Combined electrical / fluid connector for powered vehicle battery

Abstract

The present disclosure provides a powered vehicle battery combination electrical / fluid connector. A powered vehicle system includes: a battery having a plurality of cells electrically connected in at least one cell array connected to an internal battery bus bar within a housing; an annular coolant fitting, the annular coolant fitting having a coolant passage, the coolant passage extending between an outer radius and an inner radius of the fitting; and an electrically conductive fastener having a closed end and a channel extending from an open end to a radial opening, the fastener extending through the annular coolant fitting with the radial opening positioned within the annular coolant fitting, and further extending through the housing and mechanically and electrically connecting an outer bus bar outside the housing to the inner bus bar, and facilitating coolant flow through the battery array.

Description

Technical Field

[0001] The present disclosure relates to a combined electrical / fluid connector that couples an electrical system and a cooling system to an immersion cooled battery, such as used in various electrified vehicles. Background Art

[0002] Electrified vehicles such as battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and hybrid electric vehicles (HEVs) include a high voltage traction battery or battery pack that acts as an energy storage device for one or more electric machines that provide propulsion torque to the wheels. Immersion cooling of high voltage battery packs used in many electrified vehicles involves direct contact of a dielectric cooling fluid with the battery cells of the battery pack. Electrical distribution system (EDS) components, particularly at connection points, can generate heat due to contact resistance. Thus, it may be desirable in various applications to use an immersion cooling fluid to cool these EDS components as well as the battery cells. Summary of the invention

[0003] In one or more embodiments, an electrified vehicle system includes: a battery having a plurality of cells electrically connected in at least one cell array having a housing, the at least one cell array being connected to an internal bus bar within the housing; an annular coolant fitting having a coolant channel extending between an outer radius and an inner radius of the fitting; and a conductive fastener having a closed end and a channel extending from an open end to a radial opening, the fastener extending through the annular coolant fitting with the radial opening positioned within the annular coolant fitting, and further extending through the housing and mechanically and electrically connecting an external bus bar to the internal bus bar. The fastener may be implemented by a bolt having a threaded area extending below the radial opening and a nut engaging the threaded area, the bolt and nut clamping the external bus bar, the annular coolant fitting, and the internal bus bar to the housing. The electrified vehicle system may further include a conductive washer disposed between the bolt and the external bus bar, an upper washer disposed between the external bus bar and the annular coolant fitting, and a lower washer disposed between the annular coolant fitting and the housing.

[0004] In one or more embodiments, the electrified vehicle system includes a first array of battery cells and a second array of battery cells, wherein the first array of battery cells and the second array of battery cells are electrically and fluidically connected in series. In one or more embodiments, the at least one array of battery cells includes a first array of battery cells and a second array of battery cells that are electrically and fluidically connected in parallel. In other embodiments, the at least one array of battery cells includes a first array of battery cells and a second array of battery cells that are electrically and fluidically connected in parallel. In other embodiments, the at least one array of battery cells includes a first array of battery cells and a second array of battery cells that are electrically and fluidically connected in series.

[0005] Embodiments may also include an electrified vehicle including: a traction battery having a plurality of cells connected in each of a plurality of arrays connected by an internal bus bar within a housing; an electric motor powered by the traction battery and configured to provide propulsion torque to a wheel; a cooling system; and a connector electrically connecting an external bus bar to the internal bus bar and fluidly connecting the cooling system to at least one of the plurality of battery cell arrays of the traction battery. In one or more embodiments, the connector is implemented by a conductive fastener having a closed end and a passage extending from an open end to a radial opening fluidly coupled to the cooling system, the fastener extending through the housing and mechanically and electrically connecting the external bus bar to the internal bus bar and fluidly coupling the plurality of arrays to the cooling system. The connector may include an annular coolant fitting having a coolant passage extending between an outer radius and an inner radius of the fitting, wherein the fastener extends through the annular coolant fitting when the radial opening is disposed within the annular coolant fitting.

[0006] In one or more embodiments, the connector can be implemented by: a tube surrounding a stranded electrical conductor and configured to contain a dielectric coolant; an end cap connected to the tube and having a plurality of openings configured to facilitate coolant flow therethrough and a central opening configured to receive the stranded electrical conductor; and a fitting secured to the tube and configured to engage a complementary housing fitting. The connector can also include a spade connector or a pin connector connected to the stranded electrical conductor.

[0007] Embodiments may include multiple arrays connected electrically and fluidically in parallel or electrically and fluidically in series. In other embodiments, the multiple arrays are connected electrically in series and fluidically in parallel or electrically in parallel and fluidically in series.

[0008] In one or more embodiments, a combined electrical and fluid connector may include: a conductive bolt having a closed end, a passage extending from an open end to a radial opening, and a threaded portion extending from the open end toward the radial opening; and an annular coolant fitting having a coolant passage extending between an outer radius and an inner radius of the fitting, the bolt extending through the annular coolant fitting with the radial opening positioned within the annular coolant fitting, and further extending through the housing of the battery, thereby mechanically and electrically connecting an external bus bar to an internal bus bar of the battery and facilitating coolant fluid flow through the battery. The connector may also include a conductive washer disposed between the conductive bolt and the annular coolant fitting. The connector may also include a threaded nut engaging the threaded portion of the bolt and clamping the external bus bar, the annular coolant fitting, and the internal bus bar to the housing. The connector also includes an upper washer disposed between the external bus bar and the annular coolant fitting and a lower washer disposed between the annular coolant fitting and the housing.

[0009] One or more embodiments according to the present disclosure may have associated advantages. Various prior art strategies for immersion cooling of battery cells utilize separate electrical and fluid connections into the array that must be sealed with pressurized fluid. In contrast, the combined electrical and fluid connection designs according to various embodiments allow cooling of battery cells and power distribution system connection points while using the same or fewer number of fluid seals at the array housing. One of ordinary skill in the art may recognize additional advantages of one or more embodiments for a particular application or implementation that are not explicitly stated based on the teachings of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a block diagram of an electrified vehicle including a combined electrical / fluid connector coupling an array of battery cells of a traction battery in accordance with the present disclosure.

[0011] Figure 2A A pin connector embodiment of a combined electrical / fluid connector is shown.

[0012] Figure 2B A spade connector embodiment of a combination electrical / fluid connector is shown.

[0013] Figure 2C and Figure 2D Combined electrical / fluid wiring and associated end caps for an electrical / fluid connector are shown.

[0014] Figure 3A combined electrical / fluid connection of a battery cell array and a banjo fitting is shown.

[0015] Figure 4 is a block diagram showing an array of battery cells electrically and fluidly connected in series using a combination electrical / fluid connector.

[0016] Figure 5 is a block diagram showing an array of battery cells electrically and fluidly connected in parallel using a combination electrical / fluid connector.

[0017] Figure 6 is a block diagram showing an array of battery cells connected electrically in series and fluidically in parallel.

[0018] Figure 7 is a block diagram showing an array of battery cells connected electrically in parallel and fluidically in series. DETAILED DESCRIPTION

[0019] As required, detailed embodiments are disclosed herein; however, it should be understood that the disclosed embodiments are merely representative and may be embodied in various and alternative forms. The drawings are not necessarily drawn to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to employ embodiments of the claimed subject matter in different ways.

[0020] As described in more detail herein, a combined electrical and fluid connector according to the present disclosure includes an embodiment that adapts a conventional spade-type or pin-type electrical connector to provide a fluid flow around a connection point for cooling and fluid transfer between a vehicle cooling system and a battery cell array. The connector is particularly suitable for applications with an array of battery cells electrically and fluidically connected in series or electrically and fluidically connected in parallel, wherein a cooling fluid flows along an electrical path. The stranded copper wiring of the combined cable is contained within a hose or pipe together with a dielectric or non-conductive cooling fluid or coolant. At the end of the pipe, a connector housing or end cap is secured by crimping or an equivalent attachment method. The end cap or connector housing has a hole to enable fluid to flow from the tube span connection interface to a receiving connector of the battery cell array. The mating pin or spade can be crimped to the stranded conductor and retained by the connector housing. The connector housing forms a sealed connection with the receiving connector at the array housing and forms an electrical connection while allowing fluid to flow around the electrical connection and into the array housing for immersion cooling of the battery cells. This same connection method can be used at the electrical / fluid outlets at the opposing terminals of the battery cell array housing. When the fluid is delivered in contact with the wiring inside the hose or pipe, this design cools the entire length of the electrical wiring between the arrays in addition to the electrical connection points.

[0021] In other embodiments, the combined electrical and fluid connector is implemented using a banjo fitting to provide coolant flow inside the electrical connection point for cooling and fluid transfer into the battery cell array. In addition to applications with battery cell arrays that are electrically connected in series and fluidically connected in parallel or electrically connected in parallel and fluidly connected in series, this embodiment is also particularly suitable for applications with battery cell arrays that are electrically and fluidically connected in parallel or electrically and fluidly connected in series because the cooling fluid path can extend separately from the electrical path. The banjo connector includes: a bolt having an internal fluid channel extending between a radial opening and an open end; and an annular fitting that surrounds the bolt in line with the radial opening to transfer fluid from a pipe or hose to the bolt channel. The bolt secures the external bus bar to the fitting, the array housing, and the internal bus bar. Conductive washers between the bus bar and the bolt head can be used to provide fluid sealing and conduction. A first or upper washer between the external bus bar and the fitting and a second or lower washer between the fitting and the array housing can be used to provide fluid sealing. These washers can be conductive or insulating. The array housing and fluid hoses are non-conductive. Current delivery flows from the external bus bar through the conductive washer into the bolt head and through the bolt to the nut and internal bus bar of the array. Cooling fluid is directed through the non-conductive hose to the fitting and into the bolt, directly cooling the electrical connection point and exiting the threaded end of the bolt into the array for immersion cooling of the battery cells. This same connection method can be used at the fluid outlet at the opposite terminal of the battery cell array.

[0022] Figure 1 An example of an electrified vehicle 100 with one or more combined electrical / fluid connectors according to the present disclosure is depicted. In this example, the electrified vehicle 100 is implemented as a plug-in hybrid electric vehicle. The electrified vehicle 100 may include one or more three-phase motors 104 mechanically connected to a transmission 106. The transmission 106 is mechanically connected to an engine 108 for hybrid implementation. The transmission 106 may also be mechanically connected to a drive shaft 110, which is mechanically connected to wheels 112. The motor or motor / generator 104 may provide propulsion regardless of whether the engine 108 is on or off. One or more motors 104 may act as a motor, a generator, or both. The electrified vehicle 100 may also be implemented as a battery electric vehicle without an engine 108 and powered solely by a traction battery 114 alone or in combination with another power source (such as, for example, a fuel cell).

[0023] The traction battery or battery pack 114 stores energy that can be used by the motor 104. The vehicle battery pack 114 generally provides a high voltage (HV) DC output provided by connecting hundreds of low voltage cell batteries 160 together in one or more battery cell modules or arrays 166. The arrays 166 can each be housed in an associated array housing 168 within the battery pack 114. The battery cells 160 can be immersed in a dielectric cooling fluid or coolant circulating within the vehicle cooling system 140. The battery cells 160 can be electrically connected through internal bus bars within the associated array housing 168. The arrays can be connected to other arrays through external bus bars outside the array housing but within the battery pack 114. The arrays can be fluidly connected through the inlet combined electrical / fluid connector 150 and the outlet combined electrical / fluid connector 152 and the associated cables, hoses or pipes within the battery pack 114. Depending on the specific application and implementation as described in more detail herein, the arrays 166 can be fluidly and electrically connected in series, in parallel, or in a combination of a series arrangement and a parallel arrangement.

[0024] The vehicle power distribution system (EDS) may also include: an HV bus that connects one or more vehicle power modules or components (such as the motor 104, the power electronics module 116, the DC / DC converter module 118, etc.); and an LV bus to the battery pack 114. The power electronics module 116 is also electrically connected to the motor 104 and provides the ability to transfer energy bidirectionally between the battery pack 114 and the motor 104. For example, a typical battery pack 114 can provide a DC voltage / current, while the motor 104 may require a three-phase AC voltage / current. The power electronics module 116 may include an inverter with a power module having switches that can be operated by a controller to convert DC power from the battery 114 to the three-phase AC power required by the motor 104. The power electronics module 116 may also include a voltage converter that increases the DC voltage of the HV DC bus supplied from the battery pack 114 to power the inverter of the power electronics module 116. In regeneration mode, the power electronics module 116 converts three-phase AC power from the electric machine 104 acting as a generator to the DC power required to recapture energy in the battery pack 114. According to one or more embodiments described herein, thermal management of heat generated by power conversion is provided by cooling the power stage assembly modules of the power electronics module.

[0025] In addition to providing energy for propulsion, the battery pack 114 can also provide energy for other vehicle electrical systems. A typical system may include a DC / DC converter module 118 that converts the high-voltage DC output of the battery pack 114 into a low-voltage DC supply compatible with other vehicle loads. Other high-voltage loads (such as compressors and electric heaters) can be connected directly from the battery pack 114 to the high-voltage bus. In a typical vehicle, the low-voltage system is electrically connected to a 12V, 24V, or 48V battery 120.

[0026] The battery pack 114 can be recharged by an external power source 126. The external power source 126 can provide AC or DC power to the vehicle 102 by being electrically connected through a charging port 124. The charging port 124 can be any type of port configured to transfer power from the external power source 126 to the vehicle 102. The charging port 124 can be electrically connected to a power conversion module 122, sometimes referred to as a charger or charging module. The power conversion module can regulate the power from the external power source 126 to provide the appropriate voltage and current levels to the battery pack 114. In some applications, the external power source 126 can be configured to provide the appropriate voltage and current levels to the battery pack 114, and the power conversion module 122 may not be necessary. In some applications, the functionality of the power conversion module 122 may reside in the external power source 126. The vehicle engine, transmission, motor, battery, power conversion, power electronics and various other control modules, components or systems can be controlled by a powertrain control module (PCM) 128. Alternatively or in combination, the various systems or subsystems may include associated control modules or controllers that communicate with the PCM 128 via a vehicle wired or wireless network to provide coordinated control of the vehicle. As used in this disclosure, a controller generally refers to one or more control modules or controllers that can cooperate to perform a specific task or function, and is not limited to a single controller or any specific dedicated controller or control module.

[0027] refer to Figure 2A and Figure 2B , respectively, show a pin connector embodiment and a spade connector embodiment of a combination electrical / fluid connector. The connector 210 may include a pin connector 212 or a spade connector 230 coupled to a stranded electrical connector 216 at a crimp point 214. The stranded electrical connector 216 extends from within an associated conduit or hose 218 of the combination electrical / fluid cable through an opening in the connector 220, which is crimped to the conduit or hose 218 to form a fluid seal. The connector 220 may be internally threaded or otherwise configured to connect to a battery cell array housing. After the pin 212 or spade 230 is connected to the stranded conductor 216, the stranded conductor 216 may be pulled back within the hose 218 to at least partially recess the pin / spade connector within the connector 220 to allow coolant flow from the hose or tubing 218 into (or out of) the connected array housing. Alternatively or in combination, one or more openings may be provided around the central opening to allow coolant to flow through the connector, as with respect to Figure 2C and Figure 2D Shown and described.

[0028] Figure 2C and Figure 2D shows the reference Figure 2A and Figure 2BThe combined electrical / fluid wiring and associated end caps of the electrical / fluid connector described above. In one embodiment, the plastic slider 250 contains the coolant flowing around the stranded wire conductor 260. The plastic slider 250 may include a retaining feature 252 to secure a pin or spade connector, which is secured to the stranded wire conductor 260 as previously described. An end cap 270 may be secured to the plastic slider 250. The end cap 270 includes a central opening 272 configured to accommodate, for example, a pin or spade connector. One or more openings 274 may be arranged around the central opening 272 and configured to facilitate coolant flow therethrough.

[0029] Figure 3 A combined electrical / fluid connection of a battery cell array to a banjo fitting is shown. As commonly understood by those of ordinary skill in the art and as used herein, a banjo fitting generally refers to a hydraulic fitting having a through-hole hollow bolt or an internal loose bolt and a spherical union to facilitate fluid transfer through the bolt. A banjo fitting can be used to connect a fluid line to a rigid internally threaded hydraulic component.

[0030] exist Figure 3 In an embodiment of the present invention, a fastener, such as a bolt 310, includes an internal passage extending from an open end 312 to a radial opening 314. In this representative embodiment, the bolt 310 provides mechanical, electrical, and fluid connections to an associated array of battery cells by securing an external bus bar 340, a banjo fitting 330, and an internal bus bar 350 to an array housing 320. A conductive gasket 322 provides a fluid seal and electrical conductivity from the external bus bar 340 to the internal bus bar 350 connected to one or more battery cells (not shown). The banjo fitting 330 is an annular fitting that includes: a central opening configured to receive the bolt 310; and at least one radial opening extending from the outer circumference of the annulus to the inner circumference of the annulus and configured to facilitate the flow of a cooling fluid 360 out of a connected tube or hose 354. A first or upper gasket 324 and a second or lower gasket 326 can be used to provide a fluid seal. Depending on the particular application and implementation, the first gasket 324 and the second gasket 326 can be conductive or insulating. The bolt 310 includes a threaded portion extending from an open end 312 that engages a complementary threaded nut 316. The bolt 310 is sized so that the radial opening 314 is positioned within the annular fitting 330 between a first or upper surface / face of the annular fitting 330 that contacts the washer 324 and a lower surface / face of the annular fitting 330 that contacts the lower washer 326.

[0031] Figure 4is a block diagram showing an array of battery cells electrically and fluidically connected in series using a combined electrical / fluid connector. A first inlet connector 410 couples a vehicle cooling system to a battery pack via a cooling fluid connection 412 and an electrical connection 414 to a first array of battery cells 420. The cooling fluid provides immersion cooling of the battery cells contained within the housing of the first array 420. The connector 410 connects an external bus bar outside the housing of the first array 420 to an internal bus bar that is connected to one or more battery cells within the housing of the first array 420, as previously described. An outlet connector 430 connects the cooling fluid within the first array 420 to an associated hose or channel that is connected to a second inlet connector 440 associated with a second array of battery cells 450. Similarly, the first outlet connector 430 connects an associated internal bus bar within the first array 420 to an external bus bar 434 that is in turn connected to a second inlet connector 440 of the second array 450. The second outlet connector 460 couples the cooling fluid to a coolant outlet 462 of another array (when present) or battery, and also couples the inner bus bar of the second array 450 to the outer bus bar 464 of the second array 450 .

[0032] Figure 5 is a block diagram showing an array of battery cells electrically and fluidically connected in parallel using a combined electrical / fluid connector. In this configuration, a cooling fluid inlet manifold 502 supplies a lower temperature coolant to the inlets of at least two battery cell arrays 520, 550 having associated inlet connectors 510, 540, respectively. Similarly, a positive external high voltage (HV) bus 504 is electrically connected in parallel to the input connectors 510, 540 for the battery cell arrays 520, 550. Outlet connectors 530, 560 electrically connect the arrays 520, 550 in parallel to the negative external HV bus 506, and fluidly connect the higher temperature cooling fluid flowing out of the arrays 520, 550 in parallel to the coolant outlet manifold 508.

[0033] Figure 66 is a block diagram showing an array of battery cells electrically connected in series and fluidically connected in parallel. In this configuration, a cooling fluid inlet manifold 602 supplies a lower temperature coolant to the inlets of at least two battery cell arrays 620, 650, each having an associated inlet or input connector 610, 640 and a corresponding outlet or output connector 630, 660. A positive external bus bar 604 is electrically connected to the input connector 610. An output connector 630 is fluidly connected to an outlet manifold 608 and electrically connected to internal and external negative bus bars, wherein the external bus bars are electrically connected in series to the input connector 640 and the associated positive internal bus bar of the array 650. The output connector 660 electrically connects the negative internal bus bar of the array 650 in series to the positive internal bus bar of another array or the negative terminal of the battery pack. The output connector 660 fluidly connects the higher temperature cooling fluid flowing out of the array 650 to the outlet manifold 608 in parallel with the cooling fluid flowing out of the array 620.

[0034] Figure 7 is a block diagram showing an array of battery cells electrically connected in parallel and fluidically connected in series. In this configuration, the positive external HV bus is electrically connected in parallel to the positive internal bus of at least two battery cell arrays 720, 750 via corresponding input connectors 710, 740. The input connector 710 is fluidly connected to the vehicle cooling system to provide a lower temperature cooling fluid for immersion cooling of the cells in the array 720. The outlet connectors 730, 760 electrically connect the negative internal bus of the arrays 720, 750 to the negative external HV bus 706 in parallel, respectively. The outlet connector 730 fluidly connects the cooling fluid from the array 720 to the array 750 in series via the inlet connector 740. The outlet connector 760 fluidly connects the cooling fluid flowing out of the array 750 to another array or vehicle cooling system (not shown).

[0035] Although representative embodiments are described above, these embodiments are not intended to describe all possible forms of the invention. The words used in the specification are words of description rather than limitation, and it should be understood that various changes can be made without departing from the claimed subject matter. In addition, the features of the various implemented embodiments can be combined to form other embodiments within the scope of the claimed subject matter that are not explicitly described or shown.

[0036] According to the present invention, an electrified vehicle system is provided, the electrified vehicle system having: a battery, the battery having a plurality of battery cells, the plurality of battery cells being electrically connected in at least one battery cell array having an array shell, the at least one battery cell array being connected to an internal battery bus within the array shell; an annular coolant accessory, the annular coolant accessory having a coolant channel, the coolant channel extending between an outer radius and an inner radius of the accessory; and a conductive fastener, the conductive fastener having a closed end and a channel extending from an open end to a radial opening, the fastener extending through the annular coolant accessory with the radial opening positioned within the annular coolant accessory, and further extending through the array shell and mechanically and electrically connecting an external bus outside the array shell to the internal bus.

[0037] According to one embodiment, the fastener includes: a bolt having a threaded area extending below the radial opening; and a nut engaging the threaded area, the bolt and the nut clamping the outer bus bar, the annular coolant fitting and the inner bus bar to the array housing.

[0038] According to one embodiment, the present invention is further characterized by a conductive washer disposed between the bolt and the external bus bar.

[0039] According to one embodiment, the present invention is further characterized by an upper gasket disposed between the external bus bar and the annular coolant fitting and a lower gasket disposed between the annular coolant fitting and the array housing.

[0040] According to one embodiment, the at least one battery cell array includes a first battery cell array and a second battery cell array, and wherein the first battery cell array and the second battery cell array are electrically and fluidically connected in series.

[0041] According to one embodiment, the at least one battery cell array includes a first battery cell array and a second battery cell array, and wherein the first battery cell array and the second battery cell array are electrically and fluidically connected in parallel.

[0042] According to one embodiment, the at least one battery cell array includes a first battery cell array and a second battery cell array, and wherein the first battery cell array and the second battery cell array are electrically connected in series and fluidically connected in parallel.

[0043] According to one embodiment, the at least one battery cell array includes a first battery cell array and a second battery cell array, and wherein the first battery cell array and the second battery cell array are electrically connected in parallel and fluidically connected in series.

[0044] According to the present invention, an electrified vehicle is provided, the electrified vehicle having: a traction battery having a plurality of cells connected in each of a plurality of arrays connected by internal bus bars within a housing; an electric machine powered by the traction battery and configured to provide propulsion torque to wheels; a cooling system; and a connector electrically connecting an external bus bar outside the housing to the internal bus bar and fluidly connecting the cooling system to at least one of the plurality of battery cell arrays of the traction battery.

[0045] According to one embodiment, the connector includes: a conductive fastener having a closed end and a channel extending from the open end to a radial opening that is fluidly coupled to the cooling system, the fastener extending through the housing and mechanically and electrically connecting the outer bus bar to the inner bus bar and fluidly coupling the plurality of arrays to the cooling system.

[0046] According to one embodiment, the invention further features an annular coolant fitting having a coolant passage extending between an outer radius and an inner radius of the fitting, wherein the fastener extends through the annular coolant fitting when the radial opening is disposed within the annular coolant fitting.

[0047] According to one embodiment, the connector includes: a tube surrounding a stranded electrical conductor and configured to contain a dielectric coolant; an end cap connected to the tube and having a plurality of openings configured to facilitate coolant flow therethrough and a central opening configured to receive the stranded electrical conductor; and a threaded fitting secured to the tube and configured to engage a complementary threaded housing fitting.

[0048] According to one embodiment, the invention further features a spade connector connected to the stranded electrical conductors.

[0049] According to one embodiment, the invention is also characterized by a pin connector connected to the stranded electrical conductor.

[0050] According to one embodiment, the plurality of arrays are electrically and fluidically connected in parallel or electrically and fluidically connected in series.

[0051] According to one embodiment, the plurality of arrays are electrically connected in series and fluidically connected in parallel or electrically connected in parallel and fluidically connected in series.

[0052] According to the present invention, a combined electrical and fluid connector is provided, which has: a conductive bolt having a closed end, a channel extending from an open end to a radial opening, and a threaded portion extending from the open end toward the radial opening; and an annular coolant fitting, the annular coolant fitting having a coolant channel extending between an outer radius and an inner radius of the fitting, the bolt extending through the annular coolant fitting with the radial opening positioned within the annular coolant fitting, and further extending through a battery cell array housing, thereby mechanically and electrically connecting an external bus bar outside the housing to an internal bus bar within the housing, and facilitating the passage of coolant fluid through the battery cell array.

[0053] According to one embodiment, the present invention is further characterized by a conductive washer disposed between the conductive bolt and the annular coolant fitting.

[0054] According to one embodiment, the invention further features a threaded nut that engages the threaded portion of the bolt and clamps the outer bus bar, the annular coolant fitting, and the inner bus bar to the housing.

[0055] According to one embodiment, the present invention is further characterized by an upper gasket disposed between the external bus bar and the annular coolant fitting and a lower gasket disposed between the annular coolant fitting and the housing.

Claims

1. An electric vehicle system, comprising: A battery having a plurality of cells electrically connected in at least one cell array having an array housing, the at least one cell array connected to internal battery bus bars within the array housing; an annular coolant fitting having a coolant passage extending between an outer radius and an inner radius of the fitting; as well as A conductive fastener having a closed end and a passage extending from the open end to a radial opening, the fastener extending through the annular coolant fitting with the radial opening positioned within the annular coolant fitting and further extending through the array housing and mechanically and electrically connecting an external bus bar external to the array housing to the internal bus bar.

2. The electrified vehicle system of claim 1, wherein the fastener comprises: a bolt having a threaded region extending below the radial opening; and a nut engaging the threaded region, the bolt and nut clamping the outer bus bar, the annular coolant fitting, and the inner bus bar to the array housing. 3 . The electrified vehicle system of claim 2 , further comprising a conductive washer disposed between the bolt and the external bus bar.

4. The electrified vehicle system of claim 3, further comprising an upper gasket disposed between the external bus bar and the annular coolant fitting and a lower gasket disposed between the annular coolant fitting and the array housing.

5. The electrified vehicle system of claim 1, wherein the at least one battery cell array comprises a first battery cell array and a second battery cell array, and wherein the first battery cell array and the second battery cell array are electrically and fluidically connected in series.

6. The electrified vehicle system of claim 1, wherein the at least one battery cell array comprises a first battery cell array and a second battery cell array, and wherein the first battery cell array and the second battery cell array are electrically and fluidically connected in parallel.

7. The electrified vehicle system of claim 1, wherein the at least one battery cell array comprises a first battery cell array and a second battery cell array, and wherein the first battery cell array and the second battery cell array are electrically connected in series and fluidically connected in parallel.

8. The electrified vehicle system of claim 1, wherein the at least one battery cell array comprises a first battery cell array and a second battery cell array, and wherein the first battery cell array and the second battery cell array are electrically connected in parallel and fluidically connected in series.

9. An electric vehicle comprising: a traction battery having a plurality of cells connected in each of a plurality of arrays connected by internal bus bars within the housing; an electric motor powered by the traction battery and configured to provide propulsion torque to wheels; Cooling system; as well as A connector electrically connects an external bus bar outside the housing to the internal bus bar and fluidly connects the cooling system to at least one of the plurality of battery cell arrays of the traction battery.

10. The electrified vehicle of claim 9, wherein the connector comprises: A conductive fastener having a closed end and a passage extending from the open end to a radial opening fluidly coupled to the cooling system, the fastener extending through the housing and mechanically and electrically connecting the outer bus bar to the inner bus bar and fluidly coupling the plurality of arrays to the cooling system.

11. The electrified vehicle of claim 10 further comprising an annular coolant fitting having a coolant passage extending between an outer radius and an inner radius of the fitting, wherein the fastener extends through the annular coolant fitting when the radial opening is disposed within the annular coolant fitting.

12. The electrified vehicle of claim 9, wherein the connector comprises: a conduit surrounding the stranded electrical conductors and configured to contain a dielectric coolant; an end cap connected to the tube and having a plurality of openings configured to facilitate coolant flow therethrough and a central opening configured to receive the stranded electrical conductor; and A threaded fitting is secured to the pipe and is configured to engage a complementary threaded housing fitting.

13. The electrified vehicle of claim 12, further comprising a spade connector connected to the stranded electrical conductor.

14. The electrified vehicle of claim 9, wherein the plurality of arrays are electrically and fluidically connected in parallel or electrically and fluidly connected in series.

15. The electrified vehicle of claim 9, wherein the plurality of arrays are electrically connected in series and fluidly connected in parallel or electrically connected in parallel and fluidly connected in series.

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