Electrically conducting device for bolted connections, and methods thereof

Abstract

Embodiments relate to electrically conducting device for connecting or joining two or more conductors, such as busbars, are disclosed. The electrically conducting device comprises an insulating component and an electrically conductive component. The electrically conductive component is positioned at least partially within at least a portion of the insulating component. Methods of using and manufacturing the electrically conducting device are also described.

Description

ELECTRICALLY CONDUCTING DEVICE FOR BOLTED CONNECTIONS, ANDMETHODS THEREOFINCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet or PCT Request as filed with the present application are hereby incorporated by reference under 37 CFR 1.57, and Rules 4.18 and 20.6. The present application claims priority to U.S. Provisional Patent Application Nos. 63 / 559,702, filed February 29, 2024 and 63 / 561,643, filed March 5, 2024, the disclosures of which are incorporated herein by reference in their entirety and for all purposes.BACKGROUNDField

[0002] The present invention relates to an electrically conducting device for joining or connecting two or more conductors. More specifically, the present invention relates to an electrically conducting device for joining two or more busbars.Description of the Related Art

[0003] Energy storage devices such as batteries can be stacked and / or connected to provide large energy storage. The energy storage devices are stacked and connected by busbars to carry high current among the energy storage devices. The busbars are normally solid metal bars made from aluminum, aluminum alloys, copper, or copper alloys, which are joined by bolts. However, aluminum oxide is easily formed on the surface of the aluminum and / or aluminum alloys in the air, which may cause durability problems for busbars joined with bolts. A current solution is to plate a layer of nickel and tin to avoid the formation of aluminum oxide. However, the plating process is expensive, hazardous and complex. Another concern for joining the busbars in the field is that the joint section of the busbars may be corroded at an elevated working temperature in air. A current solution is to use a sealant paint to seal the joint section of the busbars. However, the sealant paint is in a form of a gel, which is messy, sticky, and difficult to use (e.g., in mass production settings involving manual assembly operations such as bolting busbar joints). In addition, the sealant paint may not properly cover the jointsection when the busbars are vertically placed and joined. Thus, advances may aid in manufacturing and using the busbars made from aluminum.SUMMARY

[0004] For purposes of summarizing the disclosure and the advantages achieved over the prior art, certain objects and advantages of the disclosure are described herein. Not all such objects or advantages may be achieved in any particular embodiment. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0005] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.

[0006] In a first aspect, an electrically conducting device is disclosed. The electrically conducting device comprises an electrically conductive component comprising an electrical conductivity of at least about 60% IACS and a tensile strength of at least about 400 MPa, and an insulating component comprising an elongation at break of at least about 200%. In some embodiments, the electrically conductive component is positioned at least partially within at least a portion of the insulating component.

[0007] In some embodiments, at least a portion of the insulating component encases at least a portion of the electrically conductive component. In some embodiments, the electrically conductive component comprises a softening temperature of at least about 400°C. In some embodiments, the insulating component encases the whole electrically conductive component. In some embodiments, the insulating component encases substantially all of the electrically conductive components. In some embodiments, the electrically conducting device further comprises a pressure sensitive adhesive (PSA) material. In some embodiments, the PSA material is perforated. In some embodiments, the electrically conducting device further comprises a bilayer tape. In some embodiments, the insulating component comprises amechanical atachment element. In some embodiments, the electrically conductive component comprises a shape of a ring. In some embodiments, a height of a cross-section of the insulating component is about 1.1 to 1.6 times of a height of a cross-section of the electrically conductive component. In some embodiments, a cross-sectional shape of the electrically conductive component is selected from the group consisting of a circular shape, an oval shape, a square shape, a rectangular shape, a triangular shape, a star shape, and combinations thereof. In some embodiments, the electrically conductive component comprises an alloy. In some embodiments, the electrically conductive component comprises a Cu-Zr alloy, a Cu-Cr alloy, or a Cu-Zr-Cr alloy. In some embodiments, the electrically conductive component comprises a coating. In some embodiments, the electrically conductive component comprises a thinner section with a smaller vertical cross section compared to that of another section of the electrically conductive component. In some embodiments, an insulating material of the insulating component comprises a silicone resin. In some embodiments, the insulating component comprises a Shore A hardness of about 30 to about 60. In some embodiments, the insulating component comprises a working temperature of about -50°C to about 150°C. In some embodiments, the insulating component comprises a tensile storage modulus of less than about 400 MPa at or above -40°C. In some embodiments, the insulating component is capable of withstanding a force of about 1000N without breaking.

[0008] In another aspect, a method of using an electrically conducting device is disclosed. The method of using the electrically conducting device comprises attaching the electrically conducting device to a surface of a first conductor, and fastening a second conductor to the first conductor wherein the electrically conducting device is disposed therebetween such that the electrically conductive component breaks through at least a portion of the insulating component and thereby contacts both the first and second conductors.

[0009] In some embodiments, the first and second conductors comprise a busbar. In some embodiments, the electrically conducting device is reusable. In some embodiments, fastening the second conductor to the first conductor results in the electrically conductive component indenting both the first and second conductors. In some embodiments, fastening the second conductor to the first conductor results in applying a force of at least about 1000N to the electrically conducting device.

[0010] In another aspect, an electrically connected busbar system is disclosed. The electrically busbar system comprises an electrically conducting device positioned between a first busbar and a second busbar, and a fastener connecting the first and second busbars through a fastening mechanism. In some embodiments, the electrically conducting device is adjacent to the fastening mechanism and in contact with each of the first and second busbars. In some embodiments, the fastener comprises a bolt. In some embodiments, the electrically conductive component is sealed by the insulating component, first busbar and second busbar.

[0011] In another aspect, a method of manufacturing an electrically conducting device is disclosed. The method of manufacturing the electrically conducting device comprises positioning an electrically conductive material at least partially within at least a portion of an insulating component. In some embodiments, the electrically conductive material comprising an electrical conductivity of at least about 60% IACS and a tensile strength of at least about 400 MPa. In some embodiments, the insulating component comprises an elongation at a break of at least about 200%.

[0012] In some embodiments, positioning the electrically conductive material at least partially within at least a portion of an insulating component comprises positioning the electrically conductive material within a mold injecting an insulating material precursor into the mold, and curing the insulating material precursor to form the insulating component and thereby forming an electrically conducting device.

[0013] In some embodiments, positioning the electrically conductive material at least partially within at least a portion of the insulating component comprises positioning the electrically conductive material between a first insulating material sheet and a second insulating material sheet. In some embodiments, the method of manufacturing the electrically conducting device further comprises laminating the first and second insulating material sheets to form the insulating component.

[0014] In some embodiments, a first pressure sensitive adhesive (PSA) layer is positioned between the second insulating material sheet and the electrically conductive material. In some embodiments, the electrically conductive material is unmachined. In some embodiments, the electrically conductive material comprises an extruded wire. In some embodiments, the electrically conductive material is cold worked to achieve a tensile strength of at least about 400 MPa. In some embodiments, the method of manufacturing the electricallyconducting device further comprises coating the electrically conductive material. In some embodiments, coating comprises coating the electrically conductive material with nickel. In some embodiments, the method of manufacturing the electrically conducting device further comprises disposing a second PSA layer on a surface of the electrically conducting device.

[0015] In another aspect, a method of manufacturing an electrically conducting device is disclosed. The method of manufacturing the electrically conducting device comprises positioning an electrically conductive material within a mold, injecting an insulating material precursor into the mold, and curing the insulating material precursor to form an insulating component and thereby forming an electrically conducting device. In some embodiments, at least a portion of the insulating component encases at least a portion of the electrically conductive material.

[0016] In another aspect, a method of manufacturing an electrically conducting device is disclosed. The method of manufacturing the electrically conducting device comprises positioning an electrically conductive material between a first insulating material sheet and a second insulating material sheet, and laminating the first and second insulating material sheets to form an insulating component. In some embodiments, at least a portion of the insulating component encases at least a portion of the electrically conductive material.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1A schematically illustrates a vertical cross section of the electrically conducting device before joining the conductors, according to some embodiments.

[0018] FIG. IB schematically illustrates a vertical cross section of the electrically conducting device after force is applied to the conductors when joining the conductors, according to some embodiments.

[0019] FIGS. 2A-2C schematically illustrate some examples of the vertical cross section of the electrically conductive component.

[0020] FIG. 3 schematically illustrates a section of the electrically conducting device having a pinched section, according to some embodiments.

[0021] FIG. 4 schematically illustrates the perspective view of a vertical cross section of an electrically conducting device, according to some embodiments.

[0022] FIG. 5 schematically illustrates the exploded view of an electrically conducting device.

[0023] FIG. 6 schematically illustrates a conductor system using an electrically conducting device to connect two conductors.

[0024] FIG. 7 schematically illustrates a top-down view of an electrically conducting device on a conductor according to some embodiment.

[0025] FIG. 8 schematically illustrates an electrically conducting device having an insulating component comprising compression features, according to some embodiment.

[0026] FIG. 9A schematically illustrates a perspective view of an electrically conducting device with a mechanical attachment component, according to some embodiments.

[0027] FIG. 9B schematically illustrates a vertical cross-section view of an electrically conducting device with a mechanical attachment component, according to some embodiments.

[0028] FIG. 10A schematically illustrates an exploded view of an electrically conducting device, according to some embodiments.

[0029] FIGS. 10B-10D schematically illustrate a method of using an electrically conducting device, according to some embodiments.

[0030] FIG. 11 illustrates a process for manufacturing the electrically conducting device, according to some embodiments.

[0031] FIG. 12 illustrates a process for manufacturing the electrically conducting device, according to some embodiments.

[0032] FIG. 13 A schematically illustrates the arrangement of different layers before lamination, according to some embodiments.

[0033] FIG. 13B schematically illustrates the configuration of the electrically conducting device after lamination, according to some embodiments.

[0034] FIG. 13C schematically illustrates an electrically conducting device manufactured by the lamination process used in a conductor system, according to some embodiments.

[0035] FIG. 14 is a graph of the contact resistance for Cu metal and Cu-Zr alloy wires tested at 130°C over time according to some embodiments.

[0036] FIG. 15 is a graph of the tensile strength of an insulating material SI tested at various temperatures according to some embodiments.

[0037] FIG. 16A shows an image of the electrically conducting device after joining and disassembling the conductors according to some embodiments.

[0038] FIG. 16B shows an image of the indentation formed on the surface of a conductor after joining and disassembling the conductors according to some embodiments.DETAILED DESCRIPTION

[0039] The present disclosure may be understood by reference to the following detailed description. It is noted that, for purposes of illustrative clarity, certain elements in various drawings may not be drawn to scale, may be represented schematically or conceptually, or otherwise may not correspond exactly to certain physical configurations of embodiments.

[0040] The electrically conducting devices described may be useful for connecting conductors and carrying current with high current density, such as for connecting busbars for stacking energy storage devices. Advantageously, such electrically conducting devices are easy to manufacture, easy to install and use, capable of working properly in the field at elevated temperatures or in a cold environment, capable of being reused, and / or can help decrease the cost of manufacturing and utilizing busbars (e.g., by eliminating and / or reducing the need for plating busbars). It may also help seal the joint section of the busbars to avoid corrosion.A. Electrically Conducting Device

[0041] The electrically conducting device may be used to electrically connect two or more conductors, such as two or more busbars. In some embodiments, the conductors may have a flat surface in contact with the electrically conducting device. In some embodiments, the conductors are unplated or unpainted. In some embodiments, the conductor comprises a layer of oxide on the surface of the conductor. In some embodiments, the conductors comprise aluminum, copper, or combinations thereof. In some embodiments, one of the two conductors in contact with one electrically conducting device comprises aluminum and the other of the two conductors comprises copper. In some embodiments, both of the two conductors in contact with one electrically conducting device comprise aluminum. In some embodiments, both of the two conductors in contact with one electrically conducting device comprise copper.In some embodiments, the two conductors are joined by fastening, such as bolting, crimping, adhesive bonding, compression couplers, welding, hydraulic press or any other appropriate method. In some embodiments, the fastening mechanism comprises bolting. In some embodiments, the bolts comprise a dimension of about 5 mm to 50 mm. In some embodiments, the electrically conducting device is positioned between two conductors and adjacent the fastening mechanism when in use. In some embodiments, electrically conducting device can conduct an electrical current from one conductor to the other conductor through the electrically conducting device after the two conductors are joined. In some embodiments, the electrical resistance of the conductor system including the two conductors with the electrically conducive component therebetween is, is about, is at most, or is at most about, 200 p , 180 p , 150 p , 130 p , 120 p , 110 p , 100 p , 90 p , 80 p , 70 p , 60 p , 50 p , 40 p , 30 p , 20 p , 10 p , 5 p , or any range of values therebetween.

[0042] In some embodiments, an electrically conducting device comprises an electrically conductive component and an insulating component. In some embodiments, the electrically conductive component is positioned at least partially within at least a portion of the insulating component. In some embodiments, at least a portion of the insulating component encases at least a portion of the electrically conductive component. In some embodiments, the insulating component is configured to insulate the electrically conductive component before being properly assembled and used to connect two or more conductors, such as busbars. In some embodiments, when in use, at least a portion of the insulating component is configured to break such that the electrically conductive component is configured to be in contact with the two conductors. In some embodiments, the electrically conductive component is positioned within the insulating component such that the insulating component encases the electrically conductive component. In some embodiments, the insulating component completely covers the outer surface of the electrically conductive component such that the entire outer surface of the electrically conductive component is in contact with the insulating component. In some embodiments, a surface of the electrically conductive component is exposed from the insulating component. The insulating component may be understood to “encase” the electrically conductive component when the insulating component covers or substantially covers the outer surface of the electrically conductive component such that the electrically conducting device is not able to electrically conduct current through conductors without a forcebeing applied. The insulating component may be understood to “at least partially encase” the electrically conductive component when at least a vertical cross section of the electrically conductive component is encased by the insulating component.

[0043] FIG. 1A schematically illustrates a portion of a vertical cross-section of an electrically conducting device 100A before a force is applied to the electrically conducting device 100A by joining the two conductors. FIG. IB schematically illustrates the deformation and breakage of the insulating component of the electrically conducting device 100B after a force is applied to the electrically conducting device 100B by joining the two conductors 106 A and 106B. The vertical cross section shown in FIGS. 1 A and IB are the vertical cross sections where the insulating component encases the electrically conductive component of the electrically conducting device 100A and 100B. As illustrated in FIG. 1 A, when the electrically conducting device 100A is free standing or when the electrically conducting device 100A is placed between two conductors but before the conductors are joined, no force or a limited amount of force is applied to the electrically conducting device 100A such that the insulating component 104 is not deformed, and the electrically conductive component 102 is encased within the insulating component, and its surfaces are completely covered by the insulating component 104. As illustrated in FIG. IB, when the conductors 106A and 106B are joined with the electrically conducting device 100B positioned therebetween, forces are applied on the upper and lower surfaces of the insulating component 104 such that the insulating component 104 is compressed and deformed to form an outer insulating component 104A and an inner insulating component 104B with the electrically conductive component 102 separating the outer insulating component 104A from the inner insulating component 104B and contacting the two conductors 106A and 106B. As schematically illustrated in FIG. IB, the electrically conductive component 102 cuts into and indents the conductors 106A and 106B.

[0044] In some embodiments, the electrically conductive component comprises a yield strength higher than the yield strength of the insulating component and / or the yield strength of the conductors, such that the electrically conductive component may cut through the insulating component. In some embodiments, the insulating component breaks after certain elongation or compression. In some embodiments, the insulating component breaks at the place where the vertical thickness of the insulating component between the electrically conducting component and the conductor is the thinnest.

[0045] In some embodiments, after breakage of the insulating component, with applied force by joining the conductors, the electrically conductive component contacts, cuts against and indents the surface of the conductor through the broken insulating component as the yield strength of the electrically conducting component is higher than that of the conductor. In some embodiments, the electrically conductive component is configured to indent and / or cut through the oxide layer on the surface of the conductor. For example, an aluminum oxide layer may be formed on the conductor when the conductor is made from aluminum or aluminum alloys, and the electrically conductive component can cut through the aluminum oxide layer and be in contact with the aluminum metal or aluminum alloy under the aluminum oxide layer, such that a highly conductive path is formed for electrons between the conductors and the electrically conductive component. In some embodiments, the electrically conductive component is configured to indent and / or cut into the conductor by, by about, by at least, or by at least about, 1pm, 5pm, 10pm, 20pm, 30pm, 40pm, 50pm, 75pm, 100pm, 150pm, 200pm, 250pm, 300pm, 400pm or 500pm, or any range of values therebetween. For example, in some embodiments, the electrically conductive component is configured to indent and / or cut into the conductor for about 1 pm to about 500pm, about 1 pm to about 400pm, about 1 pm to about 300pm, about 1pm to about 200pm, about 1pm to about 100pm, about 5pm to about 200pm, about 5pm to about 100pm, about 10pm to about 200pm, about 10pm to about 100pm, about 10pm to about 50pm in depth, or any other ranges therebetween.

[0046] In some embodiments, the electrically conducting device can be taken out after the two conductors are dissembled. In some embodiments, the electrically conducting device may be reused for 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, 50, 100 times, or any values therebetween. In some embodiments, the working temperature for the electrically conducting device is, is about, is at least, or is at least about, 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, 160°C, 170°C, 180°C, 190°C, 200°C, or any range of values therebetween. Thus, the electrically conducting device and each of its component is capable of working at an elevated temperature range.

[0047] In some embodiments, the electrically conductive component comprises an electrically conductive material. In some embodiments, the electrically conductive component and / or material comprises a material that has a high electrical conductivity and high thermal stability. In some embodiments, the electrically conductive component and / or material is creepresistant at an elevated working temperature. In some embodiments, the thermal stability of the electrically conductive component and / or material is indicated by the softening temperature of the electrically conductive component and / or material. The softening temperature may be measured by annealing the material at an elevated temperature for a period of time, such as an hour, and then measuring the hardness of the material after cooling the material to the room temperature. The elevated temperature is the softening temperature if the measured hardness is or less than about 80% of the hardness of the material without the annealing. In some embodiments, the electrical conductive component and / or material comprises a softening temperature of, of about, of at least, or of at least about 300°C, 310°C, 320°C, 330°C, 340°C, 350°C, 360°C, 370°C, 380°C, 390°C, 400°C, 410°C, 420°C, 430°C, 440°C, 450°C, 460°C, 470°C, 480°C, 490°C, 500°C, 510°C, 520°C, 530°C, 540°C, 550°C, 560°C, 570°C, 580°C, 590°C, 600°C, 650°C, and any range of values therebetween.

[0048] In some embodiments, the electrically conductive component and / or material comprises an electrical conductivity of, of about, of at least, or of at least about, 20% IACS, 21% IACS, 22% IACS, 23% IACS, 24% IACS, 25% IACS, 26% IACS, 27% IACS, 28% IACS, 29% IACS, 30% IACS, 31% IACS, 32% IACS, 33% IACS, 34% IACS, 35% IACS, 36% IACS, 37% IACS, 38% IACS, 39% IACS, 40% IACS, 45% IACS, 50% IACS, 55% IACS, 60% IACS, 65% IACS, 70% IACS, 75% IACS, 80% IACS, 85% IACS, 90% IACS, 95% IACS, 100% IACS at 20°C, or any range of values therebetween.

[0049] In some embodiments, the electrically conductive component and / or material comprises a yield or tensile strength of, of about, of at least, or of at least about, 200MPa, 210MPa, 220MPa, 230MPa, 240MPa, 250MPa, 260MPa, 270MPa, 280MPa, 290MPa, 200MPa, 310MPa, 320MPa, 330MPa, 340MPa, 350MPa, 360MPa, 370MPa, 380MPa, 390MPa, 400MPa, 450MPa, 500MPa, 550MPa, 600MPa, 700MPa, or any range of values therebetween. In some embodiments, the electrically conductive material is cold worked to achieve a high yield or tensile strength. In some embodiments, the tensile strength and / or the hardness of the electrically conductive component and / or material is at least larger than that of the conductors to be connected, such that the electrically conductive component and / or material is capable of indenting the conductors to break through the oxide layer on the surface of the conductor.

[0050] In some embodiments, the electrically conductive material comprises a metal. In some embodiments, the electrically conductive material comprises an alloy. In some embodiments, the electrically conductive material comprises a metal selected from Cu, Al, Co, Ni, Si, Be, Mg, Sn, Cr, Zr, Ti, Fe, P, Ag, Cd, and combinations thereof. In some embodiments, the electrically conductive material comprises a copper alloy, an aluminum alloy, and combinations thereof. In some embodiments, the alloy comprises an additive in an amount of, of about, of at most, or of at most about, 40%, 30%, 20%, 10%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.3%, 0.2%, 0.1%, 0.50 %, 0.45 %, 0.4%, 0.35%, 0.2%, 0.15%, 0.1%, 0.05% or 0.01% by weight, or any range of values therebetween. In some embodiments, the additive in the alloy comprises Co, Ni, Si, Be, Mg, Sn, Cr, Zr, Ti, Fe, P, Ag, Cd, and combinations thereof.

[0051] In some embodiments, the electrically conductive material comprises a Cu- Zr alloy, a Cu-Cr alloy, a Cu-Cd alloy, a Cu-Be alloy, a Cu-Cr-Zr alloy, or any other copper alloy. In some embodiments, the copper alloy comprises Cl 5000 alloy, C16200 alloy, C17510 alloy, Cl 8150 alloy, Cl 8200 alloy, etc.

[0052] In some embodiments, the electrically conductive material comprises a Cu- Zr alloy comprising Zr in an amount of, or of about, of at most, of at most about, of at least, or of at least about 0.01 wt.%, 0.02 wt.%, 0.03 wt. %, 0.04 wt. %, 0.05 wt. %, 0.06 wt. %, 0.07 wt. %, 0.08 wt. %, 0.09 wt. %, 0.1 wt. %, 0.11 wt. %, 0.12 wt. %, 0.13 wt. %, 0.14 wt. %, 0.15 wt. %, 0.16 wt. %, 0.17 wt. %, 0.18 wt. %, 0.19 wt. %, 0.2 wt. %, 0.21 wt. %, 0.22 wt. %, 0.23 wt. %, 0.24 wt. %, 0.25 wt. %, 0.26 wt. %, 0.27 wt. %, 0.28 wt. %, 0.29 wt. %, 0.3 wt. %, 0.35 wt. %, 0.4 wt. %, 0.45 wt. %, 0.5 wt. % of the Cu-Zr alloy, or any values therebetween. In some embodiments, the electrically conductive material consists of, or consists essentially of Cu and Zr. In some embodiments, the electrically conductive material comprises a Cu-Zr alloy including about 0.25wt% Zr and / or has a softening temperature higher than about 500°C.

[0053] In some embodiments, the electrically conductive material comprises a Cu- Cr alloy comprising Cr in an amount of, or of about, of at most, of at most about, of at least, or of at least about 0.1 wt. %, 0.11 wt. %, 0.12 wt. %, 0.13 wt. %, 0.14 wt. %, 0.15 wt. %, 0.2 wt. %, 0.3 wt. %, 0.4 wt. %, 0.5 wt. %, 0.6 wt. %, 0.7 wt. %, 0.8 wt. %, 0.9 wt. %, 1 wt. %, 1.1 wt. %, 1.2 wt. %, 1.3 wt. %, 1.4 wt. %, 1.5 wt. %, 2 wt. % of the Cu-Cr alloy, or any values therebetween. In some embodiments, the electrically conductive material consists of, or consists essentially of Cu and Cr. In some embodiments, the electrically conductive materialcomprises a Cu-Cr alloy including more than about 0.5 wt. % Cr and / or has a softening temperature higher than about 500°C.

[0054] In some embodiments, the electrically conductive material comprises a Cu- Cr-Zr alloy comprising Cr and Zr. In some embodiments, the total amount of Cr and Zr is, is about, is at most, is at most about, is at least, or is at least about 0.05 wt. %, 0.1 wt. %, 0.2 wt. %, 0.3 wt. %, 0.4 wt. %, 0.5 wt. %, 0.6 wt. %, 0.7 wt. %, 0.8 wt. %, 0.9 wt. %, 1 wt. %, 1.1 wt. %, 1.2 wt. %, 1.3 wt. %, 1.4 wt. %, 1.5 wt. %, 2 wt. % of the Cu-Cr-Zr alloy, or any values therebetween. In some embodiments, the electrically conductive material consists of, or consists essentially of Cu, Zr and Cr.

[0055] In some embodiments, the electrically conductive material comprises a metal-metal oxide composite. In some embodiments, the electrically conductive material comprises Cu-AhCh composite.

[0056] In some embodiments, the electrically conductive component comprises a coating. In some embodiments, the coating is formed on the surface of the electrically conductive material. In some embodiments, the coating is a metal selected from gold, nickel, silver, zinc, tin, or combinations thereof. In some embodiments, the coating consists of one pure metal. In some embodiments, the coating of the electrically conductive component does not comprise organic additives. In some embodiments, the coating of the electrically conductive component does not comprise brighteners, hardeners, and / or a combination thereof. In some embodiments, the electrically conductive material is coated to produce a pristine wire surface free of oxides and / or organic matters. In addition, the coating on the electrically conductive material may also prevent formation of intermetallic copper and aluminum at the interface which are low in electrical conductivity. In some embodiments, the coating of the electrically conductive component may be formed with electrolytic plating, electroless plating, physical vapor deposition, or combinations thereof. In some embodiments, the coating of the electrically conductive component comprises a thickness of, of about, of at most, or of at most about, 0.1 pm, 0.2 pm, 0.3 pm, 0.4 pm, 0.5 pm, 0.6 pm, 0.7 pm, 0.8 pm, 0.9 pm, 1 pm, 1.1 pm, 1.2 pm, 1.3 pm, 1.4 pm or 1.5 pm, or any range of values therebetween.

[0057] In some embodiments, electrically conductive component comprises any shape such that the electrically conductive component can or can at least partially surrounds the fastening mechanisms of the conductor for joining the conductors. In some embodiments,the electrically conductive component comprises a ring shape, including but not limited to a circular ring, a D-shaped ring, an oval ring, a heart-shaped ring, a square ring, a rectangular ring, a triangular ring, an irregular shape ring, or any other ring shapes that could at least partially surround the fastening mechanisms for joining the conductors. In some embodiments, the ring shape is a closed ring shape. In some embodiments, the ring shape is an incomplete ring and includes a gap. In some embodiments, the largest dimension of the electrically conductive component is, is about, is at least, or is at least about 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 150 mm or 200 mm, or any range of values therebetween. For example, in some embodiments, the largest dimension of the electrically conductive component is about to 5 to about 100 mm, about to 10 to about 100 mm, about to 15 to about 100 mm, about to 20 to about 100 mm, about to 25 to about 100 mm, about to 30 to about 100 mm, about to 35 to about 100 mm, about to 40 to about 100 mm, about to 5 to about 90 mm, about to 5 to about 80 mm, about to 5 to about 70 mm, about to 5 to about 60 mm, about to 5 to about 50 mm, about to 10 to about 50 mm, or any ranges therebetween. In some embodiments, the largest dimension of the electrically conductive component is at least larger than the dimension of the joining mechanism for joining the conductors. A largest dimension refers to the greatest measurement between two points on the object, such as the longest length, width, height, or diagonal of an object, depending on its shape and orientation. For example, the largest dimension of the circular ring-shaped electrically conductive component is the outer diameter of the circular ring.

[0058] In some embodiments, a vertical cross-section of the electrically conductive component comprises a circular shape, an oval shape, a square shape, a rectangular shape, a triangular shape, a star shape, or combinations thereof. In some embodiments, the vertical cross-section of the insulating component is selected from the group consisting of circular shape, an oval shape, a square shape, a rectangular shape, a triangular shape, a star shape, and combinations thereof. FIGS. 2 A and 2B illustrate some examples of the vertical cross section of the electrically conductive component. A vertical cross section refers to the cross section of the object cut in a direction perpendicular to the ground when the object is placed parallel to the ground. In some embodiments, the vertical cross section of the electrically conductive component comprises a largest dimension of, of about, of at least, or of at least about, 0.1 mm,0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.2 mm, 1.5 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm, or any range of values therebetween. For example, in some embodiments, the vertical cross section of the electrically conductive component comprises a largest dimension of about 0.1 mm to about 5 mm, about 0.2 to about 5 mm, about 0.3 to about 5 mm, about 0.4 to about 5 mm, about 0.5 to about 5 mm, about 0.6 to about 5 mm, about 0.7 to about 5 mm, about 0.8 to about 5 mm, about 0.9 to about 5 mm, about 1 to about 5 mm, about 0.5 to about 4 mm, about 0.5 to about 3 mm, about 0.5 to about 2 mm, or any ranges therebetween.

[0059] In some embodiments, the electrically conductive component comprises a uniform vertical cross section and / or largest dimension along the electrically conductive component. In some embodiments, the electrically conductive component comprises different vertical cross sections and / or different largest dimension of the vertical cross section along the electrically conductive component. In some embodiments, the electrically conductive component comprises one or more pinched sections that comprises a smaller vertical cross section. In some embodiments, the pinched section of the electrically conductive component would not be able to cut through the insulating component around that section when the two conductors are joined, allowing the inner and outer portions of the insulating component to remain connected after the electrically conductive component cuts through the other sections of the insulating component. FIG. 3 schematically illustrates a section of the electrically conducting device 300 comprising an insulating material 304 and an electrically conductive component 302 having a pinched section 308. As illustrated in FIG. 3, the electrically conductive component 302 comprises a pinched section 308 with a thickness of T2 and a normal section 306 with a thickness Tl, wherein T2 is less than Tl.

[0060] In some embodiments, the insulating component comprises an insulating material. In some embodiments, the insulating material is electrically insulating. In some embodiments, the insulating component and / or material comprises a high thermal stability. In some embodiments, the insulating component and / or material comprises a Shore A hardness of, of about, of at most, or of at most about, 20, 25, 30, 35, 40, 50, 60, 70, or 80, or any range of values therebetween. In some embodiments, the insulating component and / or material comprises an elongation at break of, of about, of at least, or of at least about, 150%, 160%, 170%, 180%, 190%, 200%, 210%, 220%, 230%, 240%, 250%, 260%, 270%, 280%, 290%,300%, 350%, 400%, 450%, 500%, 550%, 600%, 650%, 700%, 800%, or any range of values therebetween. The elongation at break is defined as the ratio between changed length and initial length after breakage of the test specimen. In some embodiments, the insulating component and / or material is configured to break after being compressed, sheared, or torn to a certain level. In some embodiments, the insulating component and / or material is capable of withstanding of a force of, of about, of at least, or of at least about, 1000N, 1100N, 1200N, BOON, MOON, 1500N, 1600N, 1700N, 1800N, 1900N, 2000N, or any range of values therebetween, without breaking. In some embodiments, the insulating component and / or material breaks after applying a force of, of about, of at least, or of at least about, 1000N, 1100N, 1200N, BOON, 1400N, MOON, I 600N, 1700N, BOON, BOON, 2000N, or any range of values therebetween, to the insulating component and / or material.

[0061] In some embodiments, the insulating component and / or material can function properly at a temperature of, of about, of at least, or of at least about, 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, 160°C, 170°C, 180°C, 190°C, 200°C, or any range of values therebetween. In some embodiments, the insulating component and / or material can function properly and remain flexible at a temperature of, of about, of at most, or of at most about, 0°C, -10°C, -20°C, -30°C, -40°C, -50°C, -60°C, or any range of values therebetween. In some embodiments, the insulating component and / or material has a working temperature of, of about, of at least, of at least about, of at most about, or of at most, -60°C, -50°C, -40°C, -30°C, -20°C, -10°C, 0°C, 10°C, 20°C, 30°C, 40°C, 50°C, 75°C, 100°C, 150°C, 200°C, 250°C, or 300°C, or any range of values therebetween. In some embodiments, the insulating component and / or material stays consistently soft within the working temperature ranges. In some embodiments, the insulating component and / or material comprises a storage modulus of, of about, of at most about, or of at most, 1 OMPa, 9MPa, 8MPa, 7MPa, 6 MPa, 5 MPa, 4 MPa, 3 MPa, or any range of values therebetween, within the working temperature range, even as low as -60°C, -50°C, -40°C, -30°C, -20°C, -10°C, or 0°C. In some embodiments, the storage modulus of the insulating component and / or material stays stable or substantially stable above or above about 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, 160°C, 170°C, 180°C, 190°C, 200°C, or any range of values therebetween.

[0062] In some embodiments, the insulating component and / or material may be compressed by, by about, by at least, or by at least about, 10%, 20%, 30%, 40%, 50%, 60%,70%, 80%, or 90% in thickness, or any range of values therebetween. For example, in some embodiments, the insulating component and / or material may be compressed by about 10% to about 80%, about 10% to about 70%, about 10% to about 60%, about 10% to about 50%, or about 10% to about 40%, in thickness. Such deformation of the insulating component creates an air-tight seal around the electrically conductive component and the air-tight seal can protect the electrically conductive component from oxygen, dust, water, salts, pollutants or any other substances in the air that may attack the interface or lower the conductance between the electrically conductive component.

[0063] In some embodiments, the insulating component and / or material comprises a shore A hardness of about 30 to 60 and / or an elongation at break of at least about 200% at a temperature of at least about 150°C and / or at a temperature of at least about -40°C. In some embodiments, the insulating material does not allow or substantially does not allow the passage of a liquid, such as water, salt, dust, and gas, such as oxygen.

[0064] In some embodiments, the insulating material comprises an elastomer. In some embodiments, the insulating material comprises a silicone resin, fluorosilicone, polytetrafluoroethylene (PTFE), ethylene-propylene, hydrogenated nitrile, fluorocarbon elastomer, or combinations thereof. In some embodiments, the insulating material is Silopren™ silicone rubber.

[0065] In some embodiments, the shape of the insulating component may be any shape that can at least partially encase the electrically conductive component. In some embodiments, the top-down view of the insulating component may be a ring shape with a band width. In some embodiments, the band width can accommodate the electrically conductive component. In some embodiments, the outside diameter of the band width is at least larger than the largest dimension of the electrically conductive component. In some embodiments, the band width is, is about, is at least, or is at least about, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 50 mm, 60 mm, 80 mm, or 100 mm, or any range of values therebetween. For example, in some embodiments, the band width is about 5 mm to about 50 mm, about 5 mm to about 40 mm, about 5 mm to about 30 mm, about 5 mm to about 20 mm, or any ranges therebetween. In some embodiments, the width of the insulating component depends at least partially on the width of the electrically conductive component.

[0066] In some embodiments, the insulating component comprises a top surface and a bottom surface. In some embodiments, the top and bottom surfaces are parallel or substantially parallel to each other. In some embodiments, the top surface and / or the bottom surface is flat or substantially flat. In some embodiments, each of the top surface and the bottom surface is configured to be in contact with a surface of a conductor, such as a busbar. In some embodiments, the insulating component comprises a top surface and a bottom surface that are curved and / or angled, but can still accommodate conductors with flat surfaces. In some embodiments, the top surface and / or the bottom surface may comprise a gap, opening, and / or void. In some embodiments the top surface and / or the bottom surface may comprise a gap, opening, and / or void that leads to and / or forms part of the conductive component chamber for housing the electrically conductive component. In some embodiments, the opening is directly above the electrically conductive component and / or the conductive component chamber. In some embodiments, the opening comprises an opening depth that separates the electrically conductive component from the top surface, thereby preventing contact with the surface of a conductor before two conductors are joined together because the thickness of the insulating component is larger than the diameter or height of the vertical cross section of the electrically conductive component such that there is a gap between the electrically conductive component and a surface of the conductor.

[0067] In some embodiments, the thickness of the insulating material is configured to result in a, an about, an at least, or an at least about, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, or 60% compression, or any range of values therebetween. For example, in some embodiments, the thickness of the insulating component is configured to result in about 10% to about 50%, more preferably, 20% to 30% compression in thickness. In some embodiments, before compression or applying a force, the thickness of the insulating component is, is about, is at least, or is at least about, 1 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2 mm, 2.5 mm, 3 mm, 4 mm, 5 mm, 6 mm, 8 mm or 10 mm, or any range of values therebetween. For example, in some embodiments, the thickness of the insulating component before compression is about 1 mm to about 2 mm, about 1.1 mm to about 2 mm, about 1.2 mm to about 2 mm, about 1.3 mm to about 2 mm, about 1 mm to about 1.9 mm, about 1 mm to about 1.8 mm, about 1 mm to about 1.7 mm, about 1 mm to about 1.6 mm, about 1 mm to about 1.5 mm, about 1 mm to about 1.4 mm, about 1.1 mm to about 1.5 mm,about 1.2 mm to about 1.5 mm, about 1.2 mm to about 1.4 mm, or any ranges therebetween. In some embodiments, the thickness or height of the vertical cross-section of the insulating component is, is about, is at least, or is at least about, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.5 or 3 times of the thickness or height of the vertical cross-section of the electrically conductive component, or any range of values therebetween. For example, in some embodiments, the thickness or height of the vertical cross-section of the insulating component is about 1.1 to 2 times, about 1.2 to 2 times, about 1.3 to 2 times, about 1.4 to 2 times, about 1.1 to 1.9 times, about 1.1 to 1.8 times, about 1.1 to 1.7 times, about 1.1 to 1.6 times, about 1.1 to 1.5 times of the height of the vertical cross-section of the electrically conductive component.

[0068] In some embodiments, the electrically conducting device may be attached to a conductor by an adhesive layer. In another embodiment, the electrically conducting device may be attached to a conductor by a mechanical attachment portion. Either the adhesive or the mechanical attachment component in the electrically conducting device ensures that the electrically conducting device can be easily attached to a conductor in a correct position and will not fall off from the conductor even when the conductor surfaces being joined with the electrically conductive device is perpendicular to or is facing the ground.1. Electrically Conducting Device with Adhesive Attachment

[0069] In some embodiments, electrically conductive device is attached to a conductor by an adhesive.

[0070] FIG. 4 schematically illustrates a perspective view of a cross section of an electrically conducting device 400. The electrically conducting device 400 comprises an electrically conductive component 402 positioned within and fully encased within an insulating component 404. The electrically conductive component 402 is in the shape of a circular wire, and the insulating component 404 is in the shape of a donut ring, wherein a void exists at the center of the insulating component 404. An adhesive material 406 is disposed directly over a top surface 412 of the insulating component 404.

[0071] FIG. 5 schematically illustrates the exploded view of the electrically conducting device 500. The electrically conducting device 500 includes an insulating component 504. The insulating component 504 includes a bottom surface 510, a top surface 512 and a conductive component chamber 508 between the bottom surface 510 and the topsurface 512. The insulating component 504 is in the shape of a flat ring, wherein a void exists at the center of the insulating component 504. The electrically conductive component 502 is a circular wire formed into a ring shape, and fits within the conductive component chamber 508. An adhesive material 506 is disposed directly over the top surface 512 of the insulating component 504.

[0072] FIG. 6 schematically illustrates a conductor system 600 using an electrically conducting device 601 to connect two conductors 603 and 605. The electrically conducting device 601 includes an electrically conductive component 602 disposed within an insulating component 604. The electrically conducting device 601 is positioned between two conductors 603 and 605. In some embodiments, the electrically conducting device 601 may share similarities to the electrically conducting devices 100A, 100B, 300, 400 and 500 of FIGS. 1 A, IB, 3, 4 and 5, respectively. In some embodiments, the electrically conducting device 601 is configured to conduct an electric current between the two conductors 603 and 605 once the bolt 606 and nut 608 are tightened such that the electrically conductive component 602 contacts the two conductors 603 and 605. The conductors 603 and 605 each comprise a through-hole 610 and 612, respectively, which the bolt 606 may be positioned through for joining the two conductors 603 and 605.

[0073] In some embodiments, the electrically conducting device comprises an adhesive, such as a pressure sensitive adhesive (PSA). In some embodiments, the adhesive is disposed or disposed directly over a top and / or bottom surface of the electrically conducting device. In some embodiments, the adhesive comprises perforations. In some embodiments, the perforations are disposed directly over the electrically conducting component, such that the electrically conducting component is configured to contact a surface of a conductor without breaking through the adhesive. In some embodiments, the adhesive does not comprise perforations. In some embodiments, the adhesive is contacted with a conductor in order to attach the electrically conducting device to the conductor.

[0074] In some embodiments, the electrically conductive component surrounds more than one fastening mechanism, such as more than one through hole and / or bolt, for joining the conductors. In some embodiments, one or more through holes and / or bolt for joining the conductors surround the electrically conductive component. In such embodiments, the largest dimension of the electrically conductive component may be larger than the largestdimension of the plurality of through holes and / or bolts. Advantageously, such design can achieve similar low electrical contact resistance between two conductors even when the conductors cannot withstand the large force applied by one bolt, which may cause the electrically conductive component to break the insulating component and indent the conductors. For example, an aluminum busbar thinner than about 3 mm may be susceptible to bending deformation. The use of more than one bolt and an electrically conductive component with a larger dimension may evenly distribute the large force needed among the several bolts. FIG. 7 schematically illustrates a top-down view of an electrically conducting device 700 comprising an electrically conductive component 702 and an insulating component 704 according to some embodiments. As illustrated in FIG. 7, in some embodiments, the electrically conductive component 702 and insulating component 704 are in the shape of an oval ring. A plurality of bolts 706 are positioned surrounding the electrically conductive component 702 and insulating component 704. The electrically conductive components 702 and insulating component 704 surround a plurality of bolts 706. The arrangement of the plurality of bolts 706 relative to the electrically conductive component 702 and the insulating component 704 allow for the load to be evenly distributed among the bolts 706 surrounding the electrically conductive component 702.

[0075] In some embodiments, the insulating component comprises compression features at the inner and / or outer edges of the insulating component. In some embodiments, the compression feature comprises a larger thickness than the thickness of another portion of the width of the insulating component. Advantageously, such compression features may reduce reactive force in the insulating component upon joining the conductors. FIG. 8 schematically illustrates an electrically conducting device 800 including an electrically conductive material 801 and an insulating component 803 comprising an outer compression feature 802 and an inner compression feature 804. The thickness Hl of the inner compression feature 804 and thickness H3 of the outer compression feature 802 are larger than the thickness H2 of the insulating component 803 at the portion 806 between the outer and inner compression features 802 and 804. The diameter DI of the electrically conductive material 801 is less than the thickness H2 of the insulating component 803 at the portion 806 between the outer and inner compression features 802 and 804.2. Electrically Conducting Device with Mechanical Attachment

[0076] In some embodiments, the electrically conducting device may be attached to a conductor by a mechanical attachment portion.

[0077] FIGS. 9 A and 9B schematically illustrate an electrically conducting device 900 according to some embodiments. FIG. 9A schematically illustrates a perspective view of an electrically conducting device 900 with a mechanical attachment component according to some embodiments. FIG. 9B schematically illustrates a vertical cross-section view of an electrically conducting device 900 with a mechanical attachment component according to some embodiments.

[0078] As shown in FIG. 9A, the electrically conducting device 900 comprises an electrically conductive component 902 and an insulating component 904. The insulating component 904 comprises a mechanical attachment element 908, one or more encasing portions 906 that encase at least a portion of the electrically conductive component, and a transition portion 912. Referring to FIG. 9B, the mechanical attachment element 908 of the insulating component 904 can mechanically attach the electrically conducting device 900 to the through-hole of a conductor. The insulating component 904 is shown further comprising a hole 910 configured to accommodate the mechanical joining method for joining the conductors, such as bolts. The transition portion 912 is shown connecting the encasing portions 906 and the mechanical attachment element 908.

[0079] In some embodiments, each portion of the insulating component (e.g., mechanical attachment element, encasing portions, transition portion) is made from the same or different material. In some embodiments, each encasing portion encases a portion of the electrically conducting component (i.e., each encasing portion completely or substantially surrounds and is in contact with a respective portion of the electrically conducting component).

[0080] In some embodiments, the mechanical attachment element is a mechanical device suitable for mechanical attachment, including but not limited to snap fit, press fit, interference fit, clips, clamps, or any other mechanical attachment devices and / or methods that can mechanically attach the electrically conducting component to the conductor. The mechanical attachment element provides the benefit that the electrically conducting device canbe easily placed at a right position for assembly and does not move after the mechanical attachment element is attached to the through hole of a conductor.

[0081] In some embodiments, the shape and dimension of the electrically conductive component is similar to that of the electrically conductive component as discussed above. In some embodiments, when the conductors are joined with an electrically conducting device with a mechanical attachment disposed therebetween, the encasing portions of the insulating component deforms, and the electrically conductive component cuts through the encasing portions to contact and indent the surfaces of the conductors.B. Method of Using Electrically Conducting Device

[0082] In some embodiments, the electrically conducting device may be used to connect two conductors. In some embodiments, the conductors are busbars for connecting a plurality of energy storage devices. In some embodiments, the method of using an electrically conducting device comprises attaching the electrically conducting device to a surface of a first conductor and fastening a second conductor to the first conductor with the electrically conducting device disposed therebetween. In some embodiments, fastening the second conductor to the first conductor comprises using screws and bolts, rivets, welding, clip and clamps, nails, or any other appropriate methods. In some embodiments, fastening the second conductor to the first conductor comprises applying a force of, of about, of at least, or of at least about, 1000N, 1100N, 1200N, BOON, MOON, 1500N, 1600N, 1700N, ISOON, 1900N, 2000N, or any range of values therebetween, to the electrically conducting device, such that the insulating component and / or material is broken by the applied force.

[0083] In some embodiments, the electrically conducting device is attached to the first conductor by an adhesive. In some embodiments, the electrically conducting device is attached to the first conductor by a mechanical attachment element.

[0084] In some embodiments, the electrically conducting device is attached to the first conductor by an adhesive. FIG. 10A schematically illustrates an exploded view of an electrically conducting device 1000 with an adhesive layer prior to use. The electrically conducting device 1000 is shown with a cover sheet 1008 comprising a hole 1009, an insulating component 1004, an electrically conductive component 1002, an adhesive layer 1006, and aliner 1010. When being used, the liner 1010 may be peeled off, and then the electrically conducting device 1000 is placed on a first conductor.

[0085] In some embodiments, the adhesive layer comprises a substrate. In some embodiments, the substrate of the adhesive layer comprises a PET material. In some embodiments, the adhesive layer comprises a bilayer tape. In some embodiments, the adhesive layer comprises an adhesive on each side of the substrate layer, which may allow for bonding the adhesive layer to the insulating component and to the surface of a conductor. In some embodiments, the adhesive layer comprises a pressure sensitive adhesive layer. In some embodiments, the suitable adhesive for bonding the adhesive layer to the insulating component comprises silicone-based adhesive. In some embodiments, the suitable adhesive for bonding the adhesive layer to the surface of the conductor comprises acrylic-based adhesive. In some embodiments, the adhesive on the adhesive layer for bonding the adhesive layer to the insulating component is activated at an elevated temperature. In some embodiments, the adhesive activation temperature is, is about, is at least, or is at least about, 50°C, 60°C, 70°C, 80°C, 90°C, 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, or any range of values therebetween. In some embodiments, the adhesive on the adhesive layer comprises a thickness of, of about, of at least, or of at least about, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, or 100 pm, or any range of values therebetween. In some embodiments, the adhesive layer comprises a thickness of, of about, of at most, or of at most about, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 110 pm, 120 pm, 130 pm, 140 pm, or 150 pm, or any range of values therebetween.

[0086] FIGS. 10B-10D schematically illustrate the method of using the electrically conducting device 1000 according to some embodiments. As illustrated in FIG. 10B, the liner 1010 is removed and the electrically conducting device 1000B is bonded onto the surface of a first conductor 1012. The hole of the cover sheet 1008 is aligned with the through hole on the first conductor 1012 to provide easy placement of the electrically conducting device when placing the electrically conducting device on the first conductor. In the next step as shown in FIG. 10C, the cover sheet 1008 is peeled off to form the electrically conducting device 1000C. As illustrated in FIG. 10D, a second conductor 1014 is placed over the first conductor 1012 with the electrically conducting device 1000C therebetween, wherein the through-hole of thefirst conductor 1012 is then aligned with the through-hole of the second conductor 1014. In some embodiments, the conductors may be joined together by fastening methods such as bolting. In some embodiments, the electrical resistance and the gap between the two conductors are checked across the electrically conducting device WOOD prior to and / or subsequent to fastening.

[0087] In some embodiments, the electrically conducting device is attached to the first conductor by a mechanical attachment element. In some embodiments, the electrically conducting device comprises an insulating component having a mechanical attachment element, and an electrically conductive component. To use the electrically conducting device, the electrically conducting device is attached to the first conductor by matching the mechanical attachment element of the insulating component to the through-hole of the conductor. A second conductor is placed over the first conductor with the electrically conducting device therebetween, wherein the through-hole of the first conductor is then aligned with the through- hole of the second conductor. In some embodiments, the conductors may be joined together by fastening methods such as bolting. In some embodiments, the electrical resistance and the gap between the two conductors are checked across the electrically conducting device prior to and / or subsequent to fastening. The mechanical attachment element of the insulating component not only provides attachment of the electrically conducting device to the conductor, but also provides good guidance of the right positioning of the electrically conducting device, such that there is no need for a cover sheet with a hole for alignment.C. Method of Manufacturing the Electrically Conducting Device

[0088] In some embodiments, the electrically conducting device is fabricated by positioning an electrically conductive material within an insulating material. In some embodiments, the electrically conducting device may be manufactured with an injection molding method. In some embodiments, the electrically conducting device may be manufactured with a lamination method.

[0089] FIG. 11 illustrates an injection molding process 1100 for manufacturing the electrically conducting device according to some embodiments. In step 1102, the method of forming the electrically conducting device comprises forming the electrically conductive component comprising an electrically conductive material. In step 1104, the electricallyconductive component is placed into a mold. In step 1106, an insulating material precursor is injected into the mold. In step 1108, the insulating material precursor is cured to form the insulating component encasing the electrically conductive component. Advantageously, in some embodiments, an injection molding method for manufacturing the electrically conducting device is simple, cost-effective, and allow for a relatively complex design of the insulating component.

[0090] In some embodiments, forming the electrically conductive component comprises shaping the electrically conductive material to a desired shape. In some embodiments, shaping the electrically conductive material to the desired shape comprises bending the electrically conductive material. In some embodiments, forming the electrically conductive component comprises cold working the electrically conductive material to improve the yield strength before shaping the electrically conductive material. In some embodiments, the electrically conductive material is in the shape of a wire before being cold worked and / or shaped to a desired shape. In some embodiments, the electrically conductive material is commercially purchased. In some embodiments, the electrically conductive material is not machined before being cold- worked and / or shaped to a desired shape. In some embodiments, the process of forming the electrically conductive component comprises extruding the electrically conductive material, cold working the extruded electrically conductive material, and / or shaping the cold-worked electrically conductive material to a desired shape. In some embodiments, the electrically conductive material is coated before or after being shaped to a desired shape. In some embodiments, the electrically conductive material is plated with a coating. In some embodiments, the coating comprises plating nickel on the surface of the electrically conductive material.

[0091] FIG. 12 illustrates a lamination method for manufacturing the electrically conducting device according to some embodiments. In step 1202, similar to step 1102, an electrically conductive component is formed with the electrically conductive material. In step 1204, the electrically conductive component is positioned between a first insulating material sheet and as second insulating material sheet. In step 1204, the electrically conductive component is positioned between a first insulating material sheet and a second insulating material sheet. In step 1206, the first and second insulating material sheets are laminated toform an insulating component with the electrically conductive component positioned therebetween.

[0092] FIG. 13 A schematically illustrates the arrangement of different layers before lamination, with the first insulating material layer 1302, the electrically conductive component 1304, the first adhesive layer 1306, the second insulating material layer 1308, and the second adhesive layer 1310 consecutively stacked in order described. FIG. 13B schematically illustrated the configuration of the electrically conducting device after lamination, wherein the first and second insulating material layers are laminated and joined together by the first adhesive layer to form the insulating component 1312, wherein the electrically conductive component 1304 is positioned within the insulating component 1312 to form an electrically conducting device. FIG. 13C schematically illustrates that the electrically conducting device which is manufactured by lamination process can function similarly as to the connecting device when the electrically conducting device is positioned between two conductors as discussed herein.

[0093] In some embodiments, each of the first insulating material sheet and / or the second first insulating material sheet are formed from an insulating material. In some embodiments, each of the first insulating material sheet and the second first insulating material sheet are formed from different insulating materials. In some embodiments, the first insulating material sheet is positioned above the electrically conductive component. In some embodiments, the second insulating material sheet is positioned below the electrically conductive component. In some embodiments, a first adhesive layer is positioned between the electrically conductive component and the second insulating material sheet. In some embodiments, a second adhesive layer is positioned on the opposite side of the second insulating material sheet relative to the first adhesive layer. In some embodiments the first insulating material sheet is thinner than the second insulating material sheet. In some embodiments the thickness of the first insulating material layer is about 1 / 10 to about 1 / 2 of the diameter DI of the electrically conductive component. In some embodiments the thickness of the second insulating material sheet is about 1 / 2 to about 2 times of the diameter DI of the electrically conductive component. Advantageously, in some embodiments, the lamination method for manufacturing the electrically conducting device is easy, low cost and may allow roll to roll processing.EXAMPLESExample 1: Contact Resistance of the Electrically Conductive Material

[0094] FIG. 14 is a graph of the contact resistance for Cu metal and Cu-Zr alloy wires tested at 13 (FC over time. The Cu metal wire and the Cu-Zr alloy wire have a diameter of about 0.5 mm and a length of about 100 mm. The Cu-Zr alloy comprises about 0.25 wt % Zr and about 99.75 wt % Cu. As illustrated in FIG. 14, the contact resistance of the Cu-Zr alloy wire and the Cu metal wire were similar at the beginning of the testing. However, the contact resistance of the Cu-Zr alloy wire remained below 10 pQ after 1000 hours of testing, while the contact resistance of Cu wire increased to above 100 pQ after less than 100 hours of testing.Example 2: Tensile Strength of the Insulating Material

[0095] FIG. 15 is a graph of the storage and loss moduli of an insulating material SI tested at various temperatures. The insulating material SI is Silopren™ LSR 2640 liquid silicone resin, which is polydimethylsiloxane containing vinyl groups, with platinum catalyst and inhibitors. The insulating material SI was vulcanized for about 10 minutes at about 175°C and then cured at about 200°C for about 2 hours. Table 1 summarizes the properties of the insulating material SI. As shown in FIG. 15, the insulating material SI has a storage modulus of about 4.4MPa at -40°C and the storage modulus stays stable even above 150°C and is about 2.1 MPa at 150°C. In addition, the insulating material SI has a shore A hardness of about 42 and an elongation at break of about 600% at room temperature.TABLE 1Example 3: Disassembly of Conductor System with Electrically Conducting Device

[0096] FIG. 16A shows an electrically conductive device with an electrically conductive component sealed between the outer and inner insulating components after the conductors are joined and then dissembled. FIG. 16B shows the indentation that the electrically conductive component has left on the conductor after the conductors are joined and then dissembled.

[0097] While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.

[0098] Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0099] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in anysuitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.

[0100] Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and / or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. For example, any of the components for an energy storage system described herein can be provided separately, or integrated together (e.g., packaged together, or attached together) to form an energy storage system.

[0101] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0102] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generallyintended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and / or steps. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and / or steps are included or are to be performed in any particular embodiment.

[0103] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0104] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount, depending on the desired function or desired result.

[0105] The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.

[0106] The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

Claims

WHAT IS CLAIMED IS:

1. An electrically conducting device, comprising: an electrically conductive component comprising an electrical conductivity of at least about 60% IACS and a tensile strength of at least about 400 MPa; and an insulating component comprising an elongation at break of at least about 200%, wherein the electrically conductive component is positioned at least partially within at least a portion of the insulating component.

2. The electrically conducting device of Claim 1, wherein at least a portion of the insulating component encases at least a portion of the electrically conductive component.

3. The electrically conducting device of Claim 1 or 2, wherein the electrically conductive component comprises a softening temperature of at least about 400°C.

4. The electrically conducting device of any one of Claims 1 -3, wherein the insulating component encases substantially all of the electrically conductive component.

5. The electrically conducting device of any one of Claims 1-4, wherein the electrically conducting device further comprises a pressure sensitive adhesive (PSA) material.

6. The electrically conducting device of Claim 5, wherein the PSA material is perforated.

7. The electrically conducting device of any one of Claims 1-6, wherein the electrically conducting device further comprises a bilayer tape.

8. The electrically conducting device of any one of Claims 1 -7, wherein the insulating component comprises a mechanical attachment element.

9. The electrically conducting device of any one of Claims 1-8, wherein the electrically conductive component comprises a shape of a ring.

10. The electrically conducting device of any one of Claims 1-9, wherein a height of a cross-section of the insulating component is about 1.1 to 1.6 times of a height of a cross-section of the electrically conductive component.

11. The electrically conducting device of any one of Claims 1-10, wherein a cross- sectional shape of the electrically conductive component is selected from the group consisting of a circular shape, an oval shape, a square shape, a rectangular shape, a triangular shape, a star shape, and combinations thereof.

12. The electrically conducting device of any one of Claims 1-11, wherein the electrically conductive component comprises an alloy.

13. The electrically conducting device of any one of Claims 1-12, wherein the electrically conductive component comprises a Cu-Zr alloy, a Cu-Cr alloy, or a Cu-Zr-Cr alloy.

14. The electrically conducting device of any one of Claims 1-13, wherein the electrically conductive component comprises a coating.

15. The electrically conducting device of any one of Claims 1-14, wherein the electrically conductive component comprises a thinner section with a smaller vertical cross section compared to that of another section of the electrically conductive component.

16. The electrically conducting device of any one of Claims 1-15, wherein an insulating material of the insulating component comprises a silicone resin.

17. The electrically conducting device of any one of Claims 1-16, wherein the insulating component comprises a Shore A hardness of about 30 to about 60.

18. The electrically conducting device of any one of Claims 1-17, wherein the insulating component comprises a working temperature of about -50°C to about 150°C.

19. The electrically conducting device of any one of Claims 1-18, wherein the insulating component comprises a tensile storage modulus of less than about 400 MPa at or above -40°C.

20. The electrically conducting device of any one of Claims 1-19, wherein the insulating component is capable of withstanding a force of about 1000N without breaking.

21. A method of using the electrically conducting device of any one of Claims 1-20, comprising: attaching the electrically conducting device to a surface of a first conductor; and fastening a second conductor to the first conductor wherein the electrically conducting device is disposed therebetween such that the electrically conductive component breaks through at least a portion of the insulating component and thereby contacts both the first and second conductors.

22. The method of Claim 21, wherein the first and second conductors comprise a busbar.

23. The method of Claim 21 or 22, wherein the electrically conducting device is reusable.

24. The method of any one of Claims 21-23, wherein fastening the second conductor to the first conductor results in the electrically conductive component indenting both the first and second conductors.

25. The method of any one of Claims 21-24, wherein fastening the second conductor to the first conductor results in applying a force of at least about 1000N to the electrically conducting device.

26. An electrically connected busbar system, comprising: the electrically conducting device of any one of Claims 1 -20 positioned between a first busbar and a second busbar; and a fastener connecting the first and second busbars through a fastening mechanism, wherein the electrically conducting device is adjacent to the fastening mechanism and in contact with each of the first and second busbars.

27. The electrically connected busbar system of Claim 26, wherein the fastener comprises a bolt.

28. The electrically connected busbar system of Claim 26 or 27, wherein the electrically conductive component is sealed by the insulating component, first busbar and second busbar.

29. A method of manufacturing an electrically conducting device, comprising: positioning an electrically conductive material at least partially within at least a portion of an insulating component, wherein the electrically conductive material comprising an electrical conductivity of at least about 60% IACS and a tensile strength of at least about 400 MPa; and wherein the insulating component comprises an elongation at break of at least about 200%.

30. The method of Claim 29, wherein positioning the electrically conductive material at least partially within at least a portion of an insulating component comprises: positioning the electrically conductive material within a mold; injecting an insulating material precursor into the mold; andcuring the insulating material precursor to form the insulating component and thereby forming an electrically conducting device.

31. The method of Claim 29, wherein positioning the electrically conductive material at least partially within at least a portion of the insulating component comprises positioning the electrically conductive material between a first insulating material sheet and a second insulating material sheet.

32. The method of Claim 31, further comprising laminating the first and second insulating material sheets to form the insulating component.

33. The method of Claim 31 or 32, wherein a first pressure sensitive adhesive (PSA) layer is positioned between the second insulating material sheet and the electrically conductive material.

34. The method of any one of Claims 29-33, wherein the electrically conductive material is unmachined.

35. The method of any one of Claims 29-34, wherein the electrically conductive material comprises an extruded wire.

36. The method of any one of Claims 29-35, wherein the electrically conductive material is cold worked to achieve the tensile strength of at least about 400 MPa.

37. The method of any one of Claims 29-36, further comprising coating the electrically conductive material.

38. The method of Claim 37, wherein coating comprises coating the electrically conductive material with nickel.

39. The method of any one of Claims 29-38, further comprising disposing a second PSA layer on a surface of the electrically conducting device.

40. A method of manufacturing an electrically conducting device, comprising: positioning an electrically conductive material within a mold; injecting an insulating material precursor into the mold; and curing the insulating material precursor to form an insulating component and thereby forming an electrically conducting device, wherein at least a portion of the insulating component encases at least a portion of the electrically conductive material.

41. A method of manufacturing an electrically conducting device, comprising:positioning an electrically conductive material between a first insulating material sheet and a second insulating material sheet; and laminating the first and second insulating material sheets to form an insulating component, wherein at least a portion of the insulating component encases at least a portion of the electrically conductive material.

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