Cell-to-cell connector

Abstract

A cell-to-cell connector includes a housing having first and second parallel slots. The first and second slots are each configured to receive an electrical terminal of a cell therein. A spring element is disposed within the housing and includes a body and first, second, and third resilient members extending therefrom. The first resilient member is adjacent the first slot and the second resilient member is adjacent the second slot. A conductive member including a plurality of contact beams is disposed in the housing and retained therein by the third resilient member. Each contact beam includes a contact surface. At least one of the contact beams is disposed in the first slot, and at least one of the contact beams is disposed in the second slot. The first and second resilient members apply a compression force to the conductive member adjacent the first and second slots, respectively.

Description

Atty Docket No. 177817.217612-WOCELL-TO-CELL CONNECTORCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application No. 63 / 703,274, filed October 4, 2024, the disclosure of which is incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] The disclosure generally relates to batteries and, more specifically, to batteries for powering electric vehicles (EVs) and connectors for electrically connecting two electrical cells of a battery together.BACKGROUND OF THE INVENTION

[0003] Battery packs, such as those used to power an electric vehicle, include a plurality of electric cells. The cells of the battery pack are typically arranged in modules, but at the lowest level, the battery pack or each module of the battery pack includes a number of individual, elementary cells. To build the battery, the individual cells need to be electrically connected to each other in parallel or in series. For example, an electrical terminal of one cell may be connected to an electrical terminal of an adjacent cell to electrically connect the two cells together. The cells may be electrically connected using a welded conductive wire. However, a need exists for a connector that can be more easily installed to electrically connect two cells and / or that can assure a sufficient electrical connection between the cells. Also, the ability to easily service the connection between cells is needed in case of replacement or recycling of the cells.BRIEF SUMMARY

[0004] An improved cell-to-cell connector for electrically connecting an electrical terminal of a first electric cell to an electrical terminal of a second electric cell is provided. The connector includes a housing having first and second parallel slots. The first slot and the second slot are each configured to receive an electrical terminal of a cell therein. A spring element is disposed within the housing. The spring element includes a body, first and second resilient members extending from the body, and a third resilient member extending from the body between the first and second resilient members. The first resilient member is adjacent the first slot in the housing and the second resilient member is adjacent the second slot in the housing. A conductive member including a plurality of contact beams is disposed in the housing and retained therein by the third resilient member. Each contact beam of the conductive member includes a contact surface. At least one of the contact beams is disposed in the first slot in the housing, and at least one of the contact beams is disposed in the secondAtty Docket No. 177817.217612-WO slot in the housing. The first and second resilient members apply a compression force to the conductive member adjacent the first and second slots, respectively.

[0005] In specific embodiments, the connector further includes a frame member defining a receptacle. The frame member has a plurality of contact windows formed therein, and the contact windows are continuous with the receptacle. The conductive member is received in the receptacle of the frame member. Each contact beam is disposed in a respective one of the contact windows of the frame member. The frame member including the conductive member received therein is disposed in the housing.

[0006] In particular embodiments, the frame member includes a planar base and a sidewall extending around a perimeter of the planar base. The planar base and sidewall define the receptacle, and the contact windows are elongated openings formed in the planar base.

[0007] In specific embodiments, the housing includes a central beam extending parallel to the first and second slots. The central beam includes a support surface for supporting the conductive member in the housing.

[0008] In specific embodiments, the first and second resilient members are flat springs, the first and second resilient members are cantilevered to the body of the spring element, and a terminal, free end of each of the first and second resilient members engages the conductive member.

[0009] In specific embodiments, the third resilient member is a flat spring, the third resilient member is cantilevered to the body of the spring element, and a terminal, free end of the third resilient member engages the conductive member.

[0010] In specific embodiments, the housing includes first and second opposite sidewalls, a first support shoulder extending inwardly from the first sidewall, and a second support shoulder extending inwardly from the second sidewall. The spring element is supported in the housing by the support shoulders.

[0011] In particular embodiments, wherein the housing includes a central beam extending parallel to the first and second slots. The first sidewall, the first support shoulder, and the central beam define the first slot. The second sidewall, the second support shoulder, and the central beam define the second slot.

[0012] In specific embodiments, each contact surface of each contact beam includes a plurality of contact points.

[0013] In particular embodiments, the plurality of contact points of each contact beam are semicircular and separated by a plurality of gaps, with the plurality of contact points of each beam being arranged in a row extending laterally across the conductive member.

[0014] In specific embodiments, the housing includes a retention tab for retaining the spring element therein.Atty Docket No. 177817.217612-WO

[0015] In specific embodiments, the housing includes first and second retention arms. The first retention arm is adjacent the first slot and the second retention arm is adjacent the second slot.

[0016] In particular embodiments, each retention arm has a clip tab for clipping to an electrical terminal.

[0017] In specific embodiments, the connector further includes an actuator moveably engaged with the housing and moveable between an unlatched position and a latched position.

[0018] In particular embodiments, the actuator includes a first arm that contacts the outer surface of the housing.

[0019] In certain embodiments, the first arm includes a confirmation window, an assembly confirmation feature is disposed on the outer surface of the housing, and the assembly confirmation feature is only fully revealed in the confirmation window when the actuator is in the latched position.

[0020] In particular embodiments, the actuator includes an actuation surface. The actuation surface of the actuator is received within the housing, and movement of the actuator from the unlatched position to the latched position moves the actuation surface into the housing such that the actuation surface contacts and applies a compressive force to the first and second resilient members to increase a contact force on the conductive member.

[0021] In certain embodiments, the actuator includes a second arm, and the second arm includes the actuation surface.

[0022] In specific embodiments, the connector further includes a flexible printed circuit inserted into the housing.

[0023] In particular embodiments, the flexible printed circuit is configured to move the actuator from the unlatched position to the latched position.

[0024] A method of connecting an electrical terminal of a first electrical cell with an electrical terminal of a second electrical cell with a connector is also provided. The connector is a connector as described in accordance with the various embodiments herein. The method includes positioning the connector to the side of the terminals of the first and second electrical cells, wherein the first and second slots are aligned with a respective one of the terminals. The method further includes sliding the connector onto the terminals such that the terminal of the first electrical cell is received in the first slot and the terminal of the second electrical cell is received in the second slot. The first and second resilient members apply a compression force to the conductive member to maintain electrical contact between the terminals and the conductive member such that an electrical connection is provided between the two terminals.Atty Docket No. 177817.217612-WO

[0025] In specific embodiments, the housing contacts an underside of the terminals in the first and second slots.

[0026] In specific embodiments, the connector further includes an actuator moveably engaged with the housing and moveable between an unlatched position and a latched position. After the connector is slid onto the terminals, the method further includes the step of moving the actuator from the unlatched position to the latched position.

[0027] In particular embodiments, in the latched position the actuator applies a compressive force to the first and second resilient members whereby the actuator provides an increased contact force against the conductive member.DESCRIPTION OF THE DRAWINGS

[0028] Various advantages and aspects of this disclosure may be understood in view of the following detailed description when considered in connection with the accompanying drawings, wherein:

[0029] Figure 1 is a perspective view of a cell-to-cell electrical connector in accordance with a first embodiment of the disclosure;

[0030] Figure 2 is an exploded view of the connector of Figure 1 ;

[0031] Figure 3 is a perspective of a cell-to-cell electrical connector in accordance with a second embodiment of the disclosure;

[0032] Figure 4 is an exploded view of the connector of Figure 3;

[0033] Figure 5 is a perspective view of a conductive member of the connector in accordance with various embodiments of the disclosure;

[0034] Figure 6 is a perspective view of a frame member of the connector in accordance with various embodiments of the disclosure;

[0035] Figure 7 is a schematic illustration of a first step of assembling the connector in accordance with various embodiments of the disclosure, with the sub-assembly shown in perspective, lateral, and plan views;

[0036] Figure 8 is a schematic illustration of a second step of assembling the connector in accordance with the first embodiment, with the subassembly shown in perspective and partially enlarged views;

[0037] Figure 9 is a schematic illustration of a third step of assembling the connector in accordance with the first embodiment, with the assembly shown in perspective, sectional, and lateral views;

[0038] Figure 10 is a schematic illustration of a second step of assembling the connector in accordance with the second embodiment, with the sub-assembly shown in sectional, perspective, and partially enlarged views;Atty Docket No. 177817.217612-WO

[0039] Figure 11 is a schematic illustration of a third step of assembling the connector in accordance with the second embodiment, with the sub-assembly shown in sectional, lateral, and partially enlarged views;

[0040] Figure 12 is a schematic illustration of a fourth step of assembling the connector in accordance with the second embodiment, with the assembly shown in perspective, sectional, and partially enlarged views;

[0041] Figure 13 is a schematic illustration of steps of electrically connecting two adjacent electrical cells of a battery with the connector in accordance with the first embodiment shown in perspective and sectional views;

[0042] Figure 14 is a schematic illustration of a first step of electrically connecting two adjacent electrical cells of a battery with the connector in accordance with the second embodiment shown in perspective views;

[0043] Figure 15 is a schematic illustration of a second step of electrically connecting two adjacent electrical cells of a battery with the connector in accordance with the second embodiment shown in perspective and lateral views;

[0044] Figure 16 is a schematic illustration of a third step of electrically connecting two adjacent electrical cells of a battery with the connector in accordance with the second embodiment shown in perspective and sectional views;

[0045] Figure 17 is a perspective view of the connector of Figure 16 after completion of the third step;

[0046] Figure 18 is a schematic illustration of a fourth step of electrically connecting two adjacent electrical cells of a battery with the connector in accordance with the second embodiment shown in perspective and sectional views;

[0047] Figure 19 is a perspective view of a conductive member of the connector in accordance with other embodiments of the disclosure;

[0048] Figure 20 is a perspective view of a connector in accordance with some embodiments of the disclosure including the conductive member of Figure 19;

[0049] Figure 21 is a side, sectional view of the connector of Figure 20;

[0050] Figure 22 is a perspective view of a connector including an actuator in accordance with other embodiments of the disclosure, and an enlarged, partial view of an interface between the actuator and a housing of the connector;

[0051] Figure 23 is a schematic, perspective view illustrating movement of the actuator relative to the housing of the connector of Figure 22;

[0052] Figure 24 is a schematic illustration of a connector in accordance with yet other embodiments of the disclosure shown in perspective and sectional views;Atty Docket No. 177817.217612-WO

[0053] Figure 25 is an environmental view of a connector in accordance with yet other embodiments of the disclosure, illustrating a flexible printed circuit of the connector being inserted into the housing;

[0054] Figure 26 is an environmental view of the connector of Figure 25, illustrating the flexible printed circuit in an inserted disposition;

[0055] Figure 27 is a perspective, sectional view of the connector of Figure 26;

[0056] Figure 28 is a partially exploded view of a connector in accordance with yet other embodiments of the disclosure; and

[0057] Figure 29 is a perspective view of the connector of Figure 28.DETAILED DESCRIPTION OF THE INVENTION

[0058] A cell-to-cell connector for electrically connecting an electrical terminal of a first electric cell to an electrical terminal of a second electric cell is provided. Referring to Figures 1-29, wherein like numerals indicate corresponding parts throughout the several views, the connector is illustrated and generally designated at 110, 210, 310, 410, 510, 610, 710. The connector provides facile connection / disconnection between two elementary battery cells, both for assembling the cells together and for dissembling the connection between the cells in the case that the cells need to be replaced and / or recycled. The connector also provides for increased contact force between the conductive element of the connector and the electrical terminals of the cells. Certain features of the connector are functional, but can be implemented in different aesthetic configurations.

[0059] With reference first to Figures 1 , 2, 5, and 6, in a first embodiment the connector 110 includes a housing 112 having first slot 114 and a second slot 116. The first slot 114 is parallel to the second slot 116. As described in more detail below, each of the first and second slots 114, 116 are configured to receive a separate electrical terminal of an electrical cell therein. The housing 112 is not limited to a specific shape or general configuration. As shown, the housing has a generally rectangular three-dimensional shape having a top and bottom with a much greater surface area than the sides such that the housing has a narrow profile. The openings to the slots 114, 116 are located in the bottom surface as well as one of the side surfaces of the housing. The housing 112 may include first and second sidewalls 120, 122, respectively. A first support shoulder 124 extends inwardly from the first sidewall 120, and likewise a second support shoulder 126 extends inwardly from the second sidewall 122. A central beam 128 in the form of a rib extends parallel to the first and second slots 114, 116 within the boundaries of the housing 112. The central beam 128 includes a support surface 130 that together with the top of the housing 112 forms a third slot 132. The first sidewall 120, the first support shoulder 124, and the central beam 128 define the first slot 114, and the second sidewall 122, the second support shoulder 126, and the central beam 128 define the second slot 116. The housing 112 is not limited to a particular material ofAtty Docket No. 177817.217612-WO construction, but in preferred embodiments the housing is made of an insulative material that does not conduct electricity. As such, the housing 112 electrically isolates a user from the internal electrical contact during assembly or disassembly of the connector 110.

[0060] A spring element 134 is disposed within the housing 1 12 and generally supported in the housing by the support shoulders 124, 126. The spring element 134 generally corresponds in shape to the housing 112 so that the spring element 134 fits into the housing 112 in a nested relationship. The spring element 134 includes a body 136. The body 136 of the spring element 134 generally includes a top and sidewalls extend from the edges of the top. Feet extend inwardly from each of the sidewalls and correspond to the support shoulders 124, 126 of the housing 112. A first resilient member 138 and a second resilient member 140 extend downward from the top of the body 136 into a space between the sidewalls, and a third resilient member 142 extends from the body 136 between the first and second resilient members 138, 140. The first resilient member 138 is adjacent the first slot 114 in the housing 112, and the second resilient member 140 is adjacent the second slot 116 in the housing 112. The first, second, and third resilient members 138, 140, 142 each extend from the body 136 in the same direction, although alternatively one or more of the resilient members could extend in an opposite direction. Each of the first, second, and third resilient members 138, 140, 142 may be formed as a flat spring that is flexibly connected at one end to the body 136 while the opposite end is a terminal, free end such that each of the resilient members 138, 140, 142 is cantilevered to the body 136. Each of the first, second, and third resilient members 138, 140, 142 may be formed by cutting and bending a portion of the material that forms the top of the body 136. In various embodiments, the spring element 134 is made of a metal or other rigid material that is capable of being elastically deformed.

[0061] The connector 110 further includes a conductive member 144. The conductive member is preferably formed of a conductive metal or metal alloy, but may be formed of any conductive material. The conductive member 144 includes a plurality of contact beams 146. In the first embodiment of the connector 110, each contact surface 148 of each contact beam 146 includes a plurality of contact point 150, and the plurality of contact points of each contact beam 146 are semicircular and separated by a plurality of gaps. The plurality of contact points 150 of each beam 146 are arranged in a row extending laterally across the conductive member 144. The conductive member may be formed of a sheet of material that is stamped to form the contact beams 146. Alternatively, the conductive member may be formed by molding, additive manufacturing, or similar.

[0062] The connector 110 further includes a frame member 152. The frame member includes a planar base 154 and a sidewall 156 extending around the perimeter of the base 154. The base 154 and sidewall 156 define a receptacle 158 in the frame member 152. The conductive member 144 is inserted into and received in the receptacle 158. The frameAtty Docket No. 177817.217612-WO member 152 also has a plurality of contact windows 160 that are elongated openings formed in the base 154. The contact windows 160 are continuous with the receptacle 158 and generally correspond in size with the contact beams 146. When the conductive member 144 is nested in the receptacle 158, each contact beam 146 is disposed in one of the contact windows 160. The frame member 152 and nested conductive member 144 is inserted into the third slot 132 in the housing 1 12 to dispose the frame member 152 and conductive member 144 in the housing 1 12. The frame member 152 and conductive member 144 are retained in the housing 112 by the third resilient member 142 as described in greater detail below, which generally compresses the frame member 152 and conductive member 144 against the support surface 130 of the central beam 128. Two of the contact beams 146 are disposed in the first slot 1 14 in the housing 1 12, and the other two of the contact beams 146 are disposed in the second slot 116 in the housing 112. The first resilient member 138 applies a compression force to the conductive member 144 adjacent the first slot 1 14 and in the vicinity of the two contact beams 146 in the first slot 114. Likewise, the second resilient member 140 applies a compression force to the conductive member 144 adjacent the second slot 116 and in the vicinity of the two contact beams 146 in the second slot 116.

[0063] Turning next to Figures 3 and 4, in a second embodiment the connector 210 generally includes a spring element 234, a conductive member 244, and a frame member 252 having the same features as the first embodiment 110. The housing 262 also generally includes all of the same feature as the first embodiment 110. Additionally, the housing 262 includes a first retention arm 264 and a second retention arm 266 that are formed in the top of the housing 262. The first retention arm 264 is adjacent the first slot 214 and the second retention arm 266 is adjacent the second slot 216. Each retention arm 264, 266 is generally cantilevered to the top of the housing 262 and has a free end that terminates in a clip tab 268 for clipping each retention arm 264, 266 to a separate electrical terminal of an electric cell. The housing 262 also includes an assembly confirmation feature 270 printed or formed on the outer surface of the top of the housing 262. The assembly confirmation feature 270 may be a one-dimensional barcode (e.g. UPC code, EAN code, code 39, code 128, ITF, code 93, codabar, GS1 databar, MSI Plessey, etc.), a two-dimensional barcode (e.g. QR code, datamatrix code, PDF417, AZTEC, etc.), a holographic code, a human-readable alphanumeric code, other codes known in the art and interpretable by machine and / or human. Additional examples of such codes include linear bar codes such as those known or otherwise characterized as Australia Post barcode, Codabar, Code 25-Non-interleaved 2 of 5, Code 25 Interleaved 2 of 5, Code 11 , Farmacode (i.e. , Code 32), Code 39, Code 49, Code 93, Code 128, CPC binary, EAN 2, EAN 5, EAN-8, EAN-13, GS1-128, GS1 DataBar, ITF- 14, JAN, Japan Post bardcode, KarTrak ACI, MSI, Pharmacode, PLANET, Plessey, PostBar, POSTNET, RM4SCC / KIX, RM Mailmark L, Telepen, or Universal Product Code, matrix barAtty Docket No. 177817.217612-WO codes such as those known or otherwise characterized as AR code, Aztec Code, BEEtag, Bee Tagg, Bokode, Code 1 , Code 16K, ColorCode, Color Construct Code, Cronto Visual Cryptogram, CyberCode, d-touch, DataGlyphs, Data Matrix, Datastrip Code, Digimarc Barcode, DotCode, DotCode A, DWCode, EZcode, Han Xin Barcode, High Capacity Color Barcode, HueCode, InterCode, JAB-Code, MaxiCode, mCode, MMCC, NexCode, PDF417, Qode, QR code, ShotCode, Snowflake Code, SPARQCode, or Trillcode, and the like, or any combination thereof.

[0064] Different than the first embodiment 110, the connector 210 further includes an actuator 272. The actuator 272 is moveably engaged with the housing 262 and moveable between an unlatched position (shown, for example, in Figure 17) and a latched position (shown, for example, in Figure 18). In the unlatched position, the actuator 272 is slid away from and to the side of the housing 262, while in the latched position a portion of the actuator 272 is inserted into the housing 262 and the actuator 272 is disposed over and on top of the housing 262. The actuator 272 includes a first arm 274 that contacts the outer surface of the housing 262. The first arm 274 is generally planar and is configured to overlap the outer surface of the housing 262. A confirmation window 276 is formed in the first arm 274. In the unlatched position, the first arm 274 blocks the assembly confirmation feature 270 from view, indicating that the connector 210 is not latched. On the other hand, in the latched position the assembly confirmation feature 270 is fully revealed in the confirmation window 276. The assembly confirmation feature 270 may then be fully read to indicate that the connector 210 is securely and properly installed. With additional reference to Figure 12, the actuator 272 further includes a pair of second arms 278 each having an actuation surface 280. The pair of second arms 278 may be two prongs that each correspond to one of the slots 214, 216. Each second arm 278 is received within the housing 262, and movement of the actuator 272 from the unlatched position to the latched position moves the second arms 278 into the housing 262 such that the actuation surface 280 contacts and applies a compressive force to the first and second resilient members 238, 240 whereby a contact surface 282 of the actuator 272 opposite the actuation surface 280 applies a contact force against the conductive member 244. The contact force further compresses the resilient members 238, 240 and increases the normal force provided on the conductive member 244 for increased electrical contact between the conductive member 244 and electrical terminals of battery cells when the connector 210 is in use. As such, the actuator 272 increases the contact force of the spring element 234 against the conductive member 244 by over constraining the resilient members of the spring element 234.

[0065] With reference now to Figures 7-9, the connector 1 10 is assembled by first placing the conductive member 144 into the receptacle 158 in the frame member 152. The contact beams 146 pass through the contact windows 160 in the frame member 152. Next, the springAtty Docket No. 177817.217612-WO element 134 is inserted into the housing 112 and is nested within the housing such that no portion of the spring element 134 extends out of the housing 112. As shown in Figure 8, in this embodiment the housing 1 12 may include a retention tab 161 on the first and / or second support shoulder 124, 126 of the housing 112 for retaining the spring element 134. The spring element 134 may include a corresponding receiving feature that snaps onto the retention tab 161. After the spring element 134 is secured in the housing 112, the frame member 152 with the conductive member 144 held therein is inserted into the third slot 132 in the housing 112. The frame member 152 is supported on the support surface 130, the third resilient member 142 pushes the conductive member 144 and frame member 152 against the support surface 130 to retain the conductive member 144 and frame member 152 in the housing 112, and the first and second resilient members 138, 140 engage the conductive member 144 in the vicinity of the first and second slots 114, 1 16.

[0066] With reference next to Figures 10-12, the connector 210 is also assembled by first placing the conductive member 244 into the receptacle 258 in the frame member 252 in the same manner as in the first embodiment 110 with the contact surface 248 extending through the windows. Next, the spring element 234 is inserted into the housing 262 in a similar manner as the first embodiment 110. In this embodiment, however, the retention tab 261 is formed in the top of the housing 262 and snaps into a corresponding feature in the top of the spring element 234. The spring element 234 alternatively may include a bent tab that bites into an edge of the housing 262 to retain the spring element 234 in the housing 262. Alternatively yet, the bent tab of the spring element 234 can engage a recess in the housing 262 that holds the spring element 234 in the housing 262.

[0067] Subsequently, the frame member 252 with the conductive member 244 held therein is inserted into the third slot 232 in the housing 262. The frame member 252 is supported on the support surface 230, the third resilient member 242 pushes the conductive member 244 and frame member 252 against the support surface 230 to retain the conductive member 244 and frame member 252 in the housing 262, and the first and second resilient members 238, 240 engage the conductive member 244 in the vicinity of the first and second slots 214, 216. In some embodiments, the conductive member 244 may include a bent portion that is stopped by the first and / or second resilient member 238, 240 to retain the conductive member 244 and frame member 252 in the housing 262. Alternatively, the conductive member 244 and frame member 252 may be retained simply by the friction force of the resilient members 238, 240 against the conductive member 244, or by edge biting of the resilient members 238, 240 against the conductive member 244.

[0068] After the conductive member 244 and frame member 252 are secured, the actuator 272 is assembled onto the housing 262 by inserting the two second arms 278 into the housing 262 opposite the two clip tabs 268. The outer, upper surface of the top of the housingAtty Docket No. 177817.217612-WO262 includes a retention tab that cooperates with the actuator 272 to snap and hold the actuator on the housing 262 in the unlatched position. The housing 262 includes another retention tab that snaps and holds the actuator 272 when the actuator is moved from the unlatched position to the latched position.

[0069] Turning next to Figure 13, to assemble the connector 1 10 onto terminals 184 of a battery cell, the connector 110 is positioned to the side of the terminals 184 of the two electrical cells so that each of the first and second slots 114, 116 is aligned with a respective one of the terminals 184. The connector 110 is then pushed towards the terminals to slide the connector onto the terminals 184 such that the terminal of the first electrical cell is received in the first slot 1 14 and the terminal of the second electrical cell is received in the second slot 116. The first and second resilient members 138, 140 apply a compression force to the conductive member 144 to maintain electrical contact between the terminals 184 and the conductive member 144 such that an electrical connection is provided between the two terminals through the conductive member 144. Further, the first and second support shoulders 124, 126 of the housing 1 12 are disposed on an underside of the terminals 184 in the first and second slots 114, 1 16 which holds the connector 110 on the terminals 184.

[0070] Similarly, with reference to Figures 14-18, to assemble the connector 210 onto terminals 284 of a battery cell, the connector is positioned to the side of the terminals 284 of the two electrical cells so that each of the first and second slots 214, 216 is aligned with a respective one of the terminals 284. The connector 210 is then pushed towards the terminals to slide the connector onto the terminals 284 such that the terminal of the first electrical cell is received in the first slot 214 and the terminal of the second electrical cell is received in the second slot 216. The first and second retention arms 264, 266, and particularly the clip tabs 268, slide on top of the terminals 284 as the connector 210 is pushed over the terminals 284. In this configuration, the retention arms 264, 266 are deflected away from the terminals 284 and upwards in the direction of the actuator 272 and thereby restrict movement of the actuator over the housing 262 to prevent the actuator 272 from moving from the unlatched disposition to the latched disposition. Once the connector 210 is completely slid over the terminals 284, the clip tabs 268 of the retention arms 264, 266 snap over the edge of the terminals 284 and allow the retention arms 264, 266 to return to a resting position. The first and second resilient members 238, 240 apply a compression force to the conductive member 244 to maintain electrical contact between the terminals 284 and the conductive member 244 such that an electrical connection is provided between the two terminals through the conductive member 244. Further, the first and second support shoulders 224, 226 of the housing 262 contact an underside of the terminals 284 in the first and second slots 214, 216 which holds the connector 210 on the terminals 284. Subsequently, the actuator 272 can then be pushed and moved from the unlatched position to the latched position by moving theAtty Docket No. 177817.217612-WO actuator further into and over the housing 262. In the latched position the actuator 272 applies an additional compressive force to the first and second resilient members 238, 240 such that the actuator 272 applies an increased contact force against the conductive member 244. Further, when the actuator 272 is secured in the latched position, the assembly confirmation feature 270 is fully revealed in the confirmation window 276 and may be read by a user or scanned by a reader.

[0071] Turning next to Figures 19-21 , in other embodiments the conductive member 344 of the connector 310 may be made thicker so that there is no need to have a frame member that receives and supports the conductive member. Further, the contact beam 346 may be a unitary raised bump or ridge in the surface of the conductive member 344, forming one continuous contact surface rather than a plurality of separate contact points along the beam.

[0072] With reference to Figures 22 and 23, in other embodiments the actuator 472 of the connector 410 may not include a first arm outside of the housing 412, and instead the actuator 472 only includes the pair of second actuator arms 478 that slide into the housing 412. In these embodiments, the central beam 428 of the housing includes a guide rail 485 along which a center arm of the actuator 472 slides to move the actuator between the unlatched and latched positions. Tabs on both the central beam 428 and center arm of the actuator 472 retain the actuator on the central beam as shown in detail in Figure 22.

[0073] Turning to Figure 24, in yet other embodiments the actuator 572 of the connector 510 may not include the second arms that are inside the housing, and instead the actuator 572 only includes the outer, first arm 574. In these embodiments, the spring element 534 floats within the housing 562, and when the actuator 572 is moved to the latched position, the first arm 574 snaps into the housing 562 and an actuation surface 581 on the first arm 574 contacts the spring element 534 to press the spring element downward into increased compression against the conductive member 544, thereby increasing the contact force applied on the conductive member 544.

[0074] With reference now to Figures 25-27, in yet other embodiments, the connector 610 may further include a flexible printed circuit (FPC) 686 that includes a tab that can be inserted into the housing and into contact with the conductive member 644. A flexible printed circuit is used for a Battery Management System (BMS), and the BMS FPC is typically welded on a busbar to monitor the cell’s voltage and temperature. However, welding cost and cycle time are high. Advantageously, in these embodiments of the connector 610, the FPC 686 can be electrically connected to the battery cells simply by inserting the FPC 686 into the connector 610 without the need to weld the FPC. The FPC 686 also can provide an additional compressive force against the resilient members of the spring element 634 in a similar manner as the actuator. Therefore, there is no need to include an actuator in these embodiments. In some other alternative embodiments, however, the FPC 786 may beAtty Docket No. 177817.217612-WO configured to move the actuator 772 of the connector 710 from the unlatched position to the latched position as shown in Figure 28 (unlatched) and Figure 29 (latched). For example, the actuator 772 may include slots in its side, and the FPC 786 may include prongs that are insertable through the slots, allowing a user to move the actuator by pushing on the FPC.

[0075] It is to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments which fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, different, special, and / or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.

[0076] Further, any ranges and subranges relied upon in describing various embodiments of the present invention independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and / or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the present invention, and such ranges and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and so on. As just one example, a range “of from 0.1 to 0.9” may be further delineated into a lower third, i.e., from 0.1 to 0.3, a middle third, i.e., from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9, which individually and collectively are within the scope of the appended claims, and may be relied upon individually and / or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language which defines or modifies a range, such as “at least,” “greater than,” “less than,” “no more than,” and the like, it is to be understood that such language includes subranges and / or an upper or lower limit. As another example, a range of “at least 10” inherently includes a subrange of from at least 10 to 35, a subrange of from at least 10 to 25, a subrange of from 25 to 35, and so on, and each subrange may be relied upon individually and / or collectively and provides adequate support for specific embodiments within the scope of the appended claims. Finally, an individual number within a disclosed range may be relied upon and provides adequate support for specific embodiments within the scope of the appended claims. For example, a range “of from 1 to 9” includes various individual integers, such as 3, as well as individual numbers including a decimal point (or fraction), such as 4.1 , which may be relied upon and provide adequate support for specific embodiments within the scope of the appended claims.Atty Docket No. 177817.217612-WO

[0077] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements by ordinal terms, for example “first,” “second,” and “third,” are used for clarity, and are not to be construed as limiting the order in which the claim elements appear. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

Atty Docket No. 177817.217612-WOCLAIMSWhat is claimed is:1 . A connector for electrically connecting an electrical terminal of a first electric cell to an electrical terminal of a second electric cell, the connector comprising: a housing having first and second parallel slots, the first slot and the second slot each being configured to receive an electrical terminal of a cell therein; a spring element disposed within the housing, the spring element including a body, first and second resilient members extending from the body, and a third resilient member extending from the body between the first and second resilient members, the first resilient member being adjacent the first slot in the housing and the second resilient member being adjacent the second slot in the housing; and a conductive member including a plurality of contact beams, each contact beam including a contact surface; the conductive member being disposed in the housing and retained therein by the third resilient member; wherein at least one of the contact beams is disposed in the first slot in the housing, at least one of the contact beams is disposed in the second slot in the housing, and the first and second resilient members apply a compression force to the conductive member adjacent the first and second slots, respectively.

2. The connector of claim 1 , further comprising a frame member defining a receptacle, the frame member having a plurality of contact windows formed therein, the contact windows being continuous with the receptacle; wherein the conductive member is received in the receptacle of the frame member, each contact beam is disposed in a respective one of the contact windows of the frame member, and the frame member including the conductive member received therein is disposed in the housing.

3. The connector of claim 2, wherein the frame member includes a planar base and a sidewall extending around a perimeter of the planar base, the planar base and sidewall defining the receptacle, and the contact windows being elongated openings formed in the planar base.

4. The connector of claim 1 , wherein the housing includes a central beam extending parallel to the first and second slots, and the central beam includes a support surface for supporting the conductive member in the housing.Atty Docket No. 177817.217612-WO5. The connector of claim 1 , wherein the first and second resilient members are flat springs, the first and second resilient members are cantilevered to the body of the spring element, and a terminal, free end of each of the first and second resilient members engages the conductive member.

6. The connector of claim 1 , wherein the third resilient member is a flat spring, the third resilient member is cantilevered to the body of the spring element, and a terminal, free end of the third resilient member engages the conductive member.

7. The connector of claim 1 , wherein the housing includes first and second opposite sidewalls, a first support shoulder extending inwardly from the first sidewall, and a second support shoulder extending inwardly from the second sidewall, and wherein the spring element is supported in the housing by the support shoulders.

8. The connector of claim 7, wherein the housing includes a central beam extending parallel to the first and second slots; the first sidewall, the first support shoulder, and the central beam define the first slot; and the second sidewall, the second support shoulder, and the central beam define the second slot.

9. The connector of claim 1 , wherein each contact surface of each contact beam includes a plurality of contact points.

10. The connector of claim 9, wherein the plurality of contact points of each contact beam are semicircular and separated by a plurality of gaps, with the plurality of contact points of each beam being arranged in a row extending laterally across the conductive member.11 . The connector of claim 1 , wherein the housing includes a retention tab for retaining the spring element therein.

12. The connector of claim 1 , wherein the housing includes first and second retention arms, the first retention arm being adjacent the first slot and the second retention arm being adjacent the second slot.Atty Docket No. 177817.217612-WO13. The connector of claim 12, wherein each retention arm has a clip tab for clipping to an electrical terminal.

14. The connector of claim 1 , further comprising an actuator moveably engaged with the housing and moveable between an unlatched position and a latched position.

15. The connector of claim 14, wherein the actuator includes a first arm that contacts the outer surface of the housing.

16. The connector of claim 15, wherein the first arm includes a confirmation window, an assembly confirmation feature is disposed on the outer surface of the housing, and the assembly confirmation feature is only fully revealed in the confirmation window when the actuator is in the latched position.

17. The connector of claim 14, wherein the actuator includes an actuation surface, the actuation surface of the actuator is received within the housing, and movement of the actuator from the unlatched position to the latched position moves the actuation surface into the housing wherein the actuation surface contacts and applies a compressive force to the first and second resilient members to increase a contact force on the conductive member.

18. The connector of claim 17, wherein the actuator includes a second arm, and the second arm includes the actuation surface.

19. The connector of claim 1 , further comprising a flexible printed circuit inserted into the housing.

20. The connector of claim 19, wherein the flexible printed circuit is configured to move the actuator from the unlatched position to the latched position.21 . A method of connecting an electrical terminal of a first electrical cell with an electrical terminal of a second electrical cell with a connector, the connector comprising: a housing having first and second parallel slots, the first slot and the second slot each being configured to receive an electrical terminal of a cell therein; a spring element disposed within the housing, the spring element including a body, first and second resilient members extending from the body, and a third resilient member extending from the body between the first and second resilient members,Atty Docket No. 177817.217612-WO the first resilient member being adjacent the first slot in the housing and the second resilient member being adjacent the second slot in the housing; and a conductive member including a plurality of contact beams, each contact beam including a contact surface; the conductive member being disposed in the housing and retained therein by the third resilient member; wherein at least one of the contact beams is disposed in the first slot in the housing, at least one of the contact beams is disposed in the second slot in the housing, and the first and second resilient members apply a compression force to the conductive member adjacent the first and second slots, respectively; the method comprising the steps of: positioning the connector to the side of the terminals of the first and second electrical cells, wherein the first and second slots are aligned with a respective one of the terminals; and sliding the connector onto the terminals such that the terminal of the first electrical cell is received in the first slot and the terminal of the second electrical cell is received in the second slot; wherein the first and second resilient members apply a compression force to the conductive member to maintain electrical contact between the terminals and the conductive member such that an electrical connection is provided between the two terminals.

22. The method of claim 21 , wherein the housing contacts an underside of the terminals in the first and second slots.

23. The method of claim 21 , wherein the connector further comprises an actuator moveably engaged with the housing and moveable between an unlatched position and a latched position; wherein after the connector is slid onto the terminals, the method further comprises the step of moving the actuator from the unlatched position to the latched position.

24. The method of claim 23, wherein in the latched position the actuator applies a compressive force to the first and second resilient members whereby the actuator provides an increased contact force against the conductive member.

Images