Patent Publication Number: US-2023163435-A1

Title: Electrical connection cover

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to batteries for electric vehicles, and more particularly to an electrical connection cover configured to conceal and protect a respective positive and negative electrical terminal with a single fastener. 
     BACKGROUND 
     Electric vehicles are becoming increasingly popular as consumers look to decrease their environmental impact and improve air quality. Instead of a traditional internal combustion engine, electric vehicles include one or more motors, powered by a rechargeable battery pack. Conventional electric vehicle battery packs are typically constructed of multiple components, including a plurality of battery modules, electrical current transmission systems, temperature control systems, safety systems, battery management systems, and one or more structural supports. 
     Conventional construction techniques begin with an empty battery tray, which represents a bottom and typically one or more sides of a structural vessel, representing a compartment, configured to contain the other components of the battery pack. Often the battery tray includes one or more structural supports (e.g., cross members, etc.), providing structural support to the battery pack, as well as surfaces within the battery tray compartment on which other components of the battery pack can be affixed. The various components, including the temperature control system (e.g., cooling panels, etc.) and plurality of battery modules can be positioned within the compartment and secured in place. Electrical current transmission systems, battery management systems, and safety systems are also positioned within the compartment. A lid or cover is then positioned on the battery tray, thereby sealing the compartment. 
     As typical voltages within a rechargeable battery pack often exceed 200 V, special attention must be paid to electrically isolating exposed positive and negative battery terminals or connection points within the battery tray. Improperly isolated battery terminals can result in arcing or other short between the terminals, which can in turn result in rapid discharge of electrical potential, thermal runaway, fire, etc. Although the various efforts have been made over the years to improve the electrical connection covers, further improvements are always desired. The present disclosure addresses this concern. 
     SUMMARY OF THE DISCLOSURE 
     Embodiments of the present disclosure provide an electrical terminal cover which can be used in connection with a battery disconnect unit or other component within a rechargeable electric vehicle battery pack to conceal a first and a second terminal end (e.g., anode and cathode) of a battery bus bar. In some embodiments, a bottom portion of the electrical terminal cover includes an extended ring having a pair of keyholes or notches configured to enable the passage of a wall therethrough, thereby advantageously enabling the electrical terminal cover to be secured by a single fastener in a manner that inhibits rotation and translation of the terminal cover relative to the terminals. 
     One embodiment of the present disclosure provides electrical connection cover operably coupleable to a supporting surface defining an electrical isolation wall and protruding boss, the electrical connection cover configured to conceal a first and second terminal and of a battery bus bar, the electrical connection including a body defining a lip at least partially surrounding a recess, the recess shaped and sized to enable the first and second terminal end of the battery bus bar to be positioned therein, wherein a portion of the body further defines a hollow ring including the wall defining interior surface shaped and sized to at least partially surround the boss of the supporting surface, and one or more notches configured to matingly receive a portion of the electrical isolation wall. 
     In one embodiment, the body is a unitary member. In one embodiment, the body is constructed of an insulative material. In one embodiment, the electrical connection cover further includes a fastener configured to enable coupling of the electrical connection cover to the supporting surface. In one embodiment, the fastener includes an integrated washer. In one embodiment, the fastener is configured to reside within a countersunk pocket to minimize the outward protrusion of a top surface of the fastener from a top surface of the body of the electrical connection cover. In one embodiment, the electrical connection cover further includes a compression limiter configured to compression support to the body. In one embodiment, the lip defines one or more steps to promote a conformed fit between the electrical connection cover and the supporting surface. In one embodiment, the electrical connection cover further includes a protruding wall extending outwardly from a planar surface of the lip to promote a conformed fit between the electrical connection cover and the supporting surface. 
     Another embodiment of the present disclosure provides an electrical connection cover system, including an electrical component mountable within an electric vehicle battery tray, the electrical component configured to receive a first and second terminal and of a battery bus bar, the electrical component having a supporting surface defining an electrical isolation wall and a protruding boss positioned between the first and second terminal, and an electrical connection cover including a body defining a lip at least partially surrounding a recess, the recess shaped and sized to enable the first and second terminal end of the battery bus bar to be positioned therein, wherein a portion of the body further defines a hollow ring including the wall defining interior surface shaped and sized to at least partially surround the boss of the electrical component, and one or more notches configured to matingly receive a portion of the electrical isolation wall Yet another embodiment of the present disclosure provides an electrical connection cover operably coupleable to a supporting surface defining an electrical isolation wall and protruding boss, the electrical connection cover configured to conceal a first and second terminal and of a battery bus bar, the electrical connection including a unitary body defining a lip at least partially surrounding a recess, the recess shaped and sized to enable the first and second terminal end of the battery bus bar to be positioned therein, wherein a portion of the unitary body is constructed of an insulative material, and further defines a hollow ring including the wall defining interior surface shaped and sized to at least partially surround the boss of the supporting surface, and one or more notches configured to matingly receive a portion of the electrical isolation wall wherein the lip defines one or more steps and a protruding wall extending outwardly from a planar surface of the lip to promote a conformed fit between the electrical connection cover and the supporting surface; a fastener including an integrated washer configured to enable coupling of the electrical connection cover to the supporting surface, wherein the fastener is configured to reside within a countersunk pocket to minimize the outward protrusion of a top surface of the fastener from a top surface of the body of the electrical connection cover; and a compression limiter operably coupled to the unitary body configured to compression support to the body. 
     The summary above is not intended to describe each illustrated embodiment or every implementation of the present disclosure. The figures and the detailed description that follow more particularly exemplify these embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which: 
         FIG.  1    is an exploded, perspective view depicting an electric vehicle including a multi-cell battery pack, in accordance with an embodiment of the disclosure. 
         FIG.  2    is a perspective view depicting a multi-cell battery pack, in accordance with an embodiment of the disclosure. 
         FIG.  3    is a top perspective view depicting a first and second terminal ends of a battery bus bar mounted to a battery disconnect unit, in accordance with an embodiment of the disclosure. 
         FIG.  4    is a perspective view depicting electrical connection cover configured to conceal the first and second terminal ends of the battery bus bar of  FIG.  3   , in accordance with an embodiment of the disclosure. 
         FIG.  5    is a top perspective view depicting a electrical connection cover, in accordance with an embodiment of the disclosure. 
         FIG.  6    is a bottom perspective view depicting the electrical connection cover of  FIG.  5   , in accordance with an embodiment of the disclosure. 
     
    
    
     While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof shown by way of example in the drawings will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims. 
     DETAILED DESCRIPTION 
     Referring to  FIG.  1   , an electric vehicle  100  comprising a multi-cell electric vehicle battery pack  102  is depicted in accordance with an embodiment of the disclosure. In some embodiments, the battery pack  102  can include a cover  104  operably coupled to a battery tray  106 , thereby creating a sealed battery cell compartment containing clusters of individual battery cells and other battery related components. The assembled battery pack  102  can then be mounted to the frame and/or chassis of the vehicle  100 , which in some embodiments can be positioned adjacent to a cabin floor  108  of the vehicle  100 , thereby maintaining a low center of gravity. 
     Various embodiments of the present disclosure will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Various directions and orientations, such as “upward,” “downward,” “top,” “bottom,” “upper,” “lower”, etc. are generally described herein with reference to the drawings in the usual gravitational frame of reference, regardless of how the components may be oriented during assembly. 
     With additional reference to  FIG.  2   , an exploded, perspective of a multi-cell electric vehicle battery pack  102  is depicted in accordance with an embodiment of the disclosure. As depicted, the battery pack  102  can include a battery tray  106 , defining a battery cell compartment containing individual battery cells and other battery related components. For example, in one embodiment, the battery tray  106  can represent a bottom and one or more sides of a structural vessel defining a compartment  110 . Further, in embodiments, the battery tray  106  can include one or more structural supports, such as cross members  112 , which can provide structural support to the battery pack  102 , as well as surfaces within the compartment  110  which other components of the battery pack can be affixed. 
     In some embodiments, individual battery cells can be grouped into a number of distinct clusters sometimes referred to as battery modules  114 . In some embodiments, the battery pack  102  can include a plurality of battery modules  114 A-D; although the grouping of the individual cells into other quantities of clusters of varying shapes and sizes other than that depicted in  FIG.  2    is also contemplated. 
     In addition to the modules  114 , the battery pack  102  can include a variety of other electrical components. For example, in one embodiment, the components can include a battery management system  116  (including current management systems), a battery disconnect unit  118 , an electrical current transmission system  120 , one or more safety systems  122 , and a battery bus bar  124  interconnecting the various components  114 A-D,  116 ,  118 ,  120 , and  122 . Once the components have been positioned within the compartment  110 , the cover  104  (as depicted in  FIG.  1   ) can be affixed to the top surface  126  of the battery tray  106  via a plurality of fasteners, adhesive, or a combination thereof. 
     It should be understood that the terms “battery,” “cell,” and “battery cell” may be used interchangeably and may refer to any of a variety of different cell chemistries and configurations including, but not limited to, lithium ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium ion polymer, nickel metal hydride, nickel cadmium, nickel hydrogen, nickel zinc, silver zinc, or other battery type/configuration. The term “battery pack” as used herein refers to multiple individual batteries contained within a single piece or multi-piece housing or tray, the individual battery cells electrically interconnected to achieve the desired voltage and capacity for a particular application. 
     Additional reference to  FIG.  3   , the terminal ends  128 ,  130  of a battery bus bar  124 , for example, as mounted to a battery disconnect unit  118 , is depicted in accordance with an embodiment of the disclosure. As depicted, in some embodiments, the terminal ends  128 ,  130  can operably couple respective portions of the battery bus bar  124  to the battery disconnect unit (BDU)  118  via one or more electrically conductive threaded connectors  132 ,  134 . For example, in one embodiment, an electrically conductive threaded rod, bolt or other fastener can protrude from the BDU  118 , thereafter the terminal ends  128 ,  130 , each defining an aperture, can be positioned over the threaded rod, bolt or other fastener and held in position with a nut, thereby electrically coupling the respective terminal ends  128 ,  130  of the battery bus bar  124  to relevant portions of the BDU  118 . 
     In embodiments, the BDU  118 , which is common across all rechargeable electric vehicle systems, can include a main fuse for the battery bus bar  124 , as well as optional switching relays and a manual service disconnect. As depicted, in some embodiments, the BDU  118  can include a supporting surface  119  defining an electrical isolation wall  134  (sometimes referred to as a “rib”) positioned between the respective electrically conductive threaded connectors  132 ,  134 . The electrical isolation wall  134 , which can be constructed of a insulative (e.g., non-electrically conductive) material, can generally serve to inhibit arcing or the formation of other electrical paths between the terminal ends  128 ,  130  of the battery bus bar  124 , thereby reducing the likelihood of a short occurring between the terminal ends  128 ,  130 . Further, in some embodiments, the electrical isolation wall  134  can include a boss  136  or other protruding feature, which can define an aperture  138 . For example, in one embodiment, the aperture can be a threaded insert. In some embodiments, the threaded insert can have a standard size (e.g., M 2 , M 3 , M 4 , M 5 , etc.); although the use of other sizes of threaded inserts is also contemplated. 
     Although the isolation wall  134  serves its purpose well in inhibiting arcing or the formation of other electrical paths between the terminal ends  128 ,  130  of the battery bus bar  124  further protective measures are desirable. With additional reference to  FIG.  4   , a terminal cover  140  configured to conceal and electrically isolate the terminal ends  128 ,  130  of the battery bus bar  124  is depicted in accordance with an embodiment of the disclosure. In some embodiments, the terminal cover  140  can be unitary member constructed of an insulative (e.g., non-electrically conductive) material, such as plastic or the like, and can be configured to operably couple to the BDU  118  (or other battery pack component) via a single fastener  142 , thereby reducing the overall number of parts or components within the battery pack  102 , as well as easing efforts in the assembly or construction of the battery pack  102 . 
     With additional reference to  FIGS.  5  and  6   , respective top and bottom perspective views of the terminal cover  140  are depicted in accordance with an embodiment of the disclosure. In some embodiments, the terminal cover  140  can include a unitary body  141  defining a lip  144  at least partially surrounding a recess  146  shaped and sized to enable the electrically conductive threaded connectors  132 ,  134  (and respective portions of the terminal ends  128 ,  130 ) to be positioned therein. 
     In some embodiments, the lip  144  can represent a substantially planar surface at least partially surrounding or circumscribing the recess  146 , which can be configured to at least partially contact an upper surface of the BDU  118  (or other battery pack component), thereby creating at least a partial steel around the recess  148  to inhibit the intrusion of water or other fluid creating the potential for the formation of an electrically conductive path between the terminal ends  128 ,  130 . In some embodiments, the lip  144  may include one or more steps  148 A-B to promote a more conformed fit between the lip  144  and the upper surface of the BDU  118  (or other battery pack component). Further, in some embodiments, the lip  144  can define a protruding wall  150  which can extend from the lip  144  to promote a better fit between the upper surface of the BDU  118  (or other battery pack component) and a planar surface of the lip  144 . For example, in some embodiments, the protruding wall  150  can extend into a corresponding recess defined in the BDU  118 . In other embodiments, the protruding wall  150  can extend outwardly from the planar surface of the lip  144  to contact an upper surface of the BDU  118  to inhibit the intrusion of water or other fluid to the recess  144 . 
     As further depicted in  FIG.  6   , the recess  146  can define a hollow ring  152 , which in some embodiments can extend outwardly from a planar surface of the recess  146 . In some embodiments, the hollow ring  152  can include a wall  154  defining an interior surface shaped and sized to at least partially surround the boss  136  defined by the electrical isolation wall  134  of the BDU  118  (or other battery pack component). Further, in some embodiments, the wall  154  can define one or more keyholes or notches  156 A-B configured to mate with a portion of the electrical isolation wall  134  of the BDU  118 . 
     Thereafter, the terminal cover  140  can be secured in position relative to the BDU  118  with a single fastener  142 , for example, a bolt or other threaded fastener, which in some embodiments can include an integrated washer. To inhibit over compression of the terminal cover  140 , in some embodiments, the terminal cover  140  can include a compression limiter  158  configured to provide and maintain joint integrity of a plastic assembly. In some embodiments, the fastener  142  can be configured to reside within a pocket  160  defined by the recess  146 , thereby enabling a top surface of the fastener  142  to be substantially flush with (or at least minimize the outward protrusion from) a top surface of the terminal cover  140 . Accordingly, embodiments of the present disclosure advantageously enable the terminal cover  142  be secured to components within the battery pack  102  to shield the terminal ends  128 ,  130  of the battery bus bar  124  by a single fastener  142  in a manner and then inhabits rotation and translation of the terminal cover  140  relative to the terminal ends  128 ,  130 . 
     The invention is further illustrated by the following embodiments: 
     An electrical connection cover, comprising: a supporting surface defining an electrical isolation wall and protruding boss; and a cover body defining a lip at least partially surrounding a recess, the recess shaped and sized to enable the first and second terminal end of the battery bus bar to be positioned therein, wherein a portion of the cover body further defines a hollow ring including the wall defining interior surface shaped and sized to at least partially surround the boss of the supporting surface, and one or more notches configured to matingly receive a portion of the electrical isolation wall, enabling the electrical connection cover to conceal a first terminal end and second terminal end of a battery bus bar. 
     A system or method according to any embodiment, wherein the cover body is a unitary member. 
     A system or method according to any embodiment, wherein the cover body is constructed of an insulative material. 
     A system or method according to any embodiment, further comprising a fastener configured to enable coupling of the cover body to the supporting surface. 
     A system or method according to any embodiment, wherein the fastener includes an integrated washer. 
     A system or method according to any embodiment, wherein the fastener is configured to reside within a countersunk pocket to minimize the outward protrusion of a top surface of the fastener from a top surface of the body of the cover body. 
     A system or method according to any embodiment, further comprising a compression limiter configured to compression support to the cover body. 
     A system or method according to any embodiment, wherein the lip defines one or more steps to promote a conformed fit between the cover body and the supporting surface. 
     A system or method according to any embodiment, further defining a protruding wall extending outwardly from a planar surface of the lip to promote a conformed fit between the cover body and the supporting surface. 
     An electric vehicle comprising the electrical connection cover according to any embodiment of the disclosure. 
     Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions. 
     Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted. 
     Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended. 
     Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein. 
     For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.