Blade terminal bus bar with finger protection

Abstract

A bus bar assembly (16) includes a non-conductive terminal cover (18) configured to at least partially surround a conductive terminal (14). The terminal cover (18) has a peripheral wall (26) configured to surround at least a portion of the terminal (14) to provide a gap (44) configured to expose the terminal (14). The terminal cover (18) includes a first attachment feature (22). The terminal cover (18) also includes a bus bar (36) having an end portion (46) configured to mechanically and electrically engage the terminal (14) in an assembled state. The terminal cover (18) also includes a non-conductive shield (20) enclosing the bus bar (36). The shield (20) includes a second attachment feature (24) configured to removably engage the first attachment feature (22) in an assembled state to secure the shield (20) to the terminal cover (18).

Description

This application is a divisional application of the invention application with application date of June 24, 2020, application number CN 202010585815.6, and title “Blade terminal busbar with finger protection”. CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 865,470, filed on June 24, 2019, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] The present disclosure relates to bus bars used, for example, to connect battery cells. Background Art

[0003] A battery module has multiple battery cells with terminals that are electrically connected to each other to provide a more powerful battery than a single battery cell. One common type of electrical connection is a cable with terminal rings at opposite ends. Each terminal ring is bolted to one of the terminals of one of the battery cells. Another common type of electrical connection is a bus bar, which is bolted to the battery cells in a similar manner to a cable.

[0004] For example, battery modules of the type used in automotive applications can provide large amounts of electrical energy. It would be desirable to design a system that electrically connects and disconnects battery cells in a manner that is safe for the battery module assembly and / or service technicians. Summary of the invention

[0005] In an exemplary embodiment, the busbar assembly mainly includes a non-conductive terminal cover, which is configured to at least partially surround a conductive terminal. The terminal cover has a peripheral wall, which is configured to surround at least a portion of the terminal to provide a gap configured to expose the terminal. The terminal cover includes a first attachment feature. The terminal cover also includes a busbar having an end, which is configured to mechanically and electrically engage the terminal in an assembled state. The terminal cover also includes a non-conductive shield enclosing the busbar. The shield includes a second attachment feature, which is configured to removably engage the first attachment feature in an assembled state to fix the shield to the terminal cover.

[0006] In another embodiment of any of the above, the peripheral wall is in the shape of a U disposed on at least three sides of the terminal.The peripheral wall extends beyond the terminal.

[0007] In another embodiment of any of the above, the terminal cover has a column that receives the terminal and is arranged inside the peripheral wall. The terminal is a male terminal. A gap is provided between the column and the peripheral wall, and the end is a female terminal configured to mate with the male terminal.

[0008] In another embodiment of any of the above, the terminal has a peripheral edge defining opposite faces of the terminal. The post receives the terminal and surrounds the peripheral edge, but leaves at least one face exposed. The peripheral wall extends beyond the post. The peripheral wall and post cooperate to provide a gap as a finger guard.

[0009] In another embodiment of any of the above, the terminal cover includes a first recess, the shield includes a second recess, and in an assembled state, the first recess and the second recess are nested with each other to enclose the terminal and the end of the bus bar.

[0010] In another embodiment of any of the above, one of the first attachment feature and the second attachment feature is a finger. The other of the first attachment feature and the second attachment feature is a protrusion. In the assembled state, the finger and the protrusion interlock with each other.

[0011] In another embodiment of any of the above, the shroud includes a plurality of shroud portions that cooperate with each other to enclose the bus bar.

[0012] In another embodiment of any of the above, the plurality of shield portions includes a first shield portion and a second shield portion nested relative to each other in an overlapping relationship.

[0013] In another embodiment of any of the above, in an assembled state, the first shield portion and the second shield portion are engaged in a snap-fit ​​relationship.

[0014] In another embodiment of any of the above, the first shield portion includes a first shell and a second shell fixed around a portion of the bus bar. The first shell and the second shell are received in an opening in the second shield portion.

[0015] In another embodiment of any of the above, the bus bar includes a U-shaped portion received in the first shield portion to provide a space between opposite ends of the bus bar. The space is configured to accommodate the blocking member

[0016] In another exemplary embodiment, a battery module mainly includes a battery cell having a conductive terminal. The battery module also includes a non-conductive terminal cover configured to at least partially surround the terminal. The terminal cover has a peripheral wall configured to surround at least a portion of the terminal to provide a gap to expose the terminal. The terminal cover includes a first attachment feature. The battery module also includes a bus bar, one end of which mechanically and electrically engages the terminal in an assembled state. The battery module also includes a non-conductive shield enclosing the bus bar. The shield includes a second attachment feature that removably engages the first attachment feature in an assembled state to secure the shield to the terminal cover.

[0017] In another embodiment of any of the above, the battery cell is a first battery cell and the terminal is a first terminal. The battery module also includes a second battery cell having a second terminal. The end is a first end, and the bus bar has a second end fixed to the second terminal.

[0018] In another embodiment of any of the above, the peripheral wall is in a U-shape arranged on at least three sides of the terminal. The terminal cover has a column arranged inside the peripheral wall. A gap is provided between the column and the peripheral wall. The terminal is a male terminal having a peripheral edge defining opposite faces of the terminal. The column receives the terminal and surrounds the peripheral edge, but leaves at least one face exposed. The end is a female terminal that matches the male terminal.

[0019] In another embodiment of any of the above, the peripheral wall extends beyond the post. The post extends beyond the terminal. The peripheral wall and the post cooperate to provide a gap that serves as a finger guard.

[0020] In another embodiment of any of the above, one of the first attachment feature and the second attachment feature is a finger. The other of the first attachment feature and the second attachment feature is a protrusion. In the assembled state, the finger and the protrusion interlock with each other.

[0021] In another embodiment of any of the above, the shield includes a plurality of shield portions cooperating with each other to enclose the bus bar. The plurality of shield portions include a first shield portion and a second shield portion nested relative to each other in an overlapping relationship.

[0022] In another exemplary embodiment, a method for electrically connecting battery cells mainly includes: step a) providing a non-conductive terminal cover above a conductive battery cell terminal. The terminal cover at least partially surrounds the terminal. The terminal is a male terminal. The terminal cover has a peripheral wall configured to surround at least a portion of the terminal. The terminal is arranged in a column of a shielding terminal. The peripheral wall and the column cooperate to provide a gap to expose the terminal. The method also includes step b): providing a busbar assembly having a busbar having an end with a female terminal. The non-conductive shield encloses the busbar, and the end is exposed through the shield. The method also includes step c) pushing the end into the gap and engaging with the terminal. The method also includes step d) mating the shield with the terminal cover to enclose the end. The mating step is performed simultaneously with the pushing step c).

[0023] In another embodiment of any of the above, the mating step d) includes connecting a first attachment feature on the terminal cover to a second attachment feature on the shield.The peripheral wall and the post cooperate to provide a gap that serves as a finger guard.

[0024] In another embodiment of any of the above, the bus bar assembly provides step b) including nesting the first shield portion relative to the second shield portion to enclose the bus bar with the shield. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present disclosure may be further understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0026] Figure 1 is a schematic diagram of a battery module having a plurality of battery cells electrically connected to each other using bus bars.

[0027] Figure 2A is a perspective view of a first bus bar assembly fixed to a terminal of a battery module.

[0028] Figure 2B is along Figure 2A A cross-sectional view of the first bus bar assembly taken along line 2B-2B in FIG.

[0029] Figure 2C is along Figure 2A A cross-sectional view of the first bus bar assembly taken along line 2C-2C in FIG.

[0030] Figure 3A yes Figure 2A A side view of a first bus bar assembly is shown in FIG.

[0031] Figure 3B is along Figure 3A A cross-sectional view of the first bus bar assembly taken along line 3B-3B in FIG.

[0032] Figure 4 It is an exploded perspective view of the first bus bar assembly in an unassembled state relative to the terminal.

[0033] Figure 5A is an exploded view of another terminal for use with the first bus bar assembly.

[0034] Figure 5B yes Figure 5A A cross-sectional view of a portion of a first bus bar assembly and a terminal is shown in FIG.

[0035] Fig. 6A is a perspective view of a second bus bar assembly.

[0036] Figure 6B yes Fig. 6A A side view of a second bus bar assembly is shown in FIG.

[0037] Fig. 7A yes Fig. 6A An enlarged perspective view of a portion of a second bus bar assembly is shown in FIG.

[0038] Figure 7B is a partial perspective side view of a second bus bar assembly with a center shroud portion removed to illustrate the bus bar shape.

[0039] Fig. 8A is along Figure 6B 8A-8A of the second bus bar assembly.

[0040] Figure 8B is along Figure 6B 8B-8B is a cross-sectional view of the second bus bar assembly taken along line 8B-8B in FIG.

[0041] Fig. 9 is an exploded perspective view of a second bus bar assembly, wherein a central portion of the bus bar is enclosed by a portion of a shroud.

[0042] The embodiments, examples and alternatives of the preceding paragraphs, claims or the following description and drawings, including any of their various aspects or corresponding single features, may be made independently or in any combination. Features described in conjunction with one embodiment are applicable to all embodiments, unless these features are incompatible. In the various figures, the same reference numerals and numbers indicate the same elements. DETAILED DESCRIPTION

[0043] Figure 1 A battery module 10 or battery pack assembly is schematically shown in FIG. The battery module 10 includes a plurality of battery cells 12 having positive and negative electrical terminals 14a, 14b (generally referred to as "terminals 14"). The terminals 14 of each cell 12 are electrically and mechanically connected to each other using a bus bar assembly 16, which is configured to provide sufficient power for a large electrical load such as an automotive hybrid propulsion system.

[0044] Reference Figure 2B , 3A 3B, the terminal 14 is provided by a male terminal provided by a quadrangular copper plate. It should be understood that the terminal 14 can be configured differently, for example, as a female terminal. There is a potential risk of electric shock when the terminal 14 is exposed. In order to mitigate the risk of electric shock when the busbar assembly 16 is connected and disconnected from the unit 12, a connector 17 ( Figure 4 ), such as a clip fitting, secures the non-conductive terminal cover 18 to the battery housing 19. The terminal cover 18 may also be integrally formed with the battery housing 19, such as during a plastic molding process.

[0045] As shown in FIGS. 2 to 4 , the bus bar assembly 16 includes a bus bar 36 ( Figure 2B , 2Cand 4). The bus bar 36 has an end 46 provided by a female terminal which mechanically and electrically engages and cooperates with the male terminal 14 in the assembled state.

[0046] A non-conductive terminal cover 18 at least partially surrounds the terminal 14. In this example, the U-shaped peripheral wall 26 surrounds at least a portion of the terminal 14 on, for example, three sides to provide a gap 44 configured to expose the terminal 14 to receive an end 46.

[0047] The terminal cover 18 also has a post 38 that receives the terminal 14 and is disposed inside the peripheral wall 26. The terminal 14 has a peripheral edge 40 that defines an opposing face 42 of the terminal 14. The post 38 extends outwardly from the base of the terminal cover 18 and, together with the peripheral wall 26, provides an E-shaped configuration. In this example, the post 38 surrounds the peripheral edge 40, but leaves at least one face 42 exposed. In this manner, the post 38 shields at least the end of the terminal 14 from being contacted. The peripheral wall 26 extends beyond the terminal 14 and beyond the post 38 to further isolate the terminal 14. The peripheral wall 26 and the post 38 cooperate to provide a gap 44 that serves as a "finger guard," i.e., to prevent undesired contact by a technician with the terminal.

[0048] In the present disclosure, "finger protection" refers to a construction that meets the standards in IEC60529 entitled "Degree of protection provided by the enclosure" and specification IP2XB related to finger entry protection. The "test finger" is based on a solid object with a diameter of 12.5 mm or more and a length of up to 80 mm being prevented from entering the enclosure. In addition, if a standard test finger with a length of 80 mm and a diameter of 12 mm enters the enclosure, there will be sufficient clearance from live parts (i.e., terminals). In this way, the disclosed finger-proof terminal cover 18 can prevent a technician from inadvertently contacting the terminals 14 when the terminal cover 18 is in place (for example, during assembly and / or removal of the bus bar assembly 16 relative to the battery cell 12).

[0049] The terminal cover 18 includes a first notch 28, and the shield 20 includes a second notch 30. The shield 20 is held to the terminal cover 18 by a retaining feature in the assembled state. In this example, a first attachment feature 22, such as a protrusion, on the terminal cover 18 can cooperate with a finger-like second attachment feature 24 on the shield 20, such as Figure 2B When the shield 20 and end 46 are pushed into the gap 44 during assembly, the first and second notches 28, 30 nest with each other (one with the other) to enclose the terminal 14, and the end 46 and fingers begin to deflect outwardly as the fingers slide over the protrusions.

[0050] Once the shield 20 is fully in place relative to the terminal cover 18, the second attachment feature 24 removably engages and interlocks with the first attachment feature 22. The engagement of the first and second attachment features 22, 24 indicates that the desired mechanical and electrical engagement has been achieved between the terminal 14 and the end 46, that is, the female terminal end 46 has engaged the opposing face 42 of the male terminal 14 and is securely enclosed. Once coupled, the retention feature prevents the bus bar 36 from being accidentally disconnected from the terminal 14 until the finger portion is depressed and the bus bar assembly 16 is pulled away from the terminal cover 18.

[0051] In this example, the shield 20 includes a plurality of shield portions that cooperate with each other to enclose the bus bar 36, which enables the bus bar to be repaired and the shield to be reused. Figure 2B , 2C 4, the plurality of shield portions include first and second shield portions 32, 34 nested relative to each other in an overlapping relationship. The first shield portion 32 includes a sleeve having an opening at one end that receives one end of the second shield portion 34. Although a retaining feature may be used between the first and second shield portions 32, 34, when the bus bar assembly 16 is in an assembled state relative to the terminal cover 18, the retaining feature is not necessarily required because the shield portions are held together by the first and second recesses 28, 30.

[0052] Figures 5A to 5B One example variation of terminal cover 18' configuration is shown. The configuration used in a battery module 10 may depend on the particular connector 17' and housing 19' arrangement and a given terminal 14a'.

[0053] exist Figures 6A to 9 Another example bus bar assembly 116 is shown in FIG. Like numbers refer to like elements. Fig. 6A , 6B 9 show an example variation of the terminal cover 18 configuration using different housings 19, 19'. Similar to the first busbar assembly 16, the non-conductive terminal cover 118 at least partially surrounds the terminal 114. There is a U-shaped peripheral wall 126 surrounding at least a portion of the terminal 114 on three sides to provide a gap 144 that exposes the terminal 114 to receive an end 146.

[0054] The posts 138 receive the terminals 114 on the interior of the peripheral wall 126. The posts 138 shield the terminals 114 from contact in a manner similar to that described above with respect to the first bus bar assembly 16. The peripheral wall 26 and posts 38 cooperate together to provide a gap 44 that acts as a "finger guard," i.e., prevents undesired contact with the terminals by a technician.

[0055] Rather than using a recess as in the first bus bar assembly 16, the second bus bar assembly 116 is received within the interior of the peripheral wall 126 rather than in an overlapping relationship. The shield 120 is retained to the terminal cover 118 by a retaining feature in the assembled state. The first attachment feature on the terminal cover is not shown in the figure, but is provided by a protrusion that cooperates with a finger-like second attachment feature 124 on the shield 20, as shown in FIG. Fig. 6A and 9 As the shroud 20 and end 46 are pushed into the gap 144 during assembly, and as the fingers slide over the protrusions, the end 146 and fingers begin to deflect outwardly.

[0056] Once the shield 120 is fully in place relative to the terminal cover 118, the second attachment feature 124 removably engages and interlocks with the first attachment feature. The engagement of the first and second attachment features indicates that the desired mechanical and electrical engagement has been achieved between the terminal 114 and the end 146, that is, the female terminal end 46 has engaged the opposing face 142 of the male terminal 114 and is securely enclosed. Once coupled, the retention feature prevents the bus bar 136 from being accidentally disconnected from the terminal 114 until the finger portion is depressed and the bus bar assembly 116 is pulled away from the terminal cover 118.

[0057] The shield 120 includes a plurality of shield portions that cooperate with each other to enclose a bus bar 136, which enables the bus bar to be repaired and the shield to be reused. The plurality of shield portions include a first shield portion and a second shield portion 132, 134 that are nested relative to each other in an overlapping relationship. In this example, the second shield portion 134 is disposed on each side of opposite sides of the central first shield portion 132. The first shield portion 132 is provided by a cover 50 that is snap-fitted to the base 48. The first shield portion 132 includes a sleeve having an opening at one end that receives a corresponding end of the second shield portion 134 using a snap fitting 52 when in an assembled state. The snap fitting including a mating window 54 and a protrusion 56 is used to connect various shield pieces.

[0058] The bus bar 136 includes a U-shaped portion 58 received in the first shroud portion 132 to provide a space between the opposing ends 46 of the bus bar 136. The space can accommodate a barrier 60 disposed between the terminals 14 to enable compact packaging of the battery module 10 relative to other components.

[0059] In operation, during assembly of the battery module 10, the non-conductive terminal cover 18 is disposed over the conductive battery cell terminal 14. If desired, the terminal cover 18 can be provided as a discrete piece fixed to the battery housing 19, or they can be integrated into the housing. The terminal cover 18 at least partially surrounds the terminal 14, which is a male terminal. The terminal cover 18 has a peripheral wall 26 configured to surround at least a portion of the terminal 14. The terminal 14 is arranged in a column 38 that shields the terminal 14. The peripheral wall 26 and the column 38 cooperate to provide a finger protection gap 44 that exposes the terminal 14.

[0060] The bus bar assembly 16 is provided with a bus bar 36 having an end 46, which is a female terminal. The non-conductive shield 20 encloses the bus bar 36, and the end 46 is exposed through the shield 20. The end 46 of the bus bar assembly 16 is pushed into the gap 44 and engaged with the terminal 14 so that the shield 20 and the terminal cover 18 are mated to enclose the end 46. During mating, the first attachment feature 22 on the terminal cover 18 interlocks with the second attachment feature 24 on the shield 20.

[0061] In this way, the terminal cover can be fixed to the battery cell around the terminal, making the terminal finger-safe. Therefore, even with the bus bar assembly disconnected, the battery module is still finger-proof, which allows the battery module to be safely assembled and handled during assembly and maintenance of the battery module.

[0062] It should also be understood that although a particular arrangement of components is disclosed in the illustrated embodiments, other arrangements will benefit from the present invention. Although a particular sequence of steps is shown, described, and claimed, it should be understood that the steps may be performed in any order, separated, or combined, unless otherwise indicated, and will still benefit from the present invention.

[0063] Although the different examples have specific components shown in the figures, the embodiments of the present invention are not limited to those specific combinations. Some components or features of one of the examples may be used in combination with features or components of another example.

[0064] Although example embodiments have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. Therefore, the following claims should be studied to determine their true scope and content.

Claims

1. A busbar assembly, comprising: a non-conductive terminal cover configured to at least partially surround a conductive terminal, the terminal cover having a peripheral wall configured to surround at least a portion of the terminal to provide a gap configured to expose the terminal, the terminal cover including a first attachment feature; a bus bar having ends configured to mechanically and electrically engage the terminals in an assembled state; and A non-conductive shield enclosing a bus bar, the shield including a second attachment feature configured to removably engage the first attachment feature in an assembled state to secure the shield to the terminal cover.

2. The bus bar assembly according to claim 1, wherein: The peripheral wall presents a U-shape arranged on at least three sides of the terminal, the peripheral wall extending beyond the terminal.

3. The bus bar assembly according to claim 1, wherein: The terminal cover has a column for receiving a terminal, the column being arranged inside the peripheral wall, the terminal being a male terminal, a gap being provided between the column and the peripheral wall, and the terminal being a female terminal configured to mate with the male terminal.

4. The bus bar assembly according to claim 3, characterized in that: The terminal has a peripheral edge defining opposite faces of the terminal, the post receives the terminal and surrounds the peripheral edge but leaves at least one face exposed, the peripheral wall extends beyond the post, the peripheral wall and post cooperate to provide a gap as a finger guard.

5. The bus bar assembly according to claim 1, wherein: The terminal cover includes a first recess, and the shield includes a second recess, and the first recess and the second recess are nested with each other in an assembled state to enclose the terminal and the end of the bus bar.

6. The bus bar assembly according to claim 1, wherein: One of the first and second attachment features is a finger, and the other of the first and second attachment features is a protrusion, and in an assembled state, the finger and the protrusion interlock with each other.

7. The bus bar assembly according to claim 1, wherein: The shroud includes a plurality of shroud portions that cooperate with each other to enclose the bus bar.

8. The bus bar assembly according to claim 7, wherein: The plurality of shroud portions include a first shroud portion and a second shroud portion nested within one another in overlapping relation.

9. The bus bar assembly according to claim 8, wherein: In an assembled state, the first shield portion and the second shield portion are engaged in a snap-fit ​​relationship.

10. The bus bar assembly according to claim 9, wherein: The first shield portion includes a first shell and a second shell fixed around a portion of the bus bar, and the first shell and the second shell are received in an opening in the second shield portion.

11. The busbar assembly according to claim 1-0, characterized in that: The bus bar includes a U-shaped portion received in the first shield portion to provide a space between opposite ends of the bus bar, the space being configured to receive a stopper.

12. A method for electrically connecting battery cells of a battery module, comprising the steps of: a) providing a non-conductive terminal cover on the conductive battery cell terminal, wherein the terminal cover at least partially surrounds the terminal, the terminal is a male terminal, the terminal cover has a peripheral wall, the peripheral wall is configured to surround at least a portion of the terminal, the terminal is arranged in a column that shields the terminal, and the peripheral wall and the column cooperate to provide a gap to expose the terminal; b) providing a bus bar assembly having a bus bar having an end portion providing a female terminal, a non-conductive shield enclosing the bus bar, the end portion being exposed through the shield; c) pushing the end portion into the gap and engaging the terminal; as well as d) mating the shield with the terminal cover to close the end, wherein the mating step is performed simultaneously with the pushing step c).

13. The method according to claim 12, characterized in that The mating step d) includes connecting a first attachment feature on the terminal cover to a second attachment feature on the shield, the peripheral wall and the post cooperating to provide a hand protection gap.

14. The method according to claim 12, characterized in that The providing step b) includes nesting the first shield portion relative to the second shield portion to enclose the busbar with the shield.

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