Elastically deformable battery module connector system

Abstract

It is an elastically deformable connector system used for connecting battery modules within a battery pack. This elastically deformable connector system includes a busbar assembly having a plurality of individual conductors arranged vertically so as to provide a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion located between the first peripheral portion and the second peripheral portion. The busbar assembly also includes a first male connector assembly coupled to the first peripheral portion of the busbar, a second male connector assembly coupled to the second peripheral portion of the busbar, and a busbar housing surrounding a substantial extent of the busbar. After the busbar assembly is electrically connected to a pair of battery modules within the battery pack, the intermediate portion is configured to elastically deform so as to compensate for each of the compression and expansion movements of the pair of battery modules.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 337,596, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.

[0002] The present disclosure relates to an elastically deformable connector system for use in modular connection of battery packs included in a vehicle's power distribution system. The battery packs include a plurality of battery modules that are electrically connected to each other using at least one elastically deformable connector system having (i) a bus bar having an elastically deformable intermediate portion located between peripheral connection portions, and (ii) a bus bar housing.

Background Art

[0003] During the past few decades, the number of electrical components used in on - road and off - road vehicles (collectively referred to as "automobiles") such as automobiles, pickup trucks, commercial vans and trucks, semi - trucks, motorcycles, all - terrain vehicles, and sports utility vehicles has increased dramatically. Electrical components are used in automobiles for various reasons including, but not limited to, monitoring, improving, and / or controlling the performance, emissions, safety, and passenger comfort of automobiles. Considerable time, resources, and energy have been spent to develop power distribution components that meet the diverse needs and complexities of the automotive market, but conventional power distribution components have had various drawbacks.

[0004] Automobiles present a challenging electrical environment for both electrical components and connector assemblies due to numerous conditions including, but not limited to, space constraints that make initial installation difficult, harsh operating conditions, a large ambient temperature range, long-term vibrations, thermal loads, and long service life, all of which can lead to component and / or connector failures. For example, incorrect connector installation, which generally occurs in assembly plants, and connector detachment, which generally occurs in the field, are two significant failure modes for electrical components and automobiles. Each of these failure modes leads to substantial repair and warranty costs. For example, the combined annual occurrence for all automobile manufacturers and their direct suppliers for warranties is estimated to range from $50 billion to $150 billion worldwide. Given such a demanding electrical environment, significant time, cost, and energy have been expended to find power distribution components that meet market needs. The present disclosure addresses the drawbacks of conventional power distribution components. A complete discussion of the features and advantages of the present disclosure is deferred to the following detailed description, which proceeds with reference to the accompanying drawings. SUMMARY OF THE INVENTION

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

[0006] To compensate for the material conditions and / or dynamic movement of battery modules, the disclosed elastically deformable battery module connector system includes a bus bar having a plurality of individual conductors arranged vertically to provide a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion located between the first peripheral portion and the second peripheral portion. The bus bar assembly also includes a first male connector assembly coupled to the first peripheral portion of the bus bar, a second male connector assembly coupled to the second peripheral portion of the bus bar, and a bus bar housing surrounding a substantial scope of the bus bar. After the bus bar assembly is electrically connected to a pair of battery modules within a battery pack, the intermediate portion is capable of elastically deforming to compensate for each of the compression and expansion movements of the pair of battery modules.

[0007] In another embodiment, the bus bar includes a plurality of individual conductors that have undergone a fusing process to form a solid single conductor in a selected area of the bus bar, and the bus bar includes a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion located between the first peripheral portion and the second peripheral portion. Most of the elastically deformable intermediate portion is not coplanar with either the first peripheral portion or the second peripheral portion, but instead includes a curved spread. Due to this configuration of the elastically deformable intermediate portion, even with an actuation force of 50 Newtons or less, its entire length can be deformed by 5% or more. Thus, this connector system improves the reliability, performance, and operating life of modules, battery packs, power distribution systems, and applications.

Brief Description of the Drawings

[0008] The accompanying drawings or figures are included to provide further understanding and are incorporated herein and constitute a part of this specification, showing the disclosed embodiments and serving with this specification to explain the principles of the disclosed embodiments. In the figures, like reference numerals indicate the same or similar elements throughout the figures.

[0009]

Figure 1

[0010]

Figure 2

[0011]

Figure 3

[0012]

Figure 4

Figure 5

[0013]

Figure 6

[0014]

Figure 7

[0015]

Figure 8

[0016]

Figure 9

[0017]

Figure 10

[0018]

Figure 11

[0019]

Figure 12

[0020]

Figure 13

[0021]

Figure 14

[0022]

Figure 15

[0023]

Figure 16

[0024]

Figure 17

[0025]

Figure 18

[0026]

Figure 19

[0027]

Figure 20

[0028]

Figure 21

[0029]

Figure 22

[0030]

Figure 23

[0031]

Figure 24

[0032]

Figure 25

[0033]

Figure 26

[0034]

Figure 27

[0035]

Figure 28

[0036]

Figure 29

[0037]

Figure 30

[0038]

Figure 31

[0039]

Figure 32

[0040]

Figure 33

[0041]

Figure 34

[0042]

Figure 35

[0043]

Figure 36

[0044]

Figure 37

[0045]

Figure 38

[0046]

Figure 39

[0047]

Figure 40

[0048]

Figure 41

[0049]

Figure 42

[0050]

Figure 43

[0051]

Figure 44

[0052]

Figure 45

[0053]

Figure 46

[0054]

Figure 47

[0055]

Figure 48

[0056]

Figure 49

[0057]

Figure 50

[0058]

Figure 51

[0059]

Figure 52

[0060]

Figure 53

[0061]

Figure 54

[0062]

Figure 55

[0063]

Figure 56

[0064]

Figure 57

[0065]

Figure 58

[0066]

Figure 59

[0067]

Figure 60

[0068]

Figure 61

[0069]

Figure 62

[0070]

Figure 63

[0071]

Figure 64

[0072]

Figure 65

[0073]

Figure 66

[0074]

Figure 67

[0075]

Figure 68

[0076]

Figure 69

[0077]

Figure 70

[0078]

Figure 71

[0079]

Figure 72

[0080]

Figure 73

[0081]

Figure 74

[0082]

Figure 75

[0083]

Figure 76A

[0084]

Figure 76B

[0085]

Figure 77

[0086]

Figure 78

[0087]

Figure 79

[0088]

Figure 80

[0089]

Figure 81

[0090]

Figure 82

[0091]

Figure 83

[0092]

Figure 84

[0093]

Figure 85

[0094]

Figure 86

[0095]

Figure 87

[0096]

Figure 88

[0097]

Figure 89

Figure 90

Figure 91

Figure 92

Figure 93

Figure 94

Figure 95

Figure 96

Figure 97

Figure 98

Figure 99

Figure 100

Figure 101

Figure 102

[0098]

Figure 103

[0099]

Figure 104

[0100]

Figure 105

Figure 106

Figure 107

Figure 108

Figure 109

[0101]

Figure 110

[0102]

Figure 111

[0103]

Figure 112

[0104]

Figure 113

[0105]

Figure 114

DETAILED DESCRIPTION OF THE INVENTION

[0106] In the following detailed description, numerous specific details are set forth by way of example in order to provide a thorough understanding of the relevant teachings. However, it will be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well-known methods, procedures, components, and / or circuits are described at a relatively high level without detailed description in order to avoid unnecessarily obscuring aspects of the present teachings.

[0107] The present disclosure includes many different forms of embodiments, but it should be understood that the present disclosure is to be considered as illustrative of the principles of the disclosed methods and systems, and is not intended to limit the broad aspects of the disclosed concepts to the illustrated embodiments. Specific embodiments are shown in the drawings and are described in detail herein. As will be realized, the disclosed methods and systems are capable of other different configurations and all details may be changed without departing from the scope of the disclosed methods and systems. For example, some or all of the following embodiments can be combined consistently with the disclosed methods and systems. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive or limiting.

[0108] For background and context, FIGS. 110 - 114 show various products and applications 10 having at least one power distribution system 50. Applications 10 include, but are not limited to, aircraft, automobiles 20 (FIG. 111), military vehicles (e.g., tanks, personnel carriers, large trucks, troop carriers), buses 25 (FIG. 112), locomotives, tractors, bulldozers, excavators, tractors, ships (e.g., boats, cargo ships, tankers, submarines, passenger ships 30 (FIGS. 113 and 114), tankers, sailboats, etc.), mining machinery, forestry machinery, agricultural machinery (e.g., tractors, loggers, planters, combines, threshers, harvesters), telecommunications hardware (e.g., servers), power storage systems (e.g., backup power storage), renewable energy hardware (e.g., wind turbines, solar cell arrays), 24 - 48 volt systems, for high power applications, for high current applications, and for high voltage applications. In these applications 10, the power distribution system 50 is configured to meet industry standards, production, and performance requirements.

[0109] Each power distribution system 50 includes a battery pack 90 having (i) a plurality of battery modules 60 and (ii) at least one elastically deformable battery module connector system 100, and the battery module connector system 100 electrically couples (a) a first battery module 62a within the plurality of battery modules 60 to a second battery module 62b within the plurality of battery modules 60, (b) a first battery module 62a within the plurality of battery modules 60 to within the range of the battery pack housing 92, (c) the range of the battery pack housing 92 to the range of an external component, or (d) the range of a first external component to the range of a second external component. As will be described in detail below, the elastically deformable battery module connector system 100 is configured to compensate for (i) material conditions associated with the module 60, the battery pack 90, the power distribution system 50, and / or the application 10, and / or (ii) dynamic movement of the battery module 60 caused by (a) charging and discharging of the battery module 60, (b) aging of the battery module 60, (c) changes in temperature including temperature changes of the module 60, the battery pack 90, the power distribution system 50, and / or the application 10, (d) movement of the module 60 within the battery pack 90 while the power distribution system 50 and / or the application 10 is being used or operated, for example, the bus 25 (see FIG. 112) traveling on a road having numerous potholes, or the ship 30 (see FIG. 113) navigating a rough or choppy sea causing pitch, heave, or aggressive maneuvering, (e) failure of a battery cell, and (f) other known reasons related to movement of the battery modules 60 within the battery pack 90. It should be understood that the material state and / or dynamic movement of the battery module 60 can occur in any direction (i.e., X, Y, Z, and rotational directions). For example, the dynamic movement of the battery module 60 in FIGS. 55-70 includes (i) expansion and / or contraction in the X-Y plane due to movement of lithium ions within individual battery cells 75, and (ii) may include expansion and / or contraction in the X-Z plane or Y-Z plane due to CTE or other known reasons.

[0110] To compensate for the material conditions and / or dynamic movements of the battery module 60, the disclosed elastically deformable battery module connector system 100 includes a bus bar 200 having an elastically deformable intermediate portion 410. This elastically deformable intermediate portion 410 enables the system 100 to: (i) be compressed by a significant amount, i.e., up to 4 mm, from the non-stress or neutral state S N and (ii) be expanded by a significant amount, i.e., up to 4 mm, from the non-stress or neutral state S N and (iii) be adjusted to minor displacements in other planes (e.g., the X-Z plane or the Y-Z plane). Since the battery module connector system 100 is designed and configured to accommodate and correspond to the material conditions and / or dynamic movements of the battery module 60, the connector system 100 minimizes and potentially eliminates failure modes that could damage or degrade the performance of the power distribution system 50, the module 60, and / or the battery pack 90. Accordingly, the connector system 100 improves the reliability, performance, and operational life of the module 60 and the battery pack 90.

[0111] Accordingly, the above advantages of the disclosed connector system 100 are to be considered essentially exemplary and not restrictive or limiting. Thus, other advantages may be disclosed within the pictorial or written disclosure included herein or may be known to those skilled in the art based on the pictorial or written disclosure.

[0112] Numerous terms are introduced and used in this application and are defined below. Some of the following terms overlap with or are not mutually exclusive of other terms, but the following provides a general organizational hierarchy where the terms "bus bar" and "bar" are at the top level of the hierarchy, the terms "end(s)", "end sector(s)", "central part", and "central sector(s)" are at the middle upper level of the hierarchy, the terms "portion(s)", "peripheral portion(s)", and "intermediate portion" are at the middle lower level of the hierarchy, the term "zone(s)" is at the lower level of the hierarchy, and the term "region(s)" is at the bottom level of the hierarchy.

[0113] The term "bus bar" means at least one conductor that extends from a first edge to a second edge and is capable of conducting current from a first location to a second location. For example, FIG. 20 is a perspective view of bus bar 200.

[0114] The term "end sector" refers to the extent of the bus bar designed to facilitate connection of the bus bar 200 to an external device or component.

[0115] The term "central sector" is the extent of the bus bar that extends between the end sectors 207 of the bus bar 200. It should be understood that a single conductor 202 of the bus bar 200 extends from a first end sector 208a across the central sector 210 to a second end sector 208b. In other words, prior to any modification of the conductor 202, the end sectors 208a, 208b of the conductor 202 are integrally formed with the central sector 210 of the conductor 202. Put another way, the end sectors 208a, 208b of the conductor 202 are not separate structures that are joined to the central sector 210 of the conductor 202 using a welding, fusing, or fastening process.

[0116] The term "peripheral portion" refers to the range of a bus bar designed to have an intermediate portion disposed at a position between any of (i) a pair of battery modules, (ii) the range of a battery module and a battery pack housing, (iii) the range of a battery pack housing and an external component, and (iv) a pair of external components.

[0117] The term "intermediate portion" refers to the range of a bus bar that extends between the peripheral portions 402a, 402b of the bus bar 200 and is designed to be elastically deformable.

[0118] The term "segment" refers to the range of the central sector of a bus bar that (i) receives a segment fusion pattern or (ii) lacks a segment fusion pattern. It should be understood that adjacent segments of a single conductor of a bus bar are integrally formed with each other and are not fixed to each other using a welding, fusing, or fixing process. It should also be understood that adjacent bus bar segments typically have different mechanical properties (e.g., different Young's moduli).

[0119] The term "fused segment" refers to the range of a bus bar that includes at least one of (i) a partially solidified region, (ii) a laterally solidified region, or (iii) a fully solidified region. A fused segment may include a non-solidified region. For example, FIGS. 14 to 17 show a fused segment 206 that includes (i) a non-solidified region 230 and (ii) a laterally solidified region 238.

[0120] The term "non-fused segment" refers to the range of a bus bar that includes only unfused or non-fused separate regions (s) of a conductor. Thus, a non-fused segment does not include (i) a partially solidified region, (ii) a limited or lateral solidified region, or (iii) a fully solidified region. For example, FIGS. 12 to 13 show a non-fused segment 204 of the central sector 210 of the bus bar 200, and the non-fused segment 204 has a non-solidified region 230 with separate non-fused conductors 202.

[0121] The term "partial solidification zone" refers to the region of the fusion segment 206 of the central sector 210 of the bus bar, and this zone (i) extends from the lowermost or bottom conductor to the uppermost or top conductor in the fusion segment, and (ii) includes a partially solidified region.

[0122] The term "partially solidified region" means the region of the partial solidification zone of the bus bar that has undergone a surface-based fusion process (e.g., the vertical partial penetration welding process 182). This surface-based fusion process joins or fuses the entire range of conductors within this partially solidified region to form a single connected conductor. A significant (e.g., about 70%) number of the conductors 202 within the partial solidification zone are joined or fused to the single connected conductor that forms the partially solidified region. In contrast, a smaller (e.g., about 30%) number of conductors 202 remain as individual separate conductors 202 in the non-solidified region 230 beyond the partially solidified region in the partial solidification zone and are not joined or fused to the single connected conductor.

[0123] The term "partial solidification volume" is the volume of the central sector 210 of the bus bar 200, and this volume (i) extends from the lowermost or bottom conductor to the uppermost or top conductor in the fusion segment, (ii) extends along the entire length of the fusion segment 206, and (iii) has a width that encompasses the partially solidified volume.

[0124] The term "partially solidified volume" means the extent of the partial solidification volume of the bus bar that has undergone a surface-based fusion process (e.g., the vertical partial penetration welding process 182). By this surface-based fusion process, all ranges of the conductors within this partially solidified volume are joined or fused to form a single connected conductor.

[0125] The term "limited solidification zone" refers to the region of the fusion segment 206 of the busbar, where the zone extends between: (i) (a) the midpoint or middle of the width or depth defined between the outermost edges of the fusion segment, and (b) one of the outermost edges of the fusion segment 206, and (ii) includes a lateral solidification region. For example, FIGS. 14-15 show a limited solidification zone 240 extending between the lateral end 216b of the busbar 200 and the midpoint MP, which includes the range through the lateral partial penetration welding process 184 or the cold forming process.

[0126] The term "lateral solidification region" means the region of the limited solidification zone of the busbar that has undergone an edge-based fusion process (e.g., the lateral partial penetration welding process 184 or the cold forming process). This edge-based fusion process joins or fuses all ranges of the conductors within this lateral solidification region to form a single connected conductor. For example, FIGS. 14-15 show a lateral solidification region 238 that (i) is adjacent to the non-solidified region 230, and both are located in the limited solidification zone 240 of the fusion segment 206 of the central sector 210 of the busbar 200, and (ii) extends from the lowermost or bottom conductor to the uppermost or top conductor. A small range (e.g., about 5%) of the busbar 200 in the limited solidification zone 240 is joined or fused to a single connected conductor to form the lateral solidification region 238. In contrast, most of the busbar 200 (e.g., about 95%) beyond the lateral solidification region 238 in the limited solidification zone 240 remains as the non-solidified region 230, meaning that they are not joined or fused to a single connected conductor.

[0127] The term "limited solidification volume" refers to the volume of the fusion segment 206 of the busbar, where the volume extends between: (i) (a) the midpoint or middle of the width or depth defined between the outermost edges of the fusion segment 206, and (b) one of the outermost edges of the fusion segment 206, (ii) extends along the entire length of the fusion segment 206, and (iii) has a width that includes the lateral solidification region.

[0128] The term "lateral solidified volume" means the volume of the limited solidified volume of the busbar that has undergone an edge-based fusion process (e.g., the lateral partial penetration welding process 184 or the cold forming process). This edge-based fusion process joins or fuses all ranges of the conductors of the lateral solidified volume to form a single continuous conductor.

[0129] The term "unsolidified region" means the region of the busbar that has not undergone the welding process 180 that joins or fuses any of the conductors within that region of the busbar. Similarly, the term "unsolidified volume" means the volume of the busbar that has not undergone a welding process that joins or fuses any of the conductors within that volume of the busbar 200. Therefore, all conductors 202 located in the unsolidified region 230 remain as individual separate conductors. For example, FIG. 13 shows the unsolidified region 230.

[0130] The term "fully solidified region" means the range of the busbar that has undergone a fusion process (e.g., the lateral welding process 184 or the longitudinal welding process 182) to join or fuse all conductors 202 included within that range of the busbar into a single continuous conductor. For example, FIG. 17 shows a fully solidified region 242 extending across the end sectors 208a, 208b of the busbar 200.

[0131] The general term "solidified region" means a partially solidified region, a lateral solidified region 238, or a fully solidified region 242.

[0132] The term "flexible portion" is the range of the busbar that does not include (i) a partially solidified region, (ii) a lateral solidified region formed using the lateral partial penetration welding process 184, or (iii) a fully solidified region. The rigidity of the flexible portion 224 of the busbar 200 is less than 25% of the rigidity of the corresponding portion of a solid reference busbar having the same shape and formed from a similar solid material.

[0133] The term "bending portion" refers to a range of a bus bar that includes at least one of (i) a partially cured region, (ii) a laterally cured region, or (iii) a fully cured region. For example, FIGS. 18-24 show a bending portion 226 that includes one or more partially cured regions (plural available) 234 formed using an uncured region (plural available) 230 of a conductor 202 and two laterally cured regions (plural available) 238 formed using a lateral partial penetration welding process 184. The rigidity of the bending portion is greater than 35% of the rigidity of the corresponding portion of a reference bus bar having the same shape and formed from a similar solid material.

[0134] The term "maximum material condition" refers to a feature of a size that includes the maximum amount of material while remaining within the specified tolerances. For example, the maximum material condition occurs when using the largest pin diameter or the smallest hole size within the specified tolerances.

[0135] The term "minimum material condition" means a feature of a size that includes the minimum amount of material while remaining within the specified tolerances. For example, the maximum material condition occurs when using the smallest pin diameter or the largest hole size within the specified tolerances.

[0136] The term "nominal material condition" refers to a material condition between the maximum material condition and the minimum material condition.

[0137] The term "in-plane" refers to a plane defined by the X-axis and the Y-axis in a three-dimensional orthogonal X, Y, Z coordinate system. In this reference frame, the longitudinal axis A-A of the bus bar 200 is in the same plane as the X-Y plane and in-plane.

[0138] The term "out-of-plane" refers to a plane defined by the Y-axis and the Z-axis in a three-dimensional orthogonal X, Y, Z coordinate system. In this reference frame, the longitudinal axis A-A of the bus bar 200 is perpendicular to the Y-Z plane and out-of-plane.

[0139] "High power" means (i) a voltage between 20 volts and 600 volts regardless of current, or (ii) a current of 80 amperes or more regardless of voltage. "High current" means a current of 80 amperes or more regardless of voltage. "High voltage" means a voltage between 20 volts and 600 volts regardless of current. I. First Embodiment of an Elastically Deformable Battery Module Connector System

[0140] Figures 1-73 illustrate a first embodiment of an elastically deformable battery module connector system 100, which includes: (i) a bus bar 200, (ii) a bus bar housing 600, and (iii) at least one male connector assembly 1000. The bus bar 200 disclosed herein is formed from a plurality of conductors 202, and a selected range of the bus bar 200 is subjected to a fusing process 180 that solidifies the range of the conductors 202 within that range of the bus bar 200. As a result of this fusing process 180, the bus bar 200 includes (i) at least one unfused segment 204 and (ii) at least one fused segment 206. Integrally forming the fused segment 204 and the unfused segment 206 in a single bus bar 200 is beneficial because it allows the bus bar 200 to combine the best features of conventional rigid bus bars and conventional flexible bus bars while limiting the negative features associated with these conventional bus bars. For example, since the unfused segment 204 is flexible, the bus bar 200 can: (i) accommodate manufacturing tolerances, (ii) expand and contract during thermal expansion and thermal contraction events such as battery charge and battery discharge cycles, and (iii) absorb vibrations caused by the operating environment (e.g., within a vehicle) in which the bus bar 200 is installed, rather than transmitting those vibrations to other components operably associated with the bus bar 200. Further, the fused segment 206 of the bus bar 200 is more rigid (e.g., having a Young's modulus of N / m 2(increasing in the out-of-plane direction), thereby enabling the bus bar 200 to be accurately bent in the out-of-plane direction and intentionally maintaining these bends over time without causing peeling of the conductor 202, so that the flow of current through the bus bar 200 can be reduced. A. Bus bar

[0141] Figures 2-3 show the first step of forming the bus bar 200. Specifically, a plurality of individual conductors 202 are obtained, cut to a predetermined length, and arranged in a vertical stack. In the embodiment shown in the figures, each conductor 202 has an elongated rectangular prism configuration. This rectangular prism configuration is beneficial over other configurations (e.g., circular or square) due to its ability to rapidly dissipate heat. The width (between 10 mm and 30 mm, preferably 20 mm) and thickness (between 0.1 mm and 0.5 mm, preferably 0.25 mm) of each conductor 202 remain substantially constant over the length of the bus bar 200, but the length of the conductors 202 included in the bus bar 200 varies significantly based on their position within the stack. In particular, the conductors 202 are arranged in a staggered pattern and increase in length as they move from the bottom conductor 203a (or shortest conductor) to the top conductor 203j (or longest conductor). Such a staggered length arrangement is desired because the elastic deformation of the intermediate portion 410 (see Figures 18-24) causes the top conductor 203j to have to move further than the bottom conductor 203a.

[0142] In this first embodiment, each conductor 202 is made of a C10200 copper alloy that has (i) an electrical conductivity of 80% or more of IACS (International Annealed Copper Standard, i.e., a standard value empirically derived for the electrical conductivity of commercially available copper) according to ASTM B747, and (ii) a coefficient of thermal expansion (CTE) of 17.6 ppm / °C (20-300°C) and 17.0 ppm / °C (20-200°C). In other embodiments, the selected copper material may be replaced with stainless steel, nickel, aluminum, silver, gold, copper, steel, zinc, brass, bronze, iron, platinum, lead, molybdenum, calcium, tungsten, lithium, tin, a combination of the listed materials, or other similar metals.

[0143] Once the desired configuration of the individual conductors 202 is formed, the conductors 202 are arranged in a layered stack with the first ends 208a of all the conductors aligned with each other. In other words, the end face of the stack of conductors 202 is substantially flat and substantially perpendicular to the top surface 215a and the bottom surface 215b of the upper and lower conductors 203j, 203a. In this configuration, the plurality of conductors 202 provide a non-fused reference rigidity. This non-fused reference rigidity is between 1 KPa and 200 GPa, preferably between 50 KPa and 2,500 KPa, more preferably between 100 KPa and 1,000 KPa, and most preferably 320 KPa. In some of the figures of this application, only the bus bar 200 having five conductors 202 is depicted due to space constraints, but it should be understood that the preferred embodiment is a layered stack of ten conductors 202. The preferred embodiment is a layered stack of ten conductors 202, but it should be understood that the present disclosure contemplates a bus bar 200 including any number of conductors 202 (e.g., one conductor 202 to one hundred conductors 202). i. Selectively fuse the first range of the bus bar

[0144] Once a layered stack of ten conductors 202 is created, the process of manufacturing the bus bar 200 continues as follows: (i) fusing the first end sector 208a of the bus bar 200, and (ii) fusing the identified segments of the central sector 210 of the bus bar 200, which are included in the first extent 212a of the bus bar 200. Before being able to selectively fuse the extents of the bus bar 200, the user or manufacturer must obtain or have access to a machine 190 capable of performing the fusing method selected to selectively fuse the bus bar 200. For example, if the designer decides to use a laser welding fusing method, the designer obtains or has access to a laser welder 192, at least as shown in FIGS. 4, 5, and 19. As shown therein, the laser welder 192 can include two separate lasers 194, 196 that can weld the bus bar 200 simultaneously from two opposite directions. The two separate lasers 194, 196 are preferably aligned in a vertical plane. However, it should be understood that the laser welder 192 may have other configurations including: (i) only one laser 194 that can interact with only one side of the bus bar 200 at a time, (ii) only one laser 194, but the light output from the laser is modified using optics and mirrors such that the laser can interact with both sides of the bus bar 200 simultaneously, or (iii) two lasers 194, 196 that are not aligned.

[0145] Next, the designer inserts the conductor 202 disposed in the above-disclosed layered stack design into the machine 192 and provides the machine 192 with fusion instructions associated with the first end sector 208a and the first range 212a of the busbar 200 (e.g., loads an engineering model). Thereafter, the laser welder 192 executes the fusion process 180 described in the instructions. For example, FIG. 4 shows a horizontal busbar 200 that lies in a plane whose width is substantially perpendicular to the lasers 194, 196. In this horizontal orientation, the machine 192 performs a surface-based fusion process (i.e., a vertical partial penetration welding process 182) on the end sector 207 of the busbar 200 in accordance with the instructions associated with the first end sector 208a of the busbar 200. Next, as shown in FIG. 5, the busbar 200 is rotated to a vertical orientation that lies in a plane whose thickness is substantially perpendicular to the lasers 194, 196. In this vertical orientation, the machine 192 performs an edge-based fusion process (i.e., a lateral partial penetration welding process 184) on the first range 212a of the busbar 200 in accordance with the instructions associated with the first range 212a.

[0146] After the selective welding of the first end sector 208a and the first range 212a of the central sector 210, the bus bar shown in FIGS. 6 to 17 is formed. It should be understood that at this stage of the manufacture of the bus bar 200, only the first end sector 208a and the first range 212a of the central sector 210 are formed. The formation of these parts, ranges, sectors, segments, zones, and regions is indicated by the solid lines shown in FIGS. 6 and 7. For the sake of simplicity of discussion, other parts, ranges, sectors, segments, zones, and regions that are identified but not formed at this stage of manufacture and are formed at a later stage of manufacture are indicated by the dotted lines in FIGS. 6 and 7. In practice, these identified and later-formed ranges, sectors, segments, zones, and regions are preferably not formed at this stage of manufacture because their inclusion is likely to introduce additional stress into the conductor 202 during the bending of the bus bar 200. To avoid the introduction of these stresses, the formation of these ranges, sectors, segments, zones, and regions is carried out after the bus bar 200 has been bent into the desired shape. Further, the disclosed configuration of the bus bar 200 should be understood as exemplary, and other configurations of ranges, sectors, segments, zones, and regions are contemplated by the present disclosure. For example, all parts, sectors, segments, zones, and regions disclosed or contemplated in U.S. Patent Application Nos. 17 / 970,116 and 17 / 699,033, and PCT Application PCT / IB2022 / 057772 may be included in or utilized by the bus bar 200.

[0147] Figures 6 to 11 show that the bus bar 200 includes (i) a central sector 210 and (ii) two end sectors 207. The central sector 210 extends between end boundary lines 214a, 214b, and the end sectors 207 extend outwardly from the end boundary lines 214a, 214b. The end boundary lines 214a, 214b separate a fusion segment 206 including a fully solidified region 242 arranged to form a densified weld from segments 204, 206 that do not include a fully solidified region. The end boundary lines 214a, 214b are arranged such that there is sufficient material in the end sectors 207 of the bus bar 200 to couple the end sectors 207 to a connector, terminal, receptacle, or any other structure that couples the bus bar 200 to an external structure or component, and it should be understood that the end boundary lines 214a, 214b are disposed inwardly by a sufficient distance from the edges 216c, 216d. For example, the end boundary lines 214a, 214b can be formed between 1 mm and 40 mm, preferably between 14 mm and 22 mm, from the end edges 216c, 216d.

[0148] At least as shown in FIG. 6, the central sector 210 includes (i) three unfused segments 204 (205a, 205b, 205c), and (ii) two fused segments 206 (209a, 209b). In particular, the unfused segments 204 are arranged as follows: (i) The first unfused segment 205a extends between the first end boundary line 214a and the first intermediate boundary line 218a, (ii) The second unfused segment 205b extends between the second intermediate boundary line 218b and the third intermediate boundary line 218c, (iii) The third unfused segment 205c extends between the fourth intermediate boundary line 218d and the second end boundary line 214b. On the other hand, the fused segments 206 are arranged as follows: (i) The first fused segment 209a (first unfused segment 205a) extends between the first intermediate boundary line 218a and the second intermediate boundary line 218b, (ii) The second fused segment (second fused unfused segment) 209b extends between the third intermediate boundary line 218c and the fourth intermediate boundary line 218d. In other words, the first intermediate boundary line 218a separates the linear range (i.e., the first peripheral portion 402a) of the bus bar 200 from the non-linear range (i.e., the elastically deformable intermediate portion 410). Further, the fourth intermediate boundary line 218d separates the linear range (i.e., the second peripheral portion 402b) of the bus bar 200 from the non-linear range (i.e., the elastically deformable intermediate portion 410). Finally, the second and third intermediate boundary lines 218c, 218d separate the unfused segments 204 from the fused segments 206.

[0149] Figures 12 to 17 are cross-sectional views for explaining how the selective fusion process changes the configuration of the individual conductors 202 included within the first range 212a of the end sector 207 and the central sector 210 of the bus bar 200. Specifically, when the bus bar 200 is sectioned along lines 13-13, 15-15, and 17-17, the following can be seen: (i) regions that have not undergone a fusion process (e.g., welding) remain non-solidified 230, and (ii) regions that have undergone a fusion process (e.g., welding): (a) that is, the end welds, particularly the right end weld and the left end weld, form a lateral solidification region 238 in the fusion segment 206 of the central sector 210 of the bus bar 200, or (b) that is, the surface welds, particularly the top weld and the bottom weld, form a fully solidified region 242 in the end sector 207 of the bus bar 200. 1. Non-fused segment

[0150] Figure 13 is a cross-sectional view of the bus bar 200 taken along the cross-sectional plane defined by line 13-13 of Figure 12. The cross-section is taken between the first end boundary line 214a and the first intermediate boundary line 218a. The boundary lines define the ends of the non-fused segment 204 (i.e., the first non-fused segment 205a). The cross-section of Figure 13 reveals a plurality of conductors 202 that do not include the solidification regions 238, 242. In other words, the plurality of conductors 202 shown in this cross-section have not undergone a fusion process that joins or fuses the conductor ranges into a single continuous conductor. Put another way, each conductor 202 of this non-fused segment 204 remains an individual and separate conductor 202. This configuration of individual and separate conductors 202 forms a flexible portion 224 that is not designed to be bent or withstand harsh handling forces. In this embodiment, the flexible portion 224 has a stiffness of less than 550 KPa or 0.55 Nm 2 (the stiffness criterion for a bus bar with one conductor is 2,200 KPa * 0.25 = 550 KPa). In particular, the flexible portion 224 has a stiffness of approximately 320 KPa. 2. Fused segment

[0151] The lateral solidification region 238 extends from the lateral ends 216a, 216b of the bus bar 200 to the edge-based fusion peak 219 of the fusion process 180. Here, the edge-based fusion peak 219 is located (i) laterally between the midpoint 217 and the lateral ends 216a, 216b of the fusion segment 206, and (ii) longitudinally at a point located between (a) the first surface 215a and (b) the second surface 215b of the bus bar 200. Thus, the lateral solidification region 238 has a height H LSR , width W LSR and is defined by the region. In an exemplary embodiment, the end fusion width or the width W of the lateral solidification region LSR is less than 0.4 mm, most preferably between 0.01 mm and 0.35 mm. For the disclosed embodiments, if an attempt is made to increase the width of the end fusion width or the lateral solidification region W LSR beyond 0.4 mm, since the bus bar 200 includes ten copper conductors 202 having a thickness of 0.25 mm, undesirable puddling may occur in the vicinity of the lateral ends 216a, 216b. However, it should be understood that for bus bars 200 having other configurations or made of other materials, the puddling may not occur up to a deeper weld or may occur at a shallower weld. Therefore, for the end fusion width or the width W of the lateral solidification region according to other embodiments LSR can be between 0.05 mm and 5 mm, preferably between 0.1 mm and 2.5 mm, and most preferably between 0.1 mm and 0.75 mm.

[0152] The restricted solidification zone 240 is a range of the bus bar 200 that: (i) extends from the midpoint 217 of the fusion segment 206 to one of the lateral ends 216a, 216b, and (ii) has undergone an edge-based fusion process (e.g., the lateral partial penetration welding process 184 or the cold forming process). The restricted solidification zone 240 has (i) a height H extending between the first and second surfaces 215a, 215b LSZ and (ii) a width W extending between the midpoint 217 of the conductor 202 and the lateral ends 216a, 216b LSZand has. In other words, the limited solidification zone 240 has (i) a height H LSZ which is (a) typically equal to the height H of the fusion segment 206 F and (b) is greater than or equal to the fusion height or the lateral solidification height H LSR and (ii) a width W LSZ which is (a) equal to half of the width of the bus bar 200 (e.g., 20 mm) (e.g., 10 mm) and (b) greater than the lateral cross-sectional width W of the lateral solidification region 238 LSR .

[0153] The end fusion width or the width W of the lateral solidification region LSR is (i) consistent in the fusion segment 206 and (ii) can vary when multiple fusion segments 206 are compared to each other. However, in other embodiments, the end fusion width or the width W of the lateral solidification region LSR can (i) remain constant throughout the fusion segment 206, or (ii) vary in the fusion segment 206, (iii) remain constant across multiple fusion segments 206, and / or (iv) vary across multiple fusion segments 206. As described above, the end fusion width or the width W of the lateral solidification region LSR is between 0.05 mm and 0.4 mm, preferably 0.2 mm. Therefore, the total fusion depth W calculated by summing the widths W of the lateral solidification regions associated with the right end and the left end LSR varies between each of the multiple fusion segments 206. Thus, the first total fusion depth associated with the fusion segment 206 extending between 218a and 218b is between 0.1 mm (i.e., 0.05 mm + 0.05 mm) and 0.8 mm (i.e., 0.4 mm + 0.4 mm), preferably 0.4 mm. Thus, the total fusion depth W T is between 0.5% and 4% of the bus bar width (i.e., 20 mm). T

[0154] Based on the above-described height and width, the bus bar 200 includes the following relationships: (i) the height H of the lateral solidification region 238 LSR ​is typically substantially equal to the height H of the limited solidification zone 240 LSZ and (ii) the width W of the lateral solidification region 238 LSR is small relative to the width W of the limited solidification zone 240, where the width W LSZ is typically less than 50% of the width W, most preferably between 0.5% (i.e., (1 - (9.95 mm / 10 mm)) * 100) and 4% (i.e., (1 - (9.6 mm / 10 mm)) * 100) of the width W of the limited solidification zone 240. Further, the height of the end weld 184 is substantially equal to the height H of the limited solidification region 238 LSR and the width of the end weld 184 is substantially equal to the width W of the lateral solidification region 238 LSZ Thus, the height of the end weld 184 is substantially equal to the height H of the limited solidification zone 240 and the width of the end weld 184 is less than the width W of the limited solidification zone 240 LSZ LSR and the width of the end weld 184 is substantially equal to the width W of the lateral solidification region 238 LSR Thus, the height of the end weld 184 is substantially equal to the height H of the limited solidification zone 240 and the width of the end weld 184 is less than the width W of the limited solidification zone 240 LSZ LSZ

[0155] The width W of the lateral solidification region LSR is less than both the width W of the limited solidification zone 240 and half the width of the bus bar 200. Since the width W of the lateral solidification region is less than half the width of the bus bar 200, an unsolidified region 230 is formed between the edge-based fusion peak 219 and the midpoint 217 of the bus bar 200. This unsolidified region 230 has an unsolidified width W LSZ which extends between the midpoint 217 of the bus bar 200 and the edge-based fusion peak 219. The unsolidified width W LSR is typically at least 10% of the width W of the limited solidification zone 240, preferably between 50% and 99.9% of the width W of the limited solidification zone 240. On the other hand, the width W of the lateral solidification region U is at least 0.1% equal to the width W of the limited solidification zone 240, preferably between 1% and 10% of the width W of the limited solidification zone 240, most preferably between the width W of the limited solidification zone 240 U is typically at least 10% of the width W of the limited solidification zone 240 LSZ and preferably between 50% and 99.9% of the width W of the limited solidification zone 240. On the other hand, the width W of the lateral solidification region LSZ is at least 0.1% equal to the width W of the limited solidification zone 240, preferably between 1% and 10% of the width W of the limited solidification zone 240, most preferably between the width W of the limited solidification zone 240 LSR is at least 0.1% equal to the width W of the limited solidification zone 240 LSZ and preferably between 1% and 10% of the width W of the limited solidification zone 240, most preferably between the width W of the limited solidification zone 240 LSZ ​​​​LSZ It is between 3% and 8%.

[0156] In this exemplary embodiment, the lateral solidification region 238 can be created by solidifying the lateral extent of the ten conductors 202 into a single conductor. Stated another way, the central sector 210 of the bus bar 200 includes a plurality of conductors 202 that traverse or span the central sector 210 of the bus bar 200. The fusion segment 206 of the central sector 210 includes a limited solidification zone 240 that extends between the midpoint 217 and the lateral ends 216a, 216b of the conductor 202. A minority of the conductors 202 contained within this limited solidification zone 240 are solidified into a single connecting conductor to form the lateral solidification region 238. Similarly, most of the conductors 202 contained within this limited solidification region 240 are non-solidified, forming the non-solidified region 230.

[0157] As best shown in FIG. 15, when the side portion welding process 184 is used to form the side solidification region 238, the side solidification region 238 can include a varying fusing density. The side portion welding process 184 can form a first or outer zone having a first fusing density and a second or inner zone having a second fusing density that is less than the first fusing density. The difference in density is due to the configuration and operating leads of the laser welder 192, and the intensity of the laser beam is lost as it penetrates the bus bar 200. The low density zone is formed within a certain distance inward from the end of the weld or inside the high density zone. It should be understood that there is a gradient of fusing density in this second zone, with the fusing density being high closest to the first zone and lowest farthest from the first zone. Also, it should be understood that the fusing density is consistent or substantially consistent within this first zone. In addition to solidifying the side ends 216a, 216b of the bus bar 200, the side portion welding process 184 rounds the corners of the bus bar 200. These rounded corners help reduce the probability that the conductor 202 will bite into or tear the insulator or housing 600. Additional aspects of the side solidification region 238 and the non-solidified region 230 are shown in the definition section at the beginning of the detailed description.

[0158] As described above, the fusion segment 206 within the central sector 210 of the bus bar 200 includes both the side solidification region 238 and the non-solidified region 230. Thus, increasing the area of the side solidification region 230 within the fusion segment 206 tends to (i) increase at least the local rigidity within the fusion segment 206, (ii) increase the rigidity of the central sector 210 of the bus bar 200, and (iii) increase the overall rigidity of the bus bar 200. For example, when these side solidification regions 238 are formed, the Young's modulus of the bus bar increases (e.g., 320 KPa or 0.32 Nm at room temperature 2Above). Further, increasing the area of the non-solidified region 230 within the fusion segment 206 tends to (i) increase at least the local flexibility within the fusion segment 206, (ii) increase the flexibility of the central sector 210 of the bus bar 200, and (iii) increase the overall flexibility of the bus bar 200.

[0159] FIG. 15 is a cross-sectional view of the bus bar 200 taken along a cross-sectional plane defined by line 15-15 of FIG. 14. The cross-section is taken between a first intermediate boundary line 218a and an intermediate boundary line 218b. These boundary lines 218a, 218b define the edge of the fusion segment 206 or the fusion segment 206 (i.e., the first fusion segment 209a). The cross-section of FIG. 15 reveals (i) two lateral solidified regions 238 formed using left and right lateral partial penetration welds extending inwardly from the lateral ends 216a, 216b of the bus bar 200, and (ii) a non-solidified region 230 extending between the two lateral solidified regions 238. Thus, the left and right lateral partial penetration welds join all of the conductors 202 contained within the lateral solidified regions 238 into a single connected conductor. This first fusion segment 206, 209a lacks the area that has undergone a surface-based fusion process to form a partially solidified region, and all of the conductors within the partially solidified region are fused to form a single connected conductor. Since this first fusion segment 206, 209a lacks a partially solidified region, it also lacks a partially solidified zone. Therefore, this bending region 226 has a stiffness greater than 770 KPa ((2,200 KPa * 0.4 for a rigid reference bus bar with one conductor) = 770 KPa). 3. Fusion End Sector

[0160] Unlike the central sector 210, since the end sectors 207 are intended to receive connectors, it is desirable for these regions to be fully solidified as a single continuous conductor. All ranges of the conductor 202 included in the fully solidified region 242 are solidified into a single conductor because a significant range of the conductor 202 is as follows: (i) solidifying downward from the top surface 215a, (ii) solidifying upward from the bottom surface 215b, and (iii) solidifying inward from the side ends 216a, 216b. Accordingly, these significant ranges of the conductor 202 meet between the top and bottom surfaces 215a, 215b, typically in the midpoint region between the two surfaces 215a, 215b, forming the fully solidified region 242. The weld depth or the height H of the fully solidified region 242 FSR is at least substantially equal to the fusion height H of the bus bar 200 F In a particular exemplary embodiment, when the welding material is deposited on one of the two surfaces 215a, 215b and a "dome effect" occurs, the fully solidified height H FSR may be greater than the fused height H F The height H of the fully solidified region 242 FSR is equal to or greater than the fusion height H F Therefore, the non-solidified region 230 is not formed between the weldment and the second surfaces 215a, 215b of the bus bar 200. In other words, all conductors 202 disposed within the fully solidified zone are solidified into a single continuous conductor. Additional aspects of the fully solidified region 242 are disclosed in PCT / US20 / 50016, which is incorporated herein by reference.

[0161] Similar to the partially solidified zone 1300, the fully solidified zone is the region of the bus bar 200 where the zone that has undergone the full welding process 182 extends between the top surface 215a and the bottom surface 215b. The fully solidified zone has a height that extends between the first and second surfaces 215a, 215b. In other words, the fully solidified zone has a height equal to the fused height H F and a fully solidified height H FSRIt may be equal to. Based on the disclosed welding, the end sectors 207 are welded in a way that densifies these sectors 207 (a sufficient solidified surface area equal to 120% of the cross-sectional area of the bus bar 200) so that they can be coupled to the connector.

[0162] Figure 17 is a cross-sectional view of the bus bar 200 taken along a cross-sectional plane defined by line 17-17 of Figure 16. The cross-section is taken between the end edge 216c and the first intermediate boundary line 218a that defines the end sectors 207, 208a and the fully solidified region 242. The cross-section of Figure 17 reveals (i) two lateral solidified regions 238 formed using left and right lateral partial penetration welds that extend inwardly from the lateral edges 216a, 216b of the bus bar 200, and (ii) thirteen partially solidified regions formed using an up and down longitudinal partial penetration welding process 182 that extend vertically from the top and bottom surfaces 215a, 215b of the bus bar 200. Therefore, this bending region 226 has a rigidity exceeding 770 KPa ((2,200 KPa * 0.35 for a rigid reference bus bar having one conductor) = 770 KPa). ii. Alternative Embodiment

[0163] As described above, the central sector 210 can include (i) any number (e.g., 0 to 1000) of unfused segments 204, and (ii) any number (e.g., 0 to 1000) of fused segments 206. The fused segment 206 can include any number (e.g., 0 to 1000) of lateral solidification regions 238, any number (e.g., 0 to 1000) of partially solidified regions, and any number (e.g., 0 to 1000) of unsolidified regions 230. Also, the fused segment(s) 206 can include any number (e.g., 0 to 100) of waveforms, preferably 1 to 6 waveforms, and most preferably 2 waveforms. Similarly, the central sector 210 of the bus bar 200 can include (i) any number (e.g., 0 to 100) of waveforms, (ii) any number (e.g., 0 to 1000) of lateral solidification regions 238, (iii) any number (e.g., 0 to 1000) of partially solidified regions, (iv) any number (e.g., 0 to 1000) of fully solidified regions 242, and / or (v) any number (e.g., 0 to 1000) of unsolidified regions 230. Finally, the bus bar 200 can include (i) any number of waveforms (e.g., 0 to 100), (ii) any number (e.g., 0 to 1000) of lateral solidification regions 238, (iii) any number (e.g., 0 to 1000) of partially solidified regions, (iv) any number (e.g., 0 to 1000) of fully solidified regions 242, and / or (v) any number (e.g., 0 to 1000) of unsolidified regions 230. With this configuration, the bus bar designer can selectively form segments, zones, regions, and / or volumes in a single bus bar, providing the bus bar 200 with the advantages associated with conventional rigid bus bars and conventional flexible bus bars.

[0164] In an alternative embodiment, the disclosed laser melting process may replace or be used in addition to resistance welding, arc welding, electron beam welding, orbital welding, ultrasonic welding, friction welding, any combination of the above methods, or other known methods for melting metals. Further, the lateral partial penetration welding process 184 or the cold forming process that forms a lateral solidification region within the limited solidification region of the central sector 210 may be omitted or its width may be expanded. Further, the lateral partial penetration welding process 184 or the cold forming process used in connection with the end sector 207 may also be omitted. iii. Formation of the intermediate portion

[0165] After the first end sector 208a and the first range 212a of the bus bar 200 are selectively fused, the process of manufacturing the bus bar 200 is continued by forming the elastically deformable intermediate portion 410 of the bus bar 200 into a desired shape. The elastically deformable intermediate portion 410 of the bus bar 200 is located between a first peripheral portion 402a and a second peripheral portion 402b. Specifically, the first peripheral portion 402a includes: (i) the first end sectors 207, 208a, and (ii) the first range of the central sector 210, i.e., the first unfused segments 204, 205a. Similarly, the second peripheral portion 402b includes: (i) the second end sectors 207, 208b, and (ii) the second range of the central sector 210, i.e., the third unfused segments 204, 205c. Based on this disclosed configuration, the first and second peripheral portions 402a include: (i) a fully solidified region 242, and (ii) an unsolidified region 230. On the other hand, the intermediate portion 410 is within the central sector 210 and is formed between the first and second ranges of the central sector 210. Thus, the intermediate portion 410 includes: (i) the first fused segments 206, 209a, (ii) the second unfused segments 204, 205b, and (iii) the second fused segments 206, 209b. Accordingly, the intermediate portion 410 includes: (i) two lateral solidified regions 238, and (ii) an unsolidified region 230 that extends between the two lateral solidified regions 238. It should be understood that other configurations are contemplated by this disclosure (see FIGS. 89-102). For example, in an alternative embodiment, the intermediate portion 410 may include a partially solidified region.

[0166] In other words, the first peripheral portion 402a is defined between the left edge 216c and the first intermediate boundary line 218a, and the second peripheral portion 402b is defined between the right edge 216d and the fourth intermediate boundary line 218d. In other words, the first and second peripheral portions 402a, 402b extend outward from the first and fourth intermediate boundary lines 218a, 218d. The first and fourth intermediate boundary lines 218a, 218d are disposed inwardly from the edges 216c, 216d by a sufficient distance so as to (i) enable a connector, terminal, receptacle, or any other structure to be properly coupled to the bus bar 200, and (ii) enable the elastically deformable intermediate portion 410 to be properly disposed at a desired position (e.g., a position that does not interfere with the position of the battery module 60). For example, the end boundary lines 214a, 214b can be formed between 15 mm and 85 mm, preferably between 35 mm and 55 mm, from the edges 216c, 216d.

[0167] The first and second peripheral portions 402a, 402b are not designed to be bent or modified at this stage of the manufacturing process. Thus, in the uninstalled state S U these peripheral portions 402a, 402b remain substantially parallel, remain substantially aligned, their top and bottom surfaces 215a, 215b are substantially coplanar, and their lateral ends 216a, 216b are substantially collinear. Thus, these peripheral portions 402a, 402b are not designed to include a curved or angled extent. Further, in the installed state S IIn this case, these peripheral portions 402a, 402b are typically and / or preferably substantially parallel and remain substantially aligned, their top and bottom surfaces 215a, 215b are substantially coplanar, and their lateral ends 216a, 216b are substantially collinear. The configuration of the first and second peripheral portions 402a, 402b is beneficial as it serves to at least minimize and preferably eliminate undesirable forces in the connection between the bus bar 200 and the male connector assembly 1000, or between the male connector assembly 1000 and the battery module 60. An example of an undesirable force can be introduced when the peripheral portions 402a, 402b of the bus bar 200 have a curved configuration. And said undesirable force can lead to a failure within the battery pack 90, which failure is extremely costly to diagnose, repair, or mitigate. Therefore, it is beneficial to minimize or eliminate these undesirable forces.

[0168] Unlike the first and second peripheral portions 402a, 402b, the elastically deformable intermediate portion 410 is designed to elastically deform when a load is applied onto the bus bar 200 (e.g., from the dynamic movement of the battery module(s) 60). In order to elastically deform when the load is applied to the bus bar 200, the elastically deformable intermediate portion 410 is in the un-installed state S UIn this case, preferably, at least one range, preferably most of the intermediate portion 410, and most preferably substantially most of the intermediate portion 410, is arranged in a position that is (i) not substantially parallel, (ii) not substantially aligned, (iii) not substantially coplanar, or (iv) not substantially collinear, with the entirety of the first and second peripheral portions 402a, 402b. In other words, the intermediate portion 410 is present outside the plane of the first and second peripheral portions 402a, 402b, which results from the fact that the intermediate portion 410 includes a substantial curved (plural possible) range or angular (plural possible) range. Stated another way, the first and second peripheral portions 402a, 402b are substantially present in a first plane, and most of the elastically deformable intermediate portion 410 is present outside the first plane. The formation of this (or these) curved or angular range in the intermediate portion 410 is facilitated by the inclusion of the fusion segment 206 in the bus bar 200 because of the fact that it helps to prevent the bus bar 200 from peeling off when the elastically deformable intermediate portion 410 is bent into its desired shape.

[0169] In the preferred embodiment shown in FIGS. 1 to 73, at least the intermediate portion 410 of the bus bar 200 has a configuration that substantially matches the configuration of the capital Greek letter omega (「Ω」), or the ohm symbol (「Ω」) which is a unit of energy management, especially when viewed in side view. Specifically, the configuration of the first peripheral portion 402a is similar to the range of the left foot or left base portion of the omega shape, the configuration of the elastically deformable intermediate portion 410 is similar to the curved shape of the omega shape, and the configuration of the second peripheral portion 402b is similar to the range of the right foot or right base portion of the omega shape. In other words, the bus bar 200 includes the following: (i) a first linear range 260a, (ii) a first foot or base of the omega shape formed by a first curved range 262a that forms a first external recess 264a, (iii) a semi-circular range 266, (iv) a second foot or base of the omega shape formed by a second curved range 262b that forms a second external recess 264b, and (v) a second linear range 260b. Further, the configuration of the bus bar 200 arranges the fusion segments 206, 209a, 209b near the foot or base of the omega shape, while the non-fusion segments 204, 205a, 205b, 205c are arranged as follows: (i) located between the end sector 207 and the fusion segments 206, 209a, 209b, and (ii) along the curved path between the fusion segments 206, 209a, 209b. In other embodiments, it should be understood that the first and second ranges of the central sector 210 may include the fusion segment 206, and the curved path between the fusion segments 209a, 209b may be fully fused or partially fused. Also, in other embodiments, it should be understood that the elastically deformable intermediate portion 410 may have alternative configurations (e.g., square, triangle, sine wave, etc.) including but not limited to the shapes disclosed in FIGS. 89 to 102. Finally, the optimal elastic deformation performance of the bus bar 200 is considered to occur when the elastically deformable intermediate portion 410 has a curved configuration lacking right angles or "sharp angles" as shown in FIGS. 89, 90, 92, 93, 95, and 98.

[0170] As shown in FIG. 6, when the bus bar 200 is in its original state or the non-bent state S of the bus bar 200 UB the lengths of the respective portions are as follows: (i) The first peripheral portion 402a has a length L extending from the edge 216c of the bus bar 200 to the first intermediate boundary line 218a P1U and (ii) the second peripheral portion 402b has a length L extending from the edge 216d of the bus bar 200 to the fourth intermediate boundary line 218d P2U and (iii) the intermediate portion 410 has a length L extending from the first intermediate boundary line 218a to the fourth intermediate boundary line 218d IPU . The lengths L P1U of the peripheral portions must be long enough to facilitate connection to external devices or components of the bus bar 200. In the disclosed embodiments, the lengths L P2U of these peripheral portions may be greater than 5 mm, preferably greater than 10 mm, more preferably greater than 14 mm, and most preferably between 30 mm and 60 mm. While the lengths L P1U of the peripheral portions contribute to the total length L P2U of the bus bar 200, the length L P1U of the intermediate portion substantially pushes back the calculations shown in the following table P2U . UB IPU

[0171] Also, as shown in FIG. 7, when the bus bar 200 is in its original state or the non-bent state S of the bus bar 200 UB the lengths of the respective portions are as follows: (i) The first end sector 208a has a length L extending from the edge 216c of the bus bar 200 to the first end boundary line 214a E1U and (ii) the second end sector 208b has a length L extending from the edge 216d of the bus bar 200 to the second end boundary line 214b E2U and (iii) the central sector 210 has a length L extending from the first end boundary line 214a to the second end boundary line 214b CU . The lengths L E1U of the end sectors E2U ​​It must be long enough to facilitate the connection of the bus bar 200 to an external device or component. In the disclosed embodiment, the length L E1U of these end sectors, L E2U can be greater than 2 mm, preferably greater than 7 mm, and most preferably between 10 mm and 20 mm. The following table shows a case of a bus bar 200 having 10 copper conductors laminated to form a bus bar 200 with a thickness T B of 2.5 mm and a width of 20 mm.

Table 1

[0172] The total length L of the unbent bus bar BU and the formed length L of the bus bar BN extend between the edges 216c and 216d of the bus bar 200 in the uninstalled state S U . As shown in Table 1 above, the ratio of the formed length L BN to the total length L BU is between 70% and 90%. In other words, the formed length L BN is at least 10% less than the total length L BU , and preferably at least 20% less than the total length L BU . Also, the above table shows that the length L of the unbent middle portion IPU is between 35% and 49% of the total length L of the unbent bus bar 200 BU , and each length L of the peripheral portion P1U , L P2U is between 25% and 32% of the total length L of the unbent bus bar 200 BU . Thus, the length L of the unbent middle portion IPU is less than half of the total bus bar length L of the bus bar 200 BU . However, as described above, other length ratios are also contemplated by the present disclosure.

[0173] The length L of the unbent middle portion IPUis approximately equal to the circumference of a circle having the relevant inner diameter. For example, a circle with a diameter of 20 mm has a circumference of approximately 62.8 mm, and thus, the length of the unbent length of the intermediate portion is approximately 63 mm. Due to the unique shape of the intermediate portion 410, at least as shown in FIGS. 21 and 69, in either the first peripheral portion 402a or the second peripheral portion 402b, the bending height H defined between the outer surface of the uppermost conductor 203j (e.g., the intermediate height of the intermediate portion 410) and the outer surface of the lowermost conductor 203a IPN exists. In the neutral state S N the intermediate portion 410 has a bending height H between 20 mm and 28 mm, preferably 23 mm IPN Also, at least as shown in FIGS. 21 and 69, there is a bending length L of the intermediate portion 410 defined between the opposite outer surfaces of the uppermost conductor 203j (e.g., the intermediate length of the intermediate portion 410) IPN exists. In the neutral state S N the intermediate portion 410 has a bending length L between 23 mm and 31 mm, preferably 27 mm IPN In other words, the design of this bus bar 200 intentionally increases the height and space required to mount this bus bar 200 within the power distribution assembly 50, that is, it includes the intermediate portion 410. This increase in space requirements runs counter to the goal of minimizing the space required by the electrical connectors. Thus, this is an unprecedented solution for solving problems related to the material conditions related to the battery module 60 and the dynamic movement of the battery module 60. It should be understood that the present disclosure contemplates other ratios or calculations based on the above table

[0174] Table 1 (above) shows the activation force F supplied by the battery modules 62a, 62b to move the bus bar 200 between the neutral state S N and the compressed state S C or between the neutral state S N and the expanded state S E Since the bus bar 200 responds linearly, the activation force F A is between the neutral state S A and the compressed state S N and the compressed state S Cbetween and the neutral state S N and the expanded state S E When moving between, the magnitudes are equal but the directions are opposite. Therefore, the activation force F A depends on ~~ and is the compressive activation force F A or the expansion activation force F A can be set as. Also, as shown in Table 1 above, even if the inner diameter of the intermediate portion 410 is made larger than 22 mm, the bus bar 200 can be moved from the neutral state S N to the compressed state S C or the expanded state S E The activation force F A (in the first column) does not decrease significantly. However, an increase in the inner diameter significantly increases the overall package volume of the bus bar 200, which represents the amount of space in the battery pack that needs to be secured for the installation and operation of the elastically deformable connector system 100. For example, when doubling the inner diameter of the intermediate portion 410 from 10 mm to 20 mm, the activation force F A decreases by more than seven times from 312 N to 42 N. However, even when increasing the inner diameter of the intermediate portion 410 from 20 mm to 30 mm, the activation force F A only decreases by more than 1.5 times from 42 N to 30 N. Therefore, the configuration with the minimum package size that requires an activation force F A of less than 50 Newtons for moving between states is the bus bar 200 with an inner diameter of 20 mm. This relationship is considered to be the optimal balance between the decrease in the activation force F A and the increase in the package size. It should be understood that the above calculations may be changed and / or the ratios between the above characteristics may be changed depending on other configurations of the bus bar 200 (e.g., material, thickness, width, configuration of the intermediate portion, welded parts, etc.). For example, increasing the thickness of each conductor 202 or the number of conductors 202 without changing other measured values may increase the force required to move the bus bar 200 from the neutral state S N to the compressed state S C or the expanded state S E Similarly, decreasing the thickness of each conductor 202 or the number of conductors 202 without changing all other measured values may cause the bus bar 200 to move from the neutral state S N to the compressed state SC or the extended state S E There is a high possibility that the force required to move to any of them will decrease.

[0175] Furthermore, the volume of the intermediate portion 410 is larger than (i) the volumes of the peripheral portions 402a, 402b, and (ii) the volume of the connector replacing the intermediate portion 410 that linearly extends between the peripheral portions 402a, 402b. Furthermore, the upper surface area of the intermediate portion 410 (e.g., 1,233 mm 2 ) is larger than (i) the surface areas of the peripheral portions 402a, 402b (e.g., 866 mm 2 ), and (ii) the surface area of the connector replacing the intermediate portion 410 that linearly extends between the peripheral portions 402a, 402b. Thus, the peripheral portions 402a, 402b contain less material than (i) the intermediate portion 410 and (ii) the connector replacing the intermediate portion 410 that extends between the peripheral portions 402a, 402b linearly. iv. Selective welding of the second range of the bus bar

[0176] Next, the designer inserts the bent bus bar 202 into the machine 192 and provides the machine 192 with fusion instructions related to the second end sectors 207, 208b and the second range 212b of the bus bar 200 (e.g., loading an engineering model). Then, the laser welder 192 executes the fusion process 180 described in the instructions. For example, FIG. 19 shows a horizontally oriented bus bar 200 existing in a plane whose width is substantially perpendicular to the lasers 194, 196. In this horizontal orientation, the machine 192 executes a surface-based fusion process (i.e., a longitudinal partial penetration welding process 182) on the end sector 207 of the bus bar 200 according to the instructions related to the second end sector 208b of the bus bar 200. Next, the bus bar 200 is rotated to a vertical orientation in a plane whose thickness is substantially perpendicular to the lasers 194, 196. In this vertical orientation, the machine 192 executes an end-based fusion process (i.e., a lateral partial penetration welding process 184) on the second range 212b of the bus bar 200 according to the instructions related to the second range 212b. After the selective welding of the second end sector 208b and the second range 212b of the central sector 210, the bus bar shown in FIGS. 20-24 is formed. v. Optional manufacturing steps

[0177] After the above-described welding process is completed, any manufacturing steps can be completed. For example, completing any manufacturing steps can include: (a) assembling and coupling the connector 1000 to the bus bar 200, (c) insulating the bus bar 200, (d) plating the range of the bus bar 200 and / or placing the bus bar 200 within the housing 600. B. Male connector assembly

[0178] Referring to FIG. 15, the male connector assembly 1000 includes (i) a housing assembly 1100 and (ii) a male terminal assembly body 1430 having a spring member 1440c and male terminals 1470. The male terminal assembly 1430 is coupled to the first and second peripheral portions 402a, 402b of the bus bar 200 using any known bonding process including laser welding and / or ultrasonic welding. It should be understood that the connector assembly 1000 is an example of a potential connector that can be coupled to the bus bar 200. The present disclosure contemplates the use of other connectors including conventional bolt-type connectors. i. Male housing assembly

[0179] The male housing assembly 1100 surrounds or encloses a substantial range of other components included within the male terminal assembly 1430. The outer housing assembly 1100 generally includes (i) an outer housing 1104 and (ii) a deformable connector position assurance (「CPA」) 1170. The outer housing 1104 includes an arrangement of two walls, where (i) the first side wall arrangement 1106 has a rectangular shape and is designed to receive a range of the bus bar 200, and (ii) the second side wall arrangement 1108 has a cubic shape and is designed to receive a substantial range of the male terminal assembly 1430. The second arrangement 1108 of the walls includes at least one, preferably two walls 1108d of the wall 1108b and a non-deformable CPA receiver 1160 designed to receive the range of the deformable CPA 1170. The two arrangements of the walls are typically formed from an insulating material designed to insulate the current flowing through the male connector assembly 1000 from other components. Additional details regarding the outer housing assembly 1100 are described in PCT / US2019 / 36070. It should be understood that the male housing assembly 1100 does not include a lever to assist in the coupling of the male connector assembly 1000 and the female connector assembly 2000. ii. Male terminal assembly

[0180] Figs. 25 - 30 provide various views of the male terminal assembly 1430, which includes a spring member 1440c and a male terminal 1470. The male terminal 1470 includes a male terminal body 1472 and a male terminal connection member or plate 1474. The male terminal body 1472 includes: (i) a first or front male terminal wall 1480 in which a touch-proof post opening 1510 is formed; (ii) an array of male terminal side walls 1482a - 1482d; and (iii) a second or rear male terminal wall 1484. The combination of these walls 1480, 1482a - 1482d forms a spring receiver 1486 designed to receive an internal spring member, male spring member, or second spring member 1440c.

[0181] Referring to Fig. 26, the internal spring member 1440c includes an array of spring member side walls 1442a - 1442d and a rear spring wall 1444. The array of spring member side walls 1442a - 1442d each includes: (i) a first spring portion or arcuate spring portion 1448a - 1448d; (ii) a second spring portion, base spring portion, or intermediate spring portion 1450a - 1450d; (iii) a third spring portion or spring arm 1452a - 1452h; and (iv) a fourth spring portion or centering means 1453. The arcuate spring portions 1448a - 1448d extend between the rear spring wall 1444 and the base spring portions 1450a - 1450d, positioning the base spring portions 1450a - 1450d substantially perpendicular to the rear spring wall 1444. In other words, the outer surfaces of the base spring portions 1450a - 1450d are substantially perpendicular to the outer surface of the rear spring wall 1444.

[0182] The base spring portions 1450a to 1450d are disposed between the arch-shaped portions 1448a to 1448d and the spring arms 1452a to 1452h. As shown in FIG. 26, since the base spring portions 1450a to 1450d are not connected to each other, a gap is formed between the base spring portions 1450a to 1450d of the spring member 1440c. This gap assists the expansion of the spring arms 1452a to 1452h in all directions and facilitates the mechanical coupling between the male terminal 1470 and the female terminal assembly 2430. The spring arms 1452a to 1452h extend away from the rear spring wall 1444 from the base spring portions 1450a to 1450d of the spring member 1440c and terminate at the free ends 1446. The spring arms 1452a to 1452h are generally planar and are arranged such that the outer surfaces of the spring arms 1452a to 1452h are coplanar with the outer surfaces of the base spring portions 1450a to 1450d. Unlike the spring arms 31 disclosed in FIGS. 4 to 8 of PCT / US2018 / 019787, the free ends 1446 of the spring arms 1452a to 1452h do not have a curved component. Instead, the spring arms 1452a to 1452h have a substantially planar outer surface. This configuration is beneficial as it ensures that the forces associated with the spring member 1440c are applied substantially perpendicular to the free end 1488 of the male terminal body 1472. In contrast, the curved component of the spring arm 31 is disclosed in FIGS. 4 to 8 of PCT / US2018 / 019787 but does not apply force in such a manner.

[0183] Similar to the base spring portions 1450a to 1450d, the spring arms 1452a to 1452h are not connected to each other. That is, a spring arm opening extends between the spring arms 1452a to 1452h. With this configuration, the spring arms 1452a to 1452h can move in all directions, facilitating the mechanical coupling between the male terminal 1470 and the female terminal assembly 2430. In other embodiments, the spring arms 1452a to 1452h may be coupled to other structures to limit their expansion in all directions. The number and width of the individual spring arms 1452a to 1452h and the opening may vary. Further, the widths of the individual spring arms 1452a to 1452h are typically equal to each other, but in other embodiments, one of the spring arms 1452a to 1452h may be wider than the other spring arms.

[0184] The previous design of the spring member 1440pd was disclosed in connection with FIGS. 5-6 of PCT / US2019 / 36127, and FIG. 13 of PCT / US2021 / 043686 shows how the spring member 1440pd can be fully aligned within the male terminal body 1472pd of the male terminal assembly 1430pd. However, due to manufacturing tolerances and incomplete assembly methods, the spring member 1440pd may be misaligned or cocked within the male terminal body 1472pd during the assembly of the male terminal assembly 1430pd. An example of such misalignment is shown in FIG. 14 of PCT / US2021 / 043686, where the angle θ indicates this misalignment extending between the inner surface of the spring receiver and the outer surface of the spring member 1440pd. In certain embodiments, the angle θ may be between 1 degree and 5 degrees. To help avoid this misalignment, the spring member 1440c disclosed herein includes centering means 1453 shown as anti-rotation protrusions 1454a-1454d. The anti-rotation protrusions 1454a-1454d assist in centering the spring member 1440c by limiting the amount by which the spring member 1440c can rotate within the male terminal body 1472 through the interaction between the outer surfaces of the protrusions 1454a-1454d and the inner surfaces of the side wall portions 1492a-1492d of the male terminal body 1472. Properly centering the spring member 1440c within the male terminal body 1472 provides numerous advantages compared to terminals that are not properly centered or aligned within the male terminal assembly 1430, including: (i) ensuring that the spring member 1440c applies an appropriate force to the male terminal body 1472 to provide a proper connection between the male terminal assembly 1430 and the female terminal assembly 2430; (ii) helping to improve the durability and useful life of the terminal assemblies 1430, 2430; and (iv) other beneficial features disclosed herein or that may be inferred by those skilled in the art from this disclosure.

[0185] In other embodiments, it should be understood that the centering or alignment means 1453 can take other forms, such as, for example, the following: (i) protrusions extending outwardly from the first and second spring arms 1452a, 1452b disposed within a single side wall; (ii) protrusions extending outwardly from the first and fifth spring arms 1452a, 1452e, the protrusions being disposed obliquely opposite to each other; (iii) protrusions extending outwardly from all of the spring arms 1452a-1452h, the protrusions associated with 1452c, 1452d, 1452g, 1452h being in an offset positional relationship compared to the protrusions associated with 1452a, 1452b, 1452e, 1452f; (iv) protrusions extending inwardly from the inner wall of the male terminal body 1472; (v) protrusions extending inwardly from the contact arms 1494a-1494h toward the center of the connector; (vi) cooperatively dimensioned spring retainers; (vii) extensions of protrusions, tabs, grooves, recesses, or other structures designed to assist in ensuring that the spring member 1440c is centered within the male terminal body 1472 and cannot rotate within the spring receptacle 1486. For example, the protrusions may extend from the front or rear wall of the male terminal body 1472 and they may be received by openings formed within the spring member 1440c.

[0186] Instead of using mechanical base centering or alignment means 1453, the centering means 1453 may be force-based, and it should be further understood that such forces that can be utilized are magnetic or chemical forces. In this embodiment, the rear wall of the spring member 1440c may be welded to the rear wall of the male terminal body 1472. In contrast to mechanical or force-based centering means 1453, the centering means 1453 may be a method or process for forming the male terminal assembly 1430. For example, the centering means 1453 may not be a structure, but instead, the spring member 1440c may be printed simultaneously into the male terminal body 1472 in a way that does not require assembly. In other words, the centering means 1453 can take many forms (e.g., mechanically based, force-based, or process-based) to achieve the purpose of centering the spring member 1440c within the male terminal body 1472.

[0187] The internal spring member 1440c is typically formed from a single piece of material (e.g., metal), and thus, the spring member 1440c is either an integral spring member 1440c or has features formed integrally. In particular, the following features are integrally formed: (i) the arched spring portions 1448a - 1448d, (ii) the base spring portions 1450a - 1450d, (iii) the spring arms 1452a - 1452h, and (iv) the centering means 1453. To integrally form these features, the spring member 1440c is typically formed using a die casting process. The die casting process mechanically and forcibly shapes the spring member 1440c. As described in more detail below and in PCT / US2019 / 036010, when the spring member 1440c is formed from a flat metal sheet, installed within the male terminal 1472, connected to the female receptacle 2472, and exposed to high temperatures, the spring member 1440c, due in part to the fact that the spring member 1440c attempts to return to the flat sheet, exerts an outward spring thermal force S on the contact arms 1494a - 1494h TFis added. However, it should be understood that other types of forming the spring member 1440c may be utilized, such as the use of a casting or an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the spring member 1440c may not be formed integrally or monolithically, and instead may be formed from separate parts that are welded together.

[0188] In an alternative embodiment (not shown), the spring member 1440c can include recesses and associated reinforcing ribs. As discussed in PCT / US2019 / 036010, these changes to the configuration of the spring member 1440c change the forces associated with the spring member 1440c. In particular, the spring bias force S BF is the amount of force applied by the spring member 1440c to resist the inward deflection of the free end 1446 of the spring member 1440c when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. Specifically, this inward deflection occurs due to the fact that during insertion of the male terminal assembly 1430, the outer surface extent of the male terminal body 1472 is slightly larger than the interior of the female receptacle 2472. Thus, when the male terminal assembly 1430 is inserted into the female terminal assembly 2430, the outer surface extent thereof is biased toward the center 1490 of the male terminal 1470. This inward force on the outer surface biases the free end 1446 of the spring member 1440c inwardly (i.e., toward the center 1490). The spring member 1440c resists this inward displacement by providing the spring bias force S F thereby.

[0189] Figs. 27 to 30 show a male terminal 1470 including a male terminal body 1472 and a male terminal connection plate 1474. Specifically, the male terminal connection plate 1474 is coupled to the male terminal body 1472 and configured to receive a structure (e.g., a bus bar) that connects the male terminal assembly 1430 to a device external to the connector system 100 (e.g., a second battery module 60). The conductor 202 is typically welded to the connection plate 1474, but other methods of connecting the conductor 202 to the connection plate 1474 (e.g., forming the conductor 202 as part of the connection plate 1474) are contemplated by the present disclosure.

[0190] As shown in FIGS. 27-30, the arrangements of the male terminal side walls 1482a-1482d are coupled to each other and generally form a rectangular prism-shaped corner post. The arrangements of the male terminal side walls 1482a-1482d include the following: (i) side wall portions 1492a-1492d having a generally "U-shaped" configuration, (ii) contact arms 1494a-1494h, and (iii) a plurality of contact arm openings 1496a-1496l. As best shown in FIGS. 28-29, the side wall portions 1492a-1492d are substantially planar and have a U-shaped configuration. The U-shaped configuration is formed from three substantially linear segments, and the second or intermediate segments 1500a-1500d are coupled at one end to the first or end segments 1498a-1498d and at the other end to the third or opposing end segments 1502a-1502d. The contact arms 1494a-1494h (i) extend from within the range of the intermediate segments 1500a-1500d of the side wall portions 1492a-1492d, (ii) extend away from the rear male terminal wall 1484, (iii) cross the range of the contact arm openings 1496a-1496l, and (iv) terminate near the front male terminal wall 1480. This configuration is more beneficial than the configurations of the terminals shown in FIGS. 9-15, 18, 21-31, 32, 41-42, 45-46, 48, and 50 of PCT / US2018 / 019787 because the following can be achieved: (i) the overall length can be shortened, so less metal material is required for formation and the male terminal 1470 can be installed in a narrowly restricted space, (ii) the current-carrying capacity is large, (iii) assembly is easy, (iv) the contact arms 1494a-1494h are arranged inside the first male terminal side wall portions 1492a-1492d, so the structural rigidity is improved, (iv) the advantages disclosed in relation to PCT / US2019 / 036010, and (v) other beneficial features disclosed herein or that can be inferred by those skilled in the art from this disclosure.

[0191] The contact arm openings 1496a - 1496l are formed integrally with the central sectors 1500a - 1500d of the male terminal side walls 1482a - 1482d. The contact arm openings 1496a - 1496l extend along the lateral length of the contact arms 1494a - 1494h to form a configuration that enables the contact arms 1494a - 1494h not to be connected laterally to the following: (i) another contact arm 1494a - 1494h, or (ii) a structure outside the range of the male terminal side wall portions 1492a - 1492d to which the contact arms 1494a - 1494h are coupled. Further, the contact arm openings 1496a - 1496l are aligned with the spring arm openings. This configuration of the openings forms the same number of spring arms 1452a - 1452h as the number of contact arms 1494a - 1494h. In other words, FIG. 28 shows eight spring arms 1452a - 1452h and eight contact arms 1494a - 1494h. It should be understood that in other embodiments, the number of spring arms 1452a - 1452h may not match the number of contact arms 1494a - 1494h. For example, the number of spring arms 1452a - 1452h may be less than one.

[0192] The contact arms 1494a - 1494h extend away from the rear male terminal wall 1484 at an outward angle. In particular, the outward angle can be between 0.1 degrees and 16 degrees, preferably between 5 degrees and 12 degrees, and most preferably between 7 degrees and 8 degrees, between the outer surface of the range of the male terminal side walls 1492a - 1492d and the outer surface of the first range of the contact arms 1494a - 1494h. This outward angle is shown in a plurality of figures and can be most preferably visualized in relation to FIGS. 28 - 29. With this configuration, when the male terminal assembly 1430 is inserted into the female terminal assembly 2430, the contact arms 1494a - 1494h can be deflected or displaced inwardly and towards the center 1490 of the male terminal 1470 by the female receptacle 2472. In particular, the male terminal body 1472 has an outer perimeter that extends around the outermost range of the contact arms 1494a - 1494h. Non - connected state S DThat is, when the male terminal body 1472 is not inserted into the female terminal assembly 2430, the outer periphery of the male terminal body has a dimension that is not compressed. The fully connected state S FC That is, in the state where the male terminal body 1472 is inserted into the female terminal assembly 2430 (see Fig. 73), the outer periphery of the male terminal body has a compressed dimension. And the compressed dimension is smaller than the dimension that is not compressed. In this disclosed embodiment, the non-compressed dimension is 1% to 15% larger than the compressed dimension due to the configuration and design of the male terminal body 1472 and the female terminal body 2430. This inward deflection is best shown in Fig. 74 and is evidenced by the gap 1550. This inward deflection helps to ensure that proper mechanical and electrical connections are formed by arranging the contact arms 1494a to 1494h to reliably contact the female receptacle 2472.

[0193] As shown in FIGS. 27 to 29, when the spring member 1440c is inserted into the spring receiver 1486, the terminal ends of the contact arms 1494a to 1494h are arranged to (i) be within the openings formed by the U-shaped side wall portions 1492a to 1492d, (ii) substantially parallel to the male terminal side wall portions 1492a to 1492d, and (iii) contact the outer flat surfaces of the spring arms 1452a to 1452h. This configuration is beneficial compared to the configuration shown in FIGS. 3 to 8 of PCT / US2018 / 019787 because the assembler of the male terminal assembly 1430 does not need to apply a large force to deform most of the contact arms 1494a to 1494h outward to receive the spring member 1440c. This necessary deformation can be best shown in FIG. 6 of PCT / US2018 / 019787, which is due to the inclination of the contact arm 11 and the outer peripheral surface of the spring arm 31 and the inner peripheral surface of the contact arm 11 being adjacent to each other without forming a gap therebetween. In contrast to FIGS. 3 to 8 of PCT / US2018 / 019787, FIG. 30 of the present application shows that the gap formed between the outer peripheral surface of the spring member 1440c and the inner peripheral surface of the contact arms 1494a to 1494h is very small. Therefore, the force required to insert the spring member 1440c into the spring receiver 1486 is very small because the fact that the assembler does not need to force the contact arms 1494a to 1494h to be greatly deformed during the insertion of the spring member 1440c.

[0194] The male terminal 1470 is typically formed from a single piece of material (e.g., metal), and thus, the male terminal 1470 is a single-piece male terminal 1470 and has features formed integrally. To integrally form these features, the male terminal 1470 is typically formed using a stamping process. However, it should be understood that other types of forming the male terminal 1470 may be utilized, such as using a casting or additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the male terminal 1470 may not be formed from a single piece or integrally formed, and instead, may be formed from separate parts that are welded together. It should be understood that any number (e.g., 1 to 100) of contact arms 1494a - 1494h may be formed within the male terminal 1470 when forming the male terminal 1470.

[0195] The positioning of the internal spring member 1440c within the male terminal assembly 1430 is performed over a plurality of steps or stages. FIG. 27 provides a first embodiment of the male terminal assembly 1430 in a disassembled state S DA and FIG. 28 provides a first embodiment of the male terminal assembly 1430 in a partially assembled state S PA and FIG. 29 provides a first embodiment of the male terminal assembly 1430 in a fully assembled state S FA The first step in assembling the male terminal assembly 1430 is where the front male terminal wall 1480 is in the open or flat position P O and the spring member 1440c is separated from the male terminal 1470. In this open position P O the front male terminal wall 1480 is substantially in the same plane as one of the male terminal side walls 1482c. This configuration of the male terminal 1470 exposes the spring receiver 1486 and readies the male terminal 1470 to receive the spring member 1440c. The second step in assembling the male terminal assembly 1430 is shown in FIG. 28, where the front male terminal wall 1480 is in the open or horizontal position P Oremains as it is, and the spring member 1440c is positioned within the spring receiver 1486 or inserted into the spring receiver 1486. The partially assembled state S PA To reach PA , an insertion force F I is applied to the spring member 1440c. The insertion force F I is applied to the spring member 1440c until the second or rear male terminal wall 1484 is disposed adjacent to the rear spring wall 1444, the free end 1488 of the male terminal 1470 substantially aligns with the free end 1446 of the spring member 1440c, and a portion of the male terminal side walls 1482a - 1482d is disposed adjacent to a portion of the spring member side walls 1442a - 1442d.

[0196] The third stage of assembling the male terminal assembly 1430 is shown in FIG. 29, where the following is done: (i) the front male terminal wall 1480 is closed or made vertical P CL , (ii) the spring member 1440c is disposed within the spring receiver 1486. To close the front male terminal wall 1480, an upward force F U is applied to the male terminal wall 1480, bending the male terminal wall 1480 about its seam to be adjacent to the side walls 1482a - 1482d. After the front male terminal wall 1480 is in the appropriate position, the upper end is coupled (e.g., welded) to the side wall 1480 of the male terminal body 1472. Here, the closed or vertical state P CL of the front male terminal wall 1480 ensures that the spring member 1440c is held within the male terminal 1470. In other embodiments, the front male terminal wall 1480 may be omitted, may not have a touch - proof post opening therethrough, may not extend entirely from the side walls 1482a - 1482d (e.g., may extend partially from any of the side walls 1482a - 1482d), and may be a separate portion coupled to both of the side walls 1482a - 1482d.

[0197] After the male terminal assembly 1430 is assembled, manufacturing performs the next step of coupling the male terminal assembly 1430 to the end sector 207 of the bus bar 200. The coupling of these terminal assemblies 1430 can be achieved by any known means including laser welding (e.g., a surface-based longitudinal partial penetration welding process). Once the terminal assembly 1430 is coupled to the bus bar 200, an elastically deformable conductive assembly 350 is assembled, as shown in FIGS. 31-35. From here, the male housing assembly 1100 can be attached around the elastically deformable conductive assembly 350. The installation of the male housing assembly 1100 forms the system 100 shown in FIGS. 36-40. Although a number of steps are disclosed herein in a particular order, it should be understood that the order of these steps is not critical to the formation of the system 100. In other words, the disclosed steps can be performed in any order, and some of the steps can be omitted or combined. C. Female Connector Assembly

[0198] Referring to FIGS. 55, 60, 63, 65, and 66, each battery module 60 includes two female connector assemblies 2000, one of the female connector assemblies 2000 being a negative female connector assembly 2000a and the other female connector assembly 2000 being a positive female connector assembly 2000b. The female connector assembly 2000 includes (i) a female housing 2100 and (ii) a female terminal assembly 2430. The female housing 2100 is designed to (i) receive the female terminal assembly 2430, (ii) facilitate the coupling of the male terminal assembly 1430 and the female terminal assembly 2430, (iii) minimize the possibility of foreign objects accidentally contacting the female terminal assembly 2430, and (iv) meet industry performance and reliability standards such as USCAR specifications.

[0199] The female housing 2100 includes a wall arrangement 2110 having four side walls 2112a to 2112d. The side walls 2112a to 2112d extend upward from the upper surface of the support structure and have a configuration that substantially adapts to the configuration of the female terminal assembly 2430. In the illustrated embodiment, the female terminal assembly 2430 has a cubic configuration, and thus the side walls 2112a to 2112d have a linear configuration, forming a cubic receiver. However, it should be understood that changes in the shape of the female terminal assembly 2430 (for example, the use of cylindrical terminals) may require changing the shape and configuration of the side walls 2112a to 2112d to reflect the shape of the terminals (for example, a hollow cylinder).

[0200] The side walls 2112a to 2112d have a height greater than the height of the female terminal assembly 2430. The delta between these heights allows the side walls 2112a to 2112d to include at least one male compression means 2140. As shown in the figure, the male compression means 2140 is a sloped or ramped surface 2144 that extends from the outermost edges 2120a to 2120d of the side walls 2112a to 2112d to the uppermost edges 2430a to 2430d of the female terminal assembly 2430. In the disclosed embodiment, the sloped or ramped surface 2144 extends from each of the outermost edges 2120a to 2120d and has a substantially linear configuration. However, it should be understood that the sloped or ramped surface 2144 may extend from only one or two of the outermost edges 2120a to 2120d. The male compression means 2140 and the sloped or ramped surface 2144 shown in the figure allow the male terminal assembly 1430 to move from a state D where it is separated from the female terminal assembly 2430 in the cut state S FCAs it moves to a position disposed within the range of the female terminal assembly 2430, the contact arms 1494a - 1494h are designed to be compressed (see FIG. 73). Thus, the distance between the opposing outermost edges 2120a - 2120d is equal to the side wall distance, and the side wall distance is greater than the trailing edge distance extending between the opposing trailing edges 2124a - 2124d of the gradient surface or inclined surface 2144. And the trailing edge distance is greater than or equal to the receiver distance extending between the opposing inner surfaces 2434a - 2434d of the receiver 2472 of the female terminal assembly 2430. In particular, the side wall distance is 0.1% to 15% greater than the receiver distance, and the receiver distance is equal to the trailing edge distance or 0.1% to 3% greater than the trailing edge distance. In other words, the gradient surface or inclined surface 2144 is angled with respect to the outer surfaces of the side walls 2112a - 2112d and / or the inner surfaces 2434a - 2434d of the receiver 2472 of the female terminal assembly 2430. In particular, the interior angle extending between the inner surface of the gradient surface or inclined surface 2144 and the outer surfaces of the side walls 2112a - 2112d is between 0.1 degrees and 10 degrees.

[0201] This gradient surface or inclined surface 2144 is made of a polymer or plastic material and thus has a coefficient of friction lower than that associated with a metal surface. In other words, when the range of the boltless male terminal assembly 1430 (e.g., the contact arms 1494a - 1494h) engages with the male terminal compression means 2140 formed from a non - metallic material (e.g., plastic), a first friction value is formed. In an alternative embodiment, a second friction value is formed when the range of the boltless male terminal assembly 1430 (e.g., the contact arms 1494a - 1494h) engages with male terminal compression means formed from a metallic material (e.g., copper). It should be understood that when comparing the friction values from the disclosed embodiment with those of the friction value alternative embodiment, the first or friction value from the disclosed embodiment is smaller than the second or friction value of the alternative embodiment.

[0202] The lower the coefficient of friction, the smaller the force required to insert the male terminal assembly 1430 into the female terminal assembly 2430. This is beneficial for the following reasons: (i) Industry specifications, including USCAR25, have a requirement that the insertion force should not exceed 45 Newtons for class 2 connectors and 75 Newtons for class 3 connectors, and (ii) it is desirable to use a greater spring bias force to ensure that the contact arms of the male terminal assembly remain in contact with the inner surfaces 2434a - 2434d of the receptacle 2472 of the female terminal assembly 2430, thereby increasing the insertion force. Further, this low coefficient of friction is beneficial in that the system 100 can move from the disconnected state S D to the fully connected state S FC without requiring a lever assist while still meeting the class 2 / class 3 USCAR specifications. Eliminating the lever assist reduces the size, weight, and manufacturing cost of the connector system 100. It should be understood that in order to further reduce the coefficient of friction, the gradient surface or inclined surface 2144 may be coated with a material that reduces this coefficient, or the gradient surface or inclined surface 2144 may be made of a material with an even lower coefficient of friction.

[0203] Due to the configuration of the male and female connector assemblies 1000, 2000, the connector system 100 can move from the disconnected state S D to the fully connected state S FCAt various stages of moving, different levels of force are required. For example, when a range of the male terminal assembly 1430 (e.g., the contact arms 1494a - 1494h of the male terminal assembly 1430) is in sliding engagement with the male terminal compressing means 2140, a first force is required to move the male terminal assembly 1430, and when a range of the male terminal assembly 1430 (e.g., the contact arms 1494a - 1494h) is positioned in the female terminal receptacle 2473, a second force is required to move the male terminal assembly 1430. It should be understood that when comparing the forces, the second force is smaller than the first force. This is beneficial as it provides the user with tactical feedback indicating that the male terminal assembly 1430 is properly seated within the female terminal assembly 2430. In fact, this tactical feedback is felt by the user as if the boltless male terminal assembly 1430 is being drawn into the female terminal assembly 2430.

[0204] To minimize the chance of foreign objects accidentally contacting the female terminal assembly 2430, the housing 2100 can include an optional touch-proof post 2200. As disclosed in PCT / US2019 / 036070, the touch-proof post 2200 is configured to fit within a touch-proof post opening 1510 formed within the front wall of the male terminal 1470. In particular, the distance between the outermost edges 2120a - 2120d of the side walls 2112a - 2112d and the outermost edge 2215 of the touch-proof post 2200 is less than 10 mm, preferably less than 6 mm. The shape of the touch-proof post opening 1510 is configured to substantially reflect the shape of the touch-proof post 2200. Here, the touch-proof probe opening 1510 has a substantially rectangular shape, more specifically a substantially square shape, while the touch-proof post 2200 has the shape of an elongated rectangular prism with two recesses formed on opposing sides of the prism. The mirroring of these shapes helps ensure proper insertion of the touch-proof post 2200 into the touch-proof probe opening 1510 and can reduce vibration between the male terminal assembly 1430 and the female terminal assembly 2430. The reduction of vibration between these components can help reduce the likelihood of connector system failure. The touch-proof post 2200 and its associated opening 1510 may be omitted or may have another configuration (e.g., a configuration as disclosed in U.S. Provisional Application No. 63 / 222,859, which is incorporated herein by reference).

[0205] To minimize changes in which the male connector assembly 1000 can be separated from the female connector assembly 2000, the female connector assembly 2000 may include an optional non-deformed female CPA structure 2300 that is designed and configured to interact with the male CPA structure 1170 when the connector assemblies 1000, 2000 are coupled to each other. The non-deformed female CPA structure 2300 is integrally formed with the side walls 2112a-2112d of the housing 2100. Additional details regarding the structure and / or function of the female CPA structure 2300 are disclosed in PCTUS2019 / 036070, PCTUS2020 / 049870, PCTUS2021 / 033446, all of which are incorporated herein by reference.

[0206] The female terminal assembly 2430 of the female connector assembly 2000 is composed of a female terminal body 2432 in which a plurality of side walls 2434a to 2434d are integrally formed with a rear wall 2434e. Each of the side walls 2434a to 2434d and the rear wall 2434e has an inner surface 2436a to 2436e, and a cubic terminal receptacle 2472 is formed by their combination. The cubic terminal receptacle 2472 has a receiver distance extending between the inner surfaces 2436a to 2436d of the opposing side walls 2434a to 2434d. As described above, the receiver distance is (i) smaller than the side wall distance, and (ii) equal to or larger than the trailing edge distance. Further, the receiver distance is 0.1% to 15% smaller than the male terminal assembly distance extending between the outermost ranges of the opposing contact arms 1494a to 1494h. By forming the terminal receptacle 2472 having a receiver distance smaller than the male terminal assembly distance, the contact arms 1494a to 1494h are surely compressed when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. This compression of the male terminal assembly 1430 compresses the internal spring member 1440c. Thus, the spring member 1440c exerts an outward biasing force on the contact arms 1494a to 1494h, helps to maintain the state where the contact arms 1494a to 1494h are surely in contact with the inner surfaces 2436a to 2436d of the terminal receptacle 2472, and facilitates the electrical and mechanical coupling between the male terminal assembly 1430 and the female terminal assembly 2430.

[0207] The female terminal assembly 2430 is typically formed from a metal, preferably a highly conductive metal such as copper. The female terminal assembly 2430 may be plated or clad with Ni-Ag to prevent corrosion of the bus bar 200 during and / or after the female terminal assembly 2430 is welded to the bus bar 200. As shown, the side walls 2434a - 2434d are not integrally formed with each other, but instead are integrally formed only with the rear wall 2434e. In other embodiments, the female terminal assembly 2430 may have integrally formed side walls 2434a - 2434d, the side walls 2434a - 2434d may be made of different materials, and / or the female terminal assembly 2430 may not be plated or clad with Ni-Ag. Once the female terminal assembly 2430 is manufactured, it can be coupled to a bus bar and installed within the female housing 2100. D. Characteristics and Functions of Terminals

[0208] FIG. 73 is a cross-sectional view of the male connector assembly 1000 coupled to the female connector assembly 2000 in the fully connected state S FC The content disclosed below is discussed in relation to one embodiment of the system 100, but it should be understood that the present disclosure is equally applicable to other systems including other embodiments shown in FIGS. 100 - 104. As best shown in FIG. 73, one or more outer surfaces of the spring arms 1452a - 1452d contact the free ends 1488 of the respective contact arms 1494a - 1494d. As described above, the outermost extent of the contact arms 1494a - 1494d is slightly larger than the inner extent of the female terminal body 2432. Thus, when these components are mated with each other, the spring member 1440c is compressed. This compression of the spring member 1440c generates an outward biasing force S BF acting away from the interior of the spring member 1440c on the contact arms 1494a - 1494d.

[0209] The male terminal body 1472 including the contact arms 1494a to 1494d can be formed from a first material such as copper, a highly conductive copper alloy (e.g., C151 or C110), aluminum, and / or other suitable conductive materials. The first material preferably has an electrical conductivity of 80% or more of IACS (International Annealed Copper Standard, i.e., a standard value empirically derived for the electrical conductivity of commercially available copper). For example, C151 typically has a conductivity of 95% of standard pure copper compliant with IACS. Similarly, the conductivity of C110 is 101% of IACS. In certain operating environments or technical applications, it may be desirable to select C151 because C151 has desirable corrosion resistance properties for high-stress and / or harsh weather applications. The first material of the male terminal body 1472 is C151, and according to ASTM B747 standard, it has been reported to have an elastic modulus (Young's modulus) of about 115 - 125 gigapascals (GPa) at room temperature, and a coefficient of thermal expansion (CTE) of the terminal of 17.6 ppm / °C (20 - 300 °C) and 17.0 ppm / °C (20 - 200 °C).

[0210] The spring member 1440c may be formed from a second material such as spring steel, stainless steel (e.g., 301SS, 1 / 4 hard), and / or other suitable materials having a rigidity (e.g., measured by Young's modulus) and elasticity greater than that of the first material of the male terminal body 1472. The second material preferably has an electrical conductivity smaller than that of the first material. The second material also has a Young's modulus that can reach about 193 GPa at room temperature, and a coefficient of thermal expansion (CTE) of the terminal of 17.8 ppm / °C (0 - 315 °C) and 16.9 ppm / °C (0 - 100 °C). In an assumed high-voltage application, the cross-sectional area of the copper alloy forming the first connector is balanced with the conductivity of the selected copper alloy. For example, if a copper alloy with a lower conductivity is selected, the contact arms 1494a to 1494d formed therefrom have a larger cross-sectional area to conduct electricity sufficiently. Similarly, if a first material with a higher conductivity is selected, contact arms 1494a to 1494d with a relatively small cross-sectional area can be obtained while meeting the conductivity specifications.

[0211] In an exemplary embodiment, the CTE of the second material may be greater than the CTE of the first material, i.e., the CTE of the spring member 1440c is greater than the CTE of the male terminal body 1472. Thus, when the assembly of the male terminal body 1472 and the spring member 1440c is exposed to the high voltage and high temperature environments typical of the use of the electrical connectors described in the present disclosure, the spring member 1440c expands relatively more than the male terminal body 1472. Accordingly, the outward force S BF exerted by the spring member 1440c on the contact arms 1494a - 1494d of the male terminal body 1472 TF increases in response to an increase in temperature and will hereinafter be referred to as the thermal spring force S

[0212] Application examples of the present disclosure, such as use in a vehicle alternator, are suitable for deployment in a Class 5 automotive environment such as found in passenger and commercial vehicles. The Class 5 environment is often under the hood of a vehicle, for example in an alternator, and the ambient temperature reaches 150 °C and routinely 200 °C. When copper or highly conductive copper alloys are exposed to temperatures above about 150 °C, the alloy becomes malleable and loses its mechanical elasticity, i.e., the copper material softens. However, the steel forming the spring member 1440c retains its hardness and mechanical properties when exposed to similar conditions. Thus, when both the male terminal body 1472 and the spring member 1440c are exposed to high temperatures, the first material of the male terminal body 1472 softens while the structural integrity of the spring member 1440c formed from the second material is retained, so that the force applied by the spring member 1440c to the softened contact arms 1494a - 1494d FC more effectively displaces the softened contact arms 1494a - 1494d outward relative to the inside of the male terminal body 1472 at the fully connected position S

[0213] The male terminal body 1472, the spring member 1440c, and the female terminal body 2432 are configured to maintain electrical conductivity and mechanical engagement while withstanding the high temperatures and thermal cycles resulting from high-power, high-voltage applications to which the system 100 is exposed. Further, the male terminal body 1472 and the female terminal body 2432 may be subject to thermal expansion as a result of the high temperatures and thermal cycles associated with high-voltage, high-temperature applications, which may increase the outward force applied to the female terminal body 2432 by the male terminal body 1472. The configuration of the male terminal body 1472, the spring member 1440c, and the female terminal body 2432 allows the connector system 100 to withstand thermal expansion resulting from thermal cycling at the connection position P C while increasing the outward connection force therebetween.

[0214] Based on the above exemplary embodiments, the Young's modulus and CTE of the spring member 1440c are greater than those of the male terminal body 1472. Thus, when the male terminal body 1472 is used in a high-power application 10 that subjects the connector system 100 to repeated thermal cycles at a high temperature (e.g., about 150° C.), (i) the male terminal body 1472 becomes malleable and loses some of its mechanical elasticity, i.e., the copper material of the male terminal body 1472 softens, and (ii) the spring member 1440c does not become malleable and does not lose as much of its mechanical rigidity as compared to the male terminal body 1472.

[0215] Accordingly, using a spring member 1440c that is mechanically cold-biased (e.g., using a die-forming process), when the spring member 1440c is exposed to high temperatures, the spring member 1440c attempts to return at least to its uncompressed state that existed prior to insertion of the male terminal assembly 1430 into the female terminal assembly 2430, and preferably to its original flat state that existed prior to the formation of the spring member 1440c. In so doing, the spring member 1440c applies a generally outward thermal spring force S TF (as depicted by the arrow labeled "S" in FIG. 73) TF to the free ends 1488 of the contact arms 1494a - 1494d. This thermal spring force S TFdepends on local temperature conditions including high and / or low temperatures in the environment where the system 100 is installed. Accordingly, the spring biasing force S BF and the thermal spring force S TF in combination provide a resulting biasing force S RBF such that when the male terminal assembly 2430 is inserted into the female terminal 2430 and during operation of the system 100, the outer surfaces of the contact arms 1494a - 1494d are forced into contact with the inner surface of the female terminal body 2432 to ensure electrical and mechanical connection. Further, as the thermal cycle events are repeated, in the male terminal assembly 1430, the resulting outward spring force S RBF applied to the female terminal assembly 2430 during repeated operation of the system 100 increases.

[0216] As further shown in FIG. 73, in the fully connected state S FC the male terminal assembly 1430 provides 360° compliance with respect to the female terminal assembly 2430, and a sufficient amount of outward force F Bis guaranteed to be added primarily for electrical and mechanical connections in all four directions. This feature allows for the omission of other features designed to ensure the desired orientation of components during keying and / or connection. The 360° compliance feature of system 100 also helps to maintain mechanical and electrical connections under severe mechanical conditions such as vibration. In conventional blade-type or fork-type connectors with 180° compliance, i.e., connectors that are connected only on two opposing sides, harmonic resonance occurs due to vibration, and the 180° compliant connector may vibrate with a larger amplitude at a specific frequency. For example, when a harmonic resonance is applied to a fork-type connector, the fork-type connector may open. When the fork-type connector is instantaneously mechanically separated from the associated terminal, an electrical arc may occur, so it is not desirable for the fork-type connector to open during electrical conduction. Arc discharge can have a significant adverse effect not only on the 180° compliant terminal but also on the entire electrical system of which the 180° compliant terminal is a component. However, the 360° compliance function of the present disclosure can prevent critical failures that may be caused by strong vibration and electrical arc discharge.

[0217] As described above, it is desirable to form the male terminal 1470 from the same material as the female terminal body 2432 for the following purposes: (i) it helps prevent corrosion and other deterioration, (ii) it reduces the resistance between these structures, and (iii) it facilitates the electrical and mechanical coupling of the structures. Thus, the male and female terminal bodies 1472, 2432 are formed from copper in this exemplary embodiment. However, it should be understood that in order to utilize a material compatible with the terminal bodies 1470, 2432 and avoid the use of a bimetallic positive bus bar, the bimetallic positive bus bar may be replaced with an aluminum bus bar, and the male terminal 1470 may also be made of aluminum. In this embodiment, the male terminal 1470 associated with the negative external connection may be formed from copper, the external bus bar may be formed from copper, the positive bus bar may be formed from aluminum, and the male terminal 1470 associated with the positive external connection may be formed from aluminum. In a further embodiment, the battery cell 75 may have a different terminal configuration where the transport structure 82 utilizes only bus bars made of a single material and the male terminal body 1470 can be made of this same material. E. Bus Bar Housing

[0218] After the bus bar 200 is manufactured and the terminal 1000 is coupled to the bus bar 200, the bus bar housing 600 can be coupled thereto to surround the substantial scope of the bus bar 200 and complete the construction of the system 100. The bus bar housing 600 is disclosed in relation to at least FIGS. 41-47 and includes a first component 602a and a second component 602b that are removably coupled via a coupler 597 (formed from the protrusion 598 and the receiver 599). When the first and second components 402a, 402b are coupled together, a receptacle 604 designed to receive the bus bar 200 is formed. The receptacle 604 has five different ranges. The first range 606 is designed to receive a part of the connector assembly 1000, the second range 608 is designed to receive a part of the first peripheral connection portion 402a, the third range 610 is designed to receive the elastically deformable intermediate portion 410, the fourth range 612 is designed to receive a part of the second peripheral connection portion 402b, and the fifth range 614 is designed to receive a part of the connector assembly 1000. The first range 606 and the fifth range 614 of the receptacle 604 are in the compressed state S C and the expanded state S E and are designed to be laterally movable (e.g., slidable) therebetween. Thus, the first range 606 and the fifth range 614 of the receptacle 604 have a depth of approximately 11 mm.

[0219] The second range 608 and the fourth range 612 of the receptacle 604 conform to the configuration of the first and second peripheral connection portions 402a, 402b of the bus bar 200 and have a height of about 2 to 7 mm. Thus, the height and length of the third range 610 of the receiver 604 are greater than the height and length of the elastically deformable intermediate portion 410, and thus are designed to allow elastic deformation of the intermediate portion 410 without interfering with or impeding the movement of the bus bar 200. In other words, the third range 610 of the receptacle 604 has a volume large enough to allow the elastically deformable intermediate portion 410 to deform within the volume without restricting or affecting its deformation.

[0220] The housing 600 is preferably made of a non-conductive plastic and is designed to isolate and protect the elastically deformable conductive assembly 350 from other foreign objects. The configuration and material selection of the housing 600 are designed to isolate the bus bar 200 while allowing the bus bar 200 to elastically deform in all directions (e.g., X, Y, Z, and rotational directions). In other words, the housing 600 can flex or move as needed without damaging, breaking, or degrading the performance of the bus bar 200. The components 602a, 602b are dimensioned symmetrically and cooperatively with each other to reduce the number of parts and simplify the manufacture / assembly of the system 100. However, in other embodiments, the components 602a, 602b may not be identical to each other. It should be understood that other configurations of the housing 600 are contemplated by the present disclosure. For example, in certain applications such as installations with a controlled operating environment, the housing 600 can be omitted. II. First Embodiment of the Battery Pack

[0221] Figures 53 to 71 show a first embodiment of a battery pack 90 including a plurality of battery modules 60 and a plurality of elastically deformable battery module connector systems 100. In particular, the battery pack 90 includes ten battery modules 60 (62a to 62j) that are electrically coupled to each other using nine elastically deformable battery module connector systems 100 (the specific numbers of the elastically deformable battery module connector systems are shown as 102a to 102i). A. Battery Module

[0222] As shown in FIGS. 58 to 67, each of the ten battery modules 60 (62a to 62j) generally includes: (i) a battery module housing 64, (ii) a battery cell 75, and (iii) an electrical transmission assembly 82. i. Battery Module Housing

[0223] The battery module housing 64 includes a plurality of walls 66 (e.g., the arrangement of four side walls 68a to 68d, a bottom wall 70a, and a top wall 70b), which form a receiver 72 configured to receive and protect (i) the battery cell 75 and (ii) the electrical transmission assembly 82. The top wall 70b includes at least two battery module openings 73a, 73b formed therethrough, and the openings 73a, 73b are configured to allow female connector assemblies 2000a, 2000b to be coupled within the scope of the electrical transmission assembly 82. In particular, the current is configured to flow through the battery module openings 73a, 73b via the connection between the female connector assemblies 2000a, 2000b and the electrical transmission assembly 82. The female connector assemblies 2000a, 2000b are shown in connection with this first embodiment of the battery module 60, but it should be understood that the use of other connectors (e.g., bolted, clamped, press-fitted) is contemplated by the present disclosure. For example, a bolted connector is disclosed in connection with a second embodiment of the battery module 60. ii. Battery Cell

[0224] Figures 58 to 67 show that the battery module 60 includes a plurality of cylindrical battery cells 75, and each battery cell 75 includes the following: (i) a housing 77, (ii) a positive terminal 80a, and (iii) a negative terminal 80b. The housing 77 has a longitudinal surface 78 and is designed to surround and hold a material that stores charge, such as lithium or other similar metals. The positive and negative terminals 80a, 80b couple the material housed within the housing 77 to an electrical transmission assembly 82. The terminals 80a, 80b can have a button-shaped configuration, but other terminal shapes are also possible (e.g., boltless connectors, bolted connectors, tabs, or other structures that can be welded, press-fitted, or sandwiched by the electrical transmission assembly 82). The positive and negative terminals 80a, 80b are typically formed from different materials to facilitate charging and discharging of the battery cell 75. For example, the positive terminal or anode 80a may be formed from (i) graphite, (ii) silicon, or (iii) graphene, and the negative terminal or cathode 80b may be formed from (i) cobalt, (ii) iron, (iii) nickel-magnesium, (iv) nickel, or (v) sulfur. It should be understood that other materials may be used for the terminals. The battery cell 75 can have an output voltage between 0.2 volts and 10 volts, an ampere-hour rating between 10 Ah and 100 Ah, and an energy density between 20 Wh / kg and 500 Wh / kg (see Qiao, Y. et al., 500 Wh / kg Lithium Metal Cells Based on Anionic Redox, Joule, this issue, pp. 1445-1458, and Jason B. Quinn et al., Review Article: Energy Density of Cylindrical Lithium-Ion Batteries: Comparison of Commercially Available 18650 and 21700 Cells 2018 J. Electrochem. Soc. 165 A3284. Both are hereby incorporated by reference herein). Examples of the cylindrical battery cell 75 include the following: (i) 18650 (i.e., 18 mm in diameter and 65 mm in length), 21700 (i.e., 21 mm in diameter and 70 mm in length), 4680 (i.e., 46 mm in diameter and 80 mm in length).The battery cell 75 can use a number of different technologies and / or materials, including a battery that utilizes (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) lithium polymer, (v) lithium ion, or (vi) other materials (e.g., LiO. 2 , AlO 2 , LiS, LTO, LFP, NMC, NCA). It should be understood that a variety of known configurations can be used, including cylindrical, prismatic, pouch-shaped, or the shapes disclosed in U.S. Patent Nos. 10,948,000; 10,429,006; 10,220,881; 10,473,177; 10,538,271; 10,300,947; 9,789,906; 9,889,887; 9,944,323, each of which is incorporated herein by reference. iii. Electrical transmission assembly

[0225] Figures 58 to 67 show the electrical transmission assemblies 82 disposed within each of the battery modules 60. This electrical transmission assembly 82 (i) couples the first layer 83a of the battery cell 75 to the second layer 83b of the Betty cell 75, (ii) couples the battery cells 75 included in the first and second layers 83a, 83b to each other, and (iii) couples the female connector assemblies 2000a, 2000b to the battery cell 75. As shown in this embodiment, each of the first and second layers 83a, 83b includes approximately 132 battery cells 75 arranged in a direction perpendicular to the X-Y plane. This vertical orientation (i) arranges the positive and negative terminals 80a, 80b in a plane substantially parallel to the X-Y plane, and (ii) the longitudinal surface 78 of the cell 75 is substantially parallel to the X-Z plane or the Y-Z plane. Thus, the conductive plate 84 can be arranged in the X-Y plane and coupled to the positive and negative terminals 80a, 80b of the cell 75. In particular, the coupling of the plate 84 has a recess cut therein to assist in laser welding the button-shaped terminals 80a, 80b to the plate 84. This embodiment discloses the above configuration of the electrical transmission assembly 82 for the battery cell 75 and related components, but it should be understood that in other embodiments, the electrical transmission assembly 82 may have a different configuration. For example, the electrical transfer assembly 82 may be designed to couple any number (e.g., between 2 and 1000) of battery cells 75 to each other and any number (e.g., between 1 and 40 layers) of battery cell layers 83a, 83b to each other.

[0226] Furthermore, at least one female connector assembly 2000 is coupled to the plate 84. Preferably, the plate 84 of the electrical transmission assembly 82 is coupled to two female connector assemblies 2000a, 2000b, where (i) the positive female connector assembly 2000b is configured to provide a positive external connection to the battery module 60 and is designed to receive the positive male terminal assembly 1430 within its range, and (ii) the negative female connector assembly 2000a is configured to provide a negative external connection to the battery module 60 and is designed to receive the negative male terminal assembly 1430 within its range. The battery module 60 shown in the figure includes two female connector assemblies 2000a, 2000b, but it should be understood that the battery module 60 may have more or fewer female connector assemblies 2000. For example, the battery module 60 may have only a single female connector assembly 2000, or the battery module 60 may include ten or more female connector assemblies 2000. B. Battery Pack

[0227] Figures 53 and 54 show a first embodiment of a battery pack 90 having a rectangular prism configuration and including the following: (i) a bottom wall 91, (ii) a first or left end wall 92a, (iii) a second or right end wall 92b, (iv) a first or top side wall 94a, (v) a second or bottom side wall 94b, and (vi) a central partition 96 coupled to the first and second end walls 92a, 92b and disposed between the first and second side walls 94a, 94b. The combination of walls 92a, 92b, 94a, 94b, 96 is arranged to form a first or top receiver 97a and a second or bottom receiver 97b, and the top and bottom receivers 97a, 97b are designed to receive the extent of battery modules 60 included in the battery pack 90. At least one of the walls 92a, 92b, 94a, 94b includes a pack connector opening formed therethrough, and the opening is configured to receive the extent of a connector that facilitates charging and discharging of the battery pack 90. Examples of such connectors that may be utilized are disclosed in PCT / US2021 / 043,686, although the present disclosure contemplates utilizing any known connector capable of passing current in and out of the pack. The above disclosure focuses on openings designed to receive connectors that facilitate charging and discharging of the battery pack 90, but it should be understood that other openings may be formed within the pack 90 to allow for the passage of fluid into and out of the pack 90, or to make other mechanical or electrical connections within the pack 90.

[0228] The top receiver 97a of the battery pack 90 is configured to receive five battery modules 60 (62a to 62e), and the bottom receiver 97b of the battery pack 90 is also configured to receive five battery modules 60 (62f to 62j). In particular, the first battery module 62a is disposed in the top receiver 97a and is disposed between (i) the first end wall 92a, (ii) the first side wall 94a, and (iii) the central partition 96. In other words, the first battery module 62a is surrounded on three sides by the walls and partition 92a, 94a, 96. Similar to the first battery module 62a, the fifth battery module 62e is surrounded on three sides by the following: (i) the second end wall 92b, (ii) the first side wall 94a, (iii) the central partition 96. The sixth battery module 62f is also surrounded on three sides by (i) the second end wall 92b, (ii) the second side wall 94b, and (iii) the central partition 96, and the tenth battery module 62j is surrounded on three sides by (i) the first end wall 92a, (ii) the second side wall 94b, and (iii) the central partition 96. In contrast to the first, fifth, sixth, and tenth battery modules 62a, 62e, 62f, 62j, the second, third, and fourth battery modules 62b, 62c, 62d are disposed in the first receiver 97a and are bounded only by two sides, (i) the first side wall 94a and (ii) the central partition 96. Finally, similar to the second, third, and fourth battery modules 62b, 62c, 62d, the seventh, eighth, and ninth battery modules 62g, 62h, 62i are disposed in the second receiver 97b and are bounded only by two sides, (i) the second side wall 94b and (ii) the central partition 96.

[0229] Figures 53 and 54 show a battery pack 90 having a rectangular prism configuration and configured to hold ten battery modules 60, but it should be understood that the present disclosure is not limited to this design. Instead, the battery pack 90 can have any known configuration (e.g., any type of polygonal prism) including a configuration where the pack 90 is constructed as part of a vehicle's frame or chassis. Also, in other embodiments, it should be understood that the battery pack 90 may be configured to hold only a single battery module 60 or may be configured to hold more than a hundred individual battery modules 60. The battery cells 75 included within the module 60 can be connected in parallel, in series, or any combination thereof. Further, the battery modules 60 included within the battery pack 90 can be connected in parallel, in series, or any combination thereof. C. Connection of Battery Modules within the Battery Pack

[0230] Once the battery modules 60 (62a - 62j) are placed and fixed within the receivers 97a, 97b of the battery pack 90, the battery modules 60 (62a - 62j) can be coupled to each other using the disclosed elastically deformable battery module connector system 100. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 100 (where the specific numbers of the elastically deformable battery module connector systems are labeled as 102a - 102i). Each of the elastically deformable battery module connector systems 100 is coupled to the battery module 90 using a downward (i.e., -Z direction) force. The disclosed configuration arranges the bottom surfaces 215b of the peripheral portions 402a, 402b substantially parallel to each of the following: (i) the X - Y plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top and bottom walls 70a, 70b of the battery module housing 64, (iv) the upper surface of the conductive plate 84 of the transmission assembly 82, and (v) the range of the positive and negative terminals 80a, 80b of the battery cell 75. Further, the configuration arranges the bottom surfaces 215b of the peripheral portions 402a, 402b substantially perpendicular to each of the following: (i) the X - Z plane, (ii) the Y - Z plane, (iii) the side and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 68a - 68d of the battery module housing 64, (iv) the longitudinal surfaces 78 of the battery cell 75. Further, due to the said configuration location, the intermediate portion 410 extends downward from the peripheral portion plane in the -Z direction and is arranged between the fourth side wall 68d of the battery module 60 (e.g., 62a) and the side wall 68a of the adjacent battery module 60 (e.g., 62b). Further, the length L of the bus bar 200 IPB extends in a direction substantially parallel to the X - axis, and the width of the bus bar 200 extends in a direction substantially parallel to the Y - axis.

[0231] The elastic deformable battery module connector system 100 of this first embodiment is attached to the battery pack 90 using the connector assemblies 1000, 2000. With these connector assemblies 1000, 2000, the connection between the battery modules 60 is (i) boltless, (ii) PCT compliant, (iii) 360° compliant, (vi) fast and efficient compared to conventional battery pack connectors, (vii) simple without the need for special tools or machinery, (viii) compliant with USCAR and other industry specifications, (ix) lighter than conventional battery pack connectors, and (x) provides other advantages obvious to those skilled in the art. When the battery module 60 and all other necessary components (e.g., battery management assembly, battery cooling or heating assembly, etc.) are attached to the battery pack 90, the pack 90 can be attached to the application 10. D. Dynamic movement of the battery module

[0232] As shown in FIGS. 53 to 54, the battery pack 90 includes a plurality of modules 60, and each module 60 experiences a certain degree of dynamic movement during the use of the battery pack 90, including during the operation of the power distribution system in which the battery pack 90 is installed. Therefore, the forces applied to the connector system 100 included in the battery pack 90 greatly depend on and are affected by the behavior of the following: (i) other interconnected battery modules 90 including the configuration of the battery cells 75 contained therein, (ii) the configuration of the battery pack 90, and (iii) the operating conditions of the battery pack 90 including the vehicle in which the battery pack 90 is installed. For example, the first set of five battery modules 62a to 62e housed in the first receptacle 97a at least substantially equalizes or completely equalizes the forces generated and applied to these modules 62a to 62d by the expansion or contraction of the battery module connector systems 102a to 102d. Similarly, the second set of five battery modules 62f to 62i housed in the second receptacle 97b at least substantially equalizes or completely equalizes the forces generated and applied to these modules 62a to 62d by the expansion or contraction of the battery module connector systems 102f to 102i. However, the forces applied between the first and tenth battery modules 62a, 62j are likely to be affected and restricted by the configuration of the battery pack 90 including the layout of the modules 62a to 62j and the connector systems 102a to i, by the walls and partitions 92a, 92b, 96.

[0233] The battery pack 90 attempts to at least substantially equalize or fully equalize the forces applied to these modules 62a - 62d due to the expansion or contraction of the connector systems 102a - 102d, but it should be understood that the configuration of the pack 90 may limit the equalization of these forces. For example, the first connector system 102a may experience different forces compared to the second connector system 102b for the following reasons: (i) the connection to the end wall 92a of the first battery module 62, and (ii) the configuration of the walls and partitions 92a, 94a, 96 of the pack 90. Specifically and as shown in FIG. 54, the expansion or contraction of the first battery module 62a can be limited by the battery pack 90 as follows: (i) in the first direction or along the negative (-) X - axis by the end wall 92a, (ii) in the second direction or along the positive (+) Y - axis by the top wall 94a, and (iii) in the fourth direction or along the negative (-) Y - axis by the central partition 96. Thus, the battery pack 90 may allow the first battery module 62a to expand or contract only along the third direction or the positive (+) X - axis. In contrast, the expansion or contraction of the second battery module 62b can be limited as follows: (i) in the second direction or along the positive (+) Y - axis by the top wall 94a, and (ii) in the fourth direction or along the negative (-) Y - axis by the central partition 96. However, the expansion or contraction of the second battery module 62b may not be limited in either of the following: (i) in the first direction or along the negative (-) X - axis by the end wall 92a, or (ii) in the third direction or along the positive (+) X - axis.

[0234] The schematic diagram of the battery cell 75 in FIG. 64 shows how the movement of lithium ions from the cathode to the anode changes the size of the battery cell 75, that is, (i) charging causes a circumferential or radially outward expansion of the cylindrical battery cell 75 in the charging diameter D max and (ii) discharging causes a reduction in the discharging diameter D minCauses circumferential or radially inward shrinkage of the cylindrical battery cell 75. In fact, within a cylindrical battery cell 75 with a diameter of 18.15 mm, due to the movement of lithium ions from the cathode to the anode, it has been demonstrated that (i) the average diameter of the battery cell 75 increases by 2 μm (a 0.01% increase), and (ii) specific positions within the diameter of the battery cell 75 can increase by up to 37 μm (a 0.2% increase). Thus, the diameter of the battery cell 75 increases to D max when the battery is 100% charged or fully charged, and varies to D normal when the battery is 50% charged or half charged, and can decrease to D min when the battery is 0% charged or in an uncharged state or fully discharged, where D max >D normal >D min That is, when charging the battery cells 75 included in the battery module 60 from the 50% charge level to the 100% charge level, the diameter of the battery cells 75 within the module 60 increases from D normal to D max ; when discharging the battery cells 75 included in the battery module 60 from the 50% charge level to the 0% charge level, the diameter of the battery cells 75 within the module 60 decreases from D normal to D min . Further, Fig. 65 shows that during the life cycle of a cylindrical lithium ion cell, as the soundness state ("SoH") of the battery decreases due to the growth of the thickness of the solid electrolyte interphase layer, defects in graphite, and pressure increase due to side reactions, the diameter of the cell 75 increases irreversibly (from D normal to D 90 to D 80 ). It should be understood that Figs. 64 - 65 are not to scale and are for illustrative purposes only.

[0235] In light of the above disclosure, the main factor contributing to the dynamic movement of the battery module 60 within the pack 90 is the state of charge of the battery module 60. In the first embodiment shown in FIGS. 53-61, the cylindrical cells 75 are arranged in a vertical direction as compared to the X-Y plane, and the range of the longitudinal surface 78 of the cells 75 is substantially parallel to the X-Z plane or the Y-Z plane. Thus, D normal from D max to D normal from D min to D, the circumferential expansion and contraction of the battery cells 75 mainly cause the expansion and contraction of the battery module 60 in the X-Y plane. The movement of lithium ions is mainly in the lateral direction, i.e., radially outward or inward, and there is no appreciable vertical or axial movement component that can be evaluated. Thus, the axial expansion and contraction in the X-Z plane or the Y-Z plane, if any, is negligible. Since the expansion and contraction of the battery module 60 is mainly within the X-Y plane, the designer of the battery pack 90 arranges (i) the bottom surfaces 215b of the peripheral portions 402a, 402b to be substantially parallel to the X-Y plane, and (ii) the intermediate portion 410 of the bus bar 200 to extend downward in the negative (-) Z direction from the peripheral portion plane. Although details will be described later, with this disclosed configuration, the intermediate portion 410 of the bus bar 200 can continuously elastically deform to absorb the expansion and contraction of the battery module 60 in the X-Y plane. i. Neutral state of the system

[0236] It is clear from the above disclosure that the individual elastically deformable battery module connector systems 100 included in the battery pack 90 can experience different expansion and / or contraction forces. However, the general concepts disclosed in the following in relation to the first battery module connector system 102a, the first battery module 62a, and the second battery module 62b apply to all systems 100 included in the battery pack 90. FIGS. 55-63 and FIG. 69 show the neutral state S in which no tension or compression is applied to the system 100 NShown is an elastically deformable battery module connector system 100 in a neutral state S N In which: (i) the battery cell 75 is in a 100% battery healthy state (「SoH」), (ii) the battery cell 75 is charged to a 50% charge level, (iii) each rear wall of the male terminal housing 1100 is spaced from the inner wall of the bus bar housing 600 by a housing gap L HG (e.g., about 2 - 4 mm), (iv) the formed length L BN of the bus bar 200 is about 110 - 120 mm, preferably 115 - 117 mm, most preferably 116 mm (i.e., the length L IPN of the middle part is 23 mm - 31 mm, preferably 27 mm), (v) the height H BN of the bus bar 200 defined between the lowermost conductor 203a and the outer surface of the outermost conductor at the midpoint of the middle part 410 is 15 - 30 mm, preferably 20 - 25 mm (i.e., the height H IPN of the middle part is 5 mm or more, preferably 12 mm or more, more preferably 20 mm - 28 mm, most preferably 23 mm), and the width W BN of the bus bar 200 is 15 - 25 mm, preferably 20 mm, (vi) the length L SN of the system 100 is about 150 - 200 mm, preferably 160 - 190 mm, most preferably 182 mm, the height of the system 100 is 35 - 40 mm, preferably 37 mm, and the width of the system 100 is 25 - 35 mm, preferably 31 mm, (vii) the distance D N between the battery modules 62a, 62b is the neutral length (e.g., 100 - 120 mm, preferably 110 mm), (viii) the length of the neck L NN defined between the outer recesses 264a, 264b of the bus bar 200 in the neutral state is 25 - 30 mm, preferably 22 mm, (ix) the length of the gap L GN defined between the opposing inner surfaces of the outer recesses 264a, 264b is 25 - 30 mm, preferably 22 mm, (x) the height H BN of the bus bar 200 and the formed length L BNThe ratio between them is 20 - 25%, preferably 21.5%. (xi) The bottom surfaces 215b of the peripheral portions 402a, 402b are substantially parallel to the X - Y plane and substantially perpendicular to the X - Z plane and the Y - Z plane. (xii) The bottom surfaces 215b of the peripheral portions 402a, 402b are substantially parallel to both the top surface of the conductive plate 84 of the transmission assembly 82 and the ranges of the positive and negative terminals 80a, 80b. (xiii) The bottom surfaces 215b of the peripheral portions 402a, 402b are substantially perpendicular to the longitudinal surface 78 of the battery cell 75. (ivx) The intermediate portion 410 is disposed between the fourth side wall 68d of the battery module 62a and the first side wall 68a of the adjacent battery module 62b. ii. System in the Contracted State

[0237] Figures 66 and 68 show the elastically deformable battery module connector system 100 in the compressed state S max where the bus bar 200 is subjected to the maximum compression C C force. In this embodiment, the maximum compression C max force is between 38 - 46 N, preferably 42 N. This maximum compression C max force is applied to the system 100 in the third direction (the direction along the positive (+) X - axis) via the battery module 62a and in the first direction (the direction along the negative (-) X - axis) via the expansion of the battery modules 62a, 62b due to an increase in the charge level of the battery cell 75. In particular, when the battery cell 75 is charged from a 50% charged state to a 100% charged state, (i) the diameter of the cell 75 increases from D normal to D max , (ii) the sizes of the battery modules 62a, 62b increase, (iii) the distance D N between the battery modules 62a, 62b decreases from the neutral length (e.g., 110 mm) to the compressed length (e.g., 106 mm), and (iv) each of the rear walls of the male - type terminal housing 1100 slides towards the inner wall of the bus bar housing 600. From the neutral state S N to the compressed state S CIt should be understood that the transition thereto occurs continuously. When the battery module 60 is charged to 75%, the compression state of the connector system 100 is the neutral state S N and the compression state S C in between. In this state, the overall distance between the connectors 1000 may be 2 mm shorter compared to the distance between the connectors 1000 in the neutral state S N .

[0238] In the compression state S C :(i) The battery cell 75 is in a 100% battery healthy state ("SoH"), (ii) the battery cell 75 is charged to the 100% charge level, (iii) the rear wall of each male terminal housing 1100 is at a housing gap L HG (e.g., about 0 - 0.05 mm (0 - 0.05 mm) or adjacent to the inner wall of the bus bar housing 600) with respect to the inner wall of the bus bar housing 600, (iv) the length L BC of the bus bar 200 is about 106 - 116 mm, preferably 111 - 113 mm, most preferably 112 mm (i.e., the length L IPC of the middle part is 23 mm - 31 mm, preferably 27 mm), the height H BC of the bus bar 200 is 15 - 30 mm, preferably 20 - 25 mm (i.e., the height H IPC of the middle part is 20 mm - 28 mm, preferably 23 mm), the width W BC of the bus bar 200 is 15 - 25 mm, preferably 20 mm, (v) the length L SC of the system 100 is about 178 mm, the height H SC of the system 100 is 37 mm, the width W SC of the system 100 is 31 mm, (vi) the distance D C between the battery modules 62a, 62b is the compressed length (e.g., 106 mm), (vii) the length L NCis 21 to 26 mm, preferably 18 mm, and (viii) the length L of the gap defined between the opposing inner surfaces of the external recesses 264a, 264b of the bus bar 200 in the compressed state GC is 10 and 18 mm, preferably 14 mm, and (ix) the height H of the bus bar 200 BC and the length L of the bus bar 200 BC The ratio between them is 22.3%. (x) The bottom surfaces 215b of the peripheral portions 402a, 402b are substantially parallel to the X - Y plane and substantially perpendicular to the X - Z plane and the Y - Z plane. (xi) The bottom surfaces 215b of the peripheral portions 402a, 402b are substantially parallel to both the top surface of the conductive plate 84 of the transmission assembly 82 and the ranges of the positive terminal 80a and the negative terminal 80b. (xii) The bottom surfaces 215b of the peripheral portions 402a, 402b are substantially perpendicular to the longitudinal surface 78 of the battery cell 75. (xiii) The intermediate portion 410 is disposed between the fourth side wall 68d of the battery module 62a and the first side wall 68a of the adjacent battery module 62b. iii. Expanded state of the system

[0239] Figures 67 and 70 show the elastically deformable battery module connector system 100 in the expanded state S E in which the bus bar 200 is the maximum tensile force TE max force. In this embodiment, the maximum tensile force TE max force is 38 to 46 N, preferably 42 N. This maximum tensile force TE max force is applied to the system 100 in the first direction (along the negative (-) X - axis) through the battery module 62a and in the third direction (along the positive (+) X - axis) through the contraction of the battery modules 62a, 62b due to the decrease in the charge level of the battery cell 75. In particular, when the battery cell 75 is charged from 50% charge state to 0% charge state, (i) the diameter of the cell 75 decreases from D normal to D min and (ii) the sizes of the battery modules 62a, 62b decrease, and (iii) the distance D between the battery modules 62a, 62b Eincreases from a neutral length (e.g., 110 mm) to an extended length (e.g., 114 mm), and (iv) the respective rear walls of the male terminal housing 1100 slide further away from the inner wall of the bus bar housing 600. From the neutral state S N to the extended state S E It should be understood that the transition to occurs continuously. When the battery module 60 is charged to 25%, the tension of the connector system 100 is in the neutral state S N and the extended state S E In this state, the overall distance between the connectors 1000 is the neutral state S N The distance between the connectors 1000 in may increase by 2 mm compared to the distance between the connectors 1000 in the neutral state S

[0240] In the extended state S E : (i) the battery cell 75 is in a 100% battery healthy state ("SoH"), (ii) the battery cell 75 is charged to a 0% charge level, (iii) the respective rear walls of the male terminal housing 1100 are from the inner wall of the bus bar housing 600 by a housing gap L HG (e.g., about 4 - 6 mm), (iv) the length L of the bus bar 200 BE is about 114 - 124 mm, preferably 119 - 121 mm, most preferably 120 mm (i.e., the length L of the middle part IPE is 23 mm - 31 mm, preferably 27 mm), the height H of the bus bar 200 BE is 15 - 30 mm, preferably 20 - 25 mm (i.e., the height H of the middle part IPE is between 20 mm and 28 mm, preferably 23 mm), the width W of the bus bar 200 BE is 15 - 25 mm, preferably 20 mm, (v) the length L of the system 100 SE is about 186 mm, the height of the system 100 is 37 mm, the width of the system 100 is 31 mm, (vi) the distance D between the battery modules 62a, 62b N is the extended length (e.g., 114 mm), (vii) the neck L defined between the external recesses 264a, 264b of the bus bar 200 in the compressed state NEThe length is 29 to 34 mm, preferably 22 mm, and (viii) the length L of the gap defined between the opposing inner surfaces of the external recesses 264a and 3264b of the busbar 200 in the compressed state GE is 18 mm and 26 mm, preferably 24 mm, (the busbar 200 in the compressed state is 10 and 18 mm, preferably 14 mm) (viii) the height H of the busbar 200 in the compressed state B and the length L of the busbar 200 BE The ratio therewith is 20.8%. (ix) The bottom surfaces 215b of the peripheral portions 402a and 402b are substantially parallel to the X - Y plane and substantially perpendicular to the X - Z plane and the Y - Z plane. (x) The bottom surfaces 215b of the peripheral portions 402a and 402b are substantially parallel to both the top surface of the conductive plate 84 of the transmission assembly 82 and the ranges of the positive and negative terminals 80a and 80b. (xi) The bottom surfaces 215b of the peripheral portions 402a and 402b are substantially perpendicular to the longitudinal surface 78 of the battery cell 75. (xii) The intermediate portion 410 is disposed between the fourth side wall 68d of the battery module 62a and the first side wall 68a of the adjacent battery module 62b. iv. Summary

[0241] In summary, the above disclosure focuses on the battery cell 75 with a battery health (「SoH」) of 100%. As shown in FIG. 65, when this health state deteriorates, the diameter of the cell 75 increases, and the ability of the system 100 to reach the expanded state S E decreases. Instead, the system 100 mainly fluctuates between the neutral state S N and the compressed state S C Also, as shown in the following table, the height of the busbar 200 and the bending height H IPN and the bending length L IPN of the intermediate portion 410 remain substantially constant regardless of the state of the busbar. Remaining substantially constant in all states is beneficial to reduce potential problems due to unexpected expansion or contraction of the height of the busbar 200. Being substantially constant means that the busbar 200 is in the neutral state SN to the compressed state S C or to the neutral state S N to the expanded state S E when it changes, it should be understood that the height or length changes by less than 2.5%. Also, as shown in the table below, the length of the formed state of the bus bar 200 (i.e., L BC from L BN from L BE ) is not necessarily substantially constant even when the bus bar 200 varies between the compressed state and the expanded state. Instead, when the bus bar 200 varies from the compressed state to the expanded state, the length of the formed state changes by about 5%. It should be understood that the numerical values included in the above paragraphs and the table below are merely exemplary and are not limiting in any way. Thus, other embodiments of the bus bar 200 can have different values associated therewith.

Table 2

[0242] The above disclosure focused on the dynamic movement of module 60 related to the state of charge of battery module 60, but other factors can cause the dynamic movement of battery modules 60 within battery pack 90. For example, increasing the temperature of battery pack 90, power distribution system 50, and / or application 10 is likely to cause expansion of all components in all planes, thus compressing system 100. Additionally, a harsh and / or rough operating environment of application 10, such as in motor vehicle 20, is also likely to cause dynamic movement in all planes, thus compressing and / or expanding system 100. Specifically, FIG. 71 shows the movement between battery modules 62a, 62b in the second and fourth (along the positive / negative (+ / −) Y-axis) directions. Finally, other mechanical or chemical forces can also compress or expand system 100. System 100 is specially designed to account for expansion and contraction in the X-Y plane and can compensate for variations in the X-Z and Y-Z planes. Thus, system 100 significantly reduces and largely eliminates a significant number of failure modes due to variations from applications 10 that include battery pack 90, such as battery pack 90 and motor vehicles. III. Second Embodiment of the Battery Pack

[0243] Figures 74 to 83 show the battery module 3060 of the second embodiment and the elastic deformable battery module connector system 3100 of a plurality of second embodiments. The combination of the battery module 3060 and the system 3100 is configured to be disposed within the battery pack 90 disclosed above. For the sake of brevity, the above disclosure related to the battery pack 90 will not be repeated hereinafter, but it should be understood that throughout the embodiments, like reference numerals represent like structures. For example, the disclosure related to the bus bar housing 600 is equally applicable to the bus bar housing 3600. Any one or more features of the battery module 60 and the system 100 can be used in combination with those disclosed with respect to the battery module 3060 and the system 3100, and it should be understood that any one or more features of the battery module 3060 and the system 3100 can be used in combination with those disclosed with respect to the battery module 60 and the system 100. A. Battery Module

[0244] As shown in FIGS. 74 to 83, each of the battery modules 3060 (3062a to 3062b) generally includes (i) a battery module housing 3064, (ii) battery cells 3076, and (iii) an electrical transmission assembly 3083. i. Battery Module Housing

[0245] The battery module housing 3064 includes a plurality of walls 3066 (e.g., the arrangement of four side walls 3068a - 3068d, a bottom wall 3070a, and a top wall 3070b), which form a receiver 3072 configured to receive and protect (i) battery cells 3076 and (ii) an electrical transmission assembly 3083. The top wall 3070b includes at least two battery module openings 3073a, 3073b formed therethrough, and the openings 3073a, 3073b are configured to allow bolted connector assemblies 4002a, 4002b to be coupled within the scope of the electrical transmission assembly 3083. In particular, current is configured to flow through the battery module openings 3073a, 3073b via the connection between the bolted connector assemblies 4002a, 4002b and the electrical transmission assembly 3083. Although the bolted connector assemblies 4002a, 4002b are shown in relation to this second embodiment 3060, it should be understood that the use of other connectors (e.g., boltless, clamp - type, press - fit) is contemplated by the present disclosure. For example, a boltless connector is disclosed in relation to the first embodiment of the battery module 3060. ii. Battery cell

[0246] Figures 75 - 80 show that the battery module 3060 includes a plurality of prismatic battery cells 3076, and each battery cell 3076 includes: (i) a housing 3077, (ii) a positive terminal 3080a, and (iii) a negative terminal 3080b. The housing 3077 has vertical side surfaces 3078a, 3078b and horizontal top and bottom surfaces 3079a, 3079b and is designed to surround and hold a material for storing charge, such as lithium or other similar metals. That is, the battery cell has a thickness T C , a width W CELL , and a length L CELLIt has. The positive and negative terminals 3080a, 3080b couple materials contained within the housing 3077 to the electrical transmission assembly 3083. The terminals 3080a, 3080b can have a tab-like configuration, although other terminal shapes are possible (e.g., boltless connectors, bolted connectors, buttons, other structures that can be welded, press-fit, or sandwiched by the electrical transmission assembly 3083). The positive and negative terminals 3080a, 3080b are typically formed from different materials to facilitate charging and discharging of the battery cell 3076. For example, the positive terminal or anode 3080a may be formed from (i) graphite, (ii) silicon, or (iii) graphene, and the negative terminal or cathode 3080b may be formed from (i) cobalt, (ii) iron, (iii) nickel-magnesium, (iv) nickel, or (v) sulfur. It should be understood that other materials may be used for the terminals. The battery cell 3076 can have an output voltage between 0.2 volts and 10 volts, a rated ampere-hour between 10 Ah and 100 Ah, and an energy density between 20 Wh / kg and 500 Wh / kg. The battery cell 3076 can utilize many different technologies and / or materials, including batteries that use (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) lithium polymer, (v) lithium ion, or (vi) other materials (e.g., LiO 2 , AlO 2 , LiS, LTO, LFP, NMC, NCA). It is to be understood that many different technologies and / or materials can be used. iii. Electrical transmission assembly

[0247] Figures 74 to 80 show the electrical transmission assembly 3083 disposed within each battery module 3060, which electrically couples the battery cells 3076 to each other and couples the female connector assemblies 4002a, 4002b to the battery cells 3076. As shown in this embodiment, each battery module 3060 includes approximately 11 battery cells 3076 disposed in a direction perpendicular to the X-Y plane. This vertical orientation positions the positive and negative terminals 3080a, 3080b in a plane substantially parallel to the X-Y plane, aligns the vertical side surfaces 3078a, 3078b of the cells 3076 substantially parallel to the Y-Z plane, and aligns the thickness T of the cells 3076 parallel to the X axis. Thus, the conductive plate 3085 can be disposed in the X-Y plane and coupled to the positive and negative terminals 3080a, 3080b of the cells 3076. In this embodiment, the above-described configuration of the electrical transmission assembly 3083 for the battery cells 3076 and associated components is disclosed, but it should be understood that in other embodiments, the electrical transmission assembly 3083 may have a different configuration. For example, the electrical transmission assembly 3083m may be designed to couple any number of battery cells 3076 to each other (e.g., between 2 and 3998). C As such, the conductive plate 3085 is disposed within the X-Y plane and can be coupled to the positive and negative terminals 3080a, 3080b of the cells 3076. In this embodiment, the above-described configuration of the electrical transmission assembly 3083 for the battery cells 3076 and associated components is disclosed, but it should be understood that in other embodiments, the electrical transmission assembly 3083 may have a different configuration. For example, the electrical transmission assembly 3083m may be designed to couple any number of battery cells 3076 to each other (e.g., between 2 and 3998).

[0248] Furthermore, the plate 3085 is coupled to at least one bolted connector 4002. Preferably, the plate 3085 of the electrical transmission assembly 3083 is coupled to two bolted connectors 4002a, 4002b, where (i) the positive bolted connector 4002b is configured to provide a positive external connection for the battery module 3060 and is designed to be received by an opening formed within the scope of the system 3100, and (ii) the negative bolted connector 4002a is configured to provide a negative external connection for the battery module 3060 and is designed to be received by an opening formed within the scope of the system 3100. It should be understood that the battery module 3060 shown in the figure includes two bolted connectors 4002a, 4002b, but the battery module 3060 may have more or fewer bolted connectors 4002. For example, the battery module 3060 may have only a single bolted connector 4002, or the battery module 3060 may include ten or more bolted connectors 4002. B. Battery Pack

[0249] As described above, the second embodiment of the battery module 3090 is designed to fit within the rectangular prism configuration of the battery pack 90 shown in FIGS. 53-54. FIGS. 53 and 54 show a battery pack 90 having a configuration and configured to hold ten battery modules 3060, but it should be understood that the present disclosure is not limited to this design. Instead, the battery pack 90 may have any known configuration (e.g., any type of polygonal prism) including a configuration in which the pack 90 is constructed as part of a vehicle's frame or chassis. Also, in other embodiments, it should be understood that the battery pack 90 may be configured to hold only a single battery module 3060 or may be configured to hold over a hundred individual battery modules 3060. The battery cells 3076 included within the module 3060 may be connected in parallel, in series, or any combination thereof. Further, the battery modules 3060 included within the battery pack 90 may be connected in parallel, in series, or any combination thereof. C. Connection of Battery Modules within the Battery Pack

[0250] Once the battery modules 3060 (3062a - 3062j) are positioned and fixed to the receivers 97a, 97b of the battery pack 3060, the battery modules 3060 (3062a - 3062j) can be coupled to each other using the disclosed elastically deformable battery module connector system 3100. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 3100 (3102a - 3102i). Each of the elastically deformable battery module connector systems 3100 positions the threaded rod of the bolted connector 4002 in the openings 3002 formed in the end sectors 3208a, 3208b of the busbar 3200 to be coupled to the battery module 90, and then uses a screw fastener to fix the end sectors 3208a, 3208b to the bolted connector 4002. The disclosed configuration arranges the bottom surfaces 3215b of the peripheral portions 3402a, 3402b to be substantially parallel to each of the following: (i) the X - Y plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top wall 3070a and the bottom wall 3070b of the battery module housing 3064, (iv) the upper surface of the conductive plate 3085 of the transmission assembly 3083, and (v) the range of the positive and negative terminals 3080a, 3080b of the battery cell 3076. Further, the said configuration arranges the bottom surfaces 3215b of the peripheral portions 3402a, 3402b to be substantially perpendicular to each of the following: (i) the X - Z plane, (ii) the Y - Z plane, (iii) the side walls and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 3068a - 3068d of the battery module housing 3064, (iv) the range of the vertical side surfaces 3078a, 3078b of the battery cell 3076. Further, due to the said configuration location, the intermediate portion 3410 extends downward in the - Z direction from the peripheral portion plane and is disposed between the fourth side wall 3068d of a battery module 3060 (e.g., 3062a) and the side wall 3068a of an adjacent battery module 3060 (e.g., 3062b). Further, the length L of the busbar 3200 B extends in a direction substantially parallel to the X - axis, and the width of the busbar 3200 extends in a direction substantially parallel to the Y - axis.

[0251] The elastically deformable battery module connector system 3100 of this first embodiment is attached to the battery pack 90 using connector assemblies 3998, 4002. These connector assemblies 3998, 4002 enable the connection between battery modules 3060 to be fixed using a bolted configuration. When the battery modules 3060 and all other necessary components (e.g., battery management assembly, battery cooling or heating assembly, etc.) are attached to the battery pack 90, the pack 90 can be attached to the application 10. D. Dynamic Movement of Battery Modules

[0252] The schematic diagram of the battery cell 3076 in FIG. 77 shows how the movement of lithium ions from the positive electrode to the negative electrode changes the size of the battery cell 3076, i.e., (i) charging causes an increase in the thickness or a lateral outward expansion of the prismatic battery cell 3076, and (ii) discharging causes a decrease in the thickness or a lateral inward contraction of the prismatic battery cell 3076. Thus, the thickness of the cell 3076 increases to T max when the battery is 100% charged or fully charged, varies to T normal when the battery is 50% charged or half charged, and may decrease to T min when the battery is 0% charged or uncharged, where T max >T normal >T min That is, when charging the battery cell 3076 included in the battery module 3060 from the 50% charge level to the 100% charge level, the thickness of the cell 3076 in the module 3060 increases from T normal to T max and when discharging the battery cell 3076 included in the battery module 3060 from the 50% charge level to the 0% charge level, the thickness of the cell 3076 in the module 3060 decreases from T normal to T minIt decreases. Further, FIG. 78 shows that as the soundness state (“SoH”) of the battery decreases due to the thickness growth of the solid electrolyte interphase layer, the defects in graphite, and the pressure increase due to side reactions over the life of the prismatic lithium-ion battery, the thickness of cell 3076 increases irreversibly (i.e., from T normal to T 80 to T 90 ). It should be understood that FIGS. 77-78 are not to scale and are for illustrative purposes only.

[0253] In light of the above disclosure, the main factor contributing to the dynamic movement of the battery module 3060 within the pack 90 is the state of charge of the battery module 3060. In this second embodiment, the prismatic cell 3076 is arranged in the vertical direction as compared to the X-Y plane, where (i) the range of the vertical side surfaces 3078a, 3078b of the cell 3076 is substantially parallel to the Y-Z plane, (ii) the range of the horizontal top and bottom surfaces 3079a, 3079b of the cell 3076 is substantially parallel to the X-Y plane, and (iii) the thickness T C of the cell 3076 is parallel to the X-axis. Accordingly, the expansion and contraction of the thickness of the battery cell 3076 from T normal to T max or from T normal to T min mainly causes the expansion and contraction of the battery module 3060 along the X-axis. Since the movement of lithium ions is mainly directed laterally and there are no other appreciable components, the expansion and contraction along the Y-axis or Z-axis, if any, are negligible. Since the expansion and contraction of the battery module 3060 are mainly in the X-axis direction, the designer arranges (i) the bottom surface 3215b of the peripheral portions 3402a, 3402b to be substantially parallel to the X-axis, and (ii) the intermediate portion 3410 to extend downward in the minus (-) Z direction from the peripheral portion plane. Details will be described later, but with this disclosed configuration of the system 100, the intermediate portion 3410 can be elastically deformed to absorb the expansion and contraction of the battery module 3060 along the X-axis. i. System in neutral state

[0254] It is clear from the above disclosure that the individual elastically deformable battery module connector systems 3100 included in the battery pack 90 may experience different expansion and / or contraction forces. However, the general concepts disclosed below in connection with the first system 3102a, the first battery module 3062a, and the second battery module 3062b apply to all systems 3100 included in the battery pack 90. FIGS. 74-76B and 81 show the elastically deformable battery module connector system 3100 in a neutral state S where no tension or compression is applied to the system 3100. N In the neutral state S, N (i) the battery cell 3076 is in a 100% battery healthy state ("SoH"), (ii) the battery cell 3076 is charged to a 50% charge level, (iii) each rear wall of the male terminal housing 1100 is spaced from the inner wall of the bus bar housing 3600 by a housing gap L HG (e.g., about 2-4 mm), (iv) the formed length L of the bus bar 200 BN is about 110-120 mm, preferably 115-117 mm, most preferably 116 mm (i.e., the length L of the middle portion IPN is 23 mm - 31 mm, preferably 27 mm), the height H of the bus bar 200 BN is 15-30 mm, preferably 20-25 mm (i.e., the height H of the middle portion IPN is between 20 mm and 28 mm, preferably 23 mm), the width W of the bus bar 200 BN is 15-25 mm, preferably 20 mm, (v) the length L of the system 3100 SN is about 150-200 mm, preferably 160-190 mm, most preferably 182 mm, the height of the system 3100 is 35-40 mm, preferably 37 mm, and the width W of the system 3100 SN is 25-35 mm, preferably 31 mm, (vi) the distance D between the battery modules 3062a, 3062b Nis a neutral length (e.g., 100 - 120 mm, preferably 110 mm), and (vii) a neck L defined between the external recesses 3264a and 3264b of the bus bar 3200 in the neutral state NN has a length of 25 - 30 mm, preferably 22 mm, and (viii) a gap L defined between the opposing inner surfaces of the external recesses 3264a and 3264b in the neutral state GN has a length of 25 - 30 mm, preferably 22 mm, and (ix) the height H of the bus bar 3200 BN and the length L of the bus bar 3200 in the formed state BN The ratio between them is 20 - 25%, preferably 21.5%. (x) The bottom surfaces 3215b of the peripheral portions 3402a and 3402b are substantially parallel to the X - Y plane and substantially perpendicular to the X - Z plane and the Y - Z plane. (xi) The bottom surfaces 3215b of the peripheral portions 3402a and 3402b are substantially parallel to both the range of the upper surface of the conductive plate 3085 of the transmission assembly 3083 and the range of the positive and negative terminal ends 3080a and 3080b of the battery cell 3076. (xii) The bottom surfaces 3215b of the peripheral portions 3402a and 3402b are substantially perpendicular to the range of the vertical side surfaces 3078a and 3078b of the cell 3076. (xiii) The intermediate portion 3410 is disposed between the fourth side wall 3068d of the battery module 3062a and the first side wall 3068a of the adjacent battery module 3062b. (xiv) The length L of the bus bar 200 in the formed state BN and the length L of the system 3100 SN are substantially parallel to both the thickness T of the battery cell 3076 C and the X - axis. ii. The system in the contracted state

[0255] Figures 79 and 82 show the elastically deformable battery module connector system 3100 in a compressed state S max where the bus bar 3200 is subjected to the maximum compression C C force. In this embodiment, the maximum compression C max force is 38 - 46 N, preferably 42 N. This maximum compression C maxForce is applied to the system 3100 in a third direction (direction along the positive (+) X-axis) via the battery module 3062a and in a first direction (direction along the negative (-) X-axis) via the expansion of the battery modules 3062a, 3062b due to an increase in the charge level of the battery cell 3076. In particular, when the battery cell 3076 is charged from 50% state of charge to 100% state of charge, (i) the thickness of the cell 3076 increases from T normal to T max , (ii) the size of the battery modules 3062a, 3062b increases, (iii) the distance D N between the battery modules 3062a, 3062b decreases from a neutral length (e.g., 110 mm) to a compressed length (e.g., 106 mm), and (iv) each of the rear walls of the male terminal housing 1100 slides towards the inner wall of the bus bar housing 3600. It should be understood that the variation from the neutral state S N to the compressed state S C occurs continuously. When the battery module 3060 is 75% charged, the compressed state of the connector system 3100 is between the neutral state S N and the compressed state S C . In this state, the overall distance between the connectors 3998 can be 2 mm shorter compared to the distance between the connectors 3998 in the neutral state S N .

[0256] In the compressed state S C , (i) the battery cell 3076 is in a 100% battery healthy state ("SoH"), (ii) the battery cell 3076 is charged to a 100% charge level, (iii) each of the rear walls of the male terminal housing 1100 is at a position of a housing gap L HG (e.g., about 0 - 0.5 mm or adjacent), (iv) the length L BC of the bus bar 200 is about 106 - 116 mm, preferably 111 - 113 mm, most preferably 112 mm (i.e., the length L IPC of the middle part is 23 mm - 31 mm, preferably 27 mm), and the height H BCis 15 to 30 mm, preferably 20 to 25 mm (i.e., the height H of the middle portion IPC is 20 mm to 28 mm, preferably 23 mm), and the width W of the bus bar 200 BC is 15 to 25 mm, preferably 20 mm, (v) the length L of the system 3100 SC is about 178 mm, the height of the system 3100 is 37 mm, the width of the system 3100 is 31 mm, (vi) the distance D between the battery modules 3062a, 3062b N is the compressed length (e.g., 106 mm), (vii) the neck L defined between the outer recesses 3264a, 3264b of the bus bar 3200 in the compressed state NC has a length of 21 to 26 mm, preferably 18 mm, (viii) the gap L defined between the opposing inner surfaces of the outer recesses 3264a, 3264b in the compressed state GC has a length of 10 mm and 18 mm, preferably 14 mm, (ix) the height H of the bus bar 3200 BC and the length L of the bus bar 3200 BC The ratio between them is 22.3%, (x) the bottom surfaces 3215b of the peripheral portions 3402a, 3402b are substantially parallel to the X-Y plane and substantially perpendicular to the X-Z plane and the Y-Z plane, (xi) the bottom surfaces 3215b of the peripheral portions 3402a, 3402b are substantially parallel to both the range of the upper surface of the conductive plate 3085 of the transmission assembly 3083 and the range of the positive and negative terminals 3080a, 3080b of the battery cell 3076, (xii) the bottom surfaces 3215b of the peripheral portions 3402a, 3402b are substantially perpendicular to the range of the vertical side surfaces 3078a, 3078b of the battery cell 3076, (xiii) the middle portion 3410 is disposed between the fourth side wall 3068d of the battery module 3062a and the first side wall 3068a of the adjacent battery module 3062b, (ivx) the length L of the bus bar 200 BC and the length L of the system 3100 SC are substantially parallel to both the thickness T of the battery cell 3076 C and the X-axis. iii. Expanded state of the system

[0257] Figures 80 and 83 show the elastic deformable battery module connector system 3100 in the extended state S when the bus bar 3200 is at the maximum tension TE max force. E In this embodiment, the maximum tension TE max force is 38 - 46 N, preferably 42 N. This maximum tension TE max force is applied to the system 3100 in the first direction (along the negative (-) X-axis) via the battery module 3062a and in the third direction (along the positive (+) X-axis) via the contraction of the battery modules 3062a, 3062b due to the decrease in the charge level of the battery cell 3076. In particular, when the battery cell 3076 is charged from 50% charge state to 0% charge state, (i) the thickness of the cell 3076 decreases from T normal to T min , (ii) the sizes of the battery modules 3062a, 3062b decrease, (iii) the distance D N between the battery modules 3062a, 3062b increases from the neutral length (e.g., 110 mm) to the extended length (e.g., 114 mm), and (iv) the respective rear walls of the male terminal housing 1100 slide further away from the inner wall of the bus bar housing 3600. It should be understood that the movement from the neutral state S N to the extended state S E occurs continuously. When the battery module 3060 is 25% charged, the tension of the connector system 3100 is between the neutral state S N and the extended state S E . In this state, the overall distance between the connectors 3998 may increase by 2 mm compared to the distance between the connectors 3998 in the neutral state S N .

[0258] Extended state S EIn this case, (i) the battery cell 3076 is in a 100% battery healthy state (SoH), (ii) the battery cell 3076 is charged to a 0% charge level, (iii) each rear wall of the male terminal housing 1100 is at a housing gap L HG (e.g., about 4 - 6 mm) from the inner wall of the bus bar housing 3600, (iv) the length L BE of the bus bar 200 is about 114 - 124 mm, preferably 119 - 121 mm, most preferably 120 mm (i.e., the length L IPE of the middle part is 23 mm - 31 mm, preferably 27 mm), the height H BE of the bus bar 200 is 15 - 30 mm, preferably 20 - 25 mm (i.e., the height H IPE of the middle part is 20 mm - 28 mm, preferably 23 mm), the width W BE of the bus bar 200 is 15 - 25 mm, preferably 20 mm, (v) the length L SE of the system 3100 is about 186 mm, the height of the system 3100 is 37 mm, and the width of the system 3100 is 31 mm, (vi) the distance D N between the battery modules 3062a and 3062b is an extended length (e.g., 114 mm), (vii) the neck L NE defined between the outer recesses 3264a and 3264b of the bus bar 3200 in the compressed state has a length of 29 - 34 mm, preferably 22 mm, (viii) the gap L GE defined between the opposing inner surfaces of the outer recesses 3264a and 3264b in the compressed state has a length of 18 mm and 26 mm, preferably 24 mm, (ix) the height H BE of the bus bar 3200 and the length L BEThe ratio to is 20.8%, (x) the bottom surfaces 3215b of the peripheral portions 3402a, 3402b are substantially parallel to the X-Y plane and substantially perpendicular to the X-Z plane and the Y-Z plane, (xi) the bottom surfaces 3215b of the peripheral portions 3402a, 3402b are substantially parallel to both the upper surface of the conductive plate 3085 of the transmission assembly 3083 and the ranges of the positive and negative terminal ends 3080a, 3080b of the battery cell 3076, (xii) the bottom surfaces 3215b of the peripheral portions 3402a, 3402b are substantially perpendicular to the ranges of the vertical side surfaces 3078a, 3078b of the battery cell 3076, (xiii) the intermediate portion 3410 is disposed between the fourth side wall 3068d of the battery module 3062a and the first side wall 3068a of the adjacent battery module 3062b, (ivx) the length L of the bus bar 200 BE and the length L of the system 3100 SE are substantially parallel to both the thickness T of the battery cell 3076 CELL and the X-axis. IV. Third Embodiment of the Battery Pack

[0259] Figures 84 to 88 show a battery module 5060 of the third embodiment and a plurality of elastic deformable battery module connector systems 5100 of the second embodiment. The combination of the battery module 5060 and the system 5100 is configured to be disposed within the battery pack 90 disclosed above. For the sake of brevity, the above disclosure related to the battery pack 90 will not be repeated hereinafter, but it should be understood that throughout the embodiments, like reference numerals represent like structures. For example, the disclosure related to the bus bar housing 5600 is equally applicable to the bus bar housing 5600. It should be understood that any one or more features of the battery module 5060 and the system 5100 can be used in combination with those disclosed with respect to the battery module 5060 and the system 5100, and that any one or more features of the battery module 5060 and the system 5100 can be used in combination with those disclosed with respect to the battery module 5060 and the system 5100. A. Battery Module

[0260] As shown in FIGS. 84 to 88, each of the battery modules 5060 (5062a to 5062j) generally includes (i) a battery module housing 5064, (ii) a battery cell 5076, and (iii) an electrical transmission assembly 5081. i. Battery Module Housing

[0261] The battery module housing 5064 includes a plurality of walls 5066 (for example, the arrangement of four side walls 5068a to 5068d, a bottom wall 5070a, and a top wall 5070b), which form a receiver 5072 configured to receive and protect (i) the battery cell 5076 and (ii) the electrical transmission assembly 5081. The top wall 5070b includes at least two battery module openings 5073a, 5073b formed therethrough, and the openings 5073a, 5073b are configured to enable the female connector assemblies 2000a, 2000b to be coupled within the scope of the electrical transmission assembly 5081. In particular, the current is configured to flow through the battery module openings 5073a, 5073b via the connection between the female connector assemblies 2000a, 2000b and the electrical transmission assembly 5081. The female connector assemblies 2000a, 2000b are shown in connection with this third embodiment of the battery module 5060, but it should be understood that the use of other connectors (for example, bolted, clamped, press-fitted) is contemplated by the present disclosure. For example, a bolted connector is disclosed in connection with a second embodiment of the battery module 5060. ii. Battery Cell

[0262] Figures 84 to 88 show that the battery module 5060 includes a plurality of pouch battery cells 5076, and each battery cell 5076 includes (i) a housing 5077, (ii) a positive electrode terminal 5080a, and (iii) a negative electrode terminal 5080b. The housing 5077 has horizontal side surfaces 5078a, 5078b and vertical top and bottom surfaces 5079a, 5079b, and is designed to surround and hold a material for storing charge, such as lithium or other similar metals. In other words, the battery cell has a thickness T C , a width W CELL , and a length L CELL . The positive and negative electrode terminals 5080a, 5080b couple the material contained within the housing 5077 to the electrical transmission assembly 5081. The terminals 5080a, 5080b can have a tab-shaped configuration, but other terminal shapes are also possible (e.g., boltless connectors, bolted connectors, buttons, or other structures that can be welded, press-fitted, or sandwiched by the electrical transmission assembly 5081). The positive and negative terminals 5080a, 5080b are typically formed from different materials to facilitate charging and discharging of the battery cell 5076. For example, the positive electrode terminal or anode 5080a may be formed from (i) graphite, (ii) silicon, or (iii) graphene, and the negative electrode terminal or cathode 5080b may be formed from (i) cobalt, (ii) iron, (iii) nickel-magnesium, (iv) nickel, or (v) sulfur. It should be understood that other materials may be used for the terminals. The battery cell 5076 can have an output voltage between 0.2 volts and 10 volts, a rated ampere-hour between 10 Ah and 100 Ah, and an energy density between 20 Wh / kg and 500 Wh / kg. The battery cell 5076 can use a number of different technologies and / or materials, including batteries that utilize (i) NiCd, (ii) NiMH, (iii) NaNiCl, (iv) lithium polymer, (v) lithium ion, or (vi) other materials (e.g., LiO 2 , AlO 2 , LiS, LTO, LFP, NMC, NCA). iii. Electrical transmission assembly

[0263] Figures 58 to 67 show the electrical transmission assemblies 5081 disposed within each of the battery modules 5060, which electrical transmission assemblies (i) couple the battery cells 5076 to each other and (iii) couple the female connector assemblies 2000a, 2000b to the battery cells 5076. As shown in this embodiment, each of the first and second stacks includes approximately 26 battery cells 5076 disposed horizontally as compared to the X-Y plane. This horizontal orientation (i) positions the positive and negative terminals 5080a, 5080b in a plane substantially parallel to the Y-Z plane, (ii) positions the horizontal side surfaces 5078a, 5078b of the cells 5076 substantially parallel to the X-Y plane, and (iii) positions the thickness T C of the cells 3076 parallel to the Z-axis. Thus, the conductive plate 5084 can be disposed in the Y-Z plane and coupled to the positive and negative terminals 5080a, 5080b of the cells 5076. In this embodiment, the above configuration of the electrical transmission assembly 5081 for the battery cells 5076 and related components is disclosed, but it should be understood that in other embodiments, the electrical transmission assembly 5081 may have a different configuration. For example, the electrical transmission assembly 5081 may be designed to couple any number of battery cells 5076 (e.g., between 2 and 1000) to each other and any number of battery rows (e.g., between 1 and 40 rows) to each other.

[0264] Furthermore, at least one female connector assembly 2000 is coupled to the plate 5086. Preferably, the plate 5086 of the electrical transmission assembly 5081 is coupled to two female connector assemblies 2000a, 2000b, where (i) the positive-side female connector assembly 2000b is configured to provide a positive-side external connection for the battery module 5060 and is designed to receive the positive-side male terminal assembly 1430, and (ii) the negative-side female connector assembly 2000a is configured to provide a negative-side external connection for the battery module 5060 and is designed to receive the negative-side male terminal assembly 1430. The battery module 5060 shown in the figure includes two female connector assemblies 2000a, 2000b, but it should be understood that the battery module 5060 may have more or fewer female connector assemblies 2000. For example, the battery module 5060 may have only a single female connector assembly 2000, or the battery module 5060 may include ten or more female connector assemblies 2000. B. Battery Pack

[0265] As described above, the third embodiment of the battery module 5090 is designed to fit within the rectangular prism configuration of the battery pack 90 shown in FIGS. 53-54. FIGS. 53 and 54 show a battery pack 90 having a configuration and configured to hold ten battery modules 5060, but it should be understood that the present disclosure is not limited to this design. Instead, the battery pack 90 may have any known configuration (e.g., any type of polygonal prism) including a configuration in which the pack 90 is constructed as part of a vehicle's frame or chassis. Also, in other embodiments, it should be understood that the battery pack 90 may be configured to hold only a single battery module 5060 or may be configured to hold over a hundred individual battery modules 5060. The battery cells 5076 included within the module 5060 may be connected in parallel, in series, or any combination thereof. Further, the battery modules 5060 included within the battery pack 90 may be connected in parallel, in series, or any combination thereof. C. Connection of Battery Modules within the Battery Pack

[0266] Once the battery modules 5060 (5062a - 5062j) are positioned and fixed to the receivers 97a, 97b of the battery pack 90, the battery modules 5060 (5062a - 5062j) can be coupled to each other using the disclosed elastically deformable battery module connector system 5100. In this embodiment, the battery pack 90 includes nine elastically deformable battery module connector systems 5100 (5102a - 5102i). Each of the elastically deformable battery module connector systems 5100 is coupled to the battery module 90 using a downward force (i.e., the negative (-) Z direction). The disclosed configuration arranges the bottom surfaces 5215b of the peripheral portions 5402a, 5402b to be substantially parallel to each of the following: (i) the X - Y plane, (ii) the bottom wall 91 of the battery pack 90, (iii) the top and bottom walls 5070a, 5070b of the battery module housing 5064, and (iv) the range of the positive and negative terminals 5080a, 5080b of the battery cell 5076. Further, the configuration arranges the bottom surfaces 5215b of the peripheral portions 5402a, 5402b to be substantially perpendicular to each of the following: (i) the X - Z plane, (ii) the Y - Z plane, (iii) the side and end walls 92a, 92b, 94a, 94b of the battery pack 90, (iii) the side walls 5068a - 5068d of the battery module housing 5064, (iv) the longitudinal surface 78 of the battery cell 5076. Further, due to the arrangement of the said configuration, the intermediate portion 5410 extends downward in the - Z direction from the peripheral portion plane and is disposed between the fourth side wall 5068d of the battery module 5060 (e.g., 5062a) and the side wall 5068a of the adjacent battery module 5060 (e.g., 5062b). Further, the length L of the bus bar 5200 B extends in a direction substantially parallel to the X - axis, and the width of the bus bar 5200 extends in a direction substantially parallel to the Y - axis.

[0267] The resiliently deformable battery module connector system 5100 of this third embodiment is attached to the battery pack 90 using the connector assemblies 1000, 2000. These connector assemblies 1000, 2000 provide for connections between battery modules 5060 that are (i) boltless, (ii) PCT compliant, (iii) 360° compliant, (vi) faster and more efficient compared to conventional battery pack connectors, (vii) simple, requiring no special tools or machinery, (viii) compliant with USCAR and other industry specifications, (ix) lighter than conventional battery pack connectors, and (x) provide other advantages apparent to those skilled in the art. Once the battery modules 5060 and all other necessary components (e.g., battery management assembly, battery cooling or heating assembly, etc.) are attached to the battery pack 90, the pack 90 can be attached to the application 10. D. Material Condition of Battery Module

[0268] In the second embodiment, due to the movement of lithium ions from the cathode to the anode, the thickness of the cell 5076 is T when the battery is 100% charged or fully charged max up to, and varies to T when the battery is 50% charged or half charged normal and may decrease to T when the battery is 0% charged or uncharged, where min T max > T normal > T min is. In light of the above disclosure, the main factor contributing to the dynamic movement of the battery module 5076 within the pack 90 is not related to the state of charge of the battery module 5076. This is because the prismatic cell 3076 is arranged horizontally compared to the X - Y plane, in which case (i) the horizontal side surfaces 5078a, 5078b of the cell 5076 are substantially parallel to the X - Y plane, and (iii) the thickness T C of the cell 3076 is parallel to the Z - axis. Thus, the T normal to T max of the battery cell 5076, or T normal to T minThe expansion and contraction of the thickness up to cause the expansion and contraction of the battery module 5076 mainly along the Z-axis. Since the movement of lithium ions is mainly directed in the vertical direction and there are no other evaluable components, the expansion and contraction along the X-axis or Y-axis are minimal, if any. Since the pack 90 lacks the requirement to electrically couple the individual modules 5060 to the top surface of the pack 90, the expansion of the individual modules 5060 along the Z-axis is independent of the other modules 5060 and the length L of the system 100 S is not arranged in a direction parallel to the Z-axis, but instead is arranged in a direction parallel to the X-axis. With this configuration, the system 100 can couple the individual modules 5060 to each other. However, as disclosed above, the expansion and contraction of the battery module 5076 due to the movement of lithium ions are mainly along the Z-axis and not along the X-axis. Therefore, the system 100 (i.e., the intermediate portion 5410) does not elastically deform to absorb the expansion and contraction of the battery module 5076 in the Z-axis.

[0269] In contrast to FIGS. 53-83 disclosing that the system 100 is configured to beneficially absorb forces associated with the dynamic movement of the module 5076, FIGS. 84-88 disclose that the system 100 can also beneficially consider various material states associated with the battery pack 90. i. System in neutral state

[0270] It is clear from the above disclosure that the individual elastically deformable battery module connector systems 5100 included in the battery pack 90 can experience different forces, but with respect to the first system 5102a, the first battery module 5062a, and the second battery module 5062b, the general concepts disclosed in the following disclosure apply to all systems 5100 included in the battery pack 90. FIGS. 85-86 show the elastically deformable battery module connector system 5100 in a neutral state S where no tension or compression is applied to the system 5100 N is shown. Neutral state SN In this case, (i) each rear wall of the male terminal housing 1100 is spaced from the inner wall of the bus bar housing 5600 by a housing gap L HG (e.g., about 2 to 4 mm), (ii) the length L of the bus bar 200 in the formed state BN is about 110 to 120 mm, preferably 115 to 117 mm, most preferably 116 mm (i.e., the length L of the middle portion IPN is 23 mm to 31 mm, preferably 27 mm), the height H of the bus bar 200 BN is 15 to 30 mm, preferably 20 to 25 mm (i.e., the height H of the middle portion IPN is 20 to 28 mm, preferably 23 mm), the width W of the bus bar 200 BN is 15 to 25 mm, preferably 20 mm, (iii) the length L of the system 5100 SN is about 150 to 200 mm, preferably 160 to 190 mm, most preferably 182 mm, the height H of the system 5100 SN is 35 to 40 mm, preferably 37 mm, the width of the system 5100 is 25 to 35 mm, preferably 31 mm, (iv) the neck L defined between the outer recesses 5264a, 5264b of the bus bar 5200 in the neutral state NN has a length of 25 to 30 mm, preferably 22 mm, (viii) the gap L defined between the opposing inner surfaces of the outer recesses 5264a, 5264b in the neutral state GN has a length of 14 to 22 mm, preferably 22 mm, (vi) the height H of the bus bar 5200 BN and the length L of the bus bar 5200 in the formed state BNThe ratio between them is 20 - 25%, preferably 21.5%. (vii) The bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the X - Y plane and substantially perpendicular to the X - Z plane and the Y - Z plane. (viii) The bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cell 5076. (ix) The intermediate portion 5410 is disposed between the fourth side wall 5068d of the battery module 5062a and the first side wall 5068a of the adjacent battery module 5062b. (x) The length L BN of the bus bar 200 SN and the length L CELL of the system 3100 are substantially perpendicular to the thickness T of the battery cell 5076 but substantially parallel to the X - axis. Thus, the system 5100 is attached to the pack 5090 in a nominal material state that is between the maximum material state and the minimum material state. ii. Shrink - state system

[0271] FIG. 87 shows that the components of the battery pack 5090 are in the maximum material state. In particular, this maximum material state occurs when: (i) the battery modules 5062a, 5062b are arranged as close to each other as possible while being within the specified tolerances of the pack 5090, and (ii) the system 5100 has the maximum possible length while being within the specified tolerances of the pack 5090. To account for this maximum material state, the elastically deformable battery module connector system 5100 is in a compressed state S C and the bus bar 5200 is subjected to the maximum compression C max force. In this embodiment, the maximum compression C max force is 38 - 46 N, preferably 42 N. This maximum compression C max force is applied to the system 5100 in the third direction (along the positive (+) X - axis) via the battery module 5062a and in the first direction (along the negative (-) X - axis) via the configuration of the battery modules 5062a, 5062b.

[0272] Compressed state SC In (i), the respective rear walls of the male terminal housing 1100 are arranged with a housing gap L (e.g., about 0 to 0.05 mm or adjacent) with respect to the inner wall of the bus bar housing 5600. HG (ii), the length L of the bus bar 200 BC is about 106 to 116 mm, preferably 111 to 113 mm, most preferably 112 mm (i.e., the length L of the middle part is 23 mm to 31 mm, preferably 27 mm), the height H of the bus bar 200 IPC is 15 to 30 mm, preferably 20 to 25 mm (i.e., the height H of the middle part is 20 mm to 28 mm, preferably 23 mm), the width W of the bus bar 200 BC is 15 to 25 mm, preferably 20 mm, (iii) the length L of the system 5100 IPC is about 178 mm, the height of the system 5100 is 37 mm, the width of the system 5100 is 31 mm, (iv) the length L of the neck defined between the outer recesses 5264a, 5264b of the bus bar 5200 in the compressed state BC is 21 to 26 mm, preferably 18 mm, (v) the length L of the gap defined between the opposing inner surfaces of the outer recesses 5264a, 5264b of the bus bar 5200 in the compressed state SC is 10 mm and 18 mm, preferably 14 mm, (vi) the height H of the bus bar 5200 NC and the length L of the bus bar 5200 GC The ratio between them is 22.3%, (vii) the bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the X-Y plane and substantially perpendicular to the X-Z plane and the Y-Z plane, (viii) the bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cell 5076, (ix) the middle portion 5410 is arranged between the fourth side wall 5068d of the battery module 5062a and the first side wall 5068a of the adjacent battery module 5062b, (ix) the length L of the bus bar 200 BC and the length L of the system 3100 BC (x) BC and the length L of the system 3100 SCis the thickness of the battery cell 5076 C , but is substantially parallel to the X-axis. iii. Expanded State System

[0273] 88 illustrates that the illustrated components of the battery pack 5090 are in a minimum material state. In particular, this minimum material state occurs when: (i) the battery modules 5062a, 5062b are spaced as far apart as possible from one another while still being within the specified tolerances of the pack 5090, and (ii) the system 5100 has the smallest length possible while still being within the specified tolerances of the pack 5090. To account for this minimum material condition, the expanded state S E The elastically deformable battery module connector system 5100 in max In this embodiment, the maximum tension TE max The tension is 38 to 46 N, preferably 42 N. max A force is applied to the system 5100 in a third direction (along the positive (+) X-axis) via the battery module 5062a and in a first direction (along the negative (-) X-axis) via the arrangement of battery modules 5062a, 5062b.

[0274] Expanded state S E In this case, (i) the rear wall of each of the male terminal housings 1100 is spaced from the inner wall of the bus bar housing 5600 by about 4 to 6 mm, and (ii) the length L of the bus bar 200 is about 1 mm to about 1 mm. BE The length of the middle part L is about 114 to 124 mm, preferably 119 to 121 mm, and most preferably 120 mm. IPE 23 mm to 31 mm, preferably 27 mm), and the height H BE is 15 to 30 mm, preferably 20 to 25 mm (i.e., the height H IPE The width W of the bus bar 200 is 20 mm to 28 mm, preferably 23 mm. BE is 15 to 25 mm, preferably 20 mm, and (iii) the length L SEis approximately 186 mm, the height H of the system 5100 SE is 37 mm, the width of the system 5100 is 31 mm, and (iv) the neck L defined between the outer recesses 264a, 264b of the bus bar 5200 in the compressed state NE has a length of 29 to 34 mm, preferably 22 mm, and (v) the gap L defined between the opposing inner surfaces of the outer recesses 5264a, 5264b of the bus bar 5200 in the compressed state GE has a length of 18 and 26 mm, preferably 24 mm, and (vi) the height H of the bus bar 5200 BE and the length L of the bus bar 5200 BE The ratio between them is 20.8%. (vii) The bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the X - Y plane and substantially perpendicular to the X - Z plane and the Y - Z plane. (viii) The bottom surfaces 5215b of the peripheral portions 5402a, 5402b are substantially parallel to the horizontal side surfaces 5078a, 5078b of the battery cell 5076. (ix) The intermediate portion 5410 is disposed between the fourth side wall 5068d of the battery module 5062a and the first side wall 5068a of the adjacent battery module 5062b. (x) The length L of the bus bar 200 BE and the length L of the system 5100 SE is substantially perpendicular to the thickness T of the battery cell 5076 C but is substantially parallel to the X - axis. V. Alternative bus bar configuration

[0275] The bus bar 200 shown in connection with FIGS. 1-83 can be replaced with any of the alternative bus bars 200 that include alternative versions of the elastically deformable intermediate portions 412a-412m shown in FIGS. 89-102. Similar to the bus bar 200 described above, each of these alternative designs includes: (i) a first peripheral connection segment 402a, (ii) a second connection segment 402b, and (iii) elastically deformable intermediate segments 412a-412m located between the first and second elastically deformable segments 402a, 402b. In these alternative embodiments, the elastically deformable intermediate segment can include a straight portion (see FIGS. 89-90, 92-93), an arched portion (see FIGS. 91, 94, 95), a parabolic portion (see FIGS. 96-97, 99-101), other shaped portions (see FIG. 98), or a plurality of discrete shapes separated by straight segments or other shaped segments (see FIG. 102). It should be understood that the disclosed shapes are not limiting and are merely illustrative in nature. Thus, other shapes or combinations of shapes are contemplated by this disclosure. VI. Third Embodiment of the System

[0276] Similar to the system 100 described above, FIGS. 103-104 show another embodiment of the system 7100. For the sake of brevity, the above disclosure related to the system 100 will not be repeated below, but it should be understood that throughout the embodiments, like reference numerals represent like structures. For example, the disclosure regarding the bus bar 200 is equally applicable to the bus bar 7200. Further, it should be understood that the compression and / or extension of the bus bar 7200 is the same as or identical to that disclosed with respect to the bus bar 200. The only difference in this embodiment of the system 7100 is that the bus bar housing 7600 includes only (i) two couplers 7597 in the upper range of the housing 7600 and two couplers 7597 in the lower range of the housing 7600, and (ii) the first range 606 and the fifth range 614 of the housing 600 are omitted in this embodiment. VII. Alternative Configuration of the Male Terminal

[0277] The male terminal assembly 1430 shown in connection with FIGS. 1-83 may be replaced with any of the following: (i) an opening for receiving a threaded connector, (ii) any one of male terminals 4430 (shown in FIG. 105), 5430 (shown in FIG. 106), 6430 (shown in FIG. 107), 7430 (shown in FIG. 108), or 8430 (shown in FIG. 109), or (iii) any male connector disclosed in a patent or patent application incorporated herein by reference. Each of male terminals 4430, 5430, 6430, 7430, or 8430 has features similar to male terminal 1430 and is described in detail in other applications or patents incorporated herein by reference, so this disclosure will not be repeated herein. For example, male terminal 4430 is disclosed in PCT / US2019 / 036,010, male terminal 5430 is disclosed in PCT / US2019 / 036,010 and PCT / US2021 / 043,686, male terminal 6430 is disclosed in PCT / US2021 / 043,788, male terminal 7430 is disclosed in U.S. Provisional Application 63 / 286,072, and male terminal 8430 is disclosed in PCT / US2021 / 047,180, each of which is incorporated herein by reference.

[0278] Connector system 100 is T4 / V4 / D2 / M2, where system 100 meets and exceeds each of the following: (i) T4 is exposure of system 100 to 150° C., (ii) V4 is severe vibration, (iii) D2 is a durability of 200k miles, and (iv) M2 is a force required to connect male terminal assembly 1430 to female terminal assemblies 2430, 3430 that is less than 45 Newtons. In other embodiments, connector system 100 may be T4 / V4 / S3 / D2 / M2, in which case system 100 also meets and exceeds the sealed high-pressure spray of S3. In addition to being T4 / V4 / S3 / D2 / M2 compliant, 360° compliant, boltless, and PCT compliant, system 100 may also be scannable and thus PCTS compliant (see PCT / US2020 / 049870).

[0279] The spring member 1440c disclosed in this specification may be replaced with the spring member shown in PCT / US2019 / 36010 or US Provisional Application No. 63 / 058,061. Further, it should be understood that alternative configurations of the connector assembly 1000 are possible. For example, any number of male terminal assemblies 1430 (e.g., between 2 and 30, preferably between 2 and 8, most preferably between 2 and 4) may be disposed within the housing 1100, and any number of female terminal assemblies 2430, 3430 (e.g., between 2 and 30, preferably between 2 and 8, most preferably between 2 and 4) may be disposed within the housings 2100, 3100. Further, alternative configurations of the connector system 998 are also possible. For example, the female connector assemblies 2000a, 2000b may be reconfigured to receive these multiple male terminal assemblies 1430 into a single female terminal assembly 2430.

[0280] It should also be understood that the male terminal assembly may have any number of contact arms 1494 (e.g., between 2 and 100, preferably between 2 and 50, most preferably between 2 and 8), and any number of spring arms 1452 (e.g., between 2 and 100, preferably between 2 and 50, most preferably between 2 and 8). As described above, the number of contact arms 1494 may not be equal to the number of spring arms. For example, the number of contact arms 1494 may be greater than the number of spring arms 1452. Alternatively, the number of contact arms 1494 may be less than the number of spring arms 1452. Incorporated References and Disclosures

[0281] The PCT application numbers PCT / US2022 / 037508, PCT / IB2022 / 057772, PCT / US2021 / 057959, PCT / US2021 / 047180, PCT / US2021 / 043788, PCT / US2021 / 043686, PCT / US2021 / 033446, PCT / US2020 / 050018, PCT / US2020 / 049870, PCT / US2020 / 014484, PCT / US2020 / 013757, PCT / US2019 / 036127, PCT / US2019 / 036070, PCT / US2019 / 036010, and PCT / US2018 / 019787, U.S. Patent Application No. 16 / 194,891, U.S. Provisional Application Nos. 62 / 897,962, 63 / 051,639, 63 / 234,320, 63 / 337,596, and U.S. Design Patent Application Nos. 29 / 749,813, 29 / 749,790 are each hereby incorporated by reference in their entirety and made a part of this specification.

[0282] Each of the SAE specifications, including J1742_201003 entitled "Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses - Test Methods and General Performance Requirements" (Final Revision March 2010), is hereby incorporated by reference in its entirety and made a part of this specification.

[0283] (i) ASTM standards including D4935-18 entitled "Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials", and (ii) ASTM D257 entitled "Standard Test Methods for DC Resistance or Conductance of Insulating Materials" are each hereby incorporated by reference in their entirety and made a part of this document.

[0284] Each of the specifications of the American National Standards Institute and / or the EOS / ESD Association, Inc., including ANSI / ESD STM11.11, "Surface Resistance Measurements of Static Dissipative Planar Materials", is hereby incorporated by reference in its entirety and made a part of this document.

[0285] The DIN standards including "Connectors for electronic equipment - Tests and measurements" Part 5-2: "Current-carrying capacity tests"; Test 5b: "Current-temperature derating" (IEC 60512-5-2:2002) are hereby incorporated by reference in their entirety and made a part of this document.

[0286] (i) SAE / USCAR-2, Revision 6, last revised in February 2013, with ISBN: 978-0-7680-7998-2, (ii) SAE / USCAR-12, Revision 5, last revised in August 2017, with ISBN: 978-0-7680-8446-7, (iii) SAE / USCAR-21, Revision 3, last revised in December 2014, (iv) SAE / USCAR-25, Revision 3, revised in March 2016, with ISBN: 978-0-7680-8319-4, (v) SAE / USCAR-37, revised in August 2008, with ISBN: 978-0-7680-2098-4, (vi) SAE / USCAR-38, Revision 1, revised in May 2016, with ISBN: 978-0-7680-8350-7. Each of the USCAR standards is hereby incorporated by reference in its entirety and made a part of this document.

[0287] Other specifications, including Federal Test Method Standard 101C and 4046, are hereby incorporated by reference in their entirety and made a part hereof. Although several embodiments have been illustrated and described, numerous modifications can be devised without departing from the spirit of the disclosure, and the scope of protection is limited only by the appended claims. For example, the overall shape of the above-described components can be changed to a triangular prism, pentagonal prism, hexagonal prism, octagonal prism, sphere, cone, tetrahedron, cube, dodecahedron, icosahedron, octahedron, ellipsoid, or other similar shapes. In another example, all the welds of the bus bar 200 can be performed before bending the bus bar 200. In a further example, the bus bar 200 may not be welded and instead may be 3D printed such that the bus bar 200 has a desired configuration, or separate components (e.g., bands) may be added to the bus bar 200 to help prevent layers from peeling during the bending process. Further, in another embodiment, the female connector assembly 2000 may be directly coupled to the system 100, and the male connector assembly 1000 may be coupled to the battery module 60. Further, the bending height H IPN and the bending length L IPN need not remain substantially constant in all states (compressed state, normal state, expanded state), and instead, the bending height H IPN and the bending length L IPN may vary by 2.5% or more of their height / length, and in some cases, by 3% - 25%.

[0288] Headings and subheadings, if any, are for convenience only and are not limiting. The term "exemplary" is used in the sense of serving as an example or illustration. To the extent terms such as "includes" and "have" are used, such terms are intended to be construed in the same inclusive manner as the term "comprise" when used as transitional words in the claims. Relative terms such as first and second can be used to distinguish one entity or act from another, but do not necessarily require or imply any actual relationship or order between such entities or acts.

[0289] Aspects, that aspect, another aspect, some aspects, one or more aspects, implementations, that implementation, another implementation, some implementations, one or more implementations, embodiments, that embodiment, another embodiment, some embodiments, one or more embodiments, configurations, that configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and the like are for convenience only and do not mean that the disclosure related to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. The disclosure related to such phrase(s) may apply to all configurations in some cases or to one or more configurations in other cases. The disclosure related to such phrase(s) can provide one or more examples. Expressions such as an aspect or some aspects may refer to one or more aspects and vice versa.

[0290] Numerous modifications to the present disclosure will be apparent to those of ordinary skill in the art in view of the foregoing description. Preferred embodiments of the present disclosure are described herein, including the best mode known to the inventors for carrying out the present disclosure. It should be understood that the illustrated embodiments are exemplary only and should not be construed as limiting the scope of the present disclosure.

Claims

1. An elastically deformable connector system used for connecting battery modules within a battery pack, Includes a busbar assembly, said busbar assembly (i) A busbar having a plurality of individual conductors arranged vertically to provide a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion located between the first peripheral portion and the second peripheral portion, (ii) A first male connector assembly coupled to the first peripheral portion of the busbar, (iii) A second male connector assembly coupled to the second peripheral portion of the busbar, (iv) a busbar housing encompassing a substantial portion of the busbar, An elastically deformable connector system characterized in that, after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the intermediate portion is capable of being elastically deformed to compensate for the compression and expansion movements of the pair of battery modules, respectively.

2. (i) The first peripheral portion is substantially coplanar with the second peripheral portion, and (ii) the majority of the elastically deformable intermediate portion is not coplanar with either the first peripheral portion or the second peripheral portion, as described in claim 1.

3. The elastically deformable connector system according to claim 2, characterized in that the elastically deformable intermediate portion includes at least one curved range.

4. The elastically deformable connector system according to claim 3, characterized in that the interaction between the first portion and the first peripheral portion of the elastically deformable intermediate portion defines a first external recess, the interaction between the second portion and the second peripheral portion of the elastically deformable intermediate portion defines a second external recess, and the first external recess and the second external recess are in a positional relationship to face each other.

5. The first external recess includes an external recess angle defined at the neutral position, and the external recess angle is defined by the compressive activation force (F Ａ The elastically deformable connector system according to claim 4, characterized in that the force decreases when applied to the busbar.

6. The first external recess includes an external recess angle defined at the neutral position, and the external recess angle is determined by the expansion activation force (F Ａ The elastically deformable connector system according to claim 4, characterized in that the force increases when the force is applied to the busbar.

7. The elastically deformable connector system according to claim 1, characterized in that the elastically deformable intermediate portion has a curved configuration substantially corresponding to the configuration of the uppercase Greek letter omega.

8. The busbar in the neutral position has a total length (L) in the formed state after it has been bent and assembled. ＢＮ ) has the overall length (L ＢＮ ) is an activation force (F) of less than 50 Newtons. Ａ The elastically deformable connector system according to claim 1, characterized in that it can be changed by the application of )

9. The activation force (F Ａ ) is the compressive force, and the compressive activation force (F) on the busbar Ａ By applying ) the total length (L) of the busbar in the formed state ＢＮ The elastically deformable connector system according to claim 8, characterized in that it can reduce the ) by 4 mm.

10. The activation force (F Ａ ) is the expansion force, and by applying the expansion activation force (F Ａ ) to the bus bar, the total length (L ＢＮ ) of the formed bus bar can be increased by 4 mm. The elastic deformable connector system according to claim 8, characterized in that.

11. The entire length (L) of the busbar when it is not bent ＵＢ ) and after the busbar is bent and assembled, the busbar in the neutral position has the total length (L) of the formed state. ＢＮ ) has the total length (L) of the formed state ＢＮ ) is the total length (L) that is not bent ＵＢ The elastically deformable connector system according to claim 1, characterized in that it is smaller than ).

12. The elastically deformable busbar comprises at least one region selectively fused to form a solid single conductor, as described in claim 1.

13. The busbar has a bending height (H ＩＰＮ ) and when the intermediate portion of the busbar elastically deforms to compensate for the compression and expansion of the pair of battery modules, the bending height (H ＩＰＮ The elastically deformable connector system according to claim 1, characterized in that ) remains substantially constant.

14. The aforementioned intermediate portion has a bending length (L) ＩＰＮ ) and when the intermediate portion elastically deforms to compensate for the compression and expansion of the pair of battery modules, the bending length (L ＩＰＮ The elastically deformable connector system according to claim 1, characterized in that ) remains substantially constant.

15. An elastically deformable connector system used for connecting battery modules within a battery pack, Includes a busbar assembly, said busbar assembly (i) A busbar having a plurality of individual conductors which have undergone a fusion process to form a solid single conductor in a selected region of the busbar, and the busbar having a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion located between the first peripheral portion and the second peripheral portion, (ii) A first male connector assembly coupled to the first peripheral portion of the busbar, (iii) A second male connector assembly coupled to the second peripheral portion of the busbar, (iv) a busbar housing encompassing a substantial portion of the busbar, An elastically deformable connector system characterized in that, after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the intermediate portion is capable of being elastically deformed to compensate for the compression and expansion movements of the pair of battery modules, respectively.

16. (i) The first peripheral portion and the second peripheral portion are substantially located in the first plane, and (ii) the majority of the elastically deformable intermediate portion is located outside the first plane, characterized in that the elastically deformable connector system according to 15.

17. The aforementioned intermediate portion has a bending height (H) greater than 10 mm. ＩＰＮ The elastically deformable connector system according to claim 15, characterized by having ).

18. The elastically deformable connector system according to claim 15, characterized in that the elastically deformable intermediate portion includes (i) a pair of fused segments and (ii) a non-fused segment located between the fused segments.

19. The elastically deformable connector system according to claim 15, characterized in that the elastically deformable intermediate portion does not have a region that is completely solidified into a single solid conductor.

20. An elastically deformable connector system used for connecting battery modules within a battery pack, Includes a busbar assembly, said busbar assembly (i) the first peripheral portion and (ii) The second peripheral part, (iii) An elastically deformable intermediate portion located between the first peripheral portion and the second peripheral portion, (iv) The length of the formed state extending between the oppositely positioned edges of the busbar assembly (L ＢＮ )and, Includes a busbar having a plurality of individual conductors arranged vertically to provide, An elastically deformable connector system characterized in that, after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the intermediate portion is capable of being elastically deformed to compensate for the compression and expansion movements of the pair of battery modules, respectively.

Images