Module to module connector

Abstract

A connector for connecting to a first battery module tab having a connection surface comprises a first frame, a flexible beam member, a first biasing insert, and a first actuator. The first frame defines at least one first frame contact window and a first receiving channel. The flexible beam member comprises an insulator and a conductor comprising at least one first conductor element. The first biasing insert defines a first contact surface. The first actuator defines a first actuation surface and a first push surface. When the first battery module tab is received in the first receiving channel of the first frame, force applied to the first actuator to engages the first actuation surface and the first push surface, biases the at least one first conductor element and the connection surface into contact, and moves the first actuator from an unlatched to a latched position.

Description

177817.208127MODULE TO MODULE CONNECTOR CROSS-REFERENCE TO RELATED PATENTS

[0001] This application claims the benefit of U.S. Provisional Application 63 / 470,029 filed May 31, 2023, the disclosure of which is incorporated by reference in its entirety. FIELD OF THE DISCLOSURE

[0002] The present disclosure generally relates to a connector for electrically connecting a terminal of a battery module to an electrical conductor. This connector can be used to electrically connect several battery modules. The connector is suited for use in the field of electric vehicles. BACKGROUND

[0003] In electrical energy storage systems, especially those used in electric vehicles, it is customary to combine several battery cells to form individual battery modules. Each module usually comprises two terminals or terminals having different poles. The battery modules are connected to each other, that is to say brought into electrical contact with each other, by means of connector such as a busbar, generally made of copper. Usually, a busbar is screwed, welded, or bolted to the terminals of the modules that it connects, which is not always suitable for a high volume of manufacture. Plus, busbar assemblies can be rigid and thus susceptible quality issues such as poor connection, excess resistance and even short circuits caused by vibrations and movement of the battery cells relative to one another. Finally, assembly can be difficult, with alignment and tolerance issues that can be unforgiving and ultimately result in poor connections and even short circuits and connection failures.

[0004] Many prior art connectors, such as busbar and flexible electrical connectors known in the art require copper amounts that are cost-prohibitive in vehicular applications. Of course, the use of connectors in vehicle manufacturing must be user friendly. Once assembled in a vehicle, connectors must provide flexible connections to ensure a robust connection.

[0005] Considering the challenges above and the evolving strategies required to deal with the challenges, there remains a continued need for an improved electrical connector which can be assembled efficiently with cost-effective components. Once assembled, the electrical connector should be designed for the efficient assembly of high-voltage electrical energy storage systems, and provide a robust electrical connection in the wide array of challenging conditions associated with the use in vehicles.SUMMARY

[0006] A connector for connecting to a first battery module tab having a connection surface is disclosed. The connector comprises a first frame, a flexible beam member, a first biasing insert, and a first actuator. The first frame has a first frame body defining at least one first frame contact window and a pair of first frame legs, which cooperate with the first frame body to define a first receiving channel. The flexible beam member has a first end and a second end and comprises a conductor and an insulator. The insulator is at least partially disposed about the conductor. The conductor comprises at least one first conductor element including a first plurality of contact extensions extending from the conductor body at the end. The at least one first conductor element is received in the at least one first frame contact window. The first biasing insert is received by the first frame and defines a first push surface and a first contact surface. The first actuator is movably mounted to the first frame and comprises a first actuation surface. The first actuation surface is positioned to contact the first push surface of the first biasing insert and bias the at least one first conductor element and the first battery module tab into contact. When the first battery module tab is received in the first receiving channel of the first frame, force applied to the first actuator to engage the first actuation surface and the first push surface, biases the at least one first conductor element and connection surface of first battery module into contact, and moves the first actuator from the unlatched position into the latched position.

[0007] In one embodiment, each of the first plurality of contact extensions are semi- circular and separated by a plurality of gaps and arranged in a row extending laterally across the conductor.

[0008] In some embodiments, the conductor comprises a primary contact having a first primary contact end, a primary contact body, and a second primary contact end, and a secondary contact having a first secondary contact end, a secondary contact body, and a second secondary contact end. The primary contact includes one of the at least one first conductor element at the first primary contact end. The secondary contact is adjacent to the primary contact and includes another of the at least one first conductor element at the first secondary contact end. In some such embodiments, the secondary contact is longer than the primary contact.

[0009] In one embodiment, the flexible beam member includes a central flex portion comprising a plurality of corrugations.

[0010] In one embodiment, the first frame includes a first of the at least one first frame contact window for a first of the at least one first conductor element and a second of the at least one first frame contact window for receiving a second of the at least one first conductor element.

[0011] In some embodiments, the first frame includes a first upper frame portion anda first lower frame portion defining the at least one first frame contact window. In these embodiments, the first end of the flexible beam member is disposed between the first upper frame portion and the first lower frame portion and one or more of the at least one first conductor element is disposed in the one or more of the at least one contact window.

[0012] In one embodiment, the first biasing insert is at least partially disposed between the first actuator and the first frame.

[0013] In some embodiments, the first biasing insert includes a first biasing insert body and a first pair of wings extending from opposite sides of the first biasing insert body. In other embodiments, the first biasing insert includes a first biasing insert body comprising a plurality of corrugations.

[0014] In some embodiments, the actuator is selected from a slide, a dial, and a button.

[0015] In some embodiments, the actuator includes at least one latch, and the frame portion includes at least one latching element. In these embodiments, the application of force to the actuator moves the at least one latch into engagement with the at least one latching element and the actuator into the latch position.

[0016] In some embodiments, at least a portion of the first actuation surface is further defined as an angled surface.

[0017] In one embodiment, the first frame comprises a pair of exterior rails, and the first actuator includes a body and a pair of arms including an inner surface defining a pair of rail channels shaped to receive each of the pair of rails of the first frame. Each of the pair of exterior rails is slidably received in each of the pair of rail channels. Sliding of the applicator engages the first actuation surface and the first push surface, biases the connection surface of first battery module tab into contact with the at least one first conductor element, and moves the first actuator from the unlatched position to the latched position. In some such embodiments, the first actuator includes a least one end latch and the first frame includes at least one latching surface. In these embodiments, sliding the actuator moves the at least one end latch into engagement with the at least one latching surface and the first actuator into the latched position.

[0018] In one embodiment, the first frame comprises a lower frame portion and a first mounting portion including a body defining an opening, and the actuator comprises a dial having a handle portion and a disc portion presenting the first actuation surface, wherein the dial is moveably received in the opening. Rotation of the dial engages the first actuation surface and the first push surface, biases the connection surface of the first battery module tab into contact with the at least one first conductor element, and moves the first actuator between the unlatched position and the latched position. In some such embodiments, a periphery of the disc portion includes a latch, and the body includes a latch opening. In these embodiments, rotation of the dial rotates the latch into engagement with the latch opening and the first actuator intothe latched position.

[0019] In one embodiment, the first frame comprises a lower frame portion, an upper frame portion, and a first mounting portion including a body defining an opening, and the actuator comprises a button having a push portion and a base portion presenting the actuation surface, wherein the button is moveably received in the opening. Pushing of the button engages the first actuation surface and the first push surface, biases the at least one first conductor element into contact with the connection surface of first battery module tab, and moves the first actuator between the unlatched position and the latched position. In some such embodiments, the button further comprises a plurality of locking extensions and the first mounting portion includes at least one locking surface. In these embodiments, pushing the button moves a portion of the plurality of locking extensions into engagement with the at least one locking surface, and the first actuator into the latched position.

[0020] In one embodiment, the connector can also connect to a second battery module tab having a second connection surface. In this embodiment, the connector further comprises a second frame, a second biasing insert, and a second actuator. The second frame has a second frame body defining at least one second frame contact window and a pair of second frame legs defining a second receiving channel. The second biasing insert is received by the second frame and defines a second push surface and a second contact surface. The second actuator is movably mounted to the second frame and defines a second actuation surface positioned to contact the second push surface of the second biasing insert and bias the at least one second conductor element and a second battery module tab into contact. When the second battery module tab is received in the second receiving channel of the second frame, force applied to the second actuator to engage the second actuation surface and the second push surface, biases the at least one second conductor element and connection surface of second battery module into contact, and moves the second actuator from the unlatched position into the latched position.

[0021] A method of connecting a connector to a first battery module tab having a first connection surface is also disclosed. The connector has a first and a second end and includes a first frame defining a first receiving channel, a first actuator, a first biasing insert, and a flexible beam member including a conductor and an insulator at least partially disposed about the conductor. The connector comprises at least one first conductor element including a first plurality of contact extensions at the first end. The method comprising the steps of: positioning the first battery module tab in the first receiving channel; and applying force to the first actuator to move the first actuator from an unlatched position to a latched position. Movement of the first actuator biases the at least one first conductor element and the first connection surface into contact to create a robust electrical connection.

[0022] In one such embodiment, the conductor comprises at least one secondconductor element including a second plurality of contact extensions, a second frame defining a second receiving channel, a second actuator, and a second biasing insert at the second end. In this embodiment, the method further comprises the steps of: positioning a second battery module tab in the second receiving channel; and applying force to the second actuator to move the second actuator into a latched position. Movement of the second actuator biases the at least one second conductor element and the second connection surface into contact to create a robust electrical connection. In one embodiment, the conductor comprises a primary contact and a secondary contact. The step of applying force to the first actuator biases a first of the at least one first conductor element on the primary contact and a second of the at least one first conductor element on the secondary contact into contact with the first battery module tab. The step of applying force to the second actuator biases a first of the at least one second conductor element on the primary contact and a second of the at least one second conductor element on the secondary contact into contact with the second battery module tab.

[0023] In some embodiments, the step applying force to first actuator and / or the second actuator and moving the first actuator and / or the second actuator from the unlatched position to the latched position uncovers a verification element comprising a power signal, a QR code, a barcode, a data matrix code, or a color code.

[0024] Advantageously, the connectors and methods of this disclosure provides, no- tool click on to provide stable contact force for long term reliability. Further, the connector allows for greater misalignment tolerances (X, Y, and / or Z / longitudinal, vertical, and / or lateral misalignment) during assembly. Once connected, the flexible beam member and the conductor elements disclosed provide multiple contact points to reduce the contact resistance.

[0025] These and other features of the disclosure will be more fully understood and appreciated by reference to the description of the examples and the drawings.

[0026] Before the examples of the disclosure are explained in detail, it is to be understood that the disclosure is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The disclosure may be implemented in various other examples and of being practiced or being conducted in alternative ways not expressly disclosed herein. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various examples. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the disclosure to any specific order or number of components. Nor should the use of enumeration be construed as excluding from thescope of the disclosure any additional steps or components that might be combined with or into the enumerated steps or components. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a cut-out perspective view of a first battery module having a first battery module tab and a second battery module having a second battery module tab.

[0028] Figure 2 is an embodiment of a prior art connector comprising a busbar that can be mounted and bolted in place to connect the first battery module tab and the second battery module tab to provide an electrical connection between the first and the second battery modules.

[0029] Figure 3 is a top perspective view of an embodiment of a connector including a first frame, a first actuator, a second frame, a second actuator, and a flexible beam member extending therebetween, wherein the first frame defines a first receiving channel for receiving a first battery module tab and the second frame defines a second receiving channel for receiving a second battery module tab.

[0030] Figure 4 is a bottom perspective view of the connector of Figure 3 illustrating the first frame defining the first receiving channel and two first contact windows and two first conductor elements framed in the first contact windows, and the second frame defining the second receiving channel and two second contact windows and two second conductor elements framed in the second contact windows.

[0031] Figure 5 is an exploded view of the connector of Figure 3.

[0032] Figure 6 is a perspective view of the connector of Figure 3 including a first connection assembly in an unlatched position and a second connection assembly in an unlatched position.

[0033] Figure 7 is a perspective view of the connector of Figure 3 with the first and the second connection assemblies in a latched position.

[0034] Figure 8 is a cross-sectional view of the first connection assembly at a first end of the connector of Figure 6 at 8-8 in an unlatched position.

[0035] Figure 9 is a cross-sectional view of the first connection assembly at a first end of the connector of Figure 7 at 9-9 in a latched position.

[0036] Figure 10 is a cross-sectional view of the connector of Figure 7 at 10-10.

[0037] Figure 11 is a cross-sectional view of the first connection assembly at a first end of the connector of Figure 7 at 11-11 in a latched position.

[0038] Figure 12 is a top perspective view of an embodiment of a connector including a first frame, a first actuator comprising a slide, and a flexible beam member, wherein the first frame defines a first receiving channel for receiving a first battery module tab.

[0039] Figure 13 is an exploded view of a first connection assembly of the connector of Figure 12.

[0040] Figure 14 is a perspective view of the connector of Figure 11 including a first connection assembly.

[0041] Figure 15 is a perspective view of the first connection assembly of Figure 14 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the actuator in an unlatched position.

[0042] Figure 16 is a perspective view of the first connection assembly of Figure 15 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the actuator in a latched position.

[0043] Figure 17 is a cross-sectional view of the first connection assembly at a first end of the connector of Figure 15 at 17-17 in an unlatched position.

[0044] Figure 18 is a cross-sectional view of the first connection assembly at a first end of the connector of Figure 16 at 18-18 in a latched position.

[0045] Figure 19 is a top perspective view of an embodiment of a connector including a first frame, a first actuator comprising a dial, and a flexible beam member, wherein the first frame defines a first receiving channel for receiving a first battery module tab.

[0046] Figure 20 is an exploded view of a first connection assembly of the connector of Figure 19.

[0047] Figure 21 is an enlarged view of the actuator or dial of Figure 19.

[0048] Figure 22 is a perspective view of the connector of Figure 19 including a first connection assembly.

[0049] Figure 23 is a perspective view of the first connection assembly of Figure 22 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the dial unexposed in an unlatched position.

[0050] Figure 24 is a perspective view of the first connection assembly of Figure 23 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the dial exposed and still in an unlatched position.

[0051] Figure 25 is a perspective view of the first connection assembly of Figure 23 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the dial rotated and in a latched position.

[0052] Figure 26 is a cross-sectional view of the first connection assembly of Figure 23 at 26-26 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the dial unexposed in an unlatched position.

[0053] Figure 27 is a cross-sectional view of the first connection assembly of Figure 24at 27-27 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the dial exposed and still in an unlatched position.

[0054] Figure 28 is a cross-sectional view of the first connection assembly of Figure 25 at 28-28 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the dial rotated and in a latched position.

[0055] Figure 29 is a perspective top cross-sectional view of the first connection assembly of Figure 23 at 29-29 including the dial having a disc portion including a latch on the periphery thereof engaged with the frame to prevent rotation of the dial.

[0056] Figure 30 is a top cross-sectional view of the first connection assembly of Figure 24 at 30-30 including the dial having a disc portion including a latch on the periphery thereof disengaged with the frame to allow rotation of the dial.

[0057] Figure 31 is a cross-sectional view of the first connection assembly of Figure 25 at 31-31 including the dial having a disc portion including a latch on the periphery thereof rotated into a latch opening on the frame and in a latched position.

[0058] Figure 32 is a perspective view of the first connection assembly of Figure 25.

[0059] Figure 33 is a cross-sectional view of the first connection assembly of Figure 32 at 33-33.

[0060] Figure 34 is a top perspective view of an embodiment of a connector including a first frame, a first actuator comprising a button, and a flexible beam member, wherein the first frame defines a first receiving channel for receiving a first battery module tab.

[0061] Figure 35 is an exploded view of a first connection assembly of the connector of Figure 34.

[0062] Figure 36 is a perspective view of the first connection assembly of Figure 34 including the first frame and the button in an unlatched position.

[0063] Figure 37 is a perspective view of the first connection assembly of Figure 36 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the button in an unlatched position.

[0064] Figure 38 is a perspective view of the first connection assembly of Figure 37 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the button pressed down and in a latched position.

[0065] Figure 39 is a cross-sectional view of the first connection assembly of Figure 36 at 39-39 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the button in an unlatched position.

[0066] Figure 40 is a cross-sectional view of the first connection assembly of Figure 37 at 40-40 including the first frame defining a first receiving channel with a first battery moduletab received in the first receiving channel and the button still in an unlatched position.

[0067] Figure 41 is a cross-sectional view of the first connection assembly of Figure 38 at 41-41 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the button compressed and in a latched position.

[0068] Figure 42 is a cross-sectional view of the first connection assembly of Figure 38 at 42-42 including the first frame defining a first receiving channel with a first battery module tab received in the first receiving channel and the button compressed and in a latched position.

[0069] Figure 43 is flow chart describing a method of connecting an embodiment of a connector to a first battery module tab. DETAILED DESCRIPTION

[0070] A connector for connecting to a first battery module tab having a connection surface is disclosed. Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, various embodiments of illustrated and generally designated at 10, 210, 410, and 610. Various embodiments of the connector disclosed herein include a first connection assembly and a second connection assembly having a flexible beam assembly disposed therebetween. It should be appreciated that the flexible beam assembly disclosed can be disposed between various types of connection assemblies and that the flexible beam assembly is not limited to use with the connection assemblies disclosed herein or use with any particular connection assembly. While the connector is discussed below in connection with battery modules, e.g., connecting electrical terminals of a plurality of batteries, the connector, connection assembly, flexible beam assembly, and the methods disclosed herein are suitable for use in a wide range of applications including applications outside of battery modules.

[0071] In some applications, the connector can be used instead of prior art connector including a busbar bolted between battery modules. Figure 1 is a cut-out perspective view of a first battery module 2 having a first battery module tab 3 and a second battery module 4 having a second battery module tab 5. Figure 2 is an example of a prior art connector comprising a busbar 6 that can be mounted and bolted in place to connect the first battery module tab 3 and the second battery module tab 5 to provide an electrical connection between the first and the second battery modules 2, 4.

[0072] The making and using of the embodiments are discussed in detail below. It should be understood, however, that the detailed description and specific examples, while indicating a particular manner of making and using the connector, are intended for purposes of illustration only and are not intended to limit the scope the connector. The structural position of the various components as described, such as upper, lower, top, bottom, etc., is not absolute, but rather relative. These orientation expressions are appropriate when the various components are arranged as shown in the figures, but when the position of the various components in thefigures is changed, these orientation expressions are also changed accordingly.

[0073] Generally, the connector has a first end and a second end and comprises a first frame, a flexible beam member, a first biasing insert, and a first actuator. The first frame, the first biasing insert, and the first actuator are collectively referred to as a first connection assembly. The first connection assembly is typically located at the first end of the connector. Some embodiments of the connector include a second connection assembly including a second frame, a second biasing insert, and a second actuator. If included, the second connection assembly is typically located at the second end of the connector. Generally, application of force to, and movement of, the first actuator to the latched position deforms and locks the first biasing insert in position to provide contact force between conductor element(s) of the flexible beam member and a battery module tab. As such, the first connection assembly provides contact force to push the contact points of the conductor element(s) into the battery module tab and retain robust contact therebetween.

[0074] It should be appreciated that the first and second connection assemblies can and often are of the same construction, e.g. the same design. As such, in a typical embodiment, the first connection assembly is simply the assembly included at the first end of the flexible beam member and the second connection assembly is simply the assembly included at the second end of the flexible beam assembly. To this end, the words first and second as used to describe the connection assemblies through this description can be used interchangeably and are most often described in the context of a “first connection assembly” and are not always described in duplicate as “a second connection assembly” for the sake of brevity.

[0075] In various embodiments, the first frame has a first frame body defining at least one first frame contact window and a pair of first frame legs, which cooperate with the first frame body to define a first receiving channel. It should be appreciated that the frame may comprise one or more portions. The flexible beam member has a first end and a second end and comprises a conductor and an insulator. The insulator is at least partially disposed about the conductor. The conductor comprises at least one first conductor element including a first plurality of contact extensions extending from the conductor body at the end. It should be appreciated that the conductor can comprise one or more contacts. The at least one first conductor element of the conductor is received in the at least one first frame contact window of the first frame. The first biasing insert is received by the first frame and defines a first push surface and a first contact surface. The first actuator is movably mounted to the first frame and defines a first push surface and a first contact surface. The first actuator comprises a first actuation surface positioned to contact the first push surface of the first biasing insert and bias the at least one first conductor element and the first battery module tab into contact. When the first battery module tab is received in the first receiving channel of the first frame, force appliedto the first actuator to engage the first actuation surface and the first push surface, biases the at least one first conductor element and connection surface of first battery module into contact, and moves the first actuator from the unlatched position into the latched position.

[0076] As is described above, the frame can comprise one or more portions. In some of the embodiments described herein the frame comprises a single portion, the frame comprises two portions, and the frame comprises three portions. The frame typically comprises a polymeric material, e.g. a thermoplastic or a thermoplastic elastomer. In many embodiments, the one or more portions of the frame are molded, e.g. injection molded.

[0077] The flexible beam member is disclosed herein, and its use is not limited to the particular connection assemblies described herein.

[0078] As described above, the flexible beam member comprises the conductor. The conductor comprises a conductive material such as, but not limited to, copper. On one embodiment, the conductor (or one or more contacts) is integrally formed by stamping. In some embodiments, the conductor (or one or more contacts) is made of pure copper. In other embodiments, the conductor (or one or more contacts) is made of a copper alloy.

[0079] It should be appreciated that the conductor can comprise multiple portions, e.g. one or more contacts. In some embodiments, the conductor comprises a primary contact having a first primary contact end, a primary contact body, and a second primary contact end, and a secondary contact having a first secondary contact end, a secondary contact body, and a second secondary contact end. The primary contact includes one of the at least one first conductor element at the first primary contact end. The secondary contact is adjacent (nested with) to the primary contact and includes another of the at least one first conductor element at the first secondary contact end. In some such embodiments, the secondary contact is longer than the primary contact. . In other embodiments, the secondary contact extends past the primary contact. In a typical embodiment, the conductor element and / or the one or more contacts have a thickness of from 0.1 to 1.0, from 0.2 to 0.7, or from 0.3 to 0.5 mm.

[0080] The one or more first conductor elements include the first plurality of contact extensions or contact points. Typically, the contact extensions extend from and are arranged systematically, e.g., in a pattern, on the conductor (or contacts). In various embodiments, each of the one or more first conductor elements have the first plurality of contact extensions or contact points that are semi-circular and separated by a plurality of gaps and arranged in a row extending laterally across the conductor. The use of multiple contact extensions reduces the contact resistance. For example, if each contact extension has a resistance of 1m-Ohm, and the conductor element has 50 contact extensions in parallel connection, the contact resistances become 0.02 m-Ohm (= 1 / 50). The lower contact resistance provides a consistent electrical connection that generates less heat. As such, the connector provides lower and stable contactresistance to prevent thermal run away.

[0081] In one embodiment, the flexible beam member includes a central flex portion comprising a plurality of corrugations. The central flex portion provides the flexible beam portion with flexibility, which helps provide a robust electrical connection throughout and after conditions involving vibration and movement of the connector and the components being connected, e.g., the battery cells.

[0082] The insulator is at least partially disposed about the conductor. In the embodiments illustrated, a polymeric sheath is utilized. The polymeric sheath can comprise a thermoplastic, a thermoplastic elastomer, an elastomer, or other material that is durable, flexible, and electrically insulating. In some embodiments, the insulator is coated on the conductor. In such embodiments, the coating composition typically comprises thermoplastic, a thermoplastic elastomer, or an elastomer that is durable, flexible, and electrically insulating. In some embodiments, the insulator comprises a plurality of layers.

[0083] As described above, in some embodiments, the conductor comprises a primary and a secondary contact, with each contact including a conductor element on its first end. In such embodiments, the first frame includes a first of the at least one first frame contact window for a first of the at least one first conductor element and a second of the at least one first frame contact window for receiving a second of the at least one first conductor element.

[0084] In some embodiments, the first frame includes a first upper frame portion and a first lower frame portion defining the at least one first frame contact window. In these embodiments, the first end of the flexible beam member is disposed between the first upper frame portion and the first lower frame portion and one or more of the at least one first conductor element is disposed in the one or more of the at least one contact window. In such embodiments, the first upper frame portion and the first lower frame portion engage one another (e.g. slidably) for efficient assembly of the connector.

[0085] The first connection assembly also comprises the biasing insert. The first biasing insert typically comprises a resilient material and is shaped and positioned to bias the one or more conductor element into the connection surface. In one embodiment, the first biasing insert is at least partially disposed between the first actuator and the first frame. In a typical embodiment, the biasing insert biases in a vertical direction. Of course, the direction of bias depends on the position of the connection surfaces and the perspective view and can thus vary accordingly. The biasing insert is typically spring like. In one embodiment, the biasing insert is a spring. In another embodiment, the first biasing insert includes a first biasing insert body and a first pair of wings extending from opposite sides of the first biasing insert body. In other embodiments, the first biasing insert includes a first biasing insert body comprising a plurality of corrugations.

[0086] The first connection assembly also comprises the first actuator. In some embodiments, the first actuator is selected from a slide, a dial, a lever, and a button. Force is applied to the first actuator to engage the first actuation surface and the first push surface, bias the at least one first conductor element and the first connection surface into contact, and move the first actuator from the unlatched position into the latched position. That is, when the first battery module tab is received in the first receiving channel of the first frame, force applied to the first actuator to engage the first actuation surface and the first push surface, biases the at least one first conductor element and connection surface of first battery module into contact, and moves the first actuator from the unlatched position into the latched position. The connector provides design options to allow for actuation in various directions, e.g. along the X, Y, and / or Z axis / longitudinal, vertical, and / or lateral axis, or even rotational actuation. Many actuation configurations are contemplated herein in addition to the specific embodiments described and illustrated. For example, actuation could occur through the application of force to the actuator along the lateral axis (the connector could have a sideways orientation). Many different design embodiments are possible.

[0087] The first actuator is movably mounted to the first frame and defines the first actuation surface, which is positioned to contact the first push surface of the first biasing insert. The first actuation surface positioned to contact the first push surface of the first biasing insert and bias the at least one first conductor element and the first battery module tab into contact. In some embodiments, at least a portion of the first actuation surface is further defined as an angled surface. In these embodiments, an angle of first activation surface relative to the push surface can be used to engage, compress and / or move the biasing insert to bias the at least one first conductor element and the first battery module tab into contact. In other embodiments, the first actuation surface is parallel with the push surface can be used to engage, compress and / or move the biasing insert to bias the at least one first conductor element and the first battery module tab into contact.

[0088] As far as latching goes, in many embodiments, the first actuator includes at least one latch, and the first frame portion includes at least one latching element. In these embodiments, the application of force to the actuator moves the at least one latch into engagement with the at least one latching element and the first actuator from the unlatched to the latched position.

[0089] In one embodiment, the first frame comprises a pair of exterior rails, and the first actuator includes a body and a pair of arms including an inner surface defining a pair of rail channels shaped to receive each of the pair of rails of the first frame. Each of the pair of exterior rails is slidably received in each of the pair of rail channels. Sliding of the applicator engages the first actuation surface and the first push surface, biases the connection surface ofthe first battery module tab into contact with the at least one first conductor element, and moves the first actuator from the unlatched position to the latched position. In some such embodiments, the first actuator includes a least one end latch and the first frame includes at least one latching surface. In these embodiments, sliding the actuator moves the at least one end latch into engagement with the at least one latching surface and the first actuator into the latched position.

[0090] In one embodiment, the first frame comprises a lower frame portion and a first mounting portion including a body defining an opening, and the actuator comprises a dial having a handle portion and a disc portion presenting the first actuation surface, wherein the dial is moveably received in the opening. Rotation of the dial engages the first actuation surface and the first push surface, biases the connection surface of the first battery module tab into contact with the at least one first conductor element, and moves the first actuator between the unlatched position and the latched position. In some such embodiments, a periphery of the disc portion includes a latch, and the body includes a latch opening. In these embodiments, rotation of the dial rotates the latch into engagement with the latch opening and the first actuator into the latched position.

[0091] In one embodiment, the first frame comprises a lower frame portion, an upper frame portion, and a first mounting portion including a body defining an opening, and the actuator comprises a button having a push portion and a base portion presenting the actuation surface, wherein the button is moveably received in the opening. Pushing of the button engages the first actuation surface and the first push surface, biases the at least one first conductor element into contact with the connection surface of first battery module tab, and moves the first actuator between the unlatched position and the latched position. In some such embodiments, the button further comprises a plurality of locking extensions and the first mounting portion includes at least one mounting surface. In these embodiments, pushing the button moves a portion of the plurality of locking extensions into engagement with the at least one locking surface, and the first actuator into the latched position.

[0092] In one embodiment, the connector can also connect to a second battery module tab having a second connection surface. In this embodiment, the connector further comprises a second frame, a second biasing insert, and a second actuator. The second frame has a second frame body defining at least one second frame contact window and a pair of second frame legs defining a second receiving channel. The second biasing insert is received by the second frame and defines a second push surface and a second contact surface. The second actuator is movably mounted to the second frame and defines a second actuation surface positioned to contact the second push surface of the second biasing insert and bias the at least one second conductor element and a second battery module tab into contact. When the second battery module tab is received in the second receiving channel of the second frame, force applied to the secondactuator to engage the second actuation surface and the second push surface, biases the at least one second conductor element and connection surface of second battery module into contact, and moves the second actuator from the unlatched position into the latched position.

[0093] In some embodiments, the step applying force to the first actuator and / or the second actuator and moving the first actuator and / or the second actuator from the unlatched position to the latched position uncovers a verification element comprising a power signal, a QR code, a barcode, a data matrix code, or a color code. The verification element can be partially or fully covered in the unlatched position. In one such embodiment, the least one verification element is on an outer surface of the insulator and is at least partially covered by the first actuator in the unlatched position and the verification element is uncovered when the first actuator is in the latched position. The connector can be designed whereby uncovering of the verification element provides confirmation of a proper connection between the connector and the first battery module tab. In some embodiments, the least one verification element encodes information and data with letters and / or digits, and could communicate part indicia, location of installation indicia, date of installation indicia, or other information. In other embodiments, the uncovering of the verification element provides a power signal that indicates a connection status of the connector and data regarding the electrical connection provided thereby.

[0094] Referring now to Figures 3-11, an embodiment of the connector is illustrated at 10. Figure 3 is a top perspective view of an embodiment of the connector 10 including: the first connection assembly 12 comprising the first frame 14, the first biasing insert 16, and the first actuator 18; the second connection assembly 20 the second frame 22, the second biasing insert 24, and the second actuator 26; and the flexible beam member 28 extending therebetween. The first frame 14 defines the first receiving channel 30 for receiving the first battery module tab 32 and the second frame 22 defines the second receiving channel 34 for receiving the second battery module tab 36. Figure 4 is a bottom perspective view of the connector of Figure 3 illustrating the first frame 14 defining the first receiving channel 30 and two first contact windows 42a, 42b with two first conductor elements 40a, 40b framed in the two first contact windows 42a, 42b, and the second frame 22 defining the second receiving channel 34 and two second contact windows 42a, 42b with two second conductor elements 44a 44b framed in the two the second contact windows 46a, 46b. Figure 5 is an exploded view of the connector of Figures 3 and 4, which illustrates the first connection assembly 12 including the first frame 14, the first biasing insert 16, and the first actuator 18; the second connection assembly 20 including the second frame 22, the second biasing insert 24, and the second actuator 26; and the flexible beam member 28.

[0095] In this particular embodiment, the flexible beam member 28 has a first end 48and a second end 50 and comprises a conductor 52 and an insulator 54. The insulator is partially disposed about the conductor 52, i.e. disposed about a central portion 56 of the flexible beam member 28. In this embodiment, the step applying force to first actuator 18 and / or the second actuator 26 and moving the first actuator 18 and / or the second actuator 26 from the unlatched position to the latched position uncovers the verification element 58 on the outer surface of the insulator 54. Uncovering of the verification element 58 provides confirmation of a proper connection between the connector 10 and the first battery module tab 32 and / or second battery module tab 36. In some embodiments, the verification element 58 encodes information and data with letters and / or digits, and could communicate part indicia, location of installation indicia, date of installation indicia, or other information. In other embodiments, the uncovering of the verification element 58 provides a power signal that indicates a connection status of the connector and data regarding the electrical connection provided thereby. It should be appreciated that the connector 10 can include more that one of the verification element 58. For example, the flexible beam member 28 could include two of the verification element 58 as is illustrated in Figure 7.

[0096] The conductor 52 comprises the primary contact 60 and the secondary contact 62. The primary contact has a first primary contact end 64, the primary contact body 66, and the second primary contact end 68. The secondary contact has the first secondary contact end 70, the secondary contact body 72, and the second secondary contact end 74. The primary contact 60 includes one of the at least one first conductor element 40a at the first primary contact end 64 and one of the at least one second conductor element 44a at the second primary contact end 68. The secondary contact 62 is longer than the primary contact 60 and, when assembled, is adjacent (nested with) to the primary contact 60. The secondary contact 62 includes another of the at least one first conductor element 40a at the first secondary contact end 70 and another of the at least one second conductor element 44b at the second secondary contact end 74. In the embodiment illustrated, the one or more first conductor elements have the first plurality of contact extensions 76 or contact points that are semi-circular and separated by a plurality of gaps and arranged in a row extending laterally across the conductor 52.

[0097] Figure 6 is a perspective view of the connector of Figure 3 including the first and second connection assemblies in the unlatched position, wherein Figure 7 is a perspective view of the connector of Figure 3 with the first and the second connection assemblies in the latched position. The arrow on the first and second actuators 18, 26 represents the direction of the force applied (along ALONG) and the distal movement of the first and second actuators 18, 26. When the first battery module tab 32 is received in the first receiving channel 30 of the first frame 14, force applied to the first actuator 18 moves the first actuator 18 and engages the first actuation surface 78 and the first push surface 80, biases the at least one first conductor element40 and first connection surface 82 of the first battery module tab 32 into contact, and moves the first actuator 18 from the unlatched position into the latched position. Likewise, when the second battery module tab 36 is received in the second receiving channel 34 of the second frame 22, force applied to the second actuator 26 to engage the second actuation surface and the second push surface, biases the at least one second conductor element 44 and the second connection surface 84 of the second battery module tab 36 into contact, and moves the second actuator 26 from the unlatched position into the latched position. Figure 10 is a cross-sectional view of the connector of Figure 7 at 10-10. In Figure 6, the verification element 58 is covered, and in Figure 7, the verification element 58 is uncovered.

[0098] Figure 8 is a cross-sectional view of the first connection assembly at a first end of the of the connector 10 of Figure 6 at 8-8 in the unlatched position whereas Figure 9 is a cross-sectional view of the first connection assembly at the first end of the of the connector 10 of Figure 7 at 9-9 in the latched position. Figure 11 is a cross-sectional view of the first connection assembly at the first end of the of the connector of Figure 7 at 11-11 in the latched position.

[0099] Referring now to Figures 8 and 9, the first connection assembly comprises 12, the first frame 14, the first biasing insert 16, and the first actuator 18 located at the first end of the connector. The first frame 14 comprises the first frame body 86 and the two first frame legs 88. The first frame body 86 defines two first frame contact windows 42a, 42b and the pair of first frame legs 88, which cooperate with the first frame body 86 to define the first receiving channel 30. In the embodiment illustrated, the first frame 14 includes one portion. The conductor 52 comprises the two of the at least one first conductor element 40a, 40b including a first plurality of contact extensions extending from the conductor body at the end. More specifically, two of the at least one first conductor elements 40a, 40b (one from the primary contact 60 and the other from the secondary contact 62) are received in the two first frame contact windows 42a, 42b. The first biasing insert 16 is received by the first frame 14 and defines the first push surface 80 and the first contact surface 90. In this embodiment, the first biasing insert 16 includes the first biasing insert body 92 and the first pair of wings 94 extending from opposite sides of the first biasing insert body 92. In this embodiment, the first biasing insert 16 is movably mounted to the first frame 14 and defines the first push surface 80 and the first contact surface 90. The first actuator 18 comprises a first actuation surface 78 positioned to contact the first push surface 80 of the first biasing insert 16 and bias the at least one first conductor element 40 and the first battery module tab 32 into contact. When the first battery module tab 32 is received in the first receiving channel 30 of the first frame 14, force applied to the first actuator 18 (in a distal direction along the longitudinal axis ALONG) engages the first actuation surface 78 and the first push surface 80, biases the at least one first conductor element40 and the first connection surface 82 of first battery module into contact, and moves the first actuator 18 from the unlatched position into the latched position.

[0100] In the embodiment illustrated in Figure 5, the primary and secondary contacts 60, 62 have alignment grooves to prevent the relative movement of the nested primary and secondary contacts 60, 62 when assembled in the flexible beam member 28. These alignment grooves are not necessary in embodiments wherein the member includes a central flex portion comprising a plurality of corrugations.

[0101] In the embodiment of Figures 3-11, the first frame 14 comprises a pair of exterior rails 96. Further, the first actuator includes a first actuator body 110 pair of arms 98 including an inner surface defining a pair of rail channels 100 shaped to receive each of the pair of exterior rails 96 of the first frame14. Each of the pair of exterior rails 96 is slidably received in each of the pair of rail channels 100 to guide the movement of the first actuator 18 between the unlatched position and the latched position.

[0102] In the embodiment of Figures 3-11, the first biasing insert 16 is flexible and comprises metal. The first biasing insert 16 includes the first pair of wings 94 extending vertically downward from opposite sides of the first insert body 92. The first insert body 92 is inwardly convex. Further, the first insert body 92 presents the first push surface 80 having a convex shape and extending vertically downward. When the first actuation surface 78 and the first push surface 80 engage, each of the pair of wings 94 is moved vertically upward and laterally inward to drive the first contact surface 90 into a lower surface of the first battery module tab 32, and drive the first connection surface 82 of the first battery module tab 32 into contact with the at least one first conductor element 40. In this embodiment, the first pair of wings 94 have a concave shape extending laterally outward presenting a pair of contact tabs. Each wing of the first pair of wings 94 includes a contact tab 102a, 102b extending laterally inward from an end of each of the pair of wings 94 to partially define the first contact surface 90a, 90b.

[0103] Referring now to the cross-sectional view of Figure 11, a distance between an inner surface of each of the first pair of wings 94 is greater than a width of the first battery module tab 32. This allows for increased positional tolerance when connecting the connector 10 to the first battery module tab 32. Importantly, the width of the first receiving channel 30 is greater than a width of the first battery module tab 32, and the flexible beam member 28 is flexible to provide greater positioning tolerances and vibration resistant contact between the first and the second battery module tabs 32, 36.

[0104] As is illustrated in Figure 11, in this embodiment, the first pair of wings 94 are disposed in a pair of first frame notches 104 on the first frame portion. Further, the first biasing insert 16 includes a first pair of release tabs 106 disposed in a pair of first tab channels 108defined by the first actuator 18. In this embodiment, the first actuator 18 can be referred to as a slide. The first actuator 18 comprises the first actuator body 110 and a pair of arms 98 extending vertically downward from opposite sides of the first actuator body 110. In this embodiment, the first actuator also includes a first actuation shelf 112 defining a first top surface that includes a portion of the first actuation surface 78 extending normally at an angle relative to the longitudinal axis to drive the first biasing insert normally outward to force contact between the first conductor element and a top surface of the first battery module tab. That is a portion of the first actuation surface 78 is angled. An inner surface of the first actuator body and the first actuation shelf define a slot 114 that is shaped to receive a portion of the first biasing insert 16 such as the first biasing insert body 92.

[0105] In this embodiment, the first actuator 18 includes a ceiling 116 substantially parallel to the first actuation shelf defining a first top surface that includes the first actuation surface 78 extending normally at an angle relative to the longitudinal axis to drive the first biasing insert normally outward to force contact between the at least one first conductor element 40 and the first connection surface 82 of the first battery module tab 32.

[0106] Further, the first frame portion includes a first end wall 118 defining a first end notch 120 and the first actuator includes a first end latch 122 which is received by the first end notch 120 when the first actuator 18 is in the latched position. In this particular embodiment, the first actuator includes a first handle 124 defining the first end latch 122 and a first operator push surface 126.

[0107] Referring now to Figures 12-18, an embodiment of the connector is illustrated at 210. Figure 12 is a top perspective view of the connector 210 including: the first connection assembly 212 comprising the first frame 214, the first biasing insert 216, and the first actuator 218; and the flexible beam member 228. The first frame 214 defines the first receiving channel 230 for receiving the first battery module tab 232.

[0108] Figure 13 is an exploded view of the connector 210 of Figure 12. The components of the first connection assembly 212 include the first frame 214, the first biasing insert 216, and the first actuator 218. In this particular embodiment, the first frame 214 includes the first upper frame portion 214a and a first lower frame portion 214b, which combine to create a first frame. The first frame body 286 defines the at least one first frame contact window 242. The first upper frame portion 214a and the first lower frame portion 214b engage one another (e.g. slidably) for efficient assembly of the connector. In the embodiment illustrated, the lower frame portion includes two exterior rails and the first upper frame portion 214a includes two interior channels. The conductor elements at the end of the flexible beam member can be disposed in the windows defined by the first lower frame portion 214b, and the first upper frame portion 214a can be slid onto the first lower frame portion 214b to secure the first end of theflexible beam member 228. Of course, alternative connection configurations (e.g. snap together type connections) can be employed to connect the first upper frame portion 214a and the first lower frame portion 214b to secure the first end of the flexible beam member 228.

[0109] In this particular embodiment, the flexible beam member 228 has a first end 248 and a second end 250 and comprises the conductor 252 and the insulator 254. The insulator 254 is partially disposed about the conductor 252, i.e. disposed about a central portion 256 of the flexible beam member 228. In the embodiment illustrated, the flexible beam member 228 includes the central flex portion 229 comprising a plurality of corrugations.

[0110] In this embodiment, the conductor 252 comprises the primary contact 260 and the secondary contact 262. The primary contact 260 has the first primary contact end, the primary contact body, and the second primary contact end. Likewise, the secondary contact has the first secondary contact end, the secondary contact body, and the second secondary contact end. The primary contact 260 includes one of the at least one first conductor element 240 at the first primary contact end and one of the at least one second conductor element 244 at the second primary contact end. The secondary contact 262 is longer than the primary contact 260 and, when assembled, is adjacent (nested with) to the primary contact 260. The secondary contact 262 includes another of the at least one first conductor element 240 at the first secondary contact end and another of the at least one second conductor element 244 at the second secondary contact end. In the embodiment illustrated, the at least one first conductor elements 240 have the first plurality of contact extensions 276 or contact points that are semi-circular and separated by a plurality of gaps and arranged in a row extending laterally across the conductor 252.

[0111] Figure 14 is a perspective view of the connector 210 of Figure 11 including the first connection assembly 212. When the first battery module tab 232 is received in the first receiving channel 230 of the first frame 214, force applied to the first actuator 218 moves the first actuator 218 and engages the first actuation surface 278 and the first push surface 280, biases the at least one first conductor element 240 and first connection surface 282 of the first battery module tab 232 into contact, and moves the first actuator 218 from the unlatched position into the latched position. Figure 10 is a cross-sectional view of the connector of Figure 7 at 10-10. In Figure 6, the verification element 58 is covered, and in Figure 7, the verification element 58 is uncovered.

[0112] Figure 15 is a perspective view of the first connection assembly 212 of Figure 14 including the first frame 214 defining a first receiving channel 230 with a first battery module tab 232 received in the first receiving channel 230 and the first actuator 218 in the unlatched position whereas Figure 16 is a perspective view of the first connection assembly 212 of Figure 15 including the first frame 214 defining the first receiving channel 230 with the first battery module tab 232 received in the first receiving channel 230 and the first actuator218 in the latched position. In Figure 15, force has been applied to the first actuator 218 and the actuator has been moved distally along ALONG.

[0113] Figure 17 is a cross-sectional view of the first connection assembly 212 at a first end of the of the connector 210 of Figure 15 at 17-17 in an unlatched position, and Figure 18 is a cross-sectional view of the first connection assembly 212 at a first end of the of the connector 210 of Figure 16 at 18-18 in a latched position. Referring now to Figures 17 and 18, the first connection assembly comprises 212, the first frame 214, the first biasing insert 216, and the first actuator 218 located at the first end of the connector. The first upper frame portion 214a and the first lower frame portion 214b cooperate to form the first frame 214. In this embodiment, the first lower frame portion 214b defines two first frame contact windows 242a, 242b and cooperates with the pair of first frame legs 288 to define the first receiving channel 230. The conductor 252 comprises the two first conductor elements 240a, 240b including a first plurality of contact extensions extending from the conductor body at the first end. More specifically, the two first conductor elements 240a, 240b (one from the primary contact 260 and the other from the secondary contact 262) are received in the two first frame contact windows 242a, 242b. The first biasing insert 216 is received by the first frame 214 and defines the first push surface 280 and the first contact surface 290. In this embodiment, the first biasing insert 216 includes the first biasing insert body 292 and the first pair of wings 294 extending from opposite sides of the first biasing insert body 292. In this embodiment, the first biasing insert 216 is movably mounted to the first frame 214 (the wings 294 are received in a pair of openings 295 in the first lower frame portion 214b) and defines the first push surface 280 and the first contact surface 290. The first actuator 218 comprises a first actuation surface 278 positioned to contact the first push surface 280 of the first biasing insert 16 and bias the at least one first conductor element 240 and the first connection surface 282 of first battery module tab 232 into contact. When the first battery module tab 232 is received in the first receiving channel 230 of the first frame 214, force applied to the first actuator 218 (in a distil direction along the longitudinal axis ALONG) engages the first actuation surface 278 and the first push surface 280, biases the at least one first conductor element 240 and the first connection surface 282 of first battery module into contact, and moves the first actuator 218 from the unlatched position into the latched position.

[0114] In the embodiment of Figures 12-18, with specific reference to Figure 13, the first frame 214 comprises a pair of exterior rails 296. Further, the first actuator includes a first actuator body 310 pair of arms 298 including an inner surface defining a pair of rail channels 300 shaped to receive each of the pair of exterior rails 296 of the first frame 214. Each of the pair of exterior rails 296 is slidably received in each of the pair of rail channels 300 to guide the movement of the first actuator 218 between the unlatched position and the latched position.

[0115] In the embodiment of Figures 12-18, the first biasing insert 216 is flexible, resilient, and comprises metal. The first biasing insert 216 includes the first pair of wings 294 extending vertically downward from opposite sides of the first insert body 292. The first insert body 292 includes a pair of contact ribs 293 extending vertically downward from a central portion of the first insert body 292. Further, the first insert body 292 presents the first push surface 280, having the contact ribs 293 thereon. When the first actuation surface 278 and the first push surface 280 engage, the first contact surface 290 is driven into a lower surface of the first battery module tab 232, and the first battery module tab 232 is driven into contact with the at least one first conductor element 240. In this embodiment, each wing of the first pair of wings 294 includes a contact tab 302a, 302b extending laterally inward from a distal end of each of the pair of wings 294 to partially define the first contact surface 290a, 290b.

[0116] Referring now to the perspective view of Figure 12, a distance between an inner surface of each of the first pair of wings 294 is greater than a width of the first battery module tab 232. This allows for increased positional tolerance when connecting the connector 210 to the first battery module tab 232. Importantly, the width of the first receiving channel 230 is greater than a width of the first battery module tab 232, and the flexible beam member 228 including the central flex portion 229 comprising a plurality of corrugations is flexible to provide greater positioning tolerances and vibration resistant connection between the first and the second battery module tabs 232, (not illustrated).

[0117] With reference to Figure 13, in this embodiment, when assembled the first pair of wings 294 are disposed in a pair of first frame notches defined by the upper and lower first frame portions 218a, 218b. Further, when assembled, the first biasing insert 216 includes a first pair of release tabs 306 disposed in a pair of first tab channels (not illustrated) defined by the first actuator 218. In this embodiment, the first actuator 218 can be referred to as a slide. The first actuator 218 comprises the first actuator body 310 and a pair of arms 298 extending vertically downward from opposite sides of the first actuator body 310. In this embodiment, the first actuator 218 also includes a first actuation shelf 312 defining a first top surface that includes a portion of the first actuation surface 278 extending normally at an angle relative to the longitudinal axis to drive the first biasing insert 216 vertically upward to force contact between the two of the at least one first conductor element 240a, 240b and the first connection surface 282 of the first battery module tab 232. That is, a portion of the first actuation surface 278 is angled and the angled portion 279 contacts the first push surface 280 to drive the first contact surface 290 vertically upward and force contact between the first connection surface 282 of the first battery module tab 232 and a top surface of the first battery module tab 232. That is, the contact tabs 302a, 302b extending laterally inward from a distal end of each of the pair of wings 294 push vertically upward so that the first contact surface 290a, 290b pushes thefirst connection surface 282 of the first battery module tab 232 into the two first conductor elements 240a, 240b. An inner surface of the first actuator body 310 and the first actuation shelf define a slot 314 that is shaped to receive a portion of the first biasing insert 216 such as the first biasing insert body 292.

[0118] In this embodiment, the first actuator 218 includes a ceiling 316 substantially parallel to the first actuation shelf defining a first top surface that includes the first actuation surface 278 extending at an angle relative to the longitudinal axis to drive the first biasing insert 416 vertically upward to force contact between the two of the at least one first conductor element 240 and the first connection surface 282 of the first battery module tab 232.

[0119] In this embodiment, the first actuator 218 includes the first end latch 322 and the upper portion of the first upper frame portion 214a includes the first latching surface 320. Sliding the first actuator 218 moves the first end latch 322 into engagement with the first latching surface 320 and the first actuator into the latched position. The first upper frame portion 214a includes a first end wall 318 defining the first latching surface 320 and the first actuator 218 includes a first end latch 322 which engages the first latching surface 320 when the first actuator 218 is in the latched position. In this particular embodiment, the first actuator 218 includes a first handle 324 defining the first end latch 322 and a first operator push surface 326.

[0120] Referring now to Figures 19-33, an embodiment of the connector is illustrated at 410. Figure 19 is a top perspective view of the connector 410 including: the first connection assembly 412 comprising the first frame 414, the first biasing insert 416, and the first actuator 418; and the flexible beam member 428. The first frame 414 defines the first receiving channel 430 for receiving the first battery module tab 432.

[0121] In this embodiment, the first frame 414 of the connector 410 comprises two portions; a first lower frame portion 414b and a first mounting portion 414a including a first mounting body 550 defining a first opening 554. Figure 21 is an enlarged view of the dial of the actuator of Figure 19. The first actuator 418 can be referred to as a dial and has two portions, the handle portion 524 and the disc portion 510 presenting the first actuation surface 478, including a portion 479 that is angled relative to the longitudinal axis ALONG. When assembled, handle portion 524 of the first actuator 418 is moveably received in the first opening 554. Rotation of the first actuator 418 engages the first actuation surface 478 and the first push surface 480, biases the first connection surface 482 surface of the first battery module tab 432 into contact with the at least one first conductor element 440, and moves the first actuator 418 between the unlatched position and the latched position. In some such embodiments, a periphery of the disc portion includes a latch 522, and the body includes a first end notch 520. In these embodiments, rotation of the first actuator 418 rotates the latch 522 into engagement with the first end notch 520 and secures the first actuator 418 into the latched position.

[0122] Referring now to the exploded view of Figure 20, the connector 410 for connecting to a first battery module tab 432 having a first connection surface 482 is disclosed. The connector 410 comprises the first frame 414, the flexible beam member 428, the first biasing insert 416, and the first actuator 418. The first frame 414 has a first frame body 486 defines two of the at least one first frame contact window 442 and a pair of first frame legs 488, which cooperate with the first frame body 486 to define the first receiving channel 430. As described above, first frame 414 comprises two portions; the first lower frame portion 414b and the first mounting portion 414a including a first mounting body 550 defining a first opening 554.

[0123] In this particular embodiment, the flexible beam member 428 has a first end 448 and a second end 450 and comprises the conductor 452 and the insulator 454. The insulator 454 is partially disposed about the conductor 452, i.e. disposed about a central portion 456 of the flexible beam member 428. In the embodiment illustrated, the flexible beam member 428 includes the central flex portion 429 comprising a plurality of corrugations.

[0124] In this embodiment, the conductor 452 comprises the primary contact 460 and the secondary contact 462. The primary contact 460 has the first primary contact end, the primary contact body, and the second primary contact end. Likewise, the secondary contact has the first secondary contact end, the secondary contact body, and the second secondary contact end. The primary contact 460 includes one of the at least one first conductor element 440 at the first primary contact end and one of the at least one second conductor element 444 at the second primary contact end. The secondary contact 462 is longer than the primary contact 460 and, when assembled, is adjacent (nested with) to the primary contact 460. The secondary contact 462 includes another of the at least one first conductor element 440 at the first secondary contact end and another of the at least one second conductor element 444 at the second secondary contact end. In the embodiment illustrated, each of the two of the at least one first conductor elements 440 and the two of the at least one second conductor elements 444 have the first plurality of contact extensions or contact points that are semicircular and separated by a plurality of gaps and arranged in a row extending laterally across the conductor 452. The two first conductor elements 440a and 440b are received in the two first frame contact windows 442a, 442b defined by the first lower frame portion 414b.

[0125] As described above, first frame 414 comprises two portions; a first lower frame portion 414b and a first mounting portion 414a including a first mounting body 550 defining the first opening 554. The first mounting portion 414a defines a receiving port 556 shaped to receive the first lower frame portion 414b, and the two portions 414a, 414b are shaped to be coupled at a first level and a second level. The first lower frame portion 414b comprises the first frame body 486 and the pair of first frame legs 488 extending from opposite sides of thefirst frame body 486. In this embodiment, the first lower frame portion 414b defines two first frame contact windows 442a, 442b. Further, the first frame body 486 and the pair of first frame legs 488 define the first receiving channel 430. In the embodiment illustrated, each of the pair of first frame legs 488 includes two locking tabs 562 extending in laterally outward.

[0126] In this embodiment, a first mounting portion 414a includes the first mounting body 550 defining the first opening 554, and the two mounting legs 552 extending from opposite sides of the first mounting body 550. In the embodiment illustrated, each of the two mounting legs 552 includes two first level locking ports 558, and two second level locking ports 560 shaped to receive the locking tabs 562 on the pair of first frame legs 488. It should be appreciated that alternative connection configurations (e.g. sliding and other snap together type connections) can be employed to connect the first upper frame portion 414b and the first lower frame portion 414b.

[0127] The first biasing insert 416 is received by the first frame 414 and defines the first push surface 480 and the first contact surface 490. In this embodiment, the first biasing insert 416 includes the first biasing insert body 492 defining an opening 493 and the first pair of wings 494 extending from opposite sides of the first biasing insert body 492. A contact tab 302a, 302b extends laterally inward from a distal end of each of the pair of wings 294 to partially define the first contact surface 290a, 290b. When assembled, the handle portion 524 of the first actuator 418 extends through the opening 493. As such, the first biasing insert 416 is at least partially disposed between the first actuator 418 and the first frame 414. In this embodiment, the first biasing insert 416 is movably mounted to the first frame 214 (the wings 494 are received in a pair of openings 495 in the first lower frame portion 414b) and defines the first push surface 480 and the first contact surface 490.

[0128] The first actuator 418 is movably mounted to the first frame 414 and defines the first actuation surface 478, which is positioned to contact the first push surface 480 of the first biasing insert 416. Upon rotation of the handle, the first actuation surface 478 contacts the first push surface 480 of the first biasing insert 416 and biases the at least one first conductor element 440 and the first connection surface 482 of the first battery module tab 432 into contact.

[0129] Figures 22-23 illustrate various stages in process of connecting the first connection assembly (e.g. the first end of the connector 410) to the first battery module tab. In Figure 22, a perspective view of the first end of the connector 410 including the first connection assembly 412 is illustrated along with the first battery module tab 432 presenting a first connection surface 482. In Figure 23, the first battery module tab 432 is received in the first receiving channel 430 and the handle portion 524 of the first actuator 418 is unexposed with the first actuator 418 in the unlatched position. In Figure 23, the first mounting portion 414a of the frame is at the first level, with the locking tabs 562 on the pair of first frame legs 488received in the first level locking ports 558 defined by the first frame legs 488.

[0130] In Figure 24, the first battery module tab 432 is received in the first receiving channel 430 and the handle portion 524 is exposed via contact with the first battery module tab 432. In Figure 24, the first mounting portion 414a of the frame is at the second level, with the locking tabs 562 on the pair of first frame legs 488 received in the second level locking ports 560 defined by the first frame legs 488. When the first battery module tab 432 is received in the first receiving channel 430 of the first frame 414, force applied to the first actuator 418 to engage the first actuation surface 478 and the first push surface 480, biases the at least one first conductor element 440 and the first connection surface 482 of first battery module tab 432 into contact, and moves the first actuator 418 from the unlatched position into the latched position.

[0131] When the first actuator 418 or dial is turned, two ramps 500 on the disc portion 510 presenting the first actuation surface, more specifically the portion 479 of the first actuation surface 478 that is angled, engages with the first push surface 480 of the first biasing insert 416, this drives the first contact surface 490a, 490b presented by the two contact tabs 502, contact tabs 502a, 502b, into the lower surface of the first battery module tab 432 and the first connection surface 482 of the first battery module tab 432 into contact with the contact elements 404 of the flexible beam member 428. As such, in this embodiment, the first actuator 418 also includes first actuation ramps 500 defining the angled portion 479 of the first actuation surface 478, the angled portion 479 extending normally at an angle relative to the longitudinal axis ALONG to drive the first biasing insert 416 upward relative to the vertical axis AV to force contact between the two first conductor elements 440a, 440b and the first connection surface 482 of the first battery module tab 432.

[0132] In Figure 25, the handle portion 524 of the first actuator 418 has been rotated (i.e. the dial has been turned or rotated) and first actuator 418 is in the latched position. In Figure 25, the first mounting portion 414a of the first frame 414 is at the second level, with the locking tabs 562 on the pair of first frame legs 488 received in the second level locking ports 560 defined by the first frame legs 488.

[0133] Figures 24-26 illustrate end cross-sectional views of Figures 23-25. As described above, Figures 23-25 various stages in process of connecting the first connection assembly (e.g. the first end of the connector 410) to the first battery module tab. During the process, the first actuator 418 of the first connection assembly 412 from the unlocked position to the locked position.

[0134] In Figure 23, the first battery module tab 432 is received in the first receiving channel 430 and the handle portion 524 of the first actuator 418 is unexposed with the first actuator 418 in the unlatched position. In the cross-sectional view of Figure 26, the first mounting portion 414a of the first frame 414 is at the first level, in an elevated position, withthe locking tabs 562 on the pair of first frame legs 488 received in the first level locking ports 558 defined by the first frame legs 488.

[0135] In Figure 24, the first battery module tab 432 is received in the first receiving channel 430 and the handle portion 524 of the first actuator 418 is exposed via contact with the first battery module tab 432. In the cross-sectional view of Figure 27, ramp portions on the contact tabs 502a and 502b have facilitated movement of the pair of wings and receipt of the first battery module tab 432 in the first receiving channel 430, and ultimately engagement between the first contact surface 490 and a bottom surface of the first battery module tab 432. In Figure 27, the first mounting portion 414a of the first frame 414 is at the second level, in a lowered position, with the locking tabs 562 on the pair of first frame legs 488 received in the second level locking ports 560 defined by the first frame legs 488. In Figure 27, the first actuator 418 is in the unlatched position.

[0136] In Figure 28, which corresponds to Figure 25, the handle portion 524 of the first actuator 418 has been rotated (i.e. the dial has been turned or rotated) and first actuator 418 is in the latched position. The arrow in Figure 25 represents the application of rotational force and the movement of the first actuator 418. Two upper tabs 503a, 503b on the first biasing insert 616 have disengaged latches 522a, 522b and rotation of the actuator 418 has moved the latches 522a, 522b into engagement with the first end notches 520a, 520b on the first frame thereby placing the first actuator 418 into the latched position.

[0137] Figures 29-30 illustrate top cross-sectional views of Figures 23-25. As described above, Figures 23-25 represent various stages in the process of connecting the first connection assembly 412 (e.g. the first end of the connector 410) to the first battery module tab 432. During the process, the first actuator 418 of the first connection assembly 412 moves from the unlocked position to the locked position. In the top cross-sectional view of Figure 29, latches 522a and 522b are engaged in two notches 523a, 523b in the first frame legs 488 of the first lower frame portion 414b, and the first mounting portion 414a is at the first level.

[0138] In the top cross-sectional view of Figure 30, the first mounting portion 414a is at the second level. Further, the upper tabs 506a, 506b on the wings 494 of the first biasing insert 416 disengage latches 522a and 522b from the notches 523a, 523b in the first frame legs 488 of the first lower portion 414b. This allows for rotation of the handle portion 524. When the handle portion 524 is rotated, i.e. rotational energy is applied to the handle portion 524, the disc portion 510 rotates. The disc portion 510 is rotated until, as is illustrated in Figure 31, the latches 522a and 522b are engaged in the first end notches 520a, 520b in the first mounting portion 414a of the frame. As such, the first actuator 418 is in the latched position.

[0139] Figure 32 is a perspective view of the first connection assembly 412 in a latched position whereas Figure 33 is a side cross-sectional view of the first connection assembly ofFigure 32 at 33-33. In Figure 33, the first actuator is in the latched position with latches 522a and 522b are engaged in the first end notches 520a, 520b in the first mounting portion 414a of the frame. Further, tension between the first actuation surface 478 and the push surface 480 has biased the contact tabs 502a, 502b extending laterally inward from a distal end of each of the pair of wings 294 of the first biasing insert 416 so that the first contact surface 290a, 290b pushes vertically upward on the lower surface of the first battery module tab 432, and the first connection surface 282 of the first battery module tab 232 is biased into the two first conductor elements 440a, 440b, on the primary contact 460 and the secondary contact 462, respectively. Of course, the two first conductor elements 440a, 440b are framed in the two first frame contact windows 442a, 442b defined by the first lower frame portion 414b.

[0140] Referring now to Figures 34-42, an embodiment of the connector is illustrated at 610. Figure 34 is a top perspective view of the connector 610 including: the first connection assembly 612 comprising the first frame 614, the first biasing insert 616, and the first actuator 618; and the flexible beam member 628. The first frame 614 defines the first receiving channel 630 for receiving the first battery module tab 632.

[0141] In this embodiment, the first frame 614 comprises a first lower frame portion 614c, a first upper frame portion 614b, and a first mounting portion 614a including a first mounting body 750 defining a first opening 754. The first actuator 618, also referred to as a button, has a push portion 712 and a base portion 710 presenting the actuation surface. The push portion 712 as illustrated defines a receiving notch for robotic assembly, it should be appreciated that the contours of the push surface can be altered to accommodate manual or automated assembly. The first actuator 618 is moveably received in the first opening 754. Pushing of the first actuator 618 engages the first actuation surface 678 and the first push surface 680, biases the at least one first conductor element 640 into contact with the first connection surface 682 of first battery module tab 632, and moves the first actuator 618 between the unlatched position and the latched position. In some such embodiments, the first actuator 618 or button further comprises a plurality of locking extensions 724 each presenting a surface and the first mounting portion 614a includes a locking surface 720 (for engaging the surface(s) of the locking extensions 724. In these embodiments, pushing the first actuator 618 moves the plurality of locking extensions 724 into engagement with the locking surface 720 thereby moving the first actuator 618 into the latched position. In the embodiment illustrated, there are six of the plurality of locking extensions 724, three locking extensions 724a on a first side of the first actuator 618, and three more locking extensions 724b opposite the three locking extensions on the first side. A portion of the plurality of locking extensions, in this embodiment four exterior locking extensions are longer than two interior locking extensions (see Figure 35). The four longer exterior locking extensions are used for assembly purposes, to secure the firstactuator 618 to the first frame 14. The shorter interior / central locking extensions are used to latch / hold the first actuator 618 in the latched position.

[0142] In this embodiment, the first frame 614 of the connector 610 comprises three portions including the first upper frame portion 614b and a first lower frame portion 614c. The first lower frame portion 614c defines the at least one first frame contact window 642. In this embodiment, the first lower frame portion 214c defines the two first frame contact windows 642a, 642b and also includes a pair of first frame legs 688 that define the first receiving channel 630. In this embodiment, the first end 648 of the flexible beam member 628 is disposed between the first upper frame portion 614b and the first lower frame portion 614c. One or more of the at least one first conductor element 640 is disposed in the one or more of the at least one contact window 642. In such embodiments, the first upper frame portion 614b and the first lower frame portion 614c engage one another for efficient assembly of the first connection assembly 612 of the connector 610. In this particular embodiment, the first upper frame portion 614b includes a central portion 615 with first and a second pair of tabs 613 opposite one another and extending vertically downward. Each of the tabs 613 defines an engagement notch 758. Each of the first frame legs 688 on the first lower frame portion 614c include a pair of tabs 760 which are received in corresponding engagement notches 758 to couple the first upper frame portion 614b and the first lower frame portion 614c with the first end 648 of the flexible beam element 628 couple therebetween (having the .

[0143] In this embodiment, the first mounting portion 614a includes the first mounting body 750 defining the first opening 754, and the two mounting legs 752 extending from opposite sides of the first mounting body 750. In the embodiment illustrated, the first opening defines a first and a second plurality of cut-outs 780, 782 opposite one another. The first and a second plurality of cut-outs 780, 782 are shaped to accommodate a first and a second plurality of locking extensions 724a, 724b on the first actuator 618. When assembled, the first actuator 618 is moveably received in the first opening 754. In this embodiment, pushing the first actuator 618 vertically downward engages the first actuation surface 678 and the first push surface 680, biases the first connection surface 682 of the first battery module tab 632 into contact with the at least one first conductor element 640, and moves the first actuator 618 between the unlatched position and the latched position.

[0144] Referring now to the exploded view of Figure 35, the connector 610 for connecting to the first battery module tab 632 having the first connection surface 682 is disclosed. The connector 610 comprises the first frame 614, the flexible beam member 628, the first biasing insert 616, and the first actuator 618. As described above, the first lower frame portion 614c defines two of the at least one first frame contact window 642 and includes a pair of first frame legs 688, which cooperate with the body the first lower frame portion 614c (firstframe body) to define the first receiving channel 630.

[0145] In this particular embodiment, the flexible beam member 628 has a first end 648 and a second end 650 and comprises the conductor 652 and the insulator 654. The insulator 654 is partially disposed about the conductor 652, i.e. disposed about a central portion 656 of the flexible beam member 628. In the embodiment illustrated, the flexible beam member 628 includes the central flex portion 629 comprising a plurality of corrugations.

[0146] In this embodiment, the conductor 652 comprises the primary contact 660 and the secondary contact 662. The primary contact 660 has the first primary contact end, the primary contact body, and the second primary contact end. Likewise, the secondary contact has the first secondary contact end, the secondary contact body, and the second secondary contact end. The primary contact 660 includes one of the at least one first conductor element 640 at the first primary contact end and one of the at least one second conductor element 644 at the second primary contact end. The secondary contact 662 is longer than the primary contact 660 and, when assembled, is adjacent (nested with) to the primary contact 660. The secondary contact 662 includes another of the at least one first conductor element 640 at the first secondary contact end and another of the at least one second conductor element 644 at the second secondary contact end. In the embodiment illustrated, each of the two of the at least one first conductor elements 640 and the two of the at least one second conductor elements 644 have the first plurality of contact extensions 676 or contact points that are semi-circular and separated by a plurality of gaps and arranged in a row extending laterally across the conductor 652. The two first conductor elements 640a and 640b are received in the two first frame contact windows 642a, 642b defined by the first lower frame portion 614c.

[0147] The first mounting portion 614a defines a receiving port 756 shaped to receive the first upper frame portion 614b and the first lower frame portion 614c. The first mounting portion 614a also includes two support extensions extending vertically downward through two openings opposite one another in 288. Each support extension 694a, 694b includes a support tab 702a, 702b extending laterally inward from a distal end of each of the support extensions to partially define a support surface 696a, 696b.

[0148] The first biasing insert 616 is received by the first frame 614 and defines the first push surface 680 and the first contact surface 690. The first biasing insert 616 is spring / like / resilient and includes a first biasing insert body 692 comprising a plurality of corrugations. When assembled, the first biasing insert 616 is positioned between the first actuator 618 and the first upper frame portion 614b. When the first actuator 618 is pressed vertically downward, the first actuation surface 678 engages and the first push surface 680, and biases a first contact surface 690 of the first upper frame portion 614b into the first end 648 of the flexible beam member 628 which biases the two first conductor elements 640a, 640b intothe first connection surface 682 of the first battery module tab 632, which is supported by the support surface 696a, 696b presented by the support extensions.

[0149] When the first actuator 618 is pressed vertically downward, a first central locking extension having a shorter length than two outer first locking extensions engages the lower surface of the first mounting body 750 of the first mounting 614a and a second central locking extension having a shorter length than two outer second locking extensions engages a locking surface 720 defined by the first mounting body 750 of the first mounting portion 614a. As such, the first actuator 618 or button moves the first and second central locking extensions into engagement with the locking surface 720 and the first actuator into the latched position. The angled surface of the first and second central locking extensions allows the first and second central locking extensions to slide past the perimeter of the first opening 754. Of course, in the latched position, the first biasing insert 616 is sandwiched in place thereby biasing the two first conductor elements 640a, 640b into the first connection surface 682 of the first battery module tab 632, which is supported by the support surface 696a, 696b presented by the support extensions.

[0150] Figures 36-38 illustrate various stages in process of connecting the first connection assembly 612 (e.g. the first end of the connector 610) to the first battery module tab 632. In Figure 36, a perspective view of the first end of the connector 610 including the first connection assembly 612 is illustrated along with the first battery module tab 632 presenting a first connection surface 682.

[0151] In Figure 37, the first battery module tab 632 is received in the first receiving channel 630. The push portion 712 of the first actuator 618 is not yet depressed as the first actuator 418 is in the unlatched position. In Figure 37, the angled surface on the support tabs 702a and 702b have facilitated receipt of the first battery module tab 632 in the first receiving channel 630, and engagement between the support surface 696a, 696b and a bottom surface of the first battery module tab 632.

[0152] In Figure 38, the first battery module tab 632 is received in the first receiving channel 630. The push portion 712 of the first actuator 618 is depressed and the first actuator 618 is in the latched position. In Figure 23, the first and second central locking extensions are engaged with the locking surface 720. Further, the first biasing insert 616 is sandwiched in place thereby biasing the two first conductor elements 640a, 640b into the first connection surface 682 of the first battery module tab 632, which is supported by the support surface 696a, 696b presented by the support extensions.

[0153] Figures 36-38 illustrate various stages in process of connecting the first connection assembly 612 (e.g. the first end of the connector 610) to the first battery module tab 632 and Figures 39-41 are corresponding end cross-sectional views. In the cross-sectional viewof Figure 39, the first battery module tab 632 is not yet engaged with the support extensions and supported by the support surface 696a, 696b. However, in Figure 40, the first battery module tab 632 is engaged with the support extensions and supported by the support surface 696a, 696b, but the first actuator is in the unlatched position. In the cross-sectional view of Figure 41, the first actuator 618 is in the latched position and the first biasing insert 616 is sandwiched in place thereby biasing the two first conductor elements 640a, 640b into the first connection surface 682 of the first battery module tab 632, which is supported by the support surface 696a, 696b presented by the support extensions. More specifically, the first actuation surface 678 engages the first push surface 680, which pushes the first biasing insert 616 into the central portion 615 of the first upper frame portion 614b and drives the first contact surface 690 into the first end of the flexible beam member 628 which presses the two first conductor elements 640a and 640b of the primary and secondary contacts 660, 662 into the first connection surface 682 of first battery module tab 632. Figure 42 is a cross-sectional view of the first connection assembly of Figure 38 at 42-42 including the first frame 614 defining the first receiving channel 630 with the first battery module tab 632 received in the first receiving channel 630 and the button compressed and in a latched position.

[0154] A method of connecting a connector to a first battery module tab having a first connection surface is also disclosed. The connector has a first and a second end and includes a first frame defining a first receiving channel, a first actuator, a first biasing insert, and a flexible beam member including a conductor and an insulator at least partially disposed about the conductor. The connector comprises at least one first conductor element including a first plurality of contact extensions at the first end. The connector can be as is described throughout this disclosure and the accompanying drawings.

[0155] The method provides no-tool click on to provide stable contact force for long term reliability. Further, the connector allows for greater misalignment tolerances (X, Y, and / or Z / longitudinal, vertical, and / or lateral misalignment) during assembly. Referring now to Figure 43, the method (4300 comprising the steps of: positioning the first battery module tab in the first receiving channel (4302); and applying force to the first actuator to move the first actuator from an unlatched position to a latched position. Movement of the first actuator biases the at least one first conductor element and the first connection surface into contact to create a robust electrical connection (4304).

[0156] In one such embodiment, the conductor comprises at least one second conductor element including a second plurality of contact extensions, a second frame defining a second receiving channel, a second actuator, and a second biasing insert at the second end. In this embodiment, the method further comprises the steps of: positioning a second battery module tab in the second receiving channel; and applying force to the second actuator to movethe second actuator into a latched position. Movement of the second actuator biases the at least one second conductor element and the second connection surface into contact to create a robust electrical connection.

[0157] In one embodiment, the conductor comprises a primary contact and a secondary contact. The step of applying force to the first actuator biases a first of the at least one first conductor element on the primary contact and a second of the at least one first conductor element on the secondary contact into contact with the first battery module tab. The step of applying force to the second actuator biases a first of the at least one second conductor element on the primary contact and a second of the at least one second conductor element on the secondary contact into contact with the second battery module tab.

[0158] In some embodiments, the step applying force to first actuator and / or the second actuator and moving the first actuator and / or the second actuator from the unlatched position to the latched position uncovers a verification element comprising a power signal, a QR code, a barcode, a data matrix code, or a color code.

[0159] The above description is that of current examples of the disclosure. Various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all examples of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connection with these examples. For example, and without limitation, any individual element(s) of the described disclosure may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed examples include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present disclosure is not limited to only those examples that include all these features or that provide all the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

CLAIMS 1. A connector for connecting to a first battery module tab having a connection surface, the connector comprising: a first frame having a first frame body defining at least one first frame contact window and a pair of first frame legs defining a first receiving channel; a flexible beam member extending from the first frame and having a first and a second end, the flexible beam member comprising: a conductor comprising at least one first conductor element including a first plurality of contact extensions at the first end and received in the at least one first frame contact window; and an insulator disposed about a least a portion of the conductor; a first biasing insert received by the first frame and defining a first push surface and a first contact surface; and a first actuator movably mounted to the first frame and defining a first actuation surface positioned to contact the first push surface of the first biasing insert and bias the at least one first conductor element and the first battery module tab into contact; wherein when the first battery module tab is received in the first receiving channel of the first frame, force applied to the first actuator to engages the first actuation surface and the first push surface, biases the at least one first conductor element and connection surface of first battery module into contact, and moves the first actuator from an unlatched position into a latched position.

2. The connector of claim 1, wherein each of the first plurality of contact extensions are semi-circular and separated by a plurality of gaps and arranged in a row extending laterally across the conductor.

3. The connector of claim 1, wherein the conductor comprises: a primary contact having a first primary contact end, a primary contact body, and a second primary contact end, the primary contact including one of the at least one first conductor element at the first primary contact end; and a secondary contact adjacent the primary contact and having a first secondary contact end, a secondary contact body, and a second secondary contact end, the secondary contact including another of the at least one first conductor element at the first secondary contact end.

4. The connector of claim 3, wherein the secondary contact is longer than or extends past the primary contact when assembled in the flexible beam member.

5. The connector of claim 3, wherein the primary contact includes a plurality of semi-circular contact extensions extending vertically from the primary contact and separated by a plurality of gaps, each of the plurality of semi-circular contact extensions arranged in a row extending laterally across the primary contact, and the secondary contact includes a plurality of semi-circular contact extensions extending vertically from the secondary contact and separated by a plurality of gaps, each of plurality of semi-circular contact extensions arranged in a row extending laterally across the secondary contact.

6. The connector of claim 1, wherein the flexible beam member includes a central flex portion comprising a plurality of corrugations.

7. The connector of claim 1, wherein the first frame defines a first of the at least one first frame contact window for a first of the at least one first conductor element and a second of the at least one first frame contact window for receiving a second of the at least one first conductor element.

8. The connector of claim 1, wherein the first frame includes a first upper frame portion and a first lower frame portion defining the at least one first frame contact window, wherein the first end of the flexible beam member is disposed between the first upper frame portion and the first lower frame portion and one or more of the at least one first conductor element is disposed in one or more of the at least one first frame contact window.

9. The connector of claim 1, wherein the first biasing insert is at least partially disposed between the first actuator and the first frame.

10. The connector of claim 1, wherein the first biasing insert includes a first biasing insert body and a first pair of wings extending from opposite sides of the first biasing insert body.

11. The connector of claim 1, wherein the first biasing insert includes a first biasing insert body comprising a plurality of corrugations.

12. The connector of claim 1, wherein the first actuator is selected from a slide, a dial, and a button.

13. The connector of claim 12, wherein the first actuator includes at least one latch, and the first frame includes at least latching element, wherein application of force to the first actuator moves the at least one latch into engagement with the at least one latching element and the first actuator from the unlatched position to the latched position.

14. The connector of claim 13, wherein at least a portion of the first actuation surface is further defined as an angled surface.

15. The connector of claim 14, wherein: the first frame comprises a pair of exterior rails; and the first actuator includes a body and a pair of arms including an inner surface defining a pair of rail channels shaped to receive each of the pair of rails of the first frame, wherein each of the pair of exterior rails is slidably received in each of the pair of rail channels; wherein sliding of the first actuator engages the first actuation surface and the first push surface, biases the connection surface of first battery module tab into contact with the at least one first conductor element, and moves the first actuator from the unlatched position to the latched position.

16. The connector of claim 15, wherein the first actuator includes at least one end latch, and the first frame includes at least one latching surface, wherein sliding the first actuator moves the at least one end latch into engagement with the at least one latching surface and the first actuator into the latched position.

17. The connector of claim 12, wherein: the first frame comprises a lower frame portion and a first mounting portion including a body defining an opening; and the first actuator comprises a dial having a handle portion and a disc portion presenting the first actuation surface, wherein the dial is moveably received in the opening; wherein rotation of the dial engages the first actuation surface and the first push surface, biases the connection surface of the first battery module tab into contact with the at least one first conductor element, and moves the first actuator between the unlatched position and the latched position.

18. The connector of claim 17, wherein a periphery of the disc portion includes a latch, and the body includes a latch opening, wherein rotation of the dial rotates the latch intoengagement with the latch opening and the first actuator from the unlatched position into the latched position.

19. The connector of claim 12, wherein: the first frame comprises a lower frame portion, an upper frame portion, and a first mounting portion including a body defining an opening; and the first actuator comprises a button having a push portion and a base portion presenting the first actuation surface, wherein the button is moveably received in the opening; wherein pushing of the button engages the first actuation surface and the first push surface, biases the at least one first conductor element into contact with the connection surface of first battery module tab, and moves the first actuator from the unlatched position and the latched position.

20. The connector of claim 19, wherein the button further comprises a plurality of locking extensions and the first mounting portion includes a locking surface, wherein pushing the button moves a portion of the plurality of locking extensions into engagement with the locking surface and the first actuator into the latched position.

21. The connector of any preceding claim for further connecting to a second battery module tab having a second connection surface, the connector further comprising: at least one second conductor element on the conductor at the second end; a second frame having a second frame body defining at least one second frame contact window and a pair of second frame legs defining a second receiving channel; a second biasing insert received by the second frame and defining a second push surface and a second contact surface; and a second actuator movably mounted to the second frame and defining a second actuation surface positioned to contact the second push surface of the second biasing insert and bias the at least one second conductor element and a second battery module tab into contact; wherein when the second battery module tab is received in the second receiving channel of the second frame, force applied to the second actuator to engages the second actuation surface and the second push surface, biases the at least one second conductor element and second connection surface of second battery module into contact, and moves the second actuator from the unlatched position into the latched position.

22. A method of connecting a first battery module tab having a first connection surface with a connector having a first and a second end and including a first frame defining afirst receiving channel, a first actuator, a first biasing insert, and a flexible beam member including an insulator at least partially disposed about a conductor comprising at least one first conductor element including a first plurality of contact extensions at the first end, said method comprising the steps of: positioning the first battery module tab in the first receiving channel; and applying force to the first actuator to move the first actuator from an unlatched position into a latched position wherein movement of the first actuator biases the at least one first conductor element and the first connection surface into contact to create an electrical connection.

23. The method of claim 22, wherein the conductor comprises at least one second conductor element including a second plurality of contact extensions, a second frame defining a second receiving channel, a second actuator, and a second biasing insert at the second end, the method further comprising the steps of: positioning a second battery module tab defining a second connection surface in the second receiving channel; and applying force to the second actuator to move the second actuator into a latched position wherein movement of the second actuator biases the at least one second conductor element and the second connection surface into contact to create an electrical connection.

24. The method of claim 23 wherein the conductor comprises a primary contact and a secondary contact, and wherein: the step of applying force to the first actuator biases a first of the at least one first conductor element on the primary contact and a second of the at least one first conductor element on the secondary contact into contact with the first battery module tab; and the step of applying force to the second actuator biases a first of the at least one second conductor element on the primary contact and a second of the at least one second conductor element on the secondary contact into contact with the second battery module tab.

25. The method of claim 24 wherein the step of applying force to the first actuator and / or the second actuator and moving the first actuator and / or the second actuator from the unlatched position to the latched position uncovers a verification element comprising a power signal, a QR code, a barcode, a data matrix code, or a color code.

Images