Electrical terminal connector for battery module

Abstract

The invention relates to an electrical terminal connector for a battery module. The electrical connector may be used with a battery module, such as a battery module containing one or more electrochemical cells, and include features for precisely positioning an electrical conductor engaged with the electrical connector and / or features for increasing the robustness of the electrical connector to overcurrent conditions. In some embodiments, each electrical connector includes a securing plate having a plurality of openings for securing the electrical connector to either the positive terminal or the negative terminal of the battery module. In some embodiments, each electrical connector includes two or more tapered bridges extending between a fixed plate and a pair of respective crimp clasps that receive respective respective current conductors or branches of a single current conductor during use. An electrical system comprising such an electrical connector is also disclosed.

Description

[0001] Public domain

[0002] The present disclosure relates generally to the field of electrochemical cells. In particular, the present disclosure relates to electrical terminal connectors for battery modules.

[0003] background

[0004] In some deployments of battery modules (e.g., battery modules containing electrochemical cells (e.g., lithium ion cells or lithium metal cells)), cables are connected to terminals of the battery module using flat ring-shaped electrical connectors that are secured to the terminals using a single threaded fastener that passes through a center opening in the connector. As will be readily appreciated by those skilled in the art, when the installer tightens the threaded fastener, the position of the wire attached to the electrical connector can be easily pivoted in the direction of tightening. In addition, such conventional electrical connectors are easily installed upside down, and these electrical connectors generally do not have sufficient overcurrent capability to withstand the high currents required in high current consumption applications of the battery module, for example, in any type of electric vehicle (EV), such as road-going EVs and airborne EVs.

[0005] Public Overview

[0006] In one embodiment, the present disclosure relates to an electrical connector for engaging a battery terminal. The electrical connector includes a fixing plate for fixing the electrical connector to the battery terminal, the fixing plate having: a first face and a second face, the first face and the second face being spaced apart from each other to provide thickness; a first end and a second end, the first end and the second end being located at opposite ends of the fixing plate; a first lateral side and a second lateral side, the first lateral side and the second lateral side being spaced apart from each other on opposite sides of a longitudinal axis and extending between the first end and the second end; and a plurality of openings, the plurality of openings being spaced apart from each other between the first end and the second end, and each opening extending from the first face to the second face, wherein the plurality of openings are configured to facilitate connecting the electrical connector to the battery terminal; a first crimping clasp and a second crimping clasp, the first crimping clasp and the second crimping clasp being located on one of the first lateral side and the second lateral side of the fixing plate and spaced apart from each other; a first tapered bridge (a tapered bridge) The invention relates to a first conical bridge, wherein the first conical bridge firmly fixes the first crimping hook to the fixing plate; and a second conical bridge, wherein the second conical bridge firmly fixes the second crimping hook to the fixing plate; wherein: each of the first conical bridge and the second conical bridge gradually narrows in width from the fixing plate to the corresponding first crimping hook and the second crimping hook; and the fixing plate, the first crimping hook and the second crimping hook and each of the first conical bridge and the second conical bridge are made of conductive material.

[0007] In some embodiments, each of the first crimp hook and the second crimp hook is an O-type crimp hook.

[0008] In some embodiments, the first and second faces of the fixing plate are located in respective first and second planes, and each of the first and second crimping hooks are spaced apart from both the first and second planes.

[0009] In some embodiments, the first crimping hook and the second crimping hook have corresponding respective first and second conductor insertion axes, and the first and second conductor insertion axes are located in a third plane parallel to each of the first and second planes.

[0010] In some embodiments, the first conductor insertion axis and the second conductor insertion axis are parallel to each other.

[0011] In some embodiments, each of the first tapered bridge and the second tapered bridge extends away from the fixation plate at an offset angle greater than zero degrees relative to each of the first plane and the second plane.

[0012] In some embodiments, the offset angle is between 5 degrees and 30 degrees.

[0013] In some embodiments, each of the first tapered bridge and the second tapered bridge has a first lateral side and a second lateral side extending from the fixing plate to the corresponding first crimping hook or the second crimping hook, and each of the first lateral side and the second lateral side has a tapered angle in the range of 5 degrees to 30 degrees.

[0014] In some embodiments, the fixing plate has three openings evenly spaced from one another to define a first inter-opening region and a second inter-opening region of the fixing plate, and each of the first tapered bridge and the second tapered bridge is centered relative to a corresponding one of the first inter-opening region and the second inter-opening region.

[0015] In another embodiment, the present disclosure is directed to an electrical system, the electrical system including a battery module, the battery module including a battery terminal, the battery terminal being used to electrically connect the battery module to an external device; and an electrical connector, the electrical connector being coupled to the battery terminal of the battery module. The electrical connector includes a fixing plate, the fixing plate being used to fix the electrical connector to the battery terminal, the fixing plate having: a first face and a second face, the first face and the second face being spaced apart from each other to provide thickness; a first end and a second end, the first end and the second end being located at opposite ends of the fixing plate; a first lateral side and a second lateral side, the first lateral side and the second lateral side being spaced apart from each other on opposite sides of a longitudinal axis and extending between the first end and the second end; and a plurality of openings, the plurality of openings being spaced apart from each other between the first end and the second end, and each opening extending from the first face to the second face, wherein the plurality of openings are configured to facilitate connecting the electrical connector to the electrical A cell terminal; a first crimping hook and a second crimping hook, the first crimping hook and the second crimping hook are located on one of the first lateral side and the second lateral side of a fixing plate and are spaced apart from each other; a first conical bridge, the first conical bridge firmly fixes the first crimping hook to the fixing plate; and a second conical bridge, the second conical bridge firmly fixes the second crimping hook to the fixing plate; wherein: each of the first conical bridge and the second conical bridge gradually narrows in width from the fixing plate to the corresponding first crimping hook and the second crimping hook; and the fixing plate, the first crimping hook and the second crimping hook and each of the first conical bridge and the second conical bridge are made of conductive material.

[0016] In some embodiments, each of the first crimp hook and the second crimp hook is an O-type crimp hook.

[0017] In some embodiments, the first and second faces of the fixing plate are located in respective first and second planes, and each of the first and second crimping hooks are spaced apart from both the first and second planes.

[0018] In some embodiments, the first crimping hook and the second crimping hook have corresponding respective first and second conductor insertion axes, and the first and second conductor insertion axes are located in a third plane parallel to each of the first and second planes.

[0019] In some embodiments, the first conductor insertion axis and the second conductor insertion axis are parallel to each other.

[0020] In some embodiments, each of the first tapered bridge and the second tapered bridge extends away from the fixation plate at an offset angle greater than zero degrees relative to each of the first plane and the second plane.

[0021] In some embodiments, the offset angle is between 5 degrees and 30 degrees.

[0022] In some embodiments, each of the first tapered bridge and the second tapered bridge has a first lateral side and a second lateral side extending from the fixing plate to the corresponding first crimping hook or the second crimping hook, and each of the first lateral side and the second lateral side has a tapered angle in the range of 5 degrees to 30 degrees.

[0023] In some embodiments, the fixing plate has three openings evenly spaced from one another to define a first inter-opening region and a second inter-opening region of the fixing plate, and each of the first tapered bridge and the second tapered bridge is centered relative to a corresponding one of the first inter-opening region and the second inter-opening region.

[0024] In some embodiments, the electrical connector is secured to the battery terminal by a plurality of threaded fasteners extending through corresponding respective ones of the plurality of openings.

[0025] In some embodiments, the battery module includes a plurality of lithium battery cells. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] For the purpose of illustrating the present disclosure, the accompanying drawings show several aspects of one or more embodiments of the present disclosure. However, it should be understood that the present disclosure is not limited to the precise arrangements and instrumentalities shown in the accompanying drawings, wherein:

[0028] Figure 1 is a partial side view / partial schematic view of an electrical system including a battery module and a pair of electrical connectors coupled to electrical terminals of the battery module;

[0029] Figure 2A It is available for Figure 1 A perspective view of the electrical connector of the present disclosure of each electrical connector;

[0030] Figure 2B yes Figure 2A A plan view of an electrical connector;

[0031] Figure 2C yes Figure 2A A front view of an electrical connector;

[0032] Figure 2D yes Figure 2A A side view of an electrical connector;

[0033] Figure 3A It is fixed to the battery module Figure 2A-2D A perspective view of an electrical connector; and

[0034] Figure 3B yes Figure 3A 0014] A plan view of an electrical connector showing an example distal end of an electrical conductor crimped to the electrical connector.

[0035] Detailed Description

[0036] In some aspects, the present disclosure relates to electrical connectors that engage electrical conductors and provide not only positioning accuracy and stability for electrical conductors (e.g., wires, cables, etc.), but also provide robust connections for high current applications (such as EVs). In one example, the high current application is a rated current of 100A, an actual current in the range of 100A to 150A, and a 150A current for at least 60 seconds. In some aspects, the present disclosure relates to an electrical system comprising one or more battery modules and an electrical connector manufactured according to the present disclosure, the electrical connector fixing the electrical conductor to at least one battery module. These and other aspects will be described in detail below and / or shown in the accompanying drawings.

[0037] Note that the terms "first", "second", "third", etc., when used herein to designate elements, features, structures, components, etc., are only used to designate different ones of these elements, features, structures, components, etc., and do not convey any particular order, importance, arrangement, etc. It should also be noted that as used herein, the terms "top", "side", or "front", and any similar terms indicating a view within a drawing of the accompanying drawings are arbitrary, as the subject matter of the drawings may have any desired orientation when put into practice. Similarly, the terms "above" and "below" as used herein apply only to the relevant views in a particular figure and not to any absolute reference frame.

[0038] Now turning to the attached figure, Figure 1 An example electrical system 100 manufactured in accordance with the present disclosure is shown. In this example, the electrical system 100 includes a battery module 104; a first electrical connector 108(1) and a second electrical connector 108(2) of the present disclosure coupled to output terminals 104(1) and 104(2) of the battery module, respectively (of opposite polarity); and one or more external devices 112 to which the battery module is electrically connected via one or both of the first electrical connector and the second electrical connector. For context, the battery module 104 can be any type of battery module, such as a battery module including one or more electrochemical cells having any suitable chemistry, such as, for example, lithium ion chemistry, lithium metal chemistry, sodium-based chemistry, or sulfur-based chemistry, etc. The battery module 104 can alternatively be a battery pack including a plurality of battery modules, such as a plurality of multi-cell battery modules.

[0039] The one or more external devices 112 may be any one or more devices that need to be connected to the battery module 104 to provide a functional system. In some cases, the two output terminals 104 (1) and 104 (2) will be connected to a single external device 112, such as a device that directly obtains power from the battery module 104 or another battery module electrically connected in series with the battery module 104. Examples of power-obtaining external devices include, but are not limited to, motor controllers and power distribution boxes, etc. In some embodiments, only one of the output terminals 104 (1) and 104 (2) will be connected to the corresponding external device 112, such as, for example, in the case where the external device is another battery module electrically connected in series with the battery module 104. Those skilled in the art will readily appreciate that the one or more external devices 112 may be a variety of types of devices. As discussed in more detail below, each of the first electrical connector 108 (1) and the second electrical connector 108 (2) is crimped to receive one or more electrical conductors (here, the first electrical conductor 116 (1) and the second electrical conductor 116 (2)), or two or more branches (not shown) of a single one of the first electrical conductor and the second electrical conductor.

[0040] FIG. 2A to FIG. 2D An example electrical connector 200 of the present disclosure is shown, which may be used, for example, Figure 1 The electrical connector 200 is a connector for use with a plurality of electrical connectors, each of which is configured to be connected to a plurality of electrical connectors, and each of which is configured to be connected to a plurality of electrical connectors, is preferably ...

[0041] The fixing plate 204 is designed and configured to engage the battery module (not shown, but see Figure 1 The battery module 104) and the electrical connector 200 is fixedly connected to the battery module. Figure 2A As best shown in FIG. 1 , the fixing plate 204 has a plurality of openings 204O (here three openings) for fixing the electrical connector 200 to the battery module. Each opening is designed to receive a head threaded fastener (not shown, but see FIG. 1 ). Figure 3A and Figure 3BThreaded fasteners 304), such as screws, bolts or similar fasteners, or as output terminals (not shown, but see Figure 1 The first output terminal 104 (1) and the second output terminal 104 (2) are part of a threaded post (not shown). In the case of a threaded post, one or more threaded nuts or similar hardware can be used to threadably engage each threaded post to complete the fixed connection.

[0042] In this example, three openings 204O are evenly spaced along the longitudinal axis 204LA of the fixing plate 204 so as to define a first inter-opening region 204IR(1) and a second inter-opening region 204IR(2). In this embodiment, the first tapered bridge 212(1) and the second tapered bridge 212(2) are aligned with the first inter-opening region 204IR(1) and the second inter-opening region 204IR(2), respectively. In other embodiments, such an alignment need not be used, nor need three openings 204O be provided. For example, other embodiments may include two openings or four openings or more. As in Figure 2B In the context of an electrical connector having two openings, the three openings 204O may be replaced by two openings 204O'.

[0043] Still reference Figure 2B , each of the tapered bridges 212(1) and 212(2) has a central axis 212CA and a pair of lateral edges 212E, nominally represented by lines 212L, each of the pair of lateral edges 212E forming a nominal non-zero taper angle α relative to the corresponding central axis 212CA. In one example, the taper angle α is 30 degrees. In other embodiments, the taper angle α is the same value. In this example, the line 212L, which nominally represents the nominal lateral edges 212E of the tapered bridges 212(1) and 212(2), each passes through a corresponding one of the openings 204O and has a width Wbp at the fixed plate 204 that is approximately equal to twice the width Wcp of the region 204 between the openings. In this manner, current flowing from the electrical terminals (not shown) can be effectively collected or dispersed from the fixed plate 204 to the fixed plate 204 (depending on the direction of the current) by each of the tapered bridges 212(1) and 212(2), and then concentrated or dispersed by the taper. In this example, the lateral edge 212E of each tapered bridge 212 ( 1 ) and 212 ( 2 ) is shaped to have a gently curved profile to divert current while avoiding heat accumulation due to excessive current concentration.

[0044] like Figure 2D As shown, in this example, each of the tapered bridges 212 (1) and 212 (2) ( Figure 2B and Figure 2C) extends away from the fixing plate 204 at a standoff angle β, the standoff angle β being formed between each central axis 212CA of the tapered bridge and each of a pair of first planes 204P(1) and second planes 204P(2) respectively including the corresponding faces 204F(1) and 204F(2) of the fixing plate. In this manner, the portion of each crimping hook 208(1) and 208(2) closest to the first plane 204P(1) is spaced a distance Dcc from the first plane of the first face 204F(1), which in some embodiments is the face of the fixing plate facing the corresponding battery module (not shown, but see Figure 1 The deviation angle is between 5 degrees and 30 degrees, which is to allow the crimping fasteners 208 (1) and 208 (2) to be crimped to the wire, and the edge of the wire's insulation outer diameter is flush with the plane of 204F (1) to facilitate installation inside the device. The narrowest point of the conical bridges 212 (1) and 212 (2) is 6mm, and the thickness of the entire terminal is 1.5mm, that is, the minimum cross-sectional area for overcurrent is 9 square millimeters. The rated current of both conical bridges 212 (1) and 212 (2) is 50A.

[0045] In the example shown, the fixing plate 204 is made of a highly conductive material (such as copper, aluminum, or a suitable alloy, etc.) and is Figure 2D As shown, the fixing plate 204 has a uniform thickness Tp. In this example, each of the tapered bridges 212(1) and 212(2) has a uniform thickness Tb and is made of a highly conductive material (such as any of the materials just mentioned for the fixing plate). In some embodiments, the fixing plate 204 and the tapered bridges 212(1) and 212(2) can be formed from a single sheet of conductive material, such as by cold stamping. In other embodiments, the bridges 212(1) and 212(2) can be formed separately from the fixing plate 204 and attached to the fixing plate 204, such as by techniques such as welding or brazing. The crimping hooks 208(1) and 208(2) are also made of a suitable highly conductive material (such as any of the materials mentioned above with respect to the fixing plate 204). In some embodiments, the crimp hooks 208(1) and 208(2) can be formed separately from the tapered bridges 212(1) and 212(2) and secured to the tapered bridges 212(1) and 212(2) by a suitable means (e.g., welding or brazing, etc.). In some embodiments, the crimp hooks 208(1) and 208(2) can be integrally formed with the tapered bridges 212(1) and 212(2), such as by cold forming or other suitable methods. In some embodiments, the entire electrical connector 200 can be formed from a single sheet of material using one or more suitable techniques (such as one or more cold forming techniques). In some embodiments, some or all of the electrical connectors can be manufactured using additive manufacturing processes (such as 3D printing) or casting, etc.

[0046] In some embodiments, each crimp hook 208(1) and 208(2) may be hollow cylindrical as shown in the figure so as to be transverse to the conductor insertion axis 208CIA ( Figure 2C ) has an annular cross-sectional shape in the direction of the crimping hooks 208 (1) and 208 (2). However, in other embodiments, each crimping hook 208 (1) and 208 (2) may have another transverse cross-sectional shape, such as a U-shape or a C-shape, etc.

[0047] Figure 3A Shows FIG. 2A to FIG. 2D The electrical connector 200 is secured to the battery module 300 via three threaded fasteners 304 , which in this example are hex head screws. Figure 3A Also shown are a pair of electrical conductors 308(1) and 308(2), such as wires or cables, which are crimped into engagement with corresponding ones of the crimp hooks 208(1) and 208(2) of the electrical connector 200. Although not shown, the ends of the electrical conductors 308(1) and 308(2) opposite the electrical connector 200 may be connected to another battery module or another device, such as the battery module mentioned above. Figure 1 any other device related to device 112. Figure 3B Shows Figure 3A , but each of the electrical conductors 308 ( 1 ) and 308 ( 2 ) are shown terminated in a conventional electrical connector 312 .

[0048] Various modifications and additions may be made without departing from the spirit and scope of the present disclosure. The features of each of the various embodiments described above may be appropriately combined with the features of other described embodiments so as to provide a variety of feature combinations in associated new embodiments. In addition, although the foregoing describes a plurality of separate embodiments, the contents described herein are merely illustrations of the application of the principles of the present disclosure. In addition, although the specific methods herein may be illustrated and / or described as being performed in a particular order, it is within the technical scope of the art that the sequencing is highly variable to implement aspects of the present disclosure. Therefore, this description is intended to be made by way of example only and does not otherwise limit the scope of the present disclosure. The attached claims are incorporated into this detailed description as if originally presented herein.

[0049] Exemplary embodiments have been disclosed above and shown in the accompanying drawings. It will be appreciated by those skilled in the art that various changes, omissions, and additions may be made to the contents specifically disclosed herein without departing from the spirit and scope of the present disclosure.

Claims

1. An electrical connector for engaging a battery terminal, the electrical connector comprising: A fixing plate, the fixing plate is used to fix the electrical connector to the battery terminal, the fixing plate having: a first side and a second side, the first side and the second side being spaced apart from each other to provide a thickness; a first end portion and a second end portion, the first end portion and the second end portion being located at opposite ends of the fixing plate; a first lateral side and a second lateral side spaced from each other on opposite sides of the longitudinal axis and extending between the first end and the second end; and a plurality of openings spaced apart from one another between the first end and the second end and each opening extending from the first face to the second face, wherein the plurality of openings are configured to facilitate connecting the electrical connector to the battery terminal; a first crimping hook and a second crimping hook, the first crimping hook and the second crimping hook being located on one of the first lateral side and the second lateral side of the fixing plate and spaced apart from each other; a first tapered bridge, the first tapered bridge firmly securing the first crimp hook to the fixing plate; and a second tapered bridge, the second tapered bridge firmly securing the second crimp hook to the fixing plate; in: Each of the first tapered bridge and the second tapered bridge gradually narrows in width from the fixing plate to the corresponding first and second crimping hooks; and Each of the fixing plate, the first and second crimping hooks, and the first and second tapered bridges are made of a conductive material.

2. The electrical connector according to claim 1, wherein: Each of the first crimping hook and the second crimping hook is an O-type crimping hook.

3. The electrical connector according to claim 1, wherein: The first and second faces of the retaining plate lie in respective first and second planes, and each of the first and second crimping hooks are spaced from both the first and second planes.

4. The electrical connector according to claim 3, wherein: The first and second crimp hooks have respective first and second conductor insertion axes, respectively, that lie in a third plane parallel to each of the first and second planes.

5. The electrical connector according to claim 4, wherein: The first conductor insertion axis and the second conductor insertion axis are parallel to each other.

6. The electrical connector according to claim 3, wherein: Each of the first tapered bridge and the second tapered bridge extends away from the fixing plate at an offset angle greater than zero degrees relative to each of the first plane and the second plane.

7. The electrical connector according to claim 6, wherein: The deviation angle is between 5 degrees and 30 degrees.

8. The electrical connector according to any one of claims 1 to 7, wherein: Each of the first tapered bridge and the second tapered bridge has a first lateral side and a second lateral side extending from the fixing plate to the corresponding first crimping hook or the second crimping hook, and each of the first lateral side and the second lateral side has a tapered angle in the range of 5 degrees to 30 degrees.

9. The electrical connector according to claim 8, wherein: The fixing plate has three openings evenly spaced from one another to define a first inter-opening region and a second inter-opening region of the fixing plate, and each of the first and second tapered bridges is centered relative to a corresponding one of the first and second inter-opening regions.

10. An electrical system comprising: a battery module, the battery module comprising a battery terminal, the battery terminal being used to electrically connect the battery module to an external device; and an electrical connector coupled to the battery terminal of the battery module, the electrical connector comprising: A fixing plate, the fixing plate is used to fix the electrical connector to the battery terminal, the fixing plate having: a first side and a second side, the first side and the second side being spaced apart from each other to provide a thickness; a first end portion and a second end portion, the first end portion and the second end portion being located at opposite ends of the fixing plate; first and second lateral sides spaced from one another on opposite sides of the longitudinal axis and extending between the first and second ends; and a plurality of openings spaced apart from one another between the first end and the second end and each opening extending from the first face to the second face, wherein the plurality of openings are configured to facilitate connecting the electrical connector to the battery terminal; a first crimping hook and a second crimping hook, the first crimping hook and the second crimping hook being located on one of the first lateral side and the second lateral side of the fixing plate and spaced apart from each other; a first tapered bridge, the first tapered bridge firmly securing the first crimp hook to the fixing plate; and a second tapered bridge, the second tapered bridge firmly securing the second crimp hook to the fixing plate; in: Each of the first tapered bridge and the second tapered bridge gradually narrows in width from the fixing plate to the corresponding first and second crimping hooks; and Each of the fixing plate, the first and second crimping hooks, and the first and second tapered bridges are made of a conductive material.

11. The electrical system of claim 10, wherein: Each of the first crimping hook and the second crimping hook is an O-type crimping hook.

12. The electrical system of claim 10, wherein: The first and second faces of the retaining plate lie in respective first and second planes, and each of the first and second crimping hooks are spaced from both the first and second planes.

13. The electrical system of claim 12, wherein: The first and second crimp hooks have respective first and second conductor insertion axes, respectively, that lie in a third plane parallel to each of the first and second planes.

14. The electrical system of claim 13, wherein: The first conductor insertion axis and the second conductor insertion axis are parallel to each other.

15. The electrical system of claim 12, wherein: Each of the first tapered bridge and the second tapered bridge extends away from the fixing plate at an offset angle greater than zero degrees relative to each of the first plane and the second plane.

16. The electrical system of claim 15, wherein: The deviation angle is between 5 degrees and 30 degrees.

17. An electrical system according to any one of claims 10 to 16, wherein: Each of the first tapered bridge and the second tapered bridge has a first lateral side and a second lateral side extending from the fixing plate to the corresponding first crimping hook or the second crimping hook, and each of the first lateral side and the second lateral side has a tapered angle in the range of 5 degrees to 30 degrees.

18. The electrical system of claim 17, wherein: The fixing plate has three openings evenly spaced from one another to define a first inter-opening region and a second inter-opening region of the fixing plate, and each of the first and second tapered bridges is centered relative to a corresponding one of the first and second inter-opening regions.

19. The electrical system of claim 18, wherein: The electrical connector is secured to the battery terminal by a plurality of threaded fasteners extending through corresponding respective ones of the plurality of openings.

20. The electrical system of claim 18, wherein: The battery module includes a plurality of lithium battery cells.

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