COMBINED ELECTRICAL / FLUID CONNECTOR FOR THE BATTERY OF AN ELECTRIFYED VEHICLE

Abstract

An electrified vehicle system comprises a battery having a plurality of cells electrically connected in at least one cell assembly, wherein the at least one cell assembly is connected to an internal battery busbar within a housing, an annular coolant connector having a coolant channel extending between an outer radius and an inner radius of the connector, and an electrically conductive fastener having a closed end and a channel extending from an open end to a radial opening, wherein the fastener extends through the annular coolant connector, the radial opening being positioned within the annular coolant connector.and furthermore extends through the housing and mechanically and electrically connects an external busbar outside the housing to the internal busbar and allows coolant flow through the battery assembly.

Description

FIELD OF TECHNOLOGY

[0001] This disclosure relates to a combined electrical / fluid connector that couples an electrical system and a cooling system to an immersion-cooled battery as used in various electrified vehicles. GENERAL STATE OF THE ART

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

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

[0004] In one or more embodiments, the system of an electrified vehicle includes a first cell assembly and a second cell assembly, the first and second cell assemblies electrically and fluidically connected in series. In one or more embodiments, at least one cell assembly includes a first cell assembly and a second cell assembly electrically and fluidically connected in parallel. In other embodiments, at least one cell assembly includes a first cell assembly and a second cell assembly electrically connected in series and fluidically connected in parallel. In other embodiments, at least one cell assembly includes a first cell assembly and a second cell assembly electrically connected in parallel and fluidly connected in series.

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

[0006] In one or more embodiments, the connector may be implemented by tubing surrounding a stranded electrical conductor and configured to contain a dielectric coolant, an end cap connected to the tubing and having a plurality of openings configured to permit coolant flow therethrough and a central opening configured to receive the stranded electrical conductor, and a fitting attached to the tubing and configured to engage a complementary housing fitting. The connector may also include a tab connector or a pin connector connected to the stranded electrical conductor.

[0007] Embodiments may include the plurality of assemblies electrically and fluidically connected in parallel or electrically and fluidically connected in series. In other embodiments, the plurality of assemblies may be either electrically connected in series and fluidically connected in parallel or electrically connected in parallel and fluidically connected in series.

[0008] In one or more embodiments, a combined electrical / fluid connector may include an electrically conductive stud having a closed end, a channel extending from an open end to a radial opening, and a threaded portion extending from the open end toward the radial opening, and an annular coolant fitting having a coolant channel extending between an outer radius and an inner radius of the fitting, wherein the stud extends through the annular coolant fitting with the radial opening positioned within the annular coolant fitting, and further extends through a housing of a battery and mechanically and electrically connects an external bus bar to an internal bus bar of the battery and enables coolant flow through the battery.The connector may further include a conductive washer disposed between the conductive bolt and the annular coolant fitting. The connector may also include a threaded nut that engages the threaded portion of the bolt and clamps the external busbar, the annular coolant fitting, and the internal busbar to the housing. The connector may also include an upper washer disposed between the external busbar and the annular coolant fitting, and a lower washer disposed between the annular coolant fitting and the housing.

[0009] One or more embodiments according to the disclosure may have associated advantages. Various prior art strategies for immersion cooling the cells utilize separate electrical and fluid connections into the assembly that must be sealed from the pressurized fluid. In contrast, the combined electrical and fluid connection configuration according to various embodiments enables cooling of the battery cells and the connection points of the electrical distribution system while using the same number or fewer fluid seals on the assembly housing. One of ordinary skill in the art may recognize additional advantages of one or more embodiments for particular applications or implementations not expressly stated based on the teachings of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a block diagram of an electrified vehicle including a combined electrical / fluidic connector coupling battery cell assemblies of a traction battery according to the disclosure. Fig. Figure 2A illustrates a pin connector embodiment of a combined electrical / fluid connector. Fig. Figure 2B illustrates a tab connector embodiment of a combined electrical / fluid connector. Fig. 2C and Fig. 2D illustrates a combined electrical / fluidic wiring harness and an associated end cap for an electrical / fluidic connector. Fig. 3 illustrates a combined electrical / fluid connection of a battery cell assembly with a hollow screw connector. Fig. Figure 4 is a block diagram illustrating battery cell assemblies electrically and fluidly connected in series using combined electrical / fluidic connectors. Fig. Figure 5 is a block diagram illustrating battery cell assemblies electrically and fluidly connected in parallel using combined electrical / fluidic connectors. Fig. Figure 6 is a block diagram illustrating battery cell assemblies electrically connected in series and fluidly connected in parallel. Fig. Figure 7 is a block diagram illustrating battery cell assemblies electrically connected in parallel and fluidly connected in series. DETAILED DESCRIPTION

[0010] Where appropriate, detailed embodiments of the claimed subject matter are disclosed herein; however, it should be understood that the disclosed embodiments are merely representative and may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be greatly exaggerated or reduced to show details of particular components. Therefore, the specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ embodiments of the claimed subject matter.

[0011] As described in more detail herein, a combined electrical and fluid connector according to the disclosure includes embodiments that adapt a conventional tab- or pin-type electrical connector to provide fluid flow around the connection point for cooling and fluid transfer between a vehicle cooling system and a battery cell assembly. The connector is particularly suitable for use in applications where the cell assemblies are electrically and fluidly connected in series or electrically and fluidly connected in parallel, with the cooling fluid flowing along the electrical path. Copper stranded wiring of the combined wiring is contained within a hose or tubing containing the dielectric or electrically non-conductive cooling fluid or coolant. At the end of the tubing, the connector housing or end cap is attached by crimping or an equivalent attachment method.The end cap or connector housing has holes to allow fluid flow from the tube through the connection interface into the receptacle connector of the battery cell assembly. The mating pin or mating flat plug can be crimped to the stranded conductor and retained by the connector housing. The connector housing creates a sealed connection with the receptacle connector on the assembly housing, establishing the electrical connection while allowing fluid flow around the electrical connection and into the assembly housing for immersion cooling of the battery cells. The same connection method can be used at the electrical / fluid outlet at the opposite port of the battery cell assembly housing. Because the fluid is dispensed into contact with the wiring in the hose or tubing, this design cools the entire length of electrical wiring between the assemblies in addition to the electrical connection points.

[0012] In other embodiments, a combined electrical and fluid connector is implemented using a hollow screw fitting to provide coolant flow internal to the electrical connection point for cooling and fluid transfer into the battery cell assembly. This embodiment is particularly suitable for use in applications having battery cell assemblies that are electrically and fluidly connected in parallel or electrically and fluidly connected in series, in addition to applications having battery cell assemblies that are electrically and fluidly connected in series or electrically and fluidly connected in parallel, since the cooling fluid path can be separate from the electrical path.The banjo bolt connection includes a bolt with an internal fluid channel extending between a radial opening and an open end, and an annular fitting surrounding the bolt in line with the radial opening to transfer fluid from the tubing or tubing into the bolt channel. The bolt secures an external busbar to the fitting, assembly housing, and internal busbar. A conductive washer between the busbar and the bolt head may be used to provide a fluid seal and electrical conduction. A first or upper washer between the external busbar and the fitting and a second or lower washer between the fitting and the assembly housing may be used to provide fluid seals. These washers may be conductive or insulating.

[0013] The assembly housing and fluid tubing are electrically non-conductive. The power output flows from the external busbar through the conductive washer into the bolt head and through the bolt to the nut and the internal busbar of the assembly. The cooling fluid is routed through non-conductive tubing to the terminal and into the bolt, directly cooling the electrical connection point, and exits the threaded end of the bolt into the assembly for immersion cooling of the battery cells. The same connection method can be used at the fluid outlet at the opposite terminal of the battery cell assembly.

[0014] Fig. 1 illustrates an example of an electrified vehicle 100 having one or more combined electric / fluid connectors according to the present disclosure. In this example, the electrified vehicle 100 is implemented as a plug-in hybrid electric vehicle. The electrified vehicle 100 may include one or more three-phase electric machines 104 mechanically connected to a transmission 106. In hybrid implementations, the transmission 106 is mechanically connected to an internal combustion engine 108. The transmission 106 may also be mechanically connected to a driveshaft 110 that is mechanically connected to the wheels 112. The electric machines or motor / generators 104 may provide propulsion whether the internal combustion engine 108 is on or off. One or more electric machines 104 may operate as motors, generators, or both.The electrified vehicle 100 may also be implemented as a battery electric vehicle without an internal combustion engine 108 and may be powered exclusively by a traction battery 114 alone or in combination with another power source, such as a fuel cell.

[0015] The traction battery or battery pack 114 stores energy that can be used by the electric machines 104. A vehicle battery pack 114 typically provides a high-voltage DC (HV DC) output by connecting hundreds of low-voltage battery cells 160 together in one or more battery cell modules or assemblies 166. The assemblies 166 may each be contained within an associated assembly housing 168 within the battery pack 114. The battery cells 160 may be immersed in a dielectric cooling fluid or coolant circulated within a vehicle cooling system 140. The battery cells 160 may be electrically connected by an internal bus bar within the associated assembly housing 168. The assemblies may be connected to other assemblies by an external bus bar outside the assembly housings but within the battery pack 114.The assemblies may be fluidly connected within the battery pack 114 by a combined electrical / fluid inlet connector 150 and a combined electrical / fluid outlet connector 152 and associated wiring, tubing, or piping. The assemblies 166 may be fluidly and electrically connected in series, parallel, or in a combination of series and parallel arrangements, depending on the specific application and implementation, as described in more detail herein.

[0016] The vehicle's electrical distribution system (EDS) may also include an HV bus connecting one or more vehicle power modules or components, such as electric machines 104, a power electronics module 116, a DC / DC converter module 118, etc., as well as an LV bus to the battery pack 114. The power electronics module 116 is also electrically connected to the electric machines 104 and provides the ability to transfer power bidirectionally between the battery pack 114 and the electric machines 104. For example, a typical battery pack 114 may provide DC voltage / current, while the electric machines 104 may require three-phase AC voltage / current.The power electronics module 116 may include an inverter having a power module with switches operable by a controller to convert the DC power from the battery 114 into three-phase AC power required by the electric machines 104. The power electronics module 116 may also include a voltage converter that boosts the DC voltage from the battery pack 114, which is supplied to the HV DC bus that powers the inverter of the power electronics module 116. In a regeneration mode, the power electronics module 116 converts the three-phase AC power from the electric machines 104, which act as generators, into DC power required to regenerate energy in the battery pack 114.Thermal management of the heat generated by power conversion is provided by cooling the power stage assembly module of the power electronics module according to one or more embodiments described herein.

[0017] In addition to providing propulsion power, the battery pack 114 can provide power to other vehicle electrical systems. A typical system may include a DC-DC converter module 118 that converts the high-voltage DC output of the battery pack 114 into a low-voltage DC power supply compatible with other vehicle loads. Other high-voltage loads, such as compressors and electric heaters, may be directly connected to the high-voltage bus of the battery pack 114. In a typical vehicle, the low-voltage systems are electrically connected to a 12V, 24V, or 48V battery 120.

[0018] The battery pack 114 can be charged by an external power source 126. The external power source 126 can provide AC or DC power to the vehicle 102 by being electrically connected via a charging port 124. The charging port 124 can be any type of port configured to transfer power from the external power source 126 to the vehicle 102. The charging port 124 can be electrically connected to a power conversion module 122, sometimes referred to as a charger or charging module. The power conversion module can condition the power from the external power source 126 to provide the proper voltage and current levels to the battery pack 114. In some applications, the external power source 126 can be configured to provide the proper voltage and current levels to the battery pack 114, and the power conversion module 122 may not be necessary.The functions of the power conversion module 122 may, in some applications, be performed by the external power source 126. The vehicle's engine, transmission, electric machines, battery, power conversion, power electronics, and various other control modules, components, or systems may be controlled by a powertrain control module (PCM) 128. Alternatively, or in combination, various systems or subsystems may include associated control modules or controllers in communication with the PCM 128 via a wired or wireless network of the vehicle to provide coordinated control of the vehicle.For the purposes of this disclosure, a controller generally refers to one or more control modules or controllers that can cooperate to perform a particular task or function, and is not limited to a single controller or a specific dedicated controller or control module.

[0019] With reference to the Fig. 2A and Fig. 2B shows one embodiment of a pin connector or a blade connector of a combined electrical / fluid connector. The connector 210 may include a pin connector 212 or a blade connector 230 coupled to a stranded electrical connector 216 at a crimp point 214. The stranded electrical connector 216 extends from within the associated tubing or tubing 218 of a combined electrical / fluid cable through an opening in the connector 220, which is crimped to the tubing or tubing 218 to form a fluid seal. The connector 220 may be internally threaded or otherwise configured to connect to a battery cell assembly housing.After connecting the pin 212 or the tab 230 to the stranded conductor 216, the stranded conductor 216 can be retracted within the tubing 218 to at least partially retract the pin / tab connector within the connector 220 to allow coolant flow from the tubing or tubing 218 into (or out of) a connected assembly housing. Alternatively, or in combination, one or more openings can be provided around the central opening to allow coolant flow through the connector, as described with respect to FIG. Fig. 2C and Fig. 2D illustrated and described.

[0020] The Fig. 2C and Fig. 2D illustrate a combined electrical / fluid cable and an associated end cap for an electrical / fluid connector, as described with reference to the Fig. 2A and Fig. 2B. In one embodiment, a plastic slider 250 contains coolant flowing around a stranded wire conductor 260. The plastic slider 250 may include a retention feature 252 to secure a pin or blade connector attached to the stranded wire conductor 260 as previously described. An end cap 270 may be attached to the plastic slider 250. The end cap 270 includes a central opening 272 configured to receive, for example, a pin or blade connector. One or more openings 274 may be disposed around the central opening 272 and configured to allow coolant flow therethrough.

[0021] Fig. Figure 3 illustrates a combined electrical / fluid connection of a battery cell assembly using a banjo fitting. As is well known to those of ordinary skill in the art and as used herein, a banjo fitting generally refers to a hydraulic fitting that includes a perforated hollow stud, or an internally exposed stud, and a spherical connection to allow fluid transfer through the stud. Banjo fittings can be used to connect a fluid line to a rigid, internally threaded hydraulic component.

[0022] In the embodiment from Fig. 3, a fastener, such as a bolt 310, includes an internal channel extending from an open end 312 to a radial opening 314. In this representative embodiment, the bolt 310 provides mechanical, electrical, and fluidic connection to an associated battery cell assembly by securing an external bus bar 340, a banjo bolt fitting 330, and an internal bus bar 350 to an assembly housing 320. A conductive washer 322 provides a fluid seal and electrical conductivity from the external bus bar 340 to the internal bus bar 350 connected to one or more battery cells (not shown).The banjo bolt fitting 330 is an annular fitting that includes a central opening configured to receive the stud 310 and at least one radial opening extending from an outer periphery of the annulus to an inner periphery of the annulus, and is configured to allow the flow of a cooling fluid 360 from a connected pipe or tube 354. A first or upper washer 324 and a second or lower washer 326 may be used to provide a fluid seal. The first and second washers 324, 326 may be conductive or insulating depending on the specific application and implementation. The stud 310 includes a threaded portion extending from the open end 312 and engaging a complementary threaded nut 316.The bolt 310 is sized such that the radial opening 314 is positioned within the annular fitting 330 between a first or upper surface of the annular fitting 330 in contact with the washer 324 and a lower surface of the annular fitting 330 in contact with the lower washer 326.

[0023] Fig. 4 is a block diagram illustrating battery cell assemblies electrically and fluidly connected in series using combined electrical / fluid connectors. A first inlet connector 410 couples a vehicle cooling system to a battery pack via a cooling fluid connection 412 and an electrical connection 414 to a first battery cell assembly 420. The cooling fluid provides immersion cooling of battery cells contained within a housing of the first assembly 420. The connector 410 connects an external bus bar outside the housing of the first assembly 420 to an internal bus bar connected to one or more cells within the housing of the first assembly 420, as previously described.An outlet connector 430 connects cooling fluid within the first assembly 420 to an associated hose or conduit coupled to a second inlet connector 440 associated with the second battery cell assembly 450. Similarly, the first outlet connector 430 connects the associated internal bus bar within the first assembly 420 to an external bus bar 434, which in turn is connected to the second inlet connector 440 of the second assembly 450. A second outlet connector 460 couples cooling fluid to another assembly (if present) or to a battery coolant outlet 462 and also couples an internal bus bar of the second assembly 450 to an external bus bar 464 of the second assembly 450.

[0024] Fig. Figure 5 is a block diagram illustrating battery cell assemblies electrically and fluidically connected in parallel using combined electrical / fluid connectors. In this configuration, a cooling fluid inlet manifold 502 supplies lower-temperature coolant to the inlet of at least two battery cell assemblies 520, 550, each having associated inlet connectors 510, 540. Similarly, an external positive-polarity high-voltage (HV) bus 504 is electrically connected in parallel with the input connectors 510, 540 for the battery cell assemblies 520, 550. The outlet connectors 530, 560 electrically couple the assemblies 520, 550 in parallel to an external negative polarity HV bus bar 506 and fluidly couple higher temperature cooling fluid exiting the assemblies 520, 550 in parallel to a coolant outlet manifold 508.

[0025] Fig. 6 is a block diagram illustrating battery cell assemblies electrically connected in series and fluidly connected in parallel. In this configuration, a cooling fluid inlet manifold 602 supplies lower temperature coolant to the inlet of at least two battery cell assemblies 620, 650, each having associated inlet or input connectors 610, 640 and respective outlet or output manifolds 630, 660. An external positive polarity bus bar 604 is electrically connected to the input connector 610. The output connector 630 is fluidly connected to an outlet manifold 608 and is electrically connected to internal and external negative polarity bus bars, with the external bus bar electrically connected in series with the input connector 640 and the associated internal positive polarity bus bar of the assembly 650.Output connector 660 electrically connects the negative internal bus bar of assembly 650 in series with a positive internal bus bar of another assembly or the negative terminal of the battery pack. Output connector 660 fluidly couples the higher-temperature cooling fluid exiting assembly 650 to the outlet manifold 608 in parallel with the cooling fluid exiting assembly 620.

[0026] Fig.7 is a block diagram illustrating battery cell assemblies electrically connected in parallel and fluidly connected in series. In this configuration, an external positive polarity HV bus bar is electrically connected in parallel to internal positive polarity bus bars of the at least two battery cell assemblies 720, 750 via respective input connectors 710, 740. The input connector 710 is fluidly coupled to the vehicle cooling system to provide lower temperature cooling fluid for immersion cooling of cells in the assembly 720. The outlet connectors 730, 760 electrically connect the internal negative polarity bus bars of the assemblies 720, 750, respectively, in parallel with the external negative polarity HV bus bar 706. The outlet connector 730 connects cooling fluid from the assembly 720 in series to the assembly 750 via the inlet connector 740.The outlet connector 760 fluidly connects the cooling fluid exiting the assembly 750 to another assembly or to the vehicle cooling system (not shown).

[0027] While representative embodiments are described above, these embodiments are not intended to describe all possible forms of the invention. The terms used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the claimed subject matter. Furthermore, the features of various practiced embodiments may be combined to form other embodiments within the scope of the claimed subject matter that are not expressly described or illustrated.

[0028] According to the present invention, an electrified vehicle system is provided, comprising: a battery having a plurality of cells electrically connected in at least one cell assembly having an assembly housing, the at least one cell assembly being connected to an internal battery bus bar within the assembly housing; an annular coolant fitting having a coolant channel extending between an outer radius and an inner radius of the fitting;and an electrically conductive fastener having a closed end and a channel extending from an open end to a radial opening, the fastener extending through the annular coolant fitting, the radial opening being positioned within the annular coolant fitting, and further extending through the assembly housing and mechanically and electrically connecting an external bus bar outside the assembly housing to the internal bus bar.;

[0029] According to one embodiment, the fastener comprises a bolt having a threaded region extending below the radial opening and a nut engaging the threaded region, the bolt and nut clamping the external busbar, the annular coolant fitting, and the internal busbar to the assembly housing.

[0030] According to one embodiment, the invention is further characterized by an electrically conductive washer arranged between the bolt and the external busbar.

[0031] According to one embodiment, the invention is further characterized by an upper washer disposed between the external bus bar and the annular coolant fitting, and a lower washer disposed between the annular coolant fitting and the assembly housing.

[0032] According to one embodiment, the at least one cell arrangement includes a first cell arrangement and a second cell arrangement, and wherein the first and second cell arrangements are electrically and fluidically connected in series.

[0033] According to one embodiment, the at least one cell arrangement includes a first cell arrangement and a second cell arrangement, and wherein the first and second cell arrangements are electrically and fluidically connected in parallel.

[0034] According to one embodiment, the at least one cell arrangement includes a first cell arrangement and a second cell arrangement, and wherein the first and second cell arrangements are electrically connected in series and fluidically connected in parallel.

[0035] According to one embodiment, the at least one cell arrangement includes a first cell arrangement and a second cell arrangement, and wherein the first and second cell arrangements are electrically connected in parallel and fluidically connected in series.

[0036] According to the present invention, an electrified vehicle is provided, comprising: a traction battery having a plurality of cells connected in each of a plurality of arrays connected by an internal bus bar within a housing; an electric machine powered by the traction battery and configured to provide drive torque to vehicle wheels; a cooling system; and a connector electrically connecting an external bus bar outside the housing to the internal bus bar and fluidly connecting the cooling system to at least one of the plurality of arrays of battery cells of the traction battery.

[0037] According to one embodiment, the connector comprises: an electrically conductive fastener having a closed end and a channel extending from an open end to a radial opening fluidly coupled to the cooling system, the fastener extending through the housing and mechanically and electrically connecting the external bus bar to the internal bus bar and fluidly coupling the plurality of assemblies to the cooling system.

[0038] According to one embodiment, the invention is further characterized by an annular coolant connector having a coolant channel extending between an outer radius and an inner radius of the connector, wherein the fastening element extends through the annular coolant connector, wherein the radial opening is arranged within the annular coolant connector.

[0039] According to one embodiment, the connector comprises: tubing surrounding a stranded electrical conductor and configured to contain a dielectric coolant; an end cap connected to the tubing and having a plurality of openings configured to permit coolant flow therethrough and a central opening configured to receive the stranded electrical conductor; a threaded fitting attached to the tubing and configured to engage a complementary threaded housing fitting.

[0040] According to one embodiment, the invention is further characterized by a flat plug connector connected to the electrical stranded conductor.

[0041] According to one embodiment, the invention is further characterized by a pin connector connected to the electrical stranded conductor.

[0042] According to one embodiment, the plurality of arrangements are either electrically and fluidically connected in parallel or electrically and fluidically connected in series.

[0043] According to one embodiment, the plurality of arrangements are either electrically connected in series and fluidically connected in parallel or electrically connected in parallel and fluidically connected in series.

[0044] According to the present invention, there is provided a combined electrical / fluid connector comprising: an electrically conductive stud having a closed end, a channel extending from an open end to a radial opening, and a threaded portion extending from the open end toward the radial opening;and an annular coolant fitting having a coolant channel extending between an outer radius and an inner radius of the fitting, wherein the bolt extends through the annular coolant fitting, the radial opening being positioned within the annular coolant fitting, and further extends through a battery cell assembly housing and mechanically and electrically connects an external bus bar outside the housing to an internal bus bar within the housing and enables coolant flow through the battery cell assembly.;

[0045] According to one embodiment, the invention is further characterized by a conductive washer arranged between the conductive bolt and the annular coolant fitting.

[0046] According to one embodiment, the invention is further characterized by a threaded nut that engages with the threaded portion of the screw and clamps the external busbar, the annular coolant connector and the internal busbar to the housing.

[0047] According to one embodiment, the invention is further characterized by an upper washer disposed between the external bus bar and the annular coolant fitting and a lower washer disposed between the annular coolant fitting and the housing.

Claims

[1] System of an electrified vehicle, comprising: a battery having a plurality of cells electrically connected in at least one cell assembly having an assembly housing, the at least one cell assembly being connected to an internal battery bus bar within the assembly housing; an annular coolant fitting having a coolant channel extending between an outer radius and an inner radius of the fitting; and an electrically conductive fastener having a closed end and a channel extending from an open end to a radial opening, the fastener extending through the annular coolant fitting, the radial opening being positioned within the annular coolant fitting, and further extending through the assembly housing and mechanically and electrically connecting an external bus bar outside the assembly housing to the internal bus bar. [2] The electrified vehicle system of claim 1, wherein the fastener comprises a bolt having a threaded region extending below the radial opening and a nut engaging the threaded region, the bolt and nut clamping the external bus bar, the annular coolant fitting, and the internal bus bar to the assembly housing. [3] The electrified vehicle system of claim 2, further comprising an electrically conductive washer disposed between the bolt and the external bus bar. [4] The electrified vehicle system of claim 3, further comprising an upper washer disposed between the external bus bar and the annular coolant fitting, and a lower washer disposed between the annular coolant fitting and the assembly housing. [5] The electrified vehicle system of claim 1, wherein the at least one cell assembly includes a first cell assembly and a second cell assembly, and wherein the first and second cell assemblies are electrically and fluidly connected in series. [6] The system of an electrified vehicle according to claim 1, wherein the at least one cell assembly includes a first cell assembly and a second cell assembly, and wherein the first and second cell assemblies are electrically and fluidly connected in parallel. [7] The electrified vehicle system of claim 1, wherein the at least one cell assembly includes a first cell assembly and a second cell assembly, and wherein the first and second cell assemblies are electrically connected in series and fluidly connected in parallel. [8] The electrified vehicle system of claim 1, wherein the at least one cell assembly includes a first cell assembly and a second cell assembly, and wherein the first and second cell assemblies are electrically connected in parallel and fluidly connected in series. [9] Electrified vehicle comprising: a traction battery having a plurality of cells connected in each of a plurality of arrays connected by an internal bus bar within a housing; an electric machine powered by the traction battery and configured to provide drive torque to vehicle wheels; a cooling system; and a connector electrically connecting an external bus bar outside the housing to the internal bus bar and fluidly connecting the cooling system to at least one of the plurality of battery cell arrays of the traction battery. [10] An electrified vehicle according to claim 9, wherein the connector comprises: an electrically conductive fastener having a closed end and a channel extending from an open end to a radial opening fluidly coupled to the cooling system, the fastener extending through the housing and mechanically and electrically connecting the external bus bar to the internal bus bar and fluidly coupling the plurality of assemblies to the cooling system. [11] The electrified vehicle of claim 10, further comprising an annular coolant fitting having a coolant channel extending between an outer radius and an inner radius of the fitting, wherein the fastener extends through the annular coolant fitting, wherein the radial opening is disposed within the annular coolant fitting. [12] An electrified vehicle according to claim 9, wherein the connector comprises: tubing surrounding a stranded electrical conductor and configured to contain a dielectric coolant; an end cap connected to the tubing and having a plurality of openings configured to allow coolant flow therethrough and a central opening configured to receive the stranded electrical conductor; a threaded fitting attached to the casing and configured to engage a complementary threaded housing fitting. [13] The electrified vehicle of claim 12, further comprising a flat plug connector connected to the stranded electrical conductor. [14] An electrified vehicle according to claim 9, wherein the plurality of assemblies are either electrically and fluidly connected in parallel or electrically and fluidly connected in series. [15] An electrified vehicle according to claim 9, wherein the plurality of assemblies are either electrically connected in series and fluidly connected in parallel or electrically connected in parallel and fluidly connected in series.

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