ELECTRICAL CONNECTOR FOR PORTABLE MULTI-CELL ELECTRICAL ENERGY STORAGE DEVICE

• US 20160336575A1
• Filed: 05/10/2016
• Published: 11/17/2016
• Est. Priority Date: 05/11/2015
• Status: Active Grant

• Current Assignee: Gogoro Inc.
• Original Assignee: Gogoro Inc.
• Inventors: LIU, Tai-Tsun
• Granted Patent: US 10,153,475 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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: H01R 13/245 by stamped-out resilient contact arm

Abstract

Electrical connectors for electrically connecting individual portable electrical energy storage cells making up a plurality of portable electrical energy storage cells that are part of a portable electrical energy storage device for powering portable devices such as vehicles or consumer electronics include bands of reduced cross-sectional area. The electrical connectors include conductive bands that promote reliable attachment between the electrical connector and portable electrical energy storage cells and provide the ability to electrically isolate failing or damaged cells.

Claims

1. An electrical connector for electrical connection to each of a plurality of portable electrical energy storage cells making up a portable electrical energy storage device, the electrical connector comprising:

a. an electrically conductive frame;

b. a plurality of integral electrically conductive tabs, each of the plurality of integral electrically conductive tabs in electrical communication with the electrically conductive frame; and

c. a plurality of integral electrically conductive supports, an integral electrically conductive support of the plurality of electrically conductive supports extending between one of the plurality of integral electrically conductive tabs and the electrically conductive frame, the integral electrically conductive support extending between one of the plurality of integral electrically conductive tabs and the electrically conductive frame including at least one electrically conductive band, the at least one electrically conductive band having a cross-sectional area less than a cross-sectional area of another portion of the integral electrically conductive support extending from one of the integral electrically conductive tabs.

2. The electrical connector of claim 1, wherein the integral electrically conductive support includes an upper surface and a lower surface and an opening extending from the upper surface to the lower surface.

3. The electrical connector of claim 2, wherein the integral electrically conductive support includes a first edge and a second edge with a first electrically conductive band between the first edge and the opening and a second electrically conductive band between the second edge and the opening.

4. The electrical connector of claim 1, wherein the one of the plurality of integral electrically conductive tabs lies in a plane different from a plane in which the electrically conductive frame lies.

5. The electrical connector of claim 1, the at least one electrically conductive band including two electrically conductive bands, each of the two electrically conductive bands having a cross-sectional area less than a cross-sectional area of the other portion of the integral electrically conductive support extending from one of the integral electrically conductive tabs.

6. The electrical connector of claim 5, wherein the at least one electrically conductive band includes more than two electrically conductive bands, each of the more than two electrically conductive bands having a cross-sectional area less than a cross-sectional area of the other portion of the integral electrically conductive support extending from one of the integral electrically conductive tabs.

7. The electrical connector of claim 5, wherein the cross-sectional area of one of the two electrically conductive bands is less than the cross-sectional area of the other one of the two electrically conductive bands.

8. The electrical connector of claim 5, wherein the integral electrically conductive support includes a section having a substantially constant width.

9. A method of manufacturing an electrical connector for electrical connection to each of a plurality of portable electrical energy storage cells making up a portable electrical energy storage device, the method comprising:

a. providing an electrically conductive substrate;

b. forming a plurality of integral electrically conductive tabs and a plurality of integral electrically conductive supports in the electrically conductive substrate, one of the plurality of integral electrically conductive supports extending from one of the integral electrically conductive tabs; and

c. forming an electrically conductive band in the one of the plurality of electrically conductive supports extending from one of the integral electrically conductive tabs, the electrically conductive band having a cross-sectional area less than a cross-sectional area of another portion of the integral electrically conductive support extending from one of the integral electrically conductive tabs.

10. The method of claim 9, wherein the step of forming a plurality of integral electrically conductive tabs further comprises displacing the integral electrically conductive tab so it lies in a plane different from the plane in which the balance of the electrically conductive substrate lies.

11. The method of claim 9, wherein the step of forming an electrically conductive band comprises forming two electrically conductive bands in the integral electrically conductive support extending from one of the plurality of integral electrically conductive tabs, each of the two electrically conductive bands having a cross-sectional area less than a cross-sectional area of the other portion of the integral electrically conductive support extending from one of the integral electrically conductive tabs.

12. The method of claim 11, wherein the cross-sectional area of one of the two electrically conductive bands is less than the cross-sectional area of the other one of the two electrically conductive bands.

13. The method of claim 9, wherein forming a plurality of integral electrically conductive supports includes forming the supports with sections having a constant width.

14. The method of claim 9, wherein forming an electrically conductive band in one of the plurality of electrically conductive supports further includes forming a plurality of bands in the one electrically conductive support.

15. The method of claim 9, wherein forming an electrically conductive band in one of the plurality of electrically conductive supports extending from one of the integral conductive tabs includes removing a portion of the integral electrically conductive support extending from one of the plurality of integral electrically conductive tabs.

16. A method of connecting a portable electrical energy storage cell of a portable electrical energy storage device to a plurality of other portable electrical energy storage cells of the portable electrical energy storage device, the method comprising:

a. providing a plurality of integral electrically conductive tabs and a plurality of integral electrically conductive supports, one of the plurality of integral electrically conductive supports extending from one of the integral electrically conductive tabs and including at least one electrically conductive band having a cross-sectional area less than a cross-sectional area of another portion of the integral electrically conductive support extending from one of the integral electrically conductive tabs;

b. heating the one integral electrically conductive tab from which the one integral electrically conductive supports extends; and

c. thermally fusing the one integral electrically conductive tab from which the one integral electrically conductive support extends to the portable electrical energy storage cell.

17. The method of claim 16, wherein the integral electrically conductive support extending from one of the integral electrically conductive tabs includes at least two electrically conductive bands, each of the two electrically conductive bands having a cross-sectional area less than the cross-sectional area of the other portion of the integral electrically conductive support extending from one of the integral electrically conductive tabs.

18. The method of claim 17, wherein the cross-sectional area of one of the at least two electrically conductive bands is less than the cross-sectional area of another of the at least two electrically conductive bands.