Connector with integrated ferrite

Abstract

A module is disclosed for insertion to a housing of a battery. The module includes a connector having one or more battery terminals, the one or more battery terminals electrically coupling to one or more cells,.Each of the one or more battery terminals includes a first portion, a second portion contiguous with the second portion and a third portion contiguous with the second portion. One or more ferrite beads each surround a corresponding second portion of a battery terminal of the one or more battery terminals.

Description

[0001] CONNECTOR WITH INTEGRATED FERRITE

[0002] TECHNICAL FIELD

[0003] This disclosure relates to devices for reducing electromagnetic interference (EMI) noise in automotive batteries, and in particular to a battery and / or module using ferrite beads to improve electromagnetic compatibility (EMC) of the battery.

[0004] BACKGROUND

[0005] As a result of the high-speed electronics used in automotive batteries to manage and convert battery power, such as, for example, DC-DC converters and inverters, high-frequency electromagnetic interference (EMI) electronic noise can interfere with sensitive electronic components throughout the vehicle, including the battery management system (BMS) in the battery itself. This could result in software malfunction and corrupted sensor data which could ultimately lead to the BMS miscalculating different battery variables, including state of charge, resulting in the degradation of the battery’s performance and / or lifespan.

[0006] One way to limit and / or filter the effects of EMI noise is the use of ferrite beads.

[0007] Ferrite beads are passive electronic components designed to filter and suppress high- frequency EMI, also known as Radio Frequency Interference (RFI), in electronic circuits. They function as frequency-dependent resistors, absorbing unwanted high-frequency noise and converting it into heat, thereby improving the electromagnetic compatibility (EMC) of a device.

[0008] Typically, ferrite beads are used on automotive battery wires, such that when current flows through a wire, the wire generates a magnetic field but because the ferrite beads are made of material that is highly permeable to magnetic fields, they act as an electrical insulator. The high permeability allows the ferrite beads to effectively contain the magnetic field generated by the wire.

[0009] However, due to the high current through battery wires and cables, placing a ferrite bead on a battery wires could potentially saturate the ferrite material of the bead causing it to lose its noise-suppressing properties. Similarly, the extreme environment under the hood of a modern automobile and the vibrations associated with the operation of a vehicle, can damage ferrite beads that are placed over the wires in the vehicle themselves. SUMMARY

[0010] Some embodiments advantageously provide a battery and / or module for reducing EMI noise in automotive batteries, and in particular to battery and / or module that uses ferrite beads to improve electromagnetic compatibility (EMC) of the battery.

[0011] In accordance with one aspect of the present disclosure, a connector module for insertion to a housing of a battery is provided. The connector module comprises a connector having one or more electrically conductive battery terminals, the one or more battery terminals electrically coupling to one or more cells, each of the one or more battery terminals comprising a first portion, a second portion contiguous with the first portion and a third portion contiguous with the second portion, and one or more ferrite beads, each of the one or more ferrite beads surrounding a corresponding second portion of a battery terminal of the one or more battery terminals.

[0012] In some embodiments, a single ferrite bead of the one or more ferrite beads surrounds the corresponding second portion of the one or more battery terminals. In some embodiments, the single ferrite bead is configured to filter common mode noise. In some embodiments, the one or more ferrite beads are configured to filter differential mode noise. In some embodiments, each of the one or more ferrite beads is overmolded to the second portion of the corresponding battery terminal. In some embodiments, each of the one or more ferrite beads is friction fit to the second portion of the corresponding battery terminal.

[0013] In some embodiments, each of the one or more ferrite beads is secured to the second portion of the corresponding battery terminal using an adhesive. In some embodiments, the connector comprises an internal side and an external side, and a separation portion separating the internal side from the external side, the first portion of the battery terminal being located on the external side and protruding through the separating portion, the first portion of the battery terminal being connectable to a wiring harness of a vehicle. In some embodiments, when the module is secured to the housing of the battery, the third portions of the battery terminals are electrically couplable to a battery management system, BMS.

[0014] In accordance with another aspect of the present disclosure, a battery is provided. The battery comprises at least one cell, a battery management system (BMS), and a housing. The housing comprises a connector having one or more electrically conductive battery terminals. Each of the one or more battery terminals comprises a first portion, a second portion contiguous with the first portion and a third portion contiguous with the second portion, the one or more battery terminals electrically coupling the one or more cells via the BMS, and one or more ferrite beads, each of the one or more ferrite beads surrounding a corresponding second portion of a battery terminal of the one or more battery terminals.

[0015] In some embodiments, the at least one cell is an ultracapacitor. In some embodiments, a single ferrite bead of the one or more ferrite beads surrounds the corresponding second portion of the one or more battery terminals. In some embodiments, the single ferrite bead is configured to filter common mode noise. In some embodiments, the one or more ferrite beads are configured to filter differential mode noise. In some embodiments, each of the one or more ferrite beads is overmolded to the second portion of the corresponding battery terminal. In some embodiments, each of the one or more ferrite beads is friction fit to the second portion of corresponding the battery terminal.

[0016] In some embodiments, each of the one or more ferrite beads is secured to the second portion of the corresponding battery terminal using an adhesive. In some embodiments, the connector comprises an internal side and an external side, and a separation portion separating the internal side from the external side, the first portion of the at least one battery terminal being located on the external side and protruding through the separating portion, the first portion of the at least one battery terminal being connectable to a wiring harness of a vehicle. In some embodiments, the second portion of the at least one battery terminal is on the internal side of the connector. In some embodiments, the connector and one or more ferrite beads secured to the corresponding second portion of the battery terminal form a separate module, the separate module configured to be secured to the housing.

[0017] BRIEF DESCRIPTION OF THE DRAWINGS

[0018] A more complete understanding of embodiments described herein, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0019] FIG. 1 is a diagram of an example system according to principles disclosed herein;

[0020] FIG. 2 shows an example battery constructed in accordance with the principles of the present disclosure;

[0021] FIG. 3 is an exploded view of several components of a battery constructed in accordance with the principles of the present disclosure;

[0022] FIG. 4a is a cut-away front view of the connector showing the terminals and ferrite beads in accordance with the principles of the present disclosure; FIG. 4b is a cut-away side view of the connector showing a terminal and a ferrite bead in accordance with the principles of the present disclosure;

[0023] FIG. 5 is a diagram of a battery housing including a connector and two ferrite beads in accordance with the principles of the present disclosure;

[0024] FIG. 6 is a diagram of a battery connector including two ferrite beads secured over corresponding battery terminals in accordance with the principles of the present disclosure;

[0025] FIG. 7 is a diagram of a battery connector including a single ferrite bead secured over multiple battery terminals in accordance with the principles of the present disclosure;

[0026] FIG. 8a is a diagram of a separate module including ferrite beads and a connector in accordance with the principles of the present disclosure;

[0027] FIG. 8b is a diagram of a separate module including ferrite beads secured over corresponding battery terminals of the connector in accordance with the principles of the present disclosure;

[0028] FIG. 9a is a diagram of a separate module including a single ferrite bead and a connector in accordance with the principles of the present disclosure; and

[0029] FIG. 9b is a diagram of a separate module including a single ferrite bead secured over multiple battery terminals of the connector in accordance with the principles of the present disclosure.

[0030] DETAILED DESCRIPTION

[0031] Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of apparatus components and processing steps related to a capacitor battery system. Accordingly, the system and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0032] As used herein, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the concepts described herein. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and / or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0033] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0034] In embodiments described herein, the joining term, “in communication with” and the like, may be used to indicate electrical or data communication, which may be accomplished by physical contact, induction, electromagnetic radiation, radio signaling, infrared signaling or optical signaling, for example. In some other embodiments, “in communication with” indicates the transmission and / or of signaling by the components that are in communication with each other. The signaling may cause one or more components to perform one or more actions based on the signaling. The term “in communication with” may also refer to being in fluid communication, such as where two spaces are in fluid communication with each other. One having ordinary skill in the art will appreciate that multiple components may interoperate, and modifications and variations are possible of achieving the electrical and data communication.

[0035] In some embodiments, the general description elements in the form of “one of A and B” corresponds to A or B. In some embodiments, at least one of A and B corresponds to A, B or AB, or to one or more of A and B. In some embodiments, at least one of A, B and C corresponds to one or more of A, B and C, and / or A, B, C or a combination thereof.

[0036] Referring to the drawing figures, in which like elements are referred to by like reference numerals, there is shown in FIG. 1 a diagram of a system 10, according to an embodiment, which comprises one or more vehicles 12, e.g., a car, motorcycle, scooter, golf cart, truck, light utility vehicle, etc. The vehicle 12 comprises battery 14 for powering at least one function of vehicle 12. In some embodiments, battery 14 (e.g., ultracapacitor battery) may include one or more energy storage modules / cells. Although an ultracapacitor battery is described herein, the teachings described herein are equally applicable to other battery types such as Lithium-Ion and lead acid batteries that may make use of DC / DC converters. Battery 14 may include one or more batteries such as a first battery 14a (not shown), second battery 14b (not shown), third battery 14c (not shown), fourth battery 14d (not shown), etc., e.g., electrically connected (e.g., in parallel, series, etc.) as part of a battery pack. Although battery 14 is shown in conjunction with a vehicle 12, battery 14 is not limited as such and may be used in conjunction with any other component (e.g.., such as to power any other system component).

[0037] Battery 14 may include battery management system (BMS) 16 that is configured to perform one or more battery management functions described herein. In some embodiments, the BMS 16 may measure / determine certain battery parameters, e.g., resistance (e.g., battery resistance), voltage (e.g., cell voltage), current, state of charge (SoC), a time parameter, a frequency parameter, etc., and transmit / receive data (and / or signals such as control signals) to / from another system / device. BMS 16 may also determine failures of battery components and perform actions such notify other components of system 10. BMS 16 may also be referred to herein as, or include, an energy management system (EMS).

[0038] In some embodiments (not shown), BMS 16 may include an EMS and / or be configured to perform EMS functions. In some other embodiments, the EMS may include BMS 16 and / or be configured to perform BMS functions. In some embodiments, the EMS is included in battery 14 and / or may be part of any other component of system 10 (e.g., vehicle 12) or standalone.

[0039] It is contemplated that one or more entities of system 10 are in communication with each other via one or more of wireless communication, power communication, wired communication, fluid communication, etc. For example, vehicle 12, battery 14, and BMS 16 (and / or any other device or server) may communicate with each other directly or indirectly using wireless communication, power communication, wired communication, etc. Further, while it may be assumed in one or more embodiments that there is no data or signal communication between BMS 16 and vehicle 12, the embodiments described herein are equally applicable to vehicles 12 where there are at least some data / signal communications between battery 14, BMS 16 and vehicle 12. Further, although battery 14 and BMS 16 are shown as part of vehicle 12 they may be standalone batteries / units, removably couplable to any component of system 10 such as vehicle 12, etc.

[0040] FIG. 2 shows an example battery 14 constructed in accordance with the principles of the present disclosure. Battery 14 includes a housing 18 into which one or more battery components may be positioned. The components may be electrically interconnected (not shown in the FIGS), such as via an electrically conductive bus bar system which electrically interconnects the components in an electrically serial, electrically parallel or combination of electrically serial and parallel manner, depending on the intended voltage and current requirements.

[0041] A battery monitoring system (BMS) 16 may be included. BMS 16 may include or be coupled to a connector 20 that allows for a removable external connection any other component of system 10 (e.g., to the vehicle’s data bus, voltage bus, to some other communication device, etc.) and / or internal connection, e.g., any components of battery 14 and / or BMS 16. Connector 20 may be comprised in BMS 16 and / or any other component of system 10. In some embodiments, connector 20 may be configured to removably couple and / or connect (electrically, physically) to another connector. The connector 20 can, in some embodiments, be integrated with the housing 18, such as in a cover 22 of the housing 18 or any other cover. Battery 14 also includes terminals, such as a positive terminal 24a and a negative terminal 24b (collectively referred to as terminals 24) to provide the contact points for electrical connection of the battery 14 (e.g., to power devices and / or the vehicle 12 and / or BMS 16). In some embodiments, terminals 24 are not used and the power and ground signals that would be provided via terminals 24 are integrated as part of connector 20. Battery 14 may also include cover 26 which may be arranged to couple to cover 22. Cover 22 may include one or more cover walls that may (e.g., along with cover 26) define cover space 28. Cover 22 may be arranged to receive BMS 16 in cover space 28 during assembly, e.g., such that BMS 16 is coupled to cover 22 and / or any other components of battery 14. Battery 14 may also have battery internal space 30, which may be defined by housing 18, cover 22, cover 26, etc. In some embodiments, battery internal space 30 may be determined to house a predetermined quantity of battery components such as cells 32, BMS 16, etc. Battery internal space 30 may be also determined to minimize unused space and to maximize the quantity or type of components it contains. Battery internal space 30 may also be arranged to contain additional battery components and to meet or exceed a predetermined internal used volume / space threshold.

[0042] In addition, terminals 24 may be arranged to protrude through housing 18, such as protruding through cover 22 and / or cover 26. Terminals 24 may be electrically connected to the bus bars inside housing 18 and / or directly connected to cells 32 (bus bars and direct connection not shown) and / or connected to BMS 16.

[0043] Further, battery 14 may be arranged to provide many power capacities and physical sizes, and to operate under various parameters and parameter ranges. It is also noted that implementations of battery 14 some can be scaled to provide various capacities. For example, in some embodiments, the power capacity of battery 14 can range from 25 Ah to 75Ah. It is noted, however, that this range is merely an example, and that it is contemplated that embodiments of battery 14 can be arranged to provide less than a 25 Ah capacity or more than a 75Ah capacity. Power capacity scaling can be accomplished, for example, by using higher or lower power capacity cells 32 in the housing 18, and / or by using fewer or more cells 32 in the housing 18. In some embodiments, battery 14 may be incorporated as part of a vehicle where battery power is needed. Other electrical parameters of the battery 14 can be adjusted / accommodated by using cells 32 that may cumulatively have the desired operational characteristics, e.g., current, voltage, charge, charging capacity / rate, discharge rate, etc. Thermal properties can be managed based on cell 32 characteristics, the use of heat sinks and / or thermal energy discharge plates, etc., within or external to the housing 18. Further, BMS 16 may be connected to at least one of the cells such as to determine / measure at least one parameter of battery 14 and / or cells 32. Links 34 couple cells 32 to BMS 16. In some arrangements, links 34 provide an electrical path to charge cells 32 and to use the stored energy in cells 32 for vehicle operation such as to boost the power on the vehicle bus. In some embodiments, cells 32 are ultracapacitor cells.

[0044] Having described the general process flow of arrangements of the disclosure, the sections below provide details and examples of arrangements for a battery 14 comprising on or more energy storage subsystems or components such as cells 32 where one or more ferrite beads 36 are affixed or otherwise brought into contact with the terminals 24 of connector 20 within housing 18 of battery 14.

[0045] In some embodiments, battery 14 is shown in FIG. 3, where battery 14 is an ultracapacitor battery system (e.g. configured for 48V) and includes housing 18, which may be arranged to receive and secure BMS 16, which may be electrically coupled to circuit elements 32 (e.g., cells). BMS 16 may couple to connector 20 and, one or more ferrite beads 36 may be coupled to a corresponding battery terminal, i.e., terminal 24a and terminal 24b of connector 20. Further, housing 18 may be coupled to cover 22 such as to enclose the components of battery 14.

[0046] FIG. 4a is a cut-away front view of connector 20. In one embodiment, terminals 24a and 24b each include three portions, which may be formed as a single contiguous electrically conductive part. For example, terminal 24a includes an elongated first portion 25a, which is on the side of connector 20 to which the vehicle wiring harness connector is mated (referred to herein as the “external side”) and protrudes through a separating portion 31 of the connector 20 that separates the exterior of connector 20 from the interior of the connector 20. Terminal 24a also includes a second portion 27a, which is the portion of terminal 24a that is within, i.e., in the interior volume / side (referred to herein as the “internal side”) of housing 18 and which receives ferrite bead 36. Terminal 24a also includes a third portion 29a within, i.e., in the interior volume / side of housing 18. Third portion 29a includes a the portion of terminal 24a that is physically and electrically coupled to BMS 16. First portion 25a is contiguous with second portion 27a, and second portion 27a is contiguous with third portion 29a.

[0047] Similarly, terminal 24b includes an elongated first portion 25b, second portion 27b and third portion 29b which correspond in arrangement to terminal 24a, discussed above. A ferrite bead 36 is shown surrounding second portion 27b. Although only two terminals 24a and 24b are shown in FIG. 4, it is understood that arrangements can have more or fewer than two terminals. First portions 25a and 25b are referred to herein collectively as “first portion 25,” second portions 27a and 27b are referred to herein collectively as “second portion 27” and third portions 29a and 29b are referred to herein collectively as “third portion 29.”

[0048] FIG. 4b is a cut-away side view of connector 20. Here, the three contiguous portions of terminal 24a can be seen, namely elongated first portion 25a, second portion 27a, and third portion 29a. As described above, third portion 29a is the portion of terminal 24a that is physically and electrically coupled to BMS 16.

[0049] In the embodiment shown in FIG. 5, housing 18 is shown. Housing 18 includes an integrated connector 20, which includes battery terminal 24a, of which second portion 27a and third portion 29a are exposed, i.e., are within housing 18 and battery terminal 24b, of which second portion 27b and third portion 29b are exposed, i.e., are within housing 18. Integrated in this case refers to the connector 20 housing being molded as a part of housing 18. It should be noted that battery 14 is not limited in any way to a specific number of battery terminals 24. Thus, although only two battery terminals 24a and 24b are shown, it is within the scope of the present disclosure where connector 20 includes any number of battery terminals 24. FIG. 5 also shows two ferrite beads 36, where each ferrite bead 36 is aligned with a corresponding terminal 24a and 24b protruding upwards from connector 20. Ferrite beads 36 may be of any size, shape and orientation, i.e., not limited to the size, shape and orientation shown in the figures. In some embodiments, each ferrite bead 36 is of a size, shape and orientation to fit over a corresponding battery terminal. Further, the present disclosure is not limited to only two ferrite beads 36. It certain embodiments, only one ferrite bead 36 is used (discussed below). In other embodiments, two or more ferrite beads 36 are used. In some embodiments, the number of ferrite beads 36 match the number of battery terminals 24 such that a single ferrite bead 36 surrounds or at least partially surrounds and is secured to a corresponding battery terminal 24. However, as discussed below, in certain embodiments, the number of ferrite beads 36 need not match the number of battery terminals 24.

[0050] As shown in FIG.6, in one embodiment, each ferrite bead 36 is affixed to or otherwise secured to a corresponding second portion, 27a and 27b (not shown) of battery terminal 24a and 24b, respectively, of connector 20. Each ferrite bead 36 may be affixed or secured to a corresponding second portion 27a and 27b of battery terminal 24a and 24b in a variety of ways. In one embodiment, ferrite bead 36 my slide over a corresponding second portion, i.e., 27a or 27b or battery terminal 24a or 24b. In another embodiment, ferrite bead 36 may be overmolded onto a corresponding second portion 27a or 27b of battery terminal 24a or 24b. In another embodiment, ferrite bead 36 may be friction fit onto a corresponding second portion 27a or 27b or battery terminal 24a or 24b. In another embodiment, ferrite bead 36 may be secured to a respective second portion 27a or 27b of battery terminal 24a or 24b using an adhesive substance, such as, for example, Room Temperature Vulcanizing (RTV). In another embodiment, ferrite bead 36 may be secured to a corresponding second portion 27a or 27b of battery terminal 24a or 24b via a friction / interference fit. Once the ferrite beads 36 are secured to the corresponding second portion of terminals 24, the BMS 16 can be secured to the housing 18 and exposed third portions 29a and 29b of terminals 24a and 24b electrically couple BMS 16 to the terminals 24.

[0051] It should be noted that if there were additional battery terminals 24, i.e., more than the two terminals 24 shown in FIG. 6, then additional ferrite beads 36 may be used, where each ferrite bead 36 is secured to a corresponding terminal 24, specifically, the second portion of terminal 24. Thus, there is no limit to the number of ferrite beads 36 (i.e., one or more) and battery terminals 24 (i.e., one or more) that may be used.

[0052] FIG. 7 illustrates another embodiment of the present disclosure. In this embodiment, rather than using multiple ferrite beads 36 as described above, where each is secured to a single, corresponding second portion of a battery terminal 24, a single ferrite bead 36 surrounds both terminals, i.e., 24a and 24b, and specifically, second portion 27a of terminal 24a and second portion 27b of terminal 24b. The determination of whether to secure one ferrite bead 36 to a portion of corresponding terminal, i.e., 24a and another ferrite bead 36 to a portion of the other battery terminal, i.e., 24b, or whether to secure a single ferrite bead 36 to portions of both terminals 24 may, in one embodiment, be based on whether there is common mode noise or a differential mode noise. Common mode describes signals or noise that flow in the same direction on multiple conductors while differential mode describes signals or noise traveling in opposite directions along two separate conductors, forming a loop. Thus in one embodiment, to suppress common mode noise, one ferrite bead 36 may be secured around second portions of both battery terminals 24a and 24b, while to suppress differential mode noise, two ferrite beads 36 may be used where each ferrite bead 36 is separately secured to a second portion of a corresponding battery terminal, i.e., 24a and 24b.

[0053] It should be noted that a single ferrite bead 36 may be secured to more than just two battery terminals 24 as shown in FIG 7. For example, a single ferrite bead 36 may encompass, i.e., be secured to, any number of battery terminals 24.

[0054] FIGS. 8a and 8b illustrate another embodiment of the present disclosure. In this embodiment, a separate module 40 may be constructed, where module 40 includes connector 20 and battery terminals 24a and 24b, where second portion 27a and third portion 29a of terminal 24a are exposed above connector 20 and second portion 27b and third portion 29b of terminal 24b are exposed above connector 20. One ferrite bead 36 may be secured over second portion 27a of terminal 24a and another ferrite bead may be secured over second portion 27b of terminal 24b in the manner described above. Module 40 is a separate component and once the ferrite beads 36 are inserted around their corresponding terminal 24, the second portion 27a and the second portion 27b on internal side of 20 , i.e., the portion of connector 20 within housing 18 that is not going to be electrically connected to BMS 16 can be overmolded to encapsulate the ferrite beads 36 into module 40, which can then be secured within housing 18. Advantageously, module 40 can be constructed with ferrite beads 36 already secured on the second portions of their respective terminals 24a and 24b of connector 20 as a unit, so that the entire module 40 can be affixed to or secured to housing 18 during the assembly process. The allows the connector 20 to be pre-assembled and also used in different types and / or capacity batteries. Alternately, module 40 can be assembled without ferrite beads 36 and once module 40 is secured within housing 18, ferrite beads 36 can be secured to their corresponding battery terminal 24 as described above. Module 40 may be secured within housing 18 of battery 14 using any known securing mechanisms such as overmolding or it can be friction fit into housing 18.

[0055] FIGS. 9a and 9b show module 40 in an alternate embodiment. In this embodiment, module 40 is formed of battery terminals 24a and 24b, and a single ferrite bead 36 secured around both the terminals 28a and 28b, specifically around second portion 27a of terminal 24a and second portion 27b of terminal 24b. As in the embodiment shown in FIGS 8a and 8b, module 40 can be formed with ferrite bead 36 secured to the two battery terminals 24 and the module 40 then secured within housing 18 of battery 14. Again, although only portions of two battery terminals 24a and 24b are shown in FIGS. 9a and 9b, it is within the scope of the present disclosure to secure a single ferrite bead 36 around any number of battery terminals 24.

[0056] In accordance with one aspect of the present disclosure, a connector module 40 for insertion to a housing 18 of a battery 14 is provided. The connector module 40 comprises a connector 20 having one or more electrically conductive battery terminals 24, the one or more battery terminals 24 electrically coupling to one or more cells 32, each of the one or more battery terminals 24 comprising a first portion 25, a second portion 27 contiguous with the first portion 25 and a third portion 29 contiguous with the second portion 27, and one or more ferrite beads 36, each of the one or more ferrite beads 36 surrounding a corresponding second portion 27 of a battery terminal 24 of the one or more battery terminals 24.

[0057] In some embodiments, a single ferrite bead 36 of the one or more ferrite beads 36 surrounds the corresponding second portion 27 of the one or more battery terminals 24. In some embodiments, the single ferrite bead 36 is configured to filter common mode noise. In some embodiments, the one or more ferrite beads 36 are configured to filter differential mode noise. In some embodiments, each of the one or more ferrite beads 36 is overmolded to the second portion 27 of the corresponding battery terminal 24. In some embodiments, each of the one or more ferrite beads 36 is friction fit to the second portion 27 of the corresponding battery terminal 24.

[0058] In some embodiments, each of the one or more ferrite beads 36 is secured to the second portion 27 of the corresponding battery terminal 24 using an adhesive. In some embodiments, the connector 20 comprises an internal side and an external side, and a separation portion 31 separating the internal side from the external side, the first portion 25 of the battery terminal 24 being located on the external side and protruding through the separating portion 31, the first portion 25 of the battery terminal 24 being connectable to a wiring harness of a vehicle 12. In some embodiments, when the module 40 is secured to the housing 18 of the battery 14, the third portions 29 of the battery terminals 24 are electrically couplable to a battery management system, BMS 16.

[0059] In accordance with another aspect of the present disclosure, a battery 14 is provided, the battery 14 comprising at least one cell 32, a battery management system (BMS) 16, and a housing 18, the housing 18 comprising a connector 20 having one or more electrically conductive battery terminals 24, each of the one or more battery terminals 24 comprising a first portion 25, a second portion 27 contiguous with the first portion 25 and a third portion 29 contiguous with the second portion 27, the one or more battery terminals 24 electrically coupling to the one or more cells 32 via the BMS 16, and one or more ferrite beads 36, each of the one or more ferrite beads 36 surrounding a corresponding second portion 27 of a battery terminal 24 of the one or more battery terminals 24.

[0060] In some embodiments, the at least one cell 32 is an ultracapacitor. In some embodiments, a single ferrite bead 36 of the one or more ferrite beads 36 surrounds the corresponding second portion 27 of the one or more battery terminals 24. In some embodiments, the single ferrite bead 36 is configured to filter common mode noise. In some embodiments, the one or more ferrite beads 36 are configured to filter differential mode noise. In some embodiments, each of the one or more ferrite beads 36 is overmolded to the second portion 27 of the corresponding battery terminal 24. In some embodiments, each of the one or more ferrite beads 36 is friction fit to the second portion 27 of corresponding the battery terminal 24.

[0061] In some embodiments, each of the one or more ferrite beads 36 is secured to the second portion 27 of the corresponding battery terminal 24 using an adhesive. In some embodiments, the connector 20 comprises an internal side and an external side, and a separation portion 31 separating the internal side from the external side, the first portion 25 of the at least one battery terminal 24 being located on the external side and protruding through the separating portion 31, the first portion 25 of the at least one battery terminal 24 being connectable to a wiring harness of a vehicle 12. In some embodiments, the second portion 27 of the at least one battery terminal 24 is on the internal side of the connector 20. In some embodiments, the connector 20 and one or more ferrite beads 36 secured to the corresponding second portion 27 of the battery terminal 24 form a separate module 40, the separate module 40 configured to be secured to the housing 18.

[0062] The connector arrangement provided herein allows for less complex and more reliable ferrite arrangements in potentially harsh environments such as vehicles as compared with using a ferrite around a wire, wiring harness, etc. By integrating the ferrite within the connector housing, the bulkiness of the ferrite-wrapped wire is avoided and the risk of damage due to the wire hitting a hard surface during operation of the vehicle is reduced.

[0063] It will be appreciated by persons skilled in the art that the present embodiments are not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings.

Claims

Claims:

1. A connector module (40) for insertion to a housing (18) of a battery (14), the connector module (40) comprising: a connector (20) having one or more electrically conductive battery terminals (24), the one or more battery terminals (24) electrically coupling to one or more cells (32), each of the one or more battery terminals (24) comprising a first portion (25), a second portion (27) contiguous with the first portion (25) and a third portion (29) contiguous with the second portion (27); and one or more ferrite beads (36), each of the one or more ferrite beads (36) surrounding a corresponding second portion (27) of a battery terminal (24) of the one or more battery terminals (24).

2. The module (40) of Claim 1, wherein a single ferrite bead (36) of the one or more ferrite beads (36) surrounds the corresponding second portion (27) of the one or more battery terminals (24).

3. The module (40) of Claim 2, wherein the single ferrite bead (36) is configured to filter common mode noise.

4. The module (40) of Claim 2, wherein the one or more ferrite beads (36) are configured to filter differential mode noise.

5. The module (40) of any one of Claims 1-4, wherein each of the one or more ferrite beads (36) is overmolded to the second portion (27) of the corresponding battery terminal (24).

6. The module (40) of any one of Claims 1-5, wherein each of the one or more ferrite beads (36) is friction fit to the second portion (27) of the corresponding battery terminal (24).

7. The module (40) of any one of Claims 1-5, wherein each of the one or more ferrite beads (36) is secured to the second portion (27) of the corresponding battery terminal (24) using an adhesive.

8. The module (40) of any one of Claims 1-7, wherein the connector (20) comprises an internal side and an external side, and a separation portion (31) separating the internal side from the external side, the first portion (25) of the battery terminal (24) being located on the external side and protruding through the separating portion (31), the first portion (25) of the battery terminal (24) being connectable to a wiring harness of a vehicle (12).

9. The module (40) of any one of Claims 1-8, wherein, when the module (40) is secured to the housing (18) of the battery (14), the third portions (29) of the battery terminals (24) are electrically couplable to a battery management system, BMS (16).

10. A battery (14) comprising: at least one cell (32); a battery management system, BMS (16); and a housing (18), the housing (18) comprising a connector (20) having one or more electrically conductive battery terminals (24), each of the one or more battery terminals (24) comprising a first portion (25), a second portion (27) contiguous with the first portion (25) and a third portion (29) contiguous with the second portion (27), the one or more battery terminals (24) electrically coupling to the one or more cells via the BMS (16); and one or more ferrite beads (36), each of the one or more ferrite beads (36) surrounding a corresponding second portion (27) of a battery terminal (24) of the one or more battery terminals (24).

11. The battery (14) of Claim 10, wherein the at least one cell (32) is an ultracapacitor.

12. The battery (14) of any one of Claims 10 and 11, wherein a single ferrite bead (36) of the one or more ferrite beads (36) surrounds the corresponding second portion (27) of the one or more battery terminals (24).

13. The battery (14) of any one of Claims 10-12, wherein the single ferrite bead (36) is configured to filter common mode noise.

14. The battery (14) of any one of Claims 10-13, wherein the one or more ferrite beads (36) are configured to filter differential mode noise.

15. The battery (14) of any one of Claims 10-14, wherein each of the one or more ferrite beads (36) is overmolded to the second portion (27) of the corresponding battery terminal (24).

16. The battery (14) of any one of Claims 10-14, wherein each of the one or more ferrite beads (36) is friction fit to the second portion (27) of corresponding the battery terminal (24).

17. The battery (14) of any one of Claims 10-14, wherein each of the one or more ferrite beads (36) is secured to the second portion (27) of the corresponding battery terminal (24) using an adhesive.

18. The battery (14) of any one of Claims 10-17, wherein the connector (20) comprises an internal side and an external side, and a separation portion (31) separating the internal side from the external side, the first portion (25) of the at least one battery terminal (24) being located on the external side and protruding through the separating portion (31), the first portion (25) of the at least one battery terminal (24) being connectable to a wiring harness of a vehicle (12).

19. The battery (14) of any one of Claims 10-18, wherein the second portion (27) of the at least one battery terminal (24) is on the internal side of the connector (20).

20. The battery (14) of any one of Claims 11-19, wherein the connector (20) and one or more ferrite beads (36) secured to the corresponding second portion (27) of the battery terminal (24) form a separate module (40), the separate module (40) configured to be secured to the housing (18).

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