[go: up one dir, main page]

WO2017201033A1 - Connecteurs de borne de batterie principale à ajustement par poussée à caractéristiques de verrouillage géométrique - Google Patents

Connecteurs de borne de batterie principale à ajustement par poussée à caractéristiques de verrouillage géométrique Download PDF

Info

Publication number
WO2017201033A1
WO2017201033A1 PCT/US2017/032885 US2017032885W WO2017201033A1 WO 2017201033 A1 WO2017201033 A1 WO 2017201033A1 US 2017032885 W US2017032885 W US 2017032885W WO 2017201033 A1 WO2017201033 A1 WO 2017201033A1
Authority
WO
WIPO (PCT)
Prior art keywords
terminal
battery
terminal connector
recess
module
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2017/032885
Other languages
English (en)
Inventor
Edward J. Soleski
Richard M. Dekeuster
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson Controls Technology Co
Original Assignee
Johnson Controls Technology Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Controls Technology Co filed Critical Johnson Controls Technology Co
Publication of WO2017201033A1 publication Critical patent/WO2017201033A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/64—Means for preventing incorrect coupling
    • H01R13/642—Means for preventing incorrect coupling by position or shape of contact members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/172—Arrangements of electric connectors penetrating the casing
    • H01M50/174—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells
    • H01M50/176—Arrangements of electric connectors penetrating the casing adapted for the shape of the cells for prismatic or rectangular cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/547—Terminals characterised by the disposition of the terminals on the cells
    • H01M50/55—Terminals characterised by the disposition of the terminals on the cells on the same side of the cell
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/552—Terminals characterised by their shape
    • H01M50/553—Terminals adapted for prismatic, pouch or rectangular cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/562—Terminals characterised by the material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/572—Means for preventing undesired use or discharge
    • H01M50/584—Means for preventing undesired use or discharge for preventing incorrect connections inside or outside the batteries
    • H01M50/59—Means for preventing undesired use or discharge for preventing incorrect connections inside or outside the batteries characterised by the protection means
    • H01M50/597—Protection against reversal of polarity
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/28—End pieces consisting of a ferrule or sleeve
    • H01R11/281—End pieces consisting of a ferrule or sleeve for connections to batteries
    • H01R11/282—End pieces consisting of a ferrule or sleeve for connections to batteries comprising means for facilitating engagement or disengagement, e.g. quick release terminal
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present disclosure relates generally to the field of batteries and battery modules. More specifically, the present disclosure relates battery module terminals.
  • a vehicle that uses one or more battery systems for providing all or a portion of the motive power for the vehicle can be referred to as an xEV, where the term "xEV” is defined herein to include all of the following vehicles, or any variations or combinations thereof, that use electric power for all or a portion of their vehicular motive force.
  • xEVs include electric vehicles (EVs) that utilize electric power for all motive force.
  • HEVs hybrid electric vehicles
  • HEVs also considered xEVs, combine an internal combustion engine propulsion system and a battery-powered electric propulsion system, such as 48 Volt (V) or 130V systems.
  • HEV may include any variation of a hybrid electric vehicle.
  • full hybrid systems FHEVs
  • MHEVs mild hybrid systems
  • MHEVs disable the internal combustion engine when the vehicle is idling and utilize a battery system to continue powering the air conditioning unit, radio, or other electronics, as well as to restart the engine when propulsion is desired.
  • the mild hybrid system may also apply some level of power assist, during acceleration for example, to supplement the internal combustion engine.
  • Mild hybrids are typically 96V to 130V and recover braking energy through a belt or crank integrated starter generator.
  • a micro-hybrid electric vehicle also uses a "Stop-Start" system similar to the mild hybrids, but the micro-hybrid systems of a mHEV may or may not supply power assist to the internal combustion engine and operates at a voltage below 60V.
  • mHEVs typically do not technically use electric power provided directly to the crankshaft or transmission for any portion of the motive force of the vehicle, but an mHEV may still be considered as an xEV since it does use electric power to supplement a vehicle's power needs when the vehicle is idling with internal combustion engine disabled and recovers braking energy through an integrated starter generator.
  • a plug-in electric vehicle is any vehicle that can be charged from an external source of electricity, such as wall sockets, and the energy stored in the rechargeable battery packs drives or contributes to drive the wheels.
  • PEVs are a subcategory of EVs that include all-electric or battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and electric vehicle conversions of hybrid electric vehicles and conventional internal combustion engine vehicles.
  • xEVs as described above may provide a number of advantages as compared to more traditional gas-powered vehicles using only internal combustion engines and traditional electrical systems, which are typically 12V systems powered by a lead acid battery.
  • xEVs may produce fewer undesirable emission products and may exhibit greater fuel efficiency as compared to traditional internal combustion vehicles and, in some cases, such xEVs may eliminate the use of gasoline entirely, as is the case of certain types of EVs or PEVs.
  • power sources particularly battery modules, for such vehicles and other
  • certain batteries or battery modules include externally-accessible terminals that enable the battery or battery module to connect to a load. These terminals are usually fastened to the housing of the battery using fasteners that require the use of certain tools. Further, such terminals may be subject to corrosion, and may not be readily replaced.
  • the present disclosure relates to a battery system having a battery module housing cover having a recess in which a module terminal is positioned, the recess having a recess geometry; and a battery terminal connector having a terminal connector interface establishing an electrical and physical connection with the module terminal, and an insulative cover covering the terminal connector interface, wherein the insulative cover has a cover geometry, and the cover geometry matches the recess geometry.
  • the present disclosure also relates to a battery terminal connector including a terminal connector interface configured to establish an electrical and physical connection with a terminal of a battery module by acting as a receptacle for the terminal; an insulative cover covering the terminal connector interface except for an opening configured to receive the terminal of the battery module; and a retention clip coupled to the insulative cover, wherein the retention clip comprises a clip opening that is coaxial with the opening of the insulative cover.
  • the present disclosure further relates to a battery terminal connector assembly for an automotive battery having a positive terminal connector having a first terminal connector interface configured to establish an electrical and physical connection with a positive terminal post of the automotive battery, and a first insulative cover covering the first terminal connector interface except for a first opening configured to receive the positive terminal post of the battery module, wherein the first insulative cover has a first cover geometry.
  • the battery terminal connector assembly also includes a negative terminal connector having a second terminal connector interface configured to establish an electrical and physical connection with a negative terminal post of a battery module, and a second insulative cover covering the second terminal connector interface except for a second opening configured to receive the negative terminal post of the automotive battery, wherein the second insulative cover has a second cover geometry that is different than the first cover geometry.
  • FIG. 1 is a perspective view of an xEV having a battery system configured in accordance with present embodiments to provide power for various components of the xEV, in accordance with an aspect of the present disclosure
  • FIG. 2 is a cutaway schematic view of an embodiment of the xEV having a start-stop system that utilizes the battery system of FIG. 1, the battery system having a lithium ion battery module, in accordance with an aspect of the present disclosure
  • FIG. 3 is a perspective view of the top of a battery module having terminal posts positioned within recesses configured to receive battery terminal connectors push fit into place;
  • FIG. 4 is a perspective view of the top of the battery module of FIG. 3, with the battery terminal connectors installed or push fit into place;
  • FIG. 5 is an expanded cross-sectional view of the top of the battery module and the positive connector of FIG. 4;
  • FIG. 6 is an overhead perspective view of the positive connector of FIG. 4;
  • FIG. 7 is a bottom perspective view of the positive connector of FIG. 6;
  • FIG. 8 is an overhead perspective view of the negative connector of FIG. 4.
  • FIG. 9 is a bottom perspective view of the negative connector of FIG. 8. DETAILED DESCRIPTION
  • the battery systems described herein may be used to provide power to various types of electric vehicles (xEVs) and other high voltage energy
  • Such battery systems may include one or more battery modules, each battery module having a housing and a number of battery cells (e.g., lithium-ion (Li-ion)
  • electrochemical cells arranged within the housing to provide particular voltages and/or currents useful to power, for example, one or more components of an xEV.
  • battery modules in accordance with present embodiments may be incorporated with or provide power to stationary power systems (e.g., non-automotive systems).
  • manufactures that generally produce traditional gas-powered vehicles may desire to utilize improved vehicle technologies (e.g., regenerative braking technology) within their vehicle lines. Often, these manufactures may utilize one of their traditional vehicle platforms as a starting point. Accordingly, since traditional gas-powered vehicles are designed to utilize 12 V battery systems, a 12 V lithium ion battery may be used to supplement a 12 V lead-acid battery. More specifically, the 12 V lithium ion battery may be used to more efficiently capture electrical energy generated during regenerative braking and subsequently supply electrical energy to power the vehicle's electrical system. Additionally, in a mHEV, the internal combustion engine may be disabled when the vehicle is idle. Accordingly, the 12 V lithium ion battery may be used to crank (e.g., restart) the internal combustion engine when propulsion is desired.
  • vehicle technologies e.g., regenerative braking technology
  • high voltage electrical devices may be included in the vehicle's electrical system.
  • the lithium ion battery may supply electrical energy to an electric motor in a FHEV.
  • these high voltage electrical devices utilize voltages greater than 12 V, for example, up to 48, 96, or 130 V.
  • the output voltage of a 12 V lithium ion battery may be boosted using a DC-DC converter to supply power to the high voltage devices.
  • a 48 V lithium ion battery may be used to supplement a 12 volt lead-acid battery.
  • the 48 V lithium ion battery may be used to more efficiently capture electrical energy generated during regenerative braking and subsequently supply electrical energy to power the high voltage devices.
  • certain batteries or battery modules include externally- accessible terminals that enable the battery or battery module to connect to a load. These terminals are usually fastened to the housing of the battery using fasteners that require the use of certain tools. Further, such terminals may be subject to corrosion, and may not be readily replaced.
  • present embodiments relate to a quick connection for a low voltage battery (e.g., less than 60 V) that makes consistently good connections.
  • the positive and negative leads of a battery module are removable and replaceable, and have different geometric shapes that index and fit within corresponding recesses in a top (e.g., terminal side) surface of the battery, thus avoiding improper connections.
  • each of the connectors pushes onto a copper post of the battery to make a high current, low resistance connection.
  • certain embodiments of the connectors use a beryllium copper interface. This interface provides a relatively low resistance, corrosion-resistant connection that does not require tools to make or break the connection.
  • the battery terminal connectors of the present disclosure push on and, further, they may interface with plastic retention or locking clips that keep the connectors from disconnecting unless the clips are squeezed and then pulled on to remove the cable from the battery. In this way, no tools are required to install or remove the battery connections.
  • the push-fit terminal connectors of the present disclosure may be applied to any battery or battery system, and may be particularly useful in battery systems employed in an xEV.
  • FIG. 1 is a perspective view of an embodiment of a vehicle 10, which may utilize a regenerative braking system.
  • the terminal connectors described herein are usable in other vehicles that capture/store electrical energy with a battery, which may include electric-powered and gas-powered vehicles.
  • the vehicle 10 may utilize a battery, as described below, which includes the terminal connectors as described herein.
  • the battery system 12 may be placed in a location in the vehicle 10 that would have housed a traditional battery system.
  • the vehicle 10 may include the battery system 12 positioned similarly to a lead-acid battery of a typical combustion-engine vehicle (e.g., under the hood of the vehicle 10).
  • the battery system 12 may be positioned to facilitate managing temperature of the battery system 12. For example, in some embodiments, positioning the battery system 12 under the hood of the vehicle 10 may enable an air duct to channel airflow over the battery system 12 and cool the battery system 12.
  • the battery system 12 includes an energy storage component 14 coupled to an ignition system 16, an alternator 18, a vehicle console 20, and optionally to an electric motor 22.
  • the energy storage component 14 may capture/store electrical energy generated in the vehicle 10 and output electrical energy to power electrical devices in the vehicle 10.
  • the battery system 12 may supply power to components of the vehicle's electrical system, which may include radiator cooling fans, climate control systems, electric power steering systems, active suspension systems, auto park systems, electric oil pumps, electric super/turbochargers, electric water pumps, heated windscreen/defrosters, window lift motors, vanity lights, tire pressure monitoring systems, sunroof motor controls, power seats, alarm systems, infotainment systems, navigation features, lane departure warning systems, electric parking brakes, external lights, or any combination thereof.
  • the energy storage component 14 supplies power to the vehicle console 20 and the ignition system 16, which may be used to start (e.g., crank) the internal combustion engine 24.
  • the energy storage component 14 may capture electrical energy generated by the alternator 18 and/or the electric motor 22.
  • the alternator 18 may generate electrical energy while the internal combustion engine 24 is running. More specifically, the alternator 18 may convert the mechanical energy produced by the rotation of the internal combustion engine 24 into electrical energy.
  • the electric motor 22 may generate electrical energy by converting mechanical energy produced by the movement of the vehicle 10 (e.g., rotation of the wheels) into electrical energy.
  • the energy storage component 14 may capture electrical energy generated by the alternator 18 and/or the electric motor 22 during regenerative braking.
  • the alternator and/or the electric motor 22 are generally referred to herein as a regenerative braking system.
  • the energy storage component 14 may be electrically coupled to the vehicle's electric system via a bus 26.
  • the bus 26 may enable the energy storage component 14 to receive electrical energy generated by the alternator 18 and/or the electric motor 22. Additionally, the bus may enable the energy storage component 14 to output electrical energy to the ignition system 16 and/or the vehicle console 20. Accordingly, when a 12 volt battery system 12 is used, the bus 26 may carry electrical power typically between 8-18 V.
  • the energy storage component 14 may include multiple battery modules.
  • the energy storage component 14 includes a lithium ion (e.g., a first) battery module 28 and a lead-acid (e.g., a second) battery module 30, which each includes one or more battery cells.
  • the energy storage component 14 may include any number of battery modules.
  • the lithium ion battery module 28 and lead-acid battery module 30 are depicted adjacent to one another, they may be positioned in different areas around the vehicle.
  • the lead-acid battery module 30 may be positioned in or about the interior of the vehicle 10 while the lithium ion battery module 28 may be positioned under the hood of the vehicle 10.
  • the energy storage component 14 may include multiple battery modules to utilize multiple different battery chemistries.
  • the lithium ion battery module 28 when used, performance of the battery system 12 may be improved since the lithium ion battery chemistry generally has a higher coulombic efficiency and/or a higher power charge acceptance rate (e.g., higher maximum charge current or charge voltage) than the lead-acid battery chemistry. As such, the capture, storage, and/or distribution efficiency of the battery system 12 may be improved.
  • the battery system 12 may additionally include a control module 32. More specifically, the control module 32 may control operations of components in the battery system 12, such as relays (e.g., switches) within energy storage component 14, the alternator 18, and/or the electric motor 22. For example, the control module 32 may regulate amount of electrical energy captured/supplied by each battery module 28 or 30 (e.g., to de-rate and re-rate the battery system 12), perform load balancing between the battery modules 28 and 30, determine a state of charge of each battery module 28 or 30, determine temperature of each battery module 28 or 30, control voltage output by the alternator 18 and/or the electric motor 22, and the like.
  • the control module 32 may control operations of components in the battery system 12, such as relays (e.g., switches) within energy storage component 14, the alternator 18, and/or the electric motor 22.
  • the control module 32 may regulate amount of electrical energy captured/supplied by each battery module 28 or 30 (e.g., to de-rate and re-rate the battery system 12), perform load balancing between the battery modules 28
  • the control unit 32 may include one or more processors 34 and one or more memory units 36. More specifically, the one or more processors 34 may include one or more application specific integrated circuits (ASICs), one or more field programmable gate arrays (FPGAs), one or more general purpose processors, or any combination thereof. Additionally, the one or more memory 36 may include volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read-only memory (ROM), optical drives, hard disc drives, or solid- state drives. In some embodiments, the control unit 32 may include portions of a vehicle control unit (VCU) and/or a separate battery control module.
  • VCU vehicle control unit
  • the lithium ion battery module 28 and the lead-acid battery module 30 are connected in parallel across their terminals.
  • the lithium ion battery module 28 and the lead-acid module 30 may be coupled in parallel to the vehicle's electrical system via the bus 26.
  • either or both of the lithium ion battery module 28 and the lead-acid battery module 30 may utilize the terminal connectors described herein. To facilitate discussion, the present embodiments are described in the context of the lithium ion battery module 28. Referring now to FIG. 3, an embodiment of the lithium ion battery module 28 is shown as including a module housing 40 and a housing cover 42 that interface with one another to form an enclosure 44 of the battery module 28.
  • the enclosure 44 seals a variety of components from the external environment, including a plurality of battery cells 46, one or more bus bars 48, and various electronics 50.
  • the battery cells 46 may include lithium ion battery cells having any shape and configuration (e.g., cylindrical, prismatic, pouch), and are coupled to one another using one or more of the bus bars 48.
  • the bus bars 48 also electrically connect the battery cells 46 to the electronics 50, which may include the control module 32 of FIG. 2.
  • the bus bars 48 may also electrically couple the battery cells 46 and the electronics 50 to terminal posts 52 (e.g., including a positive or first terminal post 52a and a negative or second terminal post 52b) positioned in the housing cover 42.
  • terminal posts 52 e.g., including a positive or first terminal post 52a and a negative or second terminal post 52b
  • the illustrated housing cover 42 may be formed of a polymeric material, and the terminal posts 52 may be molded into the housing cover 42.
  • other securement methods may be used to secure the terminal posts 52 to the housing cover 42 in other embodiments.
  • the terminal posts 52 are positioned in recesses 54 formed in the housing cover 42 (e.g., formed during molding).
  • the terminal posts 52 are illustrated as having a cylindrical geometry, the terminal posts 52 may have other geometries, such as geometries that are different from one another, to facilitate proper connection to a corresponding connector.
  • the illustrated recesses 54 include a first recess 54a and a second recess 54b where the positive terminal post 52a and the negative terminal post 52b are positioned, respectively.
  • the recesses 54 are formed in a top surface 56 of the housing cover 42, the top surface 56 being positioned opposite of a base 58 of the module housing 40 when the cover 42 is secured to the housing 40.
  • the recesses 54a, 54b are also each associated with notches 60a, 60b, respectively, formed into a side surface 62 of the housing cover 42.
  • the side surface 62 is contiguous with the top surface 56, and the notches 60 are formed to be contiguous with the recesses 54.
  • each of the notches 60 is formed may be the same or different.
  • the recesses 54 are configured to receive (e.g., sized and shaped to receive) a corresponding terminal connector, and the notches 60 enable portions of the terminal connector to extend outwardly for ready connection with a load (e.g., cables).
  • the recesses 54a, 54b have geometries that are different from one another, as defined by internal recess walls 64a, 64b, respectively.
  • the first recess 54a has a hexagonal geometry defined by first intemal recess walls 64a
  • the second recess 54b has a square geometry defined by second intemal recess walls 64b.
  • certain of the intemal recess walls 64 may include mating features 66, such as additional recesses, that enable mating with and securement of the terminal connectors of the present disclosure.
  • FIG. 4 illustrates an embodiment of the housing cover 42 in having a positive terminal connector 70a installed in the first recess 54a and a negative terminal connector 70b installed in the second recess 54b.
  • the positive and negative terminal connectors 70a, 70b have geometries that match the geometries of the first and second recesses 54a, 54b, respectively (e.g., the terminal connectors 70 are indexed to the recesses 54).
  • the positive and negative terminal connectors 70a, 70b include insulative covers 72a, 72b that are formed (e.g., molded) to have the corresponding geometries to appropriately interface with the recesses 54.
  • the insulative covers 72a, 72b may extend to cover a portion of respective terminal extensions 74a, 74b that interface with a load (e.g., the xEV 10).
  • the terminal extensions 74a, 74b may be connected to (e.g., welded to, soldered to, crimped to) cables associated with the xEV 10, or may be the battery cables themselves.
  • the insulative covers 72 may be sized and shaped so as to fasten the terminal connectors 70 to the housing cover 42 via an interference fit in which the insulative covers 72 directly contact the inner recess walls 64.
  • the terminal connectors 70 are fastened to the housing cover 42 via retention clips 76 (including a first retention clip 76a for the positive terminal connector 70a and a second retention clip 76b for the negative terminal connector 70b).
  • the insulative covers 72 may be sized and shaped to index to the recesses 54.
  • the polymeric material forming the insulative covers 72 may be blended with a colorant to allow the positive and negative terminal connectors to be distinguished.
  • the insulative cover 72a of the positive terminal connector 70a may be colored red
  • the insulative cover 72b of the negative terminal connector 70b may be colored black.
  • FIG. 5 is a cross-sectional expanded view of the positive terminal connector 70a installed in the first recess 54a.
  • the positive terminal post 52a which is positioned inside the recess 54a, extends into a corresponding opening 80a of a terminal connector interface 81a such that the terminal post 52 contacts the interface 81 a. Because this forms an electrical connection between the terminal post 52a and the terminal connector 70a, the terminal post 52a and the terminal connector interface 81 a may be formed from electrically compatible materials (e.g., being able to electrically connect without appreciable Galvanic corrosion).
  • the terminal post 52a may be made of copper, and the terminal connector interface 81 a may be formed from or include beryllium copper, which is a copper base alloy with beryllium.
  • the beryllium copper may also include nickel and cobalt.
  • the terminal extensions 74a, 74b may be formed from copper, or beryllium copper
  • the terminal connectors 70 are retained in the recesses 54 using retention clips 76.
  • the first retention clip 76a includes tabs 82a, 82b that protrude outwardly from the recess 54a.
  • the tabs 82a, 82b are situated at opposing sides of the terminal connector 70a, which enables the tabs 82a, 82b to be biased inwardly toward one another and toward the terminal connector 70a by a squeezing force (e.g., by a human operator, technician, a robot, or the like).
  • the tabs 82a, 82b are biased outwardly by the natural spring force created by the material composition of the first retention clip 76a, as well as the shape of the first retention clip 76a.
  • the tabs 82a, 82b extend from a clip body 84a that partially wraps around the terminal connector 70a.
  • the clip body 84a surrounds the terminal connector 70a on at least two sides that are aligned with the terminal post 52a, and partially surrounds a bottom side 86a of the terminal connector 70a through which the terminal post 52a protrudes.
  • the retention clip 76a includes an opening 88a at the bottom side 86a, and a flange 90a of the insulative cover 72a protrudes through the opening 88a to secure the terminal connector 70a to the retention clip 76a.
  • the clip body 84 also includes at least one mating protrusion 92 configured to retain the retention clip 76a and the terminal connector 70a in the first recess 54a.
  • the clip body 84a includes two mating protrusions 92a, 92b positioned adj acent to the tabs 82.
  • the mating protrusions 92a, 92b are configured to protrude into the additional recesses 66 when the terminal connector 70a and the retention clip 76a are installed in the housing cover 42.
  • the mating protrusions 92a, 92b taper outwardly away from the terminal connector interface 81 a in a direction extending from the bottom side 88a toward the tabs 82a, 82b.
  • the mating protrusions 92a, 92b also each include a shelf 94, which abuts against a top surface 96 of the additional recesses to prevent movement in the axial direction 98 of the terminal post 52a. Preventing such movement also prevents inadvertent disconnection of the terminal connector 70a from the terminal post 52a.
  • the taper and the shelves 94 of the mating protrusions 92a, 92b allow the terminal connector 70a to be push-fit into the first recess 54a. Because the retention clip 76a has a natural spring force that biases the tabs 82 away from the terminal connector 70a, pushing the terminal connector 70a and the retention clip 76a into the first recess 54a causes the mating protrusions 92a, 92b to snap the terminal connector 70a into place once the mating protrusions 92a, 92b reach the additional recesses 66.
  • FIGS. 4 and 5 a substantial portion of the conductive portions of the terminal connectors 70 are surrounded by the insulative covers 72, which helps prevent inadvertent electrical contact with external features.
  • the terminal connector interfaces 81 may be overmolded with the insulative covers 72 using an appropriate mold geometry. Further details relating to the positive and negative terminal connectors 70a, 70b may be appreciated with reference to FIGS. 6-9, which are perspective views of the terminal connectors 70 and associated retention clips 76.
  • FIGS. 6 and 7 respectively depict overhead and bottom perspective views of the positive terminal connector 70a interfacing with the first retention clip 76a
  • FIGS. 8 and 9 respectively depict overhead and bottom perspective views of the negative terminal connector 70b interfacing with the second retention clip 76b
  • the retention clips 76 include tabs 82 82 disposed at opposing sides of the terminal connectors 70.
  • the tabs 82 form two sides of the retention clips 76
  • the protrusions 92 extend from the tabs 82 to form the shelves 94.
  • the protrusions 92 only extend through a portion of the tabs 82.
  • other embodiments of the protrusions 92 may be such that the taper of the protrusions extends substantially the entire length of the tabs 82.
  • the terminal connectors 70 each include two main conductive portions - the terminal connector interface 81 , and the terminal extension 74.
  • the terminal connector interface 81 is configured to be positioned within the corresponding recess 54 of the housing cover 42, and the terminal extension 74 extends away from the terminal connector interface 81 and is configured to extend away from the module housing 40 and housing cover 42.
  • the terminal extension 74 is configured to be accessible for ready electrical connection to external connectors, such as a battery cable connected to the xEV 10 (see FIGS. 1 and 2).
  • the terminal connector interface 81 and the terminal extension 74 may be integral.
  • the terminal connector interface 81 is configured to mate with a respective terminal of the module (e.g., terminal post 52), while the terminal extension 74 provides a more readily accessible connection feature that is a high current, low resistance connection to the battery module 28.
  • the terminal extension 74 in certain embodiments, may be a hollow extension that allows conductors (e.g., wires) to be inserted for crimping. Again, the terminal extension 74, in other embodiments, may simply be a cable.
  • the insulative cover 72 which electrically insulates portions of the terminal connector 70, includes a first insulting portion 98 and a second insulating portion 100.
  • the first insulating portion 98 may be considered to cover the terminal connector interface 81 , except for the opening 80, which is shown in FIG. 7 for the positive terminal connector 70a and FIG. 9 for the negative terminal connector 70b.
  • the second insulating portion 100 extends from the first insulating portion 98, and only partially covers the terminal extension 74 to allow for ready electrical connection.
  • the insulative covers 72 may be indexed to their respective recesses 54 in the housing cover 42 (see, e.g., FIG. 4).
  • the first insulating portion 98a of FIG. 6 includes a geometry (e.g., shape and size) that is indexed to the first recess 54a of the housing cover 42
  • the first insulation portion 98b of FIG. 8 includes a geometry that is indexed to the second recess 54b of the housing cover 42.
  • the first insulating portions 98 may also each include a marking 102, such as a "+" sign, as shown in FIG. 6, denoting that the terminal connector is a positive terminal connector, or a "-" sign, as shown in FIG. 8, denoting that the terminal connector is a negative terminal connector.
  • FIGS. 7 and 9 which are perspective bottom views of the positive terminal connector 70a and the negative terminal connector 70b, provide a more detailed view of the manner in which the retention clips 76 interface with the terminal connectors 70.
  • the tabs 82 are connected to one another by a bottom piece 110 having the opening 88 through which the flange 90 protrudes to mechanically couple the retention clips 76 and the terminal connectors 70.
  • One or more of the disclosed embodiments may provide one or more technical effects including the manufacture of battery terminal connectors that are able to readily connect and disconnect to battery terminals without the use of tools or specialized equipment. Further, the battery terminal connectors may be formed from materials that are resistant to corrosion, while also enabling a very low resistance connection to the battery terminal.
  • the technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Connection Of Batteries Or Terminals (AREA)

Abstract

Un système de batterie comprend un couvercle de boîtier de module de batterie ayant un évidement dans lequel est positionnée une borne de module, l'évidement ayant une géométrie d'évidement ; et un connecteur de borne de batterie ayant une interface de connecteur de borne établissant une connexion électrique et physique avec la borne de module, et un couvercle isolant recouvrant l'interface de connecteur de borne, le couvercle isolant ayant une géométrie de couvercle, et la géométrie de couvercle correspondant à la géométrie d'évidement.
PCT/US2017/032885 2016-05-16 2017-05-16 Connecteurs de borne de batterie principale à ajustement par poussée à caractéristiques de verrouillage géométrique Ceased WO2017201033A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201662337169P 2016-05-16 2016-05-16
US62/337,169 2016-05-16

Publications (1)

Publication Number Publication Date
WO2017201033A1 true WO2017201033A1 (fr) 2017-11-23

Family

ID=58772984

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2017/032885 Ceased WO2017201033A1 (fr) 2016-05-16 2017-05-16 Connecteurs de borne de batterie principale à ajustement par poussée à caractéristiques de verrouillage géométrique

Country Status (1)

Country Link
WO (1) WO2017201033A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115207546A (zh) * 2022-08-26 2022-10-18 安徽五行动力新能源有限公司 一种封装结构、软包电池及其封装工艺
WO2023280343A1 (fr) * 2021-07-05 2023-01-12 Harting Electric Stiftung & Co. Kg Système de raccordement de module pour systèmes de stockage d'énergie
WO2022246289A3 (fr) * 2021-05-21 2023-02-23 Cps Technology Holdings Llc Connecteur de batterie et couvercle de batterie
DE102021102681B4 (de) 2020-02-07 2024-10-10 Honda Motor Co., Ltd. Sperrstruktur eines batteriepacks
EP4546553A1 (fr) * 2023-10-24 2025-04-30 DIN-Dietmar Nocker Facilitymanagement GmbH Accumulateur d'énergie et protection contre l'inversion de polarité pour ledit accumulateur d'énergie

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1133007A1 (fr) * 2000-03-09 2001-09-12 Sumitomo Wiring Systems, Ltd. Une construction et un bouchon terminal pour éviter une connexion erronée
US20010053636A1 (en) * 2000-06-14 2001-12-20 Yazaki Corporation Connecting structure for battery terminals
WO2008049112A2 (fr) * 2006-10-19 2008-04-24 Amphenol Corporation Système de connecteur pour connecter des câbles à une batterie
US20130034765A1 (en) * 2011-08-01 2013-02-07 Kowalski Gerald A Automotive battery connection system

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1133007A1 (fr) * 2000-03-09 2001-09-12 Sumitomo Wiring Systems, Ltd. Une construction et un bouchon terminal pour éviter une connexion erronée
US20010053636A1 (en) * 2000-06-14 2001-12-20 Yazaki Corporation Connecting structure for battery terminals
WO2008049112A2 (fr) * 2006-10-19 2008-04-24 Amphenol Corporation Système de connecteur pour connecter des câbles à une batterie
US20130034765A1 (en) * 2011-08-01 2013-02-07 Kowalski Gerald A Automotive battery connection system

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102021102681B4 (de) 2020-02-07 2024-10-10 Honda Motor Co., Ltd. Sperrstruktur eines batteriepacks
WO2022246289A3 (fr) * 2021-05-21 2023-02-23 Cps Technology Holdings Llc Connecteur de batterie et couvercle de batterie
WO2023280343A1 (fr) * 2021-07-05 2023-01-12 Harting Electric Stiftung & Co. Kg Système de raccordement de module pour systèmes de stockage d'énergie
CN115207546A (zh) * 2022-08-26 2022-10-18 安徽五行动力新能源有限公司 一种封装结构、软包电池及其封装工艺
EP4546553A1 (fr) * 2023-10-24 2025-04-30 DIN-Dietmar Nocker Facilitymanagement GmbH Accumulateur d'énergie et protection contre l'inversion de polarité pour ledit accumulateur d'énergie

Similar Documents

Publication Publication Date Title
US9520587B2 (en) Bus bar assembly carrier
EP3243235B1 (fr) Extensions enfichables et parois de guidage pour des ponts de barre omnibus d'un module de batterie
EP3183763B1 (fr) Cadre de contacts pour un module de batterie ayant interconnexions sacrificiels
US20210280381A1 (en) Integrated connector having sense and switching conductors for a relay used in a battery module
EP2858848B1 (fr) Fabrication d'unité de déconnexion de service faisant partie d'une barre omnibus
US9533639B2 (en) High voltage connector system and method
US10543795B2 (en) Battery module connector barrel
CN107408661B (zh) 电池组模块端子系统和方法
WO2017201033A1 (fr) Connecteurs de borne de batterie principale à ajustement par poussée à caractéristiques de verrouillage géométrique
EP3323162B1 (fr) Système et procédé de surmoulage de bornes d'un module de batterie
US10297812B2 (en) Terminals of an electrochemical cell
EP3424096A1 (fr) Fixation de cellules électrochimiques dans un boîtier d'un module de batterie
EP3201975B1 (fr) Ensemble de connexion de barre omnibus de module de batterie
US20220271394A1 (en) Battery module and bus bar having stress-relieving features

Legal Events

Date Code Title Description
NENP Non-entry into the national phase

Ref country code: DE

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 17726079

Country of ref document: EP

Kind code of ref document: A1

122 Ep: pct application non-entry in european phase

Ref document number: 17726079

Country of ref document: EP

Kind code of ref document: A1