ELASTICLY DEFORMABLE BATTERY MODULE CONNECTOR SYSTEM

Abstract

An elastically deformable connector system for use in connecting battery modules in a battery pack. The elastically deformable connector system comprises a busbar assembly with a busbar containing a plurality of individual conductors arranged vertically to provide a first edge region, a second edge region, and an elastically deformable intermediate region located between the first and second edge regions. The busbar assembly further comprises a first male connector assembly connected to the first edge region of the busbar, a second male connector assembly connected to the second edge region of the busbar, and a busbar enclosure that encloses a substantial extent of the busbar.Whereas, after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the intermediate area is configured to deform elastically in order to compensate for both compression and expansion movements of the pair of battery modules.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application 63 / 337,596, the disclosure of which is hereby incorporated by reference for all purposes. AREA OF DISCLOSURE

[0002] The present disclosure relates to an elastically deformable connector system for use in connecting modules in a battery pack included in a power distribution system of a vehicle. The battery pack includes a plurality of battery modules electrically connected to one another using at least one elastically deformable connector system comprising: (i) a bus bar having an elastically deformable intermediate portion located between edge connection portions; and (ii) a bus bar housing. BACKGROUND

[0003] Over the past few decades, the number of electrical components in cars and other on- and off-road vehicles such as pickup trucks, commercial vans, trucks, semi-trailers, motorcycles, sport utility vehicles, and sports cars (collectively, "motor vehicles") has increased dramatically. Electrical components are used in motor vehicles for a variety of reasons, including monitoring, enhancing, and / or controlling vehicle performance, emissions, safety, and providing comfort for vehicle occupants. Considerable time, resources, and energy have been devoted to developing power distribution components that meet the diverse needs and complexities of the motor vehicle market; however, conventional power distribution components suffer from several shortcomings.

[0004] Automotive vehicles present challenging electrical environments for both electrical components and connector assemblies due to a number of circumstances, including space constraints that complicate initial installation, harsh operating conditions, wide ambient temperature ranges, sustained vibration, thermal stress, and longevity, all of which can lead to component and / or connector failure. For example, improperly installed connectors, which typically occur in the assembly plant, and loose connectors, which typically occur in the field, are two significant failure modes for electrical components and automotive vehicles. Each of these failure modes results in significant repair and warranty costs. For example, the combined annual warranty costs of all automotive manufacturers and their direct suppliers are estimated at $50 billion to $150 billion worldwide.Given these demanding electrical environments, considerable time, money, and energy have been spent finding power distribution components that meet market demands. This disclosure addresses the shortcomings of conventional power distribution components. A complete discussion of the features and advantages of the present disclosure can be found in the following detailed description, which is presented with reference to the accompanying drawings. SUMMARY

[0005] This disclosure generally relates to an elastically deformable connector system configured to electrically connect: (i) a first battery module within the plurality of battery modules to a second battery module within the plurality of battery modules, (ii) the first battery module within the plurality of battery modules to a spatial region of the battery pack housing, (iii) an extension of the battery pack housing to an extension of an external component, or (iv) an extension of a first external component to an extension of a second external component.The elastically deformable connector system is designed and configured to compensate for: (i) material conditions associated with the modules, the battery pack, the power distribution system and / or the application, and / or (ii) dynamic movements of the battery modules caused by: (a) charging and discharging of the battery modules, (b) aging of the battery modules, (c) temperature changes, including temperature changes of the modules, the battery pack, the power distribution system and / or the application, (d) movement of the modules within the battery pack during use or operation of the power distribution system and / or the application, (e) failure of battery cells and (f) other known reasons for movement of the battery modules within the battery pack.

[0006] To compensate for the material conditions and / or dynamic movement of the battery modules, the disclosed elastically deformable battery module connector system includes a bus bar having a plurality of individual conductors vertically arranged to provide a first edge region, a second edge region, and an elastically deformable intermediate region located between the first and second edge regions. The bus bar assembly further includes a first male connector assembly coupled to the first edge region of the bus bar, a second male connector assembly coupled to the second edge region of the bus bar, and a bus bar housing enclosing a substantial extent of the bus bar.After the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the intermediate region can elastically deform to accommodate both the compression and expansion movement of the battery module pair.

[0007] In another embodiment, the busbar comprises a plurality of individual conductors that have undergone a fusion process to form a solid single conductor in selected regions of the busbar, the busbar having a first edge region, a second edge region, and an elastically deformable intermediate region located between the first and second edge regions. A majority of the elastically deformable intermediate region is not coplanar with either the first or second edge regions and instead comprises a curvilinear extension. This configuration of the elastically deformable intermediate region allows an activation force of less than 50 Newtons or less to deform its entire length by more than 5%. As a result, the connector system improves the reliability, performance, and lifetime of the modules, battery pack, power distribution system, and application. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings or figures, which are included for convenience and are incorporated in and constitute a part of this specification, illustrate the disclosed embodiments and, together with the description, serve to explain the principles of the disclosed embodiments. In the drawings, like reference numerals refer to like or similar elements throughout the drawings. In the drawings: Fig. 1 is a perspective view of a first embodiment of an elastically deformable battery module connector system, with a spatial portion of the bus bar housing omitted to show the bus bar; Fig. 2 is a plan view of a plurality of electrical conductors cut to the specified length; Fig. 3 is an enlarged view of Fig. 2, showing the staggered end configuration of the multiple electrical conductors; Fig. 4 and Fig. 5 are perspective views of the Fig. 2 while being selectively welded together by a laser welding machine to form a busbar having a first connecting segment; Fig. Figure 6 is a plan view of the busbar after it has been subjected to the Fig. 4-5 has been subjected to the selective welding process shown; Fig. 7 is a bottom view of the busbar from Fig. 6; Fig. 8 is a first side view of the busbar from Fig. 6; Fig. 9 is a second side view of the busbar from Fig. 6; Fig. 10 is a first end view of the busbar of Fig. 6; Fig. 11 is a second end view of the busbar from Fig. 6; Fig. 12 is a bottom view of the busbar of Fig. 6; Fig. 13 is a cross-sectional view of the bus bar taken along line 13-13 of Fig. 12, showing an unfused segment with an unsolidified area; Fig. 14 is a bottom view of the busbar from Fig. 6; Fig. 15 is a cross-sectional view of the bus bar taken along line 15-15 of Fig. 14, showing a fused segment containing (i) two laterally solidified regions and (ii) one unsolidified region; Fig. 16 is a bottom view of the busbar of Fig. 6; Fig. 17 is a cross-sectional view of the bus bar taken along line 17-17 of Fig. 14, showing a fused segment with a fully solidified area; Fig. 18 is a perspective view of the Fig. 6-11, wherein the busbar has been subjected to a process to form an elastically deformable intermediate region of the busbar; Fig. 19 is a perspective view of the busbar of Fig. 18, wherein the second end of the busbar is being selectively welded together by a laser welding machine to form a second connecting segment; Fig. 20 is a perspective view of the busbar after it has been Fig. 19, wherein the busbar is configured to be integrated into the elastically deformable battery module connection system of Fig. 1 is integrated; Fig. 21 is a side view of the busbar from Fig. 20; Fig. 22 is a bottom view of the busbar of Fig. 20; Fig. 23 is an end view of the busbar from Fig. 20; Fig. 24 is a plan view of the busbar of Fig. 20; Fig. 25 is an exploded view of a male conductor assembly of the elastically deformable battery module connector system of Fig. 1, wherein the male conductor assembly comprises a male terminal assembly having a male terminal body, a spring element and a male terminal housing; Fig. 26 is a perspective view of the spring element of the male terminal assembly of Fig. 25; Fig. 27 is a perspective view of the male connector body of the male connector assembly of Fig. 25; Fig. 28 is a perspective view of the male terminal assembly in a partially assembled state S PA ; Fig. 29 is a side view of the male connector assembly in a fully assembled state S FA ; Fig. 30 is a cross-sectional view of the male terminal assembly taken along line 30-30 of Fig. 29; Fig. 31 is a top perspective view of an elastically deformable electrically conductive assembly of the elastically deformable battery module connector system, wherein the elastically deformable electrically conductive assembly connects opposing male terminal assemblies of Fig. 29, which is connected to the busbar of the Fig. 20-24 are connected; Fig. 32 is a side view of the elastically deformable electrically conductive assembly of Fig. 31; Fig. 33 is a plan view of the elastically deformable electrically conductive assembly of Fig. 31; Fig. 34 is an end view of the elastically deformable electrically conductive assembly of Fig. 31; Fig. 35 is a bottom view of the elastically deformable electrically conductive assembly of Fig. 31; Fig. 36 is a perspective view of the elastically deformable battery module connector system with the bus bar housing removed to show a spatial portion of the bus bar; Fig. 37 is a side view of a spatial portion of the elastically deformable battery module connector system of Fig. 36; Fig. 38 is a cross-sectional view of the elastically deformable battery module connector system taken along line 38-38 of Fig. 37; Fig. 39 is a plan view of a spatial portion of the elastically deformable battery module connector system of Fig. 36; Fig. 40 is a cross-sectional view of the elastically deformable battery module connector system taken along line 40-40 of Fig. 39; Fig. 41 is a perspective view of the bus bar housing, the housing being formed of first and second portions removably connected to each other; Fig. 42 is a side view of the busbar housing of Fig. 41; Fig. 43 is a bottom view of the busbar housing of Fig. 41; Fig. 44 is an end view of the busbar housing of Fig. 41; Fig. 45 is a plan view of the busbar housing of Fig. 41; Fig. 46 is a perspective view of the first component of the busbar housing of Fig. 41; Fig. 47 is a side view of the first component of the busbar housing of Fig. 46; Fig. 48 is a perspective view of the elastically deformable battery module connector system; Fig. 49 is a side view of the elastically deformable battery module connector system of Fig. 48; Fig. 50 is a plan view of the elastically deformable battery module connector system of Fig. 48; Fig. 51 is an end view of the elastically deformable battery module connector system of Fig. 48; Fig. 52 is a bottom view of the elastically deformable battery module connector system of Fig. 48; Fig. 53 is a perspective view of a first embodiment of a battery pack including a plurality of battery modules electrically connected together by a plurality of elastically deformable battery module connector systems; Fig. 54 is a plan view of the first embodiment of the battery pack of Fig. 53; Fig. 55 is a perspective view of two battery modules and an elastically deformable battery module connector system shown in Fig. 53 and Fig. 54 shown battery pack were insulated; Fig. 56 is an elevated perspective view of the battery modules of Fig. 55, which are connected to each other by the elastically deformable battery module connector system, wherein the battery module housing has been omitted to make the battery cells and the electrical transport structure visible; Fig. 57 is a side view of the battery modules from Fig. 56, which are connected to each other by the elastically deformable battery module connector system; Fig. 58 is a plan view of the battery modules of Fig. 56, which are connected to each other by the elastically deformable battery module connector system; Fig. 59 is a cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 59-59 of Fig. 56; Fig. 60 is an enlarged view of Fig. 59, which shows the interface between the battery module and the elastically deformable battery module connector system; Fig. 61 is an enlarged perspective cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 61-61 of Fig. 56, which shows the interface between the battery module and the elastically deformable battery module connector system; Fig. 62 is a cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 62-62 of Fig. 58, wherein the battery cells have a charge level of 50% and the elastically deformable battery module connector system is in a neutral state S N is located; Fig. 63 is an enlarged view of Fig. 62, which shows the elastically deformable battery module connector system in a neutral state S N shows; Fig. 64 is a schematic representation of the expansion and contraction of the cylindrical battery cells due to charging and discharging of the battery cells; Fig. Figure 65 is a schematic representation of the irreversible expansion of the cylindrical battery cells due to battery cell aging; Fig. 66 is an enlarged cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 66-66 of Fig. 58, wherein the battery cells have a charge level of 100% and the elastically deformable battery module connector system is in a compressed state S C is located; Fig. 67 is an enlarged cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 67-67 of Fig. 58, wherein the battery cells have a charge level of 0% and the elastically deformable battery module connector system is in an expanded state S E is located; Fig. 68 is an enlarged view of Fig. 62, which shows the elastically deformable battery module connector system in the compressed state S C shows; Fig. 69 is an enlarged view of Fig. 66, which shows the elastically deformable battery module connector system in the neutral state S N shows; Fig. 70 is an enlarged view of Fig. 67, which shows the elastically deformable battery module connector system in the expanded state S E shows; Fig. 71 is an enlarged perspective cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 71-71 of Fig. 56, which shows how the elastically deformable battery module connector system accommodates lateral movements between the battery modules; Fig. 72 is a side view of a spatial portion of the battery module and a spatial portion of the elastically deformable battery module connector system; Fig. 73 is a cross-sectional view of the spatial area of ​​the battery module and the spatial area of ​​the elastically deformable battery module connector system taken along line 73-73 of Fig. 72; Fig. 74 is a perspective view of a second embodiment of two battery modules interconnected by a second embodiment of the elastically deformable battery module connector system; Fig. 75 is an exploded view of a Fig. 74 shown battery module; Fig. 76A is a cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 76A-76A of Fig. 74, wherein the battery cells have a charge level of 50% and the elastically deformable battery module connector system is in a neutral state S N is located; Fig. 76B is an enlarged view of Fig. 76A, which shows the elastically deformable battery module connector system in a neutral state S N shows; Fig. Figure 77 is a schematic diagram showing the expansion and contraction of the pouch battery cells due to charging and discharging of the battery cells; Fig. Figure 78 is a schematic representation of the irreversible expansion of the pouch battery cells due to battery cell aging; Fig. 79 is an enlarged cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 79-79 of Fig. 74, wherein the battery cells have a charge level of 100% and the elastically deformable battery module connector system is in a compressed state S C is located; Fig. 80 is an enlarged cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 80-80 of Fig. 74, wherein the battery cells have a charge level of 0% and the elastically deformable battery module connector system is in an expanded state S E is located; Fig. 81 is an enlarged view of Fig. 79, which shows the elastically deformable battery module connector system in the compressed state S C shows; Fig. 82 is an enlarged view of Fig. 76A, B showing the elastically deformable battery module connector system in the neutral state S N shows; Fig. 83 is an enlarged view of Fig. 80, which shows the elastically deformable battery module connector system in the expanded state S E shows; Fig. 84 is a perspective view of a third embodiment of two battery modules interconnected by the first embodiment of the elastically deformable battery module connector system; Fig. 85 is a perspective view of the battery modules of Fig. 84, which are connected to each other by the elastically deformable battery module connector system, wherein the battery module housing is transparent to make the battery cells and the electrical transport structure visible; Fig. 86 is a cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 86-86 of Fig. 85, wherein the battery modules are in a nominal material state and the elastically deformable battery module connector system is in a neutral state S N is; Fig. 87 is a cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 87-87 of Fig. 85, wherein the battery modules are in a minimal material state and the elastically deformable battery module connector system is in a compressed state S C condition; Fig. 88 is a cross-sectional view of the battery modules and the elastically deformable battery module connector system taken along line 88-88 of Fig. 85, wherein the battery modules are in a maximum material state and the elastically deformable battery module connector system is in an extended state S E is; Fig. 89-102 show alternative configurations of the bus bar configured to be integrated into the elastically deformable battery module connector system, each bus bar including at least one elastically deformable segment; Fig. 103 is a bottom perspective view of a fourth embodiment of the elastically deformable battery module connector system; Fig. 104 is a top perspective view of the fourth embodiment of the elastically deformable battery module connector system of Fig. 103; Fig. 105-109 show alternative configurations of the male terminal assemblies that may be used in conjunction with the elastically deformable battery module connector system; Fig. 110 is a perspective view of a second embodiment of a battery pack installed in a skateboard mounting platform of a vehicle, the battery pack including a plurality of battery modules electrically connected together with a plurality of elastically deformable battery module connector systems; Fig. 111 is a perspective view of a vehicle carrying the skateboard mounting platform of Fig. 110 contains; Fig. 112 is a perspective view of a passenger bus having a third embodiment of a battery pack with a plurality of elastically deformable battery module connector systems interconnecting the battery modules; Fig. 113 is a perspective view of a large vessel incorporating a fourth embodiment of a battery pack having a plurality of elastically deformable battery module connector systems interconnecting the battery modules; and Fig. 114 is a perspective view of a vessel having a fifth embodiment of a battery pack with a plurality of elastically deformable battery module connector systems connecting the battery modules together. DETAILED DESCRIPTION

[0009] In the following detailed description, numerous specific details are set forth by way of example to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well-known methods, processes, components, and / or circuits have been described at a relatively high level without detail to avoid unnecessarily obscuring aspects of the present teachings.

[0010] While this disclosure includes a number of embodiments in many different forms, specific embodiments are illustrated in the drawings and described in detail herein. This disclosure is to be considered an exemplary illustration of the principles of the disclosed methods and systems and is not intended to limit the broad aspects of the disclosed concepts to the illustrated embodiments. As will be apparent, the disclosed methods and systems are capable of other and different configurations, and several details may be modified without departing from the scope of the disclosed methods and systems. For example, one or more of the following embodiments may be combined, in whole or in part, with the disclosed methods and systems.Accordingly, the drawings and detailed descriptions are to be considered as illustrative and not restrictive or limiting.

[0011] As background and context, the Fig. 110-114 various products and applications 10 with at least one power distribution system 50. The applications 10 include, but are not limited to: an aircraft, a motor vehicle 20 ( Fig. 111), a military vehicle (e.g. a tank, a personnel carrier, a heavy goods vehicle and a troop transporter), a bus 25 ( Fig. 112), a locomotive, a tractor, a bulldozer, an excavator, a tractor, a ship (e.g. a boat, a cargo ship, a tanker, a submarine, a passenger ship 30 ( Fig. 113 and Fig. 114), a tanker, a sailing yacht), mining machinery, forestry machinery, agricultural machinery (e.g., tractors, mowers, planters, combine harvesters, threshing machines, harvesters), telecommunications equipment (e.g., servers), an energy storage system (e.g., emergency power storage), renewable energy equipment (e.g., wind turbines and solar cell arrays), a 24-48 volt system, for a high-power application, for a high-current application, for a high-voltage application. In these applications 10, the power distribution system 50 is configured to meet industry standards, production, and performance requirements.

[0012] Each power distribution system 50 includes a battery pack 90 having: (i) a plurality of battery modules 60 and (ii) at least one elastically deformable battery module connector system 100 that electrically couples: (a) a first battery module 62a within the plurality of battery modules 60 to a second battery module 62b within the plurality of battery modules 60, (b) the first battery module 62a within the plurality of battery modules 60 to a spatial region of the battery pack housing 92, (c) a spatial region of the battery pack housing 92 to a spatial region of an external component, or (d) a spatial region of a first external component to a spatial region of a second external component.As explained in detail below, the elastically deformable battery module connector system 100 is configured to compensate for: (i) material conditions associated with the modules 60, the battery pack 90, the power distribution system 50, and / or the application 10, and / or (ii) dynamic movements of the battery modules 60 caused by: (a) charging and discharging of the battery modules 60, (b) aging of the battery modules 60, (c) temperature changes, including temperature changes of the modules 60, the battery pack 90, the power distribution system 50, and / or the application 10, (d) movement of the modules 60 within the battery pack 90 during use or operation of the power distribution system 50 and / or the application 10 - such as the bus 25 (see . Fig. 112) driving on a road with numerous potholes, or a ship 30 (see Fig. 113) operating in rough or choppy water causing the vessel 30 to pitch, heave, or maneuver aggressively, (e) battery cell failures, and (f) other known reasons for the movement of the battery modules 60 within the battery pack 90. ​​It should be understood that the material conditions and / or dynamic movement of the battery modules 60 can occur in all directions (i.e., X, Y, Z, and rotation). For example, the dynamic movement of the battery modules 60 in the Fig. 55-70: (i) expansion and / or contraction in the XY plane due to the movement of lithium ions within the individual battery cells 75, and (ii) may include expansion and / or contraction in the XZ or YZ plane due to CTE or other known reasons.

[0013] To compensate for the material properties and / or dynamic movement of the battery modules 60, the disclosed elastically deformable battery module connector system 100 includes a bus bar 200 having an elastically deformable intermediate region 410. This elastically deformable intermediate region 410 enables the system 100 to: (i) deform by a significant amount—namely, up to 4 mm—from the unstressed or neutral state S N to be compressed, (ii) by a considerable amount - namely up to 4 mm - from the unstressed or neutral state S Nto expand and (iii) adapt to minor displacements in other planes (e.g., XZ plane or YZ plane). Because the battery module connector system 100 is designed and configured to accommodate and accommodate the material conditions and / or dynamic movement of the battery modules 60, the connector system 100 minimizes and potentially eliminates failure modes that could degrade or reduce the performance of the power distribution system 50, the modules 60, and / or the battery pack 90. ​​Thus, the connector system 100 improves the reliability, performance, and operational life of the modules 60 and the battery pack 90.

[0014] Accordingly, the above-mentioned advantages of the disclosed connector system 100 are to be considered illustrative and not restrictive or limiting. As such, other advantages may be disclosed within the pictorial or written disclosure contained herein or may be known to one of ordinary skill in the art based on the pictorial or written disclosure.

[0015] Numerous terms are introduced and used throughout this application, which are defined below. While some of the following terms overlap with other terms or are not mutually exclusive, the following represents a general organizational hierarchy: The terms "busbar" and "rail" are at an upper level of the hierarchy; the terms "end(s)", "end sector(s)", "central", and "central sector(s)" are at an upper middle level of the hierarchy; the terms "area(s)", "edge area(s)", and "intermediate area" are at a lower middle level of the hierarchy; the terms "zone(s)" are at a lower level of the hierarchy; and the term "region(s)" is at a lower level of the hierarchy.

[0016] The term “busbar” means at least one conductor extending from a first end edge to a second end edge and capable of conducting electrical current from a first location to a second location. Fig. For example, Figure 20 shows a perspective view of busbar 200.

[0017] The term “end sector” refers to an area of ​​the busbar designed to facilitate the connection of the busbar 200 to an external device or component.

[0018] The term "middle sector" refers to a region of the busbar that extends between the end sectors 207 of the busbar 200. A single conductor 202 of the busbar 200 is considered to extend from a first end sector 208a through the middle sector 210 to a second end sector 208b. In other words, the end sectors 208a, 208b of the conductor 202 are integrally formed with the middle sector 210 of the conductor 202 prior to any modification of the conductor 202. In other words, the end sectors 208a, 208b of the conductor 202 are not separate structures connected to the middle sector 210 of the conductor 202 by welding, fusing, or a fastening process.

[0019] The term "edge region" is a region of the bus bar used to position the intermediate region at a location between (i) a pair of battery modules, (ii) a battery module and a region of the battery pack enclosure, (iii) a region of the battery pack enclosure and a region of an external component, (iv) a pair of external components.

[0020] The term “intermediate region” refers to a region of the busbar that extends between the edge regions 402a, 402b of the busbar 200 and is elastically deformable.

[0021] The term "segment" refers to a region of the central sector of the busbar that either (i) receives a segmented weld pattern or (ii) does not have a segmented weld pattern. Adjacent segments of a single busbar conductor are assumed to be integrally formed and not joined by any welding, fusion, or fastening process. It should also be understood that adjacent busbar segments typically have different mechanical properties (e.g., a different Young's modulus).

[0022] The term "fused segment" means a portion of the busbar that contains at least one of the following: (i) a partially solidified region, (ii) a laterally solidified region, or (iii) a fully solidified region. The fused segment may also contain an unsolidified region. Fig. For example, show fused segments 206 comprising: (i) unsolidified regions 230, and (ii) laterally solidified regions 238.

[0023] The term "unfused segment" means a portion of the busbar that contains only an unconsolidated or unfused area or areas of conductors. The unfused segment does not contain: (i) a partially consolidated area, (ii) a limited or laterally consolidated area, or (iii) a fully consolidated area. Fig. For example, show the unfused segment 204 of the middle sector 210 of the busbar 200, wherein the unfused segment 204 has an unsolidified region 230 with individual, unfused conductors 202.

[0024] The term "partial consolidation zone" means a region of the fused segment 206 of the middle sector 210 of the busbar, the zone: (i) extending in the fused segment from the lowest or lower conductor to the highest or upper conductor, and (ii) comprising a partially consolidation region.

[0025] The term "partially solidified region" refers to a region of the partial solidification zone of the busbar that has undergone a surface-based fusion process (e.g., vertically oriented, partial penetration welding process 182). This surface-based fusion process combines or fuses all extensions of conductors in this partially solidified region into a single consolidated conductor. A substantial number (e.g., about 70%) of the conductors 202 in the partial solidification zone are combined or fused into a single consolidated conductor to form a partially solidified region. In contrast, in a non-solidified region 230, a smaller number (e.g., about 30%) of the conductors 202 remain in the partial solidification zone and beyond the partially solidified region as individual, separate conductors 202—i.e., they are not combined or fused into a single combined conductor.

[0026] The term “partial consolidation volume” refers to a volume of the middle sector 210 of the busbar 200, the volume: (i) extending in the fused segment from the lowest or lower conductor to the highest or upper conductor, (ii) extending the entire length of the fused segment 206, and (iii) having a width that encapsulates a partially consolidation volume.

[0027] The term "partially solidified volume" refers to a region of the partial solidification volume of the busbar that has undergone a surface-based fusion process (e.g., vertically oriented partial penetration welding process 182). This surface-based fusion process combines or fuses all conductor sections within this partially solidified volume into a single consolidated conductor.

[0028] The term "limited solidification zone" is a region of the fused segment 206 of the busbar, the zone extending (i) between (a) a midpoint or the midpoint of the width or depth as defined between the outermost edges of the fused segment and (b) one of the outermost edges of the fused segment 206, and (ii) including a laterally solidified region. For example, Fig. 14-15 a limited solidification zone 240 extending between the lateral edge 216b and the center point MP of the busbar 200, which includes an area that has been subjected to a lateral partial penetration welding process 184 or a cold working process.

[0029] The term "laterally solidified region" refers to a region of the limited solidification zone of the busbar that has been subjected to an edge-based fusion process (e.g., a lateral partial penetration welding process 184 or a cold forming process). This edge-based fusion process combines or fuses all extensions of conductors in this laterally solidified region into a single consolidated conductor. Fig. For example, Figures 14-15 show the laterally consolidated region 238: (i) adjacent to the unconsolidated region 230, both located within the limited consolidation zone 240 of the fused segment 206 of the middle sector 210 of the busbar 200, and (ii) extending from the lowest or lower conductor to the top or upper conductor. A small portion (e.g., about 5%) of the busbar 200 in the limited consolidation zone 240 is combined or fused into a single consolidated conductor to form a laterally consolidated region 238. In contrast, in an unconsolidated region 230, a majority (e.g., about 95%) of the busbar 200 remains in the confined consolidation zone 240 and beyond the laterally consolidated region 238 as individual, separate conductors 202—that is, they are not combined or fused into a single combined conductor.

[0030] The term "confined solidification volume" means a volume of the fused segment 206 of the busbar, such volume: (i) extending between (a) a midpoint or the midpoint of the width or depth as defined between the outermost edges of the fused segment 206 and (b) one of the outermost edges of the fused segment 206, (ii) extending the entire length of the fused segment 206, and (ii) having a width that encapsulates a laterally solidified region.

[0031] The term "laterally solidified volume" refers to a volume of the confined solidification volume of the busbar that has undergone an edge-based fusion process (e.g., a lateral partial penetration welding process 184 or a cold forming process). In this edge-based fusion process, all conductor extensions within this laterally solidified volume are combined or fused into a single consolidated conductor.

[0032] The term "unsolidified region" refers to a region of the busbar in which no welding process 180 has taken place to connect or fuse the conductors in that region of the busbar. Similarly, the term "unsolidified volume" refers to a volume of the busbar that has not undergone a welding process to connect or fuse the conductors in that volume of the busbar 200. Thus, all conductors 202 in a non-solidified region 230 remain as individual, discrete conductors. For example, Fig. 13 shows a non-solidified area 230.

[0033] The term "fully consolidated region" refers to an extension of the busbar that has undergone a fusion process (e.g., a lateral welding process 184 or a vertical welding process 182) to combine or fuse all of the conductors 202 contained within that extension of the busbar into a single consolidated conductor. For example, Fig. 17 shows a fully solidified region 242 extending over the end sector 208a, 208b of the busbar 200.

[0034] The general term “consolidated region” refers to a partially consolidated region, a laterally consolidated region 238, or a fully consolidated region 242.

[0035] The term "flexible section" refers to an extension of the busbar that does not include (i) a partially solidified region, (ii) a laterally solidified region formed by a lateral partial penetration welding process 184, or (iii) a fully solidified region. The stiffness of the flexible section 224 of the busbar 200 is less than 25% of the stiffness of a corresponding section of a rigid reference busbar having the same geometry and made of a similar rigid material.

[0036] The term "bent section" means a region of the busbar that contains at least one of the following: (i) a partially solidified region, (ii) a laterally solidified region, or (iii) a fully solidified region. Fig. For example, Figures 18-24 show a bent section 226 including one or more unconsolidated regions 230 of conductors 202 and one or more partially consolidated regions 234 formed using two laterally consolidated regions 238 formed using a lateral partial penetration welding process 184. The stiffness of the bent section is greater than 35% of the stiffness of a corresponding section of a reference busbar having the same geometry and formed from a similar rigid material.

[0037] The term "maximum material condition" refers to a size feature that contains the largest amount of material while remaining within the specified tolerance. For example, the maximum material condition occurs when the largest pin diameter or the smallest hole size is used within the specified tolerance.

[0038] The term "minimal material condition" refers to a size feature that contains the least amount of material while remaining within the specified tolerance. For example, the maximum material condition occurs when the smallest pin diameter or the largest hole size is used within the specified tolerance.

[0039] The term “nominal material state” refers to a material state that lies between the maximum material state and the minimum material state.

[0040] The term "in-plane" refers to a plane defined by the X and Y axes in a three-dimensional Cartesian X, Y, and Z coordinate system. In this reference system, a longitudinal axis AA of the busbar 200 is coplanar and in-plane with the XY planes.

[0041] The term "out-of-plane" refers to a plane defined by the Y and Z axes in the three-dimensional Cartesian X, Y, and Z coordinate system. In this reference system, the longitudinal axis AA of the busbar 200 is perpendicular and oriented out-of-plane to the YZ plane.

[0042] The term "high power" means (i) a voltage between 20 volts and 600 volts, regardless of the amperage, or (ii) at any amperage greater than or equal to 80 amperes, regardless of the voltage. The term "high amperage" means a amperage of 80 amperes or more, regardless of the voltage. The term "high voltage" means a voltage between 20 volts and 600 volts, regardless of the amperage. I. First embodiment of an elastically deformable battery module connector system

[0043] The Fig. 1-73 illustrate a first embodiment of an elastically deformable battery module connector system 100 comprising: (i) the bus bar 200, (ii) the bus bar housing 600, and (iii) at least one male connector assembly 1000. The bus bar 200 disclosed herein is formed from a plurality of conductors 202, with selected portions of the bus bar 200 undergoing a fusing process 180 that solidifies a portion of the conductors 202 within that portion of the bus bar 200. As a result of this fusing process 180, the bus bar 200 comprises: (i) at least one unfused segment 204, and (ii) at least one fused segment 206.The integral formation of fused and unfused segments 204, 206 in a single busbar 200 is advantageous because it allows the busbar 200 to combine the best characteristics of conventional rigid busbars and conventional flexible busbars into a single busbar, while limiting the negative characteristics associated with these conventional busbars. For example, the unfused segments 204 are flexible, which allows the busbar 200 to: (i) accommodate manufacturing tolerances, (ii) expand and contract during thermal expansion and contraction events, such as battery charging and discharging cycles, and (iii) help absorb vibrations induced by the operating environment (e.g.,within a vehicle) in which the busbar 200 is installed, rather than transmitting these vibrations to other components operatively connected to the busbar 200. Furthermore, the fused segments 206 of the busbar 200 are stiffer (e.g., increased Young's modulus in N / m). 2 ), which allows the busbar 200 to be bent precisely out of plane and to intentionally maintain these bends over time without the conductors 202 delaminating and thus reducing the current flow through the busbar 200. A. Busbar

[0044] The Fig. 2-3 show the first step in the manufacture of busbar 200. Specifically, a plurality of individual conductors 202 are manufactured, cut to specific lengths, and arranged in a vertical stack. In the embodiment shown in the figures, each conductor 202 has an elongated, rectangular prism shape. The rectangular prism shape is advantageous over other shapes (e.g., round or square) because of its ability to dissipate heat quickly. While the width (between 10 mm and 30 mm, preferably 20 mm) and thickness (between 0.1 mm and 0.5 mm, preferably 0.25 mm) of each conductor 202 remain substantially constant over the length of busbar 200, the length of the conductors 202 contained in busbar 200 depends heavily on their positional relationship within the stack.In particular, the conductors 202 are staggered, increasing in length as one moves from the lower conductor 203a (or shortest conductor) to the upper conductor 203j (or longest conductor). This staggered length arrangement is desirable because the upper conductor 203j must travel a further distance compared to the lower conductor 203a due to the curvature of the elastically deformable intermediate region 410 (see ). Fig. 18-24).

[0045] In this first embodiment, each conductor 202 is made of a C10200 copper alloy, which has (i) an electrical conductivity greater than 80% of the IACS (International Annealed Copper Standard, i.e., the empirically derived standard value for the electrical conductivity of commercial copper) according to ASTM B747 and (ii) a coefficient of thermal expansion (CTE) of 17.6 ppm / degree Celsius (from 20-300 degrees Celsius) and 17.0 ppm / degree Celsius (from 20-200 degrees Celsius). In other embodiments, the selected copper material may be replaced with stainless steel, nickel, aluminum, silver, gold, copper, steel, zinc, brass, bronze, iron, platinum, lead, molybdenum, calcium, tungsten, lithium, tin, a combination of the aforementioned materials, or other similar metals.

[0046] Once the desired configuration of the individual conductors 202 is formed, the conductors 202 are arranged in a layered stack with the first end 208a of all conductors aligned with each other. In other words, the end surface of the stack of conductors 202 is substantially flat and substantially perpendicular to the top and bottom surfaces 215a, 215b of the top and bottom conductors 203j, 203a. In this configuration, the majority of conductors 202 provide an unfused reference stiffness. This unfused reference stiffness is between 1 KPa and 200 GPa, preferably between 50 KPa and 2,500 KPa, more preferably between 100 KPa and 1,000 KPa, and most preferably 320 KPa. While some figures in this application depict the busbar 200 with only five conductors 202 for reasons of space, the preferred embodiment is a layered stack of ten conductors 202.It should be understood that while the preferred embodiment is a layered stack of ten conductors 202, this disclosure contemplates bus bars 200 comprising any number of conductors 202 (e.g., one conductor 202 up to one hundred conductors 202). i. Selectively fusing a first portion of the busbar

[0047] Once the layered stack of ten conductors 202 is created, the process of manufacturing the busbar 200 continues by (i) fusing the first end sector 208a of the busbar 200 and (ii) fusing the identified segments of the middle sector 210 of the busbar 200 included in the first extension 212a of the busbar. Before a section of the busbar 200 can be selectively welded, the user or manufacturer must acquire or gain access to a machine 190 capable of performing the welding process chosen for selectively welding said busbar 200. For example, if the designer chooses a laser welding fusion process, he will acquire the Fig. 4, Fig. 5 and Fig. 19. As shown therein, the laser welding machine 192 may include two separate lasers 194, 196 capable of welding the busbar 200 simultaneously from two opposite directions. The two separate lasers 194, 196 are preferably aligned in a vertical plane. However, it should be understood that the laser welding machine 192 may also have other configurations, including: (i) only one laser 194 capable of interacting with only one side of the busbar 200 at a time, (ii) only one laser 194, but whose light output is modified using optics and mirrors so that the laser can interact with both sides of the busbar 200 simultaneously, or (iii) two lasers 194, 196 that are not aligned with each other.

[0048] Next, the designer will: (i) feed the conductors 202, arranged in the layered configuration described above, into the machine 192; and (ii) provide the machine 192 with welding instructions (e.g., load a design model) associated with the first end sector 208a and the first extension 212a of the busbar 200. The laser welding machine 192 then performs the fusing process 180 described in its instructions. Fig. 4, for example, shows the busbar 200 in a horizontal orientation in which its width lies in a plane oriented substantially perpendicular to the lasers 194, 196. In this horizontal orientation, the machine 192 performs a surface-based welding process (i.e., a vertical partial penetration welding process 182) on the end sector 207 of the busbar 200 according to the instructions associated with the first end sector 208a of the busbar 200. Next, as shown in Fig. 5, the busbar 200 is rotated to a vertical orientation in which its thickness lies in a plane oriented substantially perpendicular to the lasers 194, 196. In this vertical orientation, the machine 192 performs an edge-based fusion process (i.e., a lateral partial penetration weld process 184) on the first extent 212a of the busbar 200 according to the instructions associated with that first extent 212a.

[0049] After the selective welding of the first end sector 208a and the first extension 212a of the middle sector 210, the Fig. 6-17 is formed. It should be understood that at this stage of manufacturing the busbar 200, only the first end sector 208a and the extension 212a of the middle sector 210 are formed. The formation of these sections, extensions, sectors, segments, zones, and regions is determined by the Fig. 6 and Fig. 7. To simplify the discussion, other areas, extensions, sectors, segments, zones and regions that are not yet formed at this stage of production, but are identified and will be formed at a later stage of production, are shown in the Fig. 6 and Fig. 7 by dashed lines. Indeed, these identified and later formed areas, sectors, segments, zones, and regions are preferably not formed at this stage of manufacturing because their inclusion is likely to introduce additional stresses on the conductors 202 during bending of the busbar 200. To avoid these stresses, the formation of these extensions, sectors, segments, zones, and areas is performed after the busbar 200 has been bent into the desired shape. Furthermore, the configuration of the disclosed busbar 200 should be understood as exemplary, and other configurations of the extensions, sectors, segments, zones, and regions are contemplated by this disclosure. For example, all of the areas, sectors, segments, zones, and regions disclosed in U.S. Patent Application Nos. 17 / 970,116 and 17 / 699,033 and PCT Application No.PCT / IB2022 / 057772 are disclosed or contemplated to be incorporated or used in the busbar 200.

[0050] From the Fig. 6-11, it can be seen that the busbar 200 comprises: (i) a central sector 210 and (ii) two end sectors 207. The central sector 210 extends between the end boundary lines 214a, 214b, while the end sectors 207 extend outward from the end boundary lines 214a, 214b. The end boundary lines 214a, 214b separate the fused segments 206, which include fully solidified regions 242 arranged to form a compaction weld, from the segments 204, 206, which do not include fully solidified regions.It is understood that the end delimiter lines 214a, 214b are positioned at a sufficient distance inward from the end edges 216c, 216d to allow sufficient material to be present in the end sectors 207 of the busbar 200 to enable the connection of the end sectors 207 to a connector, terminal, receptacle, or other structure connecting the busbar 200 to an external structure or component. For example, the end delimiter lines 214a, 214b may be positioned between 1 mm and 40 mm, and preferably between 14 mm and 22 mm, from the end edges 216c, 216d.

[0051] As in at least Fig. 6, the central sector 210 comprises: (i) three unfused segments 204 (205a, 205b, 205c), and (ii) two fused segments 206 (209a, 209b). In particular, the unfused segments 204 are arranged such that: (i) the first unfused segment 205a extends between the first end boundary line 214a and a first intermediate boundary line 218a, (ii) the second unfused segment 205b extends between a second intermediate boundary line 218b and a third intermediate boundary line 218c, and (iii) the third unfused segment 205c extends between a fourth intermediate boundary line 218d and the second end boundary line 214b.Meanwhile, the fused segments 206 are arranged such that: (i) the first non-fused segment 205a extends between the first intermediate boundary line 218a and the second intermediate boundary line 218b, and (ii) the second fused non-fused segment 209b extends between the third intermediate boundary line 218c and the fourth intermediate boundary line 218d. In other words, the first intermediate boundary line 218a separates a linear extension (i.e., the first edge region 402a) of the busbar 200 from the non-linear extension (i.e., the elastically deformable intermediate region 410). Furthermore, the fourth intermediate boundary line 218d separates a linear extension (i.e., the second edge region 402b) of the busbar 200 from the non-linear extension (i.e., the elastically deformable intermediate region 410).Finally, the second and third intermediate boundary lines 218c, 218d separate an unfused segment 204 from the fused segments 206.

[0052] The Fig. 12-17 show cross-sectional views to illustrate how the selective fusion process changes the configuration of the individual conductors 202 contained in the end sectors 207 and the first extension 212a of the middle sector 210 of the busbar 200. In particular, the cross-section of this busbar 200 along lines 13-13, 15-15, 17-17 shows that: (i) areas that have not been subjected to a fusion process (e.g., welding) remain unconsolidated 230, (ii) areas that have been subjected to a fusion process (e.g.,welding): (a) namely edge welds, and in particular right edge welds and left edge welds - forming laterally solidified regions 238 in the fused segments 206 of the middle sector 210 of the busbar 200, or (b) namely surface welds, and in particular top surface welds and bottom surface welds - forming fully solidified regions 242 in the end sector 207 of the busbar 200. 1. Unfused segment

[0053] Fig. Figure 13 shows a cross-sectional view of the busbar 200 along the section plane defined by line 13-13 of Fig. 12. The cross section is taken between the first end boundary line 214a and the first intermediate boundary line 218a. These boundary lines define the edges of the unfused segment 204 (ie, the first unfused segment 205a). The cross section of Fig. 13 shows a plurality of conductors 202 that do not include a consolidated region 238, 242. In other words, the multiple conductors 202 shown in this cross-section have not undergone a fusion process to combine or fuse a number of conductors into a single consolidated conductor. In other words, each conductor 202 in this unfused segment 204 remains a single and distinct conductor 202. This configuration of individual and separate conductors 202 forms a flexible portion 224 that is not designed to be bent or withstand harsh handling forces. In this embodiment, the flexible portion 224 has a stiffness of less than 550 KPa or 0.55 Nm 2 (2,200 kPa for a rigid reference busbar with 1 conductor * 0.25) = 550 kPa). In particular, the flexible section 224 has a stiffness of approximately 320 kPa. 2. Fused segment

[0054] The laterally solidified regions 238 extend from the side edges 216a, 216b of the busbar 200 to an edge-based fusion peak 219 of the fusion process 180. The edge-based fusion point 219 is located at a point that is (i) laterally between a center point 217 and the side edges 216a, 216b of the fused segment 206 and (ii) vertically between (a) a first surface 215a and (b) a second surface 215b of the busbar 200. As such, the laterally solidified region 238 has an area defined by a height H LSR and a width W LSR In an exemplary embodiment, the edge fusion width or the width of the laterally solidified region W LSR less than 0.4 mm, and most preferably between 0.01 mm and 0.35 mm. Attempting to determine the edge fusion width or width of the laterally solidified area W LSRIncreasing the weld width beyond 0.4 mm may, in the disclosed embodiment, lead to undesirable pooling near the lateral edges 216a, 216b, since the busbar 200 includes copper and ten conductors 202 with a thickness of 0.25 mm. However, it should be understood that for busbars 200 having other configurations or made of other materials, pooling may only occur at deeper welds or at shallower welds. For example, the edge fusion width or the width of the laterally solidified region W LSR in other embodiments between 0.05 mm and 5 mm, preferably between 0.1 mm and 2.5 mm and particularly preferably between 0.1 mm and 0.75 mm.

[0055] The limited solidification zone 240 is a region of the busbar 200 that (i) extends from the center point 217 of the fused segment 206 to one of the side edges 216a, 216b and (ii) has undergone an edge-based fusion process (e.g., the lateral partial penetration welding process 184 or a cold working process). The limited solidification zone 240 has: (i) a height H LSZ extending between the first and second surfaces 215a, 215b, and (ii) a width W LSZ , which extends between the center point 217 and the lateral edges 216a, 216b of the conductors 202. In other words, the limited solidification zone 240 has: (i) a height H LSZ which: (a) typically equal to the height H F of the fused segment 206, and (b) equal to or greater than a fusion height or laterally solidified height H LSR and (ii) a width W LSZwhich: (a) is equal to half (e.g., 10 mm) as large as the width (e.g., 20 mm) of the busbar 200, and (b) is greater than the lateral cross-sectional width W LSR of the laterally solidified area 238.

[0056] The edge fusion width or width of the laterally solidified area W LSR is: (i) constant in a fused segment 206 and (ii) may vary when multiple fused segments 206 are compared. In other embodiments, the width of the edge fusion or the width of the laterally solidified region W LSRhowever: (i) remain constant across the entire fused segment 206, or (ii) vary within a fused segment 206, (iii) remain constant across a plurality of fused segments 206, and / or (iv) vary across a plurality of fused segments 206. As described above, the edge fusion width or width of the laterally solidified region W LSR between 0.05 mm and 0.4 mm, preferably 0.2 mm. Accordingly, the total fusion depth W varies T , which is calculated by summing the width of the laterally consolidated area W LSRis calculated, which is associated with the right and left edges, between each of the plurality of fused segments 206. Thus, the first total fusion depth associated with the fused segment 206 extending between 218a and 218b is between 0.1 mm (i.e., 0.05 mm + 0.05 mm) and 0.8 mm (i.e., 0.4 mm + 0.4 mm), preferably 0.4 mm. The total fusion depth W T is therefore between 0.5% and 4% of the busbar width (ie 20 mm).

[0057] Based on the heights and widths described above, the busbar 200 includes the following relationships: (i) the height H LSR of the laterally solidified region 238 is typically substantially equal to the height H LSZ the limited hardening zone 240, and (ii) the width W LSR of the laterally solidified area 238 is less than the width W LSZ the limited hardening zone 240, where the width W LSRis typically 50% less than the width W LSZ and most preferably between 0.5% (ie, (1 - (9.95 mm / 10 mm)) * 100) and 4% (ie, (1 - (9.6 mm / 10 mm)) * 100) of the width W LSZ the limited hardening zone 240. In addition, the height of the edge weld 184 is essentially equal to the height H LSR of the limited solidification region 238, and the width of the edge weld 184 is substantially equal to the width W LSR of the laterally hardened area 238. Thus, the height of the edge weld 184 is essentially equal to the height H LSZ the limited hardening zone 240, and the width of the edge weld 184 is less than the width W LSZ the limited hardening zone 240.

[0058] The width of the laterally consolidated area W LSR is less than the width of the limited hardening zone 240 W LSZ and half the width of the busbar 200. Since the width W LSRof the laterally solidified region is smaller than half the width of the busbar 200, an unsolidified region 230 forms between the edge-based fusion peak 219 and the center point 217 of the busbar 200. This unsolidified region 230 has an unsolidified width W U , which extends between the center point 217 of the busbar 200 and the edge-based fusion peak 219. The unconsolidated width W U is typically at least 10% of the width W LSZ the limited hardening zone 240 and is preferably between 50% and 99.9% of the width W LSZ the limited hardening zone 240. The width W LSR the laterally consolidated area corresponds to at least 0.1% of the width W LSZ the limited hardening zone 240, is preferably between 1% and 10% of the width W LSZ the limited hardening zone 240 and is particularly preferably between 3% and 8% of the width WLSZ the limited hardening zone 240.

[0059] In this exemplary embodiment, a laterally solidified region 238 may be created by solidifying a lateral extent of ten conductors 202 into a single conductor. In other words, the central sector 210 of the busbar 200 includes a plurality of conductors 202 that traverse or span the central sector 210 of the busbar 200. The fused segment 206 of the central sector 210 includes a limited solidification zone 240 extending between a center point 217 and the side edges 216a, 216b of the conductors 202. A minority of the conductors 202 contained within this limited solidification zone 240 are solidified into a single consolidated conductor and form a laterally solidified region 238. Likewise, a majority of the conductors 202 contained within this limited solidification zone 240 are not solidified and form an unsolidified region 230.

[0060] As in Fig. 15, the laterally solidified regions 238 may have different weld densities when a lateral partial welding process 184 is used to form these regions 238. The lateral partial welding process 184 may form a first, or outer, zone with a first weld density and the second, or inner, zone with a second weld density that is less than the first weld density. The density differences arise from the design and operation of the laser welding machine 192, in which the laser beam loses power as it penetrates the busbar 200. The lower density zone is formed at a certain distance from the edge of the weld or within the higher density zone.It is understood that this second zone may have a fusion density gradient, having a higher fusion density near the first zone and the lowest fusion density at a point farthest from the first zone. It is also understood that the fusion density within this first zone may be constant or substantially constant. In addition to solidifying the side edges 216a, 216b of the busbar 200, the lateral partial welding process 184 rounds the corners of the busbar 200. These rounded corners help reduce the likelihood of the conductors 202 fraying or tearing the insulation or housing 600. Additional aspects of the laterally solidified regions 238 and the unsolidified region 230 are presented in the Definitions section at the beginning of the detailed description.

[0061] As previously mentioned, the fused segment 206 within the central sector 210 of the busbar 200 includes both laterally strengthened regions 238 and unstrengthened regions 230. It should therefore be understood that increasing the area of ​​the laterally strengthened regions 238 within the fused segment 206: (i) increases at least the local stiffness in the fused segment 206, (ii) tends to increase the stiffness of the central sector 210 of the busbar 200, and (iii) tends to increase the overall stiffness of the busbar 200. For example, by creating these laterally strengthened regions 238, the Young's modulus of the busbar is increased (e.g., above 320 KPa or 0.32 Nm 2at room temperature). It should further be understood that increasing the area of ​​the unconsolidated region 230 within the fused segment 206: (i) at least increases the local flexibility within the fused segment 206, (ii) tends to increase the flexibility of the central sector 210 of the busbar 200, and (iii) tends to increase the overall flexibility of the busbar 200.

[0062] Fig. Figure 15 shows a cross-sectional view of the busbar 200 along the section plane defined by line 15-15 of Fig. 14. The cross section is taken between the first intermediate boundary line 218a and the intermediate boundary line 218b. These boundary lines 218a, 218b define the edges of the fused segment 206 or the fused segment 206 (namely the first fused segment 209a). The cross section of Fig. Figure 15 shows: (i) two laterally solidified regions 238 formed by right and left lateral partial penetration welds extending inward from the side edges 216a, 216b of the busbar 200, and (ii) an unconsolidated region 230 extending between the two laterally solidified regions 238. The right and left lateral partial penetration welds connect all of the conductors 202 contained within the laterally solidified regions 238 into a single consolidated conductor. This first fused segment 206, 209a lacks a region that has undergone a surface-based fusion process to form a partially solidified region in which all of the conductors in this partially solidified region are fused into a single consolidated conductor. Since this first fused segment 206, 209a does not have a partially solidified region, it also lacks a partial solidification zone.Therefore, this bending area 226 has a stiffness of more than 770 KPa ((2,200 KPa for a rigid reference busbar with 1 conductor * 0.4) = 770 KPa). 3. Merged end sector

[0063] In contrast to the central sector 210, the end sectors 207 are intended to receive a connector; therefore, it is desirable that these regions be fully consolidated as a single consolidated conductor. All extensions of the conductors 202 contained within the fully consolidated regions 242 are consolidated into a single conductor because a significant portion of the conductors 202 are: (i) consolidated downwardly from the top surface 215a, (ii) consolidated upwardly from the bottom surface 215b, and (iii) consolidated inwardly from the side edges 216a, 216b. Accordingly, these significant extensions of the conductors 202 meet between the upper and lower surfaces 215a, 215b, typically in the middle region between the two surfaces 215a, 215b, and form a fully solidified region 242. The weld depth or height of the fully solidified region 242 H FSRis at least substantially equal to the fused height H F the busbar 200. In certain exemplary embodiments, the fully solidified height H FSR be greater than the merged height H F when welding material is applied to one of the two surfaces 215a, 215b, creating a “dome effect”. Since the height H FSR of the fully solidified region 242 equal to or greater than the fused height H F , no unconsolidated region 230 is formed between the weld and the second surface 215a, 215b of the busbar 200. In other words, all conductors 202 located within the fully consolidated zone are consolidated into a single consolidated conductor. Further aspects of the fully consolidated region 242 are disclosed in PCT / US20 / 50016, which is hereby incorporated by reference.

[0064] Like the partially solidified zone 1300, the fully solidified zone is a region of the busbar 200 that extends between the upper surface 215a and the lower surface 215b and has undergone a full welding process 182. The fully solidified zone has a height that extends between the first and second surfaces 215a, 215b. In other words, the fully solidified zone has a height equal to the fused height H F and is equal to the fully consolidated height H FSR Based on the disclosed welds, the end sectors 207 are welded in a manner that causes these sectors 207 to be compacted (sufficient compacted surface to correspond to 120% of the cross-sectional area of ​​the busbar 200) so that they can be connected with a connector.

[0065] Fig. Figure 17 shows a cross-sectional view of the busbar 200 along the section plane defined by line 17-17 of Fig. 16. The cross section is taken between the end edge 216c and the first intermediate boundary line 218a, which defines the end sector 207, 208a and the fully solidified regions 242. The cross section of Fig. Figure 17 shows: (i) two laterally solidified regions 238 formed by right and left lateral partial penetration welds extending inward from the side edges 216a, 216b of the busbar 200, and (ii) thirteen partially solidified regions formed by upper and lower vertical partial penetration welds 182 extending upward and downward from the upper and lower surfaces 215a, 215b of the busbar 200. This bending region 226 has a stiffness of more than 770 kPa ((2,200 kPa for a rigid reference busbar with 1 conductor * 0.35) = 770 kPa). ii. Alternative embodiments

[0066] As described above, the central sector 210 may include: (i) any number (e.g., 0-1000) of unfused segments 204 and (ii) any number (e.g., 0-1000) of fused segments 206. The fused segments 206 may include any number (e.g., 0-1000) of laterally solidified regions 238, any number (e.g., 0-1000) of partially solidified regions, and any number (e.g., 0-1000) of unsolidified regions 230. Additionally, the fused segments 206 may include any number of waveforms (e.g., 0-100), preferably between 1-6 waveforms, and most preferably two waveforms. Likewise, the central sector 210 of the busbar 200 may include: (i) any number of waveforms (e.g., 0-100), (ii) any number (e.g., 0-1000) of laterally solidified regions 238, (iii) any number (e.g.,0-1000) of partially solidified regions, (iv) any number of fully solidified regions 242 and / or (v) any number (e.g., 0-1000) of unsolidified regions 230. Finally, the busbar 200 may include: (i) any number of waveforms (e.g., 0-100), (ii) any number (e.g., 0-1000) of laterally solidified regions 238, (iii) any number (e.g., 0-1000) of partially solidified regions, (iv) any number of fully solidified regions 242 and / or (v) any number (e.g., 0-1000) of unsolidified regions 230. This configuration allows the busbar designer to selectively form segments, zones, regions and / or volumes in a single busbar, thereby allowing the busbar 200 to have the advantages conventional rigid and conventional flexible busbars.

[0067] In alternative embodiments, the disclosed laser melting processes may be used in addition to or in place of resistance welding, arc welding, electron beam welding, orbital welding, ultrasonic welding, friction welding, any combination of the above-mentioned processes, or other known metal melting processes. Furthermore, the lateral partial penetration welding process 184 or a cold forming process that forms the laterally solidified region within the limited solidification zone of the central sector 210 may be omitted or expanded in width. Furthermore, the lateral partial penetration welding process 184 or a cold forming process used in conjunction with the end sectors 207 may be omitted. iii. Formation of the intermediate area

[0068] After the first end sector 208a and the first extension 212a of the busbar 200 have been selectively fused, the process of manufacturing the busbar 200 continues by forming the elastically deformable intermediate region 410 of the busbar 200 into the desired shape. The elastically deformable intermediate region 410 of the busbar 200 is located between a first edge region 402a and a second edge region 402b. In particular, the first edge region 402a comprises: (i) the first end sector 207, 208a, and (ii) a first extension of the middle sector 210, namely the first non-fused segment 204, 205a. Similarly, the second edge region 402b comprises: (i) the second end sector 207, 208b, and (ii) a second extension of the middle sector 210, namely the third unfused segment 204, 205c.Based on this disclosed configuration, the first and second edge regions 402a comprise: (i) a fully solidified region 242, and (ii) an unsolidified region 230. Meanwhile, the intermediate region 410 is formed in the central sector 210 and between the first and second extensions of the central sector 210. As such, the intermediate region 410 comprises: (i) the first fused segment 206, 209a, (ii) the second unfused segment 204, 205b, and (iii) the second fused segment 206, 209b. Thus, the intermediate region 410 comprises: (i) two laterally solidified regions 238, and (ii) an unsolidified region 230 extending between the two laterally solidified regions 238. It is understood that other configurations are contemplated in this disclosure (see FIG. Fig. 89-102). For example, in an alternative embodiment, the intermediate region 410 may include partially solidified regions.

[0069] In other words, the first edge region 402a is defined between the left end edge 216c and the first intermediate boundary line 218a, and the second edge region 402b is defined between the right end edge 216d and the fourth intermediate boundary line 218d. In other words, the first and second edge regions 402a, 402b extend outward from the first and fourth intermediate boundary lines 218a, 218d. It should be understood that the first and fourth intermediate boundary lines 218a, 218d are positioned inward from the end edges 216c, 216d by a sufficient distance to: (i) properly connect a connector, terminal, receptacle, or other structure to the bus bar 200, and (ii) properly position the elastically deformable intermediate portion 410 at a desired location (e.g., at a location that does not interfere with the position of the battery modules 60).For example, the end boundary lines 214a, 214b may be formed between 15 mm and 85 mm and preferably between 35 mm and 55 mm from the end edges 216c, 216d.

[0070] The first and second edge regions 402a, 402b are not designed to be bent or modified at this stage of the manufacturing process. Thus, these edge regions 402a, 402b remain in the unassembled state S U substantially parallel, substantially aligned, their upper and lower surfaces 215a, 215b are substantially coplanar, and their side edges 216a, 216b are substantially collinear. As such, these edge regions 402a, 402b are not configured to have curved or angular extensions. Furthermore, these edge regions 402a, 402b remain in an installed state S ITypically and / or preferably, the first and second edge portions 402a, 402b are substantially parallel, substantially aligned, their top and bottom surfaces 215a, 215b are substantially coplanar, and their lateral edges 216a, 216b are substantially collinear. The configuration of the first and second edge portions 402a, 402b is advantageous because it helps ensure that unwanted forces are at least minimized and preferably not applied to the connections between the bus bar 200 and the male connector assemblies 1000, or between the male connector assemblies 1000 and the battery module 60. Undesirable forces can occur, for example, if the edge portion 402a, 402b of the bus bar 200 has a curved configuration. And these unwanted forces can lead to failures within the battery pack 90 that are extremely costly to diagnose, repair, or mitigate.Therefore, it is beneficial to minimize or eliminate these unwanted forces.

[0071] In contrast to the first and second edge regions 402a, 402b, the elastically deformable intermediate region 410 is designed to deform elastically when a load is applied to the busbar 200 (e.g., by dynamic movement of the battery module(s) 60). In order to deform elastically when the load is applied to the busbar 200, the elastically deformable intermediate region 410 has, in an uninstalled state S Ua configuration that preferably positions at least a portion, preferably a majority, and most preferably a substantial majority of the intermediate region 410 in a position that is: (i) not substantially parallel to, (ii) not substantially aligned with, (iii) not substantially coplanar with, or (iv) not substantially collinear with the entirety of the first and second edge regions 402a, 402b. In other words, the intermediate region 410 is out of plane with the first and second edge regions 402a, 402b, resulting from the fact that the intermediate region 410 has a substantial curvilinear extent or an angular extent. In other words, the first and second edge regions 402a, 402b lie substantially in a first plane, and the majority of the elastically deformable intermediate region 410 lies outside the first plane.The formation of these (or these) curved or angular extensions in the intermediate region 410 is facilitated by the inclusion of the fused segment 206 within the busbar 200 due to the fact that the fused segment 206 helps prevent the busbar 200 from detaching when the elastically deformable intermediate region 410 is bent into its desired shape.

[0072] In the Fig. In the preferred embodiment shown in Figures 1-73, at least the intermediate portion 410 of the bus bar 200, particularly in side view, has a configuration substantially corresponding to the configuration of the capital letter Omega ("Ω") in the Greek alphabet or the Ohm symbol ("Ω"), which is a unit of energy management. Specifically, the configuration of the first edge portion 402a is similar to an extension of the left foot or left base portion of the Omega shape, the configuration of the elastically deformable intermediate portion 410 is similar to the curved shape of the Omega shape, and the configuration of the second edge portion 402b is similar to an extension of the right foot or right base portion of the Omega shape.In other words, the busbar 200 comprises: (i) a first linear extension 260a, (ii) a first foot or base of the omega shape formed by a first curved extension 262a creating a first outer recess 264a, (iii) a semi-circular extension 266, (iv) a second foot or base of the omega shape formed by a second curved extension 262b creating a second outer recess 264b, and (v) a second linear extension 260b. Additionally, the configuration of the busbar 200 positions the fused segments 206, 209a, 209b near the feet or base of the omega shape, while the unfused segments 204, 205a, 205b, 205c are arranged (i) between the end sectors 207 and the fused segments 206, 209a, 209b and (ii) along a curved path between the fused segments 206, 209a, 209b.It should be understood that in other embodiments, the first and second extents of the central sector 210 may include fused segments 206, and the curved path between the fused segments 209a, 209b may be fully or partially fused. It should also be understood that in other embodiments, the elastically deformable intermediate region 410 may have a different configuration (e.g., square, triangular, sinusoidal, etc.), including, but not limited to, those illustrated in FIGS. Fig. 89-102. Finally, it is believed that optimal elastic deformation performance of the busbar 200 occurs when the elastically deformable intermediate region 410 has a curved configuration that does not have right angles or “acute angles” as described in the Fig. 89, Fig. 90, Fig. 92, Fig. 93, Fig. 95 and Fig. 98 is shown.

[0073] If the busbar 200 is in an original or unbent state S UB the busbar 200, as shown in Fig. 6, the length of each region is as follows: (i) the first edge region 402a has a length L PIU , which extends from the end edge 216c of the busbar 200 to the first intermediate boundary line 218a, (i) the second edge region 402b has a length L P2U , which extends from the end edge 216d of the busbar 200 to the fourth intermediate boundary line 218d, and (iii) the intermediate region 410 has a length L IPU , which extends from the first intermediate boundary line 218a to the fourth intermediate boundary line 218d. The lengths of the edge regions L PIU , L P2U must be sufficiently long to facilitate the connection of the busbar 200 to an external device or component. In the disclosed embodiment, these edge region lengths L PIU, L P2U greater than 5 mm, preferably greater than 10 mm, more preferably greater than 14 mm, and most preferably between 30 mm and 60 mm. While the lengths of the edge regions L PIU , L P2U to the total length L UB the busbar 200, the length of the intermediate area L IPU relevant for the calculations shown in the table below.

[0074] As in Fig. 7, the length of each section is as follows when the busbar 200 is in the original or unbent state S UB the busbar 200: (i) the first end sector 208a has a length L E1U , which extends from the end edge 216c of the busbar 200 to the first end boundary line 214a, (ii) the second end sector 208b has a length L E2U, which extends from the end edge 216d of the busbar 200 to the second end boundary line 214b, and (iii) the middle sector 210 has a length L CU , which extends from the first end boundary line 214a to the second end boundary line 214b. The end sector lengths L E1U , L E2U must be sufficiently long to facilitate the connection of the busbar 200 to an external device or component. In the disclosed embodiment, these end sector lengths L E1U , L E2U greater than 2 mm, preferably greater than 7 mm, and most preferably between 10 mm and 20 mm. The table below refers to a busbar 200 with ten copper conductors stacked to form a busbar 200 with a thickness T B of 2.5 mm and a width of 20 mm. Table 1: Busbar forces and dimensions Aktivierungskraft (N) Innendurchmesser des Zwischenbereichs (mm) L IPU (mm) L P1U , L P2U (mm) L BU (mm) L BN (mm) Total volume (mm 3 ) 312 10 32 22 76 58 1.570 211 12 38 26 90 72 2.261 155 14 44 30 104 84 3.077 98 16 51 34 119 96 4.019 67 18 57 38 133 108 5.087 42 20 63 44 151 116 6.280 35 22 69 48 165 130 7.599 32 24 75 52 179 140 9.043 31 26 82 56 194 152 10.613 30 28 88 60 208 164 12.308 29 30 95 64 223 175 14.130 28 32 101 68 237 187 16.076 26 34 107 72 251 198 18.149 24 36 113 76 265 209 20.347

[0075] The total length LBU the non-bent busbar and the formed length L BN the busbar extend between the end edges 216c, 216d of the busbar 200 in the non-installed state S U . As shown in Table 1 above, the proportion of the formed length L BN on the total length L BU between 70% and 90%. In other words, the formed length L BN is more than 10% smaller than the total length L BU and preferably more than 20% smaller than the total length L BU . The table above also shows that the length of the non-bent intermediate area L IPU between 35% and 49% of the total length L BU of the non-bent busbar is 200 and each of the lengths of the edge areas L PIU , L P2U between 25% and 32% of the total length L BU of the unbent busbar is 200. Thus, the length of the unbent intermediate piece L IPUless than a large part of the total length L BU the busbar 200. However, as described above, other length ratios are also conceivable.

[0076] The length of the non-bent intermediate piece L IPU corresponds approximately to the circumference of a circle with the corresponding inner diameter. For example, a circle with a diameter of 20 mm has a circumference of about 62.8 mm, so the length of the unbent intermediate piece is about 63 mm. As at least in the Fig. 21 and Fig. 69, due to the unique geometry of the intermediate region 410, there is a bending height H IPN , which is defined between the outer surface of the uppermost conductor 203j (e.g., at the middle height of the intermediate region 410) and the outer surface of the lowermost conductor 203a, either in the first edge region 402a or in the second edge region 402b. In the neutral state S N the intermediate region 410 has a bending height H IPNwhich is between 20 mm and 28 mm, preferably 23 mm. As at least in the Fig. 21 and Fig. 69, there is also a bending length L IPN of the intermediate region 410, which is defined between the opposite outer surfaces of the uppermost conductor 203j (e.g., at the middle length of the intermediate region 410). In the neutral state S N the intermediate area 410 has a bending length L IPN, which is between 23 mm and 31 mm, preferably 27 mm. In other words, the design of this busbar 200 includes an extension—namely, the intermediate region 410—that intentionally increases the height and space required for mounting this busbar 200 within the power distribution assembly 50. This increased space requirement contradicts the goal of minimizing the space required by electrical connectors. It is therefore an unconventional solution to address issues related to the material conditions of the battery modules 60 and the dynamic movement of the battery modules 60. It is understood that this disclosure contemplates other ratios or calculations based on the table above.

[0077] Table 1 (above) shows an activation force F A , which is applied by the battery modules 62a, 62b and which connects the busbar 200 between the neutral state S Nand the compressed state S C or between the neutral state S N and the extended state S E Since the busbar 200 reacts linearly, the activation force F A when moving between the neutral state S N and the compressed state S C compared to the movement between the neutral state S N and the extended state S E equal in size but opposite in direction. The activation force F A can therefore be a pressure activation force F A or a stretch activation force F A be, depending on the case. As shown in Table 1 above, increasing the inner diameter of the intermediate region 410 beyond 22 mm does not result in a significant reduction in the activation force F A (first column) required to connect the busbar 200 between the neutral state S Nand either the compressed state S C or the extended state S E However, increasing the inner diameter significantly increases the total package volume of the busbar 200, i.e., the space in the battery pack that must be reserved for the installation and operation of the elastically deformable connector system 100. For example, doubling the inner diameter of the intermediate region 410 from 10 mm to 20 mm reduces the activation force F A by more than seven times from 312 N to 42 N. In contrast, an increase in the inner diameter of the intermediate area 410 from 20 mm to 30 mm reduces the activation force F A but only by more than 1.5 times from 42 N to 30 N. The configuration with the smallest total package size, which has less than 50 Newton activation force F Arequired to move between the states is a busbar 200 with an inner diameter of 20 mm. This ratio is assumed to be an optimal balance between the decrease in the activation force F A and the increase in package size. It should be understood that other configurations of the busbar 200 (e.g., material, thickness, width, intermediate section configuration, welds, etc.) may alter the above calculations and / or change the relationships between the above-mentioned properties. For example, if the thickness of each conductor 202 or the number of conductors 202 is increased without changing other dimensions, the force required to move the busbar 200 from the neutral state S N either into the compressed state S C or into the extended state S ELikewise, reducing the thickness of each conductor 202 or the number of conductors 202, without changing any other dimensions, is likely to reduce the force required to move the busbar 200 from the neutral state S N either into the compressed state S C or into the extended state S E to move.

[0078] In addition, the volume of the intermediate region 410 is greater than: (i) the volume of the edge regions 402a, 402b, and (ii) the volume of a connector replacing the intermediate region 410, which is linear and extends between the edge regions 402a, 402b. Furthermore, the area of ​​the upper surface (e.g., 1,233 mm 2 ) of the intermediate region 410 is greater than: (i) the surface (e.g. 866 mm 2) of the edge regions 402a, 402b, and (ii) the surface of a connector replacing the intermediate region 410, which is linear and extends between the edge regions 402a, 402b. As such, the edge regions 402a, 402b contain less material than: (i) the intermediate region 410, and (ii) a connector replacing the intermediate region 410, which is linear and extends between the edge regions 402a, 402b. iv. Selective welding of a second extension of the busbar

[0079] Next, the designer will: (i) insert the bent busbar 202 into the machine 192 and (ii) give the machine 192 fusion instructions (e.g., load a design model) associated with the second end sector 207, 208b and the second extension 212b of the busbar 200. The laser welding machine 192 then performs the fusion process 180 described in its instructions. For example, Fig.19 shows the busbar 200 in a horizontal orientation in which its width lies in a plane oriented substantially perpendicular to the lasers 194, 196. In this horizontal orientation, the machine 192 performs a surface-based fusion process (i.e., a vertical partial penetration weld process 182) on the end sector 207 of the busbar 200 according to the instructions associated with the second end sector 208b of the busbar 200. Subsequently, the busbar 200 is rotated to a vertical orientation in which its thickness lies in a plane oriented substantially perpendicular to the lasers 194, 196. In this vertical orientation, the machine 192 performs an edge-based welding process (i.e., a lateral partial penetration weld process 184) on the second extension 212b of the busbar 200 according to the instructions associated with this second extension 212b.After selectively welding the second end sector 208b and the second extension 212b of the middle sector 210, the section shown in FIGS. Fig. The busbar shown in 20-24 is formed. v. Optional manufacturing steps

[0080] After the welding operations described above are completed, the optional manufacturing steps may be completed. Completion of the optional manufacturing steps may include, for example, (a) assembling and connecting the connectors 1000 to the busbar 200, (c) insulating the busbar 200, (d) coating a spatial area of ​​the busbar 200, and / or inserting the busbar 200 into the housing 600. B. Male connector assembly

[0081] As in Fig. 15, the male connector assembly 1000 consists of: (i) a housing assembly 1100 and (ii) a male terminal assembly 1430 having a spring element 1440c and a male terminal 1470. The male terminal assembly 1430 is connected to the first and second edge regions 402a, 402b of the busbar 200 using any known coupling method, including laser welding and / or ultrasonic welding. It should be understood that the connector assembly 1000 is an example of a possible connector that may be connected to the busbar 200. The use of other connectors, including conventional screw connectors, is contemplated within the scope of this disclosure. i. Male housing assembly

[0082] The male housing assembly 1100 encloses or surrounds a substantial extent of the other components contained within the male terminal assembly 1430. The outer housing assembly 1100 generally includes: (i) an outer housing 1104 and (ii) a deformable connector position assurance ("CPA") 1170. The outer housing 1104 includes two arrangements of walls, wherein: (i) the first sidewall arrangement 1106 has a rectangular shape and is configured to receive an extension of the bus bar 200, and (ii) the second sidewall arrangement 1108 has a cubic shape and is configured to receive a substantial extension of the male terminal assembly 1430. The second arrangement of walls 1108 includes a non-deformable CPA receptacle 1160 extending from at least one of the walls 1108b and preferably two walls 1108d and configured to receive a portion of the deformable CPA 1170.The two arrangements of walls are typically formed from an insulating material designed to isolate the electrical current flowing through the male connector assembly 1000 from other components. Further details about the outer housing assembly 1100 are described in PCT / US2019 / 36070. It should be understood that the male housing assembly 1100 does not include a lever to assist in coupling the male connector assembly 1000 to the female connector assembly 2000. ii. Male connector assembly

[0083] The Fig. 25-30 show various views of the male terminal assembly 1430, wherein the assembly 1430 includes a spring member 1440c and a male terminal 1470. The male terminal 1470 includes a male terminal body 1472 and a male terminal connecting member or plate 1474. The male terminal body 1472 includes: (i) a first or front male terminal wall 1480 having a touch-safe pin opening 1510 formed therein, (ii) an array of male terminal side walls 1482a-1482d, and (iii) a second or rear male terminal wall 1484. The combination of these walls 1480, 1482a-1482d forms a spring receptacle 1486 configured to receive the inner spring member, the male spring member, or the second spring member 1440c.

[0084] As in Fig. 26, the inner spring member 1440c includes an array of spring member side walls 1442a-1442d and a rear spring wall 1444. The array of spring member side walls 1442a-1442d each consists of: (i) a first or arcuate spring region 1448a-1448d, (ii) a second spring region, a base spring region, or a middle spring region 1450a-1450d, (iii) a third region or spring arm 1452a-1452h, and (iv) a fourth region or centering means 1453. The arcuate spring regions 1448a-1448d extend between the rear spring wall 1444 and the base spring regions 1450a-1450d and position the base spring regions 1450a-1450d substantially perpendicular to the rear spring wall 1444. In other words, the outer surface of the base spring regions 1450a-1450d is substantially perpendicular to the outer surface of the rear spring wall 1444.

[0085] The base spring portions 1450a-1450d are disposed between the arcuate portions 1448a-1448d and the spring arms 1452a-1452h. As shown in Fig. As shown in Figure 26, the base spring portions 1450a-1450d are not interconnected, forming gaps between the base spring portions 1450a-1450d of the spring element 1440c. The gaps support the omnidirectional extension of the spring arms 1452a-1452h, facilitating the mechanical coupling between the male terminal 1470 and the female terminal assembly 2430. The spring arms 1452a-1452h extend from the base spring portions 1450a-1450d of the spring element 1440c, away from the rear spring wall 1444, and terminate at a free end 1446. The spring arms 1452a-1452h are generally planar and arranged such that the outer surface of the spring arms 1452a-1452h is coplanar with the outer surface of the base spring portions 1450a-1450d. In contrast to the spring arm 31 shown in the Fig. 4-8 of PCT / US2018 / 019787, the free end 1446 of the spring arms 1452a-1452h does not have a curved component. Instead, the spring arms 1452a-1452h have a substantially flat surface. This configuration is advantageous because it ensures that the forces associated with the spring element 1440c are applied substantially perpendicular to the free end 1488 of the male connector body 1472. In contrast, the curved components of the spring arm 31, which are shown in the Fig. 4-8 of PCT / US2018 / 019787 do not have force in this way.

[0086] Like the base spring regions 1450a-1450d, the spring arms 1452a-1452h are not connected to each other. In other words, there are spring arm openings extending between the spring arms 1452a-1452h. This configuration enables omnidirectional movement of the spring arms 1452a-1452h, which facilitates the mechanical coupling between the male terminal 1470 and the female terminal assembly 2430. In other embodiments, the spring arms 1452a-1452h may be coupled to other structures to limit their omnidirectional extension. The number and width of the individual spring arms 1452a-1452h and the openings may vary. Furthermore, the width of the individual spring arms 1452a-1452h is typically the same; However, in other embodiments, one of the spring arms 1452a-1452h may be wider than the other spring arms.

[0087] An earlier version of the spring element 1440pd is in connection with the Fig. 5-6 of PCT / US2019 / 36127 and Fig. 13 of PCT / US2021 / 043686 shows how the spring element 1440pd can be perfectly aligned within the male terminal body 1472pd of the male terminal assembly 1430pd. However, due to manufacturing tolerances and imperfect assembly procedures, the spring element 1440pd can become misaligned or tilted during assembly of the male terminal assembly 1430pd in the plug body 1472pd. An example of this misalignment is shown in Fig. 14 of PCT / US2021 / 043686, where angle theta θ illustrates this misalignment as it extends between the inner surface of the spring retainer and the outer surface of spring element 1440pd. In certain embodiments, angle theta θ can be between 1 degree and 5 degrees. To prevent this misalignment, spring element 1440c disclosed herein includes centering features 1453, illustrated as anti-rotation protrusions 1454a-1454d. The anti-rotation projections 1454a-1454d help to center the spring element 1440c by limiting the amount that the spring element 1440c can rotate within the male connector body 1472 due to the interaction between the outer surface of the projections 1454a-1454d and an inner surface of the sidewall portions 1492a-1492d of the male connector body 1472.Proper centering of the spring element 1440c within the male terminal body 1472 provides many advantages over terminals that are not properly centered or aligned within the male terminal assembly 1430, these advantages including: (i) ensuring that the spring element 1440c exerts adequate force on the male terminal body 1472 to establish a proper connection between the male terminal assembly 1430 and the female terminal assembly 2430, (ii) helping to improve the durability and useful life of the terminal assemblies 1430, 2430, and (iv) other advantageous features disclosed herein or that may be derived by one of ordinary skill in the art from this disclosure.

[0088] It is understood that in other embodiments, the centering or alignment means 1453 may take other forms, such as. E.g.: (i) projections extending outwardly from the first and second spring arms 1452a, 1452b, which are arranged within a single side wall, (ii) projections extending outwardly from the first and fifth spring arms 1452a, 1452e, wherein the projections are diagonally opposite each other, (iii) projections extending outwardly from all spring arms 1452a-1452h, wherein the projections belonging to 1452c, 1452d, 1452g, 1452h are positionally offset compared to the projections belonging to 1452a, 1452b, 1452e, 1452f, (iv) projections extending inwardly from the inner walls of the male terminal body 1472, (v) projections extending from the contact arms 1494a-1494h extend inwardly toward the center of the connector, (vi) cooperatively dimensioned spring retainer, (vii) projections, tabs, grooves,Recesses or areas of other structures designed to ensure that the spring element 1440c is centered within the male connector body 1472 and cannot rotate within the spring receptacle 1486. ​​For example, a projection may extend from the front or rear walls of the male connector body 1472 and be received by an opening formed in the spring element 1440c.

[0089] It should be further understood that instead of using a mechanically based centering or alignment means 1453, the centering means 1453 may be force-based, where such forces may be used include magnetic forces or chemical forces. In this example, the back wall of the spring element 1440c may be welded to the back wall of the male terminal body 1472. In contrast to a mechanical or force-based centering means 1453, the centering means 1453 may be a method or process for manufacturing the male terminal assembly 1430. For example, the centering means 1453 may not be a structure, but may instead comprise simultaneously printing the spring element 1440c within the male terminal body 1472 in a manner that does not require assembly. In other words, the centering means 1453 may take many forms (e.g.,mechanically based, force-based, or process-based) to achieve the purpose of centering the spring element 1440c within the male connector body 1472.

[0090] The inner spring element 1440c is typically formed from a single piece of material (e.g., metal); therefore, the spring element 1440c is a one-piece spring element 1440c or has integrally formed features. In particular, the following features are integrally formed: (i) the arcuate spring portion 1448a-1448d, (ii) the base spring portion 1450a-1450d, (iii) the spring arm 1452a-1452h, and (iv) the centering means 1453. To integrally form these features, the spring element 1440c is typically formed by a forming process. During forming, the spring element 1440c is mechanically pressed into shape. As further explained below and in PCT / US2019 / 036010, the spring element 1440c exerts an outwardly directed thermal spring force S TFon the contact arms 1494a-1494h when the spring element 1440c is formed from a flat metal sheet, installed in the male terminal 1472, and mated to the female receptacle 2472, and exposed to elevated temperatures, in part due to the spring element 1440c attempting to return to a flat sheet. However, it should be understood that other types of forming the spring element 1440c may be used, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the spring element 1440c may not be formed in one piece or integrally, but rather from separate parts that are welded together.

[0091] In an alternative embodiment, not shown, the spring element 1440c may include recesses and associated reinforcing ribs. As discussed in PCT / US2019 / 036010, these changes in the configuration of the spring element 1440c alter the forces associated with the spring element 1440c. In particular, the spring preload force S BFthe amount of force applied by the spring element 1440c to counteract the inward deflection of the free end 1446 of the spring element 1440c when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. In particular, this inward deflection occurs during insertion of the male terminal assembly 1430 due to the fact that an extension of an outer surface of the male terminal body 1472 is slightly larger than the interior of the female receptacle 2472. Thus, when the male terminal assembly 1430 is inserted into the female terminal assembly 2430, the extension of the outer surface is forced toward the center 1490 of the male terminal 1470. This inward force on the outer surface displaces the free end 1446 of the spring element 1440c inward (i.e., toward the center 1490). The spring element 1440c resists this inward displacement by applying a spring preload force S.F provides.

[0092] The Fig. 27-30 show a male terminal 1470 including the male terminal body 1472 and a male terminal connection plate 1474. In particular, the male terminal connection plate 1474 is coupled to the male terminal body 1472 and configured to receive a portion of a structure (e.g., a bus bar) that connects the male terminal assembly 1430 to a device (e.g., a second battery module 60) external to the connector system 100. The conductor 202 is typically welded to the connection plate 1474; however, other methods of connecting the conductor 202 to the connection plate 1474 (e.g., molding the conductor 202 as part of the connection plate 1474) are contemplated in this disclosure.

[0093] As in the Fig. 27-30, the assembly of sidewalls 1482a-1482d of the male terminal are interconnected and form a generally rectangular prism. The assembly of sidewalls 1482a-1482d of the male terminal includes: (i) a sidewall portion 1492a-1492d having a generally "U-shaped" configuration, (ii) contact arms 1494a-1494h, and (iii) a plurality of contact arm openings 1496a-1496h. As shown in FIGS. Fig. As best illustrated in Figures 28-29, the sidewall portions 1492a-1492d are substantially planar and have a U-shaped configuration. The U-shaped configuration is formed from three substantially linear segments, with a second or middle segment 1500a-1500d connected at one end to a first or end segment 1498a-1498d and at the other end to a third or opposite end segment 1502a-1502d. The contact arms 1494a-1494h extend: (i) from an extension of the intermediate segment 1500a-1500d of the sidewall portion 1492a-1492d, (ii) away from the rear wall 1484 of the male terminal, (iii) across an extension of the contact arm openings 1496a-1496i, and (iv) terminate short of the front wall 1480 of the male terminal. This configuration is advantageous over the configuration of the Fig. 9-15, 18, 21-31, 32, 41-42, 45-46, 48 and 50 in PCT / US2018 / 019787 because it allows: (i) it to be shorter in overall length, which means less metal material is needed to form it and the male terminal 1470 can be installed in tighter, restrictive spaces, (ii) it has a higher current carrying capacity, (iii) it is easier to assemble, (iv) it has improved structural rigidity because the contact arms 1494a-1494h are disposed within the first male terminal sidewall region 1492a-1492d, (iv) it has advantages disclosed in connection with PCT / US2019 / 036010, and (v) other advantageous features disclosed herein or that can be derived by one of ordinary skill in the art from this disclosure.

[0094] The contact arm openings 1496a-14961 are formed integrally with the central sector 1500a-1500d of the male terminal sidewalls 1482a-1482d. The contact arm openings 1496a-14961 extend along the lateral length of the contact arms 1494a-1494h to provide a configuration that allows the contact arms 1494a-1494h to not be laterally connected to: (i) another contact arm 1494a-1494h or (ii) any structure other than the extension of the male terminal sidewall portion 1492a-1492d to which the contact arms 1494a-1494h are connected. Furthermore, the contact arm openings 1496a-14961 are aligned with the spring arm openings. This configuration of the openings results in the same number of spring arms 1452a-1452h as the number of contact arms 1494a-1494h. In other words: Fig. Figure 28 shows eight spring arms 1452a-1452h and eight contact arms 1494a-1494h. It should be understood that in other embodiments, the number of spring arms 1452a-1452h may not match the number of contact arms 1494a-1494h. For example, there may be fewer than one spring arm 1452a-1452h.

[0095] The contact arms 1494a-1494h extend at an outward angle away from the rear wall 1484 of the male terminal. In particular, the outward angle may be between 0.1 degrees and 16 degrees between the outer surface of the extension of the side wall 1492a-1492d of the male terminal and the outer surface of the first extension of the contact arms 1494a-1494h, preferably between 5 degrees and 12 degrees, and most preferably between 7 degrees and 8 degrees. This outward angle is illustrated in several figures, but is best understood in conjunction with the Fig. 28-29. This configuration allows the contact arms 1494a-1494h to be deflected or displaced inward and toward the center 1490 of the male terminal 1470 by the female receptacle 2472 when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. In particular, the male terminal body 1472 has an outer perimeter that extends around the outermost extent of the contact arms 1494a-1494h. In an unmated state S D (i.e., when the male connector body 1472 is not inserted into the female connector assembly 2430), the outer circumference of the male connector body has an uncompressed dimension. In a fully mated state S FC (i.e., when the male connector body 1472 is inserted into the female connector assembly 2430 (see Fig. 73)), the outer circumference of the male connector body has a compressed dimension. The compressed dimension is smaller than the uncompressed dimension. In the present embodiment, the uncompressed dimension is between 1% and 15% larger than the compressed dimension due to the configuration and design of the male connector body 1472 and the female connector body 2430. This inward deformation is best achieved in Fig. 74, which is evident through the gap 1550. This inward deformation helps to establish a proper mechanical and electrical connection by ensuring that the contact arms 1494a-1494h are in contact with the female receptacle 2472.

[0096] As in Fig. 27-29, the terminal ends of the contact arms 1494a-1494h are positioned as follows: (i) within an opening formed by the U-shaped sidewall portions 1492a-1492d, (ii) substantially parallel to the sidewall 1492a-1492d of the male terminal, and (iii) in contact with the planar outer surface of the spring arms 1452a-1452h when the spring element 1440c is inserted into the spring receptacle 1486. ​​This configuration is advantageous over the Fig. 3-8 in PCT / US2018 / 019787, because the assembler of the male terminal assembly 1430 does not need to exert significant force to deform a large portion of the contact arms 1494a-1494h outward to accommodate the spring element 1440c. This required deformation can best be achieved in Fig. 6 of PCT / US2018 / 019787, due to the inclination of the contact arm 11 and the fact that the outer surface of the spring arm 31 and the inner surface of the contact arm 11 are adjacent to each other without a gap formed therebetween. In contrast to the Fig. 3-8 in PCT / US2018 / 019787 shows Fig. 30 of the present application, a very small gap is formed between the outer surfaces of the spring element 1440c and the inner surface of the contact arms 1494a-1494h. Accordingly, very little force is required to insert the spring element 1440c into the spring receptacle 1486, since the installer does not need to force the contact arms 1494a-1494h to deform significantly during insertion of the spring element 1440c.

[0097] The male terminal 1470 is typically formed from a single piece of material (e.g., metal); therefore, the male terminal 1470 is a one-piece male terminal 1470 and includes integrally formed features. To integrally form these features, the male terminal 1470 is typically formed using a stamping process. However, it should be understood that other types of forming the male terminal 1470 may be used, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the male terminal 1470 may not be formed from one piece or integrally, but rather from separate parts that are welded together. It should be understood that during the manufacture of the male terminal 1470, any number (e.g., between 1 and 100) of contact arms 1494a-1494h may be formed within the male terminal 1470.

[0098] The positioning of the inner spring element 1440c within the male connector assembly 1430 occurs in several steps or stages. Fig. 27 shows the first embodiment of the male connector assembly 1430 in a disassembled state S DA , Fig. 28 shows the first embodiment of the male connector assembly 1430 in a partially assembled state S PA , and Fig. 29 shows the first embodiment of the male connector assembly 1430 in a fully assembled state S FA . In the first stage of assembly of the male connector assembly 1430, the front wall 1480 of the male connector is in an open or flat position P O and the spring element 1440c is separated from the male connector 1470. In this open position P OThe front wall 1480 of the male terminal is substantially coplanar with one of the side walls 1482c of the male terminal. This configuration of the male terminal 1470 exposes the spring receptacle 1486 and places the male terminal 1470 in a state ready to receive the spring element 1440c. The second stage of assembly of the male terminal assembly 1430 is shown in Fig. 28, with the front wall 1480 of the male connector in the open or horizontal position P O remains and the spring element 1440c is positioned or inserted into the spring receptacle 1486. ​​To achieve the partially assembled state S PA To achieve this, an introductory force F I applied to the spring element 1440c to insert the spring element 1440c into the spring receptacle 1486. ​​The insertion force F Iis applied to the spring element 1440c until the second or rear wall 1484 of the male terminal is positioned adjacent the rear spring wall 1444, a free end 1488 of the male terminal 1470 is substantially aligned with a free end 1446 of the spring element 1440c, and a portion of the side walls 1482a-1482d of the male terminal are positioned adjacent a portion of the side walls 1442a-1442d of the spring element.

[0099] The third stage of assembly of the male connector assembly 1430 is in Fig. 29, wherein: (i) the front wall 1480 of the male connector is closed or vertically P CL and (ii) the spring element 1440c is positioned within the spring receptacle 1486. ​​To close the front wall 1480 of the male connector, an upward force F Uapplied to the wall 1480 of the male connector to bend it around its seam and position it adjacent to the side walls 1482a-1482d. After the front wall 1480 of the male connector is in the correct position, the upper edge is connected (e.g., welded) to the side wall 1480 of the male connector body 1472. Here, the closed or vertical P CL the front wall 1480 of the male terminal ensures that the spring element 1440c is retained in the male terminal 1470. It should be understood that in other embodiments, the front wall 1480 of the male terminal may be omitted, may not have a touch-safe opening therethrough, may not extend all the way from the side wall 1482a-1482d (e.g., may extend partially from each side wall 1482a-1482d), or may be a separate piece connected to both side walls 1482a-1482d.

[0100] After assembling the male terminal assembly 1430, in a next assembly step, the male terminal assemblies 1430 are connected to the end sectors 207 of the busbar 200. The connection of this terminal assembly 1430 can be performed by any known method, including laser welding (e.g., surface-based vertical partial penetration welding). Once the terminal assemblies 1430 are connected to the busbar 200, the elastically deformable electrically conductive assembly 350 is assembled, as shown in the Fig. 31-35. From here, the male housing assembly 1100 can be installed around the elastically deformable, electrically conductive assembly 350. Installation of the male housing assembly 1100 results in the formation of the Fig. 36-40. Although a number of steps are given here in a particular order, it should be understood that the order of these steps is not critical to the formation of the system 100. In other words, the given steps may be performed in any order, and some of the steps may be skipped or combined. C. Female connector assembly

[0101] With reference to the Fig. 55, Fig. 60, Fig. 63, Fig. 65 and Fig. 66, each battery module 60 includes two female connector assemblies 2000, where one female connector assembly 2000 is a negative female connector assembly 2000a and the other female connector assembly 2000 is a positive female connector assembly 2000b. The female connector assemblies 2000 consist of: (i) a female housing 2100 and (ii) a female terminal assembly 2430. The female housing 2100 is configured to: (i) receive the female terminal assembly 2430, (ii) facilitate the coupling of the male terminal assembly 2430 to the female terminal assembly 2430, (iii) minimize the likelihood of a foreign object inadvertently coming into contact with the female terminal assembly 2430, and (iv) meet industry performance and reliability standards, such as USCAR specifications.

[0102] The female housing 2100 includes a wall assembly 2110 having four sidewalls 2112a-2112d. The sidewalls 2112a-2112d extend upwardly from a top surface of a support structure and have a configuration substantially corresponding to the configuration of the female terminal assembly 2430. In the embodiment shown in the figures, the female terminal assembly 2430 has a cuboid configuration, and therefore, the sidewalls 2112a-2112d have a linear configuration and form a cuboid-shaped receptacle. However, it should be understood that changes in the shape of the female terminal assembly 2430 (e.g., use of a cylindrical terminal) may require the shape and configuration of the sidewalls 2112a-2112d to be changed to reflect the shape of the terminal (e.g., hollow cylinder).

[0103] The side walls 2112a-2112d have a height greater than the height of the female terminal assembly 2430. The difference between these heights allows the side walls 2112a-2112d to contain at least one male compression means 2140. As shown in the figures, the male compression means 2140 is an inclined or tapered surface 2144 extending from the outermost edges 2120a-2120d of the side walls 2112a-2112d to the uppermost edges 2430a-2430d of the female terminal assembly 2430. In the disclosed embodiment, the inclined or tapered surface 2144 extends from each of the outermost edges 2120a-2120d and has a substantially linear configuration. It should be understood, however, that the inclined or slanted surface 2144 may extend from only one or two of the outermost edges 2120a-2120d.The male compression means 2140 and the inclined or slanted surface 2144 shown in the figures are designed to compress the contact arms 1494a-1494h when the male terminal assembly 1430 moves from a state S separated from the female terminal assembly 2430. D to a position within an extension of the female terminal assembly 2430 in a fully mated state S FC moved (see Fig. 73). As such, the distance between opposite outermost edges 2120a-2120d is equal to a sidewall distance, wherein the sidewall distance is greater than the rearmost edge distance extending between opposite rearmost edges 2124a-2124d of the inclined or sloped surface 2144. And wherein the rearmost edge distance is greater than or equal to a receptacle distance extending between opposite inner surfaces 2434a-2434d of the receptacle 2472 of the female terminal assembly 2430. More specifically, the sidewall distance is between 0.1% and 15% greater than the receptacle distance, and wherein the receptacle distance is equal to or between 0.1% and 3% greater than the rearmost edge distance. In other words, the inclined or tapered surface 2144 is inclined relative to the outer surface of the side walls 2112a-2112d and / or the inner surfaces 2434a-2434d of the receptacle 2472 of the female terminal assembly 2430.In particular, the interior angle extending between the inner surface of the inclined or slanted surface 2144 and the outer surface of the side walls 2112a-2112d is between 0.1 degrees and 10 degrees.

[0104] This inclined or tapered surface 2144 is made of a polymer or plastic material and, as such, has a coefficient of friction lower than a coefficient of friction associated with a metal surface. In other words, a first friction value is established when the extension (e.g., a contact arm 1494a-1494h) of the screwless male terminal assembly 1430 engages a male terminal compression means 2140 made of a non-metallic material (e.g., plastic). In an alternative embodiment, a second friction value would be established when the extension (e.g., a contact arm 1494a-1494h) of the screwless male terminal assembly 1430 engages a male terminal compression means made of a metallic material (e.g., copper).Comparing the friction value from the disclosed embodiment with the friction value of the alternative embodiment, it is understood that the first or friction value from the disclosed embodiment is lower than the second or friction value of the alternative embodiment.

[0105] The lower coefficient of friction reduces the force required to insert the male terminal assembly 1430 into the female terminal assembly 2430. This is advantageous because: (i) industry specifications, including USCAR 25, require that the insertion force be no greater than 45 Newtons for a Class 2 connector and 75 Newtons for a Class 3 connector, and (ii) the use of a larger spring preload, thereby increasing the insertion force, is desirable to ensure that the contact arms of the male terminal assembly remain in contact with the inner surfaces 2434a-2434d of the receptacle 2472 of the female terminal assembly 2430. Furthermore, this lower coefficient of friction is advantageous because the system 100 can be removed from the disconnected state S D into a fully connected state S FCwhile meeting USCAR Class 2 / Class 3 specifications without the need for lever assistance. Eliminating the lever assistance reduces the size, weight, and cost of manufacturing the connector system 100. It should be understood that to further reduce the coefficient of friction, the inclined or tapered surface 2144 may be coated with a substance that reduces this coefficient, or the inclined or tapered surface 2144 may be made of a material that has an even lower coefficient of friction.

[0106] Due to the configuration of the male and female connector assemblies 1000, 2000, different force levels are required during different stages of movement of the connector system 100 from the separated state S D into the fully connected state S FCrequired. For example, a first force is required to move the male terminal assembly 1430 when an extension (e.g., a contact arm 1494a-1494h) of the male terminal assembly 1430 is in sliding engagement with the male terminal compression means 2140, and a second force is required to move the male terminal assembly 1430 when the extension (e.g., a contact arm 1494a-1494h) of the male terminal assembly 1430 is positioned in the female terminal receptacle 2473. Comparing the forces, it will be appreciated that the second force is less than the first. This is advantageous because it provides the user with tactile feedback that the male terminal assembly 1430 has been properly inserted into the female terminal assembly 2430.In fact, this tactile feedback feels to the user as if the screwless male connector assembly 1430 is being pulled into the female connector assembly 2430.

[0107] To minimize the likelihood of a foreign object inadvertently coming into contact with the female connector assembly 2430, the housing 2100 may include an optional touch-proof pin 2200. As disclosed in PCT / US2019 / 036070, the touch-proof pin 2200 is configured to fit within a touch-proof pin opening 1510 formed in the front wall of the male connector 1470. In particular, the distance between the outermost edges 2120a-2120d of the side walls 2112a-2112d and an outermost edge 2215 of the touch-proof pin 2200 is less than 10 mm and preferably less than 6 mm. The shape of the touch-proof pin opening 1510 is designed to substantially mirror the shape of the touch-proof pin 2200.In this case, the touch-proof probe opening 1510 has a substantially rectangular, and more particularly, a substantially square, shape, while the touch-proof pin 2200 has the shape of an elongated, rectangular prism with two recesses on opposite sides of the prism. The mirroring of these shapes helps ensure that the touch-proof pin 2200 can be properly inserted into the touch-proof probe opening 1510 and can result in a reduction in vibration between the male terminal assembly 1430 and the female terminal assembly 2430. This reduction in vibration between these components can help reduce failures of the connector system. It should be understood that the touch-proof pin 2200 and the associated opening 1510 can be omitted or have a different configuration (e.g., as described in U.S. Provisional Application No.63 / 222,859, which is incorporated herein by reference).

[0108] To minimize the possibility that the male connector assembly 1000 may become separated from the female connector assembly 2000, the female connector assembly 2000 may include an optional non-deformable female CPA structure 2300 designed and configured to cooperate with the male CPA structures 1170 when the connector assemblies 1000, 2000 are coupled together. The non-deformable female CPA structure 2300 is integrally formed with a sidewall 2112a-2112d of the housing 2100. Additional details regarding the construction and / or function of the female CPA structure 2300 are disclosed in PCTUS2019 / 036070, PCTUS2020 / 049870, PCTUS2021 / 033446, all of which are incorporated herein by reference.

[0109] The female terminal assembly 2430 of the female connector assembly 2000 consists of a female terminal body 2432 having a plurality of sidewalls 2434a-2434d formed integrally with a rear wall 2434e. Each of the sidewalls 2434a-2434d and the rear wall 2434e have inner surfaces 2436a-2436e, the combination of which forms a cuboid-shaped terminal receptacle 2472. The cuboid-shaped terminal receptacle 2472 has a receptacle pitch extending between the inner surfaces 2436a-2436d of the opposing sidewalls 2434a-2434d. As described above, the receptacle pitch is: (i) less than the sidewall pitch; and (ii) equal to or greater than the rearmost edge pitch. In addition, the pickup pitch is between 0.1% and 15% smaller than the male terminal assembly pitch extending between the outermost ends of the opposing contact arms 1494a-1494h.By forming a terminal receptacle 2472 with a receptacle pitch that is less than the pitch of the male terminal assembly, it is ensured that the contact arms 1494a-1494h are compressed when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. This compression of the male terminal assembly 1430 compresses the inner spring element 1440c. As such, the spring element 1440c exerts an outward biasing force on the contact arms 1494a-1494h, which helps ensure that they remain in contact with the inner surfaces 2436a-2436d of the terminal receptacle 2472 to facilitate the electrical and mechanical coupling of the male terminal assembly 1430 to the female terminal assembly 2430.

[0110] The female terminal assembly 2430 is typically made of metal, and preferably of a highly conductive metal, such as copper. The female terminal assembly 2430 may be coated or plated with Ni-Ag to prevent the busbar 200 from corroding during and / or after welding the female terminal assembly 2430 to the busbar 200. As shown in the figures, the sidewalls 2434a-2434d are not integrally formed with each other and are instead integrally formed only with the backwall 2434e. In other embodiments, the female terminal assembly 2430 may have integrally formed sidewalls 2434a-2434d, the sidewalls 2434a-2434d may be made of a different material, and / or the female terminal assembly 2430 may not be coated or plated with Ni-Ag.Once the 2430 female terminal assembly is manufactured, it can be connected to the busbar and installed into the 2100 female housing. D. Connection properties and functionality

[0111] Fig. 73 shows a cross-section of the male connector assembly 1000 in the fully mated state S FC coupled to the female connector assembly 2000. While the disclosure below is discussed in connection with one embodiment of the system 100, it should be understood that this disclosure applies equally to other systems, including the other systems described in the Fig. 100-104 shown embodiments. As in Fig. 73, one or more outer surfaces of the spring arms 1452a-1452d contact the free ends 1488 of the respective contact arms 1494a-1494d. As previously mentioned, the outermost extent of the contact arms 1494a-1494d is slightly greater than the inner extent of the female terminal body 2432. When these components are connected together, the spring element 1440c is compressed. This compression of the spring element 1440c creates an outward biasing force S BF against the contact arms 1494a-1494d and away from the interior of the spring element 1440c.

[0112] The male terminal body 1472, including the contact arms 1494a-1494d, may be constructed from a first material such as copper, a highly conductive copper alloy (e.g., C151 or C110), aluminum, and / or another suitable electrically conductive material. The first material preferably has an electrical conductivity greater than 80% of the IACS (International Annealed Copper Standard, i.e., the empirically derived standard value for the electrical conductivity of commercially available copper). For example, C151 typically has 95% of the conductivity of standard, pure copper, which meets the IACS. Likewise, C110 has a conductivity of 101% of the IACS value. In certain operating environments or engineering applications, it may be advantageous to select C151 because of its corrosion-inhibiting properties, which are desirable for high-stress and / or harsh weather applications.The first material for the 1472 male connector body is C151 and, according to ASTM B747, has a Young's modulus of approximately 115-125 gigapascals (GPa) at room temperature and a coefficient of thermal expansion (CTE) of 17.6 ppm / degree Celsius (from 20-300 degrees Celsius) and 17.0 ppm / degree Celsius (from 20-200 degrees Celsius).

[0113] The spring element 1440c may be formed from a second material such as spring steel, stainless steel (e.g., 301SS, 1 / 4 hard), and / or another suitable material with greater stiffness (e.g., as measured by Young's modulus) and toughness than the first material of the male connector body 1472. The second material preferably has an electrical conductivity that is lower than the electrical conductivity of the first material. The second material also has a Young's modulus that may be approximately 193 GPa at room temperature and a coefficient of thermal expansion (CTE) of 17.8 ppm / degree Celsius (from 0-315 degrees Celsius) and 16.9 ppm / degree Celsius (from 0-100 degrees Celsius). For the contemplated high-voltage applications, the cross-sectional area of ​​the copper alloy constituting the first connector is matched to the conductivity of the selected copper alloy.For example, if a copper alloy with lower conductivity is selected, the resulting contact arms 1494a-1494d will have a larger cross-sectional area to conduct sufficient current. Similarly, selecting a first material with a higher conductivity may enable contact arms 1494a-1494d with a relatively smaller cross-sectional area while still meeting the conductivity specifications.

[0114] In one embodiment, the CTE of the second material may be greater than the CTE of the first material, i.e., the CTE of the spring element 1440c is greater than the CTE of the male terminal body 1472. Therefore, when the assembly of male terminal body 1472 and spring element 1440c is exposed to the high voltage and high temperature environment typical of use of the electrical connector described in the present disclosure, the spring element 1440c expands relatively more than the male terminal body 1472. Accordingly, the outward force S BF , which is generated by the spring element 1440c on the contact arms 1494a-1494d of the male terminal body 1472, increases according to the increased temperature, which is referred to below as the thermal spring force S TF is called.

[0115] An exemplary application of the present disclosure, e.g., for use in a vehicle alternator, is suitable for use in a "Class 5 Automotive Environment," such as those found in passenger and commercial vehicles. "Class 5 Environments" are commonly found under the hood of a vehicle, e.g., an alternator, and have ambient temperatures of 150° Celsius, routinely reaching 200° Celsius. When copper and / or highly conductive copper alloys are exposed to temperatures greater than approximately 150° Celsius, these alloys become malleable and lose mechanical elasticity, i.e., the copper material softens. However, the steel from which the 1440c spring element is made retains its hardness and mechanical properties when exposed to similar conditions.Thus, when both the male terminal body 1472 and the spring element 1440c are exposed to high temperatures, the first material of the male terminal body 1472 softens, and the structural integrity of the spring element 1440c, which is made of the second material, is maintained, so that the force exerted by the spring element 1440c on the softened contact arms 1494a-1494d maintains the softened contact arms 1494a-1494d in the fully mated position S. FC more effectively displaced outward relative to the interior of the male connector body 1472.

[0116] The male connector body 1472, the spring element 1440c, and the female connector body 2432 are configured to maintain conductive and mechanical engagement while withstanding elevated temperatures and thermal cycling resulting from the high-power and high-voltage applications to which the system 100 is subjected. Furthermore, the male connector body 1472 and the female connector body 2432 may experience thermal expansion as a result of the elevated temperatures and thermal cycling resulting from the high-voltage and high-temperature applications, thereby increasing the outward force exerted by the male connector body 1472 on the female connector body 2432.The configuration of the male terminal body 1472, the spring element 1440c, and the female terminal body 2432 increases the outward connection force between them while the connector system 100 withstands the thermal expansion resulting from thermal cycling in the mated position P. C results.

[0117] Based on the above exemplary embodiment, the Young's modulus and CTE of the spring element 1440c are greater than the Young's modulus and CTE of the male terminal body 1472. Therefore, when the male terminal body 1472 is used in a high-performance application 10 that subjects the connector system 100 to repeated thermal cycles at elevated temperatures (e.g., about 150°C), then: (i) the male terminal body 1472 becomes malleable and loses some mechanical elasticity, i.e., the copper material in the male terminal body 1472 becomes softer, and (ii) the spring element 1440c does not become as malleable or lose as much mechanical stiffness compared to the male terminal body 1472.

[0118] Thus, when using a spring element 1440c that is mechanically cold-pressed into shape (e.g., using a swaging process) and the spring element 1440c is exposed to elevated temperatures, the spring element 1440c will attempt to return to at least its uncompressed state prior to insertion of the male terminal assembly 1430 into the female terminal assembly 2430, and preferably to its original flat state prior to formation of the spring element 1440c. In doing so, the spring element 1440c exerts a generally outward thermal spring force, S TF , (as indicated by the "S TF “ labeled arrows in Fig. 73) onto the free ends 1488 of the contact arms 1494a-1494d. This thermal spring force, S TF, depends on the local temperature conditions, including high and / or low temperatures, in the environment in which the System 100 is installed. Accordingly, the combination of the spring preload force S BF and the thermal spring force S TF for a resulting preload force S RBF , which ensures that the outer surface of the contact arms 1494a-1494d is forced into contact with the inner surface of the female terminal body 2432 when the male terminal assembly 2430 is inserted into the female terminal 2430 and during operation of the system 100 to ensure an electrical and mechanical connection. In addition, upon repeated thermal cycling, the male terminal assembly 1430 develops an increase in the outward resultant spring forces, S RBF exerted on the female connector assembly 2430 during repeated operation of the system 100.

[0119] As in Fig. 73, the male connector assembly 1430 in the fully connected state provides S FC a 360° compliance with the female terminal assembly 2430 to ensure that a sufficient amount of outward force F Bfrom the male terminal assembly 1430 to the female terminal assembly 2430 to establish an electrical and mechanical connection in all four cardinal directions. This feature eliminates the need for keying and / or any other feature designed to ensure the desired alignment of the components during mating. The 360° compliance feature of the system 100 also helps maintain the mechanical and electrical connection under stressful mechanical conditions, such as vibration. In a conventional leaf- or fork-shaped connector with 180° compliance, i.e., a connection on only two opposite sides, vibrations can develop a harmonic resonance that causes the 180° compliant connector to oscillate at greater amplitudes at certain frequencies.For example, subjecting a bifurcated connector to harmonic resonance may cause the bifurcated connector to open. Opening the bifurcated connector during electrical conduction is undesirable because momentary mechanical separation of the bifurcated connector from a mating terminal may result in an electrical arc. Arcing can have significant adverse effects on the 180° compliant terminal, as well as on the overall electrical system of which the 180° compliant terminal is a component. However, the 360° compliance feature of the present disclosure may prevent the potentially catastrophic failures caused by severe vibration and electrical arcing.

[0120] As described above, it is desirable to fabricate the male terminal 1470 from the same material as the female terminal body 2432 to: (i) prevent corrosion and other deterioration, (ii) reduce the resistance between these structures, and (iii) facilitate the electrical and mechanical coupling of these structures. In this exemplary embodiment, the male and female terminal bodies 1472, 2432 are fabricated from copper. However, to utilize matching materials for the terminal bodies 1470, 2432 and avoid the use of a positive bimetallic busbar, it is understood that the positive bimetallic busbar may be replaced with an aluminum busbar, and the male terminal 1470 may also be fabricated from aluminum.In this embodiment, the male terminal 1470 associated with the negative external connection may be made of copper, the outer bus bar may be made of copper, the positive bus bar may be made of aluminum, and the male terminal 1470 associated with the positive external connection may be made of aluminum. In further embodiments, the battery cells 75 may have different terminal configurations, wherein the materials of the transport structure 82 may use only bus bars of a single material, and the male terminal bodies 1470 may be made of the same material. E. Busbar housing

[0121] After the busbar 200 has been manufactured and the terminals 1000 are coupled to the busbar 200, the busbar housing 600 can be coupled thereto to enclose a substantial extent of the busbar 200 and complete the construction of the system 100. The busbar housing 600 is used at least in conjunction with the Fig. 41-47 and includes a first component 602a and a second component 602b, which are releasably connected to each other via couplings 597 (formed from projections 598 and receptacles 599). When the first and second components 402a, 402b are connected to each other, they form a receptacle 604 designed to receive the busbar 200. The receptacle 604 has five different extensions, wherein the first extension 606 is configured to receive a portion of the connector assembly 1000, the second extension 608 is configured to receive a portion of the first connector edge region 402a, the third extension 610 is configured to receive the elastically deformable intermediate region 410, the fourth extension 612 is configured to receive a portion of the second circumferential connection region 402b, and the fifth extension 614 is configured to receive a portion of the connector assembly 1000.The first extension 606 and the fifth extension 614 are configured such that the male terminal 1430 and its housing 1100 can move laterally (e.g., sliding movement) between the compressed state S. C and the extended state S E can move without exposing the busbar 200 or compressing the housing 600. Thus, the first extension 606 and the fifth extension 614 of the receptacle 604 have a depth of approximately 11 mm.

[0122] The second extension 608 and the fourth extension 612 of the receptacle 604 correspond to the configuration of the first and second connector edge regions 402a, 402b of the busbar 200 and have a height of approximately 2-7 mm. As such, the height and length of the third extension 610 of the receptacle 604 are greater than the height and length of the elastically deformable intermediate region 410 and are therefore designed to allow the elastic deformation of the intermediate region 410 without impeding or hindering the movement of the busbar 200. In other words, the third extension 610 of the receptacle 604 has a volume large enough to allow the deformation of the elastically deformable intermediate region 410 within that volume without restricting or impeding that deformation.

[0123] The housing 600 is preferably made of a non-conductive plastic and is designed to insulate and protect the elastically deformable electrically conductive assembly 350 from other foreign objects. The configuration and material selection of the housing 600 are designed to insulate the busbar 200 while still allowing the busbar 200 to elastically deform in all directions (e.g., X, Y, Z, and rotation). In other words, the housing 600 can bend or move as needed without damaging, breaking, or reducing the performance of the busbar 200. The components 602a, 602b are symmetrical and dimensionally matched to reduce the number of parts and simplify assembly during manufacture of the system 100. However, in other embodiments, the components 602a, 602b may not be identical to one another.It should be understood that this disclosure also contemplates other configurations of the enclosure 600. For example, in certain applications, such as an installation with a controlled operating environment, the enclosure 600 may be omitted. II. First embodiment of a battery pack

[0124] The Fig. 53-71 show a first embodiment of a battery pack 90 including a plurality of battery modules 60 and a plurality of elastically deformable battery module connector systems 100. Specifically, the battery pack 90 includes ten battery modules 60 (62a-62j) electrically coupled to one another via nine elastically deformable battery module connector systems 100 (with certain of the elastically deformable battery module connector systems designated 102a-102i). A. Battery module

[0125] As in the Fig. 58-67, each of the ten battery modules 60 (62a-62j) generally includes: (i) a battery module housing 64, (ii) the battery cells 75, and (iii) the electrical transfer assembly 82. i. Battery module housing

[0126] The battery module housing 64 includes a plurality of walls 66 (e.g., an array of four side walls 68a-68d, a bottom wall 70a, and a top wall 70b) forming a receptacle 72 configured to receive and protect: (i) the battery cells 75 and (ii) the electrical transmission assembly 82. The top wall 70b includes at least two battery module openings 73a, 73b formed therethrough, the openings 73a, 73b being configured to allow the female connector assembly 2000a, 2000b to be coupled to an extension of the electrical transmission assembly 82. In particular, the configuration is such that the current flows through the battery module openings 73a, 73b via the connection between the female connector assembly 2000a, 2000b and the electrical transmission assembly 82.While the female connector assemblies 2000a, 2000b are shown in connection with this first embodiment of the battery modules 60, the use of other connectors (e.g., threaded, clamped, pressurized) is contemplated within the scope of this disclosure. For example, a threaded connector is disclosed in connection with the second embodiment of the battery modules 60. ii. Battery cells

[0127] The Fig. 58-67 show that the battery modules 60 include a plurality of cylindrical battery cells 75, each battery cell 75 having (i) a housing 77, (ii) a positive terminal 80a, and (iii) a negative terminal 80b. The housing 77 has a longitudinal surface 78 and is designed to enclose and retain the electrical charge storing materials, such as lithium or other similar metals. The positive and negative terminals 80a, 80b connect the materials contained in the housing 77 to the electrical transfer assembly 82. The terminals 80a, 80b may have a button-shaped configuration; however, other terminal shapes are also possible (e.g., screwless terminals, bolted terminals, tabs, other structures that may be welded, press-fitted, or clamped by the electrical transfer assembly 82).The positive and negative terminals 80a, 80b are typically made of different materials to facilitate charging and discharging of the battery cell 75. For example, the positive terminal or anode 80a may be formed from (i) graphite, (ii) silicon, or (iii) graphene, while the negative terminal or cathode 80b may be formed from (i) cobalt, (ii) iron, (iii) nickel-magnesium, (iv) nickel, or (v) sulfur. It is understood that other materials may also be used for the terminals. The battery cells 75 may have an output voltage between 0.2 volts and 10 volts, an ampere-hour rating between 10 Ah and 100 Ah, and an energy density between 20 Wh / kg and 500 Wh / kg (see Qiao, Y., et. al. A 500 Wh / kg Lithium-Metal Cell Based on Anionic Redox. Joule, this issue, 1445-1458, and Jason B. Quinn et al., Paper Review: Energy Density of Cylindrical Li-Ion Cells: A Comparison of Commercial 18650 to the 21700 Cells 2018 J. Electrochem. Soc. 165 A3284, both of which are incorporated herein by reference). Examples of cylindrical battery cells 75 are: (i) 18650 (i.e., 18 mm diameter and 65 mm length), 21700 (i.e., 21 mm diameter and 70 mm length), 4680 (i.e., 46 mm diameter and 80 mm length). It is understood that the battery cells 75 may utilize a variety of technologies and / or materials, including: (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) Li-polymer, (v) Li-ion, or (vi) batteries utilizing other materials (e.g., LiO2, AlO2, LiS, LTO, LFP, NMC, NCA).Furthermore, the battery cells may have any known configuration, including cylindrical, prismatic, pouch cells, or other shapes disclosed in U.S. Patent Nos. 10948000, 10429006, 10220881, 10473177, 10538271, 10300947, 9789906, 9889887, 9944323, each of which is incorporated herein by reference. iii. Electrical transmission assembly

[0128] The Fig. 58-67 show the electrical transfer assembly 82 positioned within each of the battery modules 60 and (i) connecting a first tier 83a of battery cells 75 to a second tier 83b of battery cells 75, (ii) interconnecting the battery cells 75 contained within the first and second tiers 83a, 83b, and (iii) interconnecting the female connector assemblies 2000a, 2000b to the battery cells 75. As illustrated in this embodiment, each of the first and second tiers 83a, 83b includes approximately 132 battery cells 75 arranged in a vertical orientation relative to the XY plane. Due to this vertical orientation, (i) the positive and negative terminals 80a, 80b are in a plane substantially parallel to the XY plane, and (ii) a portion of the longitudinal surface 78 of the cells 75 is substantially parallel to the XZ plane or YZ plane.Thus, conductive plates 84 can be arranged in the XY plane and coupled to the positive and negative terminals 80a, 80b of the cells 75. In particular, recesses are cut into the coupling of the plates 84 to facilitate laser welding of the button-shaped terminals 80a, 80b to the plates 84. While this embodiment discloses the above-described configuration of the battery cells 75 and the associated components of the electrical transfer assembly 82, it should be understood that the electrical transfer assembly 82 may have a different configuration in other embodiments. For example, the electrical transfer assembly 82 may be configured to couple any number of battery cells 75 (e.g., between 2 and 1000) and any number of battery cell layers 83a, 83b (e.g., between 1 and 40 layers).

[0129] Additionally, at least one female connector assembly 2000 is connected to the plates 84. Preferably, the plates 84 of the electrical transmission assembly 82 are coupled to two female connector assemblies 2000a, 2000b, wherein: (i) a positive female connector assembly 2000b is (a) configured to provide a positive external connection for the battery module 60, and (b) is adapted to receive a portion of a positive male terminal assembly 1430, and (ii) a negative female connector assembly 2000a is (a) configured to provide a negative external connection for the battery module 60, and (b) is adapted to receive a portion of a negative male terminal assembly 1430.While the battery module 60 illustrated in the figures includes two female connector assemblies 2000a, 2000b, it should be understood that the battery module 60 may include more or fewer female connector assemblies 2000. For example, the battery module 60 may include only a single female connector assembly 2000, or the battery module 60 may include more than ten female connector assemblies 2000. B. Battery pack

[0130] The Fig. 53 and Fig. 54 show a first embodiment of a battery pack 90 having a rectangular prism shape and comprising: (i) a bottom wall 91, (ii) a first or left end wall 92a, (iii) a second or right end wall 92b, (iv) a first or upper side wall 94a, (v) a second or lower side wall 94b, and (vi) a central divider 96 connected to the first and second end walls 92a, 92b and disposed between the first and second side walls 94a, 94b. The combinations of walls 92a, 92b, 94a, 94b, 96 are arranged to form a first or upper receptacle 97a and a second or lower receptacle 97b, the upper and lower receptacles 97a, 97b being adapted to receive a portion of the battery modules 60 contained in the battery pack 90.At least one wall 92a, 92b, 94a, 94b includes a pack connector opening formed therethrough, the opening(s) being configured to receive an extension of a connector that facilitates charging and discharging of the battery pack 90. ​​An example of such a connector that may be used is disclosed in PCT / US2021 / 043,686, which disclosure contemplates the use of any known connector capable of transferring electrical current into and out of the pack. While the above disclosure focuses on the opening intended to receive the connector that facilitates charging and discharging of the battery pack 90, it should be understood that other openings may be formed in the pack 90 to enable the transfer of fluid into and out of the pack 90 or to establish other mechanical or electrical connections within the pack 90.

[0131] The upper receptacle 97a of the battery pack 90 is designed to accommodate five battery modules 60 (62a-62e), while the lower receptacle 97b of the battery pack 90 is also designed to accommodate five battery modules 60 (62f-62j). In particular, the first battery module 62a is positioned in the upper receptacle 97a and is located between: (i) the first end wall 92a, (ii) the first side wall 94a, and (iii) the central partition 96. In other words, the first battery module 62a is bounded on three sides by the walls and partition 92a, 94a, and 96. Like the first battery module 62a, the fifth battery module 62e is also bounded on three sides by: (i) the second end wall 92b, (ii) the first side wall 94a, and (iii) the central partition 96.The sixth battery module 62f is also bounded on three sides by: (i) the second end wall 92b, (ii) the second side wall 94b and (iii) the central partition 96, while the tenth battery module 62j is bounded on three sides by: (i) the first end wall 92a, (ii) the second side wall 94a and (iii) the central partition 96. In contrast to the first, fifth, sixth and tenth battery modules 62a, 62e, 62f, 62j, the second, third and fourth battery modules 62b, 62c, 62d are arranged in the first receptacle 97a and are bounded only by two sides: (i) by the first side wall 94a and (ii) by the central partition 96. Like the second, third and fourth battery modules 62b, 62c and 62d, the seventh, eighth and ninth Battery modules 62g, 62h and 62i are arranged in the second receptacle 97b and are bounded only by two sides: (i) the second side wall 94b and (ii) the central partition wall 96.

[0132] While the Fig. 53 and Fig. 54 illustrate a battery pack 90 having a rectangular prism configuration and configured to receive ten battery modules 60, it should be understood that the present disclosure is not limited to this construction. Rather, the battery pack 90 may have any known configuration (e.g., any type of polygonal prism), including a configuration in which the pack 90 is constructed as part of the frame or chassis of the vehicle. It should also be understood that in other embodiments, the battery pack 90 may be configured to receive only a single battery module 60 or over one hundred individual battery modules 60. The battery cells 75 included in the modules 60 may be connected in parallel, in series, or in any combination.Furthermore, the battery modules 60 contained in the battery pack 90 may be connected in parallel, in series, or in any combination. C. Connection of the battery modules within the battery pack

[0133] Once the battery modules 60 (62a-62j) are positioned and secured in the receptacles 97a, 97b of the battery pack 90, the battery modules 60 (62a-62j) can be interconnected using the disclosed elastically deformable battery module connector systems 100. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 100 (with certain of the elastically deformable battery module connector systems designated 102a-102i). Each of the elastically deformable battery module connector systems 100 is connected to the battery modules 90 with a downward force (i.e., in the -Z direction).The disclosed configuration places the lower surface 215b of the edge regions 402a, 402b substantially parallel to each of the following: (i) the XY plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top and bottom walls 70a, 70b of the battery module housing 64, (iv) the top surface of the conductive plates 84 of the transfer assembly 82, and (v) an extension of the positive and negative terminals 80a, 80b of the battery cells 75. Furthermore, the configuration places the lower surface 215b of the edge regions 402a, 402b substantially perpendicular to each of the following: (i) XZ plane, (ii) YZ plane, (iii) the side and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 68a-68d of the battery module housing 64, (iv) the longitudinal surface 78 of the battery cells 75.Furthermore, the configuration causes the intermediate region 410 to extend downward from the circumferential plane in the -Z direction and to be disposed between a fourth sidewall 68d of one battery module 60 (e.g., 62a) and a sidewall 68a of an adjacent battery module 60 (e.g., 62b). Furthermore, the length L extends. IPB of the busbar 200 in a direction substantially parallel to the X-axis, while the width of the busbar 200 extends in a direction substantially parallel to the Y-axis.

[0134] This first embodiment of the elastically deformable battery module connector systems 100 installed in the battery pack 90 utilizes connector assemblies 1000, 2000. These connector assemblies 1000, 2000 enable the following connections between the battery modules 60: (i) screwless, (ii) PCT compliant, (iii) 360° compliant, (vi) fast and efficient compared to conventional battery pack connectors, (vii) straightforward, requiring no special tools or machinery, (viii) conforming to USCAR and other industry specifications, (ix) lighter than conventional battery pack connectors, and (x) other advantages apparent to one skilled in the art. Once the battery modules 60 and any other required components (e.g., battery management assembly, battery cooling or heating assemblies, etc.) are installed in the battery pack 90, the pack 90 can be installed in an application 10. D. Dynamic movement of the battery modules

[0135] As in the Fig. 53-54, the battery pack 90 includes a plurality of modules 60, each of which will experience some degree of dynamic movement during use of the battery pack 90, including operation of a power distribution system in which the battery pack 90 is installed. Therefore, the forces acting on the connector systems 100 included in the battery pack 90 are largely dependent on and influenced by the behavior of (i) other interconnected battery modules 90, including the configuration of the battery cells 75 contained therein, (ii) the configuration of the battery pack 90, and (iii) the operating conditions of the battery pack 90, including the vehicle in which the battery pack 90 is installed.For example, the first set of five battery modules 62a-62e contained within the first receptacle 97a at least substantially or completely balances the forces generated by the expansion or contraction of the battery module connector systems 102a-102d and exerted on these modules 62a-62d. Similarly, the second set of five battery modules 62f-62i contained within the second receptacle 97b at least substantially or completely balances the forces generated by the expansion or contraction of the battery module connector systems 102f-102i and exerted on these modules 62a-62d. However, the forces acting between the first and tenth battery modules 62a, 62j are influenced and likely limited by the walls and partition 92a, 92b, 96 due to the configuration of the battery pack 90, including the arrangement of the modules 62a-62j and the connector systems 102a-i.

[0136] While the battery pack 90 attempts to at least largely or completely balance the forces acting on the modules 62a-62d by expanding or contracting the connector systems 102a-102d, the configuration of the pack 90 may limit the balancing of these forces. For example, different forces may act on the first connector system 102a compared to the second connector system 102b due to (i) the coupling of the first battery module 62 to the end wall 92a and (ii) the configuration of the walls and the partition wall 92a, 94a, 96 of the pack 90. ​​In particular, and as shown in Fig. 54, the expansion or contraction of the first battery module 62a may be limited by the battery pack 90 in the: (i) first direction or along the negative (-) X-axis by the end wall 92a, (ii) second direction or along the positive (+) Y-axis by the top wall 94a, and (iii) fourth direction or along the negative (-) Y-axis by the central partition 96. Thus, the battery pack 90 may allow expansion or contraction of the first battery module 62a only in the third direction or along the positive (+) X-axis. In contrast, the expansion or contraction of the second battery module 62b may be limited in the: (i) second direction or along the positive (+) Y-axis by the top wall 94a, and (ii) fourth direction or along the negative (-) Y-axis by the central partition 96.However, the expansion or contraction of the second battery module 62b may not be limited in either direction: (i) first direction or along the negative (-) X-axis by the end wall 92a, or (ii) third direction or along the positive (+) X-axis.

[0137] The schematic views of the battery cells 75 in Fig. 64 illustrate how the movement of lithium ions from the cathode to the anode changes the size of the battery cells 75, namely: (i) charging causes the cylindrical battery cell 75 to expand circumferentially or radially outwards to the charging diameter D max , and (ii) discharging causes the cylindrical battery cell 75 to contract circumferentially or radially inwardly to the discharge diameter D minIt has been demonstrated that the movement of lithium ions from the cathode to the anode within a cylindrical battery cell 75 with a diameter of 18.15 mm can cause: (i) an increase in the average diameter of the battery cell 75 by 2 µm (0.01%) and (ii) an increase in the diameter of specific locations within the diameter of the battery cell 75 by up to 37 µm (0.2%). Thus, the diameter of the battery cell 75 can be reduced to D max increase when the battery is 100% charged or fully charged, to Dnormal when the battery is 50% charged or half charged and switch to D min remove when the battery is 0% charged or not charged or completely discharged, where D max > Dnormaı > D min . In other words, charging the battery cells 75 contained in the battery module 60 from a 50% charge level to a 100% charge level increases the diameter of the cells 75 in the module 60 fromDnormal on D max , and discharging the battery cells 75 contained in the battery module 60 from a 50% charge level to a 0% charge level reduces the diameter of the cells 75 in the module 60 from Dnormal on D min . In addition, Fig. 65, as the diameter of the cells 75 increases irreversibly (from Dnormal about D 90 to D 80 ) when the battery's state of health (“SoH”) decreases due to the thickness growth of the solid electrolyte interlayer, defects in the graphite, and pressure increase due to side reactions during the lifetime of a cylindrical Li-ion cell. It is understood that the Fig. 64-65 are not to scale and are for schematic purposes only.

[0138] In view of the above disclosure, a major factor contributing to the dynamic movement of the battery modules 60 within the pack 90 is the state of charge of the battery modules 60. In the Fig. 53-61, the cylindrical cells 75 are arranged in a vertical orientation relative to the XY plane, with an extension of the longitudinal surface 78 of the cells 75 being substantially parallel to the XZ or YZ planes. Accordingly, the expansion and contraction of the battery cell 75 in the circumferential direction, from Dnormal to D max or Dnormal to D min, primarily an expansion and contraction of the battery modules 60 in the XY plane. Axial expansion and contraction in the XZ or YZ plane occurs only minimally, if at all, since the movement of the lithium ions is primarily lateral, i.e., radially outward or inward, and has no appreciable vertical or axial component of movement. Since the expansion and contraction of the battery modules 60 occurs primarily in the XY plane, the designer of the battery pack 90 proceeds as follows: (i) he positions the lower surface 215b of the edge regions 402a, 402b substantially parallel to the XY plane and (ii) arranges the intermediate region 410 of the bus bar 200 so that it extends downward from the edge region plane in the negative (-) Z direction.As discussed in detail below, this disclosed configuration allows the intermediate region 410 of the bus bar 200 to continuously deform elastically to absorb the expansion and contraction of the battery modules 60 in the XY plane. i. System in neutral state

[0139] Although it is clear from the above disclosure that the individual elastically deformable battery module connector systems 100 included in the battery pack 90 may be subject to different expansion and / or contraction forces, the general concepts disclosed in the following disclosure with respect to the first battery module connector system 102a, the first battery module 62a, and the second battery module 62b apply to all systems 100 included in the battery pack 90. ​​The Fig. 55-63 and 69 show the elastically deformable battery module connector system 100 in a neutral state S N, in which neither tension nor pressure is exerted on the system 100. In the neutral state S N : (i) the battery cells 75 are at a battery state of health of 100% (“SoH”), (ii) the battery cells 75 are charged to 50%, (iii) the rear wall of each of the male terminal housings 1100 is provided with a housing gap L HG (e.g., about 2-4 mm) from an inner wall of the busbar housing 600, (iv) the formed length L BN the busbar 200 is approximately 110-120 mm, preferably 115-117 mm and most preferably 116 mm (i.e., the length L IPN of the intermediate zone is between 23 mm and 31 mm and preferably 27 mm), (v) the height H BN of the busbar 200, which is defined between the lowest conductor 203a and the outer surface of the outermost conductor in the middle of the intermediate region 410, is 15-30 mm, preferably 20-25 mm (ie, the height H IPNof the intermediate region is greater than 5 mm, preferably greater than 12 mm, more preferably between 20 mm and 28 mm and most preferably 23 mm), and the width W BN the busbar 200 is 15-25 mm, preferably 20 mm, (vi) the length L SN of the system 100 is approximately 150-200 mm, preferably 160-190 mm and most preferably 182 mm, the height of the system 100 is 35-40 mm, preferably 37 mm, and the width of the system 100 is 25-35 mm, preferably 31 mm, (vii) the distance D N between the battery modules 62a, 62b is at a neutral length (e.g., 100-120 mm, preferably 110 mm), (viii) the length of the neck L NN , which is defined between the outer recesses 264a, 264b of the busbar 200, is 25-30 mm, preferably 22 mm, in the neutral state, (ix) the length of the gap L GN, which is defined between opposite inner surfaces of the outer recesses 264a, 264b of the busbar 200, is 14 to 22 mm, preferably 22 mm, in the neutral state, (x) the ratio between the height H BN the busbar 200 and the formed length L BNof the busbar 200 is 20-25%, preferably 21.5%, (xi) the lower surface 215b of the edge regions 402a, 402b are substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xii) the lower surface 215b of the edge regions 402a, 402b are substantially parallel to both the upper surface of the conductive plates 84 of the transfer assembly 82 and an extension of the positive and negative terminals 80a, 80b of the battery cells 75, (xiii) the lower surface 215b of the edge regions 402a, 402b is substantially perpendicular to the longitudinal surface 78 of the battery cells 75, and (ivx) the intermediate region 410 is between a fourth side wall 68d of a battery module 62a and a first side wall 68a of an adjacent battery module 62b. ii. System in the contracted state

[0140] The Fig. 66 and Fig. 68 show the elastically deformable battery module connector system 100 in a compressed state S C , in which the busbar 200 is subjected to a maximum compression force C max In this embodiment, the maximum compression force C max between 38 and 46 N, preferably 42 N. This maximum compression force C max is exerted on the system 100 in the third direction (along the positive (+) X-axis) via the battery module 62a and in the first direction (along the negative (-) X-axis) via the extension of the battery modules 62a, 62b due to the increased state of charge of the battery cells 75. In particular, charging the battery cells 75 from a 50% state of charge to a 100% charge causes: (i) an increase in the diameter of the cells 75 from Dnormal on D max , (ii) an increase in the size of the battery modules 62a, 62b, (iii) a reduction in the distance D Nbetween the battery modules 62a, 62b from the neutral length (e.g., 110 mm) to a compressed length (e.g., 106 mm), and (iv) that each of the rear walls of the male connector housings 1100 slides towards the inner wall of the busbar housings 600. It should be clear that the movement from the neutral state S N to the compressed state S c is continuous. When the battery modules are 60 to 75% charged, the compression of the connector system 100 is between the neutral state S N and the compressed state S C . In this state, the total distance between the connectors 1000 can be increased by 2 mm compared to the distance between the connectors 1000 in the neutral state S N be reduced.

[0141] In the compressed state S C: (i) the battery cells 75 are at a battery state of health of 100% (“SoH”), (ii) the battery cells 75 are charged to 100%, (iii) the back wall of each of the male connector housings 1100 is provided with a housing gap L HG (e.g., about 0-0.05 mm or adjacent) to the inner wall of the busbar housing 600, (iv) the length L BC the busbar 200 is about 106-116 mm, preferably 111-113 mm, and most preferably 112 mm (i.e., the length L IPC of the intermediate range is between 23 mm and 31 mm, preferably 27 mm), the height H BC of the busbar 200 is 15-30 mm, preferably 20-25 mm (ie, the height H IPC of the intermediate area is between 20 mm and 28 mm, preferably 23 mm), and the width W BC the busbar 200 is 15-25 mm, preferably 20 mm, (v) the length L SC of the system 100 is about 178 mm, the height H SCof the system 100 is 37 mm and the width W SC of the system 100 is 31 mm, (vi) the distance D C between the battery modules 62a, 62b is at a compressed length (e.g., 106 mm), (vii) the length of the neck L NC , which is defined between the outer recesses 264a, 264b of the busbar 200, is 21-26 mm, preferably 18 mm, in the compressed state, (viii) the length of the gap L GC , which is defined between opposite inner surfaces of the outer recesses 264a, 264b of the busbar 200, is 10 to 18 mm, preferably 14 mm, in the compressed state, (ix) the ratio between the height H BC the busbar 200 and the length L BCof the busbar 200 is 22.3%, (x) the lower surface 215b of the edge regions 402a, 402b are substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xi) the lower surface 215b of the edge regions 402a, 402b are substantially parallel to both the upper surface of the conductive plates 84 of the transfer assembly 82 and an extension of the positive and negative terminals 80a, 80b of the battery cells 75, (xii) the lower surface 215b of the edge regions 402a, 402b are substantially perpendicular to the longitudinal surface 78 of the battery cells 75, and (xiii) the intermediate region 410 is arranged between a fourth side wall 68d of a battery module 62a and a first side wall 68a of an adjacent battery module 62b. iii. System in the extended state

[0142] The Fig. 67 and Fig. 70 show the elastically deformable battery module connector system 100 in an expanded state SE , in which the busbar 200 has a maximum voltage force TE max In this embodiment, the maximum tension force TE max between 38 and 46 N, preferably 42 N. This maximum tension force TE max is exerted on the system 100 in the first direction (along the negative (-) X-axis) via the battery module 62a and in the third direction (along the positive (+) X-axis) via the contraction of the battery modules 62a, 62b due to the decrease in the state of charge of the battery cells 75. In particular, charging the battery cells 75 from a 50% state of charge to a 0% charge causes: (i) a reduction in the diameter of the cells 75 from Dnormal on D min , (ii) a reduction in the size of the battery modules 62a, 62b, (iii) an increase in the distance D Ebetween the battery modules 62a, 62b from the neutral length (e.g., 110 mm) to an extended length (e.g., 114 mm), and (iv) that the rear wall of each of the male terminal housings 1100 slides further away from the inner wall of the busbar housings 600. It should be clear that the movement from the neutral state S N to the extended state S E is continuous. When the battery modules 60 are charged to 25%, the voltage of the connector system 100 is between the neutral state S N and the extended state S E . In this state, the total distance between the connectors 1000 can be compared to the distance between the connectors 1000 in the neutral state S N be enlarged by 2 mm.

[0143] In the expanded state S E: (i) the battery cells 75 are at a battery state of health of 100% (“SoH”), (ii) the battery cells 75 are charged to 0% state of charge, (iii) the rear wall of each of the male terminal housings 1100 is provided with a housing gap L HG (e.g. about 4-6 mm) from the inner wall of the busbar housing 600, (iv) the length L BE the busbar 200 is approximately 114-124 mm, preferably 119-121 mm and most preferably 120 mm (i.e., the length L IPE of the intermediate range is between 23 mm and 31 mm, preferably 27 mm), the height H BE of the busbar 200 is 15-30 mm, preferably 20-25 mm (ie, the height H IPE of the intermediate range between 20 mm and 28 mm, preferably 23 mm), and the width W BE the busbar 200 is 15-25 mm, preferably 20 mm, (v) the length L SEof the system 100 is approximately 186 mm, the height of the system 100 is 37 mm and the width of the system 100 is 31 mm, (vi) the distance D N between the battery modules 62a, 62b at an extended length (e.g., 114 mm), (vii) the length of the neck L NE , which is defined between the outer recesses 264a, 264b of the busbar 200 in the compressed state, is 29-34 mm, preferably 22 mm, (viii) the length of the gap L GE , which is defined between opposite inner surfaces of the outer recesses 264a, 264b of the busbar 200, in the compressed state is 18 to 26 mm, preferably 24 mm [of the busbar 200, in the compressed state is 10 to 18 mm, preferably 14 mm], (viii) the ratio between the height H BE the busbar 200 and the length L BEof the busbar 200 is 20.8%, (ix) the lower surface 215b of the edge regions 402a, 402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (x) the lower surface 215b of the edge regions 402a, 402b is substantially parallel to both the upper surface of the conductive plates 84 of the transfer assembly 82 and an extension of the positive and negative terminals 80a, 80b of the battery cells 75, (xi) the lower surface 215b of the edge regions 402a, 402b is substantially perpendicular to the longitudinal surface 78 of the battery cells 75, and (xii) the intermediate region 410 is arranged between a fourth sidewall 68d of a battery module 62a and a first sidewall 68a of an adjacent battery module 62b. iv. Summary

[0144] In summary, the above disclosure focuses on battery cells 75 that have a battery state of health (“SoH”) of 100%. As described in Fig. 65, as the health state decreases, the diameter of the cells 75 increases, making the system 100 less able to maintain the expanded state S E to achieve; instead, the system 100 will mainly move between the neutral state S N and the compressed state S C As shown in the table below, the busbar height 200 and the bending height H IPN and the bending length L IPNof the intermediate region 410 remains substantially constant regardless of the state of the busbar. Maintaining the height of the busbar 200 substantially constant in all states is advantageous because it reduces potential failures due to unplanned expansions or contractions of the height of the busbar 200. Remaining substantially constant should be understood to mean that the height or length changes by less than 2.5% when the busbar 200 is moved from the neutral state S N into the compressed state S C or from the neutral state S N into the expanded state S E As shown in the table below, the formed length (ie L BC to L BN to L BE) of the busbar 200 is not substantially constant as the busbar 200 moves between states from the compressed state to the expanded state. Instead, the molded length changes by approximately 5% as the busbar 200 moves from the compressed state to the expanded state. It should be understood that the numbers contained in the above paragraphs and the table below are exemplary only and are not limiting in any way. Thus, other embodiments of the busbar 200 may have different values. Table 2: Load heights and dimensions for different busbar conditions Sammelschiene Zustand Ladezustand der Batteriezelle (%) L BC , L BN , L BE (mm) H BC , H BN , H BE (mm) H IPC , H IPN , H IPE (mm) L GC , L GN , L GE (mm) L SC , L SN , L SE (mm) Neutral state S N 50% 116 25 ± 2.5% 23 ± 2.5% 20 182 Compressed state S C 100% 112 25 ± 2.5% 23 ± 2.5% 16 178 Extended state S E 0% 120 25 ± 2.5% 23 ± 2.5% 24 186 v. Other Movement

[0145] While the above disclosure focused on the dynamic movement of the modules 60 in connection with the state of charge of the battery module 60, other factors may cause dynamic movement of the battery modules 60 within the battery pack 90. ​​For example, an increase in the temperature of the battery pack 90, the power distribution system 50, and / or the application 10 is likely to cause expansion of all components in all planes, thereby compressing the system 100. Furthermore, harsh and / or rough operating environments for the application 10, such as the motor vehicle 20, are also likely to cause dynamic movement in all planes, thereby compressing and / or expanding the system 100. In particular, Fig. 71, movement between the battery modules 62a, 62b in the second and fourth (along the positive / negative (+ / -) Y-axis) directions. Finally, other mechanical or chemical forces may also compress or expand the system 100. Because the system 100 is specifically designed to account for expansion and contraction in the XY plane and to compensate for movements in the XZ plane and the YZ plane, the system 100 reduces and largely eliminates a significant number of motion-related failure modes of battery packs 90 and applications 10 incorporating a battery pack 90, such as an automotive vehicle. III. Second embodiment of the battery pack

[0146] The Fig. 74-83 illustrate a second embodiment of battery modules 3060 and a plurality of elastically deformable battery module connector systems 3100 of the second embodiment. The combination of battery modules 3060 and systems 3100 is configured to be positioned within the battery pack 90 disclosed above. For brevity, the above disclosure relating to battery pack 90 will not be repeated below, but it should be understood that like numerals represent like structures throughout all embodiments. For example, the disclosure relating to bus bar housing 600 applies equally to bus bar housing 3600.It should be understood that any one or more features of battery modules 60 and systems 100 may be used in conjunction with those disclosed with respect to battery modules 3060 and systems 3100, and that any one or more features of battery modules 3060 and systems 3100 may be used in conjunction with those disclosed with respect to battery modules 60 and systems 100. A. Battery module

[0147] As in the Fig. 74-83, each of the battery modules 3060 (3062a-3062b) generally includes: (i) a battery module housing 3064, (ii) the battery cells 3076, and (iii) the electrical transfer unit 3083. i. Battery module housing

[0148] The battery module housing 3064 includes a plurality of walls 3066 (e.g., an array of four side walls 3068a-3068d, a bottom wall 3070a, and a top wall 3070b) forming a receptacle 3072 configured to receive and protect: (i) the battery cells 3076; and (ii) the electrical transmission assembly 3083. The top wall 3070b includes at least two battery module openings 3073a, 3073b formed therethrough, the openings 3073a, 3073b being configured to allow the threaded connector assembly 4002a, 4002b to be coupled to an extension of the electrical transmission assembly 3083. In particular, the configuration is such that the current flows through the battery module openings 3073a, 3073b via the connection between the screwed connector assembly 4002a, 4002b and the electrical transmission assembly 3083.While the screwed connector assembly 4002a, 4002b is shown in connection with this second embodiment 3060, it should be understood that the use of other connectors (e.g., screwless, clamped, pressure-fit) is contemplated within the scope of this disclosure. For example, a screwless connector is disclosed in connection with the first embodiment of the battery modules 3060. ii. Battery cells

[0149] The Fig. 75-80 show that the battery modules 3060 include a plurality of prismatic battery cells 3076, each battery cell 3076 comprising: (i) a housing 3077, (ii) a positive terminal 3080a, and (iii) a negative terminal 3080b. The housing 3077 has vertical side surfaces 3078a, 3078b and horizontal top and bottom surfaces 3079a, 3079b and is designed to enclose and retain the materials that store the electrical charge, such as lithium or other similar metals. In other words, the battery cells have a thickness T C , a width W CELL and a length L CELLThe positive and negative terminals 3080a, 3080b connect the materials contained within the housing 3077 to the electrical transfer unit 3083. The terminals 3080a, 3080b may have a tab-like configuration; however, other connection forms are also possible (e.g., screwless connectors, threaded connectors, buttons, or other structures that can be welded, crimped, or clamped to the electrical transfer assembly 3083). The positive and negative terminals 3080a, 3080b are typically made of different materials to facilitate charging and discharging of the battery cell 3076. For example, the positive terminal or anode 3080a may be formed from: (i) graphite, (ii) silicon, or (iii) graphene, while the negative terminal or cathode 3080b may be formed from: (i) cobalt, (ii) iron, (iii) nickel-magnesium, (iv) nickel, or (v) sulfur.It is understood that other materials may also be used for the terminals. The battery cells 3076 may have an output voltage between 0.2 volts and 10 volts, a current between 10 Ah and 100 Ah, and an energy density between 20 Wh / kg and 500 Wh / kg. It should be understood that the battery cells 3076 may use a variety of different technologies and / or materials, including: (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) Li-polymer, (v) Li-ion, or (vi) batteries using other materials (e.g., LiO2, AlO2, LiS, LTO, LFP, NMC, NCA). iii. Electrical transmission unit

[0150] The Fig. 74-80 show the electrical transfer assembly 3083 positioned within each of the battery modules 3060 and (i) interconnecting the battery cells 3076 and (ii) connecting the female terminal assemblies 4002a, 4002b to the battery cells 3076. As shown in this embodiment, each battery module 3060 includes approximately 11 battery cells 3076 arranged in a vertical orientation relative to the XY plane. This vertical orientation positions: (i) the positive and negative terminals 3080a, 3080b in a plane substantially parallel to the XY plane, (ii) an extension of the vertical side surfaces 3078a, 3078b of the cells 3076 substantially parallel to the YZ plane, and (iii) the thickness T Cof the cell 3076 parallel to the X-axis. Thus, conductive plates 3085 can be arranged in the XY plane and connected to the positive and negative terminals 3080a, 3080b of the cells 3076. While this embodiment discloses the above configuration of the battery cells 3076 and the associated components of the electrical transfer assembly 3083, it should be understood that in other embodiments, the electrical transfer assembly 3083 may have a different configuration. For example, the electrical transfer assembly 3083 may be configured to couple any number of battery cells 3076 together (e.g., between 2 and 3998).

[0151] Additionally, the plates 3085 are connected to at least one screw connector 4002. Preferably, the plates 3085 of the electrical transmission assembly 3083 are connected to two screw connectors 4002a, 4002b, wherein: (i) a positive screw connector 4002b is (a) configured to provide a positive external connection for the battery module 3060, and (b) configured to be received by an opening formed in a region of the system 3100, and (ii) a negative screw connector 4002a is (a) configured to provide a negative external connection for the battery module 3060, and (b) configured to be received by an opening formed in a region of the system 3100. While the battery module 3060 shown in the figures includes two screw connectors 4002a, 4002b, the battery module 3060 may have more or fewer screw connectors 4002.For example, the battery module 3060 may have only a single screw connector 4002, or the battery module 3060 may contain more than ten screw connectors 4002. B. Battery pack

[0152] As described above, the second embodiment of the battery module 3090 is designed to fit into the rectangular prism configuration of the battery pack 90, as shown in the Fig. 53-54. While the Fig. 53 and Fig. 54 illustrate a battery pack 90 configured to accommodate ten battery modules 3060, the present disclosure is not limited to this design. Instead, the battery pack 90 may have any known configuration (e.g., any type of polygonal prism), including a configuration where the pack 90 is constructed as a portion of the frame or chassis of the vehicle. It should also be understood that in other embodiments, the battery pack 90 may be configured to accommodate as little as a single battery module 3060 or over one hundred individual battery modules 3060. The battery cells 3076 included in the modules 3060 may be connected together in parallel, in series, or in any combination. Furthermore, the battery modules 3060 included in the battery pack 90 may be connected together in parallel, in series, or in any combination. C. Connection of the battery modules within the battery pack

[0153] Once the battery modules 3060 (3062a-3062j) are positioned and secured in the receptacles 97a, 97b of the battery pack 3060, the battery modules 3060 (3062a-3062j) can be interconnected using the disclosed elastically deformable battery module connector systems 3100. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 3100 (3102a-3102i). Each of the elastically deformable battery module connector systems 3100 is connected to the battery modules 90 by positioning the threaded rod of the screw connectors 4002 into the opening 3002 formed in the end sectors 3208a, 3208b of the busbar 3200 and then attaching the end sectors 3208a, 3208b to the screw connectors 4002 using a threaded connector.The disclosed configuration places the bottom surface 3215b of the edge regions 3402a, 3402b substantially parallel to each of the following: (i) the XY plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top and bottom walls 3070a, 3070b of the battery module housing 3064, (iv) the top surface of the conductive plates 3085 of the transfer assembly 3083, and (v) an extension of the positive and negative terminals 3080a, 3080b of the battery cells 3076. Furthermore, this configuration places the bottom surface 3215b of the edge regions 3402a, 3402b substantially perpendicular to each of the following: (i) the XZ plane, (ii) the YZ plane, (iii) the side and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 3068a-3068d of the battery module housing 3064, (iv) the extension of the vertical side surfaces 3078a, 3078b of the battery cells 3076.Furthermore, the configuration causes the intermediate region 3410 to extend downward from the edge region plane in the -Z direction and to be disposed between a fourth sidewall 3068d of a battery module 3060 (e.g., 3062a) and a sidewall 3068a of an adjacent battery module 3060 (e.g., 3062b). Furthermore, the length L extends. B of the busbar 3200 in a direction substantially parallel to the X-axis, while the width of the busbar 3200 extends in a direction substantially parallel to the Y-axis.

[0154] This first embodiment of the elastically deformable battery module connector systems 3100 is installed in the battery pack 90 using the connector assemblies 3998, 4002. These connector assemblies 3998, 4002 enable the connections between the battery modules 3060 to be secured with a screw configuration. Once the battery modules 3060 and any other required components (e.g., battery management assembly, battery cooling or heating assemblies, etc.) are installed in the battery pack 90, the pack 90 can be installed in an application 10. D. Dynamic movement of the battery modules

[0155] The schematic views of the battery cells 3076 in Fig. 77 illustrate how the movement of lithium ions from the cathode to the anode changes the size of the battery cells 3076, namely: (i) charging causes an increase in thickness or a lateral expansion of the prismatic battery cell 3076 outwards, and (ii) discharging causes a decrease in thickness or a lateral contraction of the prismatic battery cell 3076 inwards. Thus, the thickness of the cell 3076 can be reduced to T max increase when the battery is 100% or fully charged, to Tnormal when the battery is 50% or ½ charged and switch to T min decrease when the battery is 0% or not charged, where T max > Tnormal > T min , In other words, charging the battery cells 3076 contained in the battery module 3060 from a 50% charge level to a 100% charge level increases the thickness of the cells 3076 in the module 3060 from Tnormal on T max, and discharging the battery cells 3076 contained in the battery module 3060 from a 50% charge level to a 0% charge level reduces the thickness of the cells 3076 in the module 3060 from Tnormal on T min . In addition, Fig. 78, how with decreasing battery state of health (“SoH”) due to the thickness growth of the solid electrolyte interlayer, defects in the graphite and the pressure increase due to side reactions during the lifetime of a prismatic lithium-ion cell, the thickness of the cells 3076 increases irreversibly (i.e., from Tnormal to T 90 to T 80 ). It is understood that the Fig. 77-78 are not to scale and are for illustrative purposes only.

[0156] In view of the above, a major factor contributing to the dynamic movement of the battery modules 3060 within the pack 90 is the state of charge of the battery modules 3060. In this second embodiment, the prismatic cells 3076 are arranged in the vertical orientation relative to the XY plane, wherein: (i) an extent of the vertical side surfaces 3078a, 3078b of the cells 3076 is substantially parallel to the YZ plane, (ii) an extent of the horizontal top and bottom surfaces 3079a, 3079b of the cells 3076 is substantially parallel to the XY plane, and (iii) the thickness T C of cell 3076 is parallel to the X-axis. Accordingly, the thickness expansion and contraction of Tnormal are max or Tnormal are min, the battery cell 3076 primarily involves expansion and contraction of the battery modules 3060 along the X-axis. Expansion and contraction along the Y-axis or the Z-axis is minimal, if any, because the movement of the Li-ions is primarily lateral and has no other significant components. Since the expansion and contraction of the battery modules 3060 occurs primarily in the X-axis, the designer: (i) positions the bottom surface 3215b of the edge regions 3402a, 3402b substantially parallel to the X-axis, and (ii) arranges the intermediate region 3410 to extend downward from the plane of the edge region in the negative (-) Z-direction. As discussed in detail below, this disclosed configuration of the system 100 enables elastic deformation of the intermediate region 3410 to absorb the expansion and contraction of the battery modules 3060 in the X-axis. i. System in neutral state

[0157] While it is clear from the above disclosure that individual elastically deformable battery module connector systems 3100 included in the battery pack 90 may be subject to different expansion and / or contraction forces, the general concepts disclosed in the context of the following disclosure with respect to the first system 3102a, the first battery module 3062a, and the second battery module 3062b apply to all systems 3100 included in the battery pack 90. ​​The Fig. 74-76B and 81 show the elastically deformable battery module connector system 3100 in a neutral state S N , in which neither tension nor pressure is exerted on the 3100 system. In the neutral state S N : (i) the battery cells 3076 are at a battery state of health of 100% (“SoH”), (ii) the battery cells 3076 are charged to 50%, (iii) the back wall of each of the male terminal housings 1100 is separated by a housing gap LHG (e.g., about 2-4 mm) from an inner wall of the busbar housing 3600, (iv) the formed length L BN the busbar 200 is approximately 110-120 mm, preferably 115-117 mm and most preferably 116 mm (i.e., the length L IPN of the intermediate range is between 23 mm and 31 mm and preferably 27 mm), the height H BN the busbar 200 15-30 mm, preferably 20-25 mm (ie, the height H IPN of the intermediate range is between 20 mm and 28 mm, preferably 23 mm), and the width W BN the busbar 200 15-25 mm, preferably 20 mm, (v) the length L SN of the system 3100 is approximately 150-200 mm, preferably 160-190 mm, and most preferably 182 mm, the height of the system 3100 is 35-40 mm, preferably 37 mm, and the width W SN of the system 3100 25-35 mm, preferably 31 mm, (vi) the distance D Nbetween the battery modules 3062a, 3062b at a neutral length (e.g., 100-120 mm, preferably 110 mm), (vii) the length of the neck L NN , which is defined between the outer recesses 3264a, 3264b of the busbar 3200, in the neutral state 25-30 mm, preferably 22 mm, (viii) the length of the gap L GN , which is defined between opposite inner surfaces of the outer recesses 3264a, 3264b of the busbar 3200, in the neutral state 14 and 22 mm, preferably 22 mm, (ix) the ratio between the height H BN the busbar 3200 and the formed length L BNof the busbar 3200 20-25%, preferably 21.5%, (x) the lower surface 3215b of the edge regions 3402a, 3402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xi) the lower surface 3215b of the edge regions 3402a, 3402b is substantially parallel to both an extension of the upper surface of the conductive plates 3085 of the transfer assembly 3083 and an extension of the positive and negative poles 3080a, 3080b of the battery cells 3076, (xii) the lower surface 3215b of the edge regions 3402a, 3402b is substantially perpendicular to an extension of the vertical side surfaces 3078a, 3078b of the cells 3076, (xiii) the Intermediate region 3410 is arranged between a fourth side wall 3068d of a battery module 3062a and a first side wall 3068a of an adjacent battery module 3062b, and (xiv) the formed length L BN the busbar 200 and the length L SNof the 3100 system is substantially parallel to both the thickness T C the battery cell 3076 as well as to the X-axis. ii. System in compressed state

[0158] The Fig. 79 and Fig. 82 show the elastically deformable battery module connector system 3100 in a compressed state S C , in which the busbar 3200 is subjected to a maximum compression force C max In this embodiment, the maximum compression force C max between 38 and 46 N, preferably 42 N. This maximum compression force C maxis exerted on the system 3100 in the third direction (along the positive (+) X-axis) across the battery module 3062a and in the first direction (along the negative (-) X-axis) across the extension of the battery modules 3062a, 3062b due to the increased state of charge of the battery cells 3076. In particular, charging the battery cells 3076 from a 50% state of charge to a 100% charge causes: (i) an increase in the thickness of the cells 3076 of Tnormal on T max , (ii) an increase in the size of the battery modules 3062a, 3062b, (iii) a decrease in the distance D N between the battery modules 3062a, 3062b from the neutral length (e.g., 110 mm) to a compressed length (e.g., 106 mm), and (iv) that each of the rear walls of the male terminal housings 1100 slides towards the inner wall of the busbar housings 3600. It is understood that the movement from the neutral state S N to the compressed state S Ccontinuously. When the battery modules 3060 are 75% charged, the compression of the connector system 3100 is between the neutral state S N and the compressed state S C . In this state, the total distance between the connectors 3998 can be increased by 2 mm compared to the distance between the connectors 3998 in the neutral state S N be reduced.

[0159] In the compressed state S C : (i) the battery cells 3076 are at a 100% battery state of health (“SoH”), (ii) the battery cells 3076 are 100% charged, (iii) the back wall of each of the male connector housings 1100 is provided with a housing gap L HG (e.g., about 0-0.5 mm or adjacent) from the inner wall of the busbar housing 3600, (iv) the length L BC the busbar 200 is approximately 106-116 mm, preferably 111-113 mm and most preferably 112 mm (i.e., the length L IPCof the intermediate area is between 23 mm and 31 mm, preferably 27 mm), the height H BC the busbar 200 15-30 mm, preferably 20-25 mm (ie, the height H IPC of the intermediate area is between 20 mm and 28 mm, preferably 23 mm, and the width W BC the busbar 200 15-25 mm, preferably 20 mm, (v) the length L SC of the system 3100 is approximately 178 mm, the height of the system 3100 is 37 mm and the width of the system 3100 is 31 mm, (vi) the distance D N between the battery modules 3062a, 3062b at a compressed length (e.g., 106 mm), (vii) the length of the neck L NC , which is defined between the outer recesses 3264a, 3264b of the busbar 3200, in the compressed state 21-26 mm, preferably 18 mm, (viii) the length of the gap L GC, which is defined between opposite inner surfaces of the outer recesses 3264a, 3264b of the busbar 3200, in the compressed state between 10 and 18 mm, preferably 14 mm, (ix) is the ratio between the height H BC the busbar 3200 and the length L BCthe busbar 3200 22.3%, (x) the lower surface 3215b of the edge regions 3402a, 3402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xi) the lower surface 3215b of the edge regions 3402a, 3402b is substantially parallel both to an extension of the upper surface of the conductive plates 3085 of the transfer assembly 3083 and to an extension of the positive and negative poles 3080a, 3080b of the battery cells 3076, (xii) the lower surface 3215b of the edge regions 3402a, 3402b is substantially perpendicular to an extension of the vertical side surfaces 3078a, 3078b of the battery cells 3076, (xiii) the intermediate region 3410 between a fourth side wall 3068d of a battery module 3062a and a first side wall 3068a of an adjacent battery module 3062b, and (ivx) the length L BC the busbar 200 and the length L SC of the 3100 system is substantially parallel to both the thickness TC the battery cell 3076 as well as to the X-axis. iii. System in the extended state

[0160] The Fig. 80 and Fig. 83 show the elastically deformable battery module connector system 3100 in an expanded state S E , in which the busbar 3200 has a maximum voltage force TE max In this embodiment, the maximum tension force TE max between 38 and 46 N, preferably 42 N. This maximum tension force TE max is exerted on the system 3100 in the first direction (along the negative (-) X-axis) via the battery module 3062a and in the third direction (along the positive (+) X-axis) via the contraction of the battery modules 3062a, 3062b due to the decrease in the state of charge in the battery cells 3076. In particular, charging the battery cells 3076 from a 50% state of charge to a 0% charge causes: (i) a decrease in the thickness of the cells 3076 fromTnormal on T min , (ii) a decrease in the size of the battery modules 3062a, 3062b, (iii) an increase in the distance D N between the battery modules 3062a, 3062b from the neutral length (e.g., 110 mm) to an extended length (e.g., 114 mm), and (iv) that the rear wall of each of the male terminal housings 1100 slides further away from the inner wall of the busbar housings 3600. It is understood that the movement from the neutral state S N to the extended state S E continuously. When the battery modules 3060 are charged to 25%, the voltage of the connector system 3100 is between the neutral state S N and the extended state S E . In this state, the total distance between the connectors 3998 can be compared to the distance between the connectors 3998 in the neutral state S N be enlarged by 2 mm.

[0161] In the expanded state S E: (i) the battery cells 3076 are at a battery state of health of 100% (“SoH”), (ii) the battery cells 3076 are charged to 0% state of charge, (iii) the back wall of each of the connector housings 1100 is provided with a housing gap L HG (e.g. about 4-6 mm) from the inner wall of the busbar housing 3600, (iv) the length L BE the busbar 200 is approximately 114-124 mm, preferably 119-121 mm and most preferably 120 mm (i.e., the length L IPE of the intermediate range is between 23 mm and 31 mm, preferably 27 mm), the height H BE of the busbar 200 is 15-30 mm, preferably 20-25 mm (ie, the height H IPE of the intermediate range is between 20 mm and 28 mm, preferably 23 mm, and the width W BE the busbar 200 is 15-25 mm, preferably 20 mm, (v) the length L SEof the system 3100 is approximately 186 mm, the height of the system 3100 is 37 mm and the width of the system 3100 is 31 mm, (vi) the distance D N between the battery modules 3062a, 3062b at an extended length (e.g., 114 mm), (vii) the length of the neck L NE , which is defined between the outer recesses 3264a, 3264b of the busbar 3200, in the compressed state 29-34 mm, preferably 22 mm, (viii) the length of the gap L GE , which is defined between opposite inner surfaces of the outer recesses 3264a, 3264b of the busbar 3200, in the compressed state 18 and 26 mm, preferably 24 mm, (ix) is the ratio between the height H BE the busbar 3200 and the length L BEthe busbar 3200 20.8%, (x) the lower surface 3215b of the edge regions 3402a, 3402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (xi) the lower surface 3215b of the edge regions 3402a, 3402b is substantially parallel to both the upper surface of the conductive plates 3085 of the transfer assembly 3083 and to an extension of the positive and negative poles 3080a, 3080b of the battery cells 3076, (xii) the lower surface 3215b of the edge regions 3402a, 3402b is substantially perpendicular to an extension of the vertical side surfaces 3078a, 3078b of the battery cells 3076, (xiii) the intermediate region 3410 is between a fourth side wall 3068d of a battery module 3062a and a first side wall 3068a of an adjacent battery module 3062b, and (ivx) the length L BE the busbar 200 and the length L SE of the 3100 system substantially parallel to both the thickness T CELLthe battery cell 3076 as well as the X-axis. IV. Third embodiment of the battery pack

[0162] The Fig. 84-88 illustrate a third embodiment of battery modules 5060 and a plurality of elastically deformable battery module connector systems 5100 of the second embodiment. The combination of battery modules 5060 and systems 5100 is configured to be positioned within the battery pack 90 disclosed above. For brevity, the above disclosure relating to battery pack 90 will not be repeated below, but it should be understood that like numerals represent like structures throughout all embodiments. For example, the disclosure relating to bus bar housing 5600 applies equally to bus bar housing 5600.It should be understood that any one or more features of the battery modules 5060 and the systems 5100 may be used in conjunction with those disclosed with respect to the battery modules 5060 and the systems 5100, and that any one or more features of the battery modules 5060 and the systems 5100 may be used in conjunction with those disclosed with respect to the battery modules 5060 and the systems 5100. A. Battery module

[0163] As in the Fig. 84-88, each of the battery modules 5060 (5062a-5062j) generally includes: (i) a battery module housing 5064, (ii) the battery cells 5076, and (iii) the electrical transfer unit 5081. i. Battery module housing

[0164] The battery module housing 5064 includes a plurality of walls 5066 (e.g., an array of four side walls 5068a-5068d, a bottom wall 5070a, and a top wall 5070b) forming a receptacle 5072 configured to receive and protect: (i) the battery cells 5076 and (ii) the electrical transmission assembly 5081. The top wall 5070b includes at least two battery module openings 5073a, 5073b formed therethrough, the openings 5073a, 5073b being configured to allow the female connector assemblies 2000a, 2000b to be coupled to an extension of the electrical transmission assembly 5081. In particular, the configuration is such that the current flows through the battery module openings 5073a, 5073b via the connection between the female connector assembly 2000a, 2000b and the electrical transmission assembly 5081.Although the female connector assemblies 2000a, 2000b are shown in connection with this third embodiment of the battery modules 5060, it should be understood that the use of other connectors (e.g., screwed, clamped, pressure-fitted) is contemplated in this disclosure. For example, a screw connector is disclosed in connection with the second embodiment of the battery modules 5060. ii. Battery cells

[0165] The Fig. 84-88 show that the battery modules 5060 include a plurality of pouch battery cells 5076, each battery cell 5076 having (i) a housing 5077, (ii) a positive terminal 5080a, and (iii) a negative terminal 5080b. The housing 5077 has horizontal side surfaces 5078a, 5078b and vertical top and bottom surfaces 5079a, 5079b and is constructed to enclose and retain the materials that store the electrical charge, such as lithium or other similar metals. In other words, the battery cells have a thickness T C , a width W CELL and a length L CELLThe positive and negative terminals 5080a, 5080b connect the materials contained in the housing 5077 to the electrical transfer unit 5081. The terminals 5080a, 5080b may have a tab-like configuration; however, other connection forms are also possible (e.g., screwless connectors, screw connectors, buttons, or other structures that can be welded, crimped, or clamped to the electrical transfer assembly 5081). The positive and negative terminals 5080a, 5080b are typically made of different materials to facilitate charging and discharging of the battery cell 5076. For example, the positive terminal or anode 5080a may be formed from (i) graphite, (ii) silicon, or (iii) graphene, while the negative terminal or cathode 5080b may be formed from (i) cobalt, (ii) iron, (iii) nickel-magnesium, (iv) nickel, or (v) sulfur.It is understood that other materials may also be used for the terminals. The battery cells 5076 may have an output voltage between 0.2 volts and 10 volts, an ampere-hour rating between 10 Ah and 100 Ah, and an energy density between 20 Wh / kg and 500 Wh / kg. It is understood that the battery cells 5076 may utilize a variety of different technologies and / or materials, including: (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) Li-polymer, (v) Li-ion, or (vi) batteries utilizing other materials (e.g., LiO2, AlO2, LiS, LTO, LFP, NMC, NCA). iii. Electrical transmission unit

[0166] The Fig. 58-67 show the electrical transfer assembly 5081 positioned within each of the battery modules 5060 and (i) interconnecting the battery cells 5076, and (iii) connecting the female connector assemblies 2000a, 2000b to the battery cells 5076. As shown in this embodiment, the first and second stacks each include approximately 26 battery cells 5076 arranged in a horizontal orientation with respect to the XY plane. This horizontal orientation positions: (i) the positive and negative terminals 5080a, 5080b in a plane substantially parallel to the YZ plane, (ii) an extension of the horizontal side surfaces 5078a, 5078b of the cells 5076 substantially parallel to the XY plane, and (iii) the thickness T Cof the cell 3076 parallel to the Z-axis. Thus, conductive plates 5084 can be arranged in the YZ plane and connected to the positive and negative terminals 5080a, 5080b of the cells 5076. While this embodiment discloses the above configuration of the battery cells 5076 and the associated components of the electrical transfer assembly 5081, it should be understood that in other embodiments, the electrical transfer assembly 5081 may have a different configuration. For example, the electrical transfer assembly 5081 may be configured to couple any number of battery cells 5076 (e.g., between 2 and 1000) and any number of battery stacks (e.g., between 1 and 40 stacks).

[0167] Additionally, at least one female connector assembly 2000 is connected to the plates 5086. Preferably, the plates 5086 of the electrical transmission assembly 5081 are coupled to two female connector assemblies 2000a, 2000b, wherein: (i) a positive female connector assembly 2000b is (a) configured to provide a positive external connection for the battery module 5060, and (b) adapted to receive a portion of a positive male terminal assembly 1430, and (ii) a negative female connector assembly 2000a is (a) configured to provide a negative external connection for the battery module 5060, and (b) adapted to receive a portion of a negative male terminal assembly 1430.While the battery module 5060 illustrated in the figures includes two female connector assemblies 2000a, 2000b, it should be understood that the battery module 5060 may have more or fewer female connector assemblies 2000. For example, the battery module 5060 may have only a single female connector assembly 2000, or the battery module 5060 may include more than ten female connector assemblies 2000. B. Battery pack

[0168] As described above, the third embodiment of the battery module 5090 is designed to fit into the rectangular prism configuration of the battery pack 90, as shown in the Fig. 53-54. While the Fig. 53 and Fig. 54 illustrate a battery pack 90 having a configuration configured to accommodate ten battery modules 5060, it should be understood that this disclosure is not limited to this design. Rather, the battery pack 90 may have any known configuration (e.g., any type of polygonal prism), including a configuration where the pack 90 is constructed as part of the frame or chassis of the vehicle. It should also be understood that in other embodiments, the battery pack 90 may be configured to accommodate only a single battery module 5060 or more than one hundred individual battery modules 5060. The battery cells 5076 included in the modules 5060 may be connected together in parallel, in series, or in any combination thereof. Furthermore, the battery modules 5060 included in the battery pack 90 may be connected together in parallel, in series, or in any combination thereof. C. Connection of the battery modules within the battery pack

[0169] Once the battery modules 5060 (5062a-5062j) are positioned and secured in the receptacles 97a, 97b of the battery pack 90, the battery modules 5060 (5062a-5062j) can be interconnected using the disclosed elastically deformable battery module connector systems 5100. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 5100 (5102a-5102i). Each of the elastically deformable battery module connector systems 5100 is connected to the battery modules 90 with a downward force (i.e., in the negative (-) Z direction).The disclosed configuration places the bottom surface 5215b of the edge regions 5402a, 5402b substantially parallel to each of the following: (i) the XY plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top and bottom walls 5070a, 5070b of the battery module housing 5064, and (iv) an extension of the positive and negative terminals 5080a, 5080b of the battery cells 5076. Furthermore, the configuration places the bottom surface 5215b of the edge regions 5402a, 5402b substantially perpendicular to each of the following: (i) XZ plane, (ii) YZ plane, (iii) the side and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 5068a-5068d of the Battery module housing 5064, (iv) the longitudinal surface 78 of the battery cells 5076. Furthermore, the configuration causes the intermediate region 5410 to extend downward from the edge region plane in the -Z direction and to be sandwiched between a fourth side wall 5068d of a battery module 5060 (e.g.5062a) and a side wall 5068a of an adjacent battery module 5060 (e.g., 5062b). Furthermore, the length L extends. B of the busbar 5200 in a direction substantially parallel to the X-axis, while the width of the busbar 5200 extends in a direction substantially parallel to the Y-axis.

[0170] This third embodiment of the elastically deformable battery module connector systems 5100 installed in the battery pack 90 utilizes the connector assemblies 1000, 2000. These connector assemblies 1000, 2000 enable the connections between the battery modules 5060 to be: (i) screwless, (ii) PCT compliant, (iii) 360° compliant, (vi) fast and efficient compared to conventional battery pack connectors, (vii) simple, without special tools or machinery, (viii) meet USCAR and other industry specifications, (ix) are lighter than conventional battery pack connectors, and (x) have other advantages that will be apparent to one skilled in the art. Once the battery modules 5060 and all other required components (e.g., battery management assembly, battery cooling or heating assemblies, etc.) are installed into the battery pack 90, the pack 90 can be installed into an application 10. D. Material condition of the battery modules

[0171] In the second embodiment, the movement of lithium ions from the cathode to the anode causes the thickness of the cell 5076 to be reduced to T max increases when the battery is 100% or fully charged, to Tnormal increases when the battery is 50% or ½ charged, and to T min drops when the battery is at 0% or not charged, where T max > Tnormal > T min . In view of the above disclosure, a major factor contributing to the dynamic movement of the battery modules 5076 within the pack 90 is not related to the state of charge of the battery modules 5076. This is because the prismatic cells 3076 are arranged in the horizontal orientation relative to the XY plane, wherein: (i) an extension of the horizontal side surfaces 5078a, 5078b of the cells 5076 is substantially parallel to the XY plane, and (iii) the thickness T Cof cell 3076 is parallel to the Z-axis. Accordingly, the thickness expansion and contraction of Tnormal are max or Tnormal are min , the battery cell 5076 primarily involves expansion and contraction of the battery modules 5076 along the Z-axis. Minimal, if any, expansion and contraction occurs along the X- or Y-axis, since the movement of the Li-ions is primarily vertical and has no other significant components. Since the pack 90 does not require the electrical coupling of individual modules 5060 to the upper surface of the pack 90, the expansion of the individual modules 5060 along the Z-axis is not dependent on other modules 5060, and the length L Sof the system 100 is not positioned in a direction parallel to the Z-axis, but in a direction parallel to the X-axis. This configuration enables the system 100 to couple the individual modules 5060 together. However, as explained above, the expansion and contraction of the battery modules 5076 due to the movement of the lithium ions occurs primarily along the Z-axis and not along the X-axis. Therefore, the system 100 (i.e., the intermediate region 5410) will not elastically deform to accommodate the expansion and contraction of the battery modules 5076 in the Z-axis.

[0172] In contrast to the Fig. 53-83 showing that the system 100 is configured to advantageously absorb the forces associated with the dynamic movement of the modules 5076, the Fig. 84-88 that the system 100 can also advantageously take into account different material states associated with the battery pack 90. i. System in neutral state

[0173] While it is clear from the above disclosure that individual elastically deformable battery module connector systems 5100 included in the battery pack 90 may be subject to different forces, the general concepts disclosed in connection with the following disclosure with respect to the first system 5102a, the first battery module 5062a, and the second battery module 5062b apply to all systems 5100 included in the battery pack 90. ​​The Fig. 85-86 show the elastically deformable battery module connector system 5100 in a neutral state S N , in which neither tension nor pressure is exerted on the 5100 system. In the neutral state S N : (i) the rear wall of each of the male connector housings 1100 is spaced apart by a housing gap L HG (e.g., about 2-4 mm) from an inner wall of the busbar housing 5600, (ii) the formed length L BNthe busbar 200 is about 110-120 mm, preferably 115-117 mm, and most preferably 116 mm (i.e., the length L IPN of the intermediate range is between 23 mm and 31 mm, preferably 27 mm), the height H BN of the busbar 200 is 15-30 mm, preferably 20-25 mm (ie, the height H IPN of the intermediate area is between 20 mm and 28 mm, preferably 23 mm, and the width W BN the busbar 200 is 15-25 mm, preferably 20 mm, (iii) the length L SN of the system 5100 approximately 150-200 mm, preferably 160-190 mm and most preferably 182 mm, the height H SN of the system 5100 is 35-40 mm, preferably 37 mm, and the width of the system 5100 is 25-35 mm, preferably 31 mm, (iv) the length of the neck is L NN , which is defined between the outer recesses 5264a, 5264b of the busbar 5200, in the neutral state 25-30 mm, preferably 22 mm, , (viii) the length of the gap LGN , which is between opposite inner surfaces of the outer recesses 5264a, 5264b of the busbar 5200 in the neutral state 14 and 22 mm, preferably 22 mm, (vi) the ratio between the height H BN the busbar 5200 and the formed length L BN the busbar 5200 20-25%, preferably 21.5%, (vii) the lower surface 5215b of the edge regions 5402a, 5402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (viii) the lower surface 5215b of the edge regions 5402a, 5402b is substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cells 5076, (ix) the intermediate region 5410 is arranged between a fourth side wall 5068d of a battery module 5062a and a first side wall 5068a of an adjacent battery module 5062b, and (x) the length L BN the busbar 200 and the length L SN of the 3100 system substantially perpendicular to the thickness TCELL of the battery cell 5076, but are substantially parallel to the X-axis. As such, the system 5100 is installed in the pack 5090 in the nominal material condition, which is between the maximum material condition and the minimum material condition. ii. System in compressed state

[0174] Fig. Figure 87 shows that the illustrated components of the battery pack 5090 are in the maximum material state. In particular, this maximum material state occurs when: (i) the battery modules 5062a, 5062b are positioned as close to each other as possible while being within the specified tolerances of the pack 5090, and (ii) the system 5100 has the greatest possible length while being within the specified tolerances of the pack 5090. To accommodate this maximum material state, the elastically deformable battery module connector system 5100 is in a compressed state S C, in which the busbar 5200 is subjected to a maximum compression force C max In this embodiment, the maximum compression force C max between 38 and 46 N, preferably 42 N. This maximum compression force C max is applied to the system 5100 in the third direction (along the positive (+) X-axis) via the battery module 5062a and in the first direction (along the negative (-) X-axis) via the configuration of the battery module 5062a, 5062b.

[0175] In the compressed state S C : (i) the rear wall of each of the male connector housings 1100 is provided with a housing gap L HG (e.g. approximately 0-.05 mm or adjacent) to the inner wall of the busbar housing 5600, (ii) the length L BC the busbar 200 is approximately 106-116 mm, preferably 111-113 mm and most preferably 112 mm (i.e., the length L IPCof the intermediate range is between 23 mm and 31 mm, preferably 27 mm), the height H BC of the busbar 200 is 15-30 mm, preferably 20-25 mm (ie the height H IPC of the intermediate range is between 20 mm and 28 mm, preferably 23 mm), and the width W BC the busbar 200 is 15-25 mm, preferably 20 mm, (iii) the length L SC of the system 5100 is approximately 178 mm, the height of the system 5100 is 37 mm, and the width of the system 5100 is 31 mm, (iv) the length of the neck is L NC , which is defined between the outer recesses 5264a, 5264b of the busbar 5200, in the compressed state 21-26 mm, preferably 18 mm, (v) the length of the gap L GC , which is defined between opposite inner surfaces of the outer recesses 5264a, 5264b of the busbar 5200, in the compressed state between 10 and 18 mm, preferably 14 mm, (vi) the ratio between the height HBC the busbar 5200 and the length L BC the busbar 5200 22.3%, (vii) the lower surface 5215b of the edge regions 5402a, 5402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (viii) the lower surface 5215b of the edge regions 5402a, 5402b is substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cells 5076, (ix) the intermediate region 5410 is arranged between a fourth side wall 5068d of a battery module 5062a and a first side wall 5068a of an adjacent battery module 5062b, and (ix) the length L BC the busbar 200 and the length L SC of the 3100 system substantially perpendicular to the thickness T C of the battery cell 5076, but are essentially parallel to the X-axis. iii. System in the extended state

[0176] Fig. Figure 88 shows that the illustrated components of the battery pack 5090 are in a minimum material state. In particular, this minimum material state occurs when: (i) the battery modules 5062a, 5062b are spaced as far apart as possible within the specified tolerances of the pack 5090, and (ii) the system 5100 is the smallest possible length within the specified tolerances of the pack 5090. To accommodate this minimum material state, the elastically deformable battery module connector system 5100 is in an expanded state S E , in which the busbar 5200 is subjected to a maximum tension force TE max In this embodiment, the maximum tension force is TE max between 38 and 46 N, preferably 42 N. This maximum tension force TE maxis applied to the system 5100 in the third direction (along the positive (+) X-axis) via the battery module 5062a and in the first direction (along the negative (-) X-axis) via the configuration of the battery module 5062a, 5062b.

[0177] In the expanded state S E : (i) the rear wall of each of the male connector housings 1100 is separated from the inner wall of the busbar housing 5600 by about 4-6 mm, (ii) the length L BE the busbar 200 is approximately 114-124 mm, preferably 119-121 mm and most preferably 120 mm (i.e., the length L IPE of the intermediate piece is between 23 mm and 31 mm, preferably 27 mm), the height H BE the busbar 200 15-30 mm, preferably 20-25 mm (ie, the height H IPE of the intermediate area is between 20 mm and 28 mm, preferably 23 mm), and the width W BE the busbar 200 15-25 mm, preferably 20 mm, (iii) the length LSE of the 5100 system is approximately 186 mm, the height H SE of the system 5100 is 37 mm, and the width of the system 5100 is 31 mm, (iv) the length of the neck is L NE , which is defined between the outer recesses 264a, 264b of the busbar 5200, in the compressed state 29-34 mm, preferably 22 mm, (v) the length of the gap L GE , which is defined between opposite inner surfaces of the outer recesses 5264a, 5264b of the busbar 5200, in the compressed state 18 to 26 mm, preferably 24 mm, (vi) the ratio between the height H BE the busbar 5200 and the length L BEthe busbar 5200 20.8%, (vii) the lower surface 5215b of the edge regions 5402a, 5402b is substantially parallel to the XY plane and substantially perpendicular to the XZ and YZ planes, (viii) the lower surface 5215b of the edge regions 5402a, 5402b is substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cells 5076, (ix) the intermediate region 5410 is arranged between a fourth side wall 5068d of a battery module 5062a and a first side wall 5068a of an adjacent battery module 5062b, and (x) the length L BE the busbar 200 and the length L SE of the 5100 system substantially perpendicular to the thickness T C of the battery cell 5076, but essentially parallel to the X-axis. V. Alternative busbar configurations

[0178] The Fig. The busbar 200 shown in Figure 1-83 can be replaced by one of the Fig. 89-102, which include alternative versions of the elastically deformable intermediate region 412a-412m. Similar to the busbar 200 described above, each of these alternative embodiments includes: (i) a first edge connection segment 402a, (ii) a second connection segment 402b, and (iii) an elastically deformable intermediate segment 412a-412m disposed between the first and second elastically deformable segments 402a, 402b. In these alternative embodiments, the elastically deformable intermediate segment may include linear regions (see Fig. 89-90, 92-93), arched areas (see Fig. 91, Fig. 94, Fig. 95), parabolic areas (see Fig. 96-97, 99-101), differently shaped areas (see Fig. 98) or several discrete shapes separated by linear or other shaped segments (see Fig. 102). It is understood that the forms specified are not limiting and are merely exemplary. As such, other forms or combinations of forms are contemplated in this disclosure. VI. Third embodiment of the system

[0179] Similar to the system 100 described above, the Fig. 103-104 illustrate another embodiment of system 7100. For brevity, the above disclosure in connection with system 100 will not be repeated below, but it should be understood that like numbers represent like structures throughout all embodiments. For example, the disclosure regarding busbar 200 applies equally to busbar 7200. Further, it is expected that the compression and / or expansion of busbar 7200 will be similar or identical to that disclosed for busbar 200. The only difference in this embodiment of the system 7100 is the fact that the busbar housing 7600: (i) includes only two couplings 7597 on the upper extent of the housing 7600 and two couplings 7597 on the lower extent of the housing 7600, and (ii) the first extent 606 and the fifth extent 614 of the housing 600 have been omitted in this embodiment. VII. Alternative male connector configurations

[0180] The ones in connection with the Fig. The male connector assembly 1430 shown in Figure 1-83 may be replaced by: (i) the openings for receiving a threaded connector, (ii) any of the male terminals 4430 (shown in Fig. 105), 5430 (shown in Fig. 106), 6430 (shown in Fig. 107), 7430 (shown in Fig. 108) or 8430 (shown in Fig.109) or (iii) any male connector disclosed in a patent or patent application incorporated herein by reference. Because each of the male terminals 4430, 5430, 6430, 7430, or 8430 has features similar to the male terminal 1430 and is described in detail in other applications or patents incorporated herein by reference, that disclosure is not repeated here. For example, the male connector 4430 is disclosed in PCT / US2019 / 036,010, the connector 5430 is disclosed in PCT / US2019 / 036,010 and PCT / US2021 / 043,686, the connector 6430 is disclosed in PCT / US2021 / 043,788, the connector 7430 is disclosed in US Provisional Patent Application 63 / 286,072, and the connector 8430 is disclosed in PCT / US2021 / 047,180, each of which is incorporated herein by reference.

[0181] The connector system 100 is T4 / V4 / D2 / M2, where the system 100 meets and exceeds the following requirements: (i) T4 means the system 100 is exposed to a temperature of 150°C, (ii) V4 means it is exposed to severe vibration, (iii) D2 means it has a durability of 200,000 miles, and (iv) M2 means a force of less than 45 Newtons is required to connect the male terminal assembly 1430 to the female terminal unit 2430, 3430. In other embodiments, the connector systems 100 may be T4 / V4 / S3 / D2 / M2, where the system 100 also meets and exceeds the S3 sealing requirements for high-pressure fog. The System 100 is not only T4 / V4 / S3 / D2 / M2 compliant, 360° compliant, screwless and PCT compliant, but can also be scannable and thus PCT compliant (see PCT / US2020 / 049870).

[0182] The spring element 1440c disclosed herein may be replaced by the spring elements illustrated in PCT / US2019 / 36010 or US Provisional 63 / 058,061. Furthermore, it should be understood that alternative configurations for connector assemblies 1000 are possible. For example, any number of male terminal assemblies 1430 (e.g., between 2-30, preferably between 2-8, and most preferably between 2-4) may be positioned in a housing 1100, and any number of female terminal assemblies 2430, 3430 (e.g., between 2-30, preferably between 2-8, and most preferably between 2-4) may be positioned in a housing 2100, 3100. Furthermore, alternative configurations for connector systems 998 are possible. For example, the female connector assembly 2000a, 2000b may be reconfigured to incorporate these multiple male terminal assemblies 1430 into a single female terminal assembly 2430.

[0183] It should also be understood that the male terminal assemblies may have any number of contact arms 1494 (e.g., between 2-100, preferably between 2-50, and most preferably between 2-8) and any number of spring arms 1452 (e.g., between 2-100, preferably between 2-50, and most preferably between 2-8). As previously mentioned, the number of contact arms 1494 does not necessarily have to equal the number of spring arms. For example, there may be more contact arms 1494 than spring arms 1452. Alternatively, there may be fewer contact arms 1494 than spring arms 1452. MATERIALS AND DISCLOSURES INCORPORATED BY REFERENCE

[0184] PCT Applications Nos. PCT / US2022 / 037508, PCT / IB2022 / 057772, PCT / US2021 / 057959, PCT / US2021 / 047180, PCT / US2021 / 043788, PCT / US2021 / 043686, PCT / US2021 / 033446, PCT / US2020 / 050018, PCT / US2020 / 049870, PCT / US2020 / 014484, PCT / US2020 / 013757, PCT / US2019 / 036127, PCT / US2019 / 036070, PCT / US2019 / 036010, and PCT / US2018 / 019787, U.S. Patent Application No. 16 / 194,891 and U.S. Provisional Patent Applications 62 / 897,962, 63 / 051,639, 63 / 234,320, 63 / 337,596 and U.S. Design Application Nos. 29 / 749,813 and 29 / 749,790, all of which are incorporated by reference in their entirety and are made a part of this document.

[0185] SAE specifications, including: J1742_201003 entitled “Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses - Test Methods and General Performance Requirements,” last revised March 2010, all of which are incorporated by reference in their entirety and made a part thereof.

[0186] ASTM specifications, including: (i) D4935-18 entitled “Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials” and (ii) ASTM D257 entitled “Standard Test Methods for DC Resistance or Conductance of Insulating Materials”, all of which are incorporated by reference in their entirety and are made a part thereof.

[0187] American National Standards Institute and / or EOS / ESD Association, Inc. specifications, including: ANSI / ESD STM11.11 Surface Resistance Measurements of Static Dissipative Planar Materials, all of which are incorporated by reference and made a part thereof.

[0188] DIN specification, including connectors for electronic equipment - Tests and measurements - Part 5-2: Current-carrying capacity tests; Test 5b: Current-temperature debate (IEC 60512-5-2:2002), all of which are incorporated by reference and made part of this standard.

[0189] USCAR specifications, including: (i) SAE / USCAR-2, Revision 6, last revised in February 2013 and ISBN: 978-0-7680-7998-2, (ii) SAE / USCAR-12, Revision 5, last revised in August 2017 and ISBN: 978-0-7680-8446-7, (iii) SAE / USCAR-21, Revision 3, last revised in December 2014, (iv) SAE / USCAR-25, Revision 3, revised in March 2016 and ISBN: 978-0-7680-8319-4, (v) SAE / USCAR-37, revised in August 2008, ISBN: 978-0-7680-2098-4, (vi) SAE / USCAR-38, Revision 1, revised May 2016, ISBN: 978-0-7680-8350-7, all of which are incorporated by reference in their entirety into and made a part of this document.

[0190] Other standards, including Federal Test Standard 101C and 4046, are all incorporated herein by reference in their entirety and made a part of this document. While some embodiments have been illustrated and described, numerous modifications are contemplated without materially departing from the spirit of the disclosure, and the scope of protection is limited only by the scope of the appended claims. For example, the overall shape of the components described above may be changed to: a triangular prism, a pentagonal prism, a hexagonal prism, an octagonal prism, a sphere, a cone, a tetrahedron, a cuboid, a dodecahedron, an icosahedron, an octahedron, an ellipsoid, or other similar shape. In another example, all fusion of the busbar 200 may be performed prior to bending the busbar 200.In another example, the busbar 200 may not be welded and instead the busbar 200 may be 3D-printed with the desired configuration, or a separate component (e.g., a band) may be added to the busbar 200 to prevent the layer from peeling off during the bending process. Furthermore, in another embodiment, the female connector assemblies 2000 may be directly connected to the system 100 and the male connector assemblies 1000 may be connected to the battery modules 60. Furthermore, the bend height H may be IPN and the bending length L IPN do not remain essentially constant in all states (compressed, normal, extended); instead, the bending height H IPN and the bending length L IPN by more than 2.5% of their height / length and possibly between 3% and 25% of their height / length.

[0191] Any headings and subheadings are for convenience only and are not limiting. The word exemplary is used to serve as an example or illustration. To the extent the term "comprises," "have," or the like is used, such term is intended to be inclusive in a similar manner to the term "comprising" interpreted as a transitional word in a claim. Relational terms such as "first" and "second" and the like may be used to distinguish one entity or act from another without necessarily requiring or implying any actual relationship or sequence between those entities or acts.

[0192] Terms such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the present technology, the disclosure, the present disclosure, other variations thereof, and the like are for convenience and do not imply that any disclosure referring to such terms is material to the subject technology or that such disclosure applies to all configurations of the present technology. A disclosure referring to such terms may apply to all configurations or to one or more configurations.A disclosure that refers to one or more such terms may include one or more examples. Phrases such as "an aspect" or "some aspects" may refer to one or more aspects, and vice versa, and this applies similarly to other phrases above.

[0193] Numerous modifications to the present disclosure will become apparent to those skilled in the art in light of the foregoing description. Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It is understood that the illustrated embodiments are merely exemplary and should not be considered as limiting the scope of the disclosure. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 337,596 [0001, 0184] US 17 / 970,116

[0049] US 17 / 699,033

[0049] WO 2022 / 057772

[0049] US 20 / 50016

[0063] US 2019 / 36070

[0082] US 2018 / 019787 [0085, 0093, 0096] US 2019 / 36127

[0087] US 2021 / 043686 [0087, 0130, 0180] US 2019 / 036010 [0090, 0091, 0093, 0180] US 2019 / 036070 [0107, 0108] US 63 / 222,859

[0107] US 2020 / 049870 [0108, 0181, 0184] US 2021 / 033446

[0108] US 10948000

[0127] US 10429006

[0127] US 10220881

[0127] US 10473177

[0127] US 10538271

[0127] US 10300947

[0127] US 9789906

[0127] US 9889887

[0127] US 9944323

[0127] US 2021 / 043,788

[0180] US 63 / 286,072

[0180] US 2021 / 047,180

[0180] US 2019 / 36010

[0182] US 63 / 058,061

[0182] US 2022 / 037508

[0184] WO 2022 / 057772

[0184] US 2021 / 057959

[0184] US 2021 / 047180

[0184] US 2021 / 043788

[0184] US 2021 / 043686

[0184] US 2021 / 033446

[0184] US 2020 / 050018

[0184] US 2020 / 014484

[0184] US 2020 / 013757

[0184] US 2019 / 036127

[0184] US 2019 / 036070

[0184] US 2019 / 036010

[0184] US 2018 / 019787

[0184] US 16 / 194,891

[0184] US 62 / 897,962

[0184] US 63 / 051,639

[0184] US 63 / 234,320

[0184] US 29 / 749,813

[0184] US 29 / 749,790

[0184] Cited non-patent literature

[0000] Jason B. Quinn et al., Paper Review: Energy Density of Cylindrical Li-Ion Cells: A Comparison of Commercial 18650 to the 21700 Cells2018 J. Electrochem. Soc. 165 A3284

[0127] Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses - Test Methods and General Performance Requirements", last revised in March 2010

[0185] ISBN: 978-0-7680-7998-2

[0189] ISBN: 978-0-7680-8446-7

[0189] ISBN: 978-0-7680-8319-4

[0189] ISBN: 978-0-7680-2098-4

[0189] ISBN: 978-0-7680-8350-7

[0189]

Claims

[1] An elastically deformable connector system for use in connecting battery modules in a battery pack, the connector system comprising: a busbar arrangement with: (i) a busbar having a plurality of individual conductors arranged vertically to form a first edge region, a second edge region and an elastically deformable intermediate region located between the first and second edge regions; (ii) a first male connector assembly connected to the first edge portion of the busbar; (iii) a second male connector assembly connected to the second edge portion of the busbar; (iv) a busbar enclosure enclosing a substantial extent of the busbar; and wherein, after the busbar assembly has been electrically connected to a pair of battery modules in the battery pack, the intermediate region is capable of elastically deforming to accommodate both compression movement and expansion movement of the pair of battery modules. [2] The elastically deformable connector system of claim 1, wherein: (i) the first edge region is substantially coplanar with the second edge region, and (ii) the majority of the elastically deformable intermediate region is not coplanar with either the first or second edge region. [3] The elastically deformable connector system of claim 1, wherein: (i) the first and second edge regions lie substantially in a first plane, and (ii) the majority of the elastically deformable intermediate region lies outside the first plane. [4] The elastically deformable connector system of claim 1, wherein the first edge region and the second edge region have a substantially linear configuration. [5] The elastically deformable connector system of claim 4, wherein the elastically deformable intermediate region has at least one curvilinear extension. [6] The elastically deformable connector system of claim 5, wherein the interaction between a first portion of the elastically deformable intermediate portion and the first edge portion defines a first outer recess, wherein the interaction between a second portion of the elastically deformable intermediate portion and the second edge portion defines a second outer recess, and wherein the first outer recess and the second outer recess are in an opposite positional relationship. [7] The elastically deformable connector system of claim 6, wherein the first outer recess has an outer recess angle defined in a neutral position, the outer recess angle being reduced when a compressive activation force FA is applied to the busbar. [8] The elastically deformable connector system of claim 6, wherein the first outer recess has an outer recess angle defined in a neutral position, the outer recess angle being increased when an expansion activation force F A is exerted on the busbar. [9] The elastically deformable connector system of claim 1, wherein the elastically deformable intermediate region has a curved configuration substantially corresponding to the configuration of the capital letter Omega in the Greek alphabet. [10] The elastically deformable connector system of claim 1, wherein the elastically deformable intermediate region has a curved configuration substantially corresponding to the configuration of the Ohm sign, a unit of energy management. [11] The elastically deformable connector system of claim 1, wherein the busbar in the neutral position has a molded overall length L BN after the busbar has been bent and assembled, and the total length L BN can change by 5% to compensate for the compression and expansion of the pair of battery modules. [12] The elastically deformable connector system of claim 1, wherein the busbar in the neutral position has a molded overall length L BN after the busbar has been bent and assembled, and the total length L BN when applying an activation force F Awhich is less than 50 Newtons. [13] The elastically deformable connector system of claim 12, wherein the activation force F A is a pressure force, and wherein the application of the pressure activation force F A on the busbar the formed total length L BN the busbar by 4 mm. [14] The elastically deformable connector system of claim 12, wherein the activation force F A is an expansion force and where the application of the expansion activation force F A on the busbar the formed total length L BN the busbar by 4 mm. [13-1] The elastically deformable connector system of any one of claims 1-10, wherein the intermediate region has a bending height H IPN of more than 10 mm. [14-1] The elastically deformable connector system of any one of claims 1 to 10, wherein the busbar has a bending height H IPNand where the bending height H IPN remains essentially constant when the intermediate region of the busbar is elastically deformed to accommodate the compression and expansion of the pair of battery modules. [15] The elastically deformable connector system of claim 1, wherein the busbar has an unbent total length L UB and wherein the busbar in the neutral position has a shaped total length L BN after the busbar has been bent and assembled, and wherein the formed total length L BN is smaller than the unbent total length L UB . [16] The elastically deformable connector system of claim 15, wherein the molded total length L BN is at least 10% less than the non-bent total length L UB . [17] The elastically deformable connector system of claim 15, wherein the molded total length L BNis at least 20% less than the non-bent total length L UB . [18] The elastically deformable connector system of claim 1, wherein the elastically deformable bus bar has at least one portion that has been selectively fused into a solid single conductor. [19] The elastically deformable connector system of any one of claims 1-18, wherein the intermediate region has a bending height H IPN of more than 10 mm. [20] The elastically deformable connector system of any one of claims 1-18, wherein the busbar has a bending height H IPN and where the bending height H IPN remains essentially constant when the intermediate region of the busbar is elastically deformed to compensate for the compression and expansion of the battery module pair. [21] The elastically deformable connector system of any one of claims 1-18, wherein the busbar has a bending height H IPNand where the bending height H IPN changes by no more than 2.5% when the intermediate region is elastically deformed to compensate for the compression and expansion of the pair of battery modules. [22] The elastically deformable connector system of any one of claims 1-18, wherein the intermediate region has a bending length L IPN which is larger than 10 mm. [23] The elastically deformable connector system of any one of claims 1-18, wherein the intermediate region has a bending length L IPN and where the bending length L IPN remains essentially constant when the intermediate region is elastically deformed to compensate for the compression and expansion of the pair of battery modules. [24] The elastically deformable connector system of any one of claims 1-18, wherein the intermediate region has a bending length L IPN and where the bending length L IPNchanges by no more than 2.5% when the intermediate region is elastically deformed to compensate for the compression and expansion of the pair of battery modules. [25] The elastically deformable connector system of any one of claims 1-18, wherein the intermediate region has a gap length L GN in a neutral state of at least 15 mm. [26] The elastically deformable connector system of claim 25, wherein the gap length L GN in a compressed state of the busbar is smaller than the gap length L GN in neutral state. [27] The elastically deformable connector system of claim 25, wherein the gap length L GN in the extended state of the busbar is greater than the gap length L GN in neutral state. [28] The elastically deformable connector system of any one of claims 1-18, wherein the elastically deformable intermediate region comprises: (i) a pair of fused segments and (ii) an unfused segment disposed between the fused segments. [29] The elastically deformable connector system of any one of claims 1 to 18, wherein the first edge region comprises (i) a fully fused region and (ii) an unfused region adjacent to the fully fused region. [30] The elastically deformable connector system of claim 29, wherein the fully fused region is included in an end sector of the busbar and (ii) the unfused region is included in the middle sector. [31] The elastically deformable connector system of any one of claims 1 to 18, wherein the elastically deformable intermediate region comprises a pair of fused regions and at least one unfused region disposed between the fused regions. [32] The elastically deformable connector system of any one of claims 1 to 18, wherein the elastically deformable intermediate region does not include a region that is completely solidified into a single solid conductor. [33] An elastically deformable connector system for use in connecting battery modules in a battery pack, the connector system comprising: a busbar arrangement with: (i) a busbar having a plurality of individual conductors that have undergone a fusion process to form a solid single conductor in selected regions of the busbar, the busbar having a first edge region, a second edge region, and an elastically deformable intermediate region disposed between the first and second edge regions; (ii) a first male connector assembly connected to the first edge portion of the busbar; (iii) a second male connector assembly connected to the second edge portion of the busbar; (iv) a busbar enclosure enclosing a substantial extent of the busbar; and wherein, after the busbar assembly has been electrically connected to a pair of battery modules in the battery pack, the intermediate region is capable of elastically deforming to accommodate both compression movement and expansion movement of the pair of battery modules. [34] The elastically deformable connector system of claim 33, wherein: (i) the first edge region is substantially coplanar with the second edge region, and (ii) the majority of the elastically deformable intermediate region is not coplanar with either the first or second edge region. [35] The elastically deformable connector system of claim 33, wherein: (i) the first and second edge regions lie substantially in a first plane; and (ii) the majority of the elastically deformable intermediate region lies outside the first plane. [36] The elastically deformable connector system of claim 33, wherein the first edge region and the second edge region have a substantially linear configuration. [37] The elastically deformable connector system of claim 36, wherein the elastically deformable intermediate region has at least one curvilinear extension. [38] The elastically deformable connector system of claim 37, wherein the cooperation between a first portion of the elastically deformable intermediate portion and the first edge portion defines a first outer recess, wherein the cooperation between a second portion of the elastically deformable intermediate portion and the second edge portion defines a second outer recess, and wherein the first outer recess and the second outer recess are in an opposite positional relationship. [39] The elastically deformable connector system of claim 38, wherein the first outer recess has an outer recess angle defined in a neutral position, the outer recess angle being reduced when a compressive activation force FA is applied to the busbar. [40] The elastically deformable connector system of claim 38, wherein the first outer recess has an outer recess angle defined in a neutral position, the outer recess angle being increased when an expansion activation force F A is exerted on the busbar. [41] The elastically deformable connector system of claim 33, wherein the elastically deformable intermediate region has a curved configuration substantially corresponding to the configuration of the capital letter Omega in the Greek alphabet. [42] The elastically deformable connector system of claim 33, wherein the busbar in the neutral position has a molded overall length L BN after the busbar has been bent and assembled, and the total length L BN by 5% to compensate for the compression and expansion of the pair of battery modules. [43] The elastically deformable connector system of claim 33, wherein the busbar in the neutral position has a molded overall length L BN after the busbar has been bent and assembled, and the total length L BN when applying an activation force F A which is less than 50 Newtons. [44] The elastically deformable connector system of claim 43, wherein the activation force F A is a pressure force and where the application of the pressure activation force F Aon the busbar the formed total length L BN the busbar by 4 mm. [45] The elastically deformable connector system of claim 43, wherein the activation force F A is an expansion force and where the application of the expansion activation force F A on the busbar the formed total length L BN the busbar by 4 mm. [46] The elastically deformable connector system of any one of claims 33-43, wherein the intermediate region has a bending height H IPN which is larger than 10 mm. [47] The elastically deformable connector system of any of claims 33-43, wherein the busbar has a bending height H IPN and where the bending height H IPN remains essentially constant when the intermediate region of the busbar is elastically deformed to compensate for the compression and expansion of the pair of battery modules. [48] The elastically deformable connector system of any one of claims 33-43, wherein the intermediate region has a bending length L IPN and where the bending length L IPN changes by no more than 2.5% when the intermediate region is elastically deformed to compensate for the compression and expansion of the pair of battery modules. [49] The elastically deformable connector system of any one of claims 33-43, wherein the intermediate region has a gap length L GN in a neutral state of at least 15 mm. [50] The elastically deformable connector system of claim 49, wherein the gap length L GN in a compressed state of the busbar is smaller than the gap length L GN in neutral state. [51] The elastically deformable connector system of claim 49, wherein the gap length L GN in the extended state of the busbar is greater than the gap length L GNin neutral state. [52] The elastically deformable connector system of any one of claims 33-43, wherein the elastically deformable intermediate region comprises: (i) a pair of fused segments and (ii) an unfused segment disposed between the fused segments. [53] The elastically deformable connector system of any one of claims 33-43, wherein the elastically deformable intermediate region does not include a region that is completely solidified into a single solid conductor. [54] An elastically deformable connector system for use in connecting battery modules in a battery pack, the connector system comprising: a busbar arrangement with: (i) a bus bar having a plurality of individual conductors arranged vertically to provide: (a) a first edge region having a first male connector assembly, (b) a second edge region having a second male connector assembly, and wherein the second edge region is substantially coplanar with the first edge region, and (c) an elastically deformable intermediate region disposed between the first and second edge regions, and wherein a majority of the elastically deformable intermediate region is not coplanar with either the first or second edge regions; (ii) a busbar housing enclosing a substantial extent of the elastically deformable intermediate region; (iii) at least one connector coupled to the busbar; and wherein, after the bus bar assembly has been electrically connected to a pair of battery modules in the battery pack, the intermediate region elastically deforms to accommodate both compression movement and expansion movement of the pair of battery modules. [55] An elastically deformable connector system for use in connecting battery modules in a battery pack, the connector system comprising: a busbar assembly comprising a busbar having a plurality of individual conductors arranged vertically to provide: (i) a first edge region located in a first plane; (ii) a second edge region located in the first plane; (iii) an elastically deformable intermediate region located between the first and second edge regions, a major portion of the elastically deformable intermediate region being located outside the first plane; and wherein, after the bus bar assembly has been electrically connected to a pair of battery modules in the battery pack, the intermediate portion elastically deforms to accommodate both compression movement and expansion movement of the pair of battery modules. [56] An elastically deformable connector system for use in connecting battery modules in a battery pack, the connector system comprising: a busbar assembly including a busbar having a plurality of individual conductors arranged vertically to provide: (i) a first edge region; (ii) a second edge region; (iii) an elastically deformable intermediate region disposed between the first and second edge regions; (iv) a shaped length L BN extending between opposite end edges of the busbar assembly; and where the formed length L BN can be changed by more than 2.5% if an activation force F A which is less than 50 Newtons, is applied to the busbar. [57] An elastically deformable connector system for use in connecting battery modules in a battery pack, the connector system comprising: a busbar assembly comprising a busbar having a plurality of individual conductors arranged vertically to provide: (i) a first edge region having a substantially linear configuration; (ii) a second edge region having a substantially linear configuration; (iii) an elastically deformable intermediate region located between the first and second edge regions and having at least one curved extension; and wherein the curved extension of the intermediate region is configured to deform elastically to absorb the effects of an activation force F A to the busbar. [58] The elastically deformable connector system of any one of claims 54-57, wherein the cooperation between a first portion of the elastically deformable intermediate portion and the first edge portion defines a first outer recess, wherein the cooperation between a second portion of the elastically deformable intermediate portion and the second edge portion defines a second outer recess, and wherein the first outer recess and the second outer recess are in an opposite positional relationship. [59] The elastically deformable connector system of claim 58, wherein the first outer recess has an outer recess angle defined in a neutral position, the outer recess angle being reduced when a pressure activation force F A exerted on the busbar arrangement. [60] The elastically deformable connector system of claim 58, wherein the first outer recess has an outer recess angle defined in a neutral position, the outer recess angle being increased when an expansion activation force F A exerted on the busbar arrangement. [61] The elastically deformable connector system of any one of claims 54-57, wherein the elastically deformable intermediate region has a curved configuration substantially corresponding to the configuration of the capital letter Omega in the Greek alphabet. [62] The elastically deformable connector system of any one of claims 54-57, wherein the busbar in the neutral position has a molded overall length L BN after the busbar has been bent and assembled, and the total length L BN can change by 5% to compensate for the compression and expansion of the pair of battery modules. [63] The elastically deformable connector system of any one of claims 54-55, wherein the busbar in the neutral position has a molded overall length L BN after the busbar has been bent and assembled, and the total length L BN when applying an activation force F A which is less than 50 Newtons. [64] The elastically deformable connector system of claim 63, wherein the activation force F A is a pressure force, and wherein the application of the pressure activation force F Aon the busbar the formed total length L BN the busbar by 4 mm. [65] The elastically deformable connector system of claim 63, wherein the activation force F A is an expansion force and where the application of the expansion activation force F A on the busbar the formed total length L BN the busbar by 4 mm. [66] The elastically deformable connector system of any one of claims 54-57, wherein the intermediate region has a bending height H IPN which is larger than 10 mm. [67] The elastically deformable connector system of any one of claims 54-57, wherein the busbar has a bending height H IPN and where the bending height H IPN remains essentially constant when the intermediate region of the busbar is elastically deformed to compensate for the compression and expansion of the battery module pair. [68] The elastically deformable connector system of any one of claims 54-57, wherein the intermediate region has a bending length L IPN and wherein the bending length L IPN changes by no more than 2.5% when the intermediate region is elastically deformed to compensate for the compression and expansion of the pair of battery modules. [69] The elastically deformable connector system of any one of claims 54-57, wherein the intermediate region has a gap length L GN in a neutral state of at least 15 mm. [70] The elastically deformable connector system of claim 69, wherein the gap length L GN in a compressed state of the busbar is smaller than the gap length L GN in neutral state. [71] The elastically deformable connector system of claim 69, wherein the gap length L GN in the extended state of the busbar is greater than the gap length L GNin neutral state. [72] The elastically deformable connector system of any one of claims 54-57, wherein the elastically deformable intermediate region comprises: (i) a pair of fused segments and (ii) an unfused segment disposed between the fused segments. [73] The elastically deformable connector system of any one of claims 54-57, wherein the elastically deformable intermediate region does not include a region that is completely solidified into a single solid conductor. [74] An elastically deformable connector system for use in connecting battery modules in a battery pack. [75] A battery pack comprising a plurality of battery modules and an elastically deformable connector system configured to interconnect the battery modules contained in the plurality of battery modules. [76] A power distribution assembly comprising a battery pack having an elastically deformable connector system configured to couple one component contained within the battery pack to another component within the battery pack. [77] Elastically deformable intermediate region of a busbar configured to compensate for (i) both compression and expansion movements of the battery module pair or (ii) material states of the battery module pair. [78] Busbar assembly connected to a pair of battery modules in the battery pack and configured to compensate for both compression movement and expansion movement of the pair of battery modules. [79] Busbar assembly connected to a pair of battery modules in the battery pack and configured to compensate for material conditions of the pair of battery modules. [80] Power distribution arrangement comprising the busbar according to any one of claims 1-79.

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