Patent Description:
Batteries have become a commonplace form of energy storage (e.g., for use in hybrid and electric vehicles). Often, one or more battery cells (e.g., modules) are connected (e.g., in series or parallel) to increase the storage capacity and/or power output of the battery system. To connect two battery cells in series, an anode of a first battery is typically connected with a cable to the cathode of a second battery.

A problem with battery cell connections arises when batteries are used, for example, in vehicles, because battery cables offer little if any mechanical support. For example, tolerances between the shape and size of the battery cells, along with vibrations experienced by the battery system from operating in a vehicle (e.g., vibrations between battery cells), can lead to mechanical and/or electrical failure of the battery system.

Examples of the prior art can be found in documents <CIT>, <CIT> and <CIT>.

Thus, there is need for battery cell connectors that provide mechanical rigidity, support and/or vibration damping. To that end, disclosed are battery module connectors that provide mechanical support and/or vibration damping when connecting battery cells.

In accordance with the invention, a battery cell connector including the features of claim <NUM> is provided.

Like reference numerals refer to corresponding parts throughout the drawings.

The embodiments and examples shown in <FIG> and <FIG> are not in accordance with the present invention.

The battery cell connectors described herein include a sheet of material (e.g., metal) with bends and turns configured in such a way as to provide mechanical rigidity and vibration dampening in one or more directions, thus providing mechanical support to the interconnects between battery cell terminals. For example, in some embodiments, the battery cell connectors described herein include segments of substantially flat sheets of metal that efficiently carry bending and shear loads along a longitudinal direction of each segment. The segments are coupled by bends (e.g., connections between two segments having non-planar longitudinal axes) and/or turns (e.g., connections between two segments having non-parallel, but planar, longitudinal axis). By coupling segments by bends and turns, the battery cell connectors described herein are configured into a three-dimensional (<NUM>-D) object that provides mechanical compressional/shearing rigidity (e.g., efficient carrying of bending and/or shear stress) in more than one direction (e.g., two or three perpendicular directions) as well as rotational rigidity along more than one rotational axis (e.g., two or three rotational axes). In addition, in some embodiments, the bends coupling segments act a stiff springs that provide vibration damping along one or more rotational axes. As described below, <FIG> illustrate exemplary embodiments which are configured to provide rigid support and vibration dampening while fitting conveniently to existing battery module geometries (e.g., the embodiments described below describe example geometries for battery cell connectors).

Reference will now be made in detail to various implementations, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure and the described implementations herein. However, implementations described herein may be practiced without these specific details. In other instances, well-known methods, procedures, components, and mechanical apparatus have not been described in detail so as not to unnecessarily obscure aspects of the implementations.

<FIG> illustrates a perspective view of a first battery cell connector <NUM> (e.g., also called a bus bar or a battery module connector), First battery cell connector <NUM> includes a plurality of segments <NUM> (e.g., segments <NUM>-<NUM> through <NUM>-<NUM>). In some embodiments, a battery cell connector includes two segments, three segments, or more segments. For example, first battery cell connector <NUM> includes five segments.

Each segment <NUM> defines a respective plane (e.g., lies in the respective plane). For example, as shown by axes <NUM>, segments <NUM>-<NUM> and <NUM>-<NUM> are parallel to an xz-plane; segments <NUM>-<NUM> and <NUM>-<NUM> are parallel to a xy-plane; segment <NUM>-<NUM> is parallel to a yz-plane. In some embodiments, a battery cell connector includes a plurality of segments that define a plurality of respective planes (e.g., two or three planes). For example, first battery cell connector <NUM> includes five segments that define three planes (e.g., xy-plane, xz-plane, and yz-plane). In some embodiments, for example, as shown in first battery cell connector <NUM>, the three planes are mutually substantially perpendicular.

Each segment has a respective longitudinal axis. For example, segments <NUM>-<NUM> and <NUM>-<NUM> have respective longitudinal axes along the x-direction (i.e., left and right direction); segment <NUM>-<NUM> has a longitudinal axis along the z-direction (i.e., front and rear direction); segments <NUM>-<NUM> and <NUM>-<NUM> have respective longitudinal axes along the y-direction (up and down direction). In some embodiments, a segment's longitudinal axis is along a direction from a center of the segment to an adjacent bend or turn. In some embodiments, a segment's longitudinal axis is along a direction connecting a bend or a turn on a first end of the segment and a bend or a turn on a second end of the segment, opposite the first.

First battery cell connector <NUM> includes a plurality of bends <NUM> (e.g., bend <NUM>-<NUM>; bend <NUM>-<NUM>; and bend <NUM>-<NUM>) coupling the plurality of segments together into a <NUM>-D object (e.g., an object having substantial spatial extent and/or substantial rigidity in three orthogonal directions). The plurality of bends coupling the plurality of segments into a <NUM>-D object comprises bends pointing in at least three different directions (e.g., having bending axes along three distinct directions). In some embodiments, the three different directions are orthogonal (perpendicular) directions. In some embodiments, at least two of the plurality of bends are not parallel to each other. In some embodiments, at least three of the plurality of bends are not parallel to each other. In some embodiments, two bends are not parallel to each other when they have respective bending axes that are not parallel to each other. Each bend <NUM> is located between (e.g., couples) a unique pair of adjacent segments of the plurality of segments. For example, bend <NUM>-<NUM> is located between segment <NUM>-<NUM> and segment <NUM>-<NUM>; bend <NUM>-<NUM> is located between segment <NUM>-<NUM> and segment <NUM>-<NUM>; and bend <NUM>-<NUM> is located between segment <NUM>-<NUM> and segment <NUM>-<NUM>. In this example, bend <NUM>-<NUM> has an axis that is approximately in the z-direction; bend <NUM>-<NUM> has an axis that is approximately in the y-direction; and bend <NUM>-<NUM> has an axis that is approximately in the x-direction. As will be described below in connection with <FIG>, the first battery cell connector <NUM> is formed from a two-dimensional U-shape metal sheet <NUM> by bending different portions of the U-shape metal sheet <NUM> into different directions at predefined locations. For example, both terminal segments are formed by bending the corresponding side portions of the U-shape metal sheet <NUM> into two opposite directions perpendicular to the plane defined by the U-shape metal sheet <NUM> (see, e.g., <NUM>-<NUM> and <NUM>-<NUM> in <FIG>) and another bend <NUM>-<NUM> is formed by bending the bottom portion of the U-shape metal sheet <NUM>. The unique pair of adjacent segments on either side of a bend defines two distinct respective planes. In some embodiments, the two distinctive planes are perpendicular to one another (e.g., the bend is a <NUM> degree bend). In some embodiments, a bend has a radius of curvature. In some embodiment, a bend is bent along a respective bending axis that is parallel with both of the two distinct respective planes (e.g., the bend is characterized by a bending axis). For example, the bending axis for bend <NUM>-<NUM> is parallel to the z-axis. In some embodiments, the plurality of bends <NUM> includes at least three bends having three distinct bending axes. In some embodiments, the three distinct bending axes are perpendicular to one another. In some embodiments, the plurality of bends serves as vibration dampening elements (e.g., damp vibrations along directions perpendicular to the bend's respective bending axis).

Specifically, a right edge of segment <NUM>-<NUM> is connected with an upper edge of segment <NUM>-<NUM> via bend <NUM>-<NUM>, a front edge of segment <NUM>-<NUM> is connected with a left edge of segment <NUM>-<NUM> via bend <NUM>-<NUM>, and an upper edge of segment <NUM>-<NUM> is connected with a front edge of segment <NUM>-<NUM> via bend <NUM>-<NUM>.

In some embodiments, the battery cell connector is for use in a vehicle (e.g., an electrical car) and the bends are elastically deformable under predefined operating conditions of the vehicle (e.g., vibration or shock). For example, in some embodiments, the bends act as springs having a stiffness designed to dampen one or more resonance modes of the vehicle and/or the battery system.

In the example shown in <FIG>, segment <NUM>-<NUM> is a first segment of the plurality of segments <NUM> that includes one or more first connecting elements <NUM> for a battery pole (e.g., an anode, a cathode, or a connecting terminal or contact for an anode or a cathode) of a first battery cell. Segment <NUM>-<NUM> is a second segment of the plurality of segments <NUM> that includes one or more second connecting elements <NUM> for a battery pole of a second battery cell. In some embodiments, the first connecting elements <NUM> include at least two connecting elements (e.g., first connecting elements <NUM>-<NUM> and <NUM>-<NUM>) to provide rotational stiffness for the connection to the first battery cell. In some embodiments, the second connecting elements include at least two connecting elements (e.g., second connecting elements <NUM>-<NUM> and <NUM>-<NUM>) to provide rotational stiffness for the connection to the second battery cell. In some embodiments, a respective connecting element of the first connecting elements and the second connecting elements comprises an opening adapted to receive a battery terminal, wherein the battery terminal is mechanically connected at least partially along a circumference of the opening (e.g., as shown in first battery cell connector <NUM>, each of the connecting elements <NUM>/<NUM> comprises an opening adapted to receive a battery terminal, which may comprise a bolt screwed into the battery). The one or more first connecting elements are electrically coupled with the one or more second connecting elements. In some embodiments, the plurality of segments comprise an electrical conductor forming the electrical coupling between the one or more first connecting elements <NUM> and the one or more second connecting elements <NUM>. In some embodiments, for example as shown in first battery cell connector <NUM>, the plurality of segments and the plurality of bends are formed by a single continuous metal sheet that comprises an electrical conductor forming the electrical coupling between the one or more first connecting elements <NUM> and the one or more second connecting elements <NUM>. In some embodiments, the connector <NUM> is made of copper or aluminum.

In some embodiments, the segments <NUM> that include connecting elements <NUM>/<NUM> do not have a clearly discernible longitudinal axis. In some embodiments, the segments <NUM> that include connecting elements <NUM>/<NUM> are respective segments in a plurality of segments that includes one or more additional segments, each additional segment having a longitudinal axis.

In some embodiments, first battery cell connector <NUM> includes one or more (or a plurality of) turns <NUM> (for visual clarity, only a single turn <NUM>-<NUM> is given a reference number in <FIG>). Each turn <NUM> couples a second unique pair of adjacent segments <NUM> in the plurality of segments <NUM>. For example, turn <NUM>-<NUM> couples segment <NUM>-<NUM> and <NUM>-<NUM>. The second unique pair of adjacent segments <NUM> have distinct respective longitudinal axes within the same respective plane. For example, segment <NUM>-<NUM> has a longitudinal axis in the y-direction, segment <NUM>-<NUM> has a longitudinal axis in the x-direction, and both segment <NUM>-<NUM> and <NUM>-<NUM> are parallel with the xy-plane. In some embodiments, the respective axes of segments coupled by a turn are perpendicular (e.g., the segments form an L-shape). In some embodiments, the plurality of segments has an L-shaped opening (e.g., at least a portion of the opening is L-shaped).

<FIG> illustrate alternate views of first battery cell connector <NUM>.

<FIG> illustrates a partially-exploded-view of a first battery system <NUM> utilizing first battery cell connector <NUM>. Battery system <NUM> includes a plurality of (e.g., two or more) battery cells (also called modules) <NUM> (e.g., battery cell/module <NUM>-<NUM> and <NUM>-<NUM>). First battery cell connector <NUM> is coupled with battery cell/module <NUM>-<NUM> and <NUM>-<NUM> by bolts <NUM> running through connecting elements <NUM>/<NUM> (<FIG>), where the bolts serve as terminals of the battery cells. For example, in some embodiments, a cathode of battery cell/module <NUM>-<NUM> is coupled with an anode of battery cell/module <NUM>-<NUM> so that battery cell/module <NUM>-<NUM> and battery cell/module <NUM>-<NUM> are electrically connected in series. <FIG> illustrates an assembly view of the first battery system <NUM> utilizing the first battery cell connector <NUM>, in accordance with some embodiments. <FIG> illustrates a close-up of a portion <NUM> of the assembly view of the first battery system <NUM> utilizing the first battery cell connector <NUM>, in accordance with some embodiments. In particular, <FIG> illustrates that first battery cell connector <NUM> fits snuggly (e.g., securely) between battery cell/module <NUM>-<NUM> and battery cell/module <NUM>-<NUM>.

<FIG> illustrate various views of a second battery cell connector <NUM>.

In particular, <FIG> illustrates a perspective view of second battery cell connector <NUM>; <FIG> illustrates a top view of second battery cell connector <NUM>; <FIG> illustrates a partially-exploded-view of second battery system <NUM> utilizing second battery cell connector <NUM>; and <FIG> illustrates a close-up of a portion <NUM> of an assembly view of the second battery system <NUM> utilizing second battery cell connector <NUM>. Second battery cell connector <NUM> is largely analogous to first battery cell connector <NUM>, but second battery cell connector <NUM> is arranged geometrically differently from first battery cell connector <NUM>. Nevertheless, second battery cell connector <NUM> includes a plurality of segments <NUM> (e.g., segments <NUM>-<NUM> through <NUM>-<NUM> and optionally others, not labeled for visual clarity), a plurality of bends <NUM> (e.g., bends <NUM>-<NUM> and optionally others, not labeled for visual clarity), connecting elements <NUM>/<NUM>, and a plurality of turns <NUM> (e.g., turn <NUM>-<NUM> and optionally others, not labeled for visual clarity). Segments <NUM>, bends <NUM>, connecting elements <NUM>/<NUM> and turns <NUM> have analogous features to those described above with reference to <FIG>. As shown in <FIG>, second battery cell connector <NUM> is used to connect battery cell/module <NUM>-<NUM> and battery cell/module <NUM>-<NUM>.

Specifically, a front edge of segment <NUM>-<NUM> is connected with an upper edge of segment <NUM>-<NUM> via a bend, a right edge of segment <NUM>-<NUM> is connected with a front edge of segment <NUM>-<NUM> via bend <NUM>-<NUM>, and an upper edge of segment <NUM>-<NUM> is connected with a left edge of segment <NUM>-<NUM> via a bend.

<FIG> illustrate various views of a third battery cell connector <NUM>, in accordance with some examples. In particular, <FIG> illustrates a partially-exploded-view of a third battery system <NUM> utilizing third battery cell connector <NUM>; <FIG> illustrates another partially-exploded-view of third battery system <NUM> utilizing third battery cell connector <NUM>; <FIG> illustrates an assembly view of third battery system <NUM> utilizing third battery cell connector <NUM>; and <FIG> illustrates a close-up of a portion <NUM> of the assembly view of third battery system <NUM> utilizing the third battery cell connector <NUM>. Third battery cell connector <NUM> includes a plurality of segments <NUM> (segment <NUM>-<NUM>, segment <NUM>-<NUM> and other segments); a plurality of bends <NUM> (e.g., bends <NUM>-<NUM> and <NUM>-<NUM>), and connecting elements <NUM>/<NUM>, which each have analogous features to those described above with reference to <FIG>. However, two respective segments <NUM> (to wit, segment <NUM>-<NUM> and <NUM>-<NUM>) of third battery cell connector <NUM> are welded together (e.g., coupled together by a weld) to form a spring (e.g., a shock absorber or vibration dampener). The spring forms a tweezer structure. In some examples, the tweezer structure includes two planar segments having planes separated by a single rotation (e.g., not a compound or multi-dimensional rotation) of a few degrees (e.g., between <NUM>-<NUM> degrees). In some examples, each longitudinal axis of the respective segments <NUM> of third battery cell connector <NUM> lie in a common plane. In some examples, third battery cell connector <NUM> does not include any turns. In some examples, the longitudinal axes of each segment of third battery cell connector <NUM> are co-planar. As shown in <FIG>, the welded segments of third battery cell connector <NUM> are configured to be positioned between respective battery/cells modules with the common plane of their longitudinal axes perpendicular to the plane of attachment to the battery terminals.

Specifically, a first fixing segment is connected with an upper edge of segment <NUM>-<NUM> via bend <NUM>-<NUM> and extended away from segment <NUM>-<NUM>, and a second fixing segment is connected with an upper edge of segment <NUM>-<NUM> via bend <NUM>-<NUM> and extended away from segment <NUM>-<NUM>. In other words, the first fixing segment is disposed on segment <NUM>-<NUM> and extended away from an included angle between segment <NUM>-<NUM> and segment <NUM>-<NUM>, and the second fixing segment is disposed on segment <NUM>-<NUM> and extended away from the included angle between segment <NUM>-<NUM> and segment <NUM>-<NUM>. Moreover, a plane in which the first fixing segment is may be parallel with a plane in which the second fixing segment is.

In some examples, the first fixing segment is disposed on an upper end of segment <NUM>-<NUM>, connected with the upper edge of segment <NUM>-<NUM> and bent leftwards to a horizontal position; the second fixing segment is disposed on an upper end of segment <NUM>-<NUM>, connected with the upper edge of segment <NUM>-<NUM> and bent rightwards to a horizontal position.

In some examples, the first fixing segment is in flush with the second fixing segment.

<FIG> illustrate various views of a fourth battery cell connector <NUM>, in accordance with some examples. In particular, <FIG> illustrates a perspective view of a fourth battery cell connector <NUM>; <FIG> illustrates a partially-exploded-view of fourth battery system <NUM> utilizing fourth battery cell connector <NUM>; <FIG> illustrates another partially-exploded-view of fourth battery system <NUM> utilizing fourth battery cell connector <NUM>; <FIG> illustrates an assembly view of fourth battery system <NUM> utilizing the fourth battery cell connector <NUM>; and <FIG> illustrates a close-up of a portion <NUM> of the assembly view of fourth battery system <NUM> utilizing fourth battery cell connector <NUM>, in accordance with some examples. Fourth battery cell connector <NUM> includes a plurality of segments <NUM> (e.g., segments <NUM>-<NUM> through <NUM>-<NUM>); a plurality of bends <NUM> (e.g., bends <NUM>-<NUM> through <NUM>-<NUM>), and connecting elements <NUM>/<NUM>, as described above. Fourth battery cell connector <NUM> electrically couples battery cell module <NUM>-<NUM> and battery cell module <NUM>-<NUM> of fourth battery system <NUM>. Fourth battery cell connector <NUM> is largely analogous to third battery cell connector <NUM> (e.g., includes two welded segments that together form a spring/tweezer structure). However, the longitudinal axes of each non-terminal segment of fourth battery cell connector <NUM> are parallel with the respective planes of the terminal segments of battery cell connector <NUM>. As shown in <FIG>, the welded segments of fourth battery cell connector <NUM> are configured to be positioned between respective battery/cells modules with their longitudinal axes lying in a plane parallel to the plane of attachment to the battery terminals. The plurality of segments <NUM> of fourth battery cell connector <NUM> has an L-shaped opening <NUM>.

Specifically, rear ends of segment <NUM>-<NUM> and segment <NUM>-<NUM> are connected with each other and front ends of segment <NUM>-<NUM> and segment <NUM>-<NUM> are separated from each other by a single rotation of a few degrees, i.e., an included angle. Segment <NUM>-<NUM> is connected with an edge of segment <NUM>-<NUM> via bend <NUM>-<NUM> and extended away from segment <NUM>-<NUM>, and segment <NUM>-<NUM> is connected with an edge of segment <NUM>- <NUM> via bend <NUM>-<NUM> and extended away from segment <NUM>-<NUM>. Segment <NUM>-<NUM> is connected with an edge of segment <NUM>-<NUM> via bend <NUM>-<NUM>.

In some examples, a right edge of segment <NUM>-<NUM> is connected with a lower edge of segment <NUM>-<NUM> via bend <NUM>-<NUM>, a left edge of segment <NUM>-<NUM> is connected with a lower edge of segment <NUM>- <NUM> via bend <NUM>-<NUM>, a rear edge of segment <NUM>-<NUM> is connected with a front edge of segment <NUM>-<NUM> via bend <NUM>-<NUM> and segment <NUM>-<NUM> is in flush with segment <NUM>-<NUM>.

<FIG> illustrate various views of a fifth battery cell connector <NUM>, in accordance with some examples. In particular, <FIG> illustrates a perspective view of fifth battery cell connector <NUM>; <FIG> illustrates a partially-exploded-view of a fifth battery system <NUM> utilizing fifth battery cell connector <NUM>; <FIG> illustrates an assembly view of fifth battery system <NUM> utilizing fifth battery cell connector <NUM>; and <FIG> illustrates a close-up of a portion <NUM> of the assembly view of fifth battery system <NUM> utilizing fifth battery cell connector <NUM>, in accordance with some examples. Fifth battery cell connector <NUM> includes a plurality of segments <NUM> (e.g., segments <NUM>-<NUM> through <NUM>-<NUM>); a plurality of bends <NUM> (e.g., bends <NUM>-<NUM> through <NUM>-<NUM>), and connecting elements <NUM>/<NUM>, as described above. Fifth battery cell connector <NUM> electrically couples battery cell/module <NUM>-<NUM> and battery cell/module <NUM>-<NUM> of fifth battery system <NUM>. Fifth battery cell connector <NUM> is largely analogous to third battery cell connector <NUM> (e.g., includes two welded segments that together form a spring/tweezer structure). As shown in <FIG>, the welded segments of fifth battery cell connector <NUM> are configured to be positioned adjacent to and outside of the respective battery/cells modules connect by fifth battery cell connector <NUM>. Moreover, the welded segments of fifth battery cell connector <NUM> have their longitudinal axes in a plane parallel to the plane of attachment to the battery terminals.

Specifically, segment <NUM>-<NUM> is attached to a left portion of segment <NUM>-<NUM>, and a right edge of segment <NUM>-<NUM> is connected with a left edge of segment <NUM>-<NUM>. A right edge of segment <NUM>-<NUM> is separated from segment <NUM>-<NUM> by an included angle so as to form a substantial V-shaped structure, a left edge of segment <NUM>-<NUM> is connected with the right edge of segment <NUM>-<NUM>, and an upper edge of segment <NUM>-<NUM> is connected with a front edge of segment <NUM>- <NUM> via bend <NUM>-<NUM>. Furthermore, a right edge of segment <NUM>-<NUM> is connected with a front edge of segment <NUM>-<NUM> via bend <NUM>-<NUM>, and an upper edge of segment <NUM>-<NUM> is connected with a left edge of segment <NUM>-<NUM>.

In some examples, segment <NUM>-<NUM> and segment <NUM>- <NUM> may be located at a same side of the substantial V-shaped structure, or may be located at different sides of the substantial V-shaped structure respectively. Moreover, segment <NUM>-<NUM> is in flush with segment <NUM>-<NUM>.

<FIG> illustrates perspective views of additional battery cell connectors. The battery cell connectors shown in <FIG> are largely analogous to the other battery cell connectors formed of a single metal sheet discussed above. However, the battery cell connectors shown in <FIG> illustrate the wide variety of arrangements of bends, segments, and turns that are contemplated. For example, in <FIG>, the battery cell connector has an elongated intermediate segment <NUM> between the first terminal segment <NUM> and the second terminal segment <NUM>. There are multiple bends and other intermediate segments connecting each end of the elongated segment <NUM> to one of the first terminal segment <NUM> and the second terminal segment <NUM>. <FIG> depicts a battery cell connector that is a slight variation of the battery cell connector shown in <FIG>. In particular, the elongated intermediate segment (<NUM>-<NUM>, <NUM>-<NUM>) between the first terminal segment <NUM> and the second terminal segment <NUM> has a bump <NUM>. This bump is formed by bending the elongated intermediate segment <NUM> and separates the elongated intermediate segment into two sub-segments <NUM>-<NUM> and <NUM>-<NUM>. This bump <NUM> serves as a spring that is elastically deformable along the axis <NUM> of the elongated intermediate segment <NUM> to absorb the vibration movement between the battery cells connected to the two terminal segments <NUM> and <NUM>. In some examples, the elongated intermediate segment <NUM> includes more than one bump; in some other examples, the bump may be present in more than one segment including both intermediate segments and terminal segments.

Specifically, as shown in <FIG>, a rear edge of the first terminal segment <NUM> is connected with a front edge of segment <NUM> via bend <NUM>, and a rear edge of segment <NUM> is connected with a lower edge of the elongated intermediate segment <NUM> via bend <NUM>. The elongated intermediate segment <NUM> has a leftwards bent portion at an upper end thereof and a left edge of the leftwards bent portion is connected with a front edge of segment <NUM> via bend <NUM>, and an upper edge of segment <NUM> is connected with a left edge of segment <NUM> via bend <NUM>.

In some examples, a plane in which segment <NUM> is may be parallel with a plane in which segment <NUM> is.

Similarly, as shown in <FIG>, a right edge of segment <NUM> is connected with a front edge of segment <NUM> via a bend. Sub-segment <NUM>-<NUM> has a rightwards bent portion at a front end thereof, and a right edge of the rightwards bent portion is connected with an upper edge of segment <NUM> via a bend. A rear edge of sub-segment <NUM>-<NUM> is connected with a front edge of sub-segment <NUM>-<NUM> via the bump <NUM>, sub-segment <NUM>-<NUM> has a rightwards bent portion at a rear end thereof, and a right edge of the rightwards bent portion is connected with an upper edge of segment <NUM> via a bend.

In some examples, a plane in which segment <NUM> is may be perpendicular to a plane in which segment <NUM> is.

As shown in <FIG>, a battery cell connector is provided that is formed of single continuous metal sheet. The battery cell connector includes a plurality of segments including a first terminal segment that includes one or more first connecting elements for a battery pole of a first battery cell; a second terminal segment that includes one or more second connecting elements for a battery pole of a second battery cell; and a plurality of additional segments connecting the first terminal segment to the second terminal segment. Each additional segment defines a respective plane and having a respective longitudinal axis. The battery cell connector also includes a plurality of bends coupling the plurality of segments together into a <NUM>-D object, each bend located between a unique pair of adj acent segments of the plurality of segments. The unique pair of adjacent segments define two distinct respective planes. The first terminal segment is not parallel to the second terminal segment and the one or more first connecting elements are electrically coupled with the one or more second connecting elements. For example, as shown in <FIG>, the plurality of bends includes a first bend <NUM> having a first bending axis <NUM> and a second bend <NUM> having a second bending axis <NUM> that is substantially perpendicular to the first bending axis. First terminal segment <NUM> is not parallel to second terminal segment <NUM>. In some examples, first terminal segment <NUM> is substantially perpendicular to second terminal segment <NUM>. In some examples, the battery cell connector includes a third bend with a bending axis parallel to either the first bending axis or the second bending axis.

Specifically, as shown in <FIG>, a rear edge of segment <NUM> is connected with an upper of segment <NUM> via the first bend <NUM>, and a right edge of segment <NUM> is connected with a front edge of segment <NUM> via bend <NUM>. A rear edge of segment <NUM> is connected with a left edge of segment <NUM> via the second bend <NUM>.

As shown in <FIG>, in some examples, the battery cell connector includes only two bends. In some examples, the battery cell connector further comprises a single turn that, together with the two bends, forms the plurality of segments into the <NUM>-D object. In <FIG>, first terminal segment <NUM> is not parallel to second terminal segment <NUM>.

Specifically, a front edge of first terminal segment <NUM> is connected with an upper edge of intermediate segment <NUM> via a bend, and a right edge of intermediate segment <NUM> is connected with a front edge of second terminal segment <NUM>. In some examples, first terminal segment <NUM> may be substantially perpendicular to second terminal segment <NUM>.

In some examples, at least two continuous sheets of metal, the at least two continuous sheets of metal coupled together by the welding of the two respective segments forming the spring. In some examples, the plurality of bends point to at least three different directions. In some examples, the first and second segments of the plurality of segments are not parallel to each other.

Alternatively, in some examples, a battery cell connector is provided that is formed of two or more continuous metal sheets. Battery cell connector <NUM> (discussed above with reference to <FIG>), battery cell connector <NUM> (discussed above with reference to <FIG>) and battery cell connector <NUM> (discussed above with reference to <FIG>) are examples of such a battery cell connector. In some examples, the battery cell connector includes a plurality of segments of a metal conducting sheet, each segment defining a respective plane and having a respective longitudinal axis. The battery cell connector also includes a plurality of bends coupling the plurality of segments together into a <NUM>-D object, each bend located between a unique pair of adjacent segments of the plurality of segments. The unique pair of adjacent segments define two distinct respective planes. The battery cell connector includes at least one spring comprising two respective segments welded together (e.g., in a "tweezer" arrangement"). A first segment of the plurality of segments includes one or more first connecting elements for a battery pole of a first battery cell. A second segment of the plurality of segments includes one or more second connecting elements for a battery pole of a second battery cell. The one or more first connecting elements are electrically coupled with the one or more second connecting elements.

<FIG> illustrate a sheet metal process <NUM>.

In some embodiments, any of the battery cell connectors described herein (e.g., with reference to <FIG>) are manufactured (e.g., formed), or partially manufactured (e.g., in the case of a battery cell connector with "tweezers"), using sheet metal process <NUM>. For ease of explanation, sheet metal process is described herein as producing a battery cell connector analogous to battery cell connector <NUM>, shown in <FIG>.

The sheet metal process involves cutting (<NUM>) a sheet of metal <NUM> into a two-dimensional (e.g., planar) U-shape <NUM> comprising a first plurality of planar segments <NUM> (e.g., planar segments <NUM>-<NUM> through <NUM>-<NUM>) separated by a plurality of turns <NUM> (e.g., turn <NUM>-<NUM> and <NUM>-<NUM>). For example, in some embodiments, the sheet of metal is a <NUM> millimeter (mm) or <NUM> copper sheet. In some embodiments, cutting the sheet of metal into the two-dimensional shape comprises blanking the sheet of metal. In some embodiments, the two-dimensional shape is substantially L-shaped or U-shaped. For example, two-dimensional shape <NUM> is substantially U-shaped.

In some embodiments, sheet metal process <NUM> includes cutting (<NUM>) (e.g., punching, sawing, milling, nibbling, or drilling) additional features into the two-dimensional shape <NUM>. For example, in some embodiments, sheet metal process <NUM> includes cutting, in a first segment <NUM>-<NUM> of the plurality of segments <NUM>, one or more first connecting elements <NUM> for a battery pole of a first battery cell. Sheet metal process <NUM> also includes cutting, in a second segment <NUM>-<NUM> of the plurality of segments, one or more second connecting elements <NUM> for a battery pole of a second battery cell. In some embodiments, cutting the one or more first connecting elements and cutting the one or more second connecting elements comprises drilling or hole punching the one or more first connecting elements and the one or more second connecting elements. In some embodiments, the additional features include L-shaped or U-shaped cutouts <NUM>.

Sheet metal process <NUM> includes bending <NUM> the two-dimensional shape <NUM> into a three-dimensional shape <NUM> comprising a second plurality of planar segments <NUM> (for visual clarity, only some of planar segments <NUM> have been labeled in <FIG>). In some embodiments, the second plurality of planar segments <NUM> having a greater number of segments than the first plurality of planar segments <NUM> (e.g., the operation of bending creates additional planar segments-that is, when a planar segment is bent, in some circumstances, it creates two planar segments coupled by a bend). The three-dimensional shape includes a plurality of bends <NUM> separating respective segments of the second plurality of planar segments and pointing to at least three different directions. In some embodiments, the three different directions are mutually orthogonal directions (e.g., the plurality of bends includes three bends with three different bending axes that are all mutually orthogonal to the other bending axes). In some embodiments, after bending, the first segment and the second segment are not parallel to each other.

The foregoing description, for purposes of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed.

It will be understood that, although the terms "first," "second," etc. may be used herein to describe various elements, these elements should not be limited by these terms. For example, a first segment could be termed a second segment, and, similarly, a second segment could be termed a first segment, without changing the meaning of the description, so long as all occurrences of the "first segment" are renamed consistently and all occurrences of the "second segment" are renamed consistently. The first segment and the second segment are both segments, but they are not the same segment.

The terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting of the claims. As used in the description of the implementations and the appended claims, the singular forms "a," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and/or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.

Claim 1:
A battery cell connector (<NUM>; <NUM>), comprising:
a plurality of segments (<NUM>-<NUM>, <NUM>-<NUM>; <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>), each segment (<NUM>-<NUM>, <NUM>-<NUM>; <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) defining a respective plane and having a respective longitudinal axis; and
a plurality of bends (<NUM>-<NUM>, <NUM>-<NUM>; <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) coupling the plurality of segments (<NUM>-<NUM>, <NUM>-<NUM>; <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) together into a <NUM>-D object and whose associated axes point to at least three different directions, each bend located between a unique pair of adjacent segments (<NUM>-<NUM>, <NUM>-<NUM>; <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) of the plurality of segments (<NUM>-<NUM>, <NUM>-<NUM>; <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>), wherein the unique pair of adjacent segments (<NUM>-<NUM>, <NUM>-<NUM>; <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) define two distinct respective planes,
wherein the battery cell connector is formed of a single metal sheet; wherein:
a first segment (<NUM>-<NUM>) of the plurality of segments includes one or more first connecting elements (<NUM>, <NUM>) for a battery pole of a first battery cell;
a second segment (<NUM>-<NUM>) of the plurality of segments includes one or more second connecting elements (<NUM>, <NUM>) for a battery pole of a second battery cell, the second connecting element being located in one and the same plane as the first connecting element; and
the one or more first connecting elements (<NUM>, <NUM>) are electrically coupled with the one or more second connecting elements;
characterized in that a third segment (<NUM>-<NUM>; <NUM>-<NUM>) and a fourth segment (<NUM>-<NUM>; <NUM>-<NUM>) of the plurality of segments are welded together to form a spring, wherein the spring forms a tweezer structure.