Electrical coupler

Abstract

The present disclosure concerns an electrical coupler for connecting a first bus bar and a second bus bar. The coupler includes a hollow body extending between a first end and a second end. The hollow body has first mounting slots and at least one second mounting slot. Each of the first mounting slots extends from the first end towards the second end, and the at least one second mounting slot extend from the second end towards the first end. The first mounting slots and the at least one second mounting slot are adapted to mount the first bus bar and the second bus bar, respectively. The hollow body is made of an electrically conducting material for electrically connecting the first bus bar mounted in the first mounting slots, with the second bus bar mounted in the at least one second mounting slot.

Description

ELECTRICAL COUPLERCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority of US provisional patent application No.63 / 744,996 filed on January 14, 2025.TECHNICAL FIELD

[0002] The technical field of the present disclosure generally relates to electrical couplers, and more particularly to electrical couplers for the connection of bus bars.BACKGROUND ART

[0003] Advancements in electrical power distribution systems have led to an increased demand for efficient and reliable components that ensure optimal performance. Some power distribution hubs, such as the electrical distribution system between a battery pack and a transformer, use bus bars to carry current.

[0004] Bus bars can be employed in a variety of settings, including industrial plants and renewable energy installations, where they facilitate the transmission of relatively high voltage.

[0005] While bus bars offer numerous advantages in terms of high current-carrying capacity, a compact and durable design for similar specifications, ease of maintenance and installation, and reduced electrical loss due to heating, they can also introduce complexity and reduce flexibility during installation and / or retrofitting. It is not difficult to imagine that a cable, even a high-voltage cable, can slip in various spaces as desired (see FIG. IB of the prior art), whereas bus bars have a fixed and rigid shape.

[0006] In conventional designs, bus bars are interconnected using electrical couplers (see FIG. 1 A of the prior art), which establish secure and conductive connections between incoming and outgoing terminals. Varying electrical couplers for bus bars exist, but they tend to be bulky as shown in FIG. 1 A, generate heat, and / or do not always allow for an easy and compact change of orientation of the bus bars. In addition, existing electrical couplers are generally time consuming to install, which may lead to a situation where the relevant certification agencies may challenge the ongoing design during commissioning, which may in turn force a user to reverse some if not all of the work in progress.

[0007] As previously explained, an electrical coupler for a bus bar should minimize excess heat, which poses risks of thermal stress and could induce electrical resistance. Finally, an electrical coupler should comply with the relevant safety and standards regulations.

[0008] There exists a need for an electrical coupler for connecting bus bars that would reduce at least one of the above-mentioned drawbacks of the prior art.BRIEF SUMMARY

[0009] In accordance with a first broad aspect, there is provided an electrical coupler for electrically connecting a first bus bar and a second bus bar, the electrical coupler comprising: a hollow body extending between a first end and a second end; the hollow body having a plurality of first mounting slots and at least one second mounting slot, each of the plurality of first mounting slots extending from the first end towards the second end, and the at least one second mounting slot extending from the second end towards the first end; the plurality of first mounting slots and the at least one second mounting slot being adapted to operatively mount the first bus bar and the second bus bar therein, respectively; and the hollow body being made at least partially of an electrically conducting material for electrically connecting the first bus bar, when being mounted in the plurality of first mounting slots, with the second bus bar, when being mounted in the at least one second mounting slot.

[0010] According to an embodiment, the plurality of first mounting slots and the at least one second mounting slot define a first free contact surface and a second free contact surface, respectively, adapted not to exceed a maximum electrical contact resistance when the electrical coupler carries current between the first bus bar and the second bus bar.

[0011] According to an embodiment, the maximum electrical contact resistance is adapted to limit heat generation in the electrical coupler and the first and second bus bars.

[0012] According to an embodiment, the at least one second mounting slot comprises a single second mounting slot.

[0013] According to an embodiment, the at least one second mounting slot comprises a pair of second mounting slots, and each one of the pair of second mounting slots extends from respective diametrically opposite points of a cross-section of the second end of the hollow body.

[0014] According to an embodiment, respective lengths of the plurality of first mounting slots and the at least one second mounting slot are equal.

[0015] According to an embodiment, the hollow body has a linear shape.

[0016] According to an embodiment, the hollow body further comprises a first hollow section having a first free end corresponding to the first end of the hollow body, a second hollow section having a second free end corresponding to the second end of the hollow body, and a third hollow section extending between the first hollow section and the second hollow section.

[0017] According to an embodiment, the first, second and third hollow sections respectively define first, second, and third longitudinal axes, respectively, and wherein at least one of the first and second longitudinal axes is oblique relative to the third longitudinal axis.

[0018] According to an embodiment, the first hollow section has a first bevelled end opposite to the first free end, the second hollow section has a second bevelled end opposite to the second end, and the third hollow section has two opposite bevelled ends each mounted to a respective one of the first bevelled end and the second bevelled end.

[0019] According to an embodiment, the third hollow section forms an elbow portion such that the first hollow section and the second hollow section are longitudinally offset.

[0020] According to an embodiment, the hollow body has a tubular shape and the plurality of first mounting slots and the at least one second mounting slot are radially offset with regard to the longitudinal axis of the hollow body by a given radial offset.

[0021] According to an embodiment, the given radial offset is 90°.

[0022] According to an embodiment, the hollow body has a cross-section having a constant diameter along the longitudinal axis.

[0023] According to an embodiment, the plurality of first mounting slots comprises a pair of first mounting slots that extend from particular antipodal points of a circumference of the first end of the hollow body.

[0024] According to a second broad aspect, there is provided an electrical assembly comprising: a plurality of first bus bars; a plurality of second bus bars; a plurality of electricalcouplers of any one of the previous embodiments for operatively coupling the plurality of first bus bars and the plurality of second bus bars.

[0025] According to a third broad aspect, there is provided a method for electrically connecting a first bus bar and a second bus bar, the method comprising: providing an electrical coupler according to any one of the previous embodiments; mounting the first bus bar into the plurality of first mounting slots of the hollow body of the electrical coupler; mounting the second bus bar into the at least one second mounting slot of the hollow body of the electrical coupler; and securing the first bus bar and the second bus bar to the hollow body of the electrical coupler.

[0026] According to an embodiment, said securing the first bus bar and the second bus bar comprises respectively welding contacting surfaces defined between the mounted first bus bar, the mounted second bus bar and the hollow body.BRIEF DESCRIPTION OF DRAWINGS

[0027] The accompanying drawings illustrate embodiment(s) of the present invention and, together with the description, serve to explain the principles of the present disclosure.

[0028] FIG. 1 A is a top perspective view of an electrical coupler for an electrical assembly including a bus bar mesh, according to an embodiment of the prior art;

[0029] FIG. IB is a top (right) perspective view of an electrical assembly including cables, according to another embodiment of the prior art;

[0030] FIG. 2 is a top (right) perspective view of a power distribution system for a battery pack system (not shown), partially disassembled, having a first electrical mating assembly and a second electrical mating assembly, in accordance with an embodiment;

[0031] FIG. 3 is an enlarged view of the power distribution system shown in FIG. 2, with a floor panel removed to expose tubular bus bars connecting the first and second electrical mating assemblies;

[0032] FIG. 4 is a top (left) perspective view, enlarged, of the power distribution system shown in FIG. 2;

[0033] FIG. 5 is an enlarged view of the power distribution system shown in FIG. 4, showing more particularly the second electrical mating assembly including two single-slotted electrical couplers and two double-slotted electrical couplers;

[0034] FIGS. 6A, 6B, 6C and 6D are respectively a top perspective view (FIG. 6A), a rear elevation view (FIG. 6B), a top plan view (FIG. 6C) and a bottom plan view (FIG. 6D) of the double-slotted electrical coupler shown in FIG. 5;

[0035] FIGS. 7A, 7B, 7C and 7D are respectively a top perspective view (FIG. 7A), a rear elevation view (FIG. 7B), a top plan view (FIG. 7C) and a bottom plan view (FIG. 7D) of the single-slotted electrical coupler shown in FIG. 5 ;

[0036] FIG. 8 A is a top (right) perspective view, enlarged, of the power distribution system shown in FIG. 2, showing more particularly the first electrical mating assembly including four extended electrical couplers connected to four tubular bus bars;

[0037] FIG. 8B is a front elevation view of the first electrical mating assembly shown in FIG. 8A;

[0038] FIG. 9 is a top perspective view, enlarged, of one of the tubular bus bars shown in FIGS. 3 and 8 A, having four protective rings; and

[0039] FIGS. 10A and 10B are respectively atop perspective view (FIG. 10A) and a front elevation view (FIG. 10B), enlarged, of one of the protective rings shown in FIG. 9.

[0040] It is understood that the drawings are for illustration purposes only and may not be to scale. The drawings are intended to depict only an embodiment according to the disclosure and therefore should not be considered as limiting.DETAILED DESCRIPTION

[0041] In at least some embodiments, the present electrical mating assemblies and the underlying electrical coupler are particularly devised to provide a relatively easy to install and / or reliable electrical connection between two bus bars (i.e., bus conductors). An embodiment of the electrical coupler may be used to connect two bus bars of different orientations, as detailed below. As it will become apparent below, the present electrical coupler allows for an improved heat dissipation through hollow dissipation portions being in free contact with the surrounding air. In at least some embodiments, the mating assemblies andcouplers described herein are particularly well suited for use in power distribution systems that include a large-scale battery pack system and / or a transformer.

[0042] Power Distribution System 100 & Battery Pack System 110

[0043] With reference to the drawings and the non-limitative embodiment shown in FIGS.2 to 10B, the present disclosure relates to a power distribution system 100 using a battery pack system 110 as an electrical power source. As it may be desirable to carry current being stored in the battery pack system 110 to another stage of the power distribution system 100, for example to a transformer (not shown), for further use or integration, the power distribution system 100 uses bus bars and electrical mating assemblies to interconnect corresponding terminals, as desired.

[0044] According to the embodiment being shown, the power distribution system 100 includes two electrical mating assemblies 200, 400, for example to connect the battery pack system 110 (partially shown) to a transformer (not shown) via an end terminal 102 (FIG. 2). Although the electrical mating assemblies 200, 400 described herein can be implemented with a battery pack system 110, this combination is not meant to be limitative since the electrical mating assemblies can be used in different types of infrastructures.

[0045] The power distribution system 100 includes a first electrical mating assembly 200 (hereinafter, the first assembly 200) and a second electrical mating assembly 400 (hereinafter, the second assembly 400). The first assembly 200 is located to the right of FIG. 2 and is adapted to directly couple to the battery pack system 110 and connect to intermediary bus bars that lead towards the end terminal 102.

[0046] It should be noted that, for the sake of simplicity, reference will be made to the frontmost battery pack system 110 (see FIG. 2), unless indicated otherwise, even though the embodiment shown in FIGS. 2 to 10B includes two identical and mirrored battery pack systems 110. The rear battery pack system also includes a first electrical mating assembly (not visible) that leads to the second electrical mating assembly 400.

[0047] The terms “first” and “second” in the present disclosure generally refer to a position of a component with regard to a direction of the current or power flow path within the power distribution system 110. In this context, a “first” component is positioned upstream and is configured to receive electrical current from a power source, while a “second” component ispositioned downstream and receives electrical current from the first component. It should be understood that said terms are not meant to be limitative as they more generally convey that a first component is distinct, but not necessarily unalike, from a second component.

[0048] The drawings purposefully do not illustrate a fully functional power distribution system 100 and battery pack system 110 for the sake of simplicity and clarity, as other elements would be known to one of ordinary skill in the art. For example, to illustrate a functional battery pack system, other missing components of a functional battery pack system would include battery modules, an inverter and a breaker. These battery pack system components are not required or essential to fully describe the first and second mating assemblies 200, 400, electrical couplers, or a method for electrically connecting bus bars.

[0049] In one embodiment, the first and second mating assemblies 200, 400 can carry an electrical current associated with a three-phase AC power system. For illustrative purposes, the first and second mating assemblies 200, 400 may be adapted for operation at voltages ranging from about 380V and about 505V, 3-phase.

[0050] When assembled, each of the first and second mating assemblies 200, 400 includes a plurality of first bus bars 140, 220 to carry an incoming current, and an equal plurality of second bus bars (or bus bar terminals) 162, 222 to carry an outgoing current. The second bus bars 162, 222 can be identical to the first bus bars 140, 220. As explained below with regard to the present embodiment, a plurality of electrical couplers can be provided to operatively couple the first bus bars 162, 222 with the second bus bars 140, 220 within their respective first and second mating assemblies 200, 400.

[0051] As shown more clearly in FIG. 3, tubular bus bars 160 can be located within an enclosure 120 of the battery pack system 110. The tubular bus bars 160 provide for electrical conduction there along, and preferably comprise a high conductivity aluminum alloy or copper. In an alternative embodiment (not shown), each tubular bus bar 160 may be substituted with three separate bus bars, each carrying a single-phase current, thereby creating a polyphase configuration.

[0052] Referring to FIGS. 3 and 4, the tubular bus bars 160 extend within and along the battery pack system 110 enclosure 120 and terminate at respective tubular bus bar terminals 162 (see FIG. 4). The tubular bus bar terminals 162 protrude beyond an outer perimeter of theenclosure 120 and are configured to electrically connect to corresponding plate bus bars 220, also referred to as non-segregated phase bus ducts.

[0053] The connection between the tubular bus bar 160 and the plate bus bars 220 can be enabled by braided electrical connectors (not shown), for instance.

[0054] It should be noted that the bus bars 140, 220, 162, 222 illustrated herein, whether tubular or non-segregated phase, are non-limitative. Bus bars may be formed or assembled from a variety of electrically conductive materials, including copper, brass, aluminum, or composite materials. Bus bars can be found in various shapes such as flat strips, hollow tubes, and other suitable geometries. Accordingly, different materials, shapes, and types of bus bars are contemplated within the scope of the present disclosure.

[0055] Protective Rings 180

[0056] Referring to FIGS. 3 and 9, one of the tubular bus bars 160 has a plurality of protective rings 180 snugly encircling a body of the tubular bus bar 160. Four of such protective rings 180 are distributed along a length of the body of said tubular bus bar 160.

[0057] In one embodiment, the protective ring 180 can be made of a resilient material suitable to absorb an external shock or vibration and thus reduce undesirable mechanical stress on the body of the tubular bus bar 160.

[0058] Referring to the embodiment shown in FIGS. 10A and 10B, around a hollow circular central portion, each protective ring 180 has eight sides and two faces; a front face and a rear face. All faces and sides are planar. Among the eight sides, two opposing sides are lateral, two sides are slanted. The lateral sides - parallel to one another - are configured to abut corresponding lateral sides of another protective ring 180 being equipped with a horizontally adjacent tubular bus bar 160. The slanted sides - parallel to one another - are configured to abut corresponding slanted sides of a diagonally adjacent protective rings (configuration now shown in the present embodiment of the power distribution system 100), for example. Accordingly, in addition to isolating and generally protecting tubular bus bars 160, the protective rings 180 may allow multiple bus bars 160 to be securely stacked together along their lengths.

[0059] A resilient material of the protective ring 180 can be selected to provide sufficient damping to conveniently absorb, reduce or minimise vibrations in the tubular bus bar 160 assembly. It also provides sufficient stiffness to enable a load to be applied to the bus bars 160, securing their respective position in the enclosure 120 of the battery pack system 110. It is understood that the protective ring 180 material is also chosen to provide sufficient electrical insulation.

[0060] First and Second Electrical Mating Assemblies 200, 400

[0061] In some embodiments of the second assembly 400, the first (upstream) bus bars 220 and the second (downstream) bus bars 222 are identical (see FIGS. 4 and 5). Other embodiments feature different types of first bus bars 140 and second bus bars 162 (see FIGS.8 A and 8B).

[0062] FIG. 4 partially shows two sets of four tubular bus bar terminals 162 emerging from two battery pack lateral sections of the battery pack system 110. Each terminal 162 set is connected to the other set of four tubular bus bar terminals 162 in the neighbouring battery pack lateral section via plate bus bars 220 (hereinafter, first bus bar 220). The plate bus bars 220 form a U-shape over the ground. At the top of the U-shape, each one of the four bus bars 220 is operably connected to a corresponding vertical second bus bar 222 (hereinafter, second bus bar 222) via a compact electrical coupler embodiment 300a, 300b , as further explained below.

[0063] Please note that for the sake of simplicity, the terms “first bus bar” and “second bus bar” are used interchangeably with reference to the bus bars 220, 222 of the first assembly 200 and the bus bars 140, 162 of the second assembly 400.

[0064] Referring more particularly to the configuration of the couplers 300a, 300b shown in FIGS. 5 to 7D, in addition to enabling an electrical connection between the bus bars 220, 222, which includes horizontal first bus bars 220, the couplers 300a, 300b can allow for a change of orientation of the second bus bars 222 with respect to the first bus bars 220 thereof up to a 90° angle, as explained further below. In other words, the second bus bars 222 are radially rotated to a vertical orientation relative to the horizontal first bus bars 220.

[0065] In the embodiment, the couplers 300a, 300b further enable an axial rotation of the second bus bars 222 with respect to the first bus bars 220 along a longitudinal axis of the second bus bars 222, up to a 90° angle, as explained further below.

[0066] In combination with a compact design, changes in radial and axial rotation may be desirable for flexible power transmission assemblies. For example, as shown more clearly in FIGS. 2 and 4, the end terminal 102 of the power distribution system 100 is spaced apart from the battery pack system 110 and is further vertically higher up than the tubular bus bar terminals 162 protruding from the enclosure 120. The couplers 300a, 300b of the second assembly 400 thus provide modularity to the system by directing the bus bars to a desired position (e.g., the end terminal 102).

[0067] The number of first and second bus bars 220, 222 illustrated in the present embodiment is not meant to be limitative. As explained in more details below, the second assembly 400 can be configured to mate and inter-connect a smaller or greater number of bus bars 220, 222, by subtracting or adding couplers for example.

[0068] With reference to FIGS. 6A to 7D, each one of the couplers 300a, 300b has a hollow body 320a, 320b extending along and around a longitudinal axis A-A’ between a first end 340a, 340b and a second end 360a, 360b. For each embodiment, the first end 340a, 340b and the second end 360a, 360b of the hollow body 320a, 320b have a circular rim with a circumference, such that the hollow body 320a, 320b has a cylindrical shape which characterises the hollow body 320a, 320b as a tubular hollow body.

[0069] In the context of the present disclosure, the term “hollow” refers to a space defined by inner walls being substantially empty. For example, in some embodiments (not shown), features such as fasteners and other mechanical or electrical elements may occupy part of the void within the hollow body 320a, 320b, which would not depart from the scope of the present disclosure.

[0070] According to an alternative embodiment (not shown), the first end and the second end of the couplers include an oval-shaped rim, each defining a perimeter.

[0071] With reference to FIGS. 6C, 6D, 7C, and 7D, the hollow bodies 320a, 320b of the couplers 300a, 300b have a (circular) cross-section with a substantially constant inner and outerdiameter along the longitudinal axis AA’. In alternative embodiments (not shown), the inner our outer diameter of the hollow body 320 varies along the longitudinal axis A-A’ .

[0072] In one embodiment, the hollow structure of the hollow body 320 provides an enlarged dissipation surface in free contact with the surrounding air for improving heat dissipation since both an outer surface and an inner surface of the hollow body 320 provide a relatively large surface area.

[0073] In the exemplary embodiments shown in FIGS. 6A to 7D, a longitudinal length of the couplers 300a, 300b between the respective first end 340a, 340b and the second end 360a, 360b of the hollow bodies 320a, 320b is between about 30 cm and about 40 cm. Furthermore, an outer diameter of the hollow body 320a, 320b of the coupler 300a, 300b - which can be defined between the longitudinal axis A-A’ and an outside periphery of the hollow body 320 -is about 7.5 cm. The inner diameter is about 6 cm. Finally, a radial thickness of the hollow body 320a, 320b (i.e., the difference between the outer diameter and the inner diameter of the hollow body) is about 0.75 cm.

[0074] Alternatively, the longitudinal length of the coupler 300a, 300b can range between about 15 cm and about 100 cm. The outer diameter of the coupler 300a, 300b can be between about 5 cm and about 30 cm, and the radial thickness of the hollow body 320a, 320b is between about 0.5 cm and about 3 cm. In one embodiment, the dimensions of the coupler 300a, 300b are chosen as a function of the characteristics of the electrical current to be carried therealong.

[0075] Still referring to the embodiments shown in FIGS. 6A to 7D, the hollow body 320a, 320b of the electrical coupler 300a, 300b has a plurality of first mounting slots 350a, 350b (hereinafter, the first mounting slots 350a, 350b) and at least one second mounting slot 370a, 370b, depending on the embodiment.

[0076] The number of slots defined by the at least one second mounting slot 370a, 370b can vary, hence the two embodiments of the electrical coupler 300a, 300b illustrated in FIGS.6 A to 7D. An electrical coupler having two second mounting slots 370b (see FIGS. 6 A to 6D) is designated as a double-slotted electrical coupler 300b (hereinafter, the double-slotted coupler 300b), whereas a coupler having a single second mounting slot 370a (see FIGS. 7A to 7D) is designated as a single-slotted electrical coupler 300a (hereinafter, the single-slotted coupler 300a).

[0077] Referring more particularly to FIG. 5, to align the second bus bars 222 one with another, the single-slotted couplers 300a are mounted and arranged on the two outer first bus bars 220 that are adapted to hold the respective second bus bars 222 about a middle of the assembly 400, whereas the double-slotted couplers 300b are mounted and arranged on the two middle first bus bars 220 with second bus bars 222 mounted thereon and positioned to enable the second bus bars 222 alignment.

[0078] Each first mounting slot 350a, 350b is recessed in the hollow body 320a, 320b and extends from the first end 340a, 340b towards the second end 360a, 360b. Each of the second mounting slots 370a, 370b is recessed in the hollow body 320a, 320b and extends from the second end 360a, 360b towards the first end 340a, 340b.

[0079] In the embodiment shown, the first and second mounting slots 350a, 350b, 370a, 370b extend along the longitudinal axis A-A’ of the coupler 300a, 300b. This disclosure also envisions first and / or second mounting slots 350a, 350b, 370a, 370b that do not extend parallel to the longitudinal axis A-A’ of the hollow body 320a, 320b (embodiment not shown). For example, the first mounting slots 350a, 350b can extend in the hollow body 320a, 320b in an oblique direction with respect to the longitudinal axis A-A’ from the first end 340, but still towards the second end 360a, 360b. In such an alternative embodiment, the bus bar 220 mating with the first mounting slot 350a, 350b will appear slanted when observed from a side elevation view.

[0080] As such, the expressions “from the first end towards the second end” and “from the second end towards the first end” are to be construed broadly and should not be limited to mounting slots 350a, 350b, 370a, 370b strictly extending along or parallel to the longitudinal axis A-A’ of the hollow body 320a, 320b.

[0081] It will be appreciated that mounting bus bars 220, 222 into the hollow body 320a, 320b, and more specifically via a recess or slot of the hollow body, provides a compact electrical arrangement for the second electrical assembly 400. Similar comments apply to the first electrical assembly 200, as explained below.

[0082] The first mounting slots 350a, 350b and the at least one second mounting slot 370a, 370b are adapted to operatively mount the first bus bar 220 and the second bus bar 222 therein, respectively.

[0083] To allow a compatible bus bar to mount the hollow body 320a, 320b, each of the first mounting slots 350a, 350b or second mounting slots 370a, 370b is sized and shaped to receive a portion of the bus bar.

[0084] As previously mentioned, the mounting slots 350a, 350b, 370a, 370b are recessed in the hollow body 320a, 320b. In the embodiments shown, each mounting slot is elongated and defines a relatively elongated and narrow parallelepiped. Each mounting slot 350a, 350b, 370a, 370b being of equal size, the following non-limitative dimensions with respect to the longitudinal axis A-A’ are: about 12.7 cm in height h, about 1.27 cm in width w, and about 0.75 cm in depth d. The first and second mounting slots 350a, 350b, 370a, 370b are dimensioned to provide sufficient welding area to match the cross-section of the bus bars conductors according to the current capacity of the arrangement.

[0085] In the embodiment shown, the first mounting slots 350a, 350b and the second mounting slots 370a, 370b have equal dimensions. Alternatively, respective dimensions of the first and second mounting slots 350a, 350b, 370a, 370b can be adapted to receive first and second bus bars 220, 222 of varying dimensions. For instance, if the first (plate) bus bar 220 is thicker than illustrated, the width h of the slots can be correspondingly increased.

[0086] It is understood that it can be desirable for the mounting slots 350a, 350b, 370a, 370b to be correspondingly shaped - preferably closely - to receive a respective portion of the bus bar 220, 222 so that the bus bar snugly fits in the first or second mounting slot 350a, 350b, 370a, 370b. A flush fit of the bus bar 220, 222 within the hollow body 320a, 320b of the coupler 300a, 300b may enhance contact consistency therebetween in terms of contact continuity and stability.

[0087] The person of ordinary skill in the art would appreciate that a consistent free contact surface between two terminals enables a low-resistance path for the electrical current, and that a stable contact surface reduces the risk of intermittent contacts or even disconnections. As explained further below, the bus bar can be further secured to a respective mounting slot. In the embodiment shown, the free contact surface area is about 16 cm2. Generally, the contact surface area should follow a relationship with the current capacity of approximately 6.45 cm2 / 1000A.

[0088] In some embodiments, the free contact surface of the mounting slots of the couplers simply refers to an inner surface of the hollow body defined inside the slots. Once the corresponding bus bar(s) has engaged the coupler, the free contact surfaces are no longer “free”.

[0089] Depending on the material chosen, the functional requirements, and the method of assembly, the above-mentioned dimensions ofthe hollow body 320a, 320b ofthe coupler 300a, 300b can be adjusted to increase or lower mechanical tolerance, as needed. For example, if a bus bar 220, 222 having been mounted into a respective mounting slot 350a, 350b, 370a, 370b is secured thereto via welding, a greater tolerance can be used since welding would bridge gaps between the contact surface of said mounting slot 370 and the bus bar 220, 222.

[0090] Considering that plate bus bars 220, 222 are substantially planar along their length and thus uniform in shape with consistent edges, the electrical coupler 300a, 300b can thus selectively mate to a desired section of the plate bus bar 220, 222 for added flexibility when assembling the electrical assembly 400. Alternatively, the person of ordinary skill in the art would also understand to adapt the mounting slots 350a, 350b, 370a, 370b to receive bus bars 220, 222 of varying shapes and dimensions, including thickness.

[0091] Referring to the different electrical coupler 300a, 300b embodiments being illustrated, the above-mentioned dimensions ofthe mounting slots 350a, 350b, 370a, 370b are adapted such that the free contact surfaces are sufficient to obtain a predetermined maximum electrical contact resistance, even if a chosen assembly method involves welding the bus bar to a corresponding mounting slot, which would increase a contacting surface for electrical conductivity. For the sake of providing an illustrative embodiment, the predetermined maximum electrical contact resistance obtained can be about 100 micro-Ohms (pQ) or lower. Tests have shown that such electrical couplers 300a, 300b have been shown to maintain below 100 micro-Ohms (pQ) of electrical resistance when carrying current within a battery pack system 110.

[0092] In some embodiments, the maximum electrical contact resistance is sufficient to limit heat generation in the electrical coupler and / or the first and second bus bars.

[0093] FIGS. 6A to 7D illustrate that the first mounting slots 350a, 350b of the singleslotted coupler 300a and the double-slotted coupler 300b include slots extending in pairs from the first end 340a, 340b of the hollow body 320a, 320b (i.e., a circumference). The mounting slot 350a, 350b pairs are sized, shaped and arranged such that a respective plate first or secondbus bar 220, 222 can be simultaneously mounted to both slots of the pair to effectively mate with the tubular hollow body 320.

[0094] As previously mentioned, the mounting slots 350a, 350b, 370a, 370b extend from their respective ends of the hollow body 320a, 320b. In the embodiments shown, the mounting slots 350a, 350b, 370a, 370b that are paired extend from given antipodal or diametrically opposite points of the circumference of the corresponding first end 340a, 340b or second end 360a, 360b. In other terms, the corresponding slots face each other.

[0095] Still referring to the embodiments shown in FIGS. 6A to 7D, the plurality of first mounting slots 350a, 350b are radially offset from the at least one second mounting slot 370a, 370b with regard to the longitudinal axis A-A’ of the hollow body 320a, 320b. This radial (angular) offset between the first and second mounting slots 350a, 350b, 370a, 370b enables the second bus bars 222 to be axially reoriented with respect to the first bus bars 220.

[0096] In the embodiment shown, the radial offset is about 90°.

[0097] According to the exemplary embodiments shown FIGS. 2 to 7D, each of the couplers 300a, 300b is made of at least two constituent parts fixed together during assembly. The two parts mirror one another such that when assembled, a contact surface between the two parts defines a plane of symmetry that crosses the longitudinal axis A-A’, and presents more specifically a bilateral symmetry. According to an alternative embodiment (not shown), the hollow body 320 of the coupler 300 can be made of a single part, for example by being cast from a single mold.

[0098] In one embodiment, the hollow body 320a, 320b of the electrical coupler 300a, 300b is made (at least partially) of an electrically conducting material, for electrically connecting the first bus bar 220 with the corresponding second bus bar 222, when the first bus bar 220 has been mounted in the first mounting slots 350a, 350b, and when the second bus bar 222 has been mounted in the at least one second mounting slot 370a, 370b.

[0099] The “conducting material” from which the coupler 300a, 300b may be chosen as a function of the characteristics of the electrical current to be carried therealong, as would be known in the art.[000100] In an embodiment (not shown), the hollow body 320a, 320b of the coupler 300a, 300b is at least partially made of an electrically conducting material. For example, the hollow body 320a, 320b can incorporate one or more strips of conducting material extending from the first mounting slot 350a, 350b to the second mounting slot 370a, 370b. Alternatively, a conductive coating can be used.[000101] In one embodiment, the coupler 300a, 300b is rigid. In another embodiment (not shown), the coupler is flexible or semi-flexible. This flexibility can be achieved by incorporating resilient material(s) into the constituent materials of the coupler's hollow body 320a, 320b.[000102] The person of ordinary skill in the art would understand how to adjust the coupler 300a, 300b to accommodate flat bus bars of varying shapes for suitable engagement.[000103] Turning now to the first assembly 200 more clearly shown in FIGS. 8A and 8B, there are shown alternative embodiments of the electrical coupler 300a, 300b described above. The four extended couplers 500a, 500b, 500c, 500d shown are similar to the couplers 300a, 300b shown in FIGS. 4 to 7D, except that each coupler 500a, 500b, 500c, 500d has a pair of first mounting slots and a pair of second mounting slots. Unlike the previously described embodiments, the first mounting slots (above) and the second mounting slots (below) are not radially offset with respect to the longitudinal axis B-B’. The extended couplers 500a, 500b, 500c, 500d each connect a battery pack terminal 140 (for incoming current) to a corresponding tubular bus bar terminal 162 positioned below (see FIG. 8A).[000104] As better shown in FIG. 8 A, mechanical fasteners may be used for performing the connection between the extended coupler 500a, 500b, 500c, 500d and the tubular bus bar terminal 162 by interposing a vertical bus bar acting as a first bus bar, although other arrangements could be considered.[000105] A hollow body 520 of the leftmost extended coupler 500a of the four couplers illustrated has a cylindrical shape. The hollow bodies of the other three couplers 500b, 500c, 500d (hereinafter, the elbowed extended couplers 500b, 500c, 500d) further include a first hollow section 580 having a first free end 540, a second hollow section 584 having a second free end 560, and a third hollow section 588 extending between the first hollow section 580 and the second hollow section 584. For the purpose of clarity and simplicity, only the longest of the three elbowed portions is fully annotated in FIGS. 8 A and 8B.[000106] The first hollow section 580 has a first bevelled end 582, which is opposite the first end 540 with respect to the hollow body 520. The second hollow section 584 has a second bevelled end 586 opposite to the second end 560 with respect to the hollow body 520. The third hollow section 588 has two opposite bevelled ends each mounted to a respective one of the first bevelled end 582 and the second bevelled end 586. The third hollow section 588 is correspondingly adapted to inter-connect the first bevelled end 582 and the second bevelled end 586. The third hollow section 588 functions as an elbow portion of the hollow body 520, such that the first hollow section 580 and the second hollow section 584 are (longitudinally and horizontally) offset. In other words, a longitudinal axis of the first hollow section (not shown) and a longitudinal axis of the second hollow section (not shown) are non-collinear.[000107] In the embodiment shown, it is understood that the first, second and third hollow sections 580, 584, 588 have a first, second, and third longitudinal axes (not shown), respectively, that are non-collinear.[000108] In some embodiments, the couplers are vermiform, i.e. worm-like.[000109] Still referring to FIGS. 8 A and 8B, it should be noted that the battery pack terminals 140 extend outwards from the panels 120 in the form of protruding plates. As better seen from FIG. 8B, at least one battery pack terminal 140 is not vertically aligned with a respective bus bars terminal below 162. The battery pack terminals 140 are generally offset to the left. This configuration of the elbowed extended couplers 500b, 500c, 500d enables them to be connected to the battery pack bus bar terminals 140 to respective tubular bus bar terminals 162 in the configuration of the first assembly 200.[000110] An Assembly Method[000111] There is further provided a method for electrically connecting bus bars. The assembly method comprises: providing an electrical coupler, for instance according to a coupler 300a, 300b, 500a, 500b, 500c, 500d embodiment previously described; mounting the first bus bar into the plurality of first mounting slots of the hollow body of the electrical coupler; mounting the second bus bar into the at least one second mounting slot of the hollow body of the electrical coupler; and securing the first bus bar and the second bus bar to the hollow body.[000112] With regard to the assembly method, to secure the first bus bar and the second bus bar to the hollow body 320, 520 of the coupler 300a, 300b, 500a, 500b, 500c, 500d, weldingcan be applied along the contacting surfaces, or at least along the proximate surfaces, defined where the bus bars mate with the hollow body 320, 520. Alternatively, the bus bars can be secured into place in the mounting slots via conventional fasteners. Also alternatively, the bus bars can be secured via clamps that are configured to exert inward pressure on the hollow body 320, 520 so that the contact surfaces of the mounting slots press and immobilize the bus bars received therein.[000113] In the previous description, non-limitative embodiments of the method are described. Although these embodiments of the assembly and corresponding parts thereof consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperation thereinbetween, as well as other suitable geometrical configurations, may be used for the method, as will be briefly explained herein and as can be easily inferred herefrom by a person skilled in the art. Moreover, it will be appreciated that positional descriptions such as “above”, “below”, “left”, “right”, “bottom”, “top”, “end” and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.[000114] Furthermore, in the previous description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and / or dimensions shown in the figures are optional and are given for exemplification purposes only.[000115] In the present description, an embodiment is an example or embodiment. The various appearances of “one embodiment”, “one embodiment”, “an embodiment” or “some embodiments” do not necessarily all refer to the same embodiment or embodiment. Although various features may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the invention may be described herein in the context of separate embodiments for clarity, it may also be implemented in a single embodiment. Reference in the specification to "some embodiments","an embodiment", "one embodiment" or "other embodiments" means that a particular feature, structure, or characteristic described in connection with the embodiments or embodiment is included in at least some embodiments, but not necessarily all embodiments.[000116] It is to be understood that the phraseology and terminology employed herein are not to be construed as limiting and are for descriptive purpose only. The principles and uses of the teachings of the present disclosure may be better understood with reference to the accompanying description, figures and examples. It is to be understood that the details set forth herein do not construe a limitation to an application of the disclosure.[000117] Furthermore, it is to be understood that the disclosure can be carried out or practiced in various ways and that the disclosure can be implemented in embodiments other than the ones outlined in the description above. It is to be understood that the terms "including", "comprising", and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers. If the specification or claims refer to "an additional" element, that does not preclude there being more than one of the additional element. It is to be understood that where the claims or specification refer to "a" or "an" element, such reference is not to be construed that there is only one of that element. It is to be understood that where the specification states that a component, feature, structure, or characteristic "may", "might", "can" or "could" be included, that particular component, feature, structure, or characteristic is not required to be included.[000118] It will be appreciated that the methods described herein may be performed in the described order, or in any suitable order.[000119] Several alternative embodiments, embodiments and examples have been described and illustrated herein. The embodiments of the invention described above are intended to be exemplary only. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to thedetails given herein. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.

Claims

CLAIMS1. An electrical coupler for electrically connecting a first bus bar with a second bus bar, the electrical coupler comprising:a hollow body extending between a first end and a second end;the hollow body having a plurality of first mounting slots and at least one second mounting slot, the plurality of first mounting slots each extending from the first end towards the second end, and the at least one second mounting slot extending from the second end towards the first end;the plurality of first mounting slots and the at least one second mounting slot being adapted to mount the first bus bar and the second bus bar therein, respectively; andthe hollow body being made at least partially of an electrically conducting material for electrically connecting the first bus bar, when being mounted in the plurality of first mounting slots, with the second bus bar, when being mounted in the at least one second mounting slot.

2. The electrical coupler of claim 1, wherein the plurality of first mounting slots and the at least one second mounting slot define a first free contact surface and a second free contact surface, respectively, adapted not to exceed a maximum electrical contact resistance when the electrical coupler carries current between the first bus bar and the second bus bar.

3. The electrical coupler of claim 2, wherein the maximum electrical contact resistance is adapted to limit heat generation in the electrical coupler and the first and second bus bars.

4. The electrical coupler of any one of claims 1 to 3, wherein the at least one second mounting slot is a single second mounting slot.

5. The electrical coupler of any one of claims 1 to 4, wherein the at least one second mounting slot comprises a pair of second mounting slots, and each one of the pair of second mounting slots extends from respective diametrically opposite points of a cross-section of the second end of the hollow body.

6. The electrical coupler of claim 1, wherein respective lengths of the plurality of first mounting slots and the at least one second mounting slot are equal.

7. The electrical coupler of any one of claims 1 to 6. wherein the hollow body has a linear shape.

8. The electrical coupler of any one of claims 1 to 7, wherein the hollow body comprises a first hollow section having a first free end corresponding to the first end of the hollow body, a second hollow section having a second free end corresponding to the second end of the hollow body, and a third hollow section extending between the first hollow section and the second hollow section.

9. The electrical coupler of claim 8, wherein the first, second and third hollow sections respectively define first, second, and third longitudinal axes, respectively, and wherein at least one of the first and second longitudinal axes is oblique relative to the third longitudinal axis.

10. The electrical coupler of claim 8, wherein the first hollow section has a first bevelled end opposite to the first free end, the second hollow section has a second bevelled end opposite to the second end, and the third hollow section has two opposite bevelled ends each mounted to a respective one of the first bevelled end and the second bevelled end.

11. The electrical coupler of claim 10, wherein the third hollow section forms an elbow portion such that the first hollow section and the second hollow section are longitudinally offset.

12. The electrical coupler of claim 1, wherein the hollow body has a tubular shape and the plurality of first mounting slots and the at least one second mounting slot are radially offset to each other with regard to a longitudinal axis of the hollow body by a radial offset.

13. The electrical coupler of claim 12, wherein the radial offset is 90°.

14. The electrical coupler of claim 12 or 13, wherein the hollow body has a circular crosssection having a constant diameter along the longitudinal axis.

15. The electrical coupler of any one of claims 12 to 14, wherein the plurality of first mounting slots comprises a pair of first mounting slots that extend from antipodal points with respect to a circumference of a cross-section of the first end of the hollow body.

16. An electrical assembly comprising:a plurality of first bus bars;a plurality of second bus bars; anda plurality of electrical couplers according to any one of claims 1 to 15 for operatively coupling the plurality of first bus bars with the plurality of second bus bars.

17. A method for electrically connecting a first bus bar with a second bus bar, the method comprising:providing an electrical coupler according to any one of claims 1 to 15; mounting the first bus bar into the plurality of first mounting slots of the hollow body of the electrical coupler;mounting the second bus bar into the at least one second mounting slot of the hollow body of the electrical coupler; andsecuring the first bus bar and the second bus bar to the hollow body of the electrical coupler.

18. The method of claim 17, wherein said securing the first bus bar and the second bus bar comprises respectively welding contacting surfaces defined between the mounted first bus bar, the mounted second bus bar and the hollow body.

Images