Battery module end connector

Abstract

A battery module (100, 700) for a powered device is disclosed, comprising a battery enclosed in a housing (101, 701), at least one end cap (103, 702) securely attached to the housing (101, 701), and a BMS board (108, 806) positioned near the at least one end cap (103, 702). The battery module (100, 700) further includes at least one end connector (109, 110, 111; 703a and 703b) detachably attached to the BMS board (108, 806). A first end connector (109, 703a) corresponding to at least one power line of the battery module (100, 700) includes at least one protection device (301, 1004) connected to the at least one power line for providing electrical protection for the battery module (100, 700). The end connectors (109, 110, 111; 703a and 703b) prevent interference between signal lines and power lines and make the battery modules (100, 700) waterproof and dustproof.

Description

TECHNICAL FIELD

[0001] The present subject matter relates to a battery module. More specifically, the end connectors of the battery module are disclosed in patent application number 202041010274 and the present subject matter provides improvements to the subject matter claimed in the aforementioned patent application. BACKGROUND

[0002] Existing battery technology research is directed towards rechargeable batteries, such as sealed, electrolyte-free lead / acid batteries, which are commonly used as power sources in different applications, such as vehicles, etc. However, lead-acid batteries are heavy, bulky, have short cycle life, short calendar life, low turnover efficiency, which limits the applications.

[0003] Therefore, to overcome the problems associated with conventional energy storage devices, including lead-acid batteries, lithium-ion batteries provide an ideal system for high energy density applications, improved rate performance, and safety. Furthermore, rechargeable energy storage devices, lithium-ion batteries exhibit one or more beneficial properties that make them useful for powered devices. First, lithium-ion batteries are constructed from all solid components for safety reasons, while still having flexibility and compactness. Second, energy storage devices including lithium-ion batteries exhibit similar conductive properties to primary batteries with liquid electrolytes, i.e., providing high power and energy density with low self-discharge rates. Third, energy storage devices as lithium-ion batteries are easy to manufacture in a reliable and cost-effective manner. Finally, energy storage devices including lithium-ion batteries are capable of maintaining the necessary minimum conductivity level at below ambient temperatures.

[0004] In known structures for energy storage devices, one or more energy storage cells including lithium-ion batteries are arranged in at least one holder structure in series and parallel combinations using at least one interconnection structure. The interconnection structure is adapted to electrically interconnect the energy storage cells with a battery management system (BMS). The output voltage and output current generated by the energy storage device, after monitoring and regulation by the BMS, are transmitted through end connectors to one or more electronic and electrical elements configured to be powered by the energy storage device. The design of the end connectors is critical for the safety, maintainability, and serviceability of the energy storage device. BRIEF DESCRIPTION OF DRAWINGS

[0005] The detailed description is described with reference to the accompanying drawings. The same numbers are used throughout the drawings to refer to like features and components.

[0006] Figures 1A-1B A perspective view and an exploded view of a first embodiment of a battery module are shown, by way of example;

[0007] Figure 2 A partial exploded view of a battery pack showing a first end connector of the first embodiment of the battery module is shown, by way of example;

[0008] Figure 3 A perspective view of the first end connector of a first embodiment of a battery module is shown as an example;

[0009] Figure 4 An exploded view of the first end connector of a first embodiment of a battery module is shown as an example;

[0010] Figure 5 A plan view of at least one connector of a terminal retainer of a first embodiment of a battery module is shown as an example;

[0011] Figure 6 A plan view of the terminal holder of a first embodiment of a battery module is shown;

[0012] Figure 7 A perspective view of a second embodiment of the battery module is shown as an example;

[0013] Figure 8 An example is shown Figure 7 An exploded perspective view of a battery module is shown as an example.

[0014] Figures 9A-9B A perspective view of the second end connector of a second embodiment of a battery module is shown as an example;

[0015] Figures 10A-10C A perspective view of the first end connector of a second embodiment of the battery module is shown as an example; and

[0016] Figures 11A-11B An exemplary perspective cross-sectional view of a second embodiment of a battery module having a first end connector and a second end connector is shown. Detailed Implementation

[0017] Energy storage devices are connected to subsequent energy storage devices, on-board or external chargers, and electrical and electronic loads in the power supply system via multiple end connectors. Typically, the output of the energy storage unit is connected to the battery management system (BMS) board via wires, and the output voltage and current from the end connectors are connected to the electronic and electrical loads in the power supply system via wires. These interconnecting wires pose a possibility of short circuits during the assembly of energy storage devices.

[0018] To prevent such adverse events, in existing energy storage device structures, end connectors are molded into the end caps of the energy storage device. These end connectors are non-removable, requiring the entire end cap to be replaced in the event of repair. In some other energy storage device structures, besides the BMS (Battery Management System), end connectors are positioned on a printed circuit board (PCB) located within the energy storage device. Such PCBs are inflexible and subject to stress during assembly, potentially leading to PCB failure. Furthermore, these additional components increase the weight of the energy storage device and the costs associated with its manufacture, repair, and replacement.

[0019] Furthermore, the battery output of the energy storage device reaches the end connector on the main body of the energy storage device via a safety device (such as a fuse). The assembly of the safety device needs to be performed before the end cap of the energy storage device is installed. This is because wires are used to connect the battery to the end connector; the safety device is connected to the wires. During the assembly of the energy storage device, the fuse gets caught on the wires, making it difficult to connect to the end connector in the end cap. The assembly difficulties of the energy storage device and the need for safety protection during assembly have driven the demand for improved designs of energy storage devices.

[0020] There is a need for improved designs of energy storage devices with end connectors that ensure the safety, maintainability, and repairability of the energy storage devices during assembly, overcoming all of the aforementioned problems as well as other issues of the prior art.

[0021] This subject matter discloses an energy storage device, namely a battery module, which includes an improved and simplified end connector design for facilitating connection of the battery module to a battery controller, charging unit, or subsequent battery module in a powered device (e.g., a vehicle). In one embodiment of the invention, a battery module for a powered device is disclosed. The battery module includes a plurality of batteries encapsulated in a housing, at least one end cap securely attached to the housing, and a battery management system (BMS) board positioned near the at least one end cap in the housing. Furthermore, the battery module includes at least one end connector detachably attached to the BMS board. In one embodiment, the at least one end connector includes a first end connector corresponding to at least one power line of the battery module, including at least one protection device connected to the at least one power line for providing electrical protection to the battery module. The first end connector includes one of a first terminal retainer and a second terminal retainer detachably attached to the battery management system board.

[0022] The first terminal retainer includes a base member having at least one connector attached to the bottom surface of the base member at a predetermined location; and an attachment member at a first corner for detachably attaching the base member to the BMS board. At least one protective device is attached to at least one connector to form the positive terminal of the battery module.

[0023] In one embodiment, a first end of at least one connector is connected to the positive terminal of a plurality of batteries at one of predetermined locations via at least one interconnecting tab, and a second end of at least one connector is connected to at least one protection device. In another embodiment, the second end of at least one connector is connected to at least one protection device, and the first end of at least one connector forms the positive terminal of a battery module. In one embodiment, at least one connector is a metal connector having mounting means molded in a base member. In one embodiment, the terminal retainer includes at least one guide for arranging at least one cable on the BMS board. In one embodiment, the base member includes at least one reinforcing member between at least one connector and at least one protection device for reinforcing the base member.

[0024] In one embodiment, the first end connector includes a second terminal holder detachably attached to the BMS board, a positive terminal and a negative terminal extending from the second terminal holder for connection to an external component, and at least one protection device connected to the positive terminal in the current path from the BMS board to the positive terminal. The positive and negative terminals protrude from the battery management system board through at least one end cap. In one embodiment, the positive and negative terminals have different geometries.

[0025] The second terminal retainer includes a base member having at least one connector attached to the bottom surface of the base member at a predetermined position. One of the at least one connector connects at least one protective device to the positive terminal. In one embodiment, at least one end connector further includes a second end connector corresponding to a signal line of the battery module.

[0026] The second end connector includes at least one female signal connector, including at least one hollow pin securely attached to the BMS board; and a corresponding at least one male signal connector, including at least one plug detachably engaged with at least one hollow pin of the at least one female signal connector for connecting the battery module to the battery controller.

[0027] In one embodiment, at least one male signal connector further includes a clip for securely and tightly locking at least one plug to at least one hollow pin of at least one female signal connector. In one embodiment, the second end connector facilitates parallel connection of the battery module with other battery modules of the same type. The battery module also includes a third end connector corresponding to the negative terminals of a plurality of batteries. In one embodiment, at least one end connector on the BMS board is connected to an external connector on at least one end cap of the battery module for charging, discharging, and control operations of the battery module. In one embodiment, the end cap further includes a guide and retaining clamp for routing power cables and signal cables respectively connected to the first end connector and the second connector.

[0028] Another embodiment of a battery module for a powered device is disclosed. The battery module includes a plurality of batteries encapsulated in a housing; at least one end cap with an external connector securely attached to the housing; and a BMS board positioned near the at least one end cap in the housing. The battery module also includes a first end connector comprising a first terminal retainer and at least one protective device positioned on the BMS board, forming the positive terminal of the battery module; a second end connector positioned on the battery management system board corresponding to a signal line of the battery module; and a third end connector positioned on the battery management system board, connected to the negative terminals of the plurality of batteries. The first, second, and third end connectors on the BMS board are connected to an external connector on at least one end cap of the battery module for charging, discharging, and control operations of the battery module.

[0029] In this embodiment, the first terminal retainer includes a base member having at least one connector attached to the bottom surface of the base member at a predetermined location; and an attachment member at a first corner for detachably attaching the base member to the battery management system board. At least one protection device is secured to at least one connector to form the positive terminal of the battery module. In one embodiment, a first end of at least one connector is connected to the positive terminals of a plurality of batteries at one of predetermined fastening locations via at least one interconnecting tab, and a second end of at least one connector is connected to at least one protection device. In another embodiment, a second end of at least one connector is connected to at least one protection device, and a first end of at least one connector forms the positive terminal of the battery module. In one embodiment, at least one connector is a metal connector having mounting means molded in the base member. The base member includes at least one guide for arranging at least one cable on the battery management system board. In another embodiment, the base member includes at least one reinforcement between at least one connector and at least one protection device for reinforcing the base member.

[0030] The subject matter is further described with reference to the accompanying drawings. It should be noted that the description and drawings are merely illustrative of the principles of the subject matter. Although not explicitly described or shown herein, various arrangements can be designed to encompass the principles of the subject matter. Furthermore, all statements herein referencing principles, aspects, and examples of the subject matter, as well as specific examples thereof, are intended to cover their equivalents.

[0031] Figures 1A-1B A perspective view and exploded view of a first embodiment of a battery module 100 are shown as an example. The battery module 100 includes a plurality of batteries forming a battery pack 105 housed within a housing. The housing 101 surrounds the battery pack 105 from the top and bottom. The battery module 100 also includes a first end cap 103 and a second end cap 104 surrounding the battery pack 105 from the rear and front, respectively. Batteries 107 in the battery pack 105 are arranged in a specific order in a battery holder 106. The batteries 107 are electrically connected in series and / or parallel configurations to form a battery array. This battery array is electrically connected to a battery management system (BMS) board 108 within the battery module 100. The BMS 108 is a printed circuit board on which one or more integrated circuits, such as… Figure 1B As exemplarily shown, the BMS board 108 is attached to one side of the battery pack 105. In one embodiment, the BMS board 108 is located between the battery pack 105 and the first end cap 103.

[0032] The housing 101 has mounting means for a second end cap 104 and a first end cap 103. The second end cap 104 and the first end cap 103 are fastened to the housing 101 using multiple attachment means such as fasteners. The battery pack 105 has mounting means for a BMS board 108. The BMS board 108 is threadedly connected to the battery holder 106 of the battery pack 105.

[0033] An external connector 102 is mounted on the first end cap 103. The external connector 102 of the battery module 100 facilitates the connection of the battery module 100 for charging, discharging, series and parallel connection with other battery modules, or operation controlled by a battery controller in a powered device. In one embodiment, the external connector 102 may be positioned in a mounting device within the end cap 103 to facilitate connection of the battery module 100 to external components in the powered device. The powered device may be a vehicle, such as a two-wheeled vehicle, a three-wheeled vehicle, or a multi-wheeled vehicle.

[0034] The battery module 100 includes power lines providing voltage and current output to the battery module 100 and signal lines providing the status of the battery module 100 for further use by external components in a powered device. As exemplarily shown, the battery module 100 includes at least one end connector 109, 110, 111 detachably attached to a BMS board 108. The at least one end connector may be a first end connector 109, a second end connector 110, and / or a third end connector 111. As exemplarily shown, all first end connectors 109, second end connectors 110, and third end connectors 111 are detachably attached to the BMS board 108. In one embodiment, at least one of the first end connectors 109, second end connectors, and third end connectors 111 is detachably attached to the BMS board 108.

[0035] Figure 1B The first end connector 109, exemplarily shown, corresponds to at least one power line, i.e., the positive terminal of the battery 107 of the battery module 100. The positive terminal of the battery 107 of the battery module 100 is ultimately located in the first end connector portion 109, and the first end connector portion 109 corresponds to the positive terminal of the battery module 100. The second end connector 110 corresponds to the signal line of the battery module 100. The third end connector 111 corresponds to the negative terminals of the plurality of batteries 107. The negative terminals of the batteries 107 are ultimately located in the third end connector 111. As shown, the first end connector 109, the second end connector 110, and the third end connector 111 are connected to an external connector 102. On the external connector 102, components of an on-board charger or a powered device are connected for charging, discharging, or controlling the battery module 100.

[0036] Figure 2 A partial exploded view of a battery pack 100 is shown as an example, illustrating a first end connector 109. As shown by example, the first end connector 109 is mounted to a BMS board 108. The first end connector 109 carries current from the BMS board 108 and carries current out of the battery module 100. Current from the battery 107 in the battery pack 105 ultimately reaches the positive and negative terminals on the BMS board 108 via interconnect 204. The first end connector 109 includes a first terminal holder 201 that is detachably attached to the BMS board 108 of the battery module 100 using at least one mounting device 202. The BMS board 108 is mounted to a battery holder 106 using a mounting device (e.g., 203).

[0037] Figure 3An exemplary perspective view of a first end connector 109 is shown. As exemplarily shown, the first end connector 109 includes a first terminal holder 201 and at least one protective device 301. The first terminal holder 201 is a busbar having mounting means 202a, 202b for mounting the first end connector 109 to a BMS board 108. The positive terminal of a battery 107 is connected to the first terminal holder 201, and the output terminal 303 of the first terminal holder 201 forms the positive terminal of a battery module 100. In one embodiment, the positive terminal of the battery 107 is ultimately connected to the BMS board 108 via an interconnect 204, and the positive terminal of the BMS board 108 is connected to the first terminal holder 201. The first terminal holder 201 includes at least one guide device 302 for wiring at least one cable on the BMS board. Figure 4 As described herein, the first terminal retainer 201 includes a base member 401 and at least one connector 202a, 202b.

[0038] Figure 4 An exploded perspective view of a first end connector 109 is shown as an example. The terminal retainer 201 of the first end connector 109 includes a base member 401 on which a protective device 301 is mounted. At least one connector 202a, 402 is attached to the bottom surface of the base member 401 at a predetermined location. The base member 401 includes at least one attachment member 202b at a first corner on the top surface of the base member 401. The attachment member 202b is a mounting device for mounting the terminal retainer 201 to the BMS board 108. The base member 401 is made of a polymeric material, such as plastic. The protective device 301 uses fasteners 403a, 403b (e.g., ...). Figure 4The screw and nut assembly shown is mounted on the base member 401 at a predetermined position. At least one protective device 301 on the terminal retainer 401 is, for example, a fuse exposed to a predetermined value of DC current. According to one embodiment, the predetermined value may be 70 amps. The fuse is a self-acting circuit breaker device for protecting the battery module 100 from overcurrent. Excessive current in the battery module 100 may be due to incorrect wiring of components within the battery module 100, a short circuit at the positive terminal of the BMS board 108, or an overload of the battery module 100, etc. The fuse is positioned close to the positive terminal of the BMS board 108 and connected to the positive terminal 303 of the battery module 100. In the event of a fault between the fuse and the electrical load connected to the external connector 102, the fuse blows and the current flowing to the load stops from the positive terminal 303 of the battery module 100. The protective device 301 is mounted on the base member 401 at predetermined positions 404a and 404b using attachment devices 403a and 403b (e.g., screws and nuts). In one embodiment, a washer (e.g., an O-ring seal) is provided around the screw to provide a tight seal at a predetermined location.

[0039] Figure 5 A plan view of at least one connector 202a, 402 of a terminal retainer 201 is shown as an example. The terminal retainer 201 includes two connectors 202a, 402 fastened to the bottom surface of a base member 401 at predetermined locations. One of the connectors, connector 202a, is connected to the positive terminal of a BMS board 108 and also serves as a mounting means for mounting the terminal retainer 201 to the BMS board 108. A first end 501a of connector 202a is connected to the positive terminal of a battery 107 at a predetermined location on the BMS board 108, and a second end 501b of connector 202a is connected to a protection device 301. The second end 502b of connector 402 is connected to one end of the protection device 301, and the first end 502a of connector 402 forms the output terminal 303 of the terminal retainer 201 and the positive terminal of the battery module 100. A protection device 301 is connected between connectors 202a and 402. The free ends 501a and 502a of connectors 202a and 402 respectively form the input terminal and output terminal 303 of terminal holder 201. Current from battery 107 flows to the metal connector 202a at end 501a, and then to end 501b. At end 501b, the protection device receives current, and if the battery module is in good condition, the protection device allows current to flow to end 502b of connector 402. Current flows from end 502b to end 502a of connector 402, and then to the output terminal 303 of terminal holder 201.

[0040] In one embodiment, connectors 202a and 402 are metal connectors encapsulated by a plastic base member 401. Connectors 202a and 402 are encapsulated in a manner that exposes the input and output terminals 303 of the terminal retainer 201 and predetermined positions for mounting the protective device 301. In one embodiment, connectors 202a and 402 are made of metal, such as cast brass. In another embodiment, connectors 202a and 402 are made of a sheet metal. The designs of connectors 202a and 402 may be the same or different. The contours of connectors 202a and 402 are formed in the base member of the terminal retainer 201 for correctly and guidedly positioning connectors 202a and 402 in their respective positions.

[0041] Figure 6 An exemplary plan view of the terminal retainer 201 is shown. The attachment member 202b, located at a first corner of the top surface of the base member 401, includes a threaded hollow metal connector encapsulated and molded within the plastic base member 401. In one embodiment, gaskets, such as O-ring seals, may be provided at all predetermined locations for a tight seal. The gaskets provide a robust, sealed connection for the input and output terminals of the terminal retainer 201 to prevent water and dust ingress, thereby ensuring the battery module 100 meets IP67 standards. Furthermore, the base member 401 includes at least one reinforcement 601, such as a groove, ridge, or any pattern, between the connectors 202a, 402 and the protective device 301 for reinforcing the base member 401.

[0042] Figure 7 A perspective view of a second embodiment of a battery module 700 is shown as an example. The battery module 700 includes a plurality of batteries arranged in a specific order within a battery holder. The batteries are electrically connected in series and / or parallel configurations to form a battery array. This battery array is electrically connected to a battery management system (BMS) within the battery module 700. The BMS is a printed circuit board on which one or more integrated circuits are integrated, such as... Figure 8 As shown in the example.

[0043] As illustrated by example, the battery module 700 includes a housing 701 with a dovetail pattern for vibration and shock resistance, a first end cap 702, a second end cap (not shown), and a battery pack. The dovetail pattern of the housing 701 facilitates easy installation and removal of the battery module 700 within the space of a device or powered product. The housing 701 surrounds the battery pack from the top and bottom. The second end cap (not shown) and the front end cap 702 surround the battery pack from the rear and front, respectively.

[0044] Terminal posts of end connectors 703a and 703b extend from the first end cap 702, as exemplarily shown. The first end cap 702 also includes a guide 704 and a retaining clamp 705 for wiring power cables 706 and signal cables connected to the end connectors 703a and 703b of the battery module 700.

[0045] Figure 8 An exploded perspective view of a second embodiment of the battery module 700 is shown as an example. As shown, a battery pack 804 is encapsulated between a second end cap 803, a housing 701, and a first end cap 702. A BMS board 806 is attached to one side of the battery pack 804. In one embodiment, the BMS board 806 is located between the battery pack 804 and the first end cap 702. End connectors 703a and 703b (in...) Figure 7 (Exemplarily shown) It is removably attached to the BMS board 806. The housing 701 has mounting means for the second end cap 803 and the first end cap 702. The second end cap 803 and the first end cap 702 are fastened to the housing 701 using a plurality of attachment means 802 and 809, respectively. According to a preferred embodiment, the attachment means may be fasteners. The battery pack 804 has mounting means for the BMS board 806. The BMS board 806 can be threadedly connected to the battery holder 804a of the battery pack 804. In addition, the end cap 803 has a vent plug 801 for releasing by-product gases from the battery pack 804.

[0046] The plurality of end connectors 703a and 703b include a first end connector 703a and a second end connector 703b. Figure 7 As exemplarily shown, the first end connector 703a corresponds to the power line of the battery module 700. The first end connector 703a is mounted on the BMS board 806. The second end connector 703b corresponds to the signal line of the battery module 700. The second end connector 703b is a two-part signal connector, including a female signal connector 807 and a male signal connector 808 fastened to the BMS board 806.

[0047] Figures 9A-9B A perspective view of a second end connector 703b of a battery module 700 is shown as an example. The second end connector 703b includes a female signal connector 807 and a corresponding male signal connector 808. The female signal connector 807 includes at least one hollow pin, such as six hollow pins 901 located at the center of its body. The corresponding male signal connector 808 is detachably engaged with the female signal connector 807. Figure 8As exemplarily shown, the female signal connector 807 is directly fastened to the BMS board 806 using fasteners 805. At least one hollow pin 901 is molded into the body of the female signal connector 807. Corresponding to the hollow pin 901, the BMS board 806 includes at least one corresponding mounting device, such as... Figure 8 The exemplary hole 806a allows for the detachable attachment of a female signal connector 807 with pins 901 to the BMS board 806 using fasteners 805 from the surface of the BMS board 806 that contacts the battery pack 804. The male signal connector 808 includes six banana-shaped plugs 902 protruding from a rear surface 808a to engage with six pins 901 in the female signal connector 807. The hollow pins 901 of the female signal connector 807 engage with the plugs 902 of the male signal connector 808. On a first surface 808b of the male signal connector 808, the six banana-shaped plugs 902 facilitate external access for signal lines from the battery pack 804.

[0048] Furthermore, the male signal connector 808 includes clips 903 on both sides to facilitate the engagement and disengagement of the male signal connector 808 with the female signal connector 807. For the banana plug 902 to engage with the hollow pin 901, the inner diameter of the hollow pin 901 is larger than or can be mated to the diameter of the banana plug 902, and the banana plug 902 is inserted into the hollow space of the hollow pin 901 to achieve operable and stable electrical contact and connection. While engaging the banana plug 902 with the hollow pin 901, the clips 903 are, for example, pressed inwards against the banana plug 902. Once the banana plug 902 engages with the hollow pin 901, the clips 903 are released. The clips 903 ensure that the banana plug 902 and the hollow pin 901 are securely and tightly locked together. To disengage the banana plug 902 from the hollow pin 901, the clips 903 are pressed together again in the lateral direction, and the banana plug 902 is pulled out of the hollow pin 901. Pin 901 corresponds to a signal from the BMS board 806. The second end connection 703b facilitates parallel connection of the battery module 700 with other similar battery modules. Furthermore, the second end connection 703b facilitates communication between the battery module 700 and the battery controller in a powered device (e.g., a vehicle).

[0049] Figures 10A-10CAn exemplary perspective view of a first end connector 703a of a battery module 700 is shown. The first end connector 703a transmits current from the battery module 700 to an electrical load from a BMS board 806. Current from the batteries in the battery pack 804 ultimately reaches the positive and negative terminals on the BMS board 806. The first end connector 703a includes a second terminal holder 1001, which is detachably attached to the BMS board 806 of the battery module 700 using at least one mounting device 1002a and 1002b. As illustrated, the second terminal holder 1001 is a busbar with mounting devices for mounting at least one protection device 1004, a positive terminal terminal 1005a, and a negative terminal terminal 1005b of the battery module 700. The positive terminal of the BMS board 806 is connected to the positive terminal terminal 1005a, and the negative terminal of the BMS board 806 is connected to the negative terminal terminal 1005b. An electrical load of the battery module 700 or a charger for the battery module 700 is connected between the positive terminal 1005a and the negative terminal 1005b to recharge the battery module 700. The positive terminal 1005a and the negative terminal 1005b protrude through a first end cap 702. Figure 7 As shown in the example, the positive terminal 1005a and the negative terminal 1005b are located in a recess (not shown) in the front cover 702.

[0050] At least one protective device 1004 on the second terminal holder 1001 is, for example, a fuse exposed to a predetermined value of DC current. According to one embodiment, the predetermined value may be 70 amps. The fuse is an automatic circuit breaker used to protect the battery module 700 from overcurrent. Excessive current in the battery module 700 may be due to incorrect wiring of components within the battery module 700, a short circuit at the positive terminal of the BMS board 806, or an overload of the battery module 700. The fuse is located near and connected to the positive terminal of the BMS board 806. The negative terminal is grounded. If a fault occurs between the fuse and the electrical load, the fuse will blow, causing the current flowing to the load to stop. The protective device 1004 is mounted on the second terminal holder 1001 using attachment devices 1003a and 1003b (e.g., screws and nuts at mounting devices 1006a and 1006b).

[0051] The positive terminal 1005a and negative terminal 1005b are securely attached to the second terminal holder 1001 at designated locations. According to one embodiment, the positive terminal 1005a is a bolt 1008a, in which the conductor of the positive terminal from the BMS board 806 is placed and fastened to the second terminal holder 1001 using a nut such as 1009. Similarly, according to one embodiment, the negative terminal 1005b is a bolt 1008b, in which the conductor of the negative terminal from the BMS board 806 is placed and fastened to the second terminal holder 1001 using a nut such as 1009. Each of the positive terminal 1005a and negative terminal 1005b is fastened to the second terminal holder 1001 from the bottom using fasteners 1009, such as screws and washers. In one embodiment, each of the positive terminal 1005a and the negative terminal 1005b includes washers 1007a and 1007b, such as O-ring seals for a tight seal at the positive terminal 1005a and the negative terminal 1005b. Washers 1007a and 1007b provide a robust, water- and dust-proof seal for the terminals 1005a and 1005b, enabling the battery module 700 to meet IP67 standards.

[0052] In one embodiment, the second terminal retainer 1001 is a plastic base member 1011, and metal connectors such as metal connectors 1010, 1012, and 1013 are threadedly attached to or molded onto the bottom surface of the plastic base member 1011 at a predetermined fastening position. Figure 10C As exemplarily shown, metal connectors 1012 and 1013 facilitate the detachable attachment of terminal retainer 1001 to BMS board 806. Metal connectors 1012 and 1013 have mounting means 1002a and 1002b for mounting plastic base member 1011 to BMS board 806 of battery module 700. Metal connector 1010 connects a fuse in series with the positive terminal of BMS board 806 at positive terminal post 1005a.

[0053] Positive terminal 1005a and negative terminal 1005b extend from the plastic base member 1011 through the first end cap 702 for supplying power to an external load. Positive terminal 1005a and negative terminal 1005b form... Figure 7The first end connector 703a is illustrated in the example. According to one embodiment, the positive terminal 1005a and the negative terminal 1005b have different geometries to avoid polarity interchange during the manufacture, assembly, or repair of the battery module 700. In one embodiment, the positive terminal 1005a and the negative terminal 1005b have anti-rotation features to ensure that the positive terminal 1005a and the negative terminal 1005b are securely fastened to the terminal retainer 1001.

[0054] Figures 11A-11B An exemplary embodiment is shown having a first end connector 703a and a second end connector 703b. Figure 7 The diagram illustrates a perspective cross-sectional view of a battery module 700. The battery pack 804 of the battery module 700 includes a plurality of batteries 1101 located on a battery holder structure 804a and connected in series and parallel using interconnecting tabs 1102, as illustrated in the diagram. Terminals of the batteries 1101 are connected to the interconnecting tabs 1102 and to the BMS board 806. Figure 11B An enlarged cross-sectional view of the second end connector 703b is shown as an example. In the second end connector 703b, at least one banana plug 902 of the male signal connector 808 engages with at least one pin 901 of the female signal connector 807. The male signal connector 808 includes locking elements or clips 903 on both sides to facilitate easy insertion and removal of the male signal connector 808 during engagement and disengagement with the female signal connector 807.

[0055] Positive terminal 1005a and negative terminal 1005b extend from BMS board 806 and protrude through first end cap 702. The eye terminals of the power cables of battery pack 804 are screwed onto terminals 1005a and 1005b. Signal cables of battery pack 804 are soldered or crimped into banana plugs 902. The signal cables originate from at least one of the following: a temperature sensor mounted on battery pack 804, a current meter for an individual cell in battery pack 804, or a voltage level detector for an individual cell in battery pack 804.

[0056] The first end cap 702 also includes a guide device 704 for guiding the leads from the positive terminal 1005a and the negative terminal 1005b, such as... Figure 7The cable 706 is illustrated exemplarily. A guide 704 is located in a recess in a first end cap 702 to guide the cable through the recess in the first end cap 702. The first end cap 702 has a protrusion above the positive terminal 1005a and the negative terminal 1005b, which do not extend beyond the protrusion. When the battery module 700 is to be compactly positioned in a powered device (e.g., a vehicle), the guide 704 and the protrusion ensure that the cable 706 extending from the positive terminal 1005a and the negative terminal 1005b is press-fitted into the guide 704 and does not protrude from the surface of the first end cap 702, avoiding stress and damage to the cable 706. A retaining clamp 705 holds the guided cable and prevents the cable 706 from dangling to avoid damage to the cable 706.

[0057] The end connections in different embodiments of the battery module provide the following technological advancements in battery technology: In a first embodiment of the battery module, such a first end connection ensures that the positive terminal of the battery is routed separately to external connections and avoids interference with the negative terminal of the cell and the signal lines of the battery module. Furthermore, the first, second, and third end connections are mounted on the BMS board, avoiding other internal components (e.g., busbars). The connection between the battery and the BMS board is achieved through interconnecting tabs that contact the battery. The common external connection of the battery module at the junction of the first, second, and third end connections ensures simplicity in the manufacture and use of the battery module. Components of the powered devices that interface with the battery module are all connected via the same external connection. The design of the first end connection includes guides for guiding cables on the BMS board and reinforcements such as grooves for reinforcing the base members of the terminal retainers. Connectors for the connection protection devices have different geometries and shapes to distinguish them during battery module assembly and maintenance. Furthermore, the presence of protection devices within the battery module protects against short circuits, fluctuations, etc., and protects the powered devices from any disasters.

[0058] In a second embodiment of the battery module, the presence of both a first end connector and a second end connector prevents interference between signal and power lines. A clamp further guides the cable from the first end connector, preventing coiling, stripping, and tangling. The robust construction of the first and second end connectors allows for repeated engagement and disengagement of the cable, improving the durability and reliability of the battery module. Gaskets in the end connectors prevent dust and water from entering the battery module, creating a waterproof and dustproof battery module. The different geometries of the terminals in the first end connector prevent polarity reversal and facilitate battery module assembly and maintenance, thus saving time on assembly, repair, and maintenance.

[0059] These different embodiments of the battery module allow for uninterrupted power supply to drive powered devices because the end connectors facilitate the interconnection of multiple such battery modules. Mounting the protection device on the BMS board reduces the chance of installing it on the wrong terminals. Furthermore, losses due to the length of the wires between the battery and external connections are also reduced. The protection device can be safely assembled with the battery module terminals. Additionally, during battery module assembly, terminal retainers prevent the positive terminal of the battery module from contacting the BMS board and its components. Terminal retainers also prevent stress from being directly transferred to the surface of the BMS board from the wires originating from the battery. Terminal retainers also ensure that the interconnecting tabs of the battery module are in place and secured. Fasteners (such as screw and nut assemblies) at predetermined locations on the end connections ensure that the end connections are securely fastened to the BMS board and also ensure a strong electrical connection is established between the different parts of the end connections and the BMS board.

[0060] Improvements and modifications may be incorporated herein without departing from the scope of the invention.

[0061] List of reference numerals

[0062] First embodiment of 100-battery module

[0063] 101-Casing

[0064] 102-External connectors

[0065] 103-First end cap

[0066] 104-Second end cap

[0067] 105-Battery Pack

[0068] 106-Battery Holder

[0069] 107-battery

[0070] 108-BMS board

[0071] 109-First end connector

[0072] 110-Second end connector

[0073] 111-Third end connector

[0074] 201-Terminal Retainer

[0075] 202-Installation Device

[0076] 202a-connector

[0077] 202b - Attachment Members

[0078] 203- Mounting device on battery holder

[0079] 204-Interconnect Chip

[0080] 301 - Protective Device

[0081] 302 - Guiding Device

[0082] 303 - Positive terminal of battery module

[0083] 401-Base Components

[0084] 402 Connector

[0085] 403a, 403b - Fasteners for securing protective devices

[0086] 404a, 404b - Location of fastening protection device

[0087] 501a, 501b - End of connector 202a

[0088] 502a, 502b - Ends of connector 402

[0089] 601-Reinforcing Component

[0090] Second embodiment of 700-battery module

[0091] 701 - Casing

[0092] 702-First End Cap

[0093] 703a, 703b - End connectors

[0094] 704 - Guiding Device

[0095] 705-Holding Clamp

[0096] 706-Cable

[0097] 801-Exhaust Plug

[0098] 802, 809 - Attachment device for end caps

[0099] 803-Second End Cap

[0100] 804 Battery Pack

[0101] 804a - Battery Holder

[0102] 805 - Fasteners for securing female signal connectors

[0103] 806-BMS board

[0104] 806a - Hole for fastening female signal connectors

[0105] 807-Female Signal Connector

[0106] 808-Main Signal Connector

[0107] Surface of 808a and 808b male signal connectors

[0108] 901-Hollow Pin

[0109] 902-banana plug

[0110] 903-Clip

[0111] 1001-Second Terminal Holder

[0112] 1002a, 1002b - Installation device

[0113] 1003a, 1003b - Attachment devices

[0114] 1004 - Protection Device

[0115] 1005a-Positive Terminal Block

[0116] 1005b - Negative terminal block

[0117] 1006a, 1006b - Mounting device on the second terminal retainer

[0118] 1007a, 1007b - Gaskets

[0119] 1008a, 1008b - Bolts

[0120] 1009-Nut

[0121] 1010, 1012, 1013 - Connectors

[0122] 1011-Base Components

[0123] 1101 - Battery in the battery holder

Claims

1. A battery module (100, 700) for a powered device, comprising: a plurality of batteries enclosed in a housing (101, 701); at least one end cap (103, 702) securely attached to the housing (101, 701); a battery management system board (108, 806) positioned proximate to the at least one end cap (103, 702) in the housing (101, 701); and at least one end connector (109, 110, 111; 703a and 703b) removably attached to the battery management system board (108, 806), wherein the at least one end connector (109, 110, 111; 703a and 703b) comprises: a first end connector (109, 703a) corresponding to at least one power supply line of the battery module (100, 700) comprising at least one protection device (301, 1004) connected to at least one power supply line for providing electrical protection for the battery module (100, 700), wherein the first end connector (109, 703a) comprises a first terminal holder (201) removably attached to the battery management system board (108, 806), wherein the first terminal holder (201) comprises a base member (401); a first connector (202a) and a second connector (402) attached to a bottom surface of the base member (401) at predetermined locations; and an attachment member (202b) at a first corner on a top surface of the base member (401) for removably attaching the base member (401) to the battery management system board (108); and wherein the at least protection device (301) is connected between the first connector (202a) and the second connector (402). a first end (501a) of the first connector (202a) is connected to a positive terminal of the plurality of batteries (107) at one of the predetermined locations through at least one interconnect tab (204), and a second end (501b) of the first connector (202a) is connected to the at least one protection device (301). a second end (502b) of the second connector (402) is connected to the at least one protection device (301), and a first end (502a) of the second connector (402) forms a positive terminal (303) of the battery module (100).

2. The battery module (100) of claim 1, wherein, the first connector (202a) and the second connector (402) are metal connectors having mounting devices molded in the base member (401).

3. The battery module (100) of claim 1, wherein, the terminal holder (201) comprises at least one guide device (302) to arrange at least one cable on the battery management system board (108).

4. The battery module (100) of claim 1, wherein, the base member (401) comprises at least one reinforcement (601) between the first connector (202a) and the second connector (402) and the at least one protection device (301) for stiffening the base member (401).

5. The battery module (100) of claim 1, wherein, ​ 6. The battery module (100) of claim 1, wherein, ​ 7. The battery module (100, 700) of claim 1, wherein said at least one end connector (109, 110, 111; 703a and 703b) further comprises a second end connector (110, 703b) corresponding to the signal wires of said battery module (100, 700).

8. The battery module (700) of claim 7, wherein, said second end connector (703b) comprises: at least one female signal connector (807) comprising at least one hollow pin (901) securely attached to said battery management system board (806), and a corresponding at least one male signal connector (808) comprising at least one plug (902) that detachably engages with the at least one hollow pin (901) of said at least one female signal connector (807) for connecting said battery module (700) to a battery controller.

9. The battery module (700) of claim 8, wherein, said at least one male signal connector (808) further comprises a clip (903) for securely and tightly locking said at least one plug (902) with the at least one hollow pin (901) of said at least one female signal connector (807).

10. The battery module (700) of claim 7, wherein, said second end connector (703b) facilitates parallel connection of said battery module (700) with other battery modules of similar type.

11. The battery module (100) as claimed in claim 1, further comprising a third end connector (111) corresponding to the negative terminals of said plurality of batteries (107).

12. The battery module (100) of claim 1, wherein, said at least one end connector (109, 110, 111) on said battery management system board (108) connects with external connectors (102) on at least one end cap (103) of said battery module (100) for charging, discharging and control operations of said battery module (100).

13. The battery module (700) of claim 1, wherein, said end cap (702) further comprises a guide arrangement (704) and a retaining clamp (705) for routing power and signal cables connected to said first (703a) and second (703b) end connectors respectively.

14. A battery module (100) for electrically powered devices, comprising: a plurality of batteries (107) encapsulated in a housing (101); at least one end cap (103) with external connectors (102) securely attached to said housing (101); a battery management system board (108) positioned proximate to said at least one end cap (103) in said housing (101); a first end connector (109) comprising a first terminal retainer (201) and at least one protection device (301) positioned on said battery management system board (108) forming a positive terminal of said battery module (100); a second end connector (110) positioned on said battery management system board (108) corresponding to signal wires of said battery module (100); and a third end connector (111) positioned on said battery management system board (108) connected to negative terminals of said plurality of batteries (107); wherein the first end connector (109), the second end connector (110) and the third end connector (111) on the battery management system board (108) are connected to the external connectors (102) on at least one end cover (103) of the battery module (100) for charging, discharging and controlling operations of the battery module (100), wherein the first terminal holder (201) comprises a base member (401); a first connector (202a) and a second connector (402) attached to a bottom surface of the base member (401) at predetermined locations; and an attachment member (202b) at a first corner on a top surface of the base member (401) for detachably attaching the base member (401) to the battery management system board (108), and wherein the at least one protection device (301) is connected between the first connector (202a) and the second connector (402).

15. The battery module (100) of claim 14, wherein, A first end (501a) of the first connector (202a) is connected to a positive terminal of the plurality of batteries (107) at one of the predetermined locations by at least one interconnecting tab (204), and a second end (501b) of the second connector (402) is connected to the at least one protection device (301).

16. The battery module (100) of claim 14, wherein, A second end (502b) of the second connector (402) is connected to the at least one protection device (301), and a first end (502a) of the second connector (402) forms a positive terminal (303) of the battery module (100).

17. The battery module (100) of claim 14, wherein, The first connector (202a) and the second connector (402) are metal connectors having mounting devices molded in the base member (401).

18. The battery module (100) of claim 14, wherein, The base member (401) comprises at least one guiding device (302) to arrange at least one cable on the battery management system board (108).

19. The battery module of claim 14, wherein, The base member (401) comprises at least one reinforcement (601) between the first connector (202a) and the second connector (402) and the at least one protection device (301) for reinforcing the base member (401).

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