Canted coil spring power terminal and sequence connection system

• US 20060270286A1
• Filed: 05/25/2005
• Published: 11/30/2006
• Est. Priority Date: 05/25/2005
• Status: Active Grant

• Current Assignee: AEES Incorporated (PKC Group OYJ)
• Original Assignee: AEES Incorporated (PKC Group OYJ)
• Inventors: Zhao, Weiping, Spadoni, Stefano, Bagchi, Ankoor
• Granted Patent: US 7,229,327 B2
• Time in Patent Office: Days
• US Class Current: 439/840
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 50/503 characterised by the shape of the interconnectors
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: H01M 50/517 by fixing means, e.g. screws, rivets or bolts
• CPC Class Codes: H01M 50/522 Inorganic material
• CPC Class Codes: H01M 50/524 Organic material
• CPC Class Codes: H01M 50/588 outside the batteries, e.g. incorrect connections of terminals or busbars
• CPC Class Codes: H01M 50/597 Protection against reversal of polarity
• CPC Class Codes: H01R 11/288 Interconnections between batteries
• CPC Class Codes: H01R 13/111 co-operating with pins having a circular transverse section
• CPC Class Codes: H01R 13/187 with spring member in the socket
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

The present invention provides an electrical power system comprising a plurality of battery modules in series connection between adjacent battery modules, wherein each of the battery modules comprises a positive male terminal, a negative male terminal, and a socket corresponding to each of the positive male terminals and the negative male terminals. The connectors connecting the adjacent battery modules include a sequence tab that provides an irreversible engagement sequence of the connectors into the sockets of the adjacent battery modules. The irreversible engagement sequence positions an insulating portion of the connectors housing on each positive male terminal of the battery modules that are in series connection in order to isolate the positive male terminals from human contact. The present invention also provides a female terminal including a canted coil spring positioned within a stamped groove that may be housed within the above-described connectors.

Claims

1. An electrical connection comprising:

a male terminal body comprising an inserting portion;

a female terminal body having at least one open end for receiving said inserting portion of said male terminal body, said female terminal body comprising a stamped groove positioned corresponding to said inserted portion of said male terminal body when said female terminal body and said male terminal body are engaged; and

a canted coil spring for providing an electrical interface between said male terminal body and said female terminal body, said canted coil spring positioned in said stamped groove.

2. The electrical connection of claim 1 wherein said canted coil spring is curvilinear in shape.

3. The electrical connection of claim 1 wherein said inserting portion of said male terminal body comprises a rounded pin comprising at least one groove, wherein said groove reversibly interlocks with said canted coil spring when said male terminal body and said female terminal body are engaged.

4. The electrical connection terminal of claim 1 wherein said female terminal body comprises a sheet of stamped metal comprising a folded portion, wherein said groove and said canted coil spring are contained within said folded portion of said stamped metal.

5. The electrical connection of claim 4 wherein a dimension defining a diameter of said canted coil spring is parallel to a dimension defining a length of said female terminal body or said dimension defining said diameter of said canted coil spring is perpendicular to said dimension defining said length of said female terminal body.

6. The electrical connection of claim 1 wherein at least one end of said female terminal body comprises a substantially cylindrical or polyhedron shape.

7. The electrical connection of claim 1 wherein said female terminal body comprises two or more open ends separated by an adjustable distance, wherein each of said two or more open ends has a geometry for independently engaging said male connector body and said adjustable distance is provided by a U-shape joint.

8. The electrical connection of claim 1 wherein said female terminal body and said male terminal body are engaged in an unsealed engagement or sealed engagement.

9. The electrical connector of claim 8 wherein said sealed engagement is provided by a female polymeric structure housing said female electrical connector and a male polymeric structure housing said male electrical connector, wherein engaging portions of said female polymeric structure and said male polymeric structure provide an interfacial seal when said male terminal body and said female terminal body are engaged.

10. A method of forming a female terminal body comprising:

providing a stamped metal panel comprising a stamped groove about an opening for inserting a male terminal;

inserting a canted coil spring into said stamped groove; and

folding a portion of said metal panel to contain said canted coil spring within said groove.

11. An electrical power system comprising:

a plurality of battery modules in series connection between adjacent battery modules, wherein each battery module of said plurality of battery modules comprises a positive male terminal, a negative male terminal, and a socket corresponding to each of said positive male terminal and said negative male terminal; and

a plurality of connectors, in which each connector of said plurality of said connectors is in engagement with said socket of said positive male terminal and said negative male terminal of said adjacent battery modules, said each connector comprises an insulating structure housing a female terminal body,

said female terminal body providing said series connection between said positive male terminal and said negative male terminal of said adjacent battery modules,

said insulating structure comprising a sequence tab configured to provide an irreversible engagement sequence for said each connector of said plurality of connectors within said sockets of said adjacent battery modules of said plurality of said battery modules, wherein said irreversible engagement sequence positions said insulating structure of said each connector on said positive male terminal of said plurality of battery modules in series connection between said adjacent battery modules.

12. The electrical power system of claim 11 wherein said female terminal body comprises at least two openings having a polyhedron shape or substantially curvilinear shape.

13. The electrical power system of claim 12 wherein said at least two openings of said female terminal body comprise a stamped groove containing a canted coil spring.

14. The electrical power system of claim 11 wherein said connector comprises at least one window and said socket comprises at least one locking protrusion, wherein when said connector is engaged in said socket said at least one locking protrusion interlocks with said at least one window.

15. The electrical power system of claim 11 wherein said insulating structure of said connector comprises at least two interlocking arms that each engage a sidewall of said socket, wherein each of said at least two interlocking arms comprises overlying portions atop an upper surface of said socket and vertical posts extending downward from said overlying portion of said interlocking arms along exterior portions of sidewalls of said each of said socket, wherein one of said interlocking arms comprises said sequence tab horizontally extending from a base portion of said one of said vertical posts, wherein said sequence tab is directly contacted by an adjacent vertical posts of an adjacent connector when said adjacent connector is engaged into an adjacent socket of said adjacent battery module.

16. The electrical power system of claim 11 further comprising a first positive male terminal positioned on a first battery module of said plurality of battery modules, said first positive male terminal comprising an insulating cap positioned atop an upper portion of said first positive male terminal leaving a lower portion of said first positive male terminal exposed and an insulating shroud around said lower portion of said first positive male terminal, wherein the dimension separating said insulating cap from said insulating shroud obstructs incidental contact to said lower portion of said first positive male terminal.

17. A method of assembling a series of battery modules comprising:

providing a plurality of battery modules, in which each battery module of said plurality of battery modules comprises a positive male terminal and a negative male terminal;

capping a first positive male terminal on a first battery module of said plurality of battery modules with an insulative cap leaving a first negative male terminal on said first battery module exposed;

engaging a first connector in series connection with said first negative male terminal of said first battery module and a second positive male terminal of a second battery module, leaving a second negative terminal of said second battery module exposed, wherein a first insulating housing of said first connector protects said second positive male terminal and comprises a first sequence proximate to said second positive male terminal and an post proximate to said first negative male terminal; and

engaging a second connector in series connection with said second negative male terminal of said second battery module and a third positive male terminal of a third battery module, leaving a third negative male terminal of said third battery module exposed, said second connector comprising a second insulating housing substantially similar in geometry to said first insulating housing that protects said third positive male terminal, wherein engagement of said first sequence tab of said first connector and a second post of said second connector provides an irreversible assembly sequence.

18. An electrical power system comprising:

a plurality of battery modules in series connection between adjacent battery modules, wherein each battery module of said plurality of battery modules comprises a positive male terminal, a negative male terminal, and a socket corresponding to each of said positive male terminal and said negative male terminal, wherein said positive male terminal comprises an insulating cap positioned atop an upper portion of said positive male terminal leaving a lower portion of said positive male terminal exposed and an insulating shroud of said socket around said lower portion of said positive male terminal, wherein a dimension separating said insulating cap from said insulating shroud obstructs incidental human contact to said lower portion of said positive male terminal; and

a plurality of connectors, in which each connector of said plurality of connectors is in engagement with said socket of said positive male terminal and said negative male terminal of said adjacent battery modules, wherein said each connector comprises an insulating structure housing a female terminal body providing said series connection between said positive male terminal and said negative male terminal of said adjacent battery modules.

19. The electrical power system of claim 18 wherein said plurality of connectors comprises windows and said socket comprises locking protrusions, wherein when said each connector of said plurality of connectors in engaged in said socket said locking protrusion interlock with said windows.

20. The electrical power system of claim 18 wherein said openings of said female terminal body comprise a stamped groove containing a canted coil spring.