications where the connector tab is PCB mounted or otherwise located on top of a cell or some other conductive structure, the connector tab is deformed to at least the thickness of the PCB. However, the connector tab can take various forms depending on the desired location of the connection to the PCB and the desired connection to the conductor.

[0105] In some embodiments, the connecting piece is configured to couple a printed circuit board to a conductor, and the piece includes a relaxed state and a tensioned state. In the relaxed state, one or more elastically deformable fusible members span between a first end connectable to the printed circuit board and a second end including a second connecting plate adapted to receive fasteners. In the tensioned state, the piece includes a first plate connected to the printed circuit board and a second plate fixed to the conductor. It is envisioned that the displacement between the relaxed and tensioned states is a distance of 1 mm or greater. However, the piece can be shaped in various forms to produce the desired displacement between the relaxed and tensioned states. In a preferred embodiment, the member 25 is held under tension between the first and second ends during use.

[0106] In some embodiments, the relaxed state of the sheet is a first configuration, wherein a first end including a printed circuit board connection portion of the sheet is connected to a printed circuit board, and a second end including a conductive connection portion is not connected to a conductor. In some embodiments, the tensioned state of the sheet is a second configuration, wherein the conductive connection portion is fastened to a conductor. In such embodiments, one or more elastically deformable fusible members span between the printed circuit board connection portion and the conductive connection portion, these one or more elastically deformable fusible members being connected and deformable in the tensioned state of the second configuration.

[0107] In some embodiments, a fusible member 25 spans between the terminal coupling region and the PCB coupling region of the sheet 20. In other embodiments, two or more fusible members are present. The fusible members can be arranged according to the desired PCB connection location. For example, two fusible members can be spaced 90 degrees or 180 degrees apart. Multiple fusible members can form individual circuit paths or can form parallel circuit paths. The PCB conductive region can be arranged to configure circuit paths from the terminal coupling region of the sheet.

[0108] In some embodiments, the connecting tab includes cooling fins 27. The cooling fins aid in heat conduction from components by providing at least a thermally efficient connection to a PCB or individual cell terminal, where one or both of these components may be heat sources. Fins 27 also serve to cool fusible components. In some embodiments, the cooling fins 27 extend from the PCB connection area 24 of the tab.

[0109] In some embodiments, the terminal coupling region of the sheet includes an area adapted to deform under compressive forces when the fastener mechanically engages the sheet into the mounting position. Figure 16 and Figure 17 In the terminal coupling region 31, there is a protrusion 32. Therefore, the protrusion provides a compressible portion of the terminal coupling region. In use, when the fastener is tightened, the protrusion of the terminal coupling region is flattened. When the compressible portion of the plate is made of an elastic material (e.g., steel), it provides a spring force against the fastener, thereby helping to secure and maintain the fastening force applied by the fastener.

[0110] In some embodiments, the protrusion is a ridge region, such that the terminal coupling region has two or more surface regions, one region situated above another. Thus, the two or more surface regions are spanned by an inclined structure having both a relaxed state and a compressed state, the compressed state being caused by fasteners connecting the sheet to the conductor or individual cell terminal.

[0111] In some embodiments, the raised ridge regions are configured to provide a preload to the fastener. Under fastener tightening load, the ridge regions are configured to elastically deform, thereby applying a counterforce to the fastener. In some embodiments, the raised ridge regions are also configured to promote a small, desired deformation of the sheet under fastener tightening load.

[0112] In some embodiments, the raised ridge region comprises the only area of ​​the sheet that elastically deforms under the load of the fastener. In these embodiments, the load is applied laterally to the fusible member. In some cases, this may be advantageous because no or only minimal vertical load is applied to the PCB.

[0113] Therefore, embodiments of the connecting piece include one or more of the following:

[0114] The first extending plane, wherein the first PCB connection end and the second terminal coupling end each have one or two extending planes when not connected, and the extending plane of the second end is at least changed by fixing the first end to the PCB and the second end to the conductor. This change is typically caused by soldering the first end to the PCB and connecting the second end to the conductor by fasteners. The change in the extending plane also causes the fusible member to remain in an elastic deformation state between the first end and the second end.

[0115] In the first configuration, a first end of a printed circuit board connection portion including a sheet is connected to the PCB, and a second end of a conductor connection portion is not connected to a conductor.

[0116] In the second configuration, the conductive connection portion is fastened to the conductive body.

[0117] One or more elastically deformable fusible components span the printed circuit board connection portion and the conductive connection portion and are connected, and one or more deform in a tensioned state of a second configuration.

[0118] The configuration change is caused by the soldered connection of the first end to the PCB and the second end being connected to the conductor via fasteners. In this configuration, the surface of the PCB connected to the first end is at a different height from the conductor. In some embodiments, the PCB is adapted to sit on the conductor (e.g., a single-cell battery terminal) such that the PCB connection surface is located at the thickness of the PCB above the single-cell battery terminal. This allows the fusible member to be held under tension between the first and second ends due to the distance the second end of the connecting piece is pulled down by the fasteners by the PCB thickness.

[0119] Therefore, in some embodiments, there is a structure including a PCB having a first surface height, a conductor having a second surface height, and in a first configuration, a connecting piece having a first end soldered to the PCB and the piece extending at the first surface height, and in a second configuration, having fasteners that mechanically and electrically connect the second end of the piece to the rigid body, such that the second end moves from the first surface height to the second surface height, thereby applying a bending force to the fusible member.

[0120] In a relaxed state, the sheet has one or more elastically deformable fusible members that span between a first end that can be connected to a printed circuit board and a second end that includes a second connecting plate adapted to receive fasteners.

[0121] In a tensioned state, the sheet has a first plate connected to a printed circuit board and a second plate fixed to a conductor.

[0122] A tensioned state is created when the first end of the connector is soldered to the PCB and the second end is connected to the conductor via fasteners. In this elastically deformed state, in some embodiments, the PCB surface connected to the first end is at a different height from the conductor. In some embodiments, the PCB is adapted to be positioned on the conductor (e.g., a single-cell battery terminal) such that the PCB connection surface is located at the PCB thickness above the single-cell battery terminal. This causes the fusible member to remain in an elastically deformed state between the first and second ends due to the distance of the PCB thickness pulled downwards by the fasteners at the second end of the connector.

[0123] In some embodiments, a second portion of the sheet is configured at the same height as the conductor, and a raised ridge region in the second portion is configured to apply a lateral deformation load to the fusible member under the load applied by the fastener. Thus, elastic deformation is stored through the lateral elastic deformation of the fusible member as it crosses between the PCB and the conductor.

[0124] Therefore, the aforementioned connecting terminals facilitate methods for assembling electronic structures such as reconfigurable battery systems. The construction of a reconfigurable battery system electronic structure includes arranging multiple individual battery terminals in a geometrically aligned manner; placing one or more PCBs near one or more individual battery terminals; soldering a first end of the aforementioned connecting piece to the PCB; and securing a second end of the connecting piece to an individual battery terminal. The action of securing the piece to the individual battery terminal (or other conductor) causes the piece to undergo one or more of the following transformations: from a first extending plane to a second extending plane, from a first configuration to a second configuration; and / or from a relaxed state to an elastically deformed state.

[0125] In some embodiments, the sheet is made of metal. In some embodiments, the metal is plated with one or more conductive materials, such as copper or gold. In some embodiments, the sheet is stamped from sheet metal. In some embodiments, the stamped sheet metal is plated with a solderable compatible material in a post-manufacturing process.

[0126] One or more fusible components 25 of the connecting piece are designed to fail when a current threshold is reached. In some embodiments, the piece is also configured to disconnect from the PCB at least when a temperature threshold is reached.

[0127] In use, the fusible member 25 of the preferred embodiment remains in an elastically deformed state to store elastic energy. This is because the failure temperature of the elastically deformed state is lower than the failure temperature of the relaxed state. The deformation force applied to the fusible member generates a force that will initiate fracture when the member's critical current or critical temperature is reached. The metallic structure of the member means that tension exacerbates fracture, causing the member to fail faster than the same member without tension. Therefore, the fusible member 25 is an elastically deformable structure that elastically deforms into an elastically deformed state during use, thus becoming a conductive material that stores elastic energy under deformation loads.

[0128] The dimensions of the fusible component correspond to the required fusing current limit. Since the material only needs to reach its melting temperature before breaking, releasing its stored elastic energy, and separating the component, the fusible component is kept under tension, making the fusing limit more reliable.

[0129] The elastic deformation state of the sheet also contributes to thermal breakage. For example, when the ambient temperature of the sheet reaches the melting point of the solder joint between the sheet and the PCB (typically around 220°C), the elastic deformation state of the sheet will release the stored elastic energy and break the solder joint. In this case, the sheet will transition from an elastic deformation state to a relaxed state, thereby physically separating at least the first end of the sheet from the PCB, thus breaking the electrical connection.

[0130] Figures 3 to 16 Various exemplary embodiments including combinations of the above features are shown. Figure 3 A side view of an electronic assembly including an exemplary connecting piece in a first configuration is shown. Figure 4 An exemplary connecting piece including the second configuration is shown. Figure 3 A side view of the electronic component. Conductor 22 is adapted to receive fastener 23. For example, the fastener is a bolt, and the conductor includes a threaded hole configured to receive the bolt. Furthermore, the connecting tab includes a hole sized to allow a fastener to pass through the tab, thereby allowing the fastener to secure the tab to the conductor.

[0131] In some embodiments, the conductor is a single-cell battery terminal. In some embodiments, the PCB is adapted to be mounted on top of the single-cell battery terminal. For example, Figure 3 and Figure 4 The diagram shows area 29 where the PCB overlaps with the surface of the individual battery terminal. Therefore, in some embodiments, the PCB includes cutouts or holes sized to allow the connecting tab to be recessed therein. In other embodiments, the PCB is supported by a structure within the assembly that maintains a gap between the PCB and the conductor. In such embodiments, the tab will span the gap between the PCB and the conductor.

[0132] The first end 24 of the sheet 20 is configured to connect to the PCB 21. As described above, a solder joint between the sheet and the PCB is ideal, therefore the PCB provides pads suitable for soldering the connection to the sheet.

[0133] In use, fastener 23 passes through hole 28 in the sheet and engages with a rigid conductor located below the sheet. Engagement of the fastener causes the second end of the sheet to be pulled downward, while the second end 26 is mechanically and electrically connected to conductor 22. Through the fixed first end connected to the PCB, fusible member 25 is placed under tension as indicated by arrow T, or is bent or otherwise flexed to store spring energy.

[0134] Figure 5 An isometric view of an electronic assembly including an exemplary connecting piece is shown. Figure 6 A plan view of an electronic assembly including an exemplary connecting piece is shown. Figure 5 and Figure 6The sheet shown includes two fusible members 25, each extending from a second end suitable for connection to individual cell terminals to a different location on the PCB. Each fusible member can be configured to connect the second end of the sheet to a different circuit via each outward branch. Upwardly extending wings 27 are also shown to facilitate heat conduction away from the PCB and terminals.

[0135] In some embodiments, wing 27 is also configured as a counterweight. Ideally, the sheet is machined onto the PCB prior to the reflow soldering process. Therefore, when the sheet is positioned at the PCB edge and at least partially extends beyond the PCB edge, the sheet needs to have a certain degree of stability, and it must have a center of mass before the PCB edge. Therefore, in some embodiments, the wing is also configured as a counterweight such that the center of mass is contained within a first end of the sheet. Relying on the adhesion of solder paste is another method of holding the sheet before reflow. Additionally, in some embodiments, adhesive dots are used to stabilize the sheet prior to the reflow process.

[0136] Figure 7 An isometric view of an electronic assembly including an exemplary connecting piece is shown. Figure 8 A side sectional view of an electronic assembly including an exemplary connector is shown. Figure 9 A plan view of an electronic component including an exemplary connecting piece is shown. Figure 10 An isometric cross-sectional view of an electronic assembly including an exemplary connecting piece is also shown. The piece shown has a single fusible member 25 adapted to be held under the tension indicated by arrow T.

[0137] Figure 11 A side view of an electronic assembly including an exemplary connecting piece in a first configuration is shown. Figure 12 An exemplary connecting piece in the second configuration is shown. Figure 11 Side view of the electronic components. Figure 13 An isometric view of an electronic assembly including an exemplary connecting piece is shown.

[0138] In the illustrated exemplary embodiment, the connecting piece has a raised ridge region within its second end. The raised ridge region is wavy in shape, wherein the upwardly sloping sides of the ridge 32 are bridged by a raised central region 31. The sloping sides are adapted to be flattened by a fastener passing through the hole 28. The pressing action promotes elasticity and axial resistance to the fastener, or a spring force that can absorb shocks and provide resistance to axial loads against vibration. This prevents the fastener from loosening over time, especially in environments subject to thermal cycling, such as when used near heat-generating electronic components.

[0139] The elastic deformation force (e.g., tension) applied to the fusible member by the fastener is represented by arrow T. The compressive force applied by the fastener in the compression ridge is represented by arrow C.

[0140] Figure 13 A second portion of the sheet located on the underside plane of the PCB is also shown. This prevents the fasteners engaging the sheet from deflecting the fusible component downwards. Instead, the raised ridges apply an outward lateral force to the fusible component, rather than a downward force as in other embodiments. This configuration can be advantageous when the downward load applied to the PCB is less desirable than a lateral or edge-facing load.

[0141] Figure 14 An isometric view of an electronic assembly including an exemplary connecting piece is shown. Figure 15 A side sectional view of an electronic assembly including an exemplary connecting piece is shown. Figure 14 and Figure 15 Each of these examples shows a slack connector attached to the PCB but not to a rigid body within a PCB hole. Specifically, the fusible member 25 includes a profile that extends upward from a first end 33, then arcs, and then downward to a second end. Compared to the previously shown examples, the fusible member shown includes an additional surface area. This additional surface area allows tension to be distributed over a larger area of ​​material, thus providing greater flexibility or range of motion. Such examples may be best suited for situations requiring a greater range of displacement or specific fusing characteristics.

[0142] Figure 16 This illustrates the outward lateral force vector F applied through engagement with the fastener (as described above regarding...). Figure 13 (as described). Figure 16 The second part of the sheet, positioned at the top height of the PCB, is also shown. In this way, a combination of lateral and downward force vectors is applied to the fusible component.

[0143] Figure 19 The structure of an exemplary electronic circuit and components within the circuit is shown. The arrangement of a battery cell AF and a switch AF is shown, the switch AF being configured to control selective connection or bypass of the series-connected battery cells. Two exemplary PCBs 40 and 41 are shown by dashed lines to illustrate the mounting of switching components within the line surface area onto the respective PCBs. This means that switch AD is mounted to the first PCB 40, and switch EF is mounted to the second PCB 41.

[0144] An exemplary arrangement of battery cells is as follows: Figure 1 As shown, the individual battery terminals of multiple individual cells are arranged in a geometrically aligned manner, and a PCB is mounted on the individual battery terminals, spanning an area covering the multiple individual battery terminals. The switch shown is configured to control the connection of the individual batteries in the group.

[0145] Due to practical size constraints in PCB manufacturing, in this arrangement, it is often necessary to span multiple PCBs across the top of a group of individual battery terminals. Coupled with significant current from the battery cell group between adjacent PCBs, this can be problematic.

[0146] Figure 18 A connecting piece 50 is shown, which is arranged to connect to the terminals of the single cell D and has a fusible member configured to span each of the first terminal 40 and the second PCB 41. Thus, the connecting piece 50 serves to provide a fusible connection between the single cell D and the first and second PCBs, and also provides physical support for the PCB on top of the single cell terminals.

[0147] In some embodiments, a single sheet having two fusible components can be replaced by a stacked combination of sheets, each sheet having a single fusible component, or some other combination. Stacking sheets individually may be necessary when the sheets are soldered to a PCB and it is desired to disconnect the PCB before mounting them into an assembly.

[0148] To simplify the explanation, Figure 18 Two connecting tabs are shown, however, the tabs can be implemented in this reconfigurable battery system circuitry at any other connection point.

[0149] Connector 51 illustrates another example use, where it provides a connection to the C terminal of a single battery cell and facilitates a separate circuit path via a fusible component connected to switches C and D. In this way, a separate fusible current path is provided that, in the event of a fuse failure, bypasses either the single battery cell or the switch without disrupting the overall output of the series-connected device.

[0150] For example, chip 50 has fusible components extending to separate current paths: path 44 connected to switch A and path 45 extending to switch F. If the fusible component in path 45 breaks, path 45 will be inoperable. A controller that determines path 45 is inoperable can be configured to control current paths in the circuit to bypass the circuitry surrounding the broken path 45. In this example, the circuit has arbitrary input 60 and arbitrary output 61. If path 45 is broken, a current path from input to output can be established through individual cell A, individual cell B, switch A, individual cell D, individual cell C, switch D, and then individual cells E and F.

[0151] In another example, if path 44 is broken, a current path from input to output can be established through individual cell A, switch B, individual cell C, switch D, and then individual cells E and F.

[0152] The circuit structure described above also offers other unique advantages. If the fuse fails, the circuit may still be usable.

[0153] Therefore, in embodiments, there exists an electronic structure comprising a single cell having a plurality of individual cell terminals arranged in a substantially uniform plane, the single cell having one or more conductors or individual cell terminals, one or more printed circuit boards configured to span the uniform plane and including a plurality of individual cell terminal coupling regions, and a connecting piece as described above according to any exemplary embodiment.

[0154] In some embodiments, the PCB has circuitry including switching devices configured to connect connected individual cells in series to one or more other individual cells, and to bypass individual cells from a series-connected sequence of individual cells. The PCB has a terminal coupling region including a connection pad adapted to receive a first end of a connector tab. In some embodiments, the PCB further includes a recess, hole, or cutout adapted to receive the connector tab. In some embodiments, the PCB further includes a recess, hole, or cutout adapted to at least partially expose a conductor adapted for connection to a fastener (e.g., a cell terminal).

[0155] In electronic structures, the fuses of the connectors electrically and mechanically connect conductors to the PCB.

[0156] In some embodiments, the electronic structure has a controller adapted to control one or more switching devices. For example, the controller may be a microprocessor or a switching device MOSFET.

[0157] In some embodiments, the controller is configured to at least measure the resistance of the fuse to determine characteristics such as voltage drop and current. In such embodiments, the connector has at least one fusible member configured to conduct main current from a rigid body to the PCB and at least one other member, such as a second fusible member, configured to connect to the controller. Thus, the controller can be configured to measure the voltage at a first end and a second end of the connector, determine any differences, and infer further characteristics. This same configuration can be used to determine whether the fuse has broken. Therefore, in some embodiments, the electronic structure also includes a resistance monitoring circuit configured to monitor the resistance of the fuse. In some embodiments, the electronic structure also includes a controller configured to determine the temperature of the fuse. For example, the thermal conductivity of the connector allows the adjacent PCB area to determine the temperature of the individual battery terminals by placing a temperature sensing device in the adjacent PCB area.

[0158] In some embodiments, the electronic structure has a battery cell connected to a PCB via two fuses, wherein a first fusible element is part of a current path and a second fusible element is configured to connect to a controller for voltage measurement. This configuration may be advantageous for accurate voltage measurement, whereas otherwise, the battery discharge current flowing in the fusible element as part of the main current path could alter the voltage measurement.

[0159] To further improve temperature sensing accuracy, the temperature sensor may have a specific location. In some embodiments, the PCB connection area of ​​sheet 24 has a hole in which one or more temperature sensors are located. This ensures that heat is conducted to the metal ring surrounding the sensor, significantly reducing heat conduction to component areas away from the sensor, and consequently reducing heat near the sensor. In another exemplary embodiment, the PCB connection area of ​​sheet 24 has a housing surrounding the temperature sensor. This effectively traps heat that may have been transferred to the surrounding air beneath the housing and near the sensor. In some embodiments, there are slots or holes in which the sensor may reside.

[0160] An exemplary temperature sensor includes an NCP18WB473J03RB thermistor from Murata in a 0603 SMD package. In some embodiments, multiple temperature sensors are located within the same thermal region to provide measurement redundancy.

[0161] Figure 21 and Figure 22 An exemplary embodiment is shown, wherein the PCB connection area of ​​chip 24 includes a hole 41 and a temperature sensor 40 located within the hole. Heat from the individual cells connected to the terminal coupling areas 26, 31 will be conducted around the temperature sensor, thereby significantly reducing thermal coupling between the remaining components and the temperature sensor. The temperature sensor can be connected to the controller via a through-hole that extends through the PCB to other board traces.

[0162] Figure 23 and Figure 24 An exemplary embodiment is shown, wherein the PCB connection area of ​​the sheet 24 includes a housing 42. The housing 42 may be formed by a stamping process, wherein metal is deformed to form a cavity below the surface surrounding the sensor 41.

[0163] In an exemplary embodiment, a single-cell battery connector is provided, having a first fusible member configured to conduct current from the battery cell to a current bus on a circuit board and a second member configured to connect the battery cell terminals to a control circuit. Here, the control circuit is configured to measure the battery cell voltage from the second member, and the measurement can be performed more accurately without measuring the voltage of the member carrying the battery cell current. Furthermore, based on the foregoing reference... Figures 21 to 24 In the described embodiment, a temperature sensor is configured within the PCB connection area of ​​the connector. In this exemplary embodiment, the first fusible component is a thermal fuse and / or a current fuse, and the second component is a thermal fuse. In a variant embodiment, the second component does not have fusing characteristics and only conducts voltage and / or heat.

[0164] In some embodiments, the electronic structure has two or more PCBs, and the connecting piece includes at least two fuses: a first fuse is connected to a first PCB and a second fuse is connected to a second PCB.

[0165] In some embodiments, the electronic structure further includes two or more individual battery cells, each having a battery cell terminal. The structure has two or more connecting tabs, including a first tab fixed to a first individual battery cell and soldered to a PCB, and a second tab fixed to a second individual battery cell and soldered to a PCB. On the printed circuit board, there are electronic switching devices, and the PCB and electronic switching devices together form a circuit path having a first state with battery cell terminals connected in series and a second state with at least one battery cell terminal bypassed from the series connection.

[0166] In some embodiments, the electronic structure has a PCB with associated connecting tabs. The PCB also has a temperature sensor connected to the PCB and located at the junction of a fuse extending from a cross-sectional portion of the tab. In this configuration, a controller is configured to connect to the temperature sensor to read an approximate temperature of the individual cell. In some embodiments, the fuse is located in the main current path. In some embodiments, the fuse is not in the main current path.

[0167] In some embodiments, the connecting piece is formed from a sheet of metal. In an example, the piece is manufactured by cutting an outer shape from the sheet of metal and then bending the cut shape into a three-dimensional form. The cutting method can be metal stamping or other cutting methods, such as laser, water, or abrasive cutting methods. The three-dimensional shape can be formed by pressing the metal onto a forming device or mold.

[0168] In some embodiments, a connector tab is part of a reconfigurable battery system for coupling multiple individual cells, each cell having one or more individual cell terminals arranged in a substantially predetermined geometrically aligned plane. One or more printed circuit boards include multiple terminal coupling regions. Each terminal coupling region is configured to connect directly to the connector tab, thereby indirectly connecting to the individual cell terminals. Therefore, the connector tab is disposed in each terminal coupling region of the PCB. The connector tab is also soldered to the circuit board at a first end and connected to the individual cell terminals via fasteners at a second end. In the reconfigurable battery system, one or more circuit boards have multiple circuit paths and switching devices arranged in these paths to configure current within the circuit paths. One circuit path is a first path in which the connector tab is connected in series with two or more individual cells. A second circuit path is a bypass tab from the first path. Thus, an individual cell can also be connected in series with one or more other individual cells, or bypassed from a series connection. In a reconfigurable battery system, there is typically a desired or target output voltage, which is achieved by selectively connecting one or more battery cells in series at a time. To control the connection of individual battery cells, the controller is configured to operate switching devices, which in turn operate to connect or bypass battery cells from a series connection. In some embodiments, the controller is also configured to determine when a fusible component fails (e.g., by detecting voltage or voltage drop in the PCB terminal coupling area). The controller is then configured to operate multiple switching devices to redirect circuit paths around the failed fusible component. In this way, the desired or target output voltage of the reconfigurable battery system is maintained. In an exemplary embodiment, the controller is configured to operate switching devices to connect a first current path, detect an open-circuit state in a circuit path including the fusible component, and then control the operation of multiple switching devices to connect a secondary current path.

[0169] In such a reconfigurable battery system, failed fusible components can be repaired without interrupting the system output. If the cause of the fusible component failure can be identified and corrected (e.g., one or more individual cells fail and can be replaced), the connector can also be replaced within the system to make the individual cells and associated circuit paths operational again. In this case, one method is to restore the failed connector by identifying the failed connector based on the transition of the connector from a closed-circuit state to an open-circuit state, removing the first end of the connector from the circuit board, detaching the second end from the individual cell terminal, and replacing the connector.

[0170] The above embodiments advantageously facilitate an apparatus that allows for the connection of multiple PCBs when mounted on top of a battery cell arrangement having individual cell terminal arrangements. The flexibility of the fusible member can tolerate slight misalignment of the individual cell terminals. Furthermore, the flexibility and elastic deformation capability of the fusible member can tolerate heating, cooling, and vibration within the individual cell arrangement. In this way, mechanical and thermal stresses that individual cells might exert on the PCB are avoided.

[0171] Another advantage is that mechanical creep problems are avoided by having the sheet provide the connection between the fastener and the PCB. Fasteners that engage directly with the metal sheet can form a durable and secure mechanical and electrical connection.

[0172] This chip also provides thermal and electrical fusing for individual battery cells and other current paths. Fusible components placed in the main current can be designed to fail at specific temperature and / or current thresholds. Placing the component under tension also ensures enhanced fusing capability and higher reliability.

[0173] The sheet advantageously provides additional thermal conductivity to remove heat from the heat-generating device and couple that heat to the environment. In some embodiments, the sheet is made of a material with poor thermal conductivity (e.g., (primarily) steel). In this way, heat from the PCB is not significantly coupled to the connected battery cells through the sheet. Cooling fins on the first end of the sheet further enhance its ability to prevent heat transfer to the second end.

[0174] Metal connectors placed between the PCB and the individual battery cells facilitate electrical compatibility. For example, steel can be plated with a material ideally suited to the current requirements of the connection to the PCB pads and / or the individual battery terminals. This eliminates any requirement for the entire PCB to be plated with a suitable material.

[0175] Furthermore, the chip can be replaced in situ. If the fuse blows, the first end of the chip may be removed from the PCB, while the second end is removed via fasteners. A new chip can be soldered onto the PCB, and the second end can be reattached via fasteners.

[0176] The connection between the chip and the PCB is best achieved using reflow soldering. This reduces assembly costs as machine mounting and / or component soldering become possible.

[0177] Another advantage is that thermal melting of the electronic component is possible when the component reaches the melting point of the solder joint. Once the solder melts, the fusible component under tension will detach from the solder joint, thereby breaking the electrical and mechanical connections between the PCB and the component. In this way, the cause of the thermal overload can be investigated before further damage occurs.

[0178] The connector also facilitates connection to various battery cells. For example, bolted prismatic, welded prismatic, pouch, and cylindrical battery cell packages can be connected to the PCB via the connector.

[0179] The embodiments described above are for illustrative purposes only. Many alternative embodiments can be devised by those skilled in the art without departing from the scope of the appended claims.

Claims

1. A connector tab configured to connect a printed circuit board to a conductor, the tab comprising a relaxed state and an elastically deformable state, wherein: In the relaxed state, the sheet comprises: One or more elastically deformable fusible members span between a first end and a second end. The first end is configured to connect to a printed circuit board. The second end is adapted to be attached to the conductor; and In the elastically deformed state, the sheet comprises: The first end is connected to the printed circuit board, and The second end is attached to the conductor.

2. The connecting piece according to claim 1, wherein, The one or more elastically deformable fusible components include fuses configured to fail when in the elastically deformed state and when a current threshold is reached.

3. The connecting piece according to claim 1 or 2, wherein, The one or more elastically deformable fusible components include an elastically deformable state failure current lower than the relaxation state failure current.

4. The connecting piece according to any one of claims 1 to 3, wherein, In the relaxed state, the first end includes a terminal or pad connected to the printed circuit board, and a second end disconnected from the conductor.

5. The connecting piece according to any one of claims 1 to 4, wherein, The second end of the sheet includes: The first extended plane when not attached to a conductor, and The second extended plane when attached to a rigid conductor; and The second end is configured to transition from the first extension plane to the second extension plane by attaching the second end to the conductor.

6. The connecting piece according to any one of claims 1 to 5, wherein, One or more fusible components are configured to elastically deform upon transition from a relaxed state to the elastically deformed state.

7. The connecting piece according to any one of claims 1 to 6, wherein, The second end of the sheet includes a plate adapted for welding to a conductor; and one or more fusible components are held in an elastically deformable state by welding.

8. The connecting piece according to claim 7, wherein, The transition from the relaxed state to the elastically deformed state is caused by the welding of components or processes.

9. The connecting piece according to any one of claims 1 to 8, wherein, The sheet is configured to transition from a relaxed state to an elastically deformed state by the force of a welded component or fastener having the sheet and the conductor.

10. The connecting piece according to any one of claims 1 to 9, wherein, The second end of the sheet includes a hole to allow a fastener to pass through, thereby engaging with a conductor, and the one or more fusible members are held in an elastically deformed state by the fastener.

11. The connecting piece according to any one of claims 1 to 10, wherein, The one or more elastically deformable fusible components include fuses configured to fail at a thermal limit when the melting temperature of the solder used to fuse the first end and the PCB is reached.

12. The connecting piece according to any one of claims 1 to 11, wherein, The conductor includes a single battery terminal, a bus, a junction point, or a ground junction point.

13. The connecting piece according to any one of claims 1 to 12, wherein, The connecting piece also includes one or more upwardly extending wings.

14. The connecting piece according to any one of claims 1 to 13, wherein, The connecting piece also includes one or more counterweights located within the first end.

15. The connecting piece according to any one of claims 1 to 14, wherein, The connecting piece also includes a sensing member spanning between the sensor end and the second end, the sensor end including a slot, hole, or housing configured to at least partially close one or more temperature sensors.

16. The connecting piece according to any one of claims 1 to 15, wherein, The second end also includes a ridge region adapted to be compressed by the attachment of the sheet to the conductor and to apply a laterally outward deformation force to the fusible member.

17. The connecting piece according to any one of claims 1 to 16, wherein, The second end also includes two or more surface regions, one region being above another, the two or more surface regions being spanned by a connector having a relaxed state and a compressed state, the compressed state being caused by the attachment of the sheet to the conductor.

18. An electronic component, comprising: One or more printed circuit boards, including one or more terminal coupling areas; One or more individual cells, including individual cell terminals aligned with one or more terminal coupling regions; One or more connectors, each connector as described in any one of claims 1 to 17, are disposed within each of one or more terminal coupling regions, connected to the terminal coupling region of the printed circuit board, and attached to the individual battery terminal.

19. The electronic component according to claim 18, wherein, The component also includes a controller configured to measure the voltage of individual cells near the fusible component.

20. The electronic component according to claim 18 or 19, wherein, The electronic components also include a temperature sensor and a controller configured to determine the temperature near the fusible component.

21. The electronic component according to any one of claims 18 to 20, wherein, The component also includes two or more printed circuit boards, and one or more of the connecting pieces include two or more fusible components, wherein: The first fusible component is connected to the first printed circuit board; and The second fusible component is connected to the second printed circuit board.

22. The electronic component according to any one of claims 18 to 20, further comprising: Two or more individual cells, each individual cell having a cell terminal; Two or more connecting pieces, including: The first piece, the first piece is fixed to the first single cell and soldered to the printed circuit board, and The second piece, the second piece being fixed to the second single cell and soldered to the printed circuit board; and Multiple electronic switching devices are mounted on the printed circuit board; The printed circuit board and the electronic switching device together form multiple circuit paths, including: In the first path, the individual battery terminals are connected in series, and The second path, wherein at least one individual battery terminal is bypassed from the series connection.

23. The electronic component according to any one of claims 18 to 22, wherein, Multiple electronic switching devices are configured to guide current flow through multiple circuit paths, said paths including: A first current path, the first current path including a series connection with the plate, and A second current path, the second current path being arranged to bypass the plate; and The controller is configured as follows: Control the operation of multiple switching devices to connect the first current path. Detect the open-circuit state of the circuit path including the fusible component, then The operation of the plurality of switching devices is controlled to connect the second current path.

24. An electronic component, comprising: A printed circuit board, the printed circuit board including a terminal coupling area; A single battery cell, the single battery cell including a single battery cell terminal aligned with the terminal coupling region; The connecting piece as claimed in claim 15, wherein the connecting piece is disposed in each terminal coupling area, is connected to a printed circuit board at a first end, and is attached to the individual battery terminal at a second end; One or more temperature sensors are located on the printed circuit board and in a hole or housing at the second end.

25. An electronic component, comprising: Printed circuit boards, including: A terminal coupling area, which is connected to a charging or discharging trace. A controller device is connected to the measurement track; A single battery cell, the single battery cell including a single battery cell terminal aligned with the terminal coupling region; Two or more connecting tabs, each connecting tab as described in any one of claims 1 to 17, are disposed within the terminal coupling region, and each connecting tab includes: A deformable fusible component, the first end of which is connected to the terminal coupling region, and the second end of which is attached to the single-cell battery terminal. A component connected to the measurement trace.

26. A reconfigurable battery system, comprising: Multiple individual cells, each having one or more individual cell terminals, the individual cell terminals being arranged in a substantially predetermined geometrically aligned plane; One or more printed circuit boards, including multiple terminal coupling areas; The connecting piece as described in any one of claims 1 to 17 is disposed in each terminal coupling area, soldered to the circuit board at a first end, and connected to the individual battery cell via a fastener at a second end; One or more circuit boards include multiple circuit paths and multiple switching devices, the multiple switching devices being arranged to configure the multiple circuit paths, the paths including: At least one first path, wherein the first piece is connected in series with two or more individual cells, and The second path, wherein the first piece is bypassed from the first path; The system further includes a controller, which is configured to: Control the operation of the plurality of switching devices to connect the first current path. Detect the open-circuit state of the circuit path including the fusible component, then The operation of the plurality of switching devices is controlled to connect a second current path.

27. A method for repairing an electronic component, the electronic component comprising a plurality of individual cells, one or more printed circuit boards, and a connector as claimed in any one of claims 1 to 17, each individual cell having one or more individual cell terminals arranged in a substantially predetermined geometrically aligned plane; The one or more printed circuit boards are aligned with a plane and include multiple terminal coupling areas; The connecting piece is disposed in the terminal coupling area of ​​the circuit board, having a first end connected to the circuit board and a second end attached to the individual battery cell; The method includes: Identify faulty chips based on their transition from a closed-circuit state to an open-circuit state. Desolder the first end of the chip from the circuit board. Remove the second end from the single cell terminal, and Replace the chip.

28. A method for assembling an electronic structure, comprising: Multiple individual battery terminals are arranged in a geometrically aligned manner; Arrange one or more PCBs near one or more individual battery terminals; The first end of the connecting piece as described in any one of claims 1 to 17 is soldered to the PCB; The second end of the connecting piece is attached to the terminal of the individual battery cell, thereby changing the piece from a relaxed state to an elastically deformed state.

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