Integrated anti-finger-touch high-voltage interface solution for battery assembly

Abstract

The present disclosure provides an integrated finger-proof high voltage interface solution for a battery assembly. A battery pack includes: a first battery array; a second battery array; and an electrical connector assembly having an electrical connector and a plurality of non-conductive fasteners, the second battery array being coupled to the first battery array via the electrical connector assembly having the plurality of non-conductive fasteners.

Description

Technical Field

[0001] The field relates to fasteners in electrical assemblies for batteries of vehicles. Background Art

[0002] A vehicle such as an electrified vehicle may have a bus bar as an electrical connector for electrically coupling electrical components. The bus bar may be rated for and have a high voltage between electrical components electrically coupled via the bus bar. The electrical component may be part of a larger system such as a battery pack. There may be a plurality of fasteners to fasten the bus bar to one or more of the electrical components.

[0003] Components of the electrical assembly, such as covers, may be installed and physically coupled via clamping. The clamping may be performed via an operator's component or a component manipulated by an operator's component, such as a tool. To reduce discharge between a bus bar and an object, the cover may reduce the likelihood that an object, such as a cylindrical object above a threshold diameter, will contact a bus bar or other live components of the electrical assembly.

[0004] Due to the increased use of packaging space by electrified components, the volume and height of the electrical assembly may be limited. This constraint may limit the ability of the cover to effectively reduce the potential discharge to an object. Similarly, a cover for an assembly may have a region referred to herein as a fastener interface area, wherein each fastener interface area may have an opening around the helical axis through which the fastener can be approached or installed. Although reducing the size of the interface area opening can reduce the possibility of discharge to an object, it may also increase the difficulty of manufacturing and / or maintenance (such as installation or removal of the fastener). Summary of the invention

[0005] The inventors herein have recognized these and other problems with such systems and have proposed methods that at least partially address these problems. In one example, a battery pack is provided. The battery pack may include: a first battery array; a second battery array; an electrical connector assembly, the electrical connector assembly including an electrical connector and a plurality of non-conductive fasteners, the second battery array being coupled to the first battery array via the electrical connector assembly having the non-conductive fasteners.

[0006] In another example, a battery pack is provided, comprising: a first battery array; and a second battery array, the second battery array being coupled to the first battery array via a bus bar assembly, the bus bar assembly being coupled to the first array and the second array via a non-conductive fastener.

[0007] It should be understood that the above summary is provided to introduce a series of concepts further described in the detailed description in a simplified form. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is uniquely defined by the claims attached to the detailed description. In addition, the claimed subject matter is not limited to implementations that solve any disadvantages described above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 An exemplary schematic diagram of a vehicle that may include a transmission of the present disclosure is shown.

[0009] Figure 2 An exemplary schematic diagram of a bus bar assembly having a bus bar electrically coupling a first array terminal and a second array terminal is shown.

[0010] Figure 3 The fasteners of the first configuration are shown fastened to Figure 2 The bus bar of the first array terminal.

[0011] Figure 4 The second configuration of the fastener is shown to be fastened to Figure 2 The bus bar of the first array terminal.

[0012] Figure 5 The third configuration of the fastener is shown to be fastened to Figure 2 The bus bar of the first array terminal.

[0013] Figure 6 A first view of a bus bar assembly of the present disclosure is shown having a bus bar cover and a certain configuration of fasteners. DETAILED DESCRIPTION

[0014] The following description relates to the configuration of fasteners, busbars, or high-voltage connectors, which may be referred to herein as mating fasteners. The mating fastener and / or a plurality of mating fasteners may fasten a busbar and place it to share contact with an electrical component or a component surface that may be charged or conductive through one or more array terminals. An electrical assembly may include a busbar, a mating fastener, a cover, and an electrical component, wherein the busbar may be fastened to the electrical component. If the busbar is used as a high-voltage connector, the assembly may also be referred to herein as a busbar assembly. The electrical assembly may electrically connect at least two array terminals via a high-voltage electrical connector. The assembly may be part of a battery pack. The assembly may electrically connect a first array and a second array, wherein the first array and the second array may be part of other components of the battery pack, joined to the other components, or physically connected to battery arrays of the other components. When sharing contact with the surface of the electrical component, the high-voltage electrical connector may be electrically connected to the electrical component. The mating fastener may be non-conductive so as to prevent or insulate and inhibit the transfer of discharge from the busbar to the fastener. Wherein the mating fastener may be a non-conductive fastener.

[0015] The non-conductive nature of the fastener can allow the fastener to share contact with the surface of an external object (such as an object that can be conductive and grounded) without releasing electrical energy. Therefore, a cover for a high voltage electrical connector may not have to prevent an external object from sharing contact with the surface of the fastener in order to reduce the possibility of discharge to the object. For example, as a non-conductive fastener, a mating fastener can reduce discharge from a busbar to an external object (such as a cylindrical object) that can be in intermittent surface sharing contact with one of the fasteners via the fastener interface area. The mating fastener can be used with or without a busbar cover.

[0016] As described herein, in order to reduce packaging space, the fastener interface area, including the z space or height above the fastener, can be shortened for holes, flanges, and / or other features of the bus bar cover around the fastener. However, the shortening of the height of the fastener interface area and / or other components of the bus bar cover can allow surface shared contact between external objects and the fastener. The fasteners as described herein can reduce such surface shared contact between objects and high voltage electrical connectors. Mating fasteners can also provide interference with external objects before forming surface shared contact with a bus bar or other electrical connector (such as when clamping the connector during manufacturing or maintenance), thereby reducing discharge to foreign objects during clamping the component near the electrical assembly or clamping a portion thereof.

[0017] For one example, the mating fastener may be made of a material including a dielectric material such that the mating fastener is substantially not electrically coupled to the bus bar when fastened to the bus bar. In other examples, the mating fastener may be coated with a dielectric material or have a component including a dielectric material such that when the mating fastener is fastened to the bus bar, the component of the mating fastener composed of the dielectric material is not electrically coupled to the bus bar. The dielectric coating for the mating fastener may include an anodized material.

[0018] A plurality of washers may be complementary to and used in conjunction with each of the fasteners to secure a bus bar or other electrical connector. Each of the washers may include or be coated with a dielectric material. The washers may evenly distribute loads and pressures over the surface of the component to which the bus bar or electrical connector is secured. The mating fastener may be heat resistant and made of a stable material that may be secured to achieve a desired clamping load. The dielectric material constituting the mating fastener, the coating of the mating fastener, and / or the components of the mating fastener may be heat resistant and a stable material that may resist degradation caused by mechanical forces and chemical corrosion.

[0019] Figure 1 An exemplary schematic diagram of a vehicle that may include a transmission of the present disclosure is shown. Figure 1 The vehicle in may be an electrified vehicle, such as an EV or hybrid vehicle, having multiple torque sources, which may include an electric motor, a hydrogen fuel cell, and / or another mover that is not an internal combustion (ICE) engine. Figure 2 An exemplary schematic diagram of a bus bar assembly having a bus bar electrically connecting a first array terminal and a second array terminal is shown. The first array terminal and the second array terminal may be part of a first battery array and a second battery array, respectively, for a battery pack. Figure 3 The fasteners of the first configuration are shown fastened to Figure 2 The first array of terminals of the bus bar. The first configuration of fasteners is formed of a dielectric material. Figure 4 The second configuration of the fastener is shown to be fastened to Figure 2 The first array of terminals has a bus bar. The second configuration of fasteners has a coating composed of a dielectric material. Figure 5 The third configuration of the fastener is shown to be fastened to Figure 2 A third configuration of the fastener has a portion constructed of a dielectric material surrounding the more conductive portion of the fastener and sandwiched between the portion of the fastener and the bus bar. Figure 6 A first view of a bus bar assembly of the present disclosure having a bus bar cover and a certain configuration of fasteners is shown.

[0020] It should also be understood that the specific assemblies and systems shown in the drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined herein. For discussion purposes, the drawings are described together. Therefore, the same elements may generally be referred to herein by the same reference numerals and may not be reintroduced.

[0021] Figure 6 however, other relative dimensions may be used. As used herein, unless otherwise specified, the term "about" is interpreted to mean a range of ±5%.

[0022] also, Figures 1 to 6 An exemplary configuration with relative positioning of various components is shown. In at least one example, if shown as being in direct contact or directly connected to each other, such elements may be referred to as being in direct contact or directly connected, respectively. Similarly, in at least one example, elements shown as being adjacent or adjacent to each other may be adjacent or adjacent to each other, respectively. As an example, components in coplanar contact with each other may be referred to as coplanar contact. As another example, in at least one example, elements that are positioned apart from each other with only space therebetween and no other components may be referred to as such. As another example, elements shown as being above / below each other, on opposite sides or on the left / right side of each other may be referred to as such relative to each other. In addition, as shown in the accompanying drawings, in at least one example, the topmost element or the vertex of an element may be referred to as the "top" of a component, and the bottommost element or the bottommost point of an element may be referred to as the "bottom" of a component. As used herein, top / bottom, upper / lower, above / below may be relative to the vertical axis of the accompanying drawings, and are used to describe the positioning of the elements of the accompanying drawings relative to each other. Thus, in one example, an element shown as being above other elements is located directly above other elements. As yet another example, the shapes of elements depicted within the drawings may be referred to as having these shapes (e.g., such as being circular, straight, planar, curved, rounded, chamfered, angled, etc.). Additionally, in at least one example, elements that are shown as intersecting each other may be referred to as intersecting elements or intersecting each other. Further, in one example, elements that are shown as being within another element or being shown as being outside another element may be referred to as such. Additionally, components may be described as they relate to reference axes included in the drawings.

[0023] Unless otherwise specified, a feature described as axial may be generally parallel to the referenced axis. Unless otherwise specified, a feature described as anti-axial may be generally perpendicular to the referenced axis. Unless otherwise specified, a feature described as radial may circumferentially surround or extend outward from an axis, such as the referenced axis, or a component or feature previously described as radial to the referenced axis.

[0024] Features described as longitudinal may be generally parallel to the longitudinal axis of the vehicle in which the system is located. A transverse axis may be perpendicular to the longitudinal axis. Features described as transverse may be generally parallel to the transverse axis or generally perpendicular to the longitudinal axis.

[0025] Now turn to Figure 1 , the vehicle 100 is shown to include a powertrain 101 and a transmission 103. The vehicle 100 may have a front end 132 and a rear end 134 located on opposite sides of the vehicle 100. Objects, components, and features of the vehicle 100 referred to as being located near the front may be closest to the front end 132 compared to the rear end 134. Objects, components, and features of the vehicle 100 referred to as being located near the rear may be closest to the rear end 132 compared to the front end 134. The powertrain 101 includes a prime mover 106 and a transmission 108. The prime mover 106 may be, for example, an internal combustion engine (ICE) or an electric motor, and is operated to provide rotational power to the transmission 108. The transmission 108 may be any type of transmission, such as a manual transmission, an automatic transmission, or a continuously variable transmission. The transmission 108 receives the rotational power generated by the prime mover 106 as input, and outputs the rotational power to the transmission 103 according to the selected gear or setting. In addition, in addition to the prime mover 106, other drive devices may also be present in the vehicle. If the prime mover 106 is an ICE, there may be at least a second drive device having an input to the transmission 108, where the second drive device may be an electric machine, such as an electric motor. In one example, if there is a single or multiple second drive devices in addition to the prime mover 106, the vehicle 100 may be a hybrid vehicle, where there are multiple torque inputs to the transmission 108. The vehicle 100 may have a longitudinal axis 130. The drivetrain 101 and the drivetrain 103 may have a length parallel to the longitudinal axis 130.

[0026] Prime mover 106 may be powered via energy from energy storage device 105. In one example, energy storage device 105 is a battery configured to store electrical energy. Inverter 107 may be disposed between energy storage device 105 and prime mover 106 and configured to adjust direct current (DC) to alternating current (AC). Inverter 107 may include a variety of components and circuits with thermal requirements that affect the efficiency of the inverter.

[0027] In some exemplary embodiments, such as Figure 1As shown, the drive train 103 includes a first axle assembly 102 and a second axle assembly 112. The first axle assembly 102 can be configured to drive a first set of wheels 104, and the second axle assembly 112 can be configured to drive a second set of wheels 114. In one example, the first axle assembly 102 is arranged near the front of the vehicle 100 and is therefore a front axle, and the second axle assembly 112 is arranged near the rear of the vehicle 100 and is therefore a rear axle. The drive train 103 is shown in a four-wheel drive configuration, but other configurations are possible. For example, the drive train 103 may include a rear-wheel drive, a front-wheel drive, or an all-wheel drive configuration. In addition, the drive train 103 may include one or more tandem axle assemblies. Therefore, without departing from the scope of the present disclosure, the drive train 103 may have other configurations and provide Figure 1 The configuration shown is for illustration and not limitation.In addition, the vehicle 100 may include additional wheels that are not coupled to the driveline 103 .

[0028] In such Figure 1 In some configurations shown, the drivetrain 103 includes a transfer case 110 configured to receive rotational power output by the transmission 108. For example, a first drive shaft 113 is drivingly coupled to a first output 111 of the transfer case 110, and a second drive shaft 122 is drivingly coupled to a second output 121 of the transfer case 110. The first drive shaft 113 (e.g., a front drive shaft) can transmit rotational power from the transfer case 110 to a first differential 116 of a first axle assembly 102 to drive a first set of wheels 104, and the second drive shaft 122 (e.g., a rear drive shaft) can transmit rotational power from the transfer case 110 to a second differential 126 of a second axle assembly 112 to drive a second set of wheels 114. For example, the first differential 116 can be drivingly coupled to a first set of axle shafts 118, which are coupled to the first set of wheels 104. For this or another example, the second differential 126 can be drivingly coupled to the second set of axle shafts 128, which are coupled to the second set of wheels 114. It can be appreciated that each of the first set of axle shafts 118 and the second set of axle shafts 128 can be positioned in a housing. The first drive shaft 113 and the second drive shaft 122 can be positioned to extend parallel to the longitudinal axis 130. For the example of the configuration of the vehicle 100, the second drive shaft 122 can be centered about the longitudinal axis 130.

[0029] For example, the first differential 116 may supply front wheel drive (FWD) to the vehicle 100 in a certain capacity as part of the rotational power transmitted via the first drive shaft 113. Likewise, for this or another example, the second differential 126 may supply rear wheel drive (RWD) to the vehicle 100 as part of the rotational power transmitted via the second drive shaft 122. The first differential 116 and the second differential 126 may supply FWD and RWD, respectively, as part of an all-wheel drive (AWD) mode of the vehicle 100.

[0030] The vehicle 100 may be a commercial vehicle, a light, medium or heavy vehicle, a passenger vehicle, an off-highway vehicle and / or a sport utility vehicle. Additionally or alternatively, the vehicle 100 and / or one or more of its components may be used in industrial, locomotive, military, agricultural and / or aerospace applications. In one example, the vehicle 100 is a pure electric vehicle or a vehicle with a pure electric operating mode, such as a plug-in hybrid vehicle. Thus, the prime mover 106 is an electric machine. In one example, the prime mover 106 is an electric motor / generator.

[0031] In some examples, additionally or alternatively, the vehicle 100 may be a hybrid vehicle including both an engine and an electric motor, each of which is configured to supply power to one or more of the first axle assembly 102 and the second axle assembly 112. For example, one or both of the first axle assembly 102 and the second axle assembly 112 may be driven via power derived from the engine in a first operating mode (e.g., an engine-only mode) in which the electric motor does not operate to provide power, driven via power derived from the electric motor in a second operating mode (e.g., a pure electric mode) in which the engine does not operate to provide power, and driven via power derived from both the engine and the electric motor in a third operating mode (e.g., an electric assist mode). As another example, one or both of the first axle assembly 102 and the second axle assembly 112 may be an electric axle assembly configured to be driven by an integrated electric motor.

[0032] Steering Figure 2, which shows a schematic diagram 200 of an electrical connector assembly 202, such as a vehicle battery. The electrical connector assembly 202 may include a first array and a second array, wherein each array is electrically connected via an electrical connector. The electrical system may include the electrical connector assembly 202 so that other components of the electrical system may be electrically connected to the electrical connector assembly 202. The other electrical components of the electrical system may be electrically connected via the electrical connector assembly 202. Each array may also be electrically connected to different electrical components, such as a first electrical component and a second electrical component, via an electrical connector. The aforementioned electrical components are not adjacent to each other or do not share surface contact, and may be electrically connected via the electrical connectors and arrays of the electrical connector assembly 202. For the example shown in the schematic diagram 200, the electrical system may include a battery assembly 203, such as a battery pack. The battery assembly 203 may include the electrical connector assembly 202 and a plurality of battery components 205. The battery assembly 203 and the battery components 205 may include one battery or a plurality of batteries, such as Figure 1 Energy storage device 105. Components and features of the electrical connector assembly 202 can be surrounded by multiple dashed lines. Other battery components 205 can be separated from the electrical connector assembly by dashed lines 207. The first array and the second array can be part of the battery assembly 203 and can be physically and electrically connected to the battery components 205. The first array can include a first array terminal 204, and the second array can include a second array terminal 206. The first array terminal 204 and the second array terminal 206 can each be electrically connected to an electrical connector. The electrical connector can be rated for high voltage power transmission between the first array terminal 204 and the second array terminal 206, and there can be a high voltage electrical connector. The electrical connector in the schematic 200 is a bus bar 208. It should be understood that the use of the bus bar can be non-limiting and another high voltage electrical connector can be used.

[0033] The bus bar 208 can be fastened to the battery assembly 203 or another electrical assembly via a plurality of non-conductive fasteners. For example, the bus bar 208 can be physically coupled to the first array terminal 204 via fastening by a first non-conductive fastener 214. The bus bar 208 can be physically coupled to the second array terminal 206 via fastening by a second non-conductive fastener 216. The first array terminal 204 can include a first mounting area 210, and the second array terminal 206 can include a second mounting area 212. When fastened to the first array terminal 204, the bus bar 208 can be placed on, supported by, and adjacent to the first mounting area 210. When fastened to the second array terminal 206, the bus bar 208 can be placed on, supported by, and adjacent to the second mounting area 212. A portion of the first non-conductive fastener 214 may pass through the bus bar 208 and the first mounting area 210 along the first axis 218, such as when the bus bar 208 is fastened to the first mounting area 210. The first non-conductive fastener 214 may be substantially centered about the first axis 218, such as when the bus bar 208 is fastened to the first mounting area 210. A portion of the second non-conductive fastener 216 may pass through the bus bar 208 and the second mounting area 212 along the first axis 218, such as when the bus bar 208 is fastened to the second mounting area 212. The second non-conductive fastener 216 may be substantially centered about the first axis 218, such as when the bus bar 208 is fastened to the first mounting area 210. The first axis 218 may be a threading axis of the first non-conductive fastener 214, and the second axis 220 may be a threading axis of the second non-conductive fastener 216. The first non-conductive fastener 214 and the second non-conductive fastener 216 can be the same type of fastener, wherein each fastener can have the same features and have substantially the same size. When of the same type, the first non-conductive fastener 214 and the second non-conductive fastener 216 can be interchangeably used to mount the bus bar 208 to the first mounting area 210 and the second mounting area 212, respectively.

[0034] The bus bar 208 may have a first hole 224, and the first mounting area 210 may have a second hole 226. The first hole 224 and the second hole 226 may be aligned so that each hole may be positioned about a first axis 218, and the first axis 218 may be substantially colinear with a centerline of the first hole 224 and the second hole 226. The first non-conductive fastener 214 may be complementary to the first hole 224 and the second hole 226 so that the first non-conductive fastener 214 may pass through and extend through the first hole 224 and the second hole 226. Likewise, the first non-conductive fastener 214 may be complementary to the first washer 228 so that the first washer 228 may be positioned around a portion of the first non-conductive fastener 214. A portion of the first non-conductive fastener 214 may pass through the hole 230 of the first washer 228. For one example, the first washer 228 may include a non-conductive material. For another example, the first washer 228 may have an outer layer coated with a non-conductive material, such as a dielectric material. The dielectric material constituting or coating the first gasket 228 may insulate the first gasket 228 from the transfer of electrical energy.

[0035] Each embodiment of the first non-conductive fastener 214 can include at least a head and a shank, such as a first head 232 and a first shank 234, respectively. The first shank 234 can have a first thread 236 consisting of a plurality of threads. The first thread 236 can be complementary to at least a surface of the hole 230. The first mounting area 210 can have a first inner surface 240. The first washer 228 can abut the first inner surface 240. The first head 232 of the first non-conductive fastener 214 can abut a mounting surface 238 of the bus bar 208. The first mounting surface 238 can surround the first hole 224.

[0036] The bus bar 208 may also have a third hole 244, and the second mounting area 212 may have a fourth hole 246. The third hole 244 and the fourth hole 246 may be aligned so that each hole may be positioned about the second axis 220, and the second axis 220 may be substantially colinear with the centerline of the third hole 244 and the fourth hole 246. The second non-conductive fastener 216 may be complementary to the third hole 244 and the fourth hole 246 so that the second non-conductive fastener 216 may pass through and extend through the third hole 244 and the fourth hole 246. Likewise, the second non-conductive fastener 216 may be complementary to the second washer 248 so that the second washer 248 may be positioned around a portion of the second non-conductive fastener 216. A portion of the second non-conductive fastener 216 may pass through the hole 250 of the second washer 248. The second washer 248 may include or have an outer layer coated with a non-conductive material, such as a dielectric material. The dielectric material constituting or coating the second washer 248 may insulate the second washer 248 from the transfer of electrical energy.

[0037] Each embodiment of the second non-conductive fastener 216 may include at least a head and a shank, such as a second head 252 and a second shank 254, respectively. The second shank 254 may have a second thread 256 consisting of a plurality of threads. The second thread 256 may be complementary to at least a surface of the hole 250. The second shank 254 may pass through the third hole 244, the fourth hole 246, and the hole 250. The second shank 254 may at least thread through the hole 250. The second mounting area 212 may have a second inner surface 259. The second washer 248 may abut the second inner surface 259. The second head 252 of the second non-conductive fastener 216 may abut a mounting surface 258 of the bus bar 208. The mounting surface 258 may surround the third hole 244. It should be understood that the mounting surface 238 and the mounting surface 258 may be continuous with each other or part of the same surface.

[0038] The structures of the first array terminal 204 and the second array terminal 206 may be different except for the first mounting area 210 and the second mounting area 212. For one example, the first array terminal 204 and the second array terminal 206 may each include a plurality of walls continuous with each other via a bent portion.

[0039] For example, both the first array terminal 204 and the second array terminal 206 may have components positioned around the first cavity 260 and the second cavity 262 and forming their peripheries. The first array terminal 204 may have a first wall 264 and a second wall 270. The first wall 264 may be a support wall for the first array terminal 204. The first wall 264 may be physically coupled to the battery component 205 and structurally support the first mounting area 210 and the bus bar 208. The first wall 264 may also electrically couple the first array terminal 204 to the battery component 205. The second wall 270 may be positioned between the first wall 264 and the first mounting area 210. The first wall 264 may be adjacent or continuous to the second wall 270 via the first bend 266 and the second bend 268. The second wall 270 may be connected and adjacent to the first mounting area 210 via the third bend 272. The first bend 266, the second bend 268, the second wall 270, the third bend 272, and the first mounting area 210 may be positioned around the first cavity 260 and form a perimeter around the first cavity 260. When the first non-conductive fastener 214 fastens the bus bar 208 to the first mounting area 210, a portion of the first shank 234 may extend into the first cavity 260.

[0040] The second array terminal 206 may have a third wall 274 and a fourth wall 280. The third wall 274 may be a support wall for the second array terminal 206. The third wall 274 may be physically coupled to the battery component 205. The third wall 274 may also electrically couple the first array terminal 204 to the battery component 205. The third wall 274 may structurally support the second mounting area 212 and the bus bar 208. The fourth wall 280 may be positioned between the third wall 274 and the first mounting area 210. The third wall 274 may be adjacent or continuous to the fourth wall 280 via the fourth bend 276 and the fifth bend 278. The fourth wall 280 may be connected to the second mounting area 212 via the sixth bend 282 and adjacent to the second mounting area 212. The fourth bend 276, the fifth bend 278, the fourth wall 280, the sixth bend 282, and the second mounting area 212 may be positioned around the second cavity 262 and form the periphery of the second cavity 262. When the second non-conductive fastener 216 fastens the bus bar 208 to the second mounting region 212 , a portion of the second shank 254 may extend into the second cavity 262 .

[0041] As an example, the first non-conductive fastener 214 can be fastened to the first washer 228 through the first hole 224 and the second hole 226. When fastened, the first hole 224 and the second hole 226 can be positioned around a portion of the first non-conductive fastener 214 and share contact with a portion of the surface of the first non-conductive fastener 214. The first washer 228 can be positioned around a portion of the first non-conductive fastener 214 and physically coupled. The first washer 228 can share contact with the surface of the first mounting area 210. The first non-conductive fastener 214 can pass through the hole 230 of the first washer 228. For one example, the first non-conductive fastener 214 can be threaded through the hole 230. The first washer 228 can be positioned around the portion of the non-conductive fastener 214 that extends below the second hole 226. The first washer 228 can include or be coated with a non-conductive material, such as a dielectric material. When constructed of or coated with a non-conductive material, the first gasket 228 may be non-conductive or insulated from receiving electrical energy when sharing contact with a surface of an electrified component, such as the first mounting area 210 .

[0042] The first shank 234 may extend through the first hole 224 and the second hole 226 in a direction perpendicular to the mounting surface 238 of the bus bar 208. The first thread 236 may be complementary to the thread or groove of the hole 230 of the first washer 228. For example, when the shank 234 extends through the first hole 224, the second hole 226, and the hole 230 and is threaded through at least the hole 230, the first non-conductive fastener 214 may be fastened to the first washer 228. When fastened to the first washer 228 as described above, the first non-conductive fastener 214 may fasten the bus bar 208 to the first mounting area 210. The first thread 236 may be complementary to the thread or groove on the surface of the first hole 224 and the second hole 226. For another example, when the first shank 234 is threaded through the first hole 224, the second hole 226, and the hole 230, the first non-conductive fastener 214 may be fastened to the bus bar 208, the first mounting area 210, and the first washer 228. When fastened to the first hole 224 , the second hole 226 , and the first gasket 228 as described above, the first non-conductive fastener 214 may fasten the bus bar 208 to the first mounting area 210 .

[0043] When the first shank 234 passes through the first hole 224, the first head 232 can abut the first mounting surface 238 of the bus bar 208. The first washer 228 can abut the first inner surface 240, such as when the first washer 228 is fastened to the shank 234 and the shank 234 extends through the first hole 224 and the second hole 226. The first head 332 can apply a compressive force in a direction perpendicular to the mounting surface 238. The first washer 228 can apply a compressive force perpendicular to the first inner surface 240. The compressive forces of the washer 228 and the first head 332 can have magnitudes in opposite directions to each other. The first head 232 can press the bus bar 208 against the first mounting area 210. The first washer 228 can press the first mounting area 210 against the bus bar 208. The compressive force from the first washer 228 and the first head 232 can fasten the bus bar 208 to the first mounting area 210.

[0044] For this or another example, the second non-conductive fastener 216 can be fastened to the second washer 248 through the third hole 244 and the fourth hole 246. The third hole 244 and the fourth hole 246 can be positioned around a portion of the non-conductive fastener 214 and share contact with a portion of the surface of the non-conductive fastener 214. The second washer 248 can be positioned around a portion of the second non-conductive fastener 216 and physically coupled. The second washer 248 can share contact with the surface of the second mounting area 212. The second non-conductive fastener 216 can pass through the hole 250 of the second washer 248. The first non-conductive fastener 214 can be threaded through the hole 250. The second washer 248 can be positioned around the portion of the non-conductive fastener 214 that extends below the fourth hole 246. The second washer 248 can include or be coated with a layer of non-conductive material, such as a dielectric material. When constructed of or coated with a non-conductive material, the second gasket 248 may be non-conductive or insulated from receiving electrical energy when sharing contact with a surface of an electrified component, such as the first mounting area 210 .

[0045] The second shank 254 may extend through the first hole 224 and the second hole 226 in a direction perpendicular to the mounting surface 258 of the bus bar 208. The second thread 256 may be complementary to the thread or groove of the hole 250 of the second washer 248. For example, when the second shank 254 extends through the third hole 244, the fourth hole 246, and the hole 250 and is threaded through at least the hole 250, the first non-conductive fastener 214 may be fastened to the second washer 248. When fastened to the second washer 248 as described above, the first non-conductive fastener may fasten the bus bar 208 to the second mounting area 212. The second thread 256 may be complementary to the thread or groove on the surface of the third hole 244 and the fourth hole 246. For another example, the second shank 254 may be threaded through and fastened to the third hole 244, the fourth hole 246, and the hole 250. The second non-conductive fastener 216 may be fastened to the bus bar 208, the second mounting area 212, and the second washer 248. When fastened to the third hole 244 , the fourth hole 246 , and the hole 250 as described above, the second non-conductive fastener 216 may fasten the bus bar 208 to the second mounting area 212 .

[0046] When the second shank 254 passes through the first hole 224, the second head 252 can abut the second mounting surface 258 of the bus bar 208. When the second washer 248 is fastened to the second shank 254 and the second shank 254 extends through the third hole 244 and the fourth hole 246, the second washer 248 can abut the second inner surface 259. The second washer 248 and the second head 252 can apply compressive forces in opposite directions perpendicular to the second mounting surface 258 and the second inner surface 259, respectively. The compressive forces from the second washer 248 and the second head 252 can fasten the bus bar 208 to the second mounting area 212. The second head 252 can press the bus bar 208 against the second mounting area 212. The second washer 248 can press the second mounting area 212 against the bus bar 208.

[0047] Steering Figure 3 , which shows a first schematic diagram of a first configuration 300 for fastening a bus bar 208 to a first mounting region 210 of a first array terminal 204. The first configuration 300 shows that the bus bar 208 can be fastened to the first mounting region 210 via a first fastener 314. For example, the bus bar can be fastened to the first mounting region 210 with at least one non-conductive fastener, such as the first fastener 314. The first fastener 314 can be Figure 2 The first non-conductive fastener 214 is a first configuration fastener. Similarly, the first fastener 314 can be Figure 2 For the example shown in the first configuration 300, the first fastener 314 can be used as the first non-conductive fastener 214. The first fastener 314 can fasten the bus bar 208 to the first mounting area 210, and by extension, fasten the first bus bar 208 to the first array terminal 204.

[0048] For example, at least one of the non-conductive fasteners that fastens the bus bar 208 can be made of a dielectric material. The first fastener 314 has a configuration that includes a dielectric material (such as a polymer) that can electrically insulate the first fastener 314 from the bus bar 208. As an example, the first fastener 314 can include nylon (such as PA6 or PA66) as a dielectric and insulating material. As another example, the first fastener 314 can include polysiloxane as a dielectric and insulating material. For one example, the first fastener 314 can be a cap screw, such as a PEEK screw (e.g., SPE-M6-10-C). The dielectric material that constitutes the first fastener 314 is a heat-resistant and stable material to prevent degradation during operation. The stability of the material refers to mechanical stability (e.g., mechanical strength), such as tensile strength, compressive strength, and hardness, so that the dielectric material can resist the stress, strain, and other factors applied to a complementary vehicle (such as a vehicle body) during assembly or operation. Figure 1Stability also refers to chemical stability, such as resistance to corrosion or other forms of chemical degradation. For example, the dielectric material of fastener 314 can resist the effects of electrical energy or other forces contained in a battery assembly such as a Figure 2 The first fastener 314 may not pass current or may prevent the passing of current from the bus bar 208 to an object that shares contact with the surface of the first fastener 314.

[0049] The first fastener 314 may include a head 332, a shank 334, and a thread 336. For the first fastener 314, the material of the head 332, the shank 334, and the thread 336 includes a dielectric material. The head 332, the shank 334, and the thread 336 may be the first head 232, the first shank 234, and the first thread 236 of the first non-conductive fastener 214, respectively. Similarly, the head 332, the shank 334, and the thread 336 may be the second head 252, the second shank 254, and the second thread 256 of the second non-conductive fastener 216, respectively.

[0050] For this example, the head 332 can abut the first mounting surface 238. The shank 334 can extend through the first hole 224 and the second hole 226 in a direction perpendicular to the mounting surface 238. The washer 228 can be positioned around the shank 334. When positioned around the shank 334, the shank 334 can extend through the hole 230 of the washer 228. The washer 228 can abut the first inner surface 240. The washer 228 and the head 332 can apply compressive forces in opposite directions perpendicular to the first mounting surface 238 and the first inner surface 240, respectively. The compressive forces from the washer 228 and the head 332 and the structure of the fastener 314 as a whole can fasten the bus bar 208 to the first mounting area 210. The hole 230 can be complementary to the shank 334 and the threads 336, so that the threads 336 can engage with the complementary threads or grooves of the hole 230. The head 332 can press the bus bar 208 against the first mounting area 210. Washer 228 can press first mounting region 210 against bus bar 208. Likewise, threading of threads 336 with first and second holes 224, 226 can secure bus bar 208 to first mounting region 210 if complementary to the surfaces of first and second holes 224, 226.

[0051] Steering Figure 4, which shows a third schematic diagram of a second configuration 400 for fastening the bus bar 208 to the first mounting area 210 of the first array terminal 204. The second configuration 400 shows that the bus bar 208 can be fastened to the first mounting area 210 via a second fastener 414. For example, the bus bar can be fastened to the first mounting area 210 with at least one non-conductive fastener (such as the second fastener 414). The second fastener 414 can be Figure 2 The second non-conductive fastener 214 may be a second configuration fastener. Similarly, the second fastener 414 may be Figure 2 The second non-conductive fastener 216 is a second configuration of the fastener. For the example shown in the second configuration 400, the second fastener 414 can be used as the first non-conductive fastener 214. The second fastener 414 can fasten the bus bar 208 to the first mounting area 210, and by extension, fasten the first bus bar 208 to the first array terminal 204.

[0052] The second fastener 414 may include a second head 432, a second shank 434, and a second thread 436. The material of the core of the second fastener 414 (such as the material composed of the head 432, the shank 434, and the thread 436) may include a metal or a metal alloy, such as aluminum or an aluminum alloy, respectively. The material of the core of the second fastener 414 (such as the material of the head 432, the shank 434, and the thread 436) may also be another material that is electrically conductive. The second head 432, the second shank 434, and the second thread 436 may be the first head 232, the first shank 234, and the first thread 236 of the first non-conductive fastener 214, respectively. Similarly, the second head 432, the second shank 434, and the second thread 436 may be the second head 252, the second shank 254, and the second thread 256 of the second non-conductive fastener 216, respectively. For example, at least one non-conductive fastener (such as the second fastener 414) may be coated with a layer of dielectric material and used to fasten an electrical connector (such as the bus bar 208) to an assembly. The surface of the second fastener 414 may be encapsulated in a layer of coating 440. The coating 440 may encapsulate and constitute the outer surfaces of the head 432, the shank 434, and the threads 436.

[0053] For this example, the coating 440 surrounding the head 432 can abut the first mounting surface 238. The shank 434 can extend through the first hole 224 and the second hole 226 in a direction perpendicular to the mounting surface 238. The coating surrounding the shank 434 and the threads 436 can share contact with the first hole 224 and the second hole 226 surfaces. The washer 228 can be positioned around the shank 434. When the washer 228 is positioned around the shank 434, a section of the shank 434 and the coating 440 surrounding the shank 434 can extend through the hole 230 of the washer 228. The washer 228 can abut the first inner surface 240. The washer 228 and the head 432 can apply compressive forces in opposite directions perpendicular to the first mounting surface 238 and the first inner surface 240, respectively. The compressive forces from the washer 228 and the head 432 can fasten the bus bar 208 to the first mounting area 210. The hole 230 can be complementary to the shank 434, the threads 436, and the coating 440 surrounding the threads 436. The threads 436 and the coating 440 surrounding the threads 436 can engage with the complementary threads or grooves of the hole 230. The head 432 can press the bus bar 208 against the first mounting area 210. The washer 228 can press the first mounting area 210 against the bus bar 208. Similarly, if the threads 436 and the coating 440 surrounding the threads 436 are complementary to the surfaces of the first hole 224 and the second hole 226, the threaded connection of the first hole 224 and the second hole 226 can secure the bus bar 208 to the first mounting area 210.

[0054] The coating 440 may include a dielectric material, such as a polymer or an anodized material, which may electrically insulate the second fastener 414 from the bus bar 208. As an example, the coating 440 may include nylon (such as PA6 or PA66) as a dielectric and insulating material. As another example, the coating 440 may include polysiloxane as a dielectric and insulating material. The dielectric material constituting the coating 440 is a heat-resistant and stable material. The stability of the material constituting the coating 440 refers to mechanical stability (e.g., mechanical strength), such as tensile strength, compressive strength, and hardness, so that the dielectric material can resist the stress, strain, and other forces applied to the complementary vehicle (such as the vehicle body) during assembly or operation. Figure 1 The stability of the material comprising coating 440 also refers to chemical stability, such as resistance to corrosion or other forms of chemical degradation. For example, the dielectric material comprising coating 440 may resist being subjected to electrical energy or other forces contained in a battery assembly such as a Figure 2The coating 440 may prevent or reduce the amount of electrical energy discharged between the bus bar 208 and the second fastener 414. Similarly, the second fastener 414 may not pass current or may prevent the passing of current from the bus bar 208 to an object sharing contact with the surface of the second fastener 414.

[0055] Steering Figure 5 , which shows a fourth schematic diagram of a third configuration 500 for fastening the bus bar 208 to the first mounting area 210 of the first array terminal 204. The third configuration 500 shows that the bus bar 208 can be fastened to the first mounting area 210 via a third fastener 514. For example, the bus bar can be fastened to the first mounting area 210 with at least one non-conductive fastener (such as the third fastener 514). The third fastener 514 can be Figure 2 The third fastener 514 may be a third configuration of the first non-conductive fastener 214. Similarly, the third fastener 514 may be Figure 2 The third configuration of the second non-conductive fastener 216 is a fastener of the third configuration. For the example shown in the third configuration 500, the third fastener 514 can be used as the first non-conductive fastener 214. The third fastener 514 can fasten the bus bar 208 to the first mounting area 210, and by extension, fasten the first bus bar 208 to the first array terminal 204.

[0056] The third fastener 514 may include a third head 532, a third shank 534, and a third thread 536. For the third fastener 514, the materials of the head 532, the shank 534, and the thread 536 may include a metal or a metal alloy, such as aluminum or an aluminum alloy, respectively. The core material of the components of the fastener 514 (such as the material of the head 532, the shank 534, and the thread 536) may also be another material that is conductive. The third head 532, the third shank 534, and the third thread 536 may be the first head 232, the first shank 234, and the first thread 236 of the first non-conductive fastener 214, respectively. Similarly, the third head 532, the third shank 534, and the third thread 536 may be the second head 252, the second shank 254, and the second thread 256 of the second non-conductive fastener 216, respectively.

[0057] For example, at least one non-conductive fastener has a component composed of a non-conductive material, such as third fastener 514. The component composed of a non-conductive material can prevent surface sharing contact between features of the non-conductive fastener that are not composed of a dielectric material and bus bar 208.

[0058] The third fastener 514 may also include an overmold 538 and an insert 540. A portion of the overmold 538 may be positioned around a portion of the head 532. Likewise, a portion of the overmold 538 may be positioned around a portion of the shank 534. A portion of the overmold 538 may be sandwiched between the head 532 and the first mounting surface 238. Likewise, the insert 540 may be positioned around a portion of the shank 534. The insert 540 may be complementary to the threads 536 such that the shank 534 may be threaded through a hole 541 of the insert 540. A portion of the insert 540 may be sandwiched between the first inner surface 240 and the washer 228. Likewise, a portion of the insert 540 may be positioned around the washer 228, such as radially around the washer 228 relative to a centerline of the washer 228. The third fastener 514 may be prevented from making surface-sharing contact with the bus bar 208 via the overmold 538 and the insert 540. The overmold 538 can prevent surface sharing contact between the head 532 and a portion of the shank 534 and the bus bar 208. For example, the overmold 538 can be positioned around the head 532 and the shank 534, a portion of the head 532. The overmold 538 can prevent the head 532 from surface sharing contact with the first mounting surface 238, such as when the third fastener 514 fastens the bus bar 208 to the first mounting area 210. Likewise, the overmold 538 can prevent the shank 534 from surface sharing contact with the first hole 224, such as when the third fastener 514 fastens the bus bar 208 to the first mounting area 210. The overmold 538 can prevent the shank 534 from surface sharing contact with the second hole 226, such as when the third fastener 514 fastens the bus bar 208 to the first mounting area 210.

[0059] The overmold 538 may include a first portion and a second portion as a head segment 542 and a handle segment 544, respectively. The head segment 542 may be positioned around a portion of the handle 534 and sandwiched between the head 532 and the first mounting surface 238. A portion of the head 532 may abut a first platform 548. The first platform 548 may act as a spacer, thereby preventing surface sharing contact between the third head 532 and the mounting surface 238. The first platform 548 may also be a first spotface, and may have a portion positioned around the head 532, such as an edge or a collar. The handle segment 544 may be positioned below the head segment 542, such as when the handle is inserted through the first hole 224 and the second hole 226. The handle segment 544 may prevent surface sharing contact between the handle 534 and the surface of the bus bar 208 surrounding the first hole 224. When the overmold 538 surrounds and is physically coupled to other components of the third fastener 514 and the third fastener 514 fastens the bus bar 208 to the first mounting area 210, the shank 534 may not be in surface-sharing contact with the surface of the bus bar 208 surrounding the first hole 224. For one example, the shank segment 544 may be positioned around a portion of the shank 534. The shank segment 544 may be positioned radially around a portion of the shank 534 relative to a centerline of the third fastener 514. For another example, the shank segment 544 may be sandwiched between the shank 534 and the head segment 542. For this example, the head segment 542 and the shank segment 544 may physically couple the shank 534 to the head 532.

[0060] The insert 540 may include a first collar 554 and a second collar 556. The first collar 554 may be positioned around the shank 534. The first collar 554 may abut the second collar 556 via a second platform 558. The first collar 554 may be positioned radially around a portion of the shank 534 relative to a centerline of the shank 534. The first collar 554 may be in surface sharing contact with the shank 534. The first collar 554 may prevent surface sharing contact between the shank 534 and a surface of the first mounting area 210 surrounding the second hole 226. When inserted into the first collar 554, the shank 534 may not be in surface sharing contact with a surface of the first mounting area 210 surrounding the second hole 226. The second collar 556 may be positioned around the washer 228 and the shank 534, wherein the washer 228 is positioned radially between the second collar 556 and a portion of the shank 534 relative to a centerline of the shank 534. The second platform 558 may be a countersink surface for the insert 540. The second platform 558 may be positioned to share surface contact with the first inner surface 240. The first gasket 228 may be positioned to share surface contact with the second platform 558. The second platform 558 may be sandwiched between the first gasket 228 and the inner surface 240 such that the first gasket 228 may not share surface contact with the first mounting area 210.

[0061] The overmold 538 and the insert 540 may be made of a dielectric material such as a polymer. As an example, the overmold 538 and the insert 540 may include nylon such as PA6 or PA66 as a dielectric and insulating material. As another example, the overmold 538 and the insert 540 may include polysiloxane as a dielectric and insulating material. Both the overmold 538 and the insert 540 may prevent the surface sharing contact between the parts of the third fastener 514 made of metal or metal alloy such as the head 532 and the handle 534 and the live parts such as the bus bar 208 and the first array terminal 204.

[0062] The dielectric material comprising the overmold 538 and the insert 540 is a heat resistant and stable material. The stability of the material comprising the overmold 538 and the insert 540 refers to mechanical stability (e.g., mechanical strength), such as tensile strength, compressive strength, and hardness, so that the dielectric material can resist the stress, strain, and other forces applied to the complementary vehicle (such as the vehicle body) during assembly or operation. Figure 1 The stability of the materials comprising the overmold 538 and the insert 540 may also refer to chemical stability, such as resistance to corrosion or other forms of chemical degradation, so that the dielectric material can resist the effects of electrical energy or other forces contained in a battery assembly such as Figure 2The third fastener 514 may prevent or reduce the amount of electrical energy discharged between the bus bar 208 and the third fastener 514. Similarly, the third fastener 514 may not pass current or may prevent the transfer of current from the bus bar 208 to an object that shares contact with the surface of the third fastener 514. If the gasket is made of a conductive material, the third fastener 514 may also prevent or prevent current from being transferred from a mounting area (such as the first mounting area 210) to a gasket (such as the first gasket 228). For example, the first gasket 228 can be positioned around the handle 534 so that the second collar 556 is positioned around the first gasket 228 and the second platform 558 is sandwiched between the first gasket 228 and the first mounting area 210. The second collar 556 and the second platform 558 may prevent or reduce the transfer of electrical energy between the first gasket 228 and the first inner surface 240 .

[0063] A set of reference axes 601 is provided for use in Figure 6 601. Reference axis 601 indicates the y-axis, x-axis, and z-axis. In one example, the z-axis may be parallel to the direction of gravity, and the xy plane may be parallel to the horizontal plane in which the busbar assembly 602 and the components physically connected to the busbar assembly 602 may be located. For this example, the z-axis may be a vertical axis, wherein the z-axis may be parallel to the vertical direction. For this example, the y-axis may be a longitudinal axis, and the x-axis may be a transverse axis, wherein the y-axis may be parallel to the longitudinal direction relative to the busbar assembly 602 and the x-axis may be parallel to the transverse direction. When referring to directions, positive may refer to the direction of the arrows of the y-axis, x-axis, and z-axis, and negative may refer to the opposite direction of the arrows of the y-axis, x-axis, and z-axis. Solid circles may represent arrows and axes facing the view or facing the view. Hollow circles may represent arrows and axes facing away from the view or facing away from the view.

[0064] Steering Figure 6 , which shows a first view 600 of a bus bar assembly 602. The first view 600 can be a side view that is not biased toward any axis in the reference axis 601. The bus bar assembly 602 can be positioned about a longitudinal axis 606. Portions of the bus bar assembly 602 can also be positioned about a central axis 608. The bus bar assembly 602 can include a bus bar 612 and a bus bar cover 610.

[0065] The bus bar assembly 602 may be Figure 2 The bus bar assembly 602 can be clamped to an electrical system, such as Figure 2 The battery assembly 203 of the battery component 205, wherein the bus bar assembly 602 can be Figure 2The bus bar assembly 602 can be fastened to the first array terminal and the second array terminal, such as Figure 2 Array terminal 204 and second array terminal 206. For example, bus bar 612 can be fastened to at least one battery array via a non-conductive fastener. Fastener 614 can fasten bus bar 612 to the array terminal. When fastened to bus bar 612, fastener 614 can be centered around central axis 608. Central axis 608 can be the thread axis of fastener 614. As an example, fastener 614 and central axis 608 can be respectively Figure 2 The first non-conductive fastener 214 and the first axis 218. As another example, the fastener 614 may be Figure 2 The second non-conductive fastener 216 and the second axis 220.

[0066] The bus bar cover 610 may have a first outer surface 611 and a second outer surface 613. The first outer surface 611 and the second outer surface 613 may be top surfaces. The first outer surface 611 may be positioned above the second outer surface 613. The portion of the bus bar below the first outer surface 611 and the second outer surface 613 may share contact with the surface of the bus bar 612. The first outer surface 611 and the second outer surface 613 may match the shape of the bus bar 612.

[0067] The busbar 612 and the fastener 614 can be visible through the opening 618. The flange 616 can be positioned around the opening 618 and form the periphery of the opening 618. The opening 618 can be a hole located above and around the centerline of the fastener 614. The opening 618 can also be a cutout. As an example, the shape of the opening 618 can be circular. The opening 618 and the flange 616 can be positioned approximately radially around the fastener 614, so that the opening 618 and the flange 616 are radial relative to the central axis 608. The opening 618 can be positioned radially around the fastener 614. The fastener interface area 619 can include the opening 618 and the flange 616. The fastener interface area 619 can include a component adjacent between the flange 616 and the second outer surface 613. The fastener interface area 619 can be raised above the second outer surface 613.

[0068] Object 620 can be positioned above opening 618 and busbar cover 610. Object 620 can be cylindrical in shape or have a generally cylindrical cross-section. Object 620 can be part of another larger object or object system, connected to or physically coupled to another larger object or object system. Object 620 and objects physically coupled to object 620 can be conductive. Object 620 and other objects physically coupled to object 620 can have a current threshold or voltage threshold. When discharged into object 620, electrical energy above the current threshold or voltage threshold can cause object 620 and / or other objects physically coupled to object 620 to degrade. The current threshold and voltage threshold can be lower than the current and voltage carried by busbar 612. Object 620 can be used for clamping or other operations that can result in surface-sharing contact between object 620 and busbar assembly 602. When participating in the aforementioned operation, object 620 can be positioned to share contact with the fastener interface area 619 surface. Similarly, object 620 can pass through opening 618.

[0069] The opening 618 can extend upwardly from the first surface 622 of the bus bar 612 by approximately a distance 624. Likewise, the flange 616 can be raised from the bus bar 612 so that the flange 616 can be separated from the first inner surface 626 of the bus bar cover 610 by a distance 624. The flange 616 can prevent an object 620 from contacting the surface 622. The flange 616 and the opening 618 can allow the object 620 to contact the fastener 614. The bus bar cover 610 can also have a second inner surface 628. The second inner surface 628 is bent from the first inner surface 626 to the flange 616.

[0070] The first outer surface 611 may be adjacent to the second outer surface 613 and connected via the chamfer 630. The bus bar cover 610 may also have a plurality of outer surfaces, such as a first side surface 634 and a second side surface 636. The first side surface 634 and the second side surface 636 may be adjacent to and connected to the first outer surface 611 and the second outer surface 613. For example, the first outer surface 611 and the chamfer 630 may be connected to and adjacent to the first side surface 634 via a plurality of first chamfers 632. Similarly, the second outer surface 613 and the chamfer 630 may be connected to and adjacent to the second side surface 636 via the first chamfer 632. The first side surface 634 and the second side surface 636 may be connected and adjacent to each other via a plurality of second chamfers 638. The first outer surface 611 and the chamfer 630 may be connected to and adjacent to the second chamfer 638 via some of the first chamfers 632.

[0071] Returning to the opening 618, the flange 616 can be continuous with the second outer surface 613. The flange 616 can be connected and continuous with the second outer surface 613 via a fillet 640. The fillet 640 can also join a portion of the flange to the chamfer 630. Between the chamfer 630 and the opening 618, the flange 616 can have an edge 642. The edge 642 can be generally straight and not rounded.

[0072] The object 620 may be in surface sharing contact with a fastener, such as the fastener 614, rather than an electrical connector, such as the bus bar 612. The opening 618 may have a first diameter 652. The fastener 614 may have a second diameter 654. The difference between the first diameter 652 and the second diameter 654 may be a difference 656. The difference 656 is a distance less than the thickness 658 of the object 620. The flange 616 and the opening 618 may prevent the object 620 from being in surface sharing contact with the surface 622 or other features of the bus bar 612. The first diameter 652, the second diameter 654, and the non-conductivity of the fastener 614 may prevent an object, such as the object 620 or an object having a width or radius greater than the thickness 658, from being in surface sharing contact with the bus bar 612 and the bus bar assembly 602 or experiencing discharge therefrom. The first diameter 652, the second diameter 654, and the non-conductivity of the fastener 614 can provide interference for an object (such as an object smaller than the object 620) to make surface-sharing contact with the bus bar 612 or experience discharge from it. The distance 624 can be a distance less than the height between the bus bar and the material of the fastener interface area of ​​the bus bar cover from the prior art. The distance 624 can be the height of the fastener interface area 619 and can be reduced compared to the fastener interface area of ​​the prior art. The reduction in the height of the fastener interface area 619 can reduce the height of the bus bar cover 610 and the bus bar assembly 602. The reduction in the height of the bus bar cover 610 and the bus bar assembly 602 can reduce the height of the electrical system to which the bus bar assembly 602 can be electrically connected and the packaging space occupied by the electrical system. In addition, the first diameter 652 can allow the fastener 614 to be manipulated via an object (e.g., object 620) or multiple objects through the opening 618. Likewise, first diameter 652 , second diameter 654 , and non-conductivity of fastener 614 may provide interference for objects to make surface-sharing contact with bus bar cover 610 and bus bar assembly 602 without using a cap or another form of cover that is removable and positioned to close opening 618 .

[0073] Fastener 614 may include land 662. Land 662 may abut surface 622. Fastener 614 may also include countersunk surface 668 around opening 666. Opening 666 may be a receiver for a key or another tool to tighten, loosen or manipulate fastener 614. For one example, opening 666 may be hexagonal in shape and may be used for a hexagonal key, such as an inner hexagon key (e.g., inner hexagon wrench) or a hexagonal screwdriver head. For another example, opening 666 may be complementary to the head of a screwdriver or another tool (such as a Philips head, a flat head, a torx head, a square head or a one-way head). Countersunk surface 668 may be positioned above land 662. Countersunk surface 668 may abut and engage with land via riser 664. For one example, riser 664 forms a conical surface around countersunk surface 668 and within the periphery of land 662. The ridges 662 may be at a height 670 from the surface 622. The height 670 may be a distance greater than a distance threshold. At or below the threshold distance, a discharge may occur between an object above the conductivity threshold and the surface of the bus bar 612. The ridges 662 may prevent a discharge between the object 620 and the bus bar 612 therein.

[0074] In this manner, an electrical connector cover, such as a bus bar cover, can be of reduced height when positioned and clamped onto an electrical connector. The reduced height of the electrical connector cover can reduce the height or z-space of an electrical assembly, such as a battery pack or another battery assembly, of which the electrical connector assembly can be a part. The reduced height of the electrical connector cover can reduce the height or z-space of an electrical system including the electrical assembly. The electrical connector can be electrically coupled to a first array and a second array, and the first array can be electrically coupled to the second array so that high voltage electricity can flow from one array to an opposing array. Reducing the z-space can lower the roof of a vehicle housing the electrical system. Reducing the z-space can also reduce the volume of the entire electrical system, thereby allowing the electrical assembly to have an increased energy density.

[0075] Although various embodiments have been described above, it should be understood that these embodiments are presented by way of example and not by way of limitation. It will be apparent to those skilled in the relevant art that the disclosed subject matter may be embodied in other specific forms without departing from the spirit of the subject matter. The embodiments described above are therefore considered to be illustrative and not restrictive in all respects. Therefore, the configurations and procedures disclosed herein are exemplary in nature, and these specific examples should not be considered to have a limiting meaning, as numerous variations are possible. For example, the above-described technology may be applied to a powertrain system including different types of propulsion sources, including different types of prime movers, internal combustion engines, and / or transmissions. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations disclosed herein and other features, functions, and / or properties.

[0076] The appended claims particularly point out certain combinations and subcombinations regarded as novel and non-obvious. These claims may refer to "an" element or "a first" element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amendment of the present claims or by presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, are also deemed to be included in the subject matter of the present disclosure.

[0077] According to the present invention, a battery pack is provided, which has: a first battery array; a second battery array; an electrical connector assembly, wherein the electrical connector assembly has an electrical connector and a plurality of non-conductive fasteners, and the second battery array is connected to the first battery array via the electrical connector assembly having the plurality of non-conductive fasteners.

[0078] According to one embodiment, the electrical connector of the electrical connector assembly is a bus bar assembly, and the electrical connector is a bus bar.

[0079] According to one embodiment, the plurality of non-conductive fasteners include a first non-conductive fastener and a second non-conductive fastener, wherein the first non-conductive fastener fastens the electrical connector to the first battery array and the second non-conductive fastener fastens the electrical connector to the second battery array.

[0080] According to one embodiment, the first non-conductive fastener is physically coupled to a first washer and the second non-conductive fastener is physically coupled to a second washer, wherein the first non-conductive fastener and the first washer fasten the electrical connector to the first battery array and the second non-conductive fastener and the second washer fasten the electrical connector to the second battery array.

[0081] According to one embodiment, the first gasket and the second gasket are non-conductive and comprise a dielectric material.

[0082] According to one embodiment, the first gasket and the second gasket are non-conductive and coated with a layer comprising a dielectric material.

[0083] According to one embodiment, at least one of the non-conductive fasteners is composed of a dielectric material.

[0084] According to one embodiment, at least one of the non-conductive fasteners is coated with a layer of dielectric material.

[0085] According to one embodiment, at least one of the non-conductive fasteners has a component composed of a dielectric material that fastens the electrical connector to the first battery array or the second battery array.

[0086] According to one embodiment, the component formed of a dielectric material includes an overmold and an insert, wherein the overmold is positioned around a shank of the non-conductive fastener and is physically coupled to the shank, wherein a first portion of the overmold is sandwiched between the heads of the non-conductive fasteners and a second portion of the overmold is positioned between the shank and the electrical connector.

[0087] According to one embodiment, the insert has a first collar and a second collar, wherein the first collar can be positioned around the washer.

[0088] According to one embodiment, the electrical connector of the electrical connector assembly has a cover made of a non-conductive material.

[0089] According to one embodiment, the cover has an opening, wherein the opening is located around a central axis of the non-conductive fastener, and the non-conductive fastener is configured to be set into the electrical terminal via the opening.

[0090] According to one embodiment, the opening is a cutout of the cover. A battery pack comprises: a bus bar assembly; a first battery array; and a second battery array, wherein the bus bar assembly comprises a bus bar and a bus bar cover, and wherein the bus bar electrically couples the first battery array to the second battery array, and the bus bar is physically coupled to one of the battery arrays via a non-conductive fastener, and the non-conductive fastener is configured to be set into the bus bar via an opening of the bus bar cover.

[0091] According to one embodiment, the opening has a first diameter and the non-conductive fastener has a second, smaller diameter.

[0092] According to the present invention, a method of forming a vehicle battery pack includes: non-removably fixedly coupling a first battery array to a second battery array via a bus bar via a plurality of non-conductive fasteners by passing the fasteners through openings in a cover of the vehicle battery pack.

[0093] In one aspect of the invention, the plurality of non-conductive fasteners include first non-conductive fasteners and second non-conductive fasteners, wherein the first non-conductive fasteners fasten the bus bar to the first battery array and the second non-conductive fasteners fasten the bus bar to the second battery array.

[0094] In one aspect of the invention, the plurality of non-conductive fasteners comprises a dielectric material.

[0095] In one aspect of the invention, the plurality of non-conductive fasteners are coated with a dielectric material.

Claims

1. A battery pack, comprising: a first battery array; a second battery array; as well as An electrical connector assembly having an electrical connector and a plurality of non-conductive fasteners, The second battery array is coupled to the first battery array via the electrical connector assembly having the plurality of non-conductive fasteners. 2 . The battery pack of claim 1 , wherein the electrical connector of the electrical connector assembly is a bus bar assembly, and the electrical connector is a bus bar.

3. The battery pack of claim 1 , wherein the plurality of non-conductive fasteners include a first non-conductive fastener and a second non-conductive fastener, wherein the first non-conductive fastener fastens the electrical connector to the first battery array and the second non-conductive fastener fastens the electrical connector to the second battery array.

4. The battery pack of claim 3, wherein the first non-conductive fastener is physically coupled to a first gasket and the second non-conductive fastener is physically coupled to a second gasket, wherein the first non-conductive fastener and the first gasket fasten the electrical connector to the first battery array and the second non-conductive fastener and the second gasket fasten the electrical connector to the second battery array. 5 . The battery pack of claim 4 , wherein the first gasket and the second gasket are non-conductive and comprise a dielectric material. 6 . The battery pack of claim 4 , wherein the first gasket and the second gasket are non-conductive and coated with a layer including a dielectric material.

7. The battery pack of claim 1, wherein at least one of the non-conductive fasteners is comprised of a dielectric material.

8. The battery pack of claim 1, wherein at least one of the non-conductive fasteners is coated with a layer of dielectric material.

9. The battery pack of claim 1, wherein at least one of the non-conductive fasteners has a component formed of a dielectric material that fastens the electrical connector to the first battery array or the second battery array.

10. A battery pack as described in claim 9, wherein the component composed of dielectric material includes an overmold and an insert, wherein the overmold is positioned around the shank of the non-conductive fastener and is physically connected to the shank, wherein a first portion of the overmold is sandwiched between the head of the non-conductive fastener and a second portion of the overmold is positioned between the shank and the electrical connector.

11. The battery pack of claim 10, wherein the insert has a first collar and a second collar, wherein the first collar is positionable around a gasket. 12 . The battery pack of claim 1 , wherein the electrical connector of the electrical connector assembly has a cover made of a non-conductive material.

13. The battery pack of claim 12, wherein the cover has an opening, wherein the opening is positioned about a central axis of the non-conductive fastener, and the non-conductive fastener is configured to be set into the electrical contact via the opening.

14. A method of forming a vehicle battery pack, comprising: The first battery array is non-removably fixedly coupled to the second battery array via the bus bar via a plurality of non-conductive fasteners by passing the fasteners through an opening in a cover of the vehicle battery pack.

15. The method of claim 14, wherein the plurality of non-conductive fasteners include a first non-conductive fastener and a second non-conductive fastener, wherein the first non-conductive fastener fastens the bus bar to the first battery array and the second non-conductive fastener fastens the bus bar to the second battery array, and / or wherein the plurality of non-conductive fasteners include a dielectric material, and / or wherein the plurality of non-conductive fasteners are coated with a dielectric material.

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