Feed-through connector for a battery pack, battery pack, and method for introducing at least one gas into a hermetically sealable casing for a battery pack

Abstract

A feedthrough connector for a battery pack having a gas-tight casing is disclosed. The feedthrough connector has a body including a gas-tight electrical portion, a first body portion defining a first connector portion, a second body portion opposite the first body portion, and a flange connected to the second body portion and projecting radially from the second body portion. The feedthrough connector also has a second connector portion selectively connected to the first connector portion and a gasket configured to abut an engagement surface of the flange and provide a gas-tight seal between the feedthrough connector and the casing. At least one of the first body portion and the second connector portion defines at least one recess for allowing gas exchange into and out of the casing. A battery pack having a feedthrough connector and a method for introducing at least one gas into a hermetically sealable casing for a battery pack are also disclosed.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 013,780, filed April 22, 2020, entitled "Pass-Through Connector for a Battery Pack, Battery Pack, and Method for Introducing at Least One Gas in a Hermetically Sealable Casing for a Battery Pack," the entire contents of which are incorporated herein by reference.

[0002] The present technology relates to a feedthrough connector for a battery pack, a battery pack having a feedthrough connector, and a method for introducing at least one gas into a hermetically sealable casing for a battery pack using a feedthrough connector. [Background technology]

[0003] Battery packs, such as those used in electric vehicles, typically include multiple high-voltage batteries connected in series. The total voltage of the battery packs in an electric vehicle can reach up to 400 volts when all the batteries are connected together.

[0004] In some cases, the battery is received in a casing that is hermetically sealed and filled with an inert gas mixture to prevent oxidation of the battery and / or components contained within the casing. It can be difficult to remove gas from the casing at an adequate flow rate, introduce gas into the casing, and then hermetically seal the introduced gas within the casing.

[0005] Additionally, batteries must be electrically connected to components located outside the casing while maintaining a hermetic seal of the casing. In this regard, feed-through connectors have been developed to connect electrical and electronic components located inside the casing with other electrical and electronic components located outside the casing. However, such feed-through connectors tend to have complex features that increase their manufacturing cost, assembly complexity, and the likelihood of gas leaking from the casing through the feed-through connector.

[0006] Therefore, there is a need for a feed-through connector that can reduce these problems. Summary of the Invention [Problem to be solved by the invention]

[0007] It is an object of the present technology to ameliorate at least some of the disadvantages present in the prior art. [Means for solving the problem]

[0008] According to one aspect of the present technology, there is provided a feedthrough connector for a battery pack having an airtight casing. The feedthrough connector has a body, a second connector portion, and a gasket. The body has an airtight electrical portion, a first body portion, a second body portion, and a flange. The airtight electrical connector has first and second sides. The first body portion defines a first connector portion on the same side as the first side of the airtight electrical connector. The second body portion is opposite the first body portion and on the same side as the second side of the airtight electrical connector. The flange is connected to the second body portion and protrudes radially away from the second body portion. The flange has an engagement surface. The second connector portion can be selectively connected to the body via the first connector portion. At least one of the first body portion and the second connector portion defines at least one recess to allow gas exchange into and out of the casing. A gasket abuts against the engagement surface of the flange. The gasket is configured to connect the second connector portion to the first connector portion and provide an airtight seal between the feedthrough connector and the casing by elastically compressing the gasket with the flange against the casing, the gasket being on the same side of the first body portion as the flange.

[0009] In some embodiments, the first connector portion has male threads and the second connector portion has female threads that are complementary to the male threads. When the second connector portion is threaded onto the first connector portion and the gasket is elastically compressed by the flange against the casing, the gasket abuts against the engagement surface of the flange, hermetically sealing the feedthrough connector to the casing.

[0010] In some embodiments, the hermetic electrical connector includes a bulkhead connected to the body, the bulkhead defining a plurality of through holes, the bulkhead having a first side on the same side as the first body portion and a second side on the same side as the second body portion, and the hermetic electrical connector also includes a plurality of connector pins that pass through the plurality of through holes and project away from the first and second sides of the bulkhead.

[0011] In some embodiments, the first body portion has at least one first sidewall extending from the bulkhead, the at least one first sidewall defining a first cavity disposed on a first side of the bulkhead, and a plurality of connector pins extending into the first cavity.

[0012] In some embodiments, at least one first sidewall has a first height, and each connector pin of the plurality of connector pins has a first pin height defined between a first free end of the connector pin disposed in the first cavity and the first side of the bulkhead, the first height being greater than the first pin height.

[0013] In some embodiments, the second body portion has at least one second sidewall extending from the bulkhead, the at least one second sidewall defining a second cavity disposed on a second side of the bulkhead, and a plurality of connector pins extending into the second cavity.

[0014] In some embodiments, at least one second sidewall has a second height. Each connector pin of the plurality of connector pins has a second pin height defined between a first free end and a second free end opposite the first free end. The second free end is disposed on the second side of the bulkhead within the second cavity. The second height is less than the second pin height.

[0015] In some embodiments, the second cavity is at least partially filled with an adhesive to adhere the plurality of connector pins to the body and hermetically seal a space between the plurality of connector pins and the plurality of through holes.

[0016] In some embodiments, the body, the second connector portion, and the gasket are made of an electrically insulating material.

[0017] In some embodiments, the body is formed from an injection molded polymeric material and the flange has a continuous seam on the mating surface.

[0018] In some embodiments, the gasket is an X-ring seal.

[0019] In some embodiments, when the second connector portion is connected to the first connector portion and the gasket hermetically seals the feedthrough connector to the casing, the gasket is elastically compressed by 10-25%.

[0020] In some embodiments, the second body portion defines a radially extending shoulder having a shoulder surface for abutting the casing, the flange extends radially away from the shoulder, and the axial distance between the engagement surface of the flange and the shoulder surface is greater than 75% of the uncompressed axial dimension of the gasket.

[0021] In some embodiments, the axial distance between the engagement surface and the shoulder surface of the flange is greater than or equal to 83% of the uncompressed axial dimension of the gasket.

[0022] In some embodiments, the first body portion has a radially extending polygonal flange configured for insertion into an opening defined in a casing of the battery pack configured to receive the feedthrough connector.

[0023] In some embodiments, the polygonal flange has an octagonal shape.

[0024] In some embodiments, the first body portion defines at least one bore configured to receive at least one threaded fastener.

[0025] In some embodiments, the first body portion has at least one guide protrusion extending away from the bulkhead, the at least one guide protrusion configured to position an electronic circuit board for operative connection with the plurality of connector pins, and the electronic circuit board configured to connect to the first body portion via the at least one drilled hole with at least one threaded fastener.

[0026] In some embodiments, at least one of the first body portion and the second connector portion that defines the at least one recess is the first body portion.

[0027] In some embodiments, the at least one recess is at least partially defined by a radially outer surface of the first body portion.

[0028] In some embodiments, the at least one recess comprises a first recess and a second recess.

[0029] In another aspect of the present technology, a battery pack is provided having a casing, at least one cell, a feedthrough connector according to the above aspect or according to one or more of the above aspects and embodiments, and at least one cable. The at least one cell has an anode and a cathode. The at least one cell is disposed inside the casing. The feedthrough connector is connected and extends through the casing. The at least one cable is electrically connected between the at least one cell and the feedthrough connector inside the casing.

[0030] In another aspect of the present technology, a method for introducing at least one gas into a hermetically sealable casing for a battery pack is provided. The method includes loosening a feedthrough connector secured to and extending through the casing. The feedthrough connector has a gasket disposed between a flange of the feedthrough connector and an inner surface of the casing. The gasket surrounds an opening in the casing through which the feedthrough connector is inserted. Loosening the feedthrough connector allows gas to pass between the gasket and the inner surface of the casing. The method also includes, after the step of loosening the feedthrough connector, removing gas contained in the casing through a recess defined by the feedthrough connector and disposed on the outside of the casing. The removed gas flows sequentially from the casing, past the gasket, and through the recess. The method also includes, after the step of removing gas contained in the casing, introducing at least one gas into the casing through the recess. The introduced at least one gas flows sequentially through the recess, past the gasket, and into the casing. The method also includes, after the step of introducing at least one gas, tightening the feedthrough connector to elastically compress the gasket between the flange and the inner surface of the casing and form an airtight seal that prevents passage of gas through the opening in the casing and through the recess in the feedthrough connector.

[0031] In some embodiments, at least one gas is an inert gas.

[0032] Embodiments of the present technology each have at least one, but not necessarily all, of the above-referenced objects and / or aspects, and it should be understood that some aspects of the present technology resulting from an attempt to achieve the above-referenced object may not meet that object and / or may meet other objects not specifically set forth herein.

[0033] Additional and / or alternative features, aspects, and advantages of embodiments of the present technology will become apparent from the following description, the accompanying drawings, and the appended claims.

[0034] For a better understanding of the present technology as well as other aspects and further features thereof, reference is made to the following description to be taken in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0035] [Figure 1] FIG. 1 is a front, top, left partially exploded view of the front of the battery pack. [Figure 2] 2 is a cross-sectional view of the feed-through connector of the battery pack of FIG. 1 taken from line 2-2 of FIG. 1. [Figure 3] FIG. 3 is a bottom, front, left perspective view of the body, connector pins, and gasket of the feed-through connector of FIG. 2. [Figure 4] FIG. 4 is a left side elevational view of the body and connector pin of FIG. 3. [Figure 5] FIG. 4 is a front elevational view of the body and connector pin of FIG. 3. [Figure 6] 6 is a cross-sectional view of the body and connector pin of FIG. 3 taken from line 6-6 of FIG. 5. [Figure 7] FIG. 4 is an exploded perspective view of the main body and connector pins of FIG. 3, seen from the top, front, left side. [Figure 8] FIG. 4 is a top, front, left-hand perspective view of the main body of FIG. 3. [Figure 9] 9 is a perspective view of the main body of FIG. 8 from the top, rear, right side. FIG. [Figure 10] FIG. 4 is a front elevational view of the gasket of FIG. 3. [Figure 11] 11 is a cross-sectional view of the gasket of FIG. 10 taken from line 11-11 of FIG. 10. [Figure 12] 3 is a top, front, left-side perspective view of the nut of the feed-through connector of FIG. 2.

[0023] FIG. [Figure 13] FIG. 13 is a bottom, rear, left-hand perspective view of the nut of FIG. 12. [Figure 14] 2 illustrates a method for introducing at least one gas into a casing for the battery pack of FIG. 1. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0036] This detailed description is intended to be a description of illustrative examples of the present technology.

[0037] The present technology relates to a feedthrough connector 100 having a body 110, a gasket 300, and a nut 350. When connected to an airtight casing 50, the feedthrough connector 100 can electrically connect an internal circuit board 16 through an electrical connector 130 to an external electrical circuit board 18 or any other electrical or electronic component suitable for connection to the connector 130, while allowing gas flow into and out of the casing 50 or hermetically sealing the casing 50. While the feedthrough connector 100 is described in connection with a battery pack 10, it is contemplated that the feedthrough connector 100 can be used with other casings requiring gas exchange and / or airtight sealing.

[0038] Referring to FIG. 1 , a battery pack 10 is described that includes a casing 50 and a feedthrough connector 100. The casing 50 has an interior 52 and an exterior 54. The battery pack 10 has a plurality of cells 12 in the interior 52. Each of the cells 12 has an anode and a cathode. The cells 12 are disposed inside the casing 50. More specifically, the cells 12 are stacked inside the casing 50. A cable 14 connects the cells 12 to the feedthrough connector 100 through an internal circuit board 16.

[0039] The battery pack 10 also has two power posts 20. One of the power posts 20 has a positive electrical polarity, and the other power post 20 has a negative electrical polarity. Each of the power posts 20 has a conductor 22, an internal gasket 24, a connector 26, an external gasket 28, and a nut 30. Each of the conductors 22 is connected to a bus bar 32. The bus bar 32 connects the cells 12 to the power posts 20. The bus bar 32 of one of the power posts 20 is connected to a pyrotechnic device 34 that, upon activation, is configured to destroy the bus bar 32 to which it is connected. This safety feature interrupts current flow through the battery pack 10 under certain conditions.

[0040] The casing 50 has a front cover 55. The front cover 55 is welded to the remainder of the casing 50, thereby forming an airtight joint. The front cover 55 defines a generally octagonal casing opening 56 and two octagonal casing openings 57. It is contemplated that the casing openings 56, 57 may have other shapes, such as pentagonal or hexagonal. The casing openings 56 receive the feedthrough connectors 100 therethrough, as described in more detail below. Each of the casing openings 57 receives one of the power posts 20 therethrough. At the exterior 54, a nut 350 connects to the body 110 of the feedthrough connector 100, and a nut 30 connects to the connection portions 26 of the power posts 20 that extend through the casing openings 57.

[0041] 2 and 3, the feedthrough connector 100 will be described in more detail. As mentioned above, the feedthrough connector 100 has a body 110, a gasket 300, and a nut 350. The feedthrough connector 100 is configured to be received within the casing opening 56 of the casing 50. The body 110 has a body portion 180 and a body portion 250 opposite the body portion 180. When the feedthrough connector 100 is attached to the casing 50, the features of the body portion 180 are on the inside 52 of the casing 50, and the features of the body portion 250 are on the outside 54 of the casing 50. The body portion 250 defines a connector portion 260 to which a nut 350 can be selectively connected, as described below. Two axially extending recesses 270 (best seen in FIGS. 3, 7, and 8) are defined in the body portion 250. As will be described in more detail below, the recess 270 allows gas exchange into and out of the casing 50 when the nut 350 is not rigidly connected to the connector 260. The body 110 also has a flange 120 connected to and projecting radially from the body portion 180. The gasket 300 is inside the casing 50 and abuts both the flange 120 and the front cover 55. When the nut 350 is rigidly connected to the connector portion 260, the gasket 300 is elastically compressed between the flange 120 and the front cover 55, causing the gasket 300 to provide an airtight seal between the feed-through connector 100 and the inner portion of the front cover 55 surrounding the casing opening 56. The battery pack 10 has an inert gas mixture sealed in the casing 50. The inert gas mixture prevents oxidation of the cells 12 and / or other components within the battery pack 10. The hermetic seal prevents the inert gas mixture from leaving the casing 50 and prevents other gases from entering the casing 50 .

[0042] The body 110, the gasket 300, and the nut 350 are made of an electrically insulating material. It is contemplated that in some embodiments, one or more of the body 110, the gasket 300, and the nut 350 may not be made of an electrically insulating material. In this embodiment, the body 110 is formed from an injection molded polymeric material. However, it is contemplated that the body 110 may be formed by other methods, such as by casting or 3D printing. The feed-through connector 100 and its various components are described in more detail below.

[0043] 4-9, the body 110 of the feedthrough connector 100 will be described in further detail. The body 110 has a hermetic electrical connector 130, a body portion 180, and a body portion 250.

[0044] Electrical connector 130 has side 131 and side 132 (best seen in FIG. 6 ). Electrical connector 130 has a bulkhead 140 connected to body 110. Bulkhead 140 has compartment side 141 and compartment side 142. Compartment side 141 is on the same side as body portion 180 and side 131, and compartment side 142 is on the same side as body portion 250 and side 132. Bulkhead 140 defines 32 through holes 145. Electrical connector 130 also has 32 connector pins 146 inserted through through holes 145. Each of connector pins 146 has a free end 147 disposed on side 131 and a free end 148 disposed on side 132, respectively. When assembled, connector pins 146 protrude away from compartment sides 141, 142. It is contemplated that the number of connector pins 146 and the number of through holes 145 may vary if another type of electrical connector 130 is used. In this embodiment, the feedthrough connector 100 implements two male connectors (i.e., the pins 146 extend on both sides of the bulkhead 140). In other embodiments, it is contemplated that the feedthrough connector 100 may implement two female connectors or one male connector and one female connector. The electrical connector 130 and how it connects to the body 110 are described in further detail below.

[0045] As best seen in FIG. 9 , in this embodiment, the body portion 180 has an upper wall 182, a left side wall 185, a right side wall 192, and a lower wall 195 that begin at the compartment side 141 and project away from the body portion 250. The walls 182, 185, 192, and 195 project generally the same distance from the bulkhead 140 and therefore share a common sidewall height 198 measured from the rear end of the walls 182, 185, 192, and 195 to the bulkhead 140 ( FIG. 6 ). The walls 182, 185, 192, and 195 form a generally rectangular shape. It is contemplated that in other embodiments, there may be more or fewer walls, which may form a circle, a pentagon, or another shape. The walls 182, 185, 192, and 195 define a side cavity 200 on the same side as the compartment side 141. The body portion 180 has two ribs 205 extending from the upper wall 182 and the lower wall 195 adjacent to the bulkhead 140 into the interior of the side cavity 200. A space is defined between the ends of the ribs 205. The side cavity 200 has an interior 202 extending from the bulkhead 140 to the rear of the ribs 205. There are 16 through holes 145 on the left side of the ribs 205 and 16 through holes 145 on the right side of the ribs 205.

[0046] The body portion 180 also has two circular protrusions 210 outside the cavity 200. One of the circular protrusions 210 is adjacent to the outer wall surface of the left side wall 185, and the other circular protrusion 210 is adjacent to the outer wall surface of the right side wall 192. The two circular protrusions 210 originate from the bulkhead 140 and extend axially away from the body portion 250. The circular protrusions 210 have a height, measured from the bulkhead 140 to their rear end, that is generally the same as the sidewall height 198. It is contemplated that in some embodiments, there may be only one circular protrusion 210. In other embodiments, there may be three or more circular protrusions 210. It is also contemplated that the circular protrusions 210 may be omitted.

[0047] The flange 120 is connected to the second body portion 180 and projects radially away from the second body portion 180. The flange 120 has a circular ring shape. The flange 120 has an engagement surface 122 that engages the gasket 300. The mold used in the injection molding process is designed so that the engagement surface 122 is seamless, thereby improving the seal between the gasket 300 and the engagement surface 122.

[0048] In this embodiment, the body portion 180 defines a shoulder 220. The shoulder 220 extends radially away from the body portion 180, while the flange 120 is connected to and extends radially away from the shoulder 220. The shoulder 220 has a smaller diameter than the flange 120 but a larger diameter than the casing opening 56. The shoulder 220 also has a shoulder surface 222 that abuts against the inside 52 of the front cover 55 when the feedthrough connector 100 is rigidly connected to the casing 50, as described in more detail below. The shoulder 220 has a shoulder height 224 ( FIG. 6 ). The shoulder height 224 is measured axially from the engagement surface 122 to the shoulder surface 222. As described in more detail below, the shoulder height 224 may depend on the compressibility of the gasket 300.

[0049] 4-9 , the body portion 250 has a radially extending polygonal flange 252. The polygonal flange 252 is connected to the shoulder 220. In this embodiment, the polygonal flange 252 is an octagonal flange 252. It is contemplated that in other embodiments, the polygonal flange 252 may have another shape, such as a pentagon or hexagon. As will be described in more detail below, the polygonal flange 252 is received within the casing opening 56.

[0050] Body portion 250 further has a sidewall 254 that originates from bulkhead 140 and projects away from body portion 180 to form a circular shape. In other embodiments, it is contemplated that sidewall 254 can have another shape, such as a rectangular shape, and thus, there can be more than one sidewall 254. Sidewall 254 has a sidewall height 255 measured from bulkhead 140 to the front end of sidewall 254 ( FIG. 6 ). Sidewall 254 also has an inner wall surface 255 and an outer wall surface 256. Sidewall 254 defines a side cavity 258 that is on the same side as bulkhead side 142.

[0051] External threads 259 are defined on the outer wall surface 256. Together, the side wall 254 and the external threads 259 form a connector portion 260, as will be described in more detail below.

[0052] Two recesses 270 are axially defined on outer wall surface 256 and on polygonal flange 252. Thus, two recesses 270 are axially defined along the entire body portion 250, including external threads 259. It is contemplated that recesses 270 may be defined in other ways. For example, in some embodiments, there may be only one recess 270. In other embodiments, there may be three or more recesses 270.

[0053] The body portion 250 also has two guide protrusions 272 disposed inside the side cavity 258. One of the guide protrusions 272 is positioned on the upper side of the side cavity 258, and the other guide protrusion 272 is positioned on the lower side of the side cavity 258. The two guide protrusions 272 originate from the partition wall 140, extend axially away from the body portion 180, and are adjacent to the inner wall surface 255. The guide protrusions 272 have a height greater than the side wall height 255, such that the guide protrusions 172 protrude beyond the front end of the side wall 254. It is contemplated that in some embodiments, only one guide protrusion 272 may be present. In other embodiments, there may be three or more guide protrusions 272. It is also contemplated that the guide protrusions 272 may be omitted.

[0054] The body portion 250 also has two circular protrusions 274 disposed inside the side cavity 258. One of the circular protrusions 274 is positioned on the left side of the side cavity 258, and the other circular protrusion 274 is positioned on the right side of the side cavity 258. The two circular protrusions 274 originate from the partition wall 140, extend axially away from the body portion 180, and are adjacent to the inner wall surface 255. The circular protrusions 274 have a protrusion height equal to the side wall height 255, such that the circular protrusions 274 are flush with the front end of the side wall 254. The circular protrusions 274 are concentric with the circular protrusions 210. It is contemplated that in some embodiments, only one circular protrusion 274 may be present. In other embodiments, there may be three or more circular protrusions 274. It is also contemplated that the circular protrusions 274 may be omitted.

[0055] Each of the two circular protrusions 274 defines a tapered perforation 276. In embodiments having a different number of circular protrusions 274, it is contemplated that the number of perforations 276 will vary accordingly. In embodiments in which circular protrusions 274 are omitted, it is also contemplated that perforations 276 may be defined elsewhere on body 110, such as in sidewall 254. Perforations 276 are defined to extend from the top of circular protrusions 274, past septum 140, and into circular protrusion 210. Perforations 276 are configured to receive threaded fasteners 62, as described below.

[0056] 2, 6 and 7, the electrical connector 130 will be described in more detail.

[0057] The portions of the connector pins 146 that extend through the side cavities 200 have a pin height 151 measured from the compartment side 141 to their free ends 147 (FIG. 6). As can be seen in FIGS. 2, 4, and 6, the pin height 151 of the connector pins 146 is higher than the side wall height 198 such that the connector pins 146 extend beyond the rear ends of the walls 189, 185, 192, and 195.

[0058] The side cavity 200 is partially filled with epoxy 201 (best seen in FIG. 6). It is contemplated that other fillers may be used in other embodiments. The epoxy 201 completely fills the interior 202 of the cavity. The epoxy 201 bonds the connector pins 146 to the body 110 and also hermetically seals any space that exists between the connector pins 146 and their corresponding through holes 145.

[0059] The portions of the connector pins 146 that extend through the side cavities 258 have a pin height 153 measured from the compartment side 142 to their free ends 148 (FIG. 6). The pin height 153 of the connector pins 146 is less than the side wall height 255 such that the connector pins 146 do not extend beyond the front ends of the side walls 254.

[0060] 10 and 11, the gasket 300 will be described in more detail. The gasket 300 is an X-ring seal 300 having an uncompressed axial height 304. However, it is contemplated that other types of ring seals, such as O-ring seals or square ring seals, may be used in other embodiments. The inner diameter of the X-ring seal 300 is large enough to surround both the shoulder 220 of the body 110 and the casing opening 56 of the front cover 55. The outer diameter of the X-ring seal 300 is smaller than the outer diameter of the flange 252. As best seen in FIG. 11, the X-ring seal 300 has a cross-section resembling an X due to recesses 302 defined on either side of the gasket 300 between the inner and outer diameters.

[0061] 12 and 13, nut 350 will be described in more detail. In this embodiment, nut 350 is a connector portion 350 that selectively connects to connector portion 260. Nut 350 has a body 360 and a flange 370. Body 360 has a hexagonal shape and defines internal threads 362. As will be described in more detail below, internal threads 362 are complementary to external threads 259. Flange 370 extends radially away from body 360 and has a circular profile with a flat end 372. Flange 370 also has a rear casing engagement surface 374.

[0062] 2, the connection of feedthrough connector 100 to casing 50 will now be described. Cells 12 are connected to internal circuit board 16, internal circuit board 16 is connected to electrical connector 130, and electrical connector 130 is connected to body 110.

[0063] A gasket 300 surrounds the shoulder 220 and engages the mating surface 122 of the flange 120. The gasket 300 is disposed between the front cover 55 and the flange 120.

[0064] The main body 110 is received within the casing opening 56. More precisely, the polygonal flange 252 is received within the casing opening 56. Assuming that both the polygonal flange 252 and the casing opening 56 have corresponding octagonal shapes, once the polygonal flange 252 is received within the casing opening 56, the feed-through connector 100 is rotatably secured relative to the front cover 55. As noted above, in other embodiments, it is contemplated that the shapes of the casing opening 56 and the polygonal flange 252 may differ. It is also contemplated that this feature may be omitted.

[0065] The nut 350 is now connected to the connector portion 260 via their complementary internal threads 362, external threads 259. It is contemplated that the manner in which the connector portions 166, 350 are connected to one another may differ from the threaded connection shown in this embodiment. The connection may be, for example, a circlip, a clevis pin, or another type of connection. Tightening the nut 350 onto the connector portion 260 elastically compresses the gasket 300, thereby achieving an airtight seal. In this scenario, during initial assembly of the feedthrough connector 100 into the casing 50, the casing 50 naturally fills with any gas mixture that was present at the location where the battery pack 10 is assembled, hereafter referred to as the atmospheric gas mixture.

[0066] Here, the external electrical circuit board 18 is connected to the electrical connector 130 and the body portion 250 by virtue of the guide projections 272 configured to position the external electrical circuit board 18 so that the external electrical circuit board 18 can be electrically connected to the connector pins 146, and by virtue of the threaded fasteners 62 that secure the threaded fasteners 62 in the drillings 276 and thereby secure the external electrical circuit board 18 to the body portion 250. It is contemplated that in some embodiments the external electrical circuit board 18 can be connected to the feed-through connector 100 in other ways, such as with an adhesive or via clips.

[0067] 14, a method will be described for introducing gas into the casing 50 of a battery pack 10 having a feedthrough connector 100. It is contemplated that the method may be performed by an automatic controller, an operator, or a combination of both.

[0068] The method begins at step 400, where the feedthrough connector 100 is loosened. The feedthrough connector 100 is loosened by unscrewing the nut 350 from the connector portion 260. When the nut 350 is unscrewed, a gas removal supply device (not shown) is disposed over and surrounds the feedthrough connector 100 and the casing opening 56 on the outside of the casing 50, so that gas can only enter and exit the casing 50 through the gas removal supply device. In some embodiments, the nut 350 can be unscrewed by the gas device. Once the nut 350 is unscrewed, the gasket 300 is no longer elastically compressed, and therefore the feedthrough connector 100 and the casing 50 are no longer hermetically sealed.

[0069] Then, in step 410, the atmospheric gas mixture inside the casing 50 is removed. The atmospheric gas mixture is removed from the casing 50 thanks to the gas removal supply device and the recess 270. Because there is no longer an airtight seal, the gas removal supply device is able to remove the atmospheric gas mixture from inside the casing 50. The atmospheric gas mixture flows from the inside 52 of the casing 50, past the gasket 300 and between the nut 350 and the body portion 250, through the recess 270, and to the outside 54 of the casing 50. Eventually, when all of the atmospheric gas mixture in the casing 50 has been removed, a vacuum is created within the casing 50.

[0070] Next, in step 420, gas is introduced into the casing 50. The gas is introduced into the casing 50 through the gas removal supply device. In this embodiment, the introduced gas is an inert gas called helium. As explained above, the inert gas is introduced to prevent oxidation of the battery pack 10 and / or its components within the casing 50. In other embodiments, it is contemplated that a different inert gas or inert gas mixture may be introduced into the casing 50 instead of helium. In yet other embodiments, a non-inert gas may be introduced into the casing 50. Similar to step 410, helium is introduced into the casing 50 thanks to the gas removal supply device and the recess 270. The introduced helium flows through the recess 270, past the gasket 300, and into the interior 52 of the casing 50. In this embodiment, helium is introduced into the interior of the casing 50 until the pressure of the helium exceeds atmospheric pressure. In some embodiments, it is contemplated that the pressure of the helium may be subatmospheric.

[0071] As explained, recess 270 allows for the passage of gas into and out of casing 50 when feed-through connector 100 is loosely connected to casing 50, as a passage is formed from inside 52 to outside 54 of casing 50. It is contemplated that in some embodiments, recess 270 may be defined on nut 350 instead of connector portion 260. In other embodiments, recess 270 may be defined on both nut 350 and connector portion 260.

[0072] Next, in step 430, the feedthrough connector 100 is tightened. The feedthrough connector 100 is tightened by threading the nut 350 onto the connector portion 260. In some embodiments, the nut 350 is threaded by a gas removal supply device. Threading the nut 350 ultimately results in elastic compression of the gasket 300 and engagement of the casing engagement surface 374 of the nut 350 with the outer side 54 of the front cover 55. When the gasket 300 is sufficiently elastically compressed, the gasket 300 provides an airtight seal, thus sealing helium inside the casing 50. In this embodiment, the gasket 300 is sufficiently compressed when the nut 350 is threaded so that at least the shoulder surface 222 abuts against the inner side 52 of the front cover 55. In this embodiment, the shoulder height 224 of the feedthrough connector 100 is 83% of the uncompressed axial height 304 of the gasket 300 such that the gasket 300 can be compressed to 17% of its uncompressed axial height 304. In other embodiments, the shoulder height 224 of the feedthrough connector 100 may be greater than 83% of the uncompressed axial height 304 of the gasket 300 such that, when the feedthrough connector 100 is tightened, the gasket 300 resiliently compresses to less than 17% of its uncompressed axial height 304 before the shoulder surface 222 abuts against the inside 52 of the front cover 55. This feature ensures that the gasket 300 is not over-compressed and does not impose unnecessary loads on the feedthrough connector 100. It is contemplated that in some embodiments, the shoulder height 224 may be greater than 75% of the uncompressed axial height 304 of the gasket 300. In such embodiments, upon tightening, the gasket 300 will elastically compress by less than 25% of its uncompressed axial height 304. It is also contemplated that in some embodiments, the shoulder 220 may be omitted. In such embodiments, the correct amount of compression of the gasket 300 can be determined by measuring the torque applied to the nut 350 as it is tightened. In some embodiments, it is contemplated that the gasket 300 can elastically compress by 10-25% of its uncompressed axial height 304. In this embodiment, elastically compressing the X-ring seal 300 as described provides a compression of 1x10 -6A helium seal below atm-cc / s is possible. Once nut 350 is tightened, the gas removal supply device can be removed.

[0073] Modifications and improvements to the above-described embodiments of the technology may become apparent to those skilled in the art. The above description is intended to be illustrative rather than limiting. The scope of the technology is therefore intended to be limited only by the scope of the appended claims. [Explanation of symbols]

[0074] 10 Battery Pack 12 cells 14 Cable 16 Internal circuit board 18 External electrical circuit board 20 Power Post 22 Conductor 24 Internal gasket 26 Connection 28 External gasket 30 nuts 32 Busbar 34 Pyrotechnic Devices 50 Airtight Casing 52 Inside 54 Outside 55 Front cover 56 Casing opening 57 Casing opening 62 Screw fastener 100 through connector 110 Main Unit 120 flange 122 Engagement surface 130 Electrical connectors, airtight electrical connectors 131 Side 132 Side 140 Bulkhead 141 Plot Side 142 compartment side 145 through hole 146 connector pins 147 Free end 148 Free end 151 pins high 153 pins high 180 Main body 182 Upper wall 185 Left side wall 192 Right side wall 195 Lower wall 198 Side wall height 200 Side cavity 201 Epoxy 202 Internal 205 Ribs 210 Circular protrusion 220 Shoulder 222 Shoulder surface 224 Shoulder height 250 Main body 252 Polygonal flange 254 Side wall 255 side wall height 255 Inner wall surface 256 Exterior wall 258 Side cavity 259 Male thread 260 Connector part 270 recess 272 Guide protrusion 274 circular protrusion 276 Tapered perforation 300 Gaskets, X-ring seals 302 recess 304 Axial Height 350 Nut, connector part 360 main unit 362 female thread 370 flange 372 End 374 Rear casing engagement surface

Claims

1. A feed-through connector for a battery pack having an airtight casing, The main body is a hermetic electrical connector having first and second sides; a first body portion defining a first connector portion and on the same side as the first side of the hermetic electrical connector; a second body portion opposite the first body portion and on the same side of the hermetic electrical connector as the second side; and a flange connected to the second body portion and projecting radially away from the second body portion, the flange having an engagement surface; a body including: a second connector portion selectively connected to the body via the first connector portion, at least one of the first body portion and the second connector portion defining at least one recess for allowing gas exchange into and out of the airtight casing; a gasket abutting the engagement surface of the flange, the gasket being configured to connect the second connector portion to the first connector portion and to provide an airtight seal between the feedthrough connector and the airtight casing by elastically compressing the gasket with the flange against the airtight casing, the gasket being on the same side of the flange as the first body portion; A feed-through connector comprising:

2. the first connector portion has a male thread; the second connector portion has female threads complementary to the male threads; 2. The feedthrough connector of claim 1, wherein when the second connector portion is screwed onto the first connector portion and the gasket is elastically compressed by the flange against the airtight casing, the gasket abuts against the engagement surface of the flange, hermetically sealing the feedthrough connector to the airtight casing.

3. The hermetic electrical connector a partition wall connected to the body and defining a plurality of through holes, the partition wall having a first side on the same side as the first body portion and a second side on the same side as the second body portion; a plurality of connector pins passing through the plurality of through holes and projecting away from the first and second sides of the bulkhead; The feedthrough connector of claim 1 , comprising:

4. the first body portion has at least one first sidewall protruding from the septum, the at least one first sidewall defining a first cavity disposed on the first side of the septum; The feed-through connector of claim 3 , wherein the plurality of connector pins extend into the first cavity.

5. the at least one first sidewall has a first height; 5. The feedthrough connector of claim 4, wherein each connector pin of the plurality of connector pins has a first pin height defined between a first free end of the connector pin disposed in the first cavity and the first side of the partition wall, the first height being greater than the first pin height.

6. the second body portion has at least one second sidewall protruding from the septum, the at least one second sidewall defining a second cavity disposed on the second side of the septum; The feed-through connector of claim 5 , wherein the plurality of connector pins extend into the second cavity.

7. the at least one second sidewall has a second height; 7. The feedthrough connector of claim 6, wherein each connector pin of the plurality of connector pins has a second pin height defined between a second free end opposite the first free end and the second free end disposed in the second cavity and on the second side of the partition wall, the second height being lower than the second pin height.

8. the second body portion defines a radially extending shoulder having a shoulder surface for abutting the gas-tight casing; the flange extending radially from the shoulder; The feedthrough connector of claim 1 , wherein the axial distance between the engagement surface and the shoulder surface of the flange is greater than 75% of the uncompressed axial dimension of the gasket.

9. 2. The feedthrough connector of claim 1, wherein the first body portion has a radially extending polygonal flange configured for insertion into an opening defined in the airtight casing of the battery pack configured to receive the feedthrough connector.

10. The feed-through connector of claim 1 , wherein the first body portion defines at least one bore configured to receive at least one threaded fastener.

11. 11. The feedthrough connector of claim 10, wherein the first body portion has at least one guide protrusion extending away from the partition wall, the at least one guide protrusion configured to position an electronic circuit board for operative connection with the plurality of connector pins, and the electronic circuit board configured to connect to the first body portion through the at least one drilling hole with the at least one screw-type fastener.

12. The feed-through connector of claim 1 , wherein at least one of the first body portion and the second connector portion defining the at least one recess is the first body portion.

13. An airtight casing; at least one cell having an anode and a cathode and disposed inside the gas-tight casing; a feed-through connector according to any one of claims 1 to 12 connected to and extending through the hermetic casing; at least one cable electrically connected between the at least one cell and the feedthrough connector inside the casing; A battery pack comprising:

14. 1. A method for introducing at least one gas into an airtight casing for a battery pack, comprising: loosening a feedthrough connector secured to and extending through the airtight casing, the feedthrough connector having a gasket disposed between a flange of the feedthrough connector and an inner surface of the airtight casing, the gasket surrounding an opening in the airtight casing through which the feedthrough connector is inserted, and loosening the feedthrough connector permits the passage of gas between the gasket and the inner surface of the airtight casing; After the step of loosening the through connector, a step of removing gas contained in the airtight casing through a recess defined by the through connector and disposed on the outside of the airtight casing, wherein the removed gas flows from the airtight casing, past the gasket, and through the recess; After the step of removing the gas contained in the airtight casing, a step of introducing the at least one gas into the airtight casing through the recess, wherein the introduced at least one gas sequentially flows through the recess, over the gasket, and into the airtight casing; after the step of introducing at least one gas, tightening the feedthrough connector to elastically compress the gasket between the flange and the inner surface of the gas-tight casing and form a gas-tight seal that prevents passage of gas through the opening in the gas-tight casing and through the recess in the feedthrough connector; A method comprising:

15. The method of claim 14 , wherein the at least one gas is an inert gas.

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