Elastically deformable battery module connector system

Abstract

An elastically deformable connector system for connecting battery modules in a battery pack. The elastically deformable connector system includes a bus bar assembly having a bus bar with a plurality of individual conductors vertically arranged to provide a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion between the first peripheral portion and the second peripheral portion. The bus bar assembly also includes a first male connector assembly coupled to the first peripheral portion of the bus bar, a second male connector assembly coupled to the second peripheral portion of the bus bar, and a bus bar housing enclosing a majority of the extent of the bus bar. Wherein, after the bus bar assembly is electrically connected to a pair of battery modules in the battery pack, the intermediate portion is configured to elastically deform to compensate for each of a compression motion and an expansion motion of the pair of battery modules.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 337,596, the disclosure of which is hereby incorporated by reference in its entirety for all purposes. Technical Field

[0003] The present disclosure relates to an elastically deformable connector system for connecting modules in a battery pack included in a power distribution system of a vehicle. The battery pack includes a plurality of battery modules that are electrically connected to each other using at least one elastically deformable connector system having: (i) a bus bar having an elastically deformable intermediate portion located between peripheral connecting portions, and (ii) a bus bar housing. Background Art

[0004] Over the past several decades, the number of electrical components used in automobiles and other on-road and off-road vehicles (such as pickup trucks, commercial vans and trucks, semi-trailer trucks, motorcycles, all-terrain vehicles, and sport utility vehicles, collectively referred to as "automobiles") has increased dramatically. Electrical components are used in automobiles for a variety of reasons, including but not limited to monitoring, improving and / or controlling vehicle performance, emissions, safety, and creating comfort for the passengers of the automobile. A great deal of time, resources, and effort have been invested in developing power distribution components that meet the various demands and complexities of the automotive market; however, conventional power distribution components suffer from various disadvantages.

[0005] Motor vehicles are extremely challenging electrical environments for both electrical components and connector assemblies due to a variety of conditions, including but not limited to space limitations that make initial installation difficult, harsh operating conditions, large ambient temperature ranges, long periods of vibration, thermal loads, and service life, all of which can lead to component and / or connector failures. For example, improper connector installation (usually occurs in the assembly plant) and connector detachment (usually occurs in the field) are two major failure modes for electrical components and motor vehicles. Each of these failure modes results in high repair and warranty costs. For example, the total annual warranty costs for all global automakers and their direct suppliers are estimated to be between $50 billion and $150 billion. In view of these extremely challenging electrical environments, people have spent a lot of time, money, and effort to find power distribution components that meet market needs. The present disclosure addresses the shortcomings of traditional power distribution components. A full discussion of the features and advantages of the present disclosure will be postponed to the following detailed description, which will be conducted with reference to the accompanying drawings. Summary of the invention

[0006] The present disclosure generally relates to an elastically deformable connector system designed to electrically couple: (i) a first battery module within a plurality of battery modules to a second battery module within a plurality of battery modules, (ii) a first battery module within a plurality of battery modules to the extent of a battery pack housing, (iii) the extent of the battery pack housing to the extent of an external component, or (iv) the extent of a first external component to the extent of a second external component. The elastically deformable connector system is designed and configured to compensate for: (i) material conditions associated with the modules, battery pack, power distribution system and / or application, and / or (ii) dynamic movement of the battery modules caused by: (a) charging and discharging the battery modules, (b) aging of the battery modules, (c) temperature changes, including temperature changes of the modules, battery pack, power distribution system and / or application, (d) movement of the modules within the battery pack while using or operating the power distribution system and / or application, (e) battery cell failure, and (f) other known causes for movement of battery modules within the battery pack.

[0007] In order to compensate for the material condition and / or dynamic movement of the battery module, the elastically deformable battery module connector system disclosed herein includes a busbar having a plurality of individual conductors, the plurality of individual conductors being arranged vertically to provide a first peripheral portion, a second peripheral portion, and an elastically deformable middle portion located between the first peripheral portion and the second peripheral portion. The busbar assembly also includes a first male connector assembly coupled to the first peripheral portion of the busbar, a second male connector assembly coupled to the second peripheral portion of the busbar, and a busbar housing enclosing most of the busbar. Wherein, after the busbar assembly is electrically connected to a pair of battery modules in a battery pack, the middle portion is capable of elastically deforming to compensate for each of the compression movement and the expansion movement of the pair of battery modules.

[0008] In another embodiment, the busbar includes a plurality of individual conductors that have undergone a fusion process to form a solid single conductor in a selected area of ​​the busbar, wherein the busbar includes a first peripheral portion, a second peripheral portion, and an elastically deformable middle portion located between the first peripheral portion and the second peripheral portion. A majority of the elastically deformable middle portion is not coplanar with the first peripheral portion or the second peripheral portion, but includes a curved range. This configuration of the elastically deformable middle portion allows an activation force of less than 50 Newtons or less to deform its total length by more than 5%. Therefore, the connector system improves the reliability, performance, and service life of modules, battery packs, power distribution systems, and applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The accompanying drawings or diagrams, which are included to provide further understanding and are incorporated into and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the specification, are used to explain the principles of the embodiments of the present disclosure. In the accompanying drawings, the same reference numerals refer to the same or similar elements throughout the drawings. In the accompanying drawings:

[0010] Figure 1 is a perspective view of a first embodiment of an elastically deformable battery module connector system, wherein the extent of a busbar housing is omitted to illustrate the busbars;

[0011] Figure 2 is a top view of a plurality of electrical conductors that have been cut to specified lengths;

[0012] Figure 3 yes Figure 2 , which shows a staggered end configuration of a plurality of electrical conductors;

[0013] Figure 4 and Figure 5 yes Figure 2 A perspective view of a plurality of electrical conductors shown in the drawings, the electrical conductors being in the process of being selectively welded together using a laser welding machine to form a busbar having a first connection segment;

[0014] Figure 6 The busbar passes through Figure 4-5 Top view after the selective soldering process shown in;

[0015] Figure 7 yes Figure 6 Bottom view of the busbar;

[0016] Figure 8 yes Figure 6 A first side view of a busbar;

[0017] Fig. 9 yes Figure 6 A second side view of the busbar;

[0018] Fig.10 yes Figure 6 A first end view of a busbar;

[0019] Fig.11 yes Figure 6 A second end view of the busbar;

[0020] Fig.12 yes Figure 6 Bottom view of the busbar;

[0021] Fig.13 is along Fig.12 A cross-sectional view of the generatrix taken along line 13-13 of FIG. 1 showing an unfused segment having an unsolidified area;

[0022] Fig.14 yes Figure 6 Bottom view of the busbar;

[0023] Fig.15 is along Fig.14 A cross-sectional view of a view of a generatrix taken along line 15-15 of , which shows a fused section including: (i) two lateral solidified regions, and (ii) an unsolidified region;

[0024] Fig.16 yes Figure 6 Bottom view of the busbar;

[0025] Fig.17 is along Fig.14 A cross-sectional view of a view of the generatrix taken along line 17-17 of FIG. 1 showing a fused section including a fully solidified region;

[0026] Fig.18 yes Figure 6-11 A perspective view of a busbar shown in , wherein the busbar has undergone a process of forming an elastically deformable middle portion of the busbar;

[0027] Fig.19 yes Fig.18 A perspective view of a busbar of FIG. 1 , wherein the second end of the busbar is in the process of being selectively welded together using a laser welding machine to form a second connection section;

[0028] Fig. 20 The busbar has experienced Fig.19 A perspective view after the selective soldering process is shown in FIG. 1 , wherein the busbar is configured to be integrated into Figure 1 In an elastically deformable battery module connector system;

[0029] Fig.21 yes Fig. 20 A side view of the busbar;

[0030] Fig. 22 yes Fig. 20 Bottom view of the busbar;

[0031] Fig.23 yes Fig. 20 An end view of a busbar;

[0032] Fig.24 yes Fig. 20 Top view of the busbar;

[0033] Fig.25 yes Figure 1 An exploded view of a male conductor assembly of an elastically deformable battery module connector system, wherein the male conductor assembly includes a male terminal assembly having a male terminal body, a spring member and a male terminal housing;

[0034] Fig.26 yes Fig.25 A perspective view of a spring member of a male terminal assembly;

[0035] Fig. 27 yes Fig.25 A perspective view of a male terminal body of a male terminal assembly;

[0036] Fig.28 is in a partially assembled state S PA A perspective view of a male terminal assembly;

[0037] Fig.29 is in fully assembled state FA A side view of a male terminal assembly;

[0038] Fig.30 is along Fig.29 A cross-sectional view of the male terminal assembly taken along line 30-30;

[0039] Fig.31 is a top perspective view of an elastically deformable conductive component of an elastically deformable battery module connector system, wherein the elastically deformable conductive component includes a Figure 20-24 The busbar Fig.29 an opposing male terminal assembly;

[0040] Fig.32 yes Fig.31 A side view of an elastically deformable conductive component;

[0041] Fig.33 yes Fig.31 A top view of an elastically deformable conductive component;

[0042] Fig.34 yes Fig.31 An end view of an elastically deformable conductive component;

[0043] Fig.35 yes Fig.31 A bottom view of an elastically deformable conductive component;

[0044] Fig.36 is a perspective view of an elastically deformable battery module connector system, wherein a busbar housing is omitted to illustrate the extent of the busbar;

[0045] Fig.37 yes Fig.36 A side view of a range of elastically deformable battery module connector systems;

[0046] Fig.38 is along Fig.37 A cross-sectional view of the elastically deformable battery module connector system taken along line 38-38;

[0047] Fig.39 yes Fig.36 A top view of a range of elastically deformable battery module connector systems;

[0048] Fig.40 is along Fig.39 A cross-sectional view of the elastically deformable battery module connector system taken along line 40-40;

[0049] Fig.41 is a perspective view of a busbar housing, wherein the housing is formed of a first portion and a second portion that are detachably coupled together;

[0050] Fig.42 yes Fig.41 A side view of the busbar housing;

[0051] Fig.43 yes Fig.41 Bottom view of the busbar housing;

[0052] Fig.44 yes Fig.41 An end view of the busbar housing;

[0053] Fig.45 yes Fig.41 Top view of the busbar housing;

[0054] Fig.46 yes Fig.41 A perspective view of a first component of a busbar housing;

[0055] Fig.47 yes Fig.46 A side view of a first part of a busbar housing;

[0056] Fig.48 is a perspective view of an elastically deformable battery module connector system;

[0057] Fig.49 yes Fig.48 A side view of an elastically deformable battery module connector system;

[0058] Fig.50 yes Fig.48 A top view of an elastically deformable battery module connector system;

[0059] Fig.51 yes Fig.48 An end view of an elastically deformable battery module connector system;

[0060] Fig.52 yes Fig.48 A bottom view of an elastically deformable battery module connector system;

[0061] Fig.53is a perspective view of a first embodiment of a battery pack including a plurality of battery modules electrically coupled together with a plurality of elastically deformable battery module connector systems;

[0062] Fig.54 yes Fig.53 A top view of a first embodiment of a battery pack;

[0063] Fig.55 yes Fig.53 and Fig.54 A perspective view of two battery modules and an elastically deformable battery module connector system isolated from a battery pack as shown in FIG.

[0064] Fig.56 are coupled together by an elastically deformable battery module connector system Fig.55 A high-view perspective view of a battery module of FIG. 1 , wherein the battery module housing is omitted to expose the battery cells and electrical transmission structures;

[0065] Fig.57 are coupled together by an elastically deformable battery module connector system Fig.56 A side view of a battery module;

[0066] Fig.58 are coupled together by an elastically deformable battery module connector system Fig.56 Top view of the battery module;

[0067] Fig.59 is along Fig.56 A cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 59-59;

[0068] Fig.60 yes Fig.59 , which shows an interface between a battery module and an elastically deformable battery module connector system;

[0069] Fig.61 is along Fig.56 an enlarged perspective cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 61-61 of FIG. 5 , illustrating an interface between the battery module and the elastically deformable battery module connector system;

[0070] Fig.62 is along Fig.58 A battery module cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 62-62, wherein the battery cells are at a 50% charge level and the elastically deformable battery module connector system is in a neutral state S N ;

[0071] Fig.63 yes Fig.62 An enlarged view showing the neutral state S N An elastically deformable battery module connector system;

[0072] Fig.64 is a schematic diagram of expansion and contraction of a cylindrical battery cell due to charging and discharging of the battery cell;

[0073] Fig.65 is a schematic diagram of irreversible expansion of a cylindrical battery cell due to aging of the battery cell;

[0074] Fig.66 is along Fig.58 An enlarged cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 66-66 of FIG. 1 , wherein the battery cells are at a 100% charge level and the elastically deformable battery module connector system is in a compressed state S C ;

[0075] Fig.67 is along Fig.58 An enlarged cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 67-67, wherein the battery cells are at a 0% charge level and the elastically deformable battery module connector system is in an extended state S E ;

[0076] Fig.68 yes Fig.62 An enlarged view showing the compressed state S C An elastically deformable battery module connector system;

[0077] Fig.69 yes Fig.66 An enlarged view showing the neutral state S N An elastically deformable battery module connector system;

[0078] Fig.70 yes Fig.67 An enlarged view showing the extended state S E An elastically deformable battery module connector system;

[0079] Fig.71 is along Fig.56 An enlarged perspective cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 71-71 of FIG. 7 , illustrating that the elastically deformable battery module connector system absorbs lateral movement between battery modules;

[0080] Fig.72 is a side view of a range of battery modules and a range of elastically deformable battery module connector systems;

[0081] Fig.73 is along Fig.72 A cross-sectional view of a range of battery modules and a range of elastically deformable battery module connector systems taken along line 73-73;

[0082] Fig.74 is a perspective view of a second embodiment of two battery modules coupled together by a second embodiment of an elastically deformable battery module connector system;

[0083] Fig.75 yes Fig.74 An exploded view of the battery module is shown in FIG.

[0084] Fig.76A is along Fig.74 A cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 76A-76A, wherein the battery cells are at a 50% charge level and the elastically deformable battery module connector system is in a neutral state S N ;

[0085] Fig.76B yes Fig.76A An enlarged view showing the neutral state S N An elastically deformable battery module connector system;

[0086] Fig.77 is a schematic diagram of expansion and contraction of a soft pack battery cell due to charging and discharging of the battery cell;

[0087] Fig.78 is a schematic diagram of irreversible expansion of a soft pack battery cell due to aging of the battery cell;

[0088] Fig.79 is along Fig.74 An enlarged cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 79-79, wherein the battery cells are at a 100% charge level and the elastically deformable battery module connector system is in a compressed state S C ;

[0089] Fig.80 is along Fig.74 An enlarged cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 80-80, wherein the battery cells are at a 0% charge level and the elastically deformable battery module connector system is in an extended state S E ;

[0090] Fig.81 yes Fig.79 An enlarged view showing the compressed state SC An elastically deformable battery module connector system;

[0091] Fig.82 yes Fig.76A , Fig.76B An enlarged view showing the neutral state S N An elastically deformable battery module connector system;

[0092] Fig.83 yes Fig.80 An enlarged view showing the extended state S E An elastically deformable battery module connector system;

[0093] Fig.84 is a perspective view of a third embodiment of two battery modules coupled together by the first embodiment of the elastically deformable battery module connector system;

[0094] Fig.85 yes Fig.84 A perspective view of a battery module coupled together by an elastically deformable battery module connector system, wherein the battery module housing is transparent to expose the battery cells and electrical transmission structure;

[0095] Fig.86 is along Fig.85 A cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 86-86, wherein the battery module is in a nominal material state and the elastically deformable battery module connector system is in a neutral state S N ;

[0096] Fig.87 is along Fig.85 A cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 87-87, wherein the battery module is in a minimum material condition and the elastically deformable battery module connector system is in a compressed state S C ;

[0097] Fig.88 is along Fig.85 A cross-sectional view of a battery module and an elastically deformable battery module connector system taken along line 88-88, wherein the battery module is in a maximum material condition and the elastically deformable battery module connector system is in an extended state S E ;

[0098] Figure 89-102 An alternative configuration of busbars configured for integration into an elastically deformable battery module connector system is shown, wherein each busbar includes at least one elastically deformable segment;

[0099] Fig.103 is a bottom perspective view of a fourth embodiment of an elastically deformable battery module connector system;

[0100] Fig.104 yes Fig.103 A top perspective view of a fourth embodiment of an elastically deformable battery module connector system;

[0101] Figures 105 to 109 An alternative configuration of a male terminal assembly that may be used in conjunction with an elastically deformable battery module connector system is shown;

[0102] Fig.110 is a perspective view of a second embodiment of a battery pack mounted within a skateboard mounting platform of a vehicle, wherein the battery pack includes a plurality of battery modules electrically coupled together with a plurality of elastically deformable battery module connector systems;

[0103] Fig.111 Yes Fig.110 A perspective view of a vehicle with a skateboard-mounted platform;

[0104] Fig.112 is a perspective view of a passenger bus including a third embodiment of a battery pack having a plurality of elastically deformable battery module connector systems coupling battery modules to one another;

[0105] Fig.113 is a perspective view of a large vessel including a fourth embodiment of a battery pack having a plurality of elastically deformable battery module connector systems coupling battery modules to one another; and

[0106] Fig.114 is a perspective view of a marine vessel including a fifth embodiment of a battery pack having a plurality of elastically deformable battery module connector systems coupling battery modules to one another. DETAILED DESCRIPTION

[0107] In the following detailed description, many specific details are set forth by way of example in order to provide a thorough understanding of the relevant teachings. However, it should be understood by those skilled in the art that the present teachings may be practiced even without these details. In other instances, well-known methods, procedures, components and / or circuits have been described at a relatively high level, but without detailed description, in order to avoid unnecessarily obscuring various aspects of the present teachings.

[0108] Although the present disclosure includes many different forms of embodiments, specific embodiments are shown in the accompanying drawings, and these embodiments will be described in detail herein, it should be understood that the present disclosure should be regarded as an illustration of the principles of the disclosed method and system, and is not intended to limit the broad aspects of the disclosed concept to the illustrated embodiments. As will be appreciated, the disclosed method and system can adopt other different configurations, and several details can be modified, all of which will not deviate from the scope of the disclosed method and system. For example, one or more of the following embodiments can be combined in part or in whole in accordance with the disclosed method and system. Therefore, the drawings and specific embodiments should be regarded as illustrative, rather than restrictive.

[0109] For background and context, Figures 110-114 Various products and applications 10 having at least one power distribution system 50 are shown. Applications 10 include, but are not limited to: aircraft, motor vehicles 20 ( Fig.111 ), military vehicles (e.g. tanks, personnel carriers, heavy trucks and troop transporters), buses25 ( Fig.112 ), locomotives, tractors, bulldozers, excavators, tractors, marine vessels (e.g., boats, cargo ships, tankers, submarines, passenger ships 30 ( Fig.113 and 114 ), tankers, sailing sailboats), mining equipment, forestry equipment, agricultural equipment (e.g., tractors, harvesters, planters, combines, threshers, harvesters), telecommunications hardware (e.g., servers), power storage systems (e.g., backup power storage), renewable energy hardware (e.g., wind turbines and solar arrays), 24-48 volt systems for high power applications, for high current applications, for high voltage applications. In these applications 10, the power distribution system 50 is configured to meet industry standards, production and performance requirements.

[0110] Each power distribution system 50 includes a battery pack 90 having: (i) a plurality of battery modules 60, and (ii) at least one elastically deformable battery module connector system 100 that electrically couples: (a) a first battery module 62a within the plurality of battery modules 60 to a second battery module 62b within the plurality of battery modules 60, (b) a first battery module 62a within the plurality of battery modules 60 to a range of a battery pack housing 92, (c) a range of the battery pack housing 92 to a range of an external component, or (d) a range of a first external component to a range of a second external component. As explained in detail below, the elastically deformable battery module connector system 100 is configured to compensate for: (i) material conditions associated with the module 60, battery pack 90, power distribution system 50 and / or application 10, and / or (ii) dynamic movement of the battery module 60 caused by: (a) charging and discharging of the battery module 60, (b) aging of the battery module 60, (c) temperature changes, including temperature changes of the module 60, battery pack 90, power distribution system 50 and / or application 10, (d) movement of the module 60 within the battery pack 90 while in use or operating the power distribution system 50 and / or application 10—such as a bus 25 (see FIG. 25 ). Fig.112 ) on streets with many potholes, or boat 30 (see Fig.113 ) sailing in rough waters causing the vessel 30 to pitch, heave, or maneuver violently, (e) battery cell failure, and (f) other known causes of movement of the battery modules 60 within the battery pack 90. ​​It should be understood that material conditions and / or dynamic movement of the battery modules 60 may occur in all directions (i.e., X, Y, Z, and rotation). For example, Figure 55-70 Dynamic movement of the battery module 60 in: (i) includes expansion and / or contraction in the XY plane due to movement of lithium ions within the individual battery cells 75, and (ii) may include expansion and / or contraction in the XZ or YZ plane due to CTE or other known reasons.

[0111] To compensate for the material condition and / or dynamic movement of the battery module 60, the elastically deformable battery module connector system 100 of the present disclosure includes a busbar 200 having an elastically deformable middle portion 410. The elastically deformable middle portion 410 allows the system 100 to: (i) be deformed from a stress-free or neutral state S N compressed by an appreciable amount - i.e., up to 4 mm, (ii) from an unstressed or neutral state S NThe invention relates to a battery module connector system 100 that is designed and configured to accommodate material conditions and / or dynamic movement of the battery module 60, and / or the battery pack 90. ​​The connector system 100 is designed and configured to accommodate material conditions and / or dynamic movement of the battery module 60, and / or the battery pack 90. ​​The connector system 100 minimizes and potentially eliminates failure modes that could damage or degrade the performance of the power distribution system 50, the module 60, and / or the battery pack 90. ​​Thus, the connector system 100 improves the reliability, performance, and service life of the module 60 and the battery pack 90.

[0112] Therefore, the above benefits of the connector system 100 of the present disclosure should be considered illustrative in nature, rather than limiting. Therefore, other benefits may be disclosed in the diagrams or written disclosures contained herein, or those skilled in the art may understand based on the diagrams or written disclosures.

[0113] A number of terms are introduced and used in this application and are defined below. Although some of the following terms overlap with other terms or are not mutually exclusive, a general organizational hierarchy is provided below, with the terms "busbar" and "bar" at the top of the hierarchy, the terms "end," "end sector," "center," and "center sector" at the middle and upper levels of the hierarchy, the terms "portion," "peripheral portion," and "middle portion" at the middle and lower levels of the hierarchy, the term "zone" at the lower levels of the hierarchy, and the term "region" at the lowest level of the hierarchy.

[0114] The term "busbar" refers to at least one conductor extending from a first end edge to a second end edge and capable of transmitting current from a first location to a second location. Fig. 20 A perspective view of the busbar 200 is shown.

[0115] The term "end sector" is an area of ​​the busbar designed to facilitate coupling of the busbar 200 with external devices or components.

[0116] The term "center sector" is the extent of the busbar 200 extending between the end sectors 207 of the busbar 200. It should be understood that a single conductor 202 of the busbar 200 spans from a first end sector 208a across the center sector 210 and to a second end sector 208b. In other words, the end sectors 208a, 208b of the conductor 202 are integrally formed with the center sector 210 of the conductor 202 prior to any modification of the conductor 202. In other words, the end sectors 208a, 208b of the conductor 202 are not separate structures coupled to the center sector 210 of the conductor 202 using a welding, fusing, or fastening process.

[0117] The term "peripheral portion" is an extent of a busbar designed to position the intermediate portion between any of the following locations: (i) a pair of battery modules, (ii) an extent of a battery module and a battery pack housing, (iii) an extent of a battery pack housing and an extent of an external component, or (iv) a pair of external components.

[0118] The term "middle portion" is a region of the busbar extending between the peripheral portions 402a, 402b of the busbar 200 and designed to be elastically deformable.

[0119] The term "segment" is the extent of the central sector of a busbar that receives: (i) a segment fusion mode, or (ii) the absence of a segment fusion mode. It should be understood that adjacent segments of a single conductor of a busbar are integrally formed with one another and are not fastened to one another using welding, fusing, or fastening processes. It should also be understood that adjacent busbar segments typically have different mechanical properties (e.g., different Young's modulus).

[0120] The term "fused section" is a region of a busbar that includes at least one of: (i) a partially solidified region, (ii) a transversely solidified region, or (iii) a fully solidified region. A fused section may also include an unsolidified region. For example, Figure 14-17 A fused section 206 is shown including: (i) an unsolidified region 230 , and (ii) a lateral solidified region 238 .

[0121] The term "unfused segment" is a region of a busbar that contains only unsolidified or unfused regions of distinct conductors. Thus, an unfused segment does not include: (i) partially solidified regions, (ii) limited or lateral solidified regions, or (iii) fully solidified regions. For example, Figure 12-13 An unfused section 204 of a central sector 210 of a busbar 200 is shown having an unsolidified region 230 with distinct unfused conductors 202 .

[0122] The term "partially solidified zone" is a region of the fused section 206 of the central sector 210 of the busbar, wherein the region: (i) extends from the lowermost or bottom conductor to the uppermost or top conductor in the fused section, and (ii) includes a partially solidified region.

[0123] The term "partially solidified region" refers to an area of ​​the partially solidified zone of the busbar that has undergone a surface-based fusion process (e.g., a vertically oriented partial penetration weld process 182). The surface-based fusion process combines or fuses all of the conductor ranges in the partially solidified region to form a single consolidated conductor. A large number (e.g., about 70%) of the conductors 202 in the partially solidified region are combined or fused into a single consolidated conductor to form the partially solidified region. In contrast, a smaller number (e.g., about 30%) of the conductors 202 in and outside the partially solidified region remain as separate, distinct conductors 202, meaning that they are not combined or fused into a single combined conductor in the unsolidified region 230.

[0124] The term “partially solidified volume” is the volume of the central sector 210 of the busbar 200, wherein the volume: (i) extends from the lowermost or bottom conductor to the uppermost or top conductor in the fused section, (ii) runs along the entire length of the fused section 206, and (iii) has a width that encapsulates the partially solidified volume.

[0125] The term "partially solidified volume" refers to an extent of a partially solidified volume of a busbar that has undergone a surface-based fusion process (e.g., vertically oriented partial penetration weldment process 182). The surface-based fusion process combines or fuses all of the conductor extents in the partially solidified volume to form a single consolidated conductor.

[0126] The term "limited solidification zone" is a region of a fused section 206 of a busbar, wherein the region: (i) extends between: (a) the midpoint or middle of the width or depth defined between the outermost edges of the fused section, and (b) one of the outermost edges of the fused section 206, and (ii) includes a lateral solidification region. For example, Figure 14-15 A limited solidification zone 240 is shown extending between the lateral edge 216b and the midpoint MP of the generatrix 200, which includes the range that has undergone the lateral partial penetration weldment process 184 or cold forming process.

[0127] The term "lateral solidification region" refers to a region of a limited solidification zone of a busbar that has undergone an edge-based fusion process (e.g., a lateral partial penetration weldment process 184 or a cold forming process). The edge-based fusion process combines or fuses all conductor areas in the lateral solidification region to form a single consolidated conductor. For example, Figure 14-15A lateral solidified region 238 is shown: (i) adjacent to the unsolidified region 230, both located in the limited solidified region 240 of the fused section 206 of the central sector 210 of the busbar 200, and (ii) extending from the lowermost or bottom conductor to the uppermost or top conductor. A smaller extent (e.g., approximately 5%) of the busbar 200 in the limited solidified region 240 is combined or fused into a single consolidated conductor to form the lateral solidified region 238. In contrast, a larger extent (e.g., approximately 95%) of the busbar 200 in the limited solidified region 240 and outside of the lateral solidified region 238 remains as separate distinct conductors 202, meaning that they are not combined or fused into a single combined conductor in the unsolidified region 230.

[0128] The term "finite solidification volume" is the volume of a fused segment 206 of a busbar, wherein the volume: (i) extends between: (a) the midpoint or middle of the width or depth defined between the outermost edges of the fused segment 206, and (b) one of the outermost edges of the fused segment 206, (ii) along the entire length of the fused segment 206, and (ii) has a width that encapsulates the lateral solidification region.

[0129] The term "lateral solidification volume" refers to the volume of the finite solidification volume of the busbar that has undergone an edge-based fusion process (e.g., a lateral partial penetration weldment process 184 or a cold forming process) that combines or fuses all conductor ranges in the lateral solidification volume to form a single consolidated conductor.

[0130] The term "uncured area" refers to an area of ​​the busbar that has not undergone the welding process 180 to combine or fuse any conductors in that area of ​​the busbar. Similarly, the term "uncured volume" refers to the volume of the busbar that has not undergone the welding process to combine or fuse any conductors in that volume of the busbar 200. Therefore, all conductors 202 located in the uncured area 230 remain as separate discrete conductors. For example, Fig.13 An uncured area 230 is shown.

[0131] The term "fully solidified region" refers to a region of the busbar that has undergone a fusion process (e.g., a transverse welding process 184 or a vertical welding process 182) to combine or fuse all of the conductors 202 contained in that region of the busbar into a single consolidated conductor. Fig.17 A fully cured region 242 is shown extending across the end sectors 208a, 208b of the busbar 200.

[0132] The general term “cured region” refers to a partially cured region, a lateral cured region 238 , or a fully cured region 242 .

[0133] The term "flexible section" is a region of the busbar that does not include: (i) a partially solidified region, (ii) a transversely solidified region formed using the transverse partial penetration weldment process 184, or (iii) a fully solidified region. The stiffness of the flexible section 224 of the busbar 200 is less than 25% of the stiffness of a corresponding section of a solid reference busbar having the same geometry and formed from a similar solid material.

[0134] The term "bend section" is a region of a busbar that includes at least one of: (i) a partially cured region, (ii) a transversely cured region, or (iii) a fully cured region. For example, Figure 18-24 A curved section 226 is shown including an unsolidified region 230 of the conductor 202 and one or more partially solidified regions 234 formed by two transverse solidified regions 238 formed using the transverse partial penetration weldment process 184. The stiffness of the curved section is greater than 35% of the stiffness of a corresponding section of a reference busbar having the same geometry and formed from a similar solid material.

[0135] The term "maximum material condition" refers to a size feature that contains the maximum amount of material but is still within specified tolerances. For example, the maximum material condition occurs when the maximum pin diameter or minimum hole size within specified tolerances is utilized.

[0136] The term "minimum material condition" refers to a size feature that contains the minimum amount of material but is still within a specified tolerance. For example, the maximum material condition occurs when using the minimum pin diameter or maximum hole size within a specified tolerance.

[0137] The term "nominal material condition" refers to a material condition between a maximum material condition and a minimum material condition.

[0138] The term "in-plane" refers to the plane defined by the X and Y axes in a three-dimensional Cartesian coordinate system of X, Y and Z. In this reference system, the longitudinal axis AA of the generatrix 200 is coplanar with the XY plane and lies in the plane.

[0139] The term "out-of-plane" refers to the plane defined by the Y and Z axes in a three-dimensional Cartesian coordinate system of X, Y, and Z. In this reference system, the longitudinal axis AA of the generatrix 200 is perpendicular to the YZ plane and is oriented out-of-plane of the YZ plane.

[0140] The term "high power" means (i) any voltage between 20 volts and 600 volts, regardless of current; or (ii) any current greater than or equal to 80 amperes, regardless of voltage. The term "high current" means any current greater than or equal to 80 amperes, regardless of voltage. The term "high voltage" means any voltage between 20 volts and 600 volts, regardless of current.

[0141] I. First Embodiment of the Elastically Deformable Battery Module Connector System

[0142] Figure 1-73 A first embodiment of an elastically deformable battery module connector system 100 is shown, which includes: (i) a busbar 200, (ii) a busbar housing 600, and (iii) at least one male connector assembly 1000. The busbar 200 disclosed herein is formed of a plurality of conductors 202, wherein a selected range of the busbar 200 undergoes a fusion process 180 that solidifies the range of conductors 202 within the range of the busbar 200. As a result of the fusion process 180, the busbar 200 includes: (i) at least one unfused segment 204 and (ii) at least one fused segment 206. Integrally forming the fused segments and unfused segments 204, 206 in a single busbar 200 is beneficial because it allows the busbar 200 to combine the optimal features of a conventional rigid busbar and a conventional flexible busbar into a single busbar while limiting the negative features associated with these conventional busbars. For example, the unfused segments 204 are flexible, which allows the busbar 200 to: (i) accommodate manufacturing tolerances, (ii) expand and contract during thermal expansion and contraction events (such as battery charging and battery discharging cycles), and (iii) help absorb vibrations caused by the operating environment in which the busbar 200 is installed (e.g., within a vehicle) rather than transmitting these vibrations to other components associated with the operation of the busbar 200. In addition, the fused segments 206 of the busbar 200 are stiffer (e.g., the Young's modulus is increased, in N / m 2 ), which allows the busbar 200 to be accurately bent out of plane and purposefully maintain those bends over time without causing delamination of the conductors 202 and thereby reducing the current flowing through the busbar 200.

[0143] A. Busbar

[0144] Figure 2-3The first step of forming the busbar 200 is shown. Specifically, a plurality of individual conductors 202 are obtained, cut into specified lengths, and arranged in a vertical stack. In the embodiment shown in the figure, each conductor 202 has an elongated rectangular prism configuration. The rectangular prism configuration is more advantageous than other configurations (such as round or square) because it can quickly dissipate heat. Although the width (between 10 mm and 30 mm, preferably 20 mm) and thickness (between 0.1 mm and 0.5 mm, preferably 0.25 mm) of each conductor 202 remain substantially constant across the length of the busbar 200, the lengths of the conductors 202 contained in the busbar 200 are largely based on their positional relationship within the stack. In particular, the conductors 202 are staggered and increase in length when moving from the bottom conductor 203a (or the shortest conductor) to the top conductor 203j (or the longest conductor). This staggered length arrangement is desirable because, due to the curvature of the elastically deformable middle portion 410, the top conductor 203j must travel farther than the bottom conductor 203a (see Figure 18-24 ).

[0145] In this first embodiment, each conductor 202 is made of C10200 copper alloy, which has: (i) an electrical conductivity greater than 80% of IACS (International Annealed Copper Standard, i.e., an empirically derived standard value for the electrical conductivity of commercially available copper) according to ASTM B747 standard, and (ii) a coefficient of thermal expansion (CTE) of 17.6 ppm / degree Celsius (20-300 degrees Celsius) and 17.0 ppm / degree Celsius (20-200 degrees Celsius). In other embodiments, the selected copper material can be replaced with stainless steel, nickel, aluminum, silver, gold, copper, steel, zinc, brass, bronze, iron, platinum, lead, molybdenum, calcium, tungsten, lithium, tin, combinations of the listed materials, or other similar metals.

[0146] Once the desired configuration of the individual conductors 202 is formed, the conductors 202 are arranged in a layered stack, wherein the first ends 208a of all the conductors are aligned with each other. In other words, the end surfaces of the stack of conductors 202 are substantially flat and substantially perpendicular to the top and bottom surfaces 215a, 215b of the top and bottom conductors 203j, 203a. In this configuration, the plurality of conductors 202 provide an unfused reference stiffness. The unfused reference stiffness is between 1 KPa and 200 GPa, preferably between 50 KPa and 2,500 KPa, and more preferably between 100 KPa and 1,000 KPa, and most preferably 320 KPa. Although some of the figures in this application depict only a busbar 200 having five conductors 202 due to space limitations, it should be understood that the preferred embodiment is a layered stack of ten conductors 202. It should be understood that while the preferred embodiment is a layered stack of ten conductors 202 , the present disclosure contemplates busbars 200 including any number of conductors 202 (eg, one conductor 202 to one hundred conductors 202 ).

[0147] i. The first range of selectively fused busbars

[0148] Once the layered stack of ten conductors 202 is created, the process of manufacturing the busbar 200 continues by: (i) fusing the first end sector 208a of the busbar 200, and (ii) fusing the identified segment of the center sector 210 of the busbar 200 that is contained within the first range 212a of the busbar 200. Before being able to selectively fuse ranges of the busbar 200, the user or manufacturer must obtain or gain access to a machine 190 that is capable of performing the selected fusing method to selectively fuse the busbar 200. For example, if the designer decides to use a laser welding fusing method, the designer obtains or gains access to a laser welding machine 192, at least as described above. Figure 4 , 5 19. As shown, the laser welding machine 192 may include two separate lasers 194, 196 that can weld the busbar 200 from two opposite directions at the same time. The two separate lasers 194, 196 are preferably aligned in a vertical plane. However, it should be understood that the laser welding machine 192 can have other configurations, including: (i) only one laser 194, which can only interact with one side of the busbar 200 at a time, (ii) only one laser 194, but using optics and mirrors to modify the light output from the laser so that the laser can interact with both sides of the busbar 200 at the same time, or (iii) two lasers 194, 196 that are not aligned.

[0149] Next, the designer will: (i) insert the conductor 202 arranged in accordance with the layered stack design disclosed above into the machine 192, and (ii) provide the machine 192 with fusing instructions (e.g., load an engineering model) associated with the first end sector 208a and the first range 212a of the busbar 200. The laser welding machine 192 will then perform the fusing process 180 described in its instructions. For example, Figure 4 The busbar 200 is shown in a horizontal orientation, wherein the width of the busbar 200 lies in a plane oriented substantially perpendicular to the lasers 194, 196. In this horizontal orientation, the machine 192 performs a surface-based fusion process (i.e., a vertical partial penetration weldment process 182) on the end sector 207 of the busbar 200 according to instructions associated with the first end sector 208a of the busbar 200. Next, as Figure 5 , the busbar 200 is rotated to a vertical orientation, wherein the thickness of the busbar 200 lies in a plane oriented substantially perpendicular to the lasers 194, 196. In this vertical orientation, the machine 192 performs an edge-based fusion process (i.e., a lateral partial penetration weldment process 184) on a first extent 212a of the busbar 200 in accordance with instructions associated with the first extent 212a.

[0150] After selectively welding the first end sector 208a and the first range 212a of the center sector 210, a Figure 6-17 It should be understood that at this stage of manufacturing the busbar 200, only the first end sector 208a and the first range 212a of the center sector 210 are formed. The formation of these parts, ranges, sectors, segments, areas and regions is determined by Figure 6 and Figure 7 To simplify the discussion, other portions, areas, sectors, segments, regions, and zones that are not currently formed at this stage of manufacturing but have been identified and will be formed at subsequent stages of manufacturing are shown in FIG. Figure 6 and Figure 7 200. In fact, these identified and subsequently formed ranges, sectors, segments, zones, and regions are preferably not formed at this manufacturing stage because their inclusion may introduce additional stresses to the conductors 202 during the bending of the busbar 200. In order to avoid introducing these stresses, the formation of these ranges, sectors, segments, zones, and regions will be performed after the busbar 200 is bent into the desired shape. In addition, the disclosed configuration of the busbar 200 should be understood as exemplary, and the present disclosure contemplates other configurations of ranges, sectors, segments, zones, and regions. For example, all parts, sectors, segments, zones, and regions disclosed or considered in U.S. Patent Application Nos. 17 / 970116 and 17 / 699033 and PCT Application No. PCT / IB2022 / 057772 may be included or used in the busbar 200.

[0151] Figure 6-11 The busbar 200 is shown to include: (i) a central sector 210 and (ii) two end sectors 207. The central sector 210 extends between end boundary lines 214a, 214b, while the end sectors 207 extend outwardly from the end boundary lines 214a, 214b. The end boundary lines 214a, 214b separate the fused section 206 containing a fully solidified region 242 arranged to form a dense weld from the sections 204, 206 that do not contain a fully solidified region. It should be understood that the end boundary lines 214a, 214b are located far enough inward from the end edges 216c, 216d to allow sufficient material to be present in the end sectors 207 of the busbar 200 to allow the end sectors 207 to be coupled to a connector, terminal, socket, or any other structure that couples the busbar 200 to an external structure or component. For example, the end boundary lines 214a, 214b may be formed between 1 mm and 40 mm, and preferably between 14 mm and 22 mm, from the end edges 216c, 216d.

[0152] like Figure 6 As shown in , the central sector 210 includes: (i) three unfused segments 204 (205a, 205b, 205c), and (ii) two fused segments 206 (209a, 209b). In particular, the unfused segments 204 are arranged such that: (i) the first unfused segment 205a extends between the first end boundary line 214a and the first intermediate boundary line 218a, (ii) the second unfused segment 205b extends between the second intermediate boundary line 218b and the third intermediate boundary line 218c, and (iii) the third unfused segment 205c extends between the fourth intermediate boundary line 218d and the second end boundary line 214b. At the same time, the fused section 206 is arranged such that: (i) the first unfused section 205a extends between the first intermediate boundary line 218a and the second intermediate boundary line 218b, and (ii) the second fused section 209b extends between the third intermediate boundary line 218c and the fourth intermediate boundary line 218d. In other words, the first intermediate boundary line 218a separates the linear range (i.e., the first peripheral portion 402a) from the nonlinear range (i.e., the elastically deformable middle portion 410) of the generatrix 200. In addition, the fourth intermediate boundary line 218d separates the linear range (i.e., the second peripheral portion 402b) from the nonlinear range (i.e., the elastically deformable middle portion 410) of the generatrix 200. Finally, the second and third intermediate boundary lines 218c, 218d separate the unfused section 204 from the fused section 206.

[0153] Figure 12-17Cross-sectional views are shown to illustrate how the selective fusion process changes the configuration of the individual conductors 202 contained within the first range 212a of the end sectors 207 and the center sector 210 of the busbar 200. Specifically, cross-sectioning the busbar 200 along lines 13-13, 15-15, 17-17 shows that: (i) areas that did not undergo the fusion process (e.g., welding) remain unsolidified 230, (ii) areas that underwent the fusion process (e.g., welding): (a) i.e., edge welds, and specifically, the right edge weld and the left edge weld, creating a lateral solidified region 238 in the fused section 206 of the center sector 210 of the busbar 200, or (b) i.e., surface welds, and specifically, the upper surface weld and the lower surface weld, creating a fully solidified region 242 in the end sector 207 of the busbar 200.

[0154] 1. Unfused section

[0155] Fig.13 Shown along Fig.12 13-13 of the cross-sectional view of the generatrix 200. The cross section is taken between the first end boundary line 214a and the first intermediate boundary line 218a. The boundary lines define the edges of the unfused segment 204 (ie, the first unfused segment 205a). Fig.13 The cross section of FIG. 204 reveals a plurality of conductors 202 that do not include the solidified regions 238, 242. In other words, the plurality of conductors 202 shown in the cross section have not yet undergone a fusion process to combine or fuse the conductor ranges into a single consolidated conductor. In other words, each conductor 202 in the unfused segment 204 is still a separate and distinct conductor 202. This configuration of separate and distinct conductors 202 forms a flexible section 224 that is not designed to bend or withstand severe operating forces. In this embodiment, the flexible section 224 has a resistance of less than 550 KPa or 0.55 Nm 2 The rigidity of the flexible section 224 is about 320 KPa (2,200 KPa for a rigid reference busbar, where 1 conductor*0.25=550 KPa). In particular, the flexible section 224 has a rigidity of about 320 KPa.

[0156] 2. Fusion section

[0157] The lateral solidification region 238 extends from the lateral edges 216a, 216b of the busbar 200 to the edge-based fusion peak 219 of the fusion process 180. The edge-based fusion peak 219 is located: (i) laterally between the midpoint 217 and the lateral edges 216a, 216b of the fusion segment 206, and (ii) vertically between (a) the first surface 215a and (b) the second surface 215b of the busbar 200. Therefore, the lateral solidification region 238 has a height H LSR and width W LSRIn an exemplary embodiment, the edge fusion width or the width of the lateral solidification area W LSR Less than 0.4 mm, and most preferably between 0.01 mm and 0.35 mm. For the embodiments of the present disclosure, it is attempted to reduce the edge fusion width or the width of the lateral solidification zone W to LSR Increasing above 0.4 mm may result in undesirable melting near the lateral edges 216a, 216b because the busbar 200 includes copper and ten conductors 202 having a thickness of 0.25 mm. However, it should be understood that for busbars 200 having other configurations or made of other materials, the melting may not occur until a deeper weld, or may occur at a shallower weld. Therefore, for other embodiments, the edge fusion width or the width of the lateral solidification zone W LSR It may be between 0.05 mm and 5 mm, preferably between 0.1 mm and 2.5 mm, and most preferably between 0.1 mm and 0.75 mm.

[0158] The limited solidification zone 240 is the region of the generatrix 200 that (i) extends from the midpoint 217 of the fusion section 206 to one of the lateral edges 216a, 216b, and (ii) has undergone an edge-based fusion process (e.g., a lateral partial penetration weldment process 184 or a cold forming process). The limited solidification zone 240 has: (i) a height H extending between the first surface 215a and the second surface 215b LSZ , and (ii) a width W extending between the midpoint 217 of the conductor 202 and the lateral edges 216a, 216b LSZ In other words, the limited solidification zone 240 has: (i) a height H LSZ , which: (a) is generally equal to the height H of the fused section 206 F , and (b) equal to or greater than the fusion height or lateral solidification height H LSR , and (ii) width W LSZ , which: (a) is equal to half (eg, 10 mm) of the width of the busbar 200 (eg, 20 mm), and (b) is greater than the lateral cross-sectional width W of the lateral solidification region 238 LSR .

[0159] Edge fusion width or width of the lateral solidification area W LSR : (i) is consistent in the fused section 206, and (ii) may vary when multiple fused sections 206 are compared to each other. However, in other embodiments, the edge fusion width or the width of the lateral solidification region W LSRThe edge fusion width or width of the lateral solidified region W may be: (i) constant across the entire fusion section 206, or (ii) may vary within the fusion section 206, (iii) constant across multiple fusion sections 206, and / or (iv) may vary across multiple fusion sections 206. As described above, the edge fusion width or width of the lateral solidified region W LSR between 0.05 mm and 0.4 mm, and preferably 0.2 mm. Thus, by dividing the width W of the lateral solidification zone associated with the right and left edges by LSR The total fusion depth W is calculated by adding T The total fusion depth W varies between each of the plurality of fusion segments 206. Thus, the first total fusion depth associated with the fusion segment 206 extending between 218a and 218b is between 0.1 mm (i.e., 0.05 mm + 0.05 mm) and 0.8 mm (i.e., 0.4 mm + 0.4 mm), and is preferably 0.4 mm. Thus, the total fusion depth W T Between 0.5% and 4% of the busbar width (i.e. 20 mm).

[0160] Based on the above height and width, busbar 200 includes the following relationship: (i) the height H of lateral solidification region 238 LSR is generally substantially equal to the height H of the limited solidification zone 240 LSZ , and (ii) the width W of the lateral solidification region 238 LSR Smaller than the width W of the limited curing zone 240 LSZ , where the width W LSR Usually larger than the width W LSZ 50% smaller, and most preferably within the width W of the limited curing zone 240 LSZ 0.5% (ie, (1-(9.95 mm / 10 mm))*100) and 4% (ie, (1-(9.6 mm / 10 mm))*100). In addition, the height of the edge weld 184 is substantially equal to the height H of the limited solidification zone 238. LSR , and the width of the edge weld 184 is substantially equal to the width W of the lateral solidification region 238 LSR Therefore, the height of the edge weld 184 is substantially equal to the height H of the limited solidification zone 240. LSZ , and the width of the edge weld 184 is less than the width W of the limited solidification zone 240 LSZ .

[0161] Width of lateral solidification area W LSR Smaller than the width W of the limited curing zone 240 LSZ and half of the width of busbar 200. Since the width of the lateral solidification region W LSRThe uncured area 230 is less than half the width of the busbar 200, so an uncured area 230 is formed between the edge-based fusion peak 219 and the midpoint 217 of the busbar 200. The uncured area 230 has an uncured width W U , which extends between the midpoint 217 of the busbar 200 and the edge-based fusion peak 219. The uncured width W U The width W of the limited curing zone 240 is usually LSZ The width W of the limited curing zone 240 is preferably at least 10% of the width W of the limited curing zone 240. LSZ On the other hand, the width of the lateral solidification area W LSR Equal to the width W of the limited curing zone 240 LSZ At least 0.1% of the width W of the limited curing zone 240 is preferred. LSZ 1% to 10% of the width W of the limited curing zone 240, and most preferably within the width W of the limited curing zone 240. LSZ Between 3% and 8%.

[0162] In this exemplary embodiment, the lateral solidified region 238 can be created by solidifying a lateral extent of ten conductors 202 into a single conductor. In other words, the central sector 210 of the busbar 200 includes a plurality of conductors 202 that traverse or span the central sector 210 of the busbar 200. The fused section 206 of the central sector 210 includes a limited solidified region 240 that extends between the midpoint 217 and the lateral edges 216a, 216b of the conductors 202. A minority of the conductors 202 contained within the limited solidified region 240 have been solidified into a single consolidated conductor to form the lateral solidified region 238. Likewise, the majority of the conductors 202 contained within the limited solidified region 240 are unsolidified and form an unsolidified region 230.

[0163] like Fig.15As best shown in FIG. 1 , when the transverse solidified region 238 is formed using the transverse partial welding process 184, the transverse solidified region 238 may include varying fusion densities. The transverse partial welding process 184 may form a first or outer zone having a first fusion density and a second or inner zone having a second fusion density less than the first fusion density. The density difference is caused by the configuration and operation of the laser welder 192, wherein the laser beam loses intensity when penetrating the busbar 200. The lower density zone is created a certain distance inward from the weld edge or inward from the higher density zone. It should be understood that the second zone may have a fusion density gradient, wherein it has a higher fusion density at the point closest to the first zone and a lowest fusion density at the point farthest from the first zone. It should also be understood that the fusion density can be uniform or substantially uniform within the first zone. In addition to solidifying the transverse edges 216a, 216b of the busbar 200, the transverse partial welding process 184 also rounds the corners of the busbar 200. These rounded corners help reduce the likelihood that conductor 202 will wear or tear the insulation or housing 600. Additional aspects of lateral cured regions 238 and uncured regions 230 are described in the definitions section at the beginning of the detailed description.

[0164] As described above, the fused section 206 within the central sector 210 of the busbar 200 contains both transverse solidified regions 238 and unsolidified regions 230. Therefore, it should be understood that increasing the area of ​​the transverse solidified regions 238 within the fused section 206: (i) will at least increase the local stiffness in the fused section 206, (ii) tend to increase the stiffness of the central sector 210 of the busbar 200, and (iii) tend to increase the overall stiffness of the busbar 200. For example, creating these transverse solidified regions 238 will increase the Young's modulus of the busbar (e.g., above 320 KPa or 0.32 Nm at room temperature). 2 ). In addition, it should be understood that increasing the area of ​​the unsolidified region 230 within the fused section 206: (i) will increase at least the local flexibility in the fused section 206, (ii) tend to increase the flexibility of the central sector 210 of the busbar 200, and (iii) tend to increase the overall flexibility of the busbar 200.

[0165] Fig.15 Shown along Fig.14 15-15 of the line 15-15. The cross section is taken between the first intermediate boundary line 218a and the intermediate boundary line 218b. These boundary lines 218a, 218b define the edge of the fusion section 206 or the fusion section 206 (i.e., the first fusion section 209a). Fig.15The cross section of FIG. 226 reveals: (i) two transverse solidified regions 238 formed using right and left transverse partial penetration welds extending inwardly from the transverse edges 216a, 216b of the busbar 200, and (ii) an unsolidified region 230 extending between the two transverse solidified regions 238. Therefore, the right and left transverse partial penetration welds combine all conductors 202 contained within the transverse solidified regions 238 into a single consolidated conductor. The first fused segment 206, 209a has no extent that has been subjected to a surface-based fusion process to form a partially solidified region (where all conductors in the partially solidified region are fused together to form a single consolidated conductor). Since the first fused segment 206, 209a has no partially solidified region, it does not yet have a partially solidified zone. Therefore, the bend region 226 has a stiffness greater than 770 KPa (2,200 KPa for a rigid reference busbar, where 1 conductor * 0.4 = 770 KPa).

[0166] 3. Fusion end sectors

[0167] Unlike the center sector 210, the end sectors 207 are intended to receive connectors; therefore, it is desirable that these areas be fully cured into a single, consolidated conductor. All extents of the conductor 202 contained within the fully cured region 242 are cured into a single conductor because the major extents of the conductor 202 are: (i) cured downward from the top surface 215a, (ii) cured upward from the bottom surface 215b, and (iii) cured inward from the lateral edges 216a, 216b. Thus, these major extents of the conductor 202 meet between the top and bottom surfaces 215a, 215b, typically at a midpoint area between the two surfaces 215a, 215b, and form the fully cured region 242. The weld depth or height H of the fully cured region 242 is FSR At least substantially equal to the fusion height H of the busbar 200 F In certain exemplary embodiments, when the weld material is deposited on one of the two surfaces 215a, 215b to create a "dome effect", the fully solidified height H FSR Can be greater than the fusion height H F Since the height H of the fully cured area 242 FSR Equal to or greater than the fusion height H F , so no uncured area 230 is formed between the weldment and the second surface 215a, 215b of the busbar 200. In other words, all conductors 202 located within the fully cured zone are cured into a single consolidated conductor. Additional aspects of the fully cured area 242 are disclosed in PCT / US20 / 50016, which is hereby incorporated by reference.

[0168] Similar to the partially solidified region 1300, the fully solidified zone is the region of the busbar 200 extending between the top surface 215a and the bottom surface 215b that has undergone the complete welding process 182. The fully solidified zone has a height extending between the first and second surfaces 215a, 215b. In other words, the fully solidified zone has a height equal to the fusion height H F The height of the solidification FSR Based on the weldment of the present disclosure, the end sectors 207 are welded in such a way that these sectors 207 are densified (sufficient solidified surface area equal to 120% of the cross-sectional area of ​​the busbar 200) so that they can be coupled to the connector.

[0169] Fig.17 Shown along Fig.16 17-17 of the line 17-17 defined by the section taken in cross-section view of the generatrix 200. The cross section is taken between the end edge 216c and the first intermediate boundary line 218a, which defines the end sectors 207, 208a and the fully cured area 242. Fig.17 The cross section of FIG. 226 reveals: (i) two lateral solidified regions 238 formed using right and left lateral partial penetration welds extending inwardly from the lateral edges 216a, 216b of the busbar 200, and (ii) thirteen partially solidified regions formed using top and bottom vertical partial penetration welds 182 extending upwardly and downwardly from the top and bottom surfaces 215a, 215b of the busbar 200. Thus, the bend region 226 has a stiffness greater than 770 KPa (2,200 KPa for the rigid reference busbar, where 1 conductor * 0.35 = 770 KPa).

[0170] ii. Alternative Embodiments

[0171] As described above, the central sector 210 may include: (i) any number (e.g., 0-1000) of unfused segments 204, and (ii) any number (e.g., 0-1000) of fused segments 206. The fused segments 206 may include any number (e.g., 0-1000) of transverse solidified regions 238, any number (e.g., 0-1000) of partially solidified regions, and any number (e.g., 0-1000) of unsolidified regions 230. Furthermore, the fused segments 206 may include any number of waveforms (e.g., 0-100), preferably between 1-6 waveforms, and most preferably 2 waveforms. Likewise, the central sector 210 of the busbar 200 may include: (i) any number of undulations (e.g., 0-100), (ii) any number (e.g., 0-1000) of transversely cured regions 238, (iii) any number (e.g., 0-1000) of partially cured regions, (iv) any number of fully cured regions 242, and / or (v) any number (e.g., 0-1000) of uncured regions 230. Finally, the busbar 200 may include: (i) any number of undulations (e.g., 0-100), (ii) any number (e.g., 0-1000) of transversely cured regions 238, (iii) any number (e.g., 0-1000) of partially cured regions, (iv) any number of fully cured regions 242, and / or (v) any number (e.g., 0-1000) of uncured regions 230. This configuration allows a busbar designer to selectively form segments, zones, regions, and / or volumes into a single busbar, which provides the busbar 200 with benefits associated with conventional rigid busbars and conventional flexible busbars.

[0172] In alternative embodiments, the laser fusion process of the present disclosure may be substituted or used in addition to resistance welding, arc welding, electron beam welding, orbital welding, ultrasonic welding, friction welding, any combination of the above methods, or other known methods for fusing metals. In addition, the transverse partial penetration weldment process 184 or cold forming process that forms the transverse solidification area within the limited solidification zone of the center sector 210 may be omitted or its width may be increased. In addition, the transverse partial penetration weldment process 184 or cold forming process used in conjunction with the end sectors 207 may be omitted.

[0173] iii. Forming the middle part

[0174] After the first end sector 208a and the first range 212a of the busbar 200 are selectively fused, the process of manufacturing the busbar 200 continues by forming the elastically deformable middle portion 410 of the busbar 200 into a desired shape. The elastically deformable middle portion 410 of the busbar 200 is located between the first peripheral portion 402a and the second peripheral portion 402b. Specifically, the first peripheral portion 402a includes: (i) the first end sectors 207, 208a, and (ii) the first range of the central sector 210, that is, the first unfused segment 204, 205a. Similarly, the second peripheral portion 402b includes: (i) the second end sectors 207, 208b, and (ii) the second range of the central sector 210, that is, the third unfused segment 204, 205c. Based on the configuration of the present disclosure, the first peripheral portion and the second peripheral portion 402a include: (i) a fully cured area 242, and (ii) an uncured area 230. At the same time, the middle portion 410 is formed in the central sector 210 and is formed between the first peripheral portion and the second range of the central sector 210. Therefore, the middle portion 410 includes: (i) the first fused section 206, 209a, (ii) the second unfused section 204, 205b, and (iii) the second fused section 206, 209b. Therefore, the middle portion 410 includes: (i) two transverse solidified regions 238, and (ii) the unsolidified region 230 extending between the two transverse solidified regions 238. It should be understood that the present disclosure contemplates other configurations (see Figures 89-102). For example, in an alternative embodiment, the middle portion 410 may include a partially solidified region.

[0175] In other words, the first peripheral portion 402a is defined between the left end edge 216c and the first intermediate boundary line 218a, and the second peripheral portion 402b is defined between the right end edge 216d and the fourth intermediate boundary line 218d. In other words, the first and second peripheral portions 402a, 402b extend outward from the first and fourth intermediate boundary lines 218a, 218d. It should be understood that the first and fourth intermediate boundary lines 218a, 218d are positioned inwardly from the end edges 216c, 216d at a sufficient distance to: (i) allow a connector, terminal, socket or any other structure to be properly coupled to the busbar 200, and (ii) properly position the elastically deformable middle portion 410 in a desired position (e.g., without interfering with the position of the battery module 60). For example, the end boundary lines 214a, 214b can be formed between 15 mm and 85 mm from the end edges 216c, 216d, and preferably between 35 mm and 55 mm.

[0176] The first and second peripheral portions 402a, 402b are not designed to bend or change at this stage of the manufacturing process. U In the installation state S, the peripheral portions 402a, 402b remain substantially parallel, substantially aligned, their top and bottom surfaces 215a, 215b are substantially coplanar, and their lateral edges 216a, 216b are substantially colinear. Therefore, the peripheral portions 402a, 402b are not designed to include curves or angle ranges. In addition, in the installation state S I In the embodiment of the present invention, these peripheral portions 402a, 402b are generally and / or preferably maintained substantially parallel, substantially aligned, their top and bottom surfaces 215a, 215b are substantially coplanar, and their lateral edges 216a, 216b are substantially colinear. The configuration of the first and second peripheral portions 402a, 402b is beneficial because it helps to ensure that undesirable forces are at least minimized and preferably not applied to the connection between the busbar 200 and the male connector assembly 1000 or the male connector assembly 1000 and the battery module 60. If the peripheral portions 402a, 402b of the busbar 200 have a curved configuration, an example of undesirable forces may be introduced. And the undesirable forces may cause a fault within the battery pack 90, which is extremely costly to diagnose, repair or mitigate. Therefore, it is beneficial to minimize or eliminate these undesirable forces.

[0177] Unlike the first and second peripheral portions 402a, 402b, the elastically deformable middle portion 410 is designed to be elastically deformed when a load is applied to the bus bar 200 (e.g., due to the dynamic movement of the battery module 60). In order to be elastically deformed when the load is applied to the bus bar 200, the elastically deformable middle portion 410 is in the unmounted state S UThe elastically deformable middle portion 410 preferably has a configuration that preferably positions at least one extent, preferably a majority, and most preferably a majority of the middle portion 410 in a position that is: (i) not substantially parallel to the entirety of the first and second peripheral portions 402a, 402b, (ii) not substantially aligned with the entirety of the first and second peripheral portions 402a, 402b, (iii) not substantially coplanar with the entirety of the first and second peripheral portions 402a, 402b, or (iv) not substantially colinear with the entirety of the first and second peripheral portions 402a, 402b. In other words, the middle portion 410 is not in the same plane as the first and second peripheral portions 402a, 402b due to the fact that the middle portion 410 includes a considerable curvilinear extent or angular extent. In other words, the first and second peripheral portions 402a, 402b are substantially located in a first plane, and a majority of the elastically deformable middle portion 410 is located outside of the first plane. By incorporating the fused segments 206 into the busbar 200, the formation of this (or these) curvilinear ranges or angular ranges in the intermediate portion 410 may be facilitated due to the fact that the fused segments 206 help prevent delamination of the busbar 200 when the elastically deformable intermediate portion 410 is bent into its desired shape.

[0178] exist Figure 1-73In the preferred embodiment shown in FIG. 1 , at least the middle portion 410 of the busbar 200 (particularly in a side view) has a configuration that substantially matches the configuration of the capital letter Omega (“Ω”) in the Greek alphabet or the symbol for Ohm (“Ω”) as a unit of energy management. Specifically, the configuration of the first peripheral portion 402a is similar to the extent of the left foot or left bottom segment of the Omega shape, the configuration of the elastically deformable middle portion 410 is similar to the curvilinear shape of the Omega shape, and the configuration of the second peripheral portion 402b is similar to the extent of the right foot or right bottom segment of the Omega shape. In other words, the busbar 200 includes: (i) a first linear extent 260a, (ii) a first foot or bottom of the Omega shape formed by a first curvilinear extent 262a that creates a first outer notch 264a, (iii) a semicircular extent 266, (iv) a second foot or bottom of the Omega shape formed by a second curvilinear extent 262b that creates a second outer notch 264b, and (v) a second linear extent 260b. In addition, the configuration of the busbar 200 positions the fused segments 206, 209a, 209b near the foot or bottom of the omega shape, while the unfused segments 204, 205a, 205b, 205c are: (i) located between the end sector 207 and the fused segments 206, 209a, 209b, and (ii) along the curved path between the fused segments 206, 209a, 209b. It should be understood that in other embodiments, the first and second ranges of the center sector 210 may include the fused segment 206, and the curved path between the fused segments 209a, 209b may be fully fused or partially fused. It should also be understood that in other embodiments, the elastically deformable middle portion 410 may have alternative configurations (e.g., square, triangle, sine wave, etc.), including but not limited to Figure 89-102 Finally, it is believed that when the elastically deformable middle portion 410 has no right angles or "sharp angles" (such as Fig.89 , 90 , 92, 93, 95 and 98), the optimal elastic deformability performance of the busbar 200 occurs.

[0179] like Figure 6 As shown in FIG. 2 , when the busbar 200 is in the original state or unbent state S of the busbar 200 UB , the length of each portion is as follows: (i) the first peripheral portion 402a has a length L extending from the end edge 216c of the busbar 200 to the first intermediate boundary line 218a; P1U , (i) the second peripheral portion 402b has a length L extending from the end edge 216d of the busbar 200 to the fourth intermediate boundary line 218d P2U, and (iii) the middle portion 410 has a length L extending from the first middle boundary line 218a to the fourth middle boundary line 218d IPU . Length of outer part L P1U , L P2U The length L of the outer portion must be long enough to facilitate coupling the busbar 200 to an external device or component. P1U , L P2U It may be greater than 5 mm, preferably greater than 10 mm, more preferably greater than 14 mm, and most preferably between 30 mm and 60 mm. P1U , L P2U Contributes to the total length L of the busbar 200 UB , but the length of the middle part is L IPU Essentially drives the calculations shown in the table below.

[0180] In addition, if Figure 7 As shown in FIG. , when the busbar 200 is in the original or unbent state S of the busbar 200 UB , the length of each section is as follows: (i) the first end sector 208a has a length L extending from the end edge 216c of the busbar 200 to the first end boundary line 214a E1U , (ii) the second end sector 208b has a length L extending from the end edge 216d of the busbar 200 to the second end boundary line 214b E2U , and (iii) the central sector 210 has a length L extending from the first end boundary line 214a to the second end boundary line 214b CU . End sector length L E1U , L E2U The busbar 200 must be long enough to couple the busbar 200 to an external device or component. In the embodiment of the present disclosure, the end sector lengths L E1U , L E2U It may be greater than 2 mm, preferably greater than 7 mm, and most preferably between 10 mm and 20 mm. Note that the following table is for a busbar 200 having ten copper conductors stacked to form a busbar having a thickness T of 2.5 mm. B and busbar 200 with a width of 20 mm.

[0181] Table 1: Busbar forces and dimensions

[0182] Activation force (N) Inner diameter of middle part (mm) <![CDATA[L IPU (mm)]]> <![CDATA[L P1U, L P2U (mm)]]> <![CDATA[L BU (mm)]]> <![CDATA[L BN (mm)]]> <![CDATA[Package volume (mm 3 )]]> 312 10 32 22 76 58 1,570 211 12 38 26 90 72 2,261 155 14 44 30 104 84 3,077 98 16 51 34 119 96 4,019 67 18 57 38 133 108 5,087 42 20 63 44 151 116 6,280 35 22 69 48 165 130 7,599 32 24 75 52 179 140 9,043 31 26 82 56 194 152 10,613 30 28 88 60 208 164 12,308 29 30 95 64 223 175 14,130 28 32 101 68 237 187 16,076 26 34 107 72 251 198 18,149 24 36 113 76 265 209 20,347

[0183] Total length of unbent busbar L BU and busbar forming length L BN In the not installed state UThe formed length L extends between the end edges 216c, 216d of the middle busbar 200. As shown in Table 1 above, the formed length L BN With total length L BU The ratio is between 70% and 90%. In other words, the forming length L BN Than total length L BU Smaller than 10% and preferably smaller than the total length L BU The above table also shows that the length of the unbent middle part L IPU The total length L of the unbent busbar 200 BU between 35% and 49% and the peripheral portion length L P1U , L P2U Each of the total length L of the unbent busbar 200 BU Therefore, the length of the unbent middle portion L IPU Less than the total bus length L of bus 200 BU However, as noted above, other length ratios are contemplated by the present disclosure.

[0184] Unbent middle section length L IPU is approximately equal to the circumference of a circle with the associated inner diameter. For example, a circle with a diameter of 20 mm would have a circumference of approximately 62.8 mm, and therefore the unbent length of the mid-portion length would be approximately 63 mm. Fig.21 and 69 As shown in FIG. 1 , due to the unique geometry of the middle portion 410, in the first peripheral portion 402a or the second peripheral portion 402b, a bend height H is defined between the outer surface of the uppermost conductor 203j (e.g., at a mid-height of the middle portion 410) and the outer surface of the lowermost conductor 203a. IPN In the neutral state S N The middle portion 410 has a bending height H between 20 mm and 28 mm. IPN , preferably 23 mm. In addition, at least Fig.21 and 69 As shown in FIG. 1 , a bending length L of the middle portion 410 is defined between the opposite outer surfaces of the uppermost conductor 203 j (eg, at a mid-length of the middle portion 410 ). IPN In the neutral state S N The middle portion 410 has a bending length L between 23 mm and 31 mm. IPN, and preferably 27 mm. In other words, the design of the busbar 200 includes a certain range (i.e., the middle portion 410) that intentionally increases the height and space required to install the busbar 200 within the power distribution assembly 50. This increased space requirement is contrary to the goal of minimizing the space required for the electrical connector. Therefore, this is an unconventional solution to the problems associated with the material conditions associated with the battery module 60 and the dynamic movement of the battery module 60. It should be understood that the present disclosure contemplates other ratios or calculations based on the above table.

[0185] Table 1 (above) shows the activation force F provided by the battery modules 62a, 62b. A , the activation force F A Make the bus 200 in the neutral state S N and compression state S C In between or neutral state S N and the extended state S E Since the busbar 200 has a linear response, it is similar to the neutral state S N and the extended state S E Compared with the neutral state S N and the compression state S C When moving between A are equal in magnitude but opposite in direction. Therefore, depending on the situation, the activation force F A It can be the compression activation force F A Or expansion activation force F A In addition, as shown in Table 1 above, increasing the inner diameter of the middle portion 410 to more than 22 mm does not significantly reduce the pressure of the busbar 200 in the neutral state S N and the compression state S C Or extended state S E The activation force F required to move between A (first column), but the increase in the inner diameter significantly increases the overall packaging volume of the busbar 200, which represents the amount of space that needs to be reserved in the battery pack for installing and operating the elastically deformable connector system 100. For example, doubling the size of the inner diameter of the middle portion 410 from 10 mm to 20 mm increases the activation force F A From 312 N to 42 N, this is a reduction of more than seven times. However, increasing the size of the inner diameter of the middle section 410 from 20 mm to 30 mm only increases the activation force F A The reduction from 42 N to 30 N is more than a factor of 1.5. Therefore, an activation force F of less than 50 Newtons is required. A The configuration with the smallest package size to move between states is busbar 200 with an inner diameter of 20 mm. This relationship is considered to be the activation force F AIt should be understood that other busbar 200 configurations (e.g., materials, thickness, width, configuration of the middle section, weldments, etc.) may change the above calculations and / or change the ratios between the above characteristics. For example, increasing the thickness of each conductor 202 or the number of conductors 202 without changing other measurements will likely increase the cost of moving the busbar 200 from the neutral state S N Move to compressed state S C Or extended state S E Similarly, reducing the thickness of each conductor 202 or the number of conductors 202 without changing all other measurements will likely reduce the force required to move the busbar 200 from the neutral state S N Move to compressed state S C Or extended state S E The force required.

[0186] In addition, the volume of the middle portion 410 is greater than: (i) the volume of the peripheral portions 402a, 402b, and (ii) the volume of a connector replacing the middle portion 410, which connector is linear and extends between the peripheral portions 402a, 402b. In addition, the upper surface area of ​​the middle portion 410 (e.g., 1,233 mm 2 ) is greater than: (i) the surface area of ​​the peripheral portions 402a, 402b (e.g., 866 mm 2 ), and (ii) the surface area of ​​a connector that replaces the middle portion 410, which is linear and extends between the peripheral portions 402a, 402b. Therefore, the peripheral portions 402a, 402b contain less material than the following portions: (i) the middle portion 410, and (ii) the connector that replaces the middle portion 410, which is linear and extends between the peripheral portions 402a, 402b.

[0187] iv. Second range of selective soldering busbars

[0188] Next, the designer will: (i) insert the bent busbar 202 into the machine 192, and (ii) provide fusing instructions (e.g., load an engineering model) to the machine 192 associated with the second end sectors 207, 208b and the second range 212b of the busbar 200. The laser welding machine 192 will then perform the fusing process 180 described in its instructions. For example, Fig.19The busbar 200 is shown in a horizontal orientation, wherein the width of the busbar 200 lies in a plane oriented substantially perpendicular to the lasers 194, 196. In the horizontal orientation, the machine 192 performs a surface-based fusion process (i.e., a vertical partial penetration weldment process 182) on the end sector 207 of the busbar 200 in accordance with instructions associated with the second end sector 208b of the busbar 200. Next, the busbar 200 is rotated to a vertical orientation, wherein the thickness of the busbar 200 lies in a plane oriented substantially perpendicular to the lasers 194, 196. In the vertical orientation, the machine 192 performs an edge-based fusion process (i.e., a lateral partial penetration weldment process 184) on the second extent 212b of the busbar 200 in accordance with instructions associated with the second extent 212b. After selectively welding the second end sector 208b and the second extent 212b of the center sector 210, a Figure 20-24 The busbar shown in .

[0189] v. Optional Manufacturing Steps

[0190] After completing the above welding process, optional manufacturing steps may be completed. For example, completing the optional manufacturing steps may include: (a) assembling and coupling the connector 1000 to the busbar 200, (c) insulating the busbar 200, (d) electroplating the range of the busbar 200 and / or placing the busbar 200 in the housing 600.

[0191] B. Male Connector Assembly

[0192] refer to Fig.15 , the male connector assembly 1000 is composed of: (i) a housing assembly 1100, and (ii) a male terminal assembly 1430 having a spring member 1440c and a male terminal 1470. The male terminal assembly 1430 is coupled to the first and second peripheral portions 402a, 402b of the busbar 200 using any known coupling process (including laser welding and / or ultrasonic welding). It should be understood that the connector assembly 1000 is an example of a potential connector that can be coupled to the busbar 200. The present disclosure contemplates the use of other connectors, including conventional bolt connectors.

[0193] i. Male housing assembly

[0194] The male housing assembly 1100 covers or surrounds the majority of the other components contained within the male terminal assembly 1430. The outer housing assembly 1100 generally includes: (i) an outer housing 1104 and (ii) a deformable connector position assurance ("CPA") 1170. The outer housing 1104 includes two wall arrangements, wherein: (i) a first side wall arrangement 1106 has a rectangular shape and is designed to receive the extent of the busbar 200, and (ii) a second side wall arrangement 1108 has a cubic shape and is designed to receive the majority of the male terminal assembly 1430. The second wall arrangement 1108 includes a non-deformable CPA receiver 1160 extending from at least one wall 1108b, and preferably from both walls 1108d, and is designed to receive the extent of the deformable CPA 1170. Both wall arrangements are generally formed of an insulating material designed to isolate the current flowing through the male connector assembly 1000 from the other components. Additional details regarding the outer housing assembly 1100 are described in PCT / US2019 / 36070. It should be understood that the male housing assembly 1100 does not include a lever for assisting in coupling the male connector assembly 1000 to the female connector assembly 2000.

[0195] ii. Male terminal assembly

[0196] Figure 25-30 Various views of a male terminal assembly 1430 are provided, wherein the assembly 1430 includes a spring member 1440c and a male terminal 1470. The male terminal 1470 includes a male terminal body 1472 and a male terminal connecting member or plate 1474. The male terminal body 1472 includes: (i) a first or front male terminal wall 1480 having an anti-touch post opening 1510 formed therein, (ii) an arrangement of male terminal side walls 1482a-1482d, and (iii) a second or rear male terminal wall 1484. The combination of these walls 1480, 1482a-1482d forms a spring receiver 1486 that is designed to receive an internal spring member, male spring member, or second spring member 1440c.

[0197] refer to Fig.26, the inner spring member 1440c includes an arrangement of spring member side walls 1442a-1442d and a rear spring wall 1444. Each of the arrangement of spring member side walls 1442a-1442d is comprised of: (i) a first or arched spring segment 1448a-1448d, (ii) a second, bottom or intermediate spring segment 1450a-1450d, (iii) a third segment or spring arm 1452a-1452h, and (iv) a fourth segment or centering device 1453. The arched spring segments 1448a-1448d extend between the rear spring wall 1444 and the bottom spring segments 1450a-1450d, and position the bottom spring segments 1450a-1450d substantially perpendicular to the rear spring wall 1444. In other words, the outer surface of the bottom spring segments 1450a - 1450d is substantially perpendicular to the outer surface of the rear spring wall 1444.

[0198] The bottom spring sections 1450a-1450d are located between the arched sections 1448a-1448d and the spring arms 1452a-1452h. Fig.26 As shown in , the bottom spring sections 1450a-1450d are not connected to each other, and therefore a gap is formed between the bottom spring sections 1450a-1450d of the spring member 1440c. The gap facilitates omnidirectional expansion of the spring arms 1452a-1452h, which facilitates mechanical coupling between the male terminal 1470 and the female terminal assembly 2430. The spring arms 1452a-1452h extend from the bottom spring sections 1450a-1450d of the spring member 1440c, away from the rear spring wall 1444, and terminate at a free end 1446. The spring arms 1452a-1452h are generally planar and are positioned so that the outer surface of the spring arms 1452a-1452h is coplanar with the outer surface of the bottom spring sections 1450a-1450d. Comparison with PCT / US2018 / 019787 Figure 4-8 Unlike the spring arms 31 disclosed in PCT / US2018 / 019787, the free ends 1446 of the spring arms 1452a-1452h do not have a curvilinear component. Instead, the spring arms 1452a-1452h have a substantially flat outer surface. This configuration is beneficial because it ensures that the force associated with the spring member 1440c is applied to the free end 1488 substantially perpendicular to the male terminal body 1472. In contrast, the Figure 4-8 The curvilinear component of the spring arm 31 disclosed in does not exert force in this manner.

[0199] As with the bottom spring portions 1450a-1450d, the spring arms 1452a-1452h are not connected to each other. In other words, the spring arm opening extends between the spring arms 1452a-1452h. This configuration allows the spring arms 1452a-1452h to move omnidirectionally, which facilitates the mechanical coupling between the male terminal 1470 and the female terminal assembly 2430. In other embodiments, the spring arms 1452a-1452h can be coupled to other structures to limit their omnidirectional expansion. The number and width of each spring arm 1452a-1452h and the opening can vary. In addition, the widths of each spring arm 1452a-1452h are generally equal to each other; however, in other embodiments, one of the spring arms 1452a-1452h can be wider than the other spring arms.

[0200] The previous design of the spring member 1440pd is similar to that of PCT / US2019 / 36127 Figure 5-6 and PCT / US2021 / 043686 Fig.13 The associated disclosure shows how the spring member 1440pd is perfectly aligned within the male terminal body 1472pd of the male terminal assembly 1430pd. However, due to manufacturing tolerances and imperfect assembly methods, the spring member 1440pd may be misaligned or lifted within the male terminal body 1472pd during assembly of the male terminal assembly 1430pd. An example of this misalignment is shown in PCT / US2021 / 043686. Fig.14 , where the angle thetaθ illustrates this misalignment as it extends between the inner surface of the spring receiver and the outer surface of the spring member 1440pd. In certain embodiments, the angle thetaθ may be between 1 degree and 5 degrees. To help avoid this misalignment, the spring member 1440c disclosed herein includes a centering device 1453, which is shown as anti-rotation protrusions 1454a-1454d. Due to the interaction between the outer surfaces of the protrusions 1454a-1454d and the inner surfaces of the side wall portions 1492a-1492d of the male terminal body 1472, the anti-rotation protrusions 1454a-1454d help center the spring member 1440c by limiting the amount that the spring member 1440c can rotate within the male terminal body 1472. Properly centering the spring member 1440c within the male terminal body 1472 provides a number of advantages over a terminal that is not properly centered or aligned within the male terminal assembly 1430, including: (i) ensuring that the spring member 1440c applies an appropriate force on the male terminal body 1472 to provide a proper connection between the male terminal assembly 1430 and the female terminal assembly 2430, (ii) helping to improve the durability and useful life of the terminal assemblies 1430, 2430, and (iv) other beneficial features disclosed herein or that may be inferred from the present disclosure by a person of ordinary skill in the art.

[0201] It should be understood that in other embodiments, the centering or alignment means 1453 may take other forms, such as: (i) a protrusion extending outwardly from the first and second spring arms 1452a, 1452b located within a single side wall, (ii) a protrusion extending outwardly from the first and fifth spring arms 1452a, 1452e, wherein the protrusions are diagonally opposite to each other, (iii) a protrusion extending outwardly from all of the spring arms 1452a-1452h, wherein the protrusions associated with 1452c, 1452d, 1452g, 1452h have an offset positional relationship compared to the protrusions associated with 1452a, 1452b, 1452e, 1452f, (iv) a protrusion extending inwardly from the inner wall of the male terminal body 1472, (v) a protrusion extending inwardly from the contact arms 1494a-1494h toward the center of the connector, (vi) a spring retainer of a matching size, (vii) A range of protrusions, tabs, grooves, notches or other structures designed to help ensure that the spring member 1440c is centered within the male terminal body 1472 and cannot rotate within the spring receiver 1486. ​​For example, the protrusions can extend from the front wall or the rear wall of the male terminal body 1472, and they can be received by the openings formed in the spring member 1440c.

[0202] It should be further understood that the centering device 1453 can be based on force, rather than utilizing a mechanical-based centering or alignment device 1453, where such forces that can be utilized are magnetic or chemical forces. In this example, the rear wall of the spring member 1440c can be welded to the rear wall of the male terminal body 1472. Compared with the mechanical or force-based centering device 1453, the centering device 1453 can be a method or process for forming the male terminal assembly 1430. For example, the centering device 1453 may not be a structure, but the spring member 1440c can be printed simultaneously in the male terminal body 1472 in a manner that does not require assembly. In other words, the centering device 1453 can take a variety of forms (e.g., mechanical, force-based, or process-based) to achieve the purpose of centering the spring member 1440c in the male terminal body 1472.

[0203] The inner spring member 1440c is typically formed from a single piece of material (e.g., metal); therefore, the spring member 1440c is a one-piece spring member 1440c or has integrally formed features. In particular, the following features are integrally formed: (i) arched spring sections 1448a-1448d, (ii) bottom spring sections 1450a-1450d, (iii) spring arms 1452a-1452h, and (iv) centering device 1453. To integrally form these features, the spring member 1440c is typically formed using a die-casting process. The die-casting process mechanically forces the spring member 1440c into shape. As discussed in more detail below and in PCT / US2019 / 036010, when the spring member 1440c is formed of a metal plate, mounted within the male terminal 1472 and connected to the female socket 2472 and subjected to high temperatures, the spring member 1440c exerts an outwardly directed spring thermal force S on the contact arms 1494a-1494h. TF , in part because the spring member 1440c attempts to return to the plate. However, it should be understood that other types of forming the spring member 1440c may be utilized, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the spring member 1440c may not be formed from one piece or integrally formed, but rather from separate pieces that are welded together.

[0204] In an alternative embodiment not shown, the spring member 1440c may include a notch and associated reinforcing ribs. As discussed in PCT / US2019 / 036010, these changes in the configuration of the spring member 1440c change the force associated with the spring member 1440c. In particular, the spring biasing force S BF is the magnitude of the force applied by the spring member 1440c to resist the inward deflection of the free end 1446 of the spring member 1440c when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. Specifically, this inward deflection occurs during the insertion of the male terminal assembly 1430 due to the fact that the extent of the outer surface of the male terminal body 1472 is slightly larger than the interior of the female receptacle 2472. Therefore, when the male terminal assembly 1430 is inserted into the female terminal assembly 2430, the extent of the outer surface is forced toward the center 1490 of the male terminal 1470. This inward force on the outer surface causes the free end 1446 of the spring member 1440c to displace inward (i.e., toward the center 1490). The spring member 1440c provides a spring biasing force S F to resist this inward displacement.

[0205] Figure 27-30A male terminal 1470 is shown, which includes a male terminal body 1472 and a male terminal connection plate 1474. Specifically, the male terminal connection plate 1474 is coupled to the male terminal body 1472 and is configured to receive a range of structures (e.g., busbars) that connect the male terminal assembly 1430 to a device (e.g., a second battery module 60) external to the connector system 100. The conductor 202 is typically welded to the connection plate 1474; however, the present disclosure contemplates other methods of connecting the conductor 202 to the connection plate 1474 (e.g., forming the conductor 202 as part of the connection plate 1474).

[0206] like Figure 27-30 As shown in , the arrangement of male terminal side walls 1482a-1482d is coupled to each other and generally forms a rectangular prism. The arrangement of male terminal side walls 1482a-1482d includes: (i) side wall portions 1492a-1492d, which generally have a "U-shaped" configuration, (ii) contact arms 1494a-1494h, and (iii) a plurality of contact arm openings 1496a-1496l. As shown in Figure 28-29 As best shown in the accompanying drawings, the side wall portions 1492a-1492d are substantially flat and have a U-shaped configuration. The U-shaped configuration is formed by three substantially linear segments, wherein the second or middle segment 1500a-1500d is coupled to the first or end segment 1498a-1498d at one end and to the third or opposite end segment 1502a-1502d at the other end. The contact arms 1494a-1494h extend: (i) from the middle segment 1500a-1500d of the side wall portions 1492a-1492d, (ii) away from the rear male terminal wall 1484, (iii) across the contact arm openings 1496a-1496l, and (iv) terminate just forward of the front male terminal wall 1480. This configuration is superior to that of PCT / US2018 / 019787 Figure 9-15 , 18, 21-31, 32, 41-42, 45-46, 48 and 50 because it allows: (i) the overall length to be shorter, which means that less metal material is required to form and the male terminal 1470 can be installed in a narrower and more confined space, (ii) having a higher current carrying capacity, (iii) being easier to assemble, (iv) because the contact arms 1494a-1494h are located inside the first male terminal side wall portions 1492a-1492d, the structural rigidity is improved, (iv) the benefits disclosed in connection with PCT / US2019 / 036010, and (v) other beneficial features disclosed herein or that can be inferred from the present disclosure by a person of ordinary skill in the art.

[0207] The contact arm openings 1496a-1496l are integrally formed with the central sectors 1500a-1500d of the male terminal side walls 1482a-1482d. The contact arm openings 1496a-1496l extend along the lateral length of the contact arms 1494a-1494h so as to form a configuration that allows the contact arms 1494a-1494h to not be laterally connected to: (i) another contact arm 1494a-1494h or (ii) a structure other than the confines of the male terminal side wall portions 1492a-1492d to which the contact arms 1494a-1494h are coupled. In addition, the contact arm openings 1496a-1496l are aligned with the spring arm openings. This opening configuration forms the same number of spring arms 1452a-1452h as the number of contact arms 1494a-1494h. In other words, Fig.28 Eight spring arms 1452a-1452h and eight contact arms 1494a-1494h are shown. It should be understood that in other embodiments, the number of spring arms 1452a-1452h may not match the number of contact arms 1494a-1494h. For example, there may be less than one spring arm 1452a-1452h.

[0208] The contact arms 1494a-1494h extend from the rear male terminal wall 1484 at an outward angle. In particular, the outward angle between the outer surface of the range of male terminal side walls 1492a-1492d and the outer surface of the first range of contact arms 1494a-1494h can be between 0.1 degrees and 16 degrees, preferably between 5 degrees and 12 degrees, and most preferably between 7 degrees and 8 degrees. This outward angle is shown in multiple figures, but in combination Figure 28-29 This configuration allows the contact arms 1494a-1494h to deflect or displace inwardly through the female receptacle 2472 and toward the center 1490 of the male terminal 1470 when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. In particular, the male terminal body 1472 has an outer perimeter extending around the outermost extent of the contact arms 1494a-1494h. In the disconnected state S D (ie, when the male terminal body 1472 is not inserted into the female terminal assembly 2430), the outer circumference of the male terminal body has an uncompressed dimension. FC (That is, when the male terminal body 1472 is inserted into the female terminal assembly 2430 (see Fig.73 )), the outer perimeter of the male terminal body has a compressed dimension. And wherein the compressed dimension is smaller than the uncompressed dimension. In the embodiment of the present disclosure, due to the configuration and design of the male terminal body 1472 and the female terminal body 2430, the uncompressed dimension is 1% to 15% larger than the compressed dimension. Fig.741472, which is evidenced by the gap 1550. This inward deflection helps to ensure that the proper mechanical and electrical connection is created by ensuring that the contact arms 1494a-1494h are placed in contact with the female socket 2472.

[0209] like Figure 27-29 As shown in , the terminal ends of the contact arms 1494a-1494h are positioned: (i) within the aperture formed by the U-shaped side wall portions 1492a-1492d, (ii) substantially parallel to the male terminal side walls 1492a-1492d, and (iii) contacting the planar outer surfaces of the spring arms 1452a-1452h when the spring member 1440c is inserted into the spring receiver 1486. ​​This configuration is superior to the configuration of PCT / US2018 / 019787 Figure 3-8 The configuration shown in , because the assembler of the male terminal assembly 1430 does not have to apply a large force to deform a large portion of the contact arms 1494a-1494h outward to receive the spring member 1440c. Due to the inclination of the contact arm 11 and the fact that the outer surface of the spring arm 31 and the inner surface of the contact arm 11 are adjacent to each other without forming a gap therebetween, the required deformation can be achieved within the scope of PCT / US2018 / 019787. Figure 6 The best illustration is shown in PCT / US2018 / 019787. Figure 3-8 In comparison, the Fig.30 A very small gap is shown formed between the outer surface of the spring member 1440c and the inner surface of the contact arms 1494a-1494h. Therefore, very little force is required to insert the spring member 1440c into the spring receiver 1486 due to the fact that the assembler does not have to force the contact arms 1494a-1494h to deform significantly during the insertion of the spring member 1440c.

[0210] The male terminal 1470 is typically formed from a single piece of material (e.g., metal); therefore, the male terminal 1470 is a one-piece male terminal 1470 and has features that are integrally formed. In order to form these features integrally, the male terminal 1470 is typically formed using a die cutting process. However, it should be understood that other types of methods of forming the male terminal 1470 may be utilized, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the male terminal 1470 may not be formed from a single piece or integrally formed, but rather from separate pieces that are welded together. When forming the male terminal 1470, it should be understood that any number (e.g., between 1 and 100) of contact arms 1494a-1494h may be formed within the male terminal 1470.

[0211] Positioning the internal spring member 1440c within the male terminal assembly 1430 occurs across multiple steps or stages. Fig. 27 Provide disassembled state S DAThe first embodiment of the male terminal assembly 1430, Fig.28 Supplied partially assembled PA The first embodiment of the male terminal assembly 1430, and Fig.29 Supplied fully assembled FA The first embodiment of the male terminal assembly 1430 in FIG. The first stage of assembling the male terminal assembly 1430 is when the front male terminal wall 1480 is in an open or flat position P O , and the spring member 1440c is separated from the male terminal 1470. In the open position P O , the front male terminal wall 1480 is substantially coplanar with one of the male terminal side walls 1482c. This configuration of the male terminal 1470 exposes the spring receiver 1486 and places the male terminal 1470 in a state ready to receive the spring member 1440c. Fig.28 14 shows a second stage of assembling the male terminal assembly 1430, wherein the front male terminal wall 1480 is maintained in an open or horizontal position P O , and the spring member 1440c is located in or inserted into the spring receiver 1486. ​​In order to achieve the partially assembled state S PA , insertion force F I An insertion force F has been applied to the spring member 1440c to insert the spring member 1440c into the spring receiver 1486. I applied to the spring member 1440c until the second or rear male terminal wall 1484 is positioned adjacent to the rear spring wall 1444, the free end 1488 of the male terminal 1470 is substantially aligned with the free end 1446 of the spring member 1440c, and a portion of the male terminal side walls 1482a-1482d are positioned adjacent to a portion of the spring member side walls 1442a-1442d.

[0212] Fig.29 The third stage of assembling the male terminal assembly 1430 is shown in FIG. 1 , wherein: (i) the front male terminal wall 1480 is closed or vertically P CL , and (ii) the spring member 1440c is located in the spring receiver 1486. ​​To close the front male terminal wall 1480, the upwardly directed force F U The front male terminal wall 1480 is applied to bend it about its seam, thereby placing it adjacent to the side walls 1482a-1482d. After the front male terminal wall 1480 is in the correct position, the top edge is coupled (e.g., welded) to the side wall 1480 of the male terminal body 1472. Here, the closed or vertical P of the front male terminal wall 1480 CLEnsure that the spring member 1440c is retained within the male terminal 1470. It should be understood that in other embodiments, the front male terminal wall 1480 may be omitted, may not have an anti-touch post opening therethrough, may not fully extend from the side walls 1482a-1482d (e.g., partially extend from any side wall 1482a-1482d), or may be a separate piece coupled to both side walls 1482a-1482d.

[0213] After assembling the male terminal assembly 1430, the manufacturer will perform the next step of coupling the male terminal assembly 1430 to the end sector 207 of the busbar 200. The coupling of these terminal assemblies 1430 can be accomplished by any known means, including laser welding (e.g., a surface-based vertical partial penetration weldment process). Once the terminal assembly 1430 is coupled to the busbar 200, the elastically deformable conductive assembly 350 is assembled, and as shown in FIG. Figure 31-35 From here, the male housing assembly 1100 can be installed around the elastically deformable conductive assembly 350. The installation of the male housing assembly 1100 results in the formation of Figure 36-40 Although many steps are disclosed herein in a particular order, it should be understood that the order of the steps is not important for the formation of the system 100. In other words, the steps of the present disclosure may be performed in any order, and certain steps may be skipped or combined.

[0214] C. Female Connector Assembly

[0215] refer to Fig.55 , 60 , 63, 65 and 66, each battery module 60 includes two female connector assemblies 2000, one of which is a negative female connector assembly 2000a, and the other female connector assembly 2000 is a positive female connector assembly 2000b. The female connector assembly 2000 is composed of: (i) a female housing 2100 and (ii) a female terminal assembly 2430. The female housing 2100 is designed to: (i) receive the female terminal assembly 2430, (ii) facilitate the coupling of the male terminal assembly 1430 with the female terminal assembly 2430, (iii) minimize the possibility of foreign matter accidentally contacting the female terminal assembly 2430, and (iv) meet industry performance and reliability standards, such as USCAR specifications.

[0216] The female housing 2100 includes a wall structure 2110 having four side walls 2112a-2112d. The side walls 2112a-2112d extend upward from the upper surface of the support structure and have a configuration that substantially matches the configuration of the female terminal assembly 2430. In the embodiment shown in the figure, the female terminal assembly 2430 has a cubic configuration, and therefore the side walls 2112a-2112d have a linear configuration and form a cubic receiver. However, it should be understood that changes to the shape of the female terminal assembly 2430 (e.g., using cylindrical terminals) may require changes in the shape and configuration of the side walls 2112a-2112d to reflect the shape of the terminal (e.g., a hollow cylinder).

[0217] The side walls 2112a-2112d have a height that is greater than the height of the female terminal assembly 2430. The difference between these heights allows the side walls 2112a-2112d to include at least one male compression device 2140. As shown in the figure, the male compression device 2140 is an inclined or ramped surface 2144 that extends from the outermost edges 2120a-2120d of the side walls 2112a-2112d to the uppermost edges 2430a-2430d of the female terminal assembly 2430. In the disclosed embodiment, the inclined or ramped surface 2144 extends from each of the outermost edges 2120a-2120d and has a substantially linear configuration. However, it should be understood that the inclined or ramped surface 2144 may extend from only one or two of the outermost edges 2120a-2120d. The male compression device 2140 and the inclined or ramped surface 2144 shown in the figure are designed to be when the male terminal assembly 1430 is from the disconnected state S D Separate from the female terminal assembly 2430 and move to the fully connected state S FC The contact arms 1494a-1494h are compressed when they are within the range of the female terminal assembly 2430 (see Fig.73 ). Thus, the distance between the opposing outermost edges 2120a-2120d is equal to the sidewall distance, wherein the sidewall distance is greater than the last edge distance extending between the opposing last edges 2124a-2124d of the inclined or ramped surface 2144. And wherein the last edge distance is greater than or equal to the receiver distance extending between the opposing inner surfaces 2434a-2434d of the socket 2472 of the female terminal assembly 2430. In particular, the sidewall distance is between 0.1% and 15% greater than the receiver distance, and wherein the receiver distance is equal to or greater than the last edge distance by between 0.1% and 3%. In other words, the inclined or ramped surface 2144 is at a certain angle relative to the outer surface of the sidewalls 2112a-2112d and / or the inner surface 2434a-2434d of the socket 2472 of the female terminal assembly 2430. In particular, the interior angle between the inner surface of the inclined or ramped surface 2144 and the outer surface of the sidewalls 2112a - 2112d is between 0.1 degrees and 10 degrees.

[0218] The inclined or ramped surface 2144 is made of a polymer or plastic material and therefore has a coefficient of friction that is lower than the coefficient of friction associated with a metal surface. In other words, when the range of the boltless male terminal assembly 1430 (e.g., the contact arms 1494a-1494h) is engaged with the male terminal compression device 2140 formed of a non-metallic material (e.g., plastic), a first friction value is formed. In an alternative embodiment, if the range of the boltless male terminal assembly 1430 (e.g., the contact arms 1494a-1494h) is engaged with the male terminal compression device formed of a metallic material (e.g., copper), a second friction value will be formed. Comparing the friction values ​​from the disclosed embodiment with the friction values ​​in the alternative embodiment, it should be understood that the first or friction value from the disclosed embodiment is less than the second or friction value in the alternative embodiment.

[0219] The lower coefficient of friction reduces the force required to insert the male terminal assembly 1430 into the female terminal assembly 2430. This is beneficial because: (i) industry specifications, including USCAR 25, require that the insertion force be no greater than 45 Newtons for Class 2 connectors and no greater than 75 Newtons for Class 3 connectors, and (ii) the use of a greater spring bias force (and thus increased insertion force) is expected to help ensure that the contact arms of the male terminal assembly maintain contact with the inner surfaces 2434a-2434d of the receptacle 2472 of the female terminal assembly 2430. In addition, the lower coefficient of friction is beneficial because the system 100 can be moved from the disconnected state S D Move to fully connected state S FC , while meeting Class 2 / Class 3 USCAR specifications without lever assistance. Eliminating the lever assistance can reduce the size, weight, and manufacturing cost of the connector system 100. It should be understood that to further reduce the coefficient of friction, the inclined or ramped surface 2144 can be coated with a substance that reduces the coefficient, or the inclined or ramped surface 2144 can be made of a material with an even lower coefficient of friction.

[0220] Due to the configuration of the male and female connector assemblies 1000, 2000, when the connector system 100 is removed from the disconnected state S D Move to fully connected state S FCDifferent levels of force are required during various stages of the male terminal assembly 1430. For example, when the range of the male terminal assembly 1430 (e.g., the contact arms 1494a-1494h) is in sliding engagement with the male terminal compression device 2140, a first force is required to move the male terminal assembly 1430, and when the range of the male terminal assembly 1430 (e.g., the contact arms 1494a-1494h) is located in the female terminal receiver 2473, a second force is required to move the male terminal assembly 1430. Comparing these forces, it should be understood that the second force is less than the first force. This is beneficial because it provides strategic feedback to the user to inform the user that the male terminal assembly 1430 has been properly installed in the female terminal assembly 2430. In fact, this strategic feedback appears to the user as if the boltless male terminal assembly 1430 is pulled into the female terminal assembly 2430.

[0221] To minimize the possibility of foreign matter accidentally contacting the female terminal assembly 2430, the housing 2100 may include an optional anti-touch post 2200. As disclosed in PCT / US2019 / 036070, the anti-touch post 2200 is configured to fit within the anti-touch post opening 1510 formed in the front wall of the male terminal 1470. In particular, the distance between the outermost edges 2120a-2120d of the side walls 2112a-2112d and the outermost edges 2215 of the anti-touch post 2200 is less than 10 mm, and preferably less than 6 mm. The shape of the anti-touch post opening 1510 is configured to be substantially mirrored with the shape of the anti-touch post 2200. Here, the anti-touch probe opening 1510 has a substantially rectangular shape, and more specifically, a substantially square shape, while the anti-touch post 2200 is in the form of an elongated rectangular prism with two notches formed on opposite sides of the prism. The mirroring of these shapes helps ensure that the anti-touch post 2200 is properly inserted into the anti-touch probe opening 1510 and can reduce vibration between the male terminal assembly 1430 and the female terminal assembly 2430. The reduction in vibration between these components may help reduce malfunctions of the connector system. It should be understood that the anti-touch post 2200 and its associated opening 1510 can be omitted or can have another configuration (e.g., as disclosed in U.S. Provisional Application No. 63 / 222,859, which is incorporated herein by reference).

[0222] In order to minimize the variation in the way the male connector assembly 1000 can be disconnected from the female connector assembly 2000, the female connector assembly 2000 may include an optional non-deformable female CPA structure 2300 that is designed and configured to interact with the male CPA structure 1170 when the connector assemblies 1000, 2000 are coupled to each other. The non-deformable female CPA structure 2300 is integrally formed with the side walls 2112a-2112d of the housing 2100. Additional details regarding the structure and / or function of the female CPA structure 2300 are disclosed in PCTUS2019 / 036070, PCTUS2020 / 049870, PCTUS2021 / 033446, all of which are incorporated herein by reference.

[0223] The female terminal assembly 2430 of the female connector assembly 2000 is composed of a female terminal body 2432 having a plurality of side walls 2434a-2434d, which are integrally formed with a rear wall 2434e. Each of the side walls 2434a-2434d and the rear wall 2434e have inner surfaces 2436a-2436e, and the combination of the inner surfaces 2436a-2436e forms a cubic terminal socket 2472. The cubic terminal socket 2472 has a receiver distance extending between the inner surfaces 2436a-2436d of the opposite side walls 2434a-2434d. As described above, the receiver distance: (i) is less than the side wall distance, and (ii) is equal to or greater than the rear edge distance. In addition, the receiver distance is 0.1% to 15% less than the male terminal assembly distance extending between the outermost ranges of the relative contact arms 1494a-1494h. By forming the terminal socket 2472 with a receiver distance that is less than the male terminal assembly distance, it is ensured that the contact arms 1494a-1494h are compressed when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. This compression of the male terminal assembly 1430 compresses the internal spring member 1440c. Therefore, the spring member 1440c exerts an outwardly directed biasing force on the contact arms 1494a-1494h to help ensure that they remain in contact with the inner surfaces 2436a-2436d of the terminal socket 2472 to facilitate electrical and mechanical coupling of the male terminal assembly 1430 with the female terminal assembly 2430.

[0224] The female terminal assembly 2430 is typically made of metal, and is preferably made of a highly conductive metal such as copper. The female terminal assembly 2430 may be plated or coated with Ni-Ag to prevent corrosion of the busbar 200 during and / or after the female terminal assembly 2430 is welded to the busbar 200. As shown, the side walls 2434a-2434d are not integrally formed with each other, but are only integrally formed with the rear wall 2434e. In other embodiments, the female terminal assembly 2430 may have integrally formed side walls 2434a-2434d, the side walls 2434a-2434d may be made of different materials, and / or the female terminal assembly 2430 may not be plated or coated with Ni-Ag. Once the female terminal assembly 2430 is manufactured, it can be coupled to the busbar and installed in the female housing 2100.

[0225] D. Terminal Features and Functions

[0226] Fig.73 Depicts the fully connected state S FC 1000 is coupled to a female connector assembly 2000. Although the following disclosure is discussed in conjunction with an embodiment of the system 100, it should be understood that the disclosure is also applicable to other systems, including Figure 100-104 Other embodiments shown in . Fig.73 As best shown in FIG. 1 , one or more outer surfaces of the spring arms 1452a-1452d contact the free ends 1488 of the corresponding contact arms 1494a-1494d. As described above, the outermost extent of the contact arms 1494a-1494d is slightly greater than the inner extent of the female terminal body 2432. Therefore, when these components are mated with each other, the spring member 1440c is compressed. This compression of the spring member 1440c generates an outwardly directed biasing force S BF , against the contact arms 1494a-1494d, and away from the interior of the spring member 1440c.

[0227] The male terminal body 1472 (including the contact arms 1494a-1494d) can be formed of a first material, such as copper, a highly conductive copper alloy (e.g., C151 or C110), aluminum), and / or another suitable conductive material. The first material preferably has an electrical conductivity greater than 80% of IACS (International Annealed Copper Standard, i.e., an empirically derived standard value for the electrical conductivity of commercially available copper). For example, C151 typically has an electrical conductivity of 95% of standard pure copper that complies with IACS. Similarly, C110 has an electrical conductivity of 101% of IACS. In certain operating environments or technical applications, C151 may be preferably selected because it has corrosion protection characteristics required for high stress and / or severe weather applications. The first material of the male terminal body 1472 is C151, and is reported to have an elastic modulus (Young's modulus) of approximately 115-125 gigapascals (GPa) at room temperature and a terminal coefficient of expansion (CTE) of 17.6 ppm / degree Celsius (from 20 to 300 degrees Celsius) and 17.0 ppm / degree Celsius (from 20 to 200 degrees Celsius) according to the ASTM B747 standard.

[0228] The spring member 1440c may be formed of a second material, such as spring steel, stainless steel (e.g., 301SS, 1 / 4 hard), and / or another suitable material having greater stiffness (e.g., as measured by Young's modulus) and elasticity than the first material of the male terminal body 1472. The second material preferably has an electrical conductivity that is less than the electrical conductivity of the first material. The second material also has a Young's modulus that may be approximately 193 GPa at room temperature and a terminal coefficient of expansion (CTE) of 17.8 ppm / degree Celsius (from 0 to 315 degrees Celsius) and 16.9 ppm / degree Celsius (from 0 to 100 degrees Celsius). In the expected high voltage application, the cross-sectional area of ​​the copper alloy forming the first connector is balanced with the electrical conductivity of the selected copper alloy. For example, when a copper alloy with a lower electrical conductivity is selected, the contact arms 1494a-1494d formed thereby have a larger cross-sectional area in order to be sufficiently conductive. Likewise, selecting a first material having a higher electrical conductivity may allow the contact arms 1494a-1494d to have a relatively smaller cross-sectional area while still meeting electrical conductivity specifications.

[0229] In an exemplary embodiment, the CTE of the second material can be greater than the CTE of the first material, that is, the CTE of the spring member 1440c is greater than the CTE of the male terminal body 1472. Therefore, when the assembly of the male terminal body 1472 and the spring member 1440c is subjected to the high voltage and high temperature environment typically used in the electrical connector described in the present disclosure, the spring member 1440c expands relatively more than the male terminal body 1472. Therefore, the outward force S generated by the spring member 1440c on the contact arms 1494a-1494d of the male terminal body 1472 is greater than the CTE of the male terminal body 1472. BF It increases with increasing temperature and is referred to as thermal spring force S in the following text.TF .

[0230] Example applications of the present disclosure, such as for vehicle alternators, are suitable for deployment in Level 5 automotive environments, such as those found in passenger cars and commercial vehicles. Level 5 environments are typically located under the hood of a vehicle, such as an alternator, and exhibit ambient temperatures of 150 degrees Celsius, and typically reach 200 degrees Celsius. When copper and / or highly conductive copper alloys are subjected to temperatures above approximately 150 degrees Celsius, the alloy becomes forgeable and loses mechanical elasticity, i.e., the copper material softens. However, the steel forming the spring member 1440c maintains hardness and mechanical properties when subjected to similar conditions. Therefore, when both the male terminal body 1472 and the spring member 1440c are subjected to high temperatures, the first material of the male terminal body 1472 softens, while the structural integrity of the spring member 1440c formed of the second material is maintained, such that in the fully connected position S FC , the force applied by the spring member 1440c to the softened contact arms 1494a - 1494d more effectively moves the softened contact arms 1494a - 1494d outward relative to the interior of the male terminal body 1472.

[0231] The male terminal body 1472, the spring member 1440c, and the female terminal body 2432 are configured to maintain electrical conduction and mechanical engagement while withstanding the high temperatures and thermal cycles that the system 100 is subjected to due to high power, high voltage applications. In addition, the male terminal body 1472 and the female terminal body 2432 may experience thermal expansion due to the high temperatures and thermal cycles that the high voltage, high temperature applications cause, which increases the outwardly directed force that the male terminal body 1472 exerts on the female terminal body 2432. The configuration of the male terminal body 1472, the spring member 1440c, and the female terminal body 2432 increases the outwardly directed connection force therebetween while the connector system 100 is subjected to the connection position P. C Thermal expansion caused by thermal cycles in the environment.

[0232] Based on the above exemplary embodiments, the Young's modulus and CTE of the spring member 1440c are greater than the Young's modulus and CTE of the male terminal body 1472. Therefore, when the male terminal body 1472 is used in a high power application 10 that subjects the connector system 100 to repeated thermal cycles with high temperatures (e.g., approximately 150 degrees Celsius), then: (i) the male terminal body 1472 becomes forgeable and loses some mechanical elasticity, i.e., the copper material in the male terminal body 1472 becomes soft, and (ii) the spring member 1440c does not become as forgeable or lose as much mechanical stiffness as the male terminal body 1472.

[0233] Thus, when the spring member 1440c is mechanically cold formed (e.g., using a die forming process) and the spring member 1440c is subjected to high temperatures, the spring member 1440c will attempt to return to at least its uncompressed state, which occurs prior to inserting the male terminal assembly 1430 into the female terminal assembly 2430, and preferably to its original flat state, which occurs prior to forming the spring member 1440c. In doing so, the spring member 1440c will exert a generally outwardly directed thermal spring force S on the free ends 1488 of the contact arms 1494a-1494d. TF (like Fig.73 Marked as "S TF ”). The thermal spring force S TF Depending on the local temperature conditions in the environment where the system 100 is installed, including high and / or low temperatures. Therefore, the spring bias force S BF and thermal spring force S TF The combination of provides a composite biasing force S RBF , which ensures that when the male terminal assembly 2430 is inserted into the female terminal 2430 and during operation of the system 100, the outer surfaces of the contact arms 1494a-1494d are forced to contact the inner surface of the female terminal body 2432 to ensure electrical and mechanical connection. In addition, with repeated thermal cycling events, the male terminal assembly 1430 will generate a composite spring force S directed outward. RBF As a result of the increase in spring force, the resultant spring force is applied to the female terminal assembly 2430 during repeated operation of the system 100.

[0234] Fig.73 It is further shown in FIG. 1 that in the fully connected state S FC In the embodiment, the male terminal assembly 1430 provides the female terminal assembly 2430 with a 360° standard to ensure that a sufficient amount of outwardly directed force F is applied by the male terminal assembly 1430 to the female terminal assembly 2430. B, for electrical and mechanical connections in all four main directions. This property allows the omission of keying features and / or another feature designed to ensure the desired orientation of the components during connection. The 360°-compliant property of system 100 also helps maintain mechanical and electrical connections under severe mechanical conditions (such as vibration). In traditional blade or fork connectors that meet the 180° standard (i.e., connected only on two opposite sides), vibrations can produce harmonic resonances, which cause the connector that meets the 180° standard to oscillate with a larger amplitude at a specific frequency. For example, subjecting the fork connector to harmonic resonance may cause the fork connector to open. Opening the fork connector during electrical conduction is undesirable because the momentary mechanical separation of the fork connector from the associated terminal may cause an arc. The arc may have a significant negative impact on the 180°-compliant terminal and the entire electrical system of which the 180°-compliant terminal is a component. However, the 360°-compliant feature of the present disclosure can prevent possible catastrophic failures caused by strong vibrations and arcs.

[0235] As described above, it is desirable to form the male terminal 1470 with the same material as the female terminal body 2432 in order to: (i) help prevent corrosion and other degradation, (ii) reduce the resistance between these structures, and (iii) facilitate electrical and mechanical coupling of the structures. Therefore, in this exemplary embodiment, the male terminal body 1472 and the female terminal body 2432 are formed of copper. However, in order to utilize matching materials as the terminal bodies 1470, 2432 and avoid utilizing a bimetallic positive busbar, it should be understood that the bimetallic positive busbar can be replaced with an aluminum busbar, and the male terminal 1470 can also be made of aluminum. In this embodiment, the male terminal 1470 associated with the negative external connection can be formed of copper, the external busbar can be formed of copper, the positive busbar can be formed of aluminum, and the male terminal 1470 associated with the positive external connection can be formed of aluminum. In further embodiments, the battery cell 75 can have a different terminal configuration, wherein the material of the transmission structure 82 can utilize only a busbar made of a single material, and the male terminal body 1470 can be made of the same material.

[0236] E. Busbar housing

[0237] After the busbar 200 is manufactured and the terminal 1000 is coupled to the busbar 200, the busbar housing 600 can be coupled thereto to enclose the majority of the busbar 200 and complete the construction of the system 100. The busbar housing 600 is combined with at least Figures 41-47The present invention discloses a connector assembly 1000, and includes a first component 602a and a second component 602b, which are detachably coupled together via a coupler 597 (formed by a protrusion 598 and a receiver 599). When the first component 402a and the second component 402b are coupled together, they form a socket 604 designed to receive the busbar 200. The socket 604 has five different ranges, wherein the first range 606 is designed to receive a portion of the connector assembly 1000, the second range 608 is designed to receive a portion of the first peripheral connection portion 402a, the third range 610 is designed to receive the elastically deformable middle portion 410, the fourth range 612 is designed to receive a portion of the second peripheral connection portion 402b, and the fifth range 614 is designed to receive a portion of the connector assembly 1000. The first range 606 and the fifth range 614 are designed to ensure that the male terminal 1430 and its housing 1100 can be in a compressed state S C and the extended state S E The first range 606 and the fifth range 614 of the socket 604 can be moved laterally (eg, slidably) between the sockets 604 without exposing the busbars 200 or compressing the housing 600. Thus, the first range 606 and the fifth range 614 of the socket 604 have a depth of approximately 11 mm.

[0238] The second range 608 and the fourth range 612 of the receptacle 604 match the configuration of the first peripheral connection portion 402a and the second peripheral connection portion 402b of the busbar 200 and have a height of about 2-7 mm. Therefore, the height and length of the third range 610 of the receptacle 604 are greater than the height and length of the elastically deformable middle portion 410, and are therefore designed to allow elastic deformation of the middle portion 410 without interfering with or hindering the movement of the busbar 200. In other words, the third range 610 of the receptacle 604 has a volume large enough to allow the elastically deformable middle portion 410 to deform within the volume without restricting or affecting the deformation.

[0239] The housing 600 is preferably made of non-conductive plastic and is designed to isolate and protect the elastically deformable conductive assembly 350 from other foreign objects. The configuration and material selection of the housing 600 are designed to isolate the busbar 200 while still allowing the busbar 200 to deform elastically in all directions (e.g., X, Y, Z and rotation). In other words, the housing 600 can be bent or moved as needed without damaging, destroying or reducing the performance of the busbar 200. Components 602a, 602b are symmetrical and coordinated in size with each other to reduce the number of parts and simplify the manufacture / assembly of the system 100. However, in other embodiments, components 602a, 602b may be different from each other. It should be understood that the present disclosure contemplates other housing 600 configurations. For example, in certain applications, such as installations with a controlled operating environment, the housing 600 can be omitted.

[0240] II. First Embodiment of Battery Pack

[0241] Figure 53-71 A first embodiment of a battery pack 90 is shown, which includes a plurality of battery modules 60 and a plurality of elastically deformable battery module connector systems 100. In particular, the battery pack 90 includes ten battery modules 60 (62a-62j) that are electrically coupled to each other using nine elastically deformable battery module connector systems 100 (where the specific number of elastically deformable battery module connector systems is labeled 102a-102i).

[0242] A. Battery Module

[0243] like Figure 58-67 As shown in FIG. 1 , each of the ten battery modules 60 ( 62 a - 62 j ) generally includes: (i) a battery module housing 64 , (ii) battery cells 75 , and (iii) an electrical transmission assembly 82 .

[0244] i. Battery module housing

[0245] The battery module housing 64 includes a plurality of walls 66 (e.g., an arrangement of four side walls 68a-68d, a bottom wall 70a, and a top wall 70b) that form a receiver 72 configured to receive and protect: (i) a battery cell 75 and (ii) an electrical transmission assembly 82. The top wall 70b includes at least two battery module openings 73a, 73b formed therethrough, wherein the openings 73a, 73b are configured to allow the female connector assemblies 2000a, 2000b to be coupled to a range of the electrical transmission assembly 82. In particular, current is configured to flow through the battery module openings 73a, 73b via the connection between the female connector assemblies 2000a, 2000b and the electrical transmission assembly 82. Although the female connector assemblies 2000a, 2000b are shown in conjunction with the first embodiment of the battery module 60, it should be understood that the present disclosure contemplates the use of other connectors (e.g., bolted, clamped, press-fit). For example, a bolted connector is disclosed in conjunction with the second embodiment of the battery module 60.

[0246] ii. Battery Cell

[0247] Figure 58-67The battery module 60 is shown to include a plurality of cylindrical battery cells 75, wherein each battery cell 75 includes: (i) a housing 77, (ii) a positive terminal 80a, and (iii) a negative terminal 80b. The housing 77 has a longitudinal surface 78 and is designed to enclose and retain a material that stores a charge, such as lithium or other similar metal. The positive terminal 80a and the negative terminal 80b couple the material contained within the housing 77 to an electrical transmission assembly 82. The terminals 80a, 80b can have a button shape configuration; however, other terminal shapes are possible (e.g., boltless connectors, bolted connectors, tabs, other structures that can be welded, press-fitted, or clamped by the electrical transmission assembly 82). The positive terminal 80a and the negative terminal 80b are typically formed of different materials to facilitate charging and discharging of the battery cell 75. For example, the positive terminal or anode 80a may be formed of (i) graphite, (ii) silicon, or (iii) graphene, while the negative terminal or cathode 80b may be formed of (i) cobalt, (ii) iron, (iii) nickel magnesium, (iv) nickel, or (v) sulfur. It should be understood that other materials may be used for the terminals. The battery cell 75 can have an output voltage between 0.2 volts and 10 volts, a rated ampere-hour between 10 amps and 100 amps, and can have an energy density between 20 Wh / kg and 500 Wh / kg (see Qiao, Y., et. al. A 500 Wh / kg Lithium-Metal Cell Based on Anionic Redox. Joule, this issue, 1445–1458, and Jason B. Quinnet al., Paper Review: Energy Density of Cylindrical Li-Ion Cells: A Comparison of Commercial 18650 to the 21700 Cells 2018 J. Electrochem. Soc. 165 A3284, both of which are incorporated herein by reference). Examples of cylindrical battery cells 75 include: (i) 18650 (i.e., 18 mm diameter and 65 mm length), 21700 (i.e., 21 mm diameter and 70 mm length), 4680 (i.e., 46 mm diameter and 80 mm length). It should be understood that the battery cells 75 may use a variety of different technologies and / or materials, including: (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) lithium polymer, (v) lithium ion, or (vi) batteries using other materials (e.g., LiO2, AlO2, LiS, LTO, LFP, NMC, NCA).Furthermore, the battery cells may have any known configuration, including cylindrical, prismatic, pouch, or any shape disclosed in U.S. Pat. Nos. 10,948,000, 10,429,006, 10,220,881, 10,473,177, 10,538,271, 10,300,947, 9,789,906, 9,889,887, 9,944,323, all of which are incorporated herein by reference.

[0248] iii. Electrical transmission components

[0249] Figure 58-67 An electrical transmission assembly 82 is shown located within each of the battery modules 60, which couples: (i) a first layer 83a of battery cells 75 with a second layer 83b of battery cells 75, (ii) battery cells 75 contained in the first layer 83a and the second layer 83b to each other, and (iii) female connector assemblies 2000a, 2000b to the battery cells 75. As shown in this embodiment, each of the first layer 83a and the second layer 83b includes approximately 132 battery cells 75 arranged in a vertical orientation relative to the XY plane. The vertical orientation places the following into position: (i) the positive terminal 80a and the negative terminal 80b in a plane substantially parallel to the XY plane, and (ii) the longitudinal surface 78 of the cell 75 is substantially parallel to the XZ plane or the YZ plane. Therefore, the conductive plate 84 can be positioned in the XY plane and coupled to the positive terminal 80a and the negative terminal 80b of the cell 75. In particular, the coupling plate 84 has notches cut therein to assist in laser welding the button-shaped terminals 80a, 80b to the plate 84. Although the present embodiment discloses the above configuration of the battery cells 75 and the associated component electrical transmission assembly 82, it should be understood that in other embodiments, the electrical transmission assembly 82 can have a different configuration. For example, the electrical transmission assembly 82 can be designed to couple any number of battery cells 75 to each other (e.g., between 2 and 1000), and to couple any number of battery cell layers 83a, 83b to each other (e.g., between 1 and 40 layers).

[0250] In addition, at least one female connector assembly 2000 is coupled to the board 84. Preferably, the board 84 of the power transmission assembly 82 is coupled to two female connector assemblies 2000a, 2000b, wherein: (i) the positive female connector assembly 2000b (a) is configured to provide a positive external connection of the battery module 60, and (b) is designed to receive a range of positive male terminal assemblies 1430, and (ii) the negative female connector assembly 2000a (a) is configured to provide a negative external connection of the battery module 60, and (b) is designed to receive a range of negative male terminal assemblies 1430. Although the battery module 60 shown in the figure includes two female connector assemblies 2000a, 2000b, it should be understood that the battery module 60 can have more or fewer female connector assemblies 2000. For example, the battery module 60 can have only a single female connector assembly 2000, or the battery module 60 can include more than ten female connector assemblies 2000.

[0251] B. Battery Pack

[0252] Fig.53 and 54 A first embodiment of a battery pack 90 is shown having a rectangular prism configuration and including: (i) a bottom wall 91, (ii) a first or left end wall 92a, (iii) a second or right end wall 92b, (iv) a first or top side wall 94a, (v) a second bottom side wall 94b, and (vi) a center divider 96 coupled to the first end wall 92a and the second end wall 92b and located between the first side wall 94a and the second side wall 94b. The combination of the walls 92a, 92b, 94a, 94b, 96 is arranged to form a first or top receiver 97a and a second or bottom receiver 97b, wherein the top receiver 97a and the bottom receiver 97b are designed to receive a range of battery modules 60 contained in the battery pack 90. ​​At least one of the walls 92a, 92b, 94a, 94b includes a pack connector opening formed therethrough, wherein the opening is configured to receive a range of connectors that facilitate charging and discharging of the battery pack 90. While PCT / US2021 / 043,686 discloses examples of such connectors that may be utilized, the present disclosure contemplates utilizing any known connector that may transfer current into and out of the pack. While the above disclosure focuses on openings designed to receive connectors that facilitate charging and discharging of the battery pack 90, it should be understood that other openings may be formed in the battery pack 90 to allow fluid transfer into and out of the battery pack 90 or to facilitate other mechanical or electrical connections within the battery pack 90.

[0253] The top receiver 97a of the battery pack 90 is configured to receive five battery modules 60 (62a-62e), while the bottom receiver 97b of the battery pack 90 is also configured to receive five battery modules 60 (62f-62j). In particular, the first battery module 62a is located in the top receiver 97a and is located between: (i) the first end wall 92a, (ii) the first side wall 94a, and (iii) the center divider 96. In other words, the first battery module 62a is bounded on three sides by the walls and dividers 92a, 94a, and 96. Like the first battery module 62a, the fifth battery module 62e is bounded on three sides by: (i) the second end wall 92b, (ii) the first side wall 94a, and (iii) the center divider 96. The sixth battery module 62f is also bounded on three sides by: (i) a second end wall 92b, (ii) a second side wall 94b, and (iii) a center divider 96, while the tenth battery module 62j is bounded on three sides by: (i) a first end wall 92a, (ii) a second side wall 94a, and (iii) a center divider 96. In contrast to the first, fifth, sixth, and tenth battery modules 62a, 62e, 62f, 62j, the second, third, and fourth battery modules 62b, 62c, 62d are located in a first receiver 97a and are bounded by only two sides: (i) a first side wall 94a, and (ii) a center divider 96. Finally, like the second, third, and fourth battery modules 62b, 62c, 62d, the seventh, eighth, and ninth battery modules 62g, 62h, and 62i are located in a second receiver 97b and are bounded by only two sides: (i) a second side wall 94b, and (ii) a center divider 96.

[0254] Although Fig.53 and 54 A battery pack 90 having a rectangular prism configuration and configured to accommodate ten battery modules 60 is shown, but it should be understood that the present disclosure is not limited to this design. Instead, the battery pack 90 can have any known configuration (e.g., any type of polygonal prism), including configurations in which the group 90 is built as part of a vehicle frame or chassis. It should also be understood that in other embodiments, the battery pack 90 can be configured to accommodate only a single battery module 60 or to accommodate more than one hundred individual battery modules 60. The battery cells 75 contained within the module 60 can be connected in parallel, in series, or any combination thereof. In addition, the battery modules 60 contained within the battery pack 90 can be connected in parallel, in series, or any combination thereof.

[0255] C. Battery module connections within the battery pack

[0256] Once the battery modules 60 (62a-62j) are positioned and secured in the receivers 97a, 97b of the battery pack 90, the battery modules 60 (62a-62j) can be coupled to each other using the elastically deformable battery module connector systems 100 of the present disclosure. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 100 (where the specific number of elastically deformable battery module connector systems is marked as 102a-102i). Each of the elastically deformable battery module connector systems 100 is coupled to the battery module 90 using a downwardly directed force (i.e., in the -Z direction). The configuration of the present disclosure places the bottom surface 215b of the peripheral portions 402a, 402b substantially parallel to each of the following: (i) the XY plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top wall 70a and the bottom wall 70b of the battery module housing 64, (iv) the upper surface of the conductive plate 84 of the transmission assembly 82, and (v) the range of the positive terminal 80a and the negative terminal 80b of the battery cell 75. In addition, the configuration places the bottom surface 215b of the peripheral portions 402a, 402b substantially perpendicular to each of the following: (i) the XZ plane, (ii) the YZ plane, (iii) the side walls and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 68a-68d of the battery module housing 64, and (iv) the longitudinal surface 78 of the battery cell 75. In addition, the configuration is such that the middle portion 410 extends downward from the plane of the peripheral portion in the -Z direction and is located between the fourth side wall 68d of the battery module 60 (e.g., 62a) and the side wall 68a of the adjacent battery module 60 (e.g., 62b). In addition, the length L of the busbar 200 is IPB The busbar 200 extends in a direction substantially parallel to the X-axis, while the width of the busbar 200 extends in a direction substantially parallel to the Y-axis.

[0257] This first embodiment of the elastically deformable battery module connector system 100 utilizes connector assemblies 1000, 2000 to be installed in a battery pack 90. ​​These connector assemblies 1000, 2000 allow connections between battery modules 60 to be: (i) boltless, (ii) PCT compliant, (iii) 360° compliant, (vi) fast and efficient compared to conventional battery pack connectors, (vii) simple and straightforward, requiring no special tools or machines, (viii) USCAR and other industry specifications compliant, (ix) lighter than conventional battery pack connectors, and (x) other benefits that will be apparent to one skilled in the art. Once the battery modules 60 and all other necessary components (e.g., battery management components, battery cooling or heating components, etc.) are installed in the battery pack 90, the pack 90 can be installed in the application 10.

[0258] D. Dynamic movement of battery modules

[0259] like Figure 53-54 As shown in , the battery pack 90 includes a plurality of modules 60, each of which will experience a range of dynamic motion during use of the battery pack 90, including during operation of the power distribution system in which the battery pack 90 is installed. Therefore, the forces applied to the connector system 100 contained in the battery pack 90 depend significantly on and are affected by the following behaviors: (i) the configuration of the other interconnected battery modules 90, including the battery cells 75 contained therein, (ii) the configuration of the battery pack 90, and (iii) the operating conditions of the battery pack 90, including the vehicle in which the battery pack 90 is installed. For example, the first group of five battery modules 62a-62e contained in the first socket 97a will at least substantially balance or completely balance the forces generated and applied to these modules 62a-62d by the expansion or contraction of the battery module connector system 102a-102d. Similarly, the second group of five battery modules 62f-62i contained in the second socket 97b will at least substantially balance or completely balance the forces generated and applied to these modules 62a-62d by the expansion or contraction of the battery module connector system 102f-102i. However, due to the configuration of the battery pack 90 (including the layout of the modules 62a-62j and the connector systems 102a-i), the forces applied between the first battery module 62a and the tenth battery module 62j will be affected by the walls 92a, 92b and the divider 96 and may be limited.

[0260] While the battery pack 90 will attempt to at least substantially balance or completely balance the forces exerted on the modules 62a-62d through expansion or contraction of the connector systems 102a-102d, it should be understood that the configuration of the battery pack 90 may limit the balance of these forces. For example, the first connector system 102a may be subject to different forces than the second connector system 102b due to (i) the coupling of the first battery module 62 to the end wall 92a, and (ii) the configuration of the walls 92a, 94a and dividers 96 of the battery pack 90. ​​Specifically, as Fig.54As shown in , the expansion or contraction of the first battery module 62a may be limited by the battery pack 90 in the following aspects: (i) the first direction or along the negative (-) X-axis is limited by the end wall 92a, (ii) the second direction or along the positive (+) Y-axis is limited by the top wall 94a, and (iii) the fourth direction or along the negative (-) Y-axis is limited by the center divider 96. Therefore, the battery pack 90 may only allow the first battery module 62a to expand or contract in the third direction or along the positive (+) X-axis. In contrast, the expansion or contraction of the second battery module 62b may be limited in the following aspects: (i) the second direction or along the positive (+) Y-axis is limited by the top wall 94a, and (ii) the fourth direction or along the negative (-) Y-axis is limited by the center divider 96. However, the expansion or contraction of the second battery module 62b may not be limited in the following aspects: (i) the first direction or along the negative (-) X-axis is limited by the end wall 92a, or (ii) the third direction or along the positive (+) X-axis.

[0261] Fig.64 The schematic diagram of the battery cell 75 in FIG. 1 shows how the movement of lithium ions from the cathode to the anode changes the size of the battery cell 75, namely: (i) charging causes the cylindrical battery cell 75 to expand circumferentially or radially outward to a charging diameter D max , and (ii) the discharge causes the cylindrical battery cell 75 to shrink circumferentially or radially inwardly to a discharge diameter D min In fact, it has been demonstrated that within a cylindrical battery cell 75 having a diameter of 18.15 mm, the movement of lithium ions from the cathode to the anode can result in: (i) an increase in the average diameter of the battery cell 75 of 2 µm (an increase of 0.01%), and (ii) an increase in the diameter of a specific location within the battery cell 75 of up to 37 µm (an increase of 0.2%). Thus, when the battery is 100% charged or fully charged, the diameter of the battery cell 75 can increase to D max When the battery is 50% charged or half charged, the diameter of the battery cell 75 can be moved to D normal , and when the battery is 0% charged or not charged or fully discharged, the diameter of the battery cell 75 can be reduced to D min , where D max >D normal >D min In other words, charging the battery cells 75 contained in the battery module 60 from a 50% charge level to a 100% charge level will cause the diameter of the cells 75 contained in the module 60 to increase from D normal Increase to D max , and discharging the battery cell 75 contained in the battery module 60 from a 50% charge level to a 0% charge level will cause the diameter of the cell 75 contained in the module 60 to change from D normal Reduce to D min .also, Fig.65shows how the diameter of the cell 75 increases irreversibly (from D normal To D 90 Then to D 80 ), which is due to the growth of solid electrolyte interface layer thickness, graphite defects and pressure rise caused by side reactions during the life of cylindrical lithium-ion batteries. It should be understood that Figure 64-65 It is not drawn to scale and is for illustration purposes only.

[0262] In view of the above disclosure, the main factor causing the dynamic movement of the battery module 60 within the battery pack 90 is the charge state of the battery module 60. Figure 53-61 In the first embodiment shown in FIG. 1 , the cylindrical cell 75 is arranged in a vertical orientation compared to the XY plane, wherein the extent of the longitudinal surface 78 of the cell 75 is substantially parallel to the XZ or YZ plane. normal To D max or D normal To D min Circumferential expansion and contraction of the battery module 60 primarily results in expansion and contraction of the battery module 60 in the XY plane. In the XZ or YZ plane, axial expansion and contraction, if any, is minimal because the movement of the lithium ions is primarily directed laterally, i.e., radially outward or inward, and lacks a significant vertical or axial component of movement. Since the expansion and contraction of the battery module 60 is primarily in the XY plane, the designer of the battery pack 90: (i) positions the bottom surface 215b of the peripheral portions 402a, 402b to be substantially parallel to the XY plane, and (ii) arranges the middle portion 410 of the busbar 200 to extend downward from the plane of the peripheral portions in the negative (-) Z direction. As discussed in detail below, the disclosed configuration will allow the middle portion 410 of the busbar 200 to continue to elastically deform so as to absorb the expansion and contraction of the battery module 60 in the XY plane.

[0263] i. System in neutral state

[0264] Although it is clear from the above disclosure that the individual elastically deformable battery module connector systems 100 included in the battery pack 90 may experience different expansion and / or contraction forces, the general concepts disclosed in the following disclosure related to the first battery module connector system 102a, the first battery module 62a and the second battery module 62b apply to all systems 100 included in the battery pack 90. Figure 55-63 and 69 shows the neutral state S N The elastically deformable battery module connector system 100 in the neutral state S is shown in FIG. 1 , wherein neither tension nor pressure is applied to the system 100. N(i) the battery cell 75 is at a battery state of health (“SoH”) of 100%, (ii) the battery cell 75 is charged to a charge level of 50%, (iii) the rear wall of each of the male terminal housings 1100 is located at a housing gap L from the inner wall of the busbar housing 600 HG (e.g., about 2-4 mm), (iv) the formed length L of the busbar 200 BN is about 110-120 mm, preferably 115-117 mm, and most preferably 116 mm (ie, the length L of the middle portion IPN Between 23 mm and 31 mm, preferably 27 mm, (v) the height H of the busbar 200 defined between the lowermost conductor 203a and the outer surface of the outermost conductor at the midpoint of the middle portion 410 BN 15-30 mm, preferably 20-25 mm (ie, the height H of the middle part IPN greater than 5 mm, preferably greater than 12 mm, more preferably between 20 mm and 28 mm, and most preferably 23 mm), and the width W of the busbar 200 BN is 15-25 mm, preferably 20 mm, (vi) the length L of the system 100 SN is about 150-200 mm, preferably 160-190 mm, and most preferably 182 mm, the height of the system 100 is 35-40 mm, preferably 37 mm, and the width of the system 100 is 25-35 mm, preferably 31 mm, (vii) the distance D between the battery modules 62a, 62b N The length L of the neck defined between the outer notches 264a, 264b of the busbar 200 in the neutral state (e.g., 100-120 mm, preferably 110 mm) (viii) NN 25-30 mm, preferably 22 mm, (ix) the length L of the gap defined between the opposing inner surfaces of the outer notches 264a, 264b of the busbar 200 in the neutral state GN 14 and 22 mm, preferably 22 mm, (x) height H of busbar 200 BN The forming length L of the busbar 200 BNThe ratio between them is 20-25%, preferably 21.5%, (xi) the bottom surface 215b of the peripheral portions 402a, 402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xii) the bottom surface 215b of the peripheral portions 402a, 402b is substantially parallel to the upper surface of the conductive plate 84 of the transmission assembly 82 and the range of the positive terminal 80a and the negative terminal 80b of the battery cell 75, (xiii) the bottom surface 215b of the peripheral portions 402a, 402b is substantially perpendicular to the longitudinal surface 78 of the battery cell 75, and (ix) the middle portion 410 is located between the fourth side wall 68d of the battery module 62a and the first side wall 68a of the adjacent battery module 62b.

[0265] ii. System in a contracted state

[0266] Fig.66 and 68 shows the compression state S C The elastically deformable battery module connector system 100, wherein the busbar 200 is subjected to a maximum compression C max In this embodiment, the maximum compression C max The force is between 38 and 46 N, and preferably 42 N. The maximum compression C max Force is applied to the system 100 in the third direction (along the positive (+) X-axis) via the battery module 62a, and in the first direction (along the negative (-) X-axis) via the expansion of the battery modules 62a, 62b due to the increase in the charge level in the battery cell 75. In particular, charging the battery cell 75 from a 50% state of charge to a 100% state of charge results in: (i) an increase in the diameter of the cell 75 from D normal Increase to D max , (ii) the size of the battery modules 62a, 62b is increased, (iii) the distance D between the battery modules 62a, 62b is increased N The length of the male terminal housing 1100 is reduced from the neutral length (eg, 110 mm) to the compressed length (eg, 106 mm), and (iv) each of the rear walls of the male terminal housing 1100 slides toward the inner wall of the busbar housing 600. It should be understood that from the neutral state S N To the compressed state S C The movement of the battery module 60 occurs continuously. When the battery module 60 is charged to 75%, the compression on the connector system 100 is between the neutral state S N and the compression state S C In this state, the neutral state S N Compared with the distance between connectors 1000 in FIG. 1 , the total distance between connectors 1000 can be reduced by 2 mm.

[0267] In the compressed state SC (i) the battery cell 75 is at a battery state of health (“SoH”) of 100%, (ii) the battery cell 75 is charged to a charge level of 100%, (iii) the rear wall of each of the male terminal housings 1100 is positioned at a housing gap L from the inner wall of the busbar housing 600 HG (eg, about 0-.05 mm or so), (iv) the length L of the busbar 200 BC is about 106-116 mm, preferably 111-113 mm, and most preferably 112 mm (i.e., the length L of the middle portion IPC The height H of the busbar 200 is between 23 mm and 31 mm, and preferably 27 mm. BC 15-30 mm, preferably 20-25 mm (ie, the height H of the middle part IPC between 20 mm and 28 mm, and preferably 23 mm), and the width W of the busbar 200 BC 15-25 mm, preferably 20 mm, (v) length L of system 100 SC The height H of the system 100 is about 178 mm. SC is 37 mm, and the width W of the system 100 SC is 31 mm, (vi) the distance D between the battery modules 62a and 62b C is the compressed length (eg, 106 mm), (vii) the length L of the neck defined between the external notches 264a, 264b of the busbar 200 in the compressed state NC is 21-26 mm, preferably 18 mm, (viii) the length L of the gap defined between the opposing inner surfaces of the outer notches 264a, 264b of the busbar 200 in the compressed state GC is 10 and 18 mm, preferably 14 mm, (ix) the height H of the busbar 200 BC The length L of busbar 200 BC The ratio between them is 22.3%, (x) the bottom surface 215b of the peripheral portions 402a, 402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xi) the bottom surface 215b of the peripheral portions 402a, 402b is substantially parallel to the upper surface of the conductive plate 84 of the transmission assembly 82 and the range of the positive terminal 80a and the negative terminal 80b of the battery cell 75, (xii) the bottom surface 215b of the peripheral portions 402a, 402b is substantially perpendicular to the longitudinal surface 78 of the battery cell 75, and (xiii) the middle portion 410 is positioned between the fourth side wall 68d of the battery module 62a and the first side wall 68a of the adjacent battery module 62b.

[0268] iii. System in extended state

[0269] Fig.67 and 70 The extended state S E The elastically deformable battery module connector system 100 in which the busbar 200 has a maximum tension TE max In this embodiment, the maximum tension TE max The force is between 38 and 46 N, preferably 42 N. The maximum tension TE max Force is applied to the system 100 in a first direction (along the negative (-) X-axis) via the battery module 62a, and in a third direction (along the positive (+) X-axis) via the contraction of the battery modules 62a, 62b due to the reduction in the charge level in the battery cell 75. In particular, charging the battery cell 75 from a 50% state of charge to a 0% state of charge results in: (i) a decrease in the diameter of the cell 75 from D normal Reduce to D min , (ii) the size of the battery modules 62a, 62b is reduced, (iii) the distance D between the battery modules 62a, 62b E The length increases from the neutral state (eg, 110 mm) to the extended length (eg, 114 mm), and (iv) the rear wall of each of the male terminal housings 1100 further slides away from the inner wall of the busbar housing 600. It should be understood that from the neutral state S N To the extended state S E The movement of the battery module 60 occurs continuously. When the battery module 60 is charged to 25%, the tension on the connector system 100 is between the neutral state S N and the extended state S E In this state, the neutral state S N Compared with the distance between connectors 1000 in FIG. 1 , the total distance between connectors 1000 can be increased by 2 mm.

[0270] In the extended state S E (i) the battery cell 75 is at a battery state of health (“SoH”) of 100%, (ii) the battery cell 75 is charged to a charge level of 0%, (iii) the rear wall of each of the male terminal housings 1100 is positioned at a housing gap L from the inner wall of the busbar housing 600 HG (eg, about 4-6 mm), (iv) the length L of the busbar 200 BE is about 114-124 mm, preferably 119-121 mm, and most preferably 120 mm (i.e., the length L of the middle portion IPE The height H of the busbar 200 is between 23 mm and 31 mm, and preferably 27 mm.BE 15-30 mm, preferably 20-25 mm (ie, the height H of the middle part IPE between 20 mm and 28 mm, preferably 23 mm), and the width W of the busbar 200 BE 15-25 mm, preferably 20 mm, (v) length L of system 100 SE is about 186 mm, the height of the system 100 is 37 mm, and the width of the system 100 is 31 mm, (vi) the distance D between the battery modules 62a, 62b N is the extended length (eg, 114 mm), (vii) the length L of the neck defined between the outer notches 264a, 264b of the busbar 200 in the compressed state NE is 29-34 mm, preferably 22 mm, (viii) the length L of the gap defined between the opposing inner surfaces of the outer recesses 264a, 3264b of the busbar 200 in the compressed state GE is 18 and 26 mm, preferably 24 mm, the busbar 200 in the compressed state is 10 and 18 mm, preferably 14 mm, (viii) the height H of the busbar 200 BE The length L of busbar 200 BE The ratio between them is 20.8%, (ix) the bottom surface 215b of the peripheral portions 402a, 402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (x) the bottom surface 215b of the peripheral portions 402a, 402b is substantially parallel to the upper surface of the conductive plate 84 of the transmission assembly 82 and the range of the positive terminal 80a and the negative terminal 80b of the battery cell 75, (xi) the bottom surface 215b of the peripheral portions 402a, 402b is substantially perpendicular to the longitudinal surface 78 of the battery cell 75, and (xii) the middle portion 410 is located between the fourth side wall 68d of the battery module 62a and the first side wall 68a of the adjacent battery module 62b.

[0271] iv. Conclusion

[0272] In summary, the above disclosure focuses on a battery cell 75 having a 100% battery state of health (“SoH”). Fig.65 As shown in FIG. 1 , as the health state decreases, the diameter of the cell 75 increases, which will reduce the system 100 from reaching the extended state S E Instead, the system 100 will be mainly in the neutral state S N and the compression state S C In addition, as shown in the following table, regardless of the state of the busbar, the height of the busbar 200 and the bending height H of the middle portion 410 IPN and bending length LIPN Maintaining substantially constant in all states is beneficial because it reduces potential failures due to unexpected expansion or contraction of the height of the busbar 200. It should be understood that maintaining substantially constant means that when the busbar 200 is moved from the neutral state S N Move to compressed state S C Or from the neutral state S N Move to extended state S E When the busbar 200 is moved from the compressed state to the extended state, the height or length will change by less than 2.5%. In addition, as shown in the following table, when the busbar 200 moves between states from the compressed state to the extended state, the formed length (i.e., L BC To L BN To L BE ) does not remain substantially constant. Instead, when the busbar 200 moves from a compressed state to an extended state, the formed length changes by about 5%. It should be understood that the numbers contained in the above paragraphs and the following table are merely exemplary and are not limiting in any way. Therefore, other embodiments of the busbar 200 may have different values ​​associated therewith.

[0273] Table 2: Charge levels and sizes at different busbar states

[0274] Bus status Battery cell charge level (%) <![CDATA[L BC , L BN , L BE (mm)]]> <![CDATA[H BC , H BN, H BE (mm)]]> <![CDATA[H IPC , H IPN , H IPE (mm)]]> <![CDATA[L GC , L GN , L GE (mm)]]> <![CDATA[L SC , L SN , L SE (mm)]]> <![CDATA[Neutral state S N > 50% 116 25 ± 2.5% 23 ± 2.5% 20 182 <![CDATA[Compressed state S C > 100% 112 25 ± 2.5% 23 ± 2.5% 16 178 <![CDATA[Extended state S E > 0% 120 25 ± 2.5% 23 ± 2.5% 24 186

[0275] v. Other sports

[0276] While the above disclosure focuses on dynamic movement of the battery modules 60 associated with the state of charge of the modules 60, other factors may also cause dynamic movement of the battery modules 60 within the battery pack 90. ​​For example, increasing the temperature of the battery pack 90, the power distribution system 50, and / or the application 10 may cause expansion of all components in all planes; thereby compressing the system 100. In addition, the harsh and / or rough operating environment of the application 10 (such as the motor vehicle 20) may also cause dynamic movement in all planes; thereby compressing and / or expanding the system 100. Specifically, Fig.71 Movement between the battery modules 62a, 62b in the second and fourth (along the positive / negative (+ / -) Y axis) directions is shown. Finally, other mechanical or chemical forces may also compress or expand the system 100. Because the system 100 is specifically designed to account for expansion and contraction in the XY plane, and can compensate for movement in the XZ plane and the YZ plane, the system 100 significantly reduces and largely eliminates a large number of motion-induced failure modes in the battery pack 90 and applications 10 that include the battery pack 90, such as a motor vehicle.

[0277] III. Second Embodiment of Battery Pack

[0278] Figures 74-83A second embodiment of a battery module 3060 and a plurality of second embodiment elastically deformable battery module connector systems 3100 are shown. The combination of the battery module 3060 and the system 3100 is configured to be positioned within the battery pack 90 disclosed above. For the sake of brevity, the above disclosure related to the battery pack 90 will not be repeated below, but it should be understood that in various embodiments, the same reference numerals represent the same structure. For example, the disclosure related to the busbar housing 600 is also applicable to the busbar housing 3600. It should be understood that any one or more features of the battery module 60 and the system 100 may be used in combination with the features disclosed with respect to the battery module 3060 and the system 3100, and any one or more features of the battery module 3060 and the system 3100 may be used in combination with the features disclosed with respect to the battery module 60 and the system 100.

[0279] A. Battery Module

[0280] like Figures 74-83 As shown in , each of the battery modules 3060 ( 3062 a - 3062 b ) generally includes: (i) a battery module housing 3064 , (ii) battery cells 3076 , and (iii) an electrical transmission assembly 3083 .

[0281] i. Battery module housing

[0282] The battery module housing 3064 includes a plurality of walls 3066 (e.g., an arrangement of four side walls 3068a-3068d, a bottom wall 3070a, and a top wall 3070b) that form a receptacle 3072 configured to receive and protect: (i) a battery cell 3076 and (ii) an electrical transmission assembly 3083. The top wall 3070b includes at least two battery module openings 3073a, 3073b formed therethrough, wherein the openings 3073a, 3073b are configured to allow the bolt connector assemblies 4002a, 4002b to couple to a range of the electrical transmission assembly 3083. In particular, electrical current is configured to flow through the battery module openings 3073a, 3073b via the connection between the bolt connector assemblies 4002a, 4002b and the electrical transmission assembly 3083. Although bolt connector assemblies 4002a, 4002b are shown in conjunction with the second embodiment 3060, it should be understood that the present disclosure contemplates the use of other connectors (e.g., boltless, clamping, press fit). For example, a boltless connector is disclosed in conjunction with the first embodiment of the battery module 3060.

[0283] ii. Battery Cell

[0284] Figures 75-80The battery module 3060 is shown to include a plurality of prismatic battery cells 3076, wherein each battery cell 3076 includes: (i) a housing 3077, (ii) a positive terminal 3080a, and (iii) a negative terminal 3080b. The housing 3077 has vertical side surfaces 3078a, 3078b and horizontal top and bottom surfaces 3079a, 3079b, and is designed to enclose and retain a material that stores a charge, such as lithium or other similar metal. In other words, the battery cell has a thickness T C , Width W CELL and length L CELL . The positive terminal 3080a and the negative terminal 3080b couple the materials contained within the housing 3077 to the electrical transmission assembly 3083. The terminals 3080a, 3080b can have a tab-like configuration; however, other terminal shapes are also possible (e.g., boltless connectors, bolted connectors, buttons, weldable, press-fit, or other structures clamped by the electrical transmission assembly 3083). The positive terminal 3080a and the negative terminal 3080b are typically formed of different materials to facilitate charging and discharging of the battery cell 3076. For example, the positive terminal or anode 3080a can be formed of the following materials: (i) graphite, (ii) silicon, or (iii) graphene, while the negative terminal or cathode 3080b can be formed of the following materials: (i) cobalt, (ii) iron, (iii) nickel magnesium, (iv) nickel, or (v) sulfur. It should be understood that other materials can be used for the terminals. The battery cell 3076 may have an output voltage between 0.2 volts and 10 volts, an ampere-hour rating between 10 Ah and 100 Ah, and may have an energy density between 20 Wh / kg and 500 Wh / kg. It should be understood that the battery cell 3076 may use a variety of different technologies and / or materials, including: (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) lithium polymer, (v) lithium ion, or (vi) batteries utilizing other materials (e.g., LiO2, AlO2, LiS, LTO, LFP, NMC, NCA).

[0285] iii. Electrical transmission components

[0286] Figures 74-80An electrical transmission assembly 3083 is shown within each of the battery modules 3060 that couples: (i) the battery cells 3076 to each other, and (iii) the female connector assemblies 4002a, 4002b to the battery cells 3076. As shown in this embodiment, each battery module 3060 includes approximately 11 battery cells 3076 arranged in a vertical orientation relative to the XY plane. The vertical orientation places the following into position: (i) the positive terminal 3080a and the negative terminal 3080b in a plane substantially parallel to the XY plane, (ii) the extent of the vertical side surfaces 3078a, 3078b of the cell 3076 substantially parallel to the YZ plane, and (iii) the thickness T of the cell 3076 parallel to the X axis. C . Thus, the conductive plate 3085 can be positioned in the XY plane and coupled to the positive terminal 3080a and the negative terminal 3080b of the cell 3076. Although the present embodiment discloses the above configuration of the battery cell 3076 and the associated component electrical transmission assembly 3083, it should be understood that in other embodiments, the electrical transmission assembly 3083 can have a different configuration. For example, the electrical transmission assembly 3083m can be designed to couple any number of battery cells 3076 (e.g., between 2 and 3998) to each other.

[0287] In addition, the plate 3085 is coupled to at least one bolt connector 4002. Preferably, the plate 3085 of the power transmission assembly 3083 is coupled to two bolt connectors 4002a, 4002b, wherein: (i) the positive bolt connector 4002b (a) is configured to provide a positive external connection for the battery module 3060, and (b) is designed to be received by an opening formed within the system 3100, and (ii) the negative bolt connector 4002a (a) is configured to provide a negative external connection for the battery module 3060, and (b) is designed to be received by an opening formed within the system 3100. Although the battery module 3060 shown in the figure includes two bolt connectors 4002a, 4002b, it should be understood that the battery module 3060 can have more or fewer bolt connectors 4002. For example, the battery module 3060 can have only a single bolt connector 4002, or the battery module 3060 can include more than ten bolt connectors 4002.

[0288] B. Battery Pack

[0289] As described above, the second embodiment of the battery module 3090 is designed to fit into the rectangular prism configuration of the battery pack 90, such as Figure 53-54 Although Fig.53 and 54A battery pack 90 having a configuration and configured to accommodate ten battery modules 3060 is shown, but it should be understood that the present disclosure is not limited to this design. Instead, the battery pack 90 can have any known configuration (e.g., any type of polygonal prism), including a configuration in which the group 90 is built as part of the frame or chassis of the vehicle. It should also be understood that in other embodiments, the battery pack 90 can be configured to accommodate only a single battery module 3060 or to accommodate more than one hundred individual battery modules 3060. The battery cells 3076 contained within the module 3060 can be connected in parallel, in series, or any combination thereof. In addition, the battery modules 3060 contained within the battery pack 90 can be connected in parallel, in series, or any combination thereof.

[0290] C. Battery module connections within the battery pack

[0291] Once the battery modules 3060 (3062a-3062j) are positioned and fastened in the receivers 97a, 97b of the battery pack 3060, the battery modules 3060 (3062a-3062j) can be coupled to each other using the elastically deformable battery module connector system 3100 of the present disclosure. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 3100 (3102a-3102i). Each of the elastically deformable battery module connector systems 3100 is coupled to the battery module 90, the threaded rod of the bolt connector 4002 is positioned into the opening 3002 formed in the end sectors 3208a, 3208b of the busbar 3200, and then the end sectors 3208a, 3208b are fastened to the bolt connector 4002 using threaded fasteners. The configuration of the present disclosure places the bottom surface 3215b of the peripheral portions 3402a, 3402b substantially parallel to each of: (i) the XY plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top wall 3070a and bottom wall 3070b of the battery module housing 3064, (iv) the upper surface of the conductive plate 3085 of the transmission assembly 3083, and (v) the range of the positive terminal 3080a and the negative terminal 3080b of the battery cell 3076. In addition, the configuration places the bottom surface 3215b of the peripheral portion 3402a, 3402b substantially perpendicular to each of the following: (i) the XZ plane, (ii) the YZ plane, (iii) the side walls and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 3068a-3068d of the battery module housing 3064, and (iv) the vertical side surfaces 3078a, 3078b of the battery cell 3076. In addition, the configuration allows the middle portion 3410 to extend downwardly in the -Z direction from the plane of the peripheral portion and be located between the fourth side wall 3068d of the battery module 3060 (e.g., 3062a) and the side wall 3068a of the adjacent battery module 3060 (e.g., 3062b). In addition, the length L of the busbar 3200 is B The busbar 3200 extends in a direction substantially parallel to the X-axis, while the width of the busbar 3200 extends in a direction substantially parallel to the Y-axis.

[0292] This first embodiment of the elastically deformable battery module connector system 3100 is installed in the battery pack 90 using connector assemblies 3998, 4002. These connector assemblies 3998, 4002 allow the connection between the battery modules 3060 to be tightened using a bolt configuration. Once the battery modules 3060 and all other necessary components (e.g., battery management components, battery cooling or heating components, etc.) are installed in the battery pack 90, the pack 90 can be installed in the application 10.

[0293] D. Dynamic movement of battery modules

[0294] Fig.77 The schematic diagram of the battery cell 3076 in FIG. 1 shows how the movement of lithium ions from the cathode to the anode changes the size of the battery cell 3076, namely: (i) charging causes the prismatic battery cell 3076 to increase in thickness or expand laterally outward, and (ii) discharging causes the prismatic battery cell 3076 to decrease in thickness or shrink laterally inward. Thus, when the battery is 100% charged or fully charged, the thickness of the cell 3076 may increase to T max , when the battery is charged to 50% or 1 / 2, the thickness of unit 3076 can move to T normal , and when the battery is charged 0% or not charged, the thickness of unit 3076 can be reduced to T min , where T max >T normal >T min In other words, charging the battery cells 3076 contained in the battery module 3060 from a 50% charge level to a 100% charge level will cause the thickness of the cells 3076 in the module 3060 to increase from T normal Increase to T max , and discharging the battery cell 3076 included in the battery module 3060 from a 50% charge level to a 0% charge level will cause the thickness of the cell 3076 in the module 3060 to change from T normal Reduce to T min .in addition, Fig.78 shows how the thickness of cell 3076 increases irreversibly as the battery state of health (“SoH”) decreases (i.e., from T normal to T 90 Then to T 80 ), which is due to the growth of solid electrolyte interface layer thickness, defects in graphite and pressure rise caused by side reactions during the service life of prismatic lithium-ion batteries. It should be understood that Figures 77-78 It is not drawn to scale and is for illustration purposes only.

[0295] In view of the above disclosure, the primary factor causing the dynamic movement of the battery module 3060 within the battery pack 90 is the charge state of the battery module 3060. In this second embodiment, the prismatic cells 3076 are arranged in a vertical orientation compared to the XY plane, wherein: (i) the vertical side surfaces 3078a, 3078b of the cells 3076 extend substantially parallel to the YZ plane, (ii) the horizontal top and bottom surfaces 3079a, 3079b of the cells 3076 extend substantially parallel to the XY plane, and (iii) the thickness T of the cells 3076 is substantially parallel to the XY plane. C is parallel to the X axis. Therefore, the battery cell 3076 is normal To T max Or from T normal To Tmin The thickness expansion and contraction mainly causes the battery module 3060 to expand and contract along the X-axis. Because the movement of lithium ions is mainly directed in the transverse direction and lacks other significant components, the expansion and contraction (if any) along the Y-axis or Z-axis is small. Since the expansion and contraction of the battery module 3060 is mainly in the X-axis, the designer: (i) positions the bottom surface 3215b of the peripheral portions 3402a, 3402b to be substantially parallel to the X-axis, and (ii) arranges the middle portion 3410 to extend downward from the plane of the peripheral portions in the negative (-) Z direction. As discussed in detail below, this disclosed configuration of the system 100 will allow the middle portion 3410 to deform elastically so as to absorb the expansion and contraction of the battery module 3060 in the X-axis.

[0296] i. System in neutral state

[0297] Although it is clear from the above disclosure that the individual elastically deformable battery module connector systems 3100 included in the battery pack 90 may experience different expansion and / or contraction forces, the general concepts disclosed in conjunction with the first system 3102a, the first battery module 3062a and the second battery module 3062b apply to all systems 3100 included in the battery pack 90. Figure 74-76B and 81 shows the neutral state S N The elastically deformable battery module connector system 3100 in FIG. 3100 , wherein neither tension nor pressure is applied to the system 3100 . In the neutral state S N (i) the battery cell 3076 is at a battery state of health (“SoH”) of 100%, (ii) the battery cell 3076 is charged to a charge level of 50%, (iii) the rear wall of each male terminal housing in the male terminal housing 1100 is located at a housing gap L from the inner wall of the busbar housing 3600 HG (e.g., about 2-4 mm), (iv) the formed length L of the busbar 200 BN is about 110-120 mm, preferably 115-117 mm, and most preferably 116 mm (ie, the length L of the middle portion IPN The height H of the busbar 200 is between 23 mm and 31 mm, and preferably 27 mm. BN 15-30 mm, preferably 20-25 mm (ie, the height H of the middle part IPN between 20 mm and 28 mm, and preferably 23 mm), and the width W of the busbar 200 BN 15-25 mm, preferably 20 mm, (v) length L of system 3100 SNis about 150-200 mm, preferably 160-190 mm, and most preferably 182 mm, the height of the system 3100 is 35-40 mm, preferably 37 mm, and the width W of the system 3100 is about 150-200 mm, preferably 160-190 mm, and most preferably 182 mm. SN 25-35 mm, preferably 31 mm, (vi) the distance D between the battery modules 3062a and 3062b N The length L of the neck defined between the outer notches 3264a, 3264b of the busbar 3200 in the neutral state (eg, 100-120 mm, preferably 110 mm) (vii) NN is 25-30 mm, preferably 22 mm, (viii) the length L of the gap defined between the opposing inner surfaces of the outer notches 3264a, 3264b of the busbar 3200 in the neutral state GN 14 and 22 mm, preferably 22 mm, (ix) the height H of the busbar 3200 BN Forming length L with busbar 3200 BN The ratio between the outer portions 3402a and 3402b is 20-25%, preferably 21.5%, (x) the bottom surface 3215b of the peripheral portions 3402a, 3402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xi) the bottom surface 3215b of the peripheral portions 3402a, 3402b is substantially parallel to both the range of the upper surface of the conductive plate 3085 of the transmission assembly 3083 and the range of the positive terminal 3080a and the negative terminal 3080b of the battery cell 3076, (xii) the bottom surface 3215b of the peripheral portions 3402a, 3402b is substantially perpendicular to the range of the vertical side surfaces 3078a, 3078b of the cell 3076, (xiii) the middle portion 3410 is positioned between the fourth side wall 3068d of the battery module 3062a and the first side wall 3068a of the adjacent battery module 3062b, and (xiv) the formed length L of the busbar 200 BN and the length L of the system 3100 SN Substantially parallel to the thickness T of the battery cell 3076 C and X-axis.

[0298] ii. System in a contracted state

[0299] Fig.79 and 82 shows the compression state S C The elastically deformable battery module connector system 3100 in which the busbar 3200 is subjected to a maximum compression C max In this embodiment, the maximum compression C max The force is between 38 and 46 N, and preferably 42 N. The maximum compression Cmax Force is applied to the system 3100 in the third direction (along the positive (+) X-axis) via the battery module 3062a, and in the first direction (along the negative (-) X-axis) via the expansion of the battery modules 3062a, 3062b due to the increase in the charge level in the battery cell 3076. In particular, charging the battery cell 3076 from a 50% state of charge to a 100% state of charge results in: (i) an increase in the thickness of the cell 3076 from T normal Increase to T max , (ii) the size of the battery modules 3062a, 3062b is increased, (iii) the distance D between the battery modules 3062a, 3062b is increased N The length of the male terminal housing 1100 is reduced from the neutral length (e.g., 110 mm) to the compressed length (e.g., 106 mm), and (iv) each of the rear walls of the male terminal housing 1100 slides toward the inner wall of the busbar housing 3600. It should be understood that from the neutral state S N To the compressed state S C The movement occurs continuously. When the battery module 3060 is charged to 75%, the compression on the connector system 3100 is between the neutral state S N and the compression state S C In this state, the neutral state S N Compared with the distance between connectors 3998 in FIG. 3 , the total distance between connectors 3998 can be reduced by 2 mm.

[0300] In the compressed state S C (i) the battery cell 3076 is at a battery state of health (“SoH”) of 100%, (ii) the battery cell 3076 is charged to a charge level of 100%, (iii) the rear wall of each of the male terminal housings 1100 is positioned at a housing gap L from the inner wall of the busbar housing 3600 HG (eg, about 0-0.5 mm or adjacent), (iv) the length L of the busbar 200 BC is about 106-116 mm, preferably 111-113 mm, and most preferably 112 mm (i.e., the length L of the middle portion IPC The height H of the busbar 200 is between 23 mm and 31 mm, and preferably 27 mm. BC 15-30 mm, preferably 20-25 mm (ie, the height H of the middle portion IPC between 20 mm and 28 mm, and preferably 23 mm), and the width W of the busbar 200 BC 15-25 mm, preferably 20 mm, (v) length L of system 3100 SCis about 178 mm, the height of the system 3100 is 37 mm, and the width of the system 3100 is 31 mm, (vi) the distance D between the battery modules 3062a, 3062b N in compressed length (eg, 106 mm), (vii) the length L of the neck defined between the external notches 3264a, 3264b of the busbar 3200 in the compressed state NC is 21-26 mm, preferably 18 mm, (viii) the length L of the gap defined between the opposing inner surfaces of the outer notches 3264a, 3264b of the busbar 3200 in the compressed state GC 10 and 18 mm, preferably 14 mm, (ix) the height H of the busbar 3200 BC The length L of busbar 3200 BC The ratio between the two is 22.3%, (x) the bottom surface 3215b of the peripheral portions 3402a, 3402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xi) the bottom surface 3215b of the peripheral portions 3402a, 3402b is substantially parallel to both the range of the upper surface of the conductive plate 3085 of the transmission assembly 3083 and the range of the positive terminal 3080a and the negative terminal 3080b of the battery cell 3076, (xii) the bottom surface 3215b of the peripheral portions 3402a, 3402b is substantially perpendicular to the range of the vertical side surfaces 3078a, 3078b of the battery cell 3076, (xiii) the middle portion 3410 is located between the fourth side wall 3068d of the battery module 3062a and the first side wall 3068a of the adjacent battery module 3062b, and (ivx) the length L of the busbar 200 is BC and the length L of the system 3100 SC Substantially parallel to the thickness T of the battery cell 3076 C and X-axis.

[0301] iii. System in extended state

[0302] Fig.80 and 83 The extended state S E The elastically deformable battery module connector system 3100 in which the busbar 3200 has a maximum tension TE max In this embodiment, the maximum tension TE max Between 38 and 46 N, and preferably 42 N. The maximum tension TE maxThe pressure applied to the system 3100 in a first direction (along the negative (-) X-axis) via the battery module 3062a and in a third direction (along the positive (+) X-axis) via the contraction of the battery modules 3062a, 3062b is due to the reduction in the charge level in the battery cell 3076. In particular, charging the battery cell 3076 from a 50% state of charge to a 0% state of charge results in: (i) a decrease in the thickness of the cell 3076 from T normal Reduce to T min , (ii) the size of the battery modules 3062a, 3062b is reduced, (iii) the distance D between the battery modules 3062a, 3062b is N The length of the busbar housing 3600 increases from the neutral state (eg, 110 mm) to the extended length (eg, 114 mm), and (iv) the rear wall of each of the male terminal housings 1100 further slides away from the inner wall of the busbar housing 3600. It should be understood that from the neutral state S N To the extended state S E The movement occurs continuously. When the battery module 3060 is charged to 25%, the tension on the connector system 3100 is between the neutral state S N and the extended state S E In this state, the neutral state S N Compared to the distance between connectors 3998 in , the total distance between connectors 3998 can be increased by 2 mm.

[0303] In the extended state S E (i) the battery cell 3076 is at a battery state of health (“SoH”) of 100%, (ii) the battery cell 3076 is charged to a charge level of 0%, (iii) the rear wall of each of the male terminal housings 1100 is positioned at a housing gap L from the inner wall of the busbar housing 3600 HG (eg, about 4-6 mm), (iv) the length L of the busbar 200 BE is about 114-124 mm, preferably 119-121 mm, and most preferably 120 mm (i.e., the length L of the middle portion IPE The height H of the busbar 200 is between 23 mm and 31 mm, preferably 27 mm. BE 15-30 mm, preferably 20-25 mm (ie, the height H of the middle part IPE between 20 mm and 28 mm, and preferably 23 mm), and the width W of the busbar 200 BE 15-25 mm, preferably 20 mm, (v) length L of system 3100 SEis about 186 mm, the height of the system 3100 is 37 mm, and the width of the system 3100 is 31 mm, (vi) the distance D between the battery modules 3062a, 3062b N is the extended length (eg, 114 mm), (vii) the length L of the neck defined between the external notches 3264a, 3264b of the busbar 3200 in the compressed state NE 29-34 mm, preferably 22 mm, (viii) the length L of the gap defined between the opposing inner surfaces of the outer notches 3264a, 3264b of the busbar 3200 in the compressed state GE 18 and 26 mm, preferably 24 mm, (ix) the height H of the busbar 3200 BE The length L of busbar 3200 BE The ratio between the two is 20.8%, (x) the bottom surface 3215b of the peripheral portion 3402a, 3402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xi) the bottom surface 3215b of the peripheral portion 3402a, 3402b is substantially parallel to both the upper surface of the conductive plate 3085 of the transmission component 3083 and the range of the positive terminals 3080a, 3080b of the battery cell 3076, (xii) the bottom surface 3215b of the peripheral portion 3402a, 3402b is substantially perpendicular to the range of the vertical side surfaces 3078a, 3078b of the battery cell 3076; (xiii) the middle portion 3410 is located between the fourth side wall 3068d of the battery module 3062a and the first side wall 3068a of the adjacent battery module 3062b; and (ix) the length L of the busbar 200 BE and the length L of the system 3100 SE Substantially parallel to the thickness T of the battery cell 3076 CELL and X-axis.

[0304] IV. Third embodiment of the battery pack

[0305] Figures 84-88A third embodiment of a battery module 5060 and a plurality of second embodiment elastically deformable battery module connector systems 5100 are shown. The combination of the battery module 5060 and the system 5100 is configured to be positioned within the battery pack 90 disclosed above. For the sake of brevity, the above disclosure in conjunction with the battery pack 90 will not be repeated below, but it should be understood that in various embodiments, the same reference numerals represent the same structure. For example, the disclosure related to the busbar housing 5600 is also applicable to the busbar housing 5600. It should be understood that any one or more features of the battery module 5060 and the system 5100 can be used in combination with the features disclosed with respect to the battery module 5060 and the system 5100, and any one or more features of the battery module 5060 and the system 5100 can be used in combination with the features disclosed with respect to the battery module 5060 and the system 5100.

[0306] A. Battery Module

[0307] like Figures 84-88 As shown in , each of the battery modules 5060 ( 5062 a - 5062 j ) generally includes: (i) a battery module housing 5064 , (ii) battery cells 5076 , and (iii) an electrical transmission assembly 5081 .

[0308] i. Battery module housing

[0309] The battery module housing 5064 includes a plurality of walls 5066 (e.g., an arrangement of four side walls 5068a-5068d, a bottom wall 5070a, and a top wall 5070b) that form a receptacle 5072 configured to receive and protect: (i) a battery cell 5076 and (ii) an electrical transmission assembly 5081. The top wall 5070b includes at least two battery module openings 5073a, 5073b formed therethrough, wherein the openings 5073a, 5073b are configured to allow the female connector assemblies 2000a, 2000b to be coupled to a range of the electrical transmission assembly 5081. In particular, electrical current is configured to flow through the battery module openings 5073a, 5073b via the connection between the female connector assemblies 2000a, 2000b and the electrical transmission assembly 5081. Although the female connector assemblies 2000a, 2000b are shown in conjunction with this third embodiment of the battery module 5060, it should be understood that the present disclosure contemplates the use of other connectors (e.g., bolted, clamped, press-fitted). For example, a bolted connector is disclosed in conjunction with the second embodiment of the battery module 5060.

[0310] ii. Battery Cell

[0311] Figures 84-88The battery module 5060 is shown to include a plurality of soft pack battery cells 5076, wherein each battery cell 5076 includes: (i) a housing 5077, (ii) a positive terminal 5080a, and (iii) a negative terminal 5080b. The housing 5077 has horizontal side surfaces 5078a, 5078b and vertical top and bottom surfaces 5079a, 5079b, and is designed to enclose and retain a material that stores a charge, such as lithium or other similar metal. In other words, the battery cell has a thickness T C , Width W CELL and length L CELL . The positive terminal 5080a and the negative terminal 5080b couple the materials contained within the housing 5077 to the electrical transmission assembly 5081. The terminals 5080a, 5080b can have a tab-like configuration; however, other terminal shapes are also possible (e.g., boltless connectors, bolted connectors, buttons, weldable, press-fit, or other structures clamped by the electrical transmission assembly 5081). The positive terminal 5080a and the negative terminal 5080b are typically formed of different materials to facilitate charging and discharging of the battery cell 5076. For example, the positive terminal or anode 5080a can be formed of the following materials: (i) graphite, (ii) silicon, or (iii) graphene, while the negative terminal or cathode 5080b can be formed of the following materials: (i) cobalt, (ii) iron, (iii) nickel magnesium, (iv) nickel, or (v) sulfur. It should be understood that other materials can be used for the terminals. The battery cell 5076 may have an output voltage between 0.2 volts and 10 volts, an ampere-hour rating between 10 Ah and 100 Ah, and may have an energy density between 20 Wh / kg and 500 Wh / kg. It should be understood that the battery cell 5076 may use a variety of different technologies and / or materials, including: (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) lithium polymer, (v) lithium ion, or (vi) batteries utilizing other materials (e.g., LiO2, AlO2, LiS, LTO, LFP, NMC, NCA).

[0312] iii. Electrical transmission components

[0313] Figure 58-67An electrical transmission assembly 5081 is shown within each of the battery modules 5060 that couples: (i) the battery cells 5076 to each other, and (iii) the female connector assemblies 2000a, 2000b to the battery cells 5076. As shown in this embodiment, each of the first and second stacks includes approximately 26 battery cells 5076 arranged in a horizontal orientation relative to the XY plane. The horizontal orientation places the following into position: (i) the positive terminal 5080a and the negative terminal 5080b in a plane substantially parallel to the YZ plane, (ii) the extent of the horizontal side surfaces 5078a, 5078b of the cell 5076 substantially parallel to the XY plane, and (iii) the thickness T of the cell 5076 parallel to the Z axis. C . Thus, the conductive plate 5084 can be located in the YZ plane and coupled to the positive terminal 5080a and the negative terminal 5080b of the cell 5076. Although the present embodiment discloses the above configuration of the battery cell 5076 and the associated component electrical transmission assembly 5081, it should be understood that in other embodiments, the electrical transmission assembly 5081 can have a different configuration. For example, the electrical transmission assembly 5081 can be designed to couple any number of battery cells 5076 to each other (e.g., between 2 and 1000), and to couple any number of battery columns (e.g., between 1 and 40 columns) to each other.

[0314] In addition, at least one female connector assembly 2000 is coupled to the plate 5086. Preferably, the plate 5086 of the power transmission assembly 5081 is coupled to two female connector assemblies 2000a, 2000b, wherein: (i) the positive female connector assembly 2000b (a) is configured to provide a positive external connection for the battery module 5060, and (b) is designed to receive a range of positive male terminal assemblies 1430, and (ii) the negative female connector assembly 2000a (a) is configured to provide a negative external connection for the battery module 5060, and (b) is designed to receive a range of negative male terminal assemblies 1430. Although the battery module 5060 shown in the figure includes two female connector assemblies 2000a, 2000b, it should be understood that the battery module 5060 can have more or fewer female connector assemblies 2000. For example, the battery module 5060 may have only a single female connector assembly 2000 , or the battery module 5060 may include more than ten female connector assemblies 2000 .

[0315] B. Battery Pack

[0316] As described above, the third embodiment of the battery module 5090 is designed to fit into the rectangular prism configuration of the battery pack 90, such as Figure 53-54 Although Fig.53 and 54A battery pack 90 having a configuration and configured to accommodate ten battery modules 5060 is shown, but it should be understood that the present disclosure is not limited to this design. Instead, the battery pack 90 can have any known configuration (e.g., any type of polygonal prism), including a configuration in which the group 90 is built as part of the frame or chassis of the vehicle. It should also be understood that the battery pack 90 can be configured to accommodate only a single battery module 5060 or to accommodate more than one hundred individual battery modules 5060. The battery cells 5076 contained within the module 5060 can be connected in parallel, in series, or any combination thereof. In addition, the battery modules 5060 contained within the battery pack 90 can be connected in parallel, in series, or any combination thereof.

[0317] C. Battery module connections within the battery pack

[0318] Once the battery modules 5060 (5062a-5062j) are positioned and secured in the receivers 97a, 97b of the battery pack 90, the battery modules 5060 (5062a-5062j) can be coupled to each other using the elastically deformable battery module connector system 5100 of the present disclosure. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 5100 (5102a-102i). Each of the elastically deformable battery module connector systems 5100 is coupled to the battery module 90 using a downwardly directed force (i.e., in the negative (-) Z direction). The configuration of the present disclosure places the bottom surface 5215b of the peripheral portions 5402a, 5402b substantially parallel to each of the following: (i) the XY plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top wall 5070a and the bottom wall 5070b of the battery module housing 5064, and (iv) the range of the positive terminal 5080a and the negative terminal 5080b of the battery cell 5076. In addition, the configuration places the bottom surface 5215b of the peripheral portions 5402a, 5402b substantially perpendicular to each of the following: (i) the XZ plane, (ii) the YZ plane, (iii) the side walls and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 5068a-5068d of the battery module housing 5064, and (iv) the longitudinal surface 78 of the battery cell 5076. In addition, the configuration is such that the middle portion 5410 extends downward from the plane of the peripheral portion in the -Z direction and is located between the fourth side wall 5068d of the battery module 5060 (e.g., 5062a) and the side wall 5068a of the adjacent battery module 5060 (e.g., 5062b). B The busbar 5200 extends in a direction substantially parallel to the X-axis, while the width of the busbar 5200 extends in a direction substantially parallel to the Y-axis.

[0319] This third embodiment of the elastically deformable battery module connector system 5100 utilizes connector assemblies 1000, 2000 to be installed in a battery pack 90. ​​These connector assemblies 1000, 2000 allow connections between battery modules 5060 that are: (i) boltless, (ii) PCT compliant, (iii) 360° compliant, (vi) fast and efficient compared to conventional battery pack connectors, (vii) simple and straightforward, requiring no special tools or machines, (viii) USCAR and other industry specifications compliant, (ix) lighter than conventional battery pack connectors, and (x) other benefits apparent to those skilled in the art. Once the battery modules 5060 and all other necessary components (e.g., battery management components, battery cooling or heating components, etc.) are installed in the battery pack 90, the battery pack 90 can be installed in the application 10.

[0320] D. Material conditions of battery modules

[0321] In the second embodiment, the movement of lithium ions from the cathode to the anode will cause the thickness of the cell 5076 to increase to T when the battery is 100% charged or fully charged. max , move to T when the battery is 50% charged or 1 / 2 charged normal , and decreases to T when the battery is 0% charged or not charged min , where T max >T normal >T min In view of the above disclosure, the main factor causing the dynamic movement of the battery module 5076 within the battery pack 90 is independent of the charge state of the battery module 5076. This is because the prismatic cells 3076 are arranged in a horizontal orientation compared to the XY plane, wherein: (i) the extent of the horizontal side surfaces 5078a, 5078b of the cell 5076 is substantially parallel to the XY plane, and (iii) the thickness T of the cell 3076 is substantially parallel to the XY plane. C is parallel to the Z axis. Therefore, the battery cell 5076 is normal to T max Or from T normal to T min The thickness expansion and contraction of the battery module 5076 mainly causes the expansion and contraction along the Z axis. Because the movement of lithium ions is mainly vertically directed and lacks other significant components, the expansion and contraction (if any) along the X axis or Y axis is small. Since the pack 90 lacks the requirement to electrically couple each module 5060 to the top surface of the battery pack 90, the expansion of each module 5060 along the Z axis does not depend on other modules 5060, so the length L of the system 100 is SRather than being positioned in a direction parallel to the Z axis, the battery module 5076 is positioned in a direction parallel to the X axis. This configuration allows the system 100 to couple the individual modules 5060 to each other. However, as described above, due to the movement of lithium ions, the expansion and contraction of the battery module 5076 is primarily along the Z axis rather than the X axis. Therefore, the system 100 (i.e., the middle portion 5410) will not be elastically deformed to absorb the expansion and contraction of the battery module 5076 in the Z axis.

[0322] and Figure 53-83 The disclosed system 100 is configured to advantageously absorb forces associated with the dynamic movement of the module 5076 in contrast to the manner in which Figures 84-88 It is disclosed that the system 100 may also advantageously take into account various material conditions associated with the battery pack 90 .

[0323] i. System in neutral state

[0324] Although it can be clearly seen from the above disclosure that the various elastically deformable battery module connector systems 5100 included in the battery pack 90 may be subjected to different forces, the following disclosure related to the first system 5102a, the first battery module 5062a and the second battery module 5062b combined with the general concept disclosed is applicable to all systems 5100 included in the battery pack 90. Figures 85-86 shows the neutral state S N An elastically deformable battery module connector system 5100 in which neither tension nor pressure is applied to the system 5100. In the neutral state S N (i) The rear wall of each male terminal housing in the male terminal housing 1100 is positioned at a housing gap L from the inner wall of the busbar housing 5600. HG (e.g., about 2-4 mm), (ii) the formed length L of the busbar 200 BN is about 110-120 mm, preferably 115-117 mm, and most preferably 116 mm (ie, the length L of the middle portion IPN The height H of the busbar 200 is between 23 mm and 31 mm, and preferably 27 mm. BN 15-30 mm, preferably 20-25 mm (ie, the height H of the middle part IPN 20 mm to 28 mm, and preferably 23 mm), and the width W of the busbar 200 BN is 15-25 mm, preferably 20 mm, (iii) the length L of the system 5100 SN The height H of the system 5100 is about 150-200 mm, preferably 160-190 mm, and most preferably 182 mm. SNis 35-40 mm, preferably 37 mm, and the width of the system 5100 is 25-35 mm, preferably 31 mm, (iv) the length L of the neck defined between the outer notches 5264a, 5264b of the busbar 5200 in the neutral state NN 25-30 mm, preferably 22 mm, (viii) the length L of the gap defined between the opposing inner surfaces of the outer notches 5264a, 5264b of the busbar 5200 in the neutral state GN 14 and 22 mm, preferably 22 mm, (vi) the height H of the busbar 5200 BN Forming length L with busbar 5200 BN is 20-25%, preferably 21.5%, (vii) the bottom surface 5215b of the peripheral portions 5402a, 5402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (viii) the bottom surface 5215b of the peripheral portions 5402a, 5402b is substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cell 5076, (ix) the middle portion 5410 is positioned between the fourth side wall 5068d of the battery module 5062a and the first side wall 5068a of the adjacent battery module 5062b, and (x) the length L of the busbar 200 is BN and the length L of the system 3100 SN Substantially perpendicular to the thickness T of the battery cell 5076 CELL , but substantially parallel to the X axis. Thus, the system 5100 is installed in the battery pack 5090 at a nominal material condition that is between the maximum material condition and the minimum material condition.

[0325] ii. System in a contracted state

[0326] Fig.87 The illustrated components of the battery pack 5090 are shown in a maximum material condition. In particular, the maximum material condition occurs when: (i) the battery modules 5062a, 5062b are positioned as close to each other as possible while being within the specified tolerances of the battery pack 5090; and (ii) the system 5100 has a maximum possible length while being within the specified tolerances of the battery pack 5090. To illustrate the maximum material state, the elastically deformable battery module connector system 5100 is in a compressed state S C , where busbar 5200 is subjected to maximum compression C max In this embodiment, the maximum compression C max The force is between 38 and 46 N, and preferably 42 N. The maximum compression C maxForce is applied to the system 5100 in the third direction (along the positive (+) X-axis) via battery module 5062a and in the first direction (along the negative (-) X-axis) via the configuration of battery modules 5062a, 5062b.

[0327] In the compressed state S C (i) The rear wall of each male terminal housing in the male terminal housing 1100 is positioned at a housing gap L from the inner wall of the busbar housing 5600. HG (eg, about 0-0.05 mm or adjacent); (ii) the length L of the busbar 200 BC is about 106-116 mm, preferably 111-113 mm, and most preferably 112 mm (i.e., the length L of the middle portion IPC between 23 mm and 31 mm, and preferably 27 mm); the height H of the busbar 200 BC 15-30 mm, preferably 20-25 mm (ie, the height H of the middle part IPC between 20 mm and 28 mm, and preferably 23 mm); and the width W of the busbar 200 BC 15-25 mm, preferably 20 mm; (iii) the length L of the system 5100 SC is about 178 mm, the height of the system 5100 is 37 mm, and the width of the system 5100 is 31 mm, (iv) the length L of the neck defined between the outer notches 5264a, 5264b of the busbar 5200 in the compressed state NC 21-26 mm, preferably 18 mm, (v) the length L of the gap defined between the opposing inner surfaces of the outer notches 5264a, 5264b of the busbar 5200 in the compressed state GC is 10 and 18 mm, preferably 14 mm, (vi) the height H of the busbar 5200 BC The length L of busbar 5200 BC The ratio between the outer portions 5402a and 5402b is 22.3%, (vii) the bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (viii) the bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cell 5076, (ix) the middle portion 5410 is positioned between the fourth side wall 5068d of the battery module 5062a and the first side wall 5068a of the adjacent battery module 5062b, and (ix) the length L of the bus bar 200 is BC and the length L of the system 3100 SCSubstantially perpendicular to the thickness T of the battery cell 5076 C , but is essentially parallel to the X-axis.

[0328] iii. System in extended state

[0329] Fig.88 The components of the battery pack 5090 are shown in a minimum material condition. In particular, the minimum material condition occurs when: (i) the battery modules 5062a, 5062b are as far apart from each other as possible while being within the specified tolerance of the battery pack 5090; and (ii) the system 5100 has a length as small as possible while being within the specified tolerance of the battery pack 5090. To illustrate the minimum material condition, the elastically deformable battery module connector system 5100 is in an extended state S E , where busbar 5200 is subjected to maximum tension TE max In this embodiment, the maximum tension TE max Between 38 and 46 N, and preferably 42 N. The maximum tension TE max It is applied to the system 5100 in the third direction (along the positive (+) X-axis) via battery module 5062a, and in the first direction (along the negative (-) X-axis) via the configuration of battery modules 5062a, 5062b.

[0330] In the extended state S E (i) the rear wall of each male terminal housing in the male terminal housing 1100 is separated from the inner wall of the busbar housing 5600 by about 4-6 mm, (ii) the length L of the busbar 200 BE is about 114-124 mm, preferably 119-121 mm, and most preferably 120 mm (i.e., the length L of the middle portion IPE The height H of the busbar 200 is between 23 mm and 31 mm, and preferably 27 mm. BE 15-30 mm, preferably 20-25 mm (ie, the height H of the middle part IPE between 20 mm and 28 mm, and preferably 23 mm), and the width W of the busbar 200 BE is 15-25 mm, preferably 20 mm, (iii) the length L of the system 5100 SE The height H of the system 5100 is approximately 186 mm. SE is 37 mm, and the width of the system 5100 is 31 mm, (iv) the length L of the neck defined between the outer notches 264a, 264b of the busbar 5200 in the compressed state NE29-34 mm, preferably 22 mm, (v) the length L of the gap defined between the opposing inner surfaces of the outer notches 5264a, 5264b of the busbar 5200 in the compressed state GE 18 and 26 mm, preferably 24 mm, (vi) the height H of the busbar 5200 BE The length L of busbar 5200 BE is 20.8%, (vii) the bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (viii) the bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cell 5076, (ix) the middle portion 5410 is positioned between the fourth side wall 5068d of the battery module 5062a and the first side wall 5068a of the adjacent battery module 5062b, and (x) the length L of the bus bar 200 is BE and the length L of the system 5100 SE Substantially perpendicular to the thickness T of the battery cell 5076 C , but is essentially parallel to the X-axis.

[0331] V. Alternative Busbar Configurations

[0332] Figure 1-83 The busbar 200 shown in the figure is available Figure 89-102 , which alternative busbars 200 include alternative versions of elastically deformable intermediate sections 412a-412m. Similar to the busbar 200 discussed above, each of these alternative designs includes: (i) a first peripheral connecting section 402a, (ii) a second connecting section 402b, and (iii) an elastically deformable intermediate section 412a-412m located between the first elastically deformable section 402a and the second elastically deformable section 402b. In these alternative embodiments, the elastically deformable intermediate section may include a linear section (see Figures 89-90 , 92-93), arched part (see Fig.91 , 94 , 95), parabola part (see Figures 96-97 , 99-101), other shapes (see Fig.98 ) or multiple discrete shapes separated by linear or other shape segments (see Fig.102 ). It should be understood that the shapes disclosed herein are not limiting and are merely exemplary in nature. Therefore, the present disclosure contemplates other shapes or combinations of multiple shapes.

[0333] VI. Third Embodiment of the System

[0334] Similar to the system 100 described above, Figure 103-104 Another embodiment of system 7100 is shown. For the sake of brevity, the above disclosure related to system 100 will not be repeated below, but it should be understood that in various embodiments, the same reference numerals represent the same structure. For example, the disclosure related to busbar 200 is also applicable to busbar 7200. In addition, it should be understood that the compression and / or extension of busbar 7200 is similar or the same as the compression and / or extension disclosed with respect to busbar 200. The only difference in this embodiment of system 7100 is the fact that busbar housing 7600: (i) only includes two couplers 7597 on the top range of housing 7600 and two couplers 7597 on the bottom range of housing 7600, and (ii) the first range 606 and the fifth range 614 of housing 600 are omitted in this embodiment.

[0335] VII. Alternative male terminal configurations

[0336] Figure 1-83 The male terminal assembly 1430 shown in FIG. 1 may be replaced with: (i) an opening to receive a threaded connector, (ii) a male terminal 4430 (eg, Fig.105 ), 5430 (as shown in Fig.106 ), 6430 (as shown in Fig.107 ), 7430 (as shown in Fig.108 ) or 8430 (as shown in Fig.109 ), or (iii) any male connector disclosed in a patent or patent application incorporated herein by reference. Since each of male terminals 4430, 5430, 6430, 7430, or 8430 has similar features to male terminal 1430 and is described in detail in other applications or patents incorporated herein by reference, this disclosure will not be repeated herein. For example, male terminal 4430 is disclosed in PCT / US2019 / 036,010, male terminal 5430 is disclosed in PCT / US2019 / 036,010 and PCT / US2021 / 043,686, male terminal 6430 is disclosed in PCT / US2021 / 043,788, male terminal 7430 is disclosed in U.S. Provisional Application No. 63 / 286,072, and male terminal 8430 is disclosed in PCT / US2021 / 047,180, each of which is incorporated herein by reference.

[0337] The connector system 100 is T4 / V4 / D2 / M2, wherein the system 100 meets and exceeds: (i) T4 is exposure of the system 100 to 150°C, (ii) V4 is severe vibration, (iii) D2 is 200k mile durability, and (iv) M2 is less than the force of less than 45 Newtons required to connect the male terminal assembly 1430 to the female terminal assembly 2430, 3430. In other embodiments, the connector system 100 can be T4 / V4 / S3 / D2 / M2, wherein the system 100 also meets and exceeds the S3 seal high pressure spray. In addition to meeting the T4 / V4 / S3 / D2 / M2 standards, meeting the 360° standard, the boltless standard, and meeting the PCT standard, the system 100 can also be scannable and therefore can meet the PCTS standard (see PCT / US2020 / 049870).

[0338] The spring member 1440c disclosed herein can be replaced with a spring member shown in PCT / US2019 / 36010 or U.S. Provisional Patent 63 / 058,061. In addition, it should be understood that alternative configurations of the connector assembly 1000 are possible. For example, any number of male terminal assemblies 1430 (e.g., between 2-30, preferably between 2-8, and most preferably between 2-4) can be located in the housing 1100, and any number of female terminal assemblies 2430, 3430 (e.g., between 2-30, preferably between 2-8, and most preferably between 2-4) can be located in the housing 2100, 3100. In addition, alternative configurations of the connector system 998 are possible. For example, the female connector assemblies 2000a, 2000b can be reconfigured to receive these multiple male terminal assemblies 1430 into a single female terminal assembly 2430.

[0339] It should also be understood that the male terminal assembly may have any number of contact arms 1494 (e.g., between 2-100, preferably between 2-50, and most preferably between 2-8) and any number of spring arms 1452 (e.g., between 2-100, preferably between 2-50, and most preferably between 2-8). As discussed above, the number of contact arms 1494 may not be equal to the number of spring arms. For example, the number of contact arms 1494 may be greater than the number of spring arms 1452. Alternatively, the number of contact arms 1494 may be less than the number of spring arms 1452.

[0340] Materials and Publications Incorporated by Reference

[0341] PCT application numbers PCT / US2022 / 037508, PCT / IB2022 / 057772, PCT / US2021 / 057959, PCT / US2021 / 047180, PCT / US2021 / 043788, PC T / US2021 / 043686, PCT / US2021 / 033446, PCT / US2020 / 050018, PCT / US2020 / 049870, PCT / US2020 / 014484, PCT / US2020 / 013757, PCT / US2019 / 036127, PCT / US2019 / 036070, PCT / US2019 / 036010 and PCT / US2018 / 019787, U.S. Patent Application No. 16 / 194891 and U.S. Provisional Applications 62 / 897962, 63 / 051639, 63 / 234320, 63 / 337596 and U.S. Design Patent Application Nos. 29 / 749813 and 29 / 749790, all of which are incorporated herein by reference in their entirety and become a part hereof.

[0342] SAE specifications, including: J1742_201003, entitled "Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses - Test Methods and General Performance Requirements," last revised March 2010, each of which is incorporated herein by reference in its entirety and made a part hereof.

[0343] ASTM specifications, including: (i) D4935-18, entitled "Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials," and (ii) ASTM D257, entitled "Standard Test Methods for DC Resistance or Conductance of Insulating Materials," each of which is incorporated herein by reference in its entirety and made a part hereof.

[0344] American National Standards Institute and / or EOS / ESD Association specifications, including: ANSI / ESDSTM 11.11 Measurement of Surface Resistivity of Static Dissipative Planar Materials, each of which is incorporated herein by reference in its entirety and made a part hereof.

[0345] DIN Specifications, including Connectors for Electronic Equipment - Tests and Measurements - Part 5-2: Current-Carrying Capacity Test; Test 5b: Current-Temperature Derating (IEC 60512-5-2:2002), each of which is hereby incorporated by reference in its entirety and made a part hereof.

[0346] USCAR specifications, including: (i) SAE / USCAR-2, Revision 6, which was last revised in February 2013 and has ISBN: 978-0-7680-7998-2, (ii) SAE / USCAR-12, Revision 5, which was last revised in August 2017 and has ISBN: 978-0-7680-8446-7, (iii) SAE / USCAR-21, Revision 3, which was last revised in December 2014, (iv) SAE / USCAR-25, Revision 3, which was revised in March 2016 and has ISBN: 978-0-7680-8319-4, (v) SAE / USCAR-37, which was revised in August 2008 and has ISBN: 978-0-7680-2098-4, (vi) SAE / USCAR-38, Revision 1, as revised in May 2016, and having ISBN: 978-0-7680-8350-7, each version is incorporated herein by reference in its entirety and made a part hereof.

[0347] Other standards, including Federal Test Standards 101C and 4046, each of which is incorporated herein by reference in its entirety and becomes a part hereof. Although some embodiments have been illustrated and described, many modifications are conceivable without significantly departing from the spirit of the present disclosure; and the scope of protection is limited only by the scope of the appended claims. For example, the overall shape of the above-mentioned components can be changed to: a triangular prism, a pentagonal prism, a hexagonal prism, an octagonal prism, a sphere, a cone, a tetrahedron, a cuboid, a dodecahedron, an icosahedron, an octahedron, an ellipsoid, or any other similar shape. In another example, all fusion of the busbar 200 may be performed before bending the busbar 200. In a further example, the busbar 200 may not be fused, but the busbar 200 may be 3D printed to have a desired configuration, or a separate component (e.g., a strip) may be added to the busbar 200 to help prevent delamination during the bending process. In addition, in another embodiment, the female connector assembly 2000 may be directly coupled to the system 100, and the male connector assembly 1000 may be coupled to the battery module 60. In addition, the bending height H IPN and bending length L IPN may not remain substantially constant in all states (compression, normal, extension); instead, the bending height H IPN and bending length L IPNIt may vary its height / length by more than 2.5%, and may vary its height / length by between 3% and 25%.

[0348] Headings and subheadings, if any, are used for convenience only and are not limiting. The word "exemplary" is used to mean serving as an example or illustration. To the extent that the terms "including," "having," or similar terms are used, such terms are intended to be inclusive in a manner similar to the term comprising, as including is interpreted to mean comprising when used as a transitional word in a claim. Relational terms (such as first and second, etc.) may be used to distinguish one entity or action from another without necessarily requiring or implying any actual relationship or order between such entities or actions.

[0349] Such as on the one hand, this aspect, on the other hand, some aspects, one or more aspects, an implementation, this implementation, another implementation, some implementations, one or more implementations, an embodiment, this embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, this configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the disclosure, its other variants, etc. are for convenience and do not mean that the disclosure related to such phrases is essential to the subject technology, or that such disclosures are applicable to all configurations of the subject technology. The disclosure related to such phrases can be applicable to all configurations, or one or more configurations. The disclosure related to such phrases can provide one or more examples. Phrases such as aspects or some aspects can refer to one or more aspects, and vice versa, which is also applicable to other aforementioned phrases.

[0350] In view of the above description, it will be clear to those skilled in the art that various modifications are made to the present disclosure. Preferred embodiments of the present disclosure are described herein, including the best mode of implementing the present disclosure known to the inventor. It should be understood that the illustrated embodiments are exemplary only and should not be considered to limit the scope of the present disclosure.

Claims

1. An elastically deformable connector system for connecting battery modules in a battery pack, the connector system comprising: A busbar assembly, comprising: (i) a busbar having a plurality of individual conductors arranged vertically to provide a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion between the first peripheral portion and the second peripheral portion; (ii) a first male connector assembly coupled to the first peripheral portion of the busbar; (iii) a second male connector assembly coupled to the second peripheral portion of the busbar; (iv) a busbar housing enclosing a substantial portion of the busbar; and Wherein, after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the middle portion is capable of elastic deformation to compensate for each of the compression movement and the expansion movement of the pair of battery modules.

2. The elastically deformable connector system according to claim 1, wherein: (i) the first peripheral portion is substantially coplanar with the second peripheral portion, and (ii) a majority of the elastically deformable intermediate portion is non-coplanar with either the first peripheral portion or the second peripheral portion.

3. The elastically deformable connector system according to claim 1, wherein: (i) the first peripheral portion and the second peripheral portion lie substantially in a first plane, and (ii) the majority of the elastically deformable intermediate portion lies outside of the first plane.

4. The elastically deformable connector system according to claim 1, wherein: The first peripheral portion and the second peripheral portion have a substantially linear configuration.

5. The elastically deformable connector system according to claim 4, wherein: The elastically deformable middle portion comprises at least one curvilinear range.

6. The elastically deformable connector system according to claim 5, wherein: The interaction between the first portion of the elastically deformable middle portion and the first peripheral portion defines a first external recess, wherein the interaction between the second portion of the elastically deformable middle portion and the second peripheral portion defines a second external recess, and wherein the first external recess and the second external recess are in a relative positional relationship.

7. The elastically deformable connector system according to claim 6, wherein: The first external notch includes an external notch angle defined in a neutral position, wherein when the compressive activation force F A When applied to the generatrix, the outer notch angle decreases.

8. The elastically deformable connector system according to claim 6, wherein: The first external notch includes an external notch angle defined in a neutral position, wherein when the expansion activation force F A When applied to the generatrix, the outer notch angle increases.

9. The elastically deformable connector system according to claim 1, wherein: The elastically deformable intermediate portion has a curvilinear configuration that substantially matches the configuration of the capital letter Omega in the Greek alphabet.

10. The elastically deformable connector system according to claim 1, wherein: The elastically deformable intermediate portion has a curvilinear configuration that substantially matches a configuration of a symbol of an energy management unit, the ohm.

11. The elastically deformable connector system according to claim 1, wherein: After the busbar has been bent and assembled, the busbar in the neutral position has an overall formed length L BN , and where the total length L BN A change of 5% can be made to compensate for the compression and expansion of the pair of battery modules.

12. The elastically deformable connector system according to claim 1, wherein: After the busbar has been bent and assembled, the busbar in the neutral position has an overall formed length L BN , and where the total length L BN Able to follow an activation force F of less than 50 Newtons A changed by the application of.

13. The elastically deformable connector system according to claim 12, wherein: The activation force F A is the compressive force, and where the compressive activation force F A The total formed length L of the busbar can be BN Reduced by 4mm.

14. The elastically deformable connector system according to claim 12, wherein: The activation force F A is the expansion force, and wherein the expansion activation force F A The total formed length L of the busbar can be BN Increase by 4mm.

15. The elastically deformable connector system according to claim 1, wherein: The busbar has a total unbent length L UB , and wherein, after the busbar has been bent and assembled, the busbar in the neutral position has an overall formed length L BN , and wherein the total forming length L BN Less than the total unbent length L UB .

16. The elastically deformable connector system according to claim 15, wherein: The total forming length L BN Than the total unbent length L UB At least 10% smaller.

17. The elastically deformable connector system according to claim 15, wherein: The total forming length L BN Than the total unbent length L UB At least 20% smaller.

18. The elastically deformable connector system of claim 1, wherein: The elastically deformable busbar includes at least one region that is selectively fused together to form a solid single conductor.

19. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The middle part has a bending height H greater than 10 mm IPN .

20. The elastically deformable connector system according to any one of claims 1 to 18, wherein: The busbar has a bending height H IPN , and wherein, when the middle portion of the busbar is elastically deformed to compensate for the compression and expansion of the pair of battery modules, the bending height H IPN Remains basically constant.

21. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The busbar has a bending height H IPN , and wherein, when the middle portion is elastically deformed to compensate for the compression and expansion of the pair of battery modules, the bending height H IPN The change does not exceed 2.5%.

22. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The middle part has a bending length L greater than 10 mm IPN .

23. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The middle part has a bending length L IPN , and wherein, when the middle portion is elastically deformed to compensate for the compression and expansion of the pair of battery modules, the bending length L IPN Remains basically constant.

24. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The middle portion has a bending length L IPN , and wherein, when the middle portion is elastically deformed to compensate for the compression and expansion of the pair of battery modules, the bending length L IPN The change does not exceed 2.5%.

25. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The middle part has a gap length L of at least 15 mm in the neutral state GN .

26. The elastically deformable connector system of claim 25, wherein: The gap length L of the busbar in the compressed state GN is smaller than the gap length L in the neutral state GN .

27. The elastically deformable connector system of claim 25, wherein: The gap length L of the busbar in the extended state GN Greater than the gap length L in the neutral state GN .

28. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The elastically deformable middle portion includes: (i) a pair of fused segments, and (ii) an unfused segment located between the fused segments.

29. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The first peripheral portion includes: (i) a fully fused region, and (ii) an unfused region located adjacent to the fully fused region.

30. The elastically deformable connector system of claim 29, wherein: The fully fused region is contained in the end sectors of the busbar, and (ii) the unfused region is contained in the central sector.

31. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The elastically deformable middle portion includes a pair of fused regions and at least one unfused region located between the fused regions.

32. An elastically deformable connector system according to any one of claims 1 to 18, wherein: The elastically deformable intermediate portion has not completely solidified into a region of a single solid conductor.

33. An elastically deformable connector system for connecting battery modules in a battery pack, the connector system comprising: A busbar assembly, comprising: (i) a busbar having a plurality of individual conductors that have undergone a fusion process to form a solid single conductor in selected areas of the busbar, wherein the busbar comprises a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion between the first peripheral portion and the second peripheral portion; (ii) a first male connector assembly coupled to the first peripheral portion of the busbar; (iii) a second male connector assembly coupled to the second peripheral portion of the busbar; (iv) a busbar housing enclosing a substantial portion of the busbar; and Wherein, after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the middle portion is capable of elastic deformation to compensate for each of the compression movement and the expansion movement of the pair of battery modules.

34. The elastically deformable connector system of claim 33, wherein: (i) the first peripheral portion is substantially coplanar with the second peripheral portion, and (ii) the majority of the elastically deformable intermediate portion is non-coplanar with both the first peripheral portion and the second peripheral portion.

35. The elastically deformable connector system of claim 33, wherein: (i) the first and second peripheral portions lie substantially in a first plane, and (ii) the majority of the elastically deformable intermediate portion lies outside of the first plane.

36. The elastically deformable connector system of claim 33, wherein: The first peripheral portion and the second peripheral portion have a substantially linear configuration.

37. The elastically deformable connector system of claim 36, wherein: The elastically deformable middle portion comprises at least one curvilinear range.

38. The elastically deformable connector system of claim 37, wherein: The interaction between the first portion of the elastically deformable middle portion and the first peripheral portion defines a first external recess, wherein the interaction between the second portion of the elastically deformable middle portion and the second peripheral portion defines a second external recess, and wherein the first external recess and the second external recess are in a relative positional relationship.

39. The elastically deformable connector system of claim 38, wherein: The first external notch includes an external notch angle defined in a neutral position, wherein when the compressive activation force F A When applied to the generatrix, the outer notch angle decreases.

40. The elastically deformable connector system of claim 38, wherein: The first external notch includes an external notch angle defined in a neutral position, wherein when the expansion activation force F A When applied to the generatrix, the outer notch angle increases.

41. The elastically deformable connector system of claim 33, wherein: The elastically deformable intermediate portion has a curvilinear configuration that substantially matches the configuration of the capital letter Omega in the Greek alphabet.

42. The elastically deformable connector system of claim 33, wherein: After the busbar has been bent and assembled, the busbar in the neutral position has an overall formed length L BN , and where the total length L BN A change of 5% can be made to compensate for the compression and expansion of the pair of battery modules.

43. The elastically deformable connector system of claim 33, wherein: After the busbar has been bent and assembled, the busbar in the neutral position has an overall formed length L BN , and where the total length L BN Able to follow an activation force F of less than 50 Newtons A changed by the application of.

44. The elastically deformable connector system of claim 43, wherein: The activation force F A is the compressive force, and where the compressive activation force F A The total formed length L of the busbar can be BN Reduced by 4mm.

45. The elastically deformable connector system of claim 43, wherein: The activation force F A is the expansion force, and wherein the expansion activation force F A The total formed length L of the busbar can be BN Increase by 4mm.

46. ​​An elastically deformable connector system according to any one of claims 33 to 43, wherein: The middle part has a bending height H greater than 10 mm IPN .

47. An elastically deformable connector system according to any one of claims 33 to 43, wherein: The busbar has a bending height H IPN , and wherein, when the middle portion of the busbar is elastically deformed to compensate for the compression and expansion of the pair of battery modules, the bending height H IPN Remains basically constant.

48. An elastically deformable connector system according to any one of claims 33 to 43, wherein: The middle part has a bending length L IPN , and wherein, when the middle portion is elastically deformed to compensate for the compression and expansion of the pair of battery modules, the bending length L IPN The change does not exceed 2.5%.

49. An elastically deformable connector system according to any one of claims 33 to 43, wherein: The middle part has a gap length L of at least 15 mm in the neutral state GN .

50. The elastically deformable connector system of claim 49, wherein: The gap length L of the busbar in the compressed state GN is smaller than the gap length L in the neutral state GN .

51. The elastically deformable connector system of claim 49, wherein: The gap length L of the busbar in the extended state GN Greater than the gap length L in the neutral state GN .

52. An elastically deformable connector system according to any one of claims 33 to 43, wherein: The elastically deformable middle portion includes: (i) a pair of fused segments, and (ii) an unfused segment located between the fused segments.

53. An elastically deformable connector system according to any one of claims 33 to 43, wherein: The elastically deformable intermediate portion has not completely solidified into a region of a single solid conductor.

54. An elastically deformable connector system for connecting battery modules in a battery pack, the connector system comprising: A busbar assembly, comprising: (i) a busbar having a plurality of individual conductors arranged vertically to provide: (a) a first peripheral portion having a first male connector component, (b) a second peripheral portion having a second male connector component, and wherein the second peripheral portion is substantially coplanar with the first peripheral portion, and (c) an elastically deformable intermediate portion between the first peripheral portion and the second peripheral portion, and wherein a majority of the elastically deformable intermediate portion is not coplanar with either the first peripheral portion or the second peripheral portion; (ii) a busbar housing enclosing a substantial portion of the elastically deformable intermediate portion; (iii) at least one connector coupled to the bus bar; and Wherein, after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the middle portion is elastically deformed to compensate for each of the compression movement and the expansion movement of the pair of battery modules.

55. An elastically deformable connector system for connecting battery modules in a battery pack, the connector system comprising: A busbar assembly having a busbar including a plurality of individual conductors arranged vertically to provide: (i) a first peripheral portion located in a first plane; (ii) a second peripheral portion located within the first plane; (iii) an elastically deformable intermediate portion located between the first peripheral portion and the second peripheral portion, and wherein a majority of the elastically deformable intermediate portion is located outside the first plane; and Wherein, after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the middle portion is elastically deformed to compensate for each of the compression movement and the expansion movement of the pair of battery modules.

56. An elastically deformable connector system for connecting battery modules in a battery pack, the connector system comprising: A busbar assembly comprising a busbar having a plurality of individual conductors arranged vertically to provide: (i) a first peripheral portion; (ii) a second peripheral portion; (iii) an elastically deformable intermediate portion between the first peripheral portion and the second peripheral portion; (iv) a formed length L extending between opposite end edges of the busbar assembly BN ;as well as Among them, when the activation force F is less than 50 Newtons A When applied to the busbar, the forming length L BN Can vary by more than 2.5%.

57. An elastically deformable connector system for connecting battery modules in a battery pack, the connector system comprising: A busbar assembly comprising a busbar having a plurality of individual conductors arranged vertically to provide: (i) a first peripheral portion having a substantially linear configuration; (ii) a second peripheral portion having a substantially linear configuration; (iii) an elastically deformable intermediate portion located between the first peripheral portion and the second peripheral portion and having at least one curvilinear extent; and The curve range of the middle part is configured to be elastically deformed so as to reduce the activation force F A Impact on the busbar.

58. An elastically deformable connector system according to any one of claims 54-57, wherein: The interaction between the first portion of the elastically deformable middle portion and the first peripheral portion defines a first external recess, wherein the interaction between the second portion of the elastically deformable middle portion and the second peripheral portion defines a second external recess, and wherein the first external recess and the second external recess are in a relative positional relationship.

59. The elastically deformable connector system of claim 58, wherein: The first external notch includes an external notch angle defined in a neutral position, wherein when the compressive activation force F A When applied to the busbar assembly, the external notch angle is reduced.

60. The elastically deformable connector system of claim 58, wherein: The first external notch includes an external notch angle defined in a neutral position, wherein when the expansion activation force F A When applied to the busbar assembly, the external notch angle increases.

61. An elastically deformable connector system according to any one of claims 54 to 57, wherein: The elastically deformable intermediate portion has a curvilinear configuration that substantially matches the configuration of the capital letter Omega in the Greek alphabet.

62. An elastically deformable connector system according to any one of claims 54 to 57, wherein: After the busbar has been bent and assembled, the busbar in the neutral position has an overall formed length L BN , and where the total length L BN A change of 5% can be made to compensate for the compression and expansion of the pair of battery modules.

63. An elastically deformable connector system according to any one of claims 54-55, wherein: After the busbar has been bent and assembled, the busbar in the neutral position has an overall formed length L BN , and where the total length L BN Able to follow an activation force F of less than 50 Newtons A changed by the application of.

64. The elastically deformable connector system of claim 63, wherein: The activation force F A is the compressive force, and where the compressive activation force F A The total formed length L of the busbar can be BN Reduced by 4mm.

65. The elastically deformable connector system of claim 63, wherein: The activation force F A is the expansion force, and wherein the expansion activation force F A The total formed length L of the busbar can be BN Increase by 4mm.

66. An elastically deformable connector system according to any one of claims 54 to 57, wherein the middle portion has a bending height H greater than 10 mm. IPN .

67. An elastically deformable connector system according to any one of claims 54 to 57, wherein: The busbar has a bending height H IPN , and wherein, when the middle portion of the busbar is elastically deformed to compensate for the compression and expansion of the pair of battery modules, the bending height H IPN Remains basically constant.

68. An elastically deformable connector system according to any one of claims 54 to 57, wherein: The middle part has a bending length L IPN , and wherein, when the middle portion is elastically deformed to compensate for the compression and expansion of the pair of battery modules, the bending length L IPN The change does not exceed 2.5%.

69. An elastically deformable connector system according to any one of claims 54 to 57, wherein: The middle part has a gap length L of at least 15 mm in the neutral state GN .

70. The elastically deformable connector system of claim 69, wherein: The gap length L of the busbar in the compressed state GN is smaller than the gap length L in the neutral state GN .

71. The elastically deformable connector system of claim 69, wherein: The gap length L of the busbar in the extended state GN Greater than the gap length L in the neutral state GN .

72. An elastically deformable connector system according to any one of claims 54 to 57, wherein: The elastically deformable middle portion includes: (i) a pair of fused segments, and (ii) an unfused segment located between the fused segments.

73. An elastically deformable connector system according to any one of claims 54 to 57, wherein: The elastically deformable intermediate portion has not completely solidified into a region of a single solid conductor.

74. An elastically deformable connector system for connecting battery modules in a battery pack.

75. A battery pack having a plurality of battery modules and an elastically deformable connector system configured to couple the battery modules included in the plurality of battery modules to each other.

76. A power distribution assembly having a battery pack with an elastically deformable connector system configured to couple a component contained in the battery pack to another component in the battery pack.

77. An elastically deformable intermediate portion of a busbar configured to compensate for: (i) each of a compressive motion and an expansion motion of the pair of battery modules, or (ii) a material condition of the pair of battery modules.

78. A bus bar assembly connected to a pair of battery modules in the battery pack and configured to compensate for each of compression movement and expansion movement of the pair of battery modules.

79. A bus bar assembly connected to a pair of battery modules in the battery pack and configured to compensate for material conditions of the pair of battery modules.

80. An electric power distribution assembly having a busbar according to any one of claims 1 to 79.

Images