Patent Description:
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. For example, xEVs include electric vehicles (EVs) that utilize electric power for all motive force. As will be appreciated by those skilled in the art, hybrid electric vehicles (HEVs), also considered xEVs, combine an internal combustion engine propulsion system and a battery-powered electric propulsion system, such as <NUM> Volt (V) or 130V systems. The term HEV may include any variation of a hybrid electric vehicle. For example, full hybrid systems (FHEVs) may provide motive and other electrical power to the vehicle using one or more electric motors, using only an internal combustion engine, or using both. In contrast, 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. Further, a micro-hybrid electric vehicle (mHEV) 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. For the purposes of the present discussion, it should be noted that 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. In addition, a plug-in electric vehicle (PEV) 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. For example, 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.

For example, <CIT> relates to a conventional connector barrel and battery module comprising the same and a housing having a wall. The wall includes an opening extending from an inner surface of the wall facing an interior of the housing to an outer surface of the wall opposite to the inner surface. The battery module also includes the connector barrel having a first open end a second open end, and a body portion extending between the first and second open ends. The body portion is positioned within the opening of the wall, the first open end is positioned within the interior of the housing and the second open end is positioned external to the housing. A ridge on the body portion is disposed proximate to the outer surface of the wall and a first circumferential bump on the body portion is disposed proximate to the inner surface of the wall. The battery module further comprises a securement component disposed within a space defined by the first circumferential bump of the connector barrel. The wall is sandwiched between the ridge of the connector barrel and the securement component. <CIT>, forming the basis for the preamble of claim <NUM>, discloses the coupling of a barrel connector in a battery housing by welding.

As technology continues to evolve, there is a need to provide improved power sources, particularly battery modules, for such vehicles. For example, in traditional configurations, battery modules may include complicated and cumbersome architecture for supporting electrical circuitry enabling communication between the battery module and external devices. It is now recognized that improved structures and techniques for supporting electrical wiring and circuitry of a battery module are desired.

It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business- related constraints, which may vary from one implementation to another.

The battery systems described herein may be used to provide power to various types of electric vehicles (xEVs) and other high voltage energy storage/expending applications (e.g., electrical grid power storage systems). Such battery systems may include one or more battery modules, each battery module having a number of battery cells (e.g., lithium-ion (Li-ion) electrochemical cells) arranged to provide particular voltages and/or currents useful to power, for example, one or more components of an xEV. As another example, battery modules may be incorporated with or provide power to stationary power systems (e.g., non-automotive systems).

The battery module includes a housing having a connector barrel disposed therein and/or coupled thereto. For example, the connector barrel interfaces with (e.g., extends through) a housing wall of the battery module, and includes a hollow passage therethrough. The hollow passage of the connector barrel is configured to receive electrical circuitry, such that electrical components internal to the battery module can connect with devices external to the battery module. The hollow passage may receive an internal electrical connector from inside the housing of the battery module and an external connector from outside the housing of the battery module, where the internal and external connectors are coupled within the hollow passage.

For example, the connector barrel may guide and/or route one or more electrical signal connectors, such as a low voltage signal connector and a vehicle control module connector that, when coupled, connect the battery module to a vehicle control module. Specifically, the low voltage signal connector and the vehicle control module connector may be inserted through opposing ends of the connector barrel to mate within the hollow passage of the connector barrel. As suggested above, the connectors may be utilized to connect the electronics and/or control circuits disposed within the housing of the battery module to a vehicle control module disposed external to the battery module. The connector barrel may guide and/or route other types of electrical circuitry, such as a high voltage connector (which may be used to connect the power output of the battery module to the vehicle power system) or a grounding stud (which may serve as a connection point to connect the battery module to the ground). Indeed, while the connector barrel may be utilized to guide and route a variety of different types of electrical circuitry disposed within the housing, embodiments of the present disclosure will be discussed with respect to the low voltage signal connector and the vehicle control module connector.

The connector barrel is a hollow conduit having a body portion, which defines a hollow passage or hollow passages, and having two open ends disposed on opposite ends of the body portion. The low voltage signal connector may mate with a complementary vehicle control module connector within the connector barrel. Specifically, the connector barrel may be configured to house both the low voltage signal connector and the vehicle control module connector within the hollow conduit. For example, the low voltage signal connector may pass through the first open end of the hollow conduit, and the voltage signal connector may pass through the second open end of the hollow conduit. The low voltage signal connector may then mate (e.g., connect) with the vehicle control module connector within the hollow conduit. In this manner, the connector barrel may be utilized to connect the electronics and/or control circuits disposed within the housing of the battery module to a vehicle control module outside the battery module.

The connector barrel is disposed through, or in, an opening within a wall of the housing. For example, the connector barrel may be coupled to the wall while the connector barrel is positioned within the opening. That is, the connector barrel may be configured such that the first open end of the connector barrel is disposed within the housing, the second open end of the connector barrel is disposed outside of the housing, and the body portion of the connector barrel is positioned within the opening in the wall of the housing. Accordingly, the low voltage signal connector may be received in the first open end within the housing, and the vehicle control module connector may be received in the second open end outside of the housing.

Continuing with the description above, the connector barrel includes a flange configured to abut the housing wall to enable intimate contact between the connector barrel and the housing wall. Indeed, the flange may be disposed on the connector barrel such that, when the flange abuts the housing wall, the first open end is on a first side of the wall and the second open end is on a second side of the wall. The flange and the wall may then be welded together to couple the connector barrel with the wall of the housing.

The connector barrel may be ultrasonically welded to the wall of the housing. In this manner, high-frequency, ultrasonic vibrations are applied to the flange and/or wall to oscillate the components. For example, the connector barrel and the housing well may be held together by a horn, which is connected to a transducer, and an anvil. The horn may apply, via the transducer, the ultrasonic activity to the connector barrel and the housing wall, causing a solid-state weld therebetween. For example, the ultrasonic oscillations produce friction between the components, which increases local temperatures and causes local melting. When the molten or partially molten material re-solidifies, a molecular bond may form between the housing wall and the flange of the connector barrel. The weld is improved by forming, prior to the ultrasonic activity, ridges along one or more of the surfaces being ultrasonically welded together. The ridges concentrate energy to induce greater movement and greater friction when ultrasonic vibrations are transmitted. In this manner, the ridges facilitate melting of the components to couple the flange and the wall of the housing together.

Additionally or alternatively, heat may be directly applied to couple the connector barrel and the wall of the housing together. For example, heat may be applied to an area of the connector barrel (e.g., an area of the flange) and/or an area of the wall to melt at least a portion of the respective areas. A heated component may be disposed between the connector barrel and the housing wall, causing a surface of the connector barrel to melt and a surface of the housing wall to melt.

The melted areas may then be placed in contact with one another to form a bond between the molten material as it solidifies. When the molten material re-solidifies, the connector barrel and the wall of the housing may be joined.

Additionally or alternatively, laser transmission may be used to provide heat to melt the connector barrel and/or the wall of the housing when the connector barrel is positioned against the wall. By way of example, one of the components (e.g., the connector barrel or the housing wall) may include a transmissive material to permit the laser to transmit through the component. The other component (e.g., the housing wall or the connector barrel) may include an absorptive material configured to absorb the laser and convert infrared radiation of the laser into heat to increase a temperature of the component. As a result, at least a portion of the component with the absorptive material may melt and heat may also be transferred to melt the component with transmissive material as well to produce the mixed molten material that re-solidifies to couple the connector barrel and the wall of the housing together. These and other features will be described in detail below with reference to the drawings.

To help illustrate, <FIG> is a perspective view of a vehicle <NUM>, which may utilize a regenerative braking system. Although the following discussion is presented in relation to vehicles with regenerative braking systems, the techniques described herein are adaptable to other vehicles that capture/store electrical energy with a battery, which may include electric-powered and gas-powered vehicles.

As discussed above, it would be desirable for a battery system <NUM> to be largely compatible with traditional vehicle designs. Accordingly, the battery system <NUM> may be placed in a location in the vehicle <NUM> that would have housed a traditional battery system. For example, as illustrated, the vehicle <NUM> may include the battery system <NUM> positioned similarly to a lead-acid battery of a typical combustion-engine vehicle (e.g., under the hood of the vehicle <NUM>). Furthermore, as will be described in more detail below, the battery system <NUM> may be positioned to facilitate managing temperature of the battery system <NUM>. For example, positioning a battery system <NUM> under the hood of the vehicle <NUM> may enable an air duct to channel airflow over the battery system <NUM> and cool the battery system <NUM>.

As depicted, the battery system <NUM> includes an energy storage component <NUM> coupled to an ignition system <NUM>, an alternator <NUM>, a vehicle console <NUM>, a vehicle control module (VCM) <NUM>, and optionally to an electric motor <NUM>.

In other words, the battery system <NUM> 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. Illustratively, the energy storage component <NUM> supplies power to the vehicle console <NUM> and the ignition system <NUM>, which may be used to start (e.g., crank) the internal combustion engine <NUM>.

Additionally, the energy storage component <NUM> may capture electrical energy generated by the alternator <NUM> and/or the electric motor <NUM>. The alternator <NUM> may generate electrical energy while the internal combustion engine <NUM> is running. More specifically, the alternator <NUM> may convert the mechanical energy produced by the rotation of the internal combustion engine <NUM> into electrical energy. Additionally or alternatively, when the vehicle <NUM> includes an electric motor <NUM>, the electric motor <NUM> may generate electrical energy by converting mechanical energy produced by the movement of the vehicle <NUM> (e.g., rotation of the wheels) into electrical energy. Thus, the energy storage component <NUM> may capture electrical energy generated by the alternator <NUM> and/or the electric motor <NUM> during regenerative braking. As such, the alternator <NUM> and/or the electric motor <NUM> are generally referred to herein as a regenerative braking system.

To facilitate capturing and supplying electric energy, the energy storage component <NUM> may be electrically coupled to the vehicle's electric system via a bus <NUM>. For example, the bus <NUM> may enable the energy storage component <NUM> to receive electrical energy generated by the alternator <NUM> and/or the electric motor <NUM>. Additionally, the bus <NUM> may enable the energy storage component <NUM> to output electrical energy to the ignition system <NUM> and/or the vehicle console <NUM>. Accordingly, when a <NUM> volt battery system <NUM> is used, the bus <NUM> may carry electrical power typically between <NUM>-<NUM> volts.

Additionally, as depicted, the energy storage component <NUM> may include multiple battery modules. For example, the energy storage component <NUM> includes a lithium ion (e.g., a first) battery module <NUM>, and a lead-acid (e.g., a second) battery module <NUM>, where each battery module <NUM>, <NUM> includes one or more battery cells. Alternatively, the energy storage component <NUM> may include any number of battery modules. Additionally, although the lithium ion battery module <NUM> and lead-acid battery module <NUM> are depicted adjacent to one another, they may be positioned in different areas around the vehicle. For example, the lead-acid battery module <NUM> may be positioned in or about the interior of the vehicle <NUM> while the lithium ion battery module <NUM> may be positioned under the hood of the vehicle <NUM>.

The energy storage component <NUM> may include multiple battery modules to utilize multiple different battery chemistries. For example, when the lithium ion battery module <NUM> is used, performance of the battery system <NUM> 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 <NUM> may be improved.

To facilitate controlling the capturing and storing of electrical energy, the battery system <NUM> may additionally include a control module <NUM>. More specifically, the control module <NUM> may control operations of components in the battery system <NUM>, such as relays (e.g., switches) within energy storage component <NUM>, the alternator <NUM>, and/or the electric motor <NUM>. For example, the control module <NUM> may regulate an amount of electrical energy captured/supplied by each battery module <NUM> or <NUM> (e.g., to de-rate and re-rate the battery system <NUM>), perform load balancing between the battery modules <NUM> and <NUM>, determine a state of charge of each battery module <NUM> or <NUM>, determine temperature of each battery module <NUM> or <NUM>, control voltage output by the alternator <NUM> and/or the electric motor <NUM>, and the like. While the control module <NUM> is illustrated external to the battery system <NUM>, the control module <NUM> may be disposed within, for example, the lithium ion battery module <NUM>.

Accordingly, the control unit <NUM> may include one or more processor <NUM> and one or more memory <NUM>. More specifically, the one or more processor <NUM> 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 <NUM> 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. The control unit <NUM> may include portions of a vehicle control unit (VCU) and/or a separate battery control module.

Additionally, the vehicle <NUM> may include the VCM <NUM> that may control one or more operational parameters of the various components of the vehicle <NUM>. The VCM <NUM> may include one or more processor <NUM> and one or more memory <NUM> programmed to perform such tasks. The battery modules <NUM>, <NUM> may be coupled to the VCM <NUM> via one or more communication lines. For example, a vehicle control module line <NUM> may be utilized to couple the VCM <NUM> to the battery module <NUM>, as further described in detail below. The VCM <NUM> may receive input from the battery modules <NUM>, <NUM> (and more specifically, from the control module <NUM>) regarding various parameters, such as a state of charge and temperature. The VCM <NUM> may be configured to utilize the received information to determine when to charge and/or discharge the battery module <NUM>, when to discontinue charging the battery module <NUM>, and so forth.

The illustrated battery module <NUM> (which is encompassed in the battery system <NUM> of <FIG>) of <FIG> may include features configured to enable electrical communication between the control module <NUM> (e.g., of the battery module <NUM>) and, for example, the vehicle control module <NUM> of the vehicle <NUM>. In accordance with the present disclosure, the battery module <NUM> includes a connector barrel configured to support mating of a connector of the control module <NUM> of the battery module <NUM> and a connector of the vehicle control module <NUM> of the vehicle <NUM>. These and other feature will be described in detail below with reference to later figures.

An overhead exploded perspective view of the battery module <NUM> for use in the vehicle <NUM> of <FIG> is shown in <FIG>. The illustrated battery module <NUM> (e.g., lithium ion [Li-ion] battery module) includes a housing <NUM> and electrochemical cells <NUM> disposed inside the housing <NUM>. For example, the electrochemical cells <NUM> are received through a cell receptacle region <NUM> of the housing <NUM> and into the inside of the housing <NUM>. In the illustrated embodiment, six prismatic lithium-ion (Li-ion) electrochemical cells <NUM> are disposed in two stacks <NUM> within the housing <NUM>, three electrochemical cells <NUM> in each stack <NUM>. However, alternatively, the battery module <NUM> may include any number of electrochemical cells <NUM> (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more electrochemical cells), any type of electrochemical cell <NUM> (e.g., Li-ion, lithium polymer, lead-acid, nickel cadmium, or nickel metal hydride, prismatic, and/or cylindrical), and any arrangement of the electrochemical cells <NUM> (e.g., stacked, separated, or compartmentalized).

As shown, the electrochemical cells <NUM> may include terminals <NUM> extending upwardly (e.g., in direction <NUM>) from terminal ends <NUM> of the electrochemical cells <NUM>. Accordingly, the terminals <NUM> may extend outwardly from the cell receptacle region <NUM> toward an upper side <NUM> (e.g., upper end or face opposite a base <NUM>) of the housing <NUM>. For example, the electrochemical cells <NUM> may be inserted into the housing <NUM> through the cell receptacle region <NUM> in the upper side <NUM>, and positioned within the housing <NUM> such that the terminals <NUM> of the electrochemical cells <NUM> are disposed in the cell receptacle region <NUM>. A bus bar carrier <NUM> may be disposed into the cell receptacle region <NUM> and may retain bus bars <NUM> disposed thereon, where the bus bars <NUM> are configured to interface with the terminals <NUM> of the electrochemical cells <NUM>. For example, the bus bars <NUM> may interface with the terminals <NUM> to electrically couple the electrochemical cells <NUM> together. Depending on the embodiment, the bus bars <NUM> may couple the electrochemical cells <NUM> in series, in parallel, or some of the electrochemical cells <NUM> in series and some of the electrochemical cells <NUM> in parallel. Further, certain of the bus bars <NUM> may be configured to electrically couple the electrically interconnected group of electrochemical cells <NUM> with major terminals <NUM> of the battery module <NUM>, where the major terminals <NUM> are configured to be coupled to a load (e.g., component(s) of the vehicle <NUM>) to power the load.

The housing <NUM> of the battery module <NUM> includes one or more covers configured to seal the housing <NUM>. For example, the cell receptacle region cover <NUM> may be disposed over the upper side <NUM> of the housing <NUM> (and over the bus bar carrier <NUM>) to seal the upper side <NUM> of the housing <NUM>. The bus bar carrier <NUM> may be coupled to the housing <NUM> to fix the bus bar carrier <NUM> within the cell receptacle region <NUM> and over the electrochemical cells <NUM>. As a further example, the housing <NUM> may include an electronics compartment cover <NUM> that fits over an electronics compartment <NUM> of the housing <NUM>, where the electronics compartment <NUM> of the housing <NUM> retains, for example, a printed circuit board (PCB) <NUM> and other electrical components <NUM> (e.g., a relay, communications lines) of the battery module <NUM>. The electronics compartment cover <NUM> and/or the cell receptacle region cover <NUM> may be welded (e.g., laser welded) to the body of the housing <NUM>.

A connector barrel <NUM> (e.g., comprising electrically insulative material, such as nylon or plastic) is disposed through an opening <NUM> within a wall <NUM> of the housing <NUM>. The opening <NUM> is a passageway between the interior of the housing <NUM> and the exterior of the housing <NUM>. Specifically, the connector barrel <NUM> may be configured to receive a low voltage signal connector <NUM> from the control module <NUM> disposed within the interior of the electronics compartment <NUM> (e.g., within the housing <NUM>). Likewise, the connector barrel <NUM> may be configured to receive a vehicle control module connector <NUM> (e.g., of the VCM <NUM>). The low voltage signal connector <NUM> may be communicatively coupled to a low voltage signal line <NUM> (e.g., spanning between the low voltage signal connector <NUM> and the control module <NUM> of the battery <NUM>), and the vehicle control module connector <NUM> may be communicatively coupled to the vehicle control module line <NUM> (e.g., spanning between the vehicle control module connector <NUM> and the VCM <NUM>). In this manner, the low voltage signal line <NUM> and the vehicle control module line <NUM> may be communication lines that are configured to communicatively couple the control module <NUM> with the VCM <NUM>, as described in detail below.

The low voltage signal connector <NUM> and the vehicle control module connector <NUM> may be configured to mate within the connector barrel <NUM>. The connectors <NUM>, <NUM> may work with the low voltage signal line <NUM> and the vehicle control module line <NUM>, respectively, to connect the control module <NUM> to the VCM <NUM>. Specifically, the low voltage signal connector <NUM> and the vehicle control module connector <NUM> (working with the low voltage signal line <NUM> and the vehicle control module line <NUM>) may be configured to provide information, related to conditions of the battery module <NUM>, to the vehicle control module <NUM>. For example, information related to a state of the charge of the battery module <NUM>, the temperature of the battery module <NUM>, one or more warnings related to the battery module <NUM>, a status change of the battery module <NUM>, or any other information related to the overall condition of the battery module <NUM> may be transmitted to the VCM <NUM>.

According to the invention, the connector barrel <NUM> is a hollow conduit having a body portion <NUM>, a first open end <NUM>, and a second open end <NUM> opposite the first open end <NUM>. In particular, the first open end <NUM> is disposed inside the housing <NUM>, and may be configured to receive the low voltage signal connector <NUM> within the housing <NUM>. Further, the second open end <NUM> is disposed outside the housing <NUM>, and may be configured to receive the vehicle control module connector <NUM> outside the housing <NUM>. Specifically, the second open end <NUM> may be disposed within a recess <NUM> of housing <NUM>, such that the connector barrel <NUM> may be inserted at the recess <NUM> into the opening <NUM>. As noted above, the low voltage signal connector <NUM> and the vehicle control module connector <NUM> may mate within the hollow conduit (e.g., body portion <NUM>) of the connector barrel <NUM>. In this manner, the connector barrel <NUM> may house the low voltage signal connector <NUM> from inside the housing <NUM> of the battery module <NUM> and the vehicle control module connector <NUM> from outside of the battery module <NUM>. Accordingly, the opening <NUM> disposed within the wall <NUM> of the housing <NUM> may be configured to secure the connector barrel <NUM>, and to allow the passage of the low voltage signal connector <NUM> and the vehicle control module connector <NUM> through the connector barrel <NUM>, as described in further detail below.

It should be noted that the opening <NUM> disposed within the wall <NUM> may be configured to receive the connector barrel <NUM>. For example, the opening <NUM> may be sized to securely receive an external perimeter of the body of the connector barrel <NUM>. In other words, the connector barrel <NUM> may have a perimeter sized to match the opening <NUM>.

The connector barrel <NUM> is welded or otherwise coupled to the wall <NUM> of the housing <NUM> to fix the connector barrel <NUM> within the opening <NUM>. For example, the connector barrel <NUM> is placed through the opening <NUM> of the housing <NUM>. In particular, an operator may insert the connector barrel <NUM> into the housing <NUM> in a desired orientation. Due to manufacturing imperfections (e.g., tolerances) and other factors, dimensions of the opening <NUM> within the housing and dimensions of the connector barrel <NUM> may only partially correspond with one another. In such situations, one or more features disposed on an exterior surface of the body portion <NUM> of the connector barrel <NUM> may help secure the connector barrel <NUM> to the wall <NUM> of the housing <NUM>, as further described in detail with respect to <FIG>. In accordance with the present disclosure, such features may include features that facilitate welding (e.g., ultrasonic or laser welding).

<FIG> is a detailed view of the battery module <NUM> of <FIG>, taken along lines <NUM>-<NUM>, illustrating the connector barrel <NUM>. As shown, the first open end <NUM> is disposed inside the housing <NUM> and may be configured to receive the low voltage signal connector <NUM> within the housing <NUM>. Further, the second open end <NUM> is disposed within a recess <NUM> of housing <NUM>, and may be configured to receive the vehicle control module connector <NUM> within the recess <NUM> outside of the housing <NUM>. A flange <NUM>, which is partially blocked from view in the illustrated <FIG> by the wall <NUM>, of the connector barrel <NUM> is disposed on and surrounds the body portion <NUM> such that, when the connector barrel <NUM> is inserted through the opening <NUM> in the wall <NUM>, the flange <NUM> is configured to contact an outer surface <NUM> of the wall <NUM>. The flange <NUM> and the outer surface <NUM> of the wall <NUM> are then welded together, such as via applied ultrasonic vibrations or heat, to couple the connector barrel <NUM> and the wall <NUM>. The re-solidified mixture coupling the flange <NUM> and the wall <NUM> may also seal an area surrounding the opening <NUM> and, thus, block unwanted particles (e.g., air, debris) from flowing through the opening <NUM> of the wall <NUM>. As shown, the wall <NUM> may include a thickness <NUM> spanning a length of the connector barrel <NUM>. The thickness <NUM> of the wall <NUM> may also be configured to support the weight of the connector barrel <NUM> and any signal connectors passing through the connector barrel <NUM>.

<FIG> is a detailed view of the battery module <NUM> of <FIG>, taken along lines <NUM>-<NUM> of <FIG>, illustrating a different placement of the connector barrel <NUM> than illustrated in <FIG>. In <FIG>, the connector barrel <NUM> is inserted through the opening <NUM> in the wall <NUM> such that the flange <NUM> contacts an inner surface <NUM> of the wall <NUM> that is positioned opposite the outer surface <NUM> of the wall <NUM>. As such, ultrasonic vibrations or heat may be applied to couple the flange <NUM> with the inner surface <NUM> of the wall <NUM>, thereby coupling the connector barrel <NUM> and the wall <NUM>. The first open end <NUM> is still disposed inside the housing <NUM> and may receive the low voltage signal connector <NUM> within the housing <NUM>, and the second open end <NUM> is still disposed within the recess <NUM> of the housing <NUM>, and may be configured to receive the vehicle control module connector <NUM> within the recess <NUM> outside of the housing <NUM>. Hence, the packaging of the battery module <NUM> may be improved by limiting a hardware footprint of the connector barrel <NUM> outside of the housing <NUM>. In other words, an amount of the connector barrel <NUM> extending outside of the housing <NUM> may be reduced by disposing the flange <NUM> of the connector barrel <NUM> inside the housing <NUM> and against the inner surface <NUM> of the wall <NUM> of the housing <NUM>.

<FIG> is an exploded perspective view of the connector barrel <NUM> for use in the battery module <NUM> of <FIG>. The connector barrel <NUM> includes, as previously described, the first open end <NUM>, the second open end <NUM>, and the body portion <NUM> extending between the first and second open ends <NUM>, <NUM>. The connector barrel <NUM> also includes the flange <NUM> disposed along the body portion <NUM>, such as approximately midway between the first open end <NUM> and the second open end <NUM>, although other positions of the flange <NUM> along the connector barrel <NUM> may be possible. According to the invention, the flange <NUM> includes ridges <NUM>, which are referred to as "energy concentrators," disposed on a first surface <NUM> of the flange <NUM>. As illustrated in <FIG>, the ridges <NUM> may extend from the first surface <NUM> with a triangularly shaped profile along the length <NUM> of the connector barrel <NUM> and toward the open end <NUM> of the connector barrel <NUM>. As shown, the ridges <NUM> on the flange <NUM> may be orthogonal to an outer surface of the body portion <NUM> of the connector barrel <NUM>. The wall <NUM> of the battery module may include a single ridge, which is configured to extend orthogonal to the ridges <NUM> of the flange <NUM>. That is, the wall <NUM> may include a single ridge that extends around the opening <NUM> in the wall <NUM>, such that the single ridge on the wall <NUM> generally follows a curvature of the body portion <NUM> of the connector barrel <NUM> once the connector barrel <NUM> is disposed in the opening <NUM>, as described below.

The connector barrel <NUM> is inserted through the opening <NUM> of the wall <NUM> such that the ridges <NUM>, or "energy concentrators," contact the outer surface <NUM> of the wall <NUM>. As previously described, the outer surface <NUM> of the wall <NUM> may include a ridge, which extends along the opening <NUM> and is configured to be orthogonal to the ridges <NUM> on the flange <NUM> of the connector barrel <NUM>. When the connector barrel <NUM> is inserted through the opening <NUM>, the first open end <NUM> may traverse the thickness <NUM> such that it is disposed adjacent to the inner surface <NUM> of the wall <NUM>, and such that the flange <NUM> of the connector barrel <NUM> contacts the wall <NUM> of the battery module. For example, when the connector barrel <NUM> is fully inserted into the opening <NUM>, tips <NUM> of the ridges <NUM> may be in contact, or close proximity, with the outer surface <NUM> (e.g., ridge of the outer surface <NUM>).

To couple the connector barrel <NUM> with the wall <NUM>, ultrasonic vibrations may be directed at the flange <NUM> and/or the wall <NUM>. As an example, the wall <NUM> (and corresponding battery module) may be positioned on, or partially within, an anvil configured to hold the assembly. The connector barrel <NUM> may then be inserted into the opening <NUM> such that the first surface <NUM> of the flange <NUM> contacts the outer surface <NUM> of the wall <NUM>, as previously described. An ultrasonic welding horn <NUM>, or "sonotrode" connected to a transducer, is configured to transmit ultrasonic vibrations and may be placed in contact with a second surface <NUM> (e.g., outer surface) of the flange <NUM> opposite to the first surface <NUM> of the flange <NUM>. As ultrasonic vibrations are transmitted, the horn <NUM> may also press into the assembly. The transmitted ultrasonic vibrations may oscillate the flange <NUM> such that the oscillations propagate through a flange thickness <NUM> to vibrate the ridges <NUM>. Vibration of the ridges <NUM> against the outer surface <NUM>, in conjunction with the pressing force of the horn <NUM>, enhance a solid-state weld therebetween. For example, the ridges <NUM> act as energy concentrators, which enhance local melting by directing the ultrasonic vibrations to a particular region or regions of the surfaces to be mated.

For example, the tips <NUM> of the ridges <NUM> concentrate the vibrational energy to enable a targeted seal. That is, the tips <NUM> of the ridges <NUM> may be specifically designed to receive and direct the ultrasonic vibrations applied to the flange <NUM> via the horn <NUM>, thereby improving an efficiency of the ultrasonic vibrations and corresponding horn <NUM> with respect to local melting. It should be noted that the ridges <NUM> may be formed on the second surface <NUM>, and the connector barrel <NUM> may be inserted through the opening <NUM> such that the ridges <NUM> on the second surface <NUM> abut the inner surface <NUM> of the wall <NUM>. Ultrasonically welding the connector barrel <NUM> to the wall <NUM> may then be performed by contacting the horn <NUM> to the first surface <NUM>. The dimensions of the flange <NUM> (e.g., the flange thickness <NUM>, a width <NUM>, a height <NUM>) are designed to accommodate the ridges <NUM> and to effectively ultrasonically weld the wall <NUM> and the connector barrel <NUM> together. That is, the flange thickness <NUM> and/or the thickness <NUM> of the wall <NUM> may be configured such that the ultrasonic vibrations may effectively propagate through to oscillate the ridges <NUM>. As previously described, a length <NUM> of the connector barrel <NUM> may be selected such that the connector barrel <NUM> is suitable for facilitating the mating of electrical components described in detail above with reference to earlier drawings.

<FIG> is an exploded perspective view of a not claimed example of a connector barrel <NUM> for use in the battery module <NUM> of <FIG>. Therein, the wall <NUM> may include the ridges <NUM> disposed around the opening <NUM>, and the flange <NUM> may not include the ridges <NUM>. When the connector barrel <NUM> is inserted through the opening <NUM>, the tips of the ridges <NUM> may abut the second surface <NUM> of the flange <NUM>. The horn <NUM> may apply ultrasonic vibrations (e.g., transmitted through the wall <NUM> and/or through the flange <NUM>) to create friction that melts the local regions adjacent to the ridges <NUM>. The ridges <NUM> may improve a magnitude and/or accuracy of the generated friction, thereby improving the local melting. Upon cooling, the melted regions may solidify to couple the second surface <NUM> with the inner surface <NUM>. Additionally or alternatively, the ridges <NUM> may be disposed around the opening at the outer surface <NUM> of the wall <NUM> to enable the first surface <NUM> of the flange <NUM> to couple to the outer surface <NUM> of the wall <NUM>.

<FIG> illustrates a front view of the connector barrel <NUM>. As shown, the ridges <NUM> are disposed on the first surface <NUM>, and each ridge <NUM> extends generally orthogonal to a curvature of, or radially outwardly from, the body portion <NUM> of the connector barrel <NUM>. Additionally, the ridges <NUM> are distributed evenly to surround a border of the body portion <NUM> of the connector barrel <NUM>, in which the body portion <NUM> may have an elliptical shape or another suitable shape (e.g., rectangular, circular) extending along the length <NUM> of the connector barrel <NUM>. For example, each ridge <NUM> may have approximately the same shape and the spaces between each ridge <NUM> may be approximately equal to one another. The even distribution of the ridges <NUM> may enable improved ultrasonic welding of the flange <NUM> onto the wall <NUM>. For example, the even distribution of the ridges <NUM> may enable the ridges <NUM> to melt readily and in an even manner with the application of ultrasonic welding, thereby enabling the flange <NUM> to couple to the wall <NUM> in a level manner. However, it should be understood that the ridges <NUM> may also be aligned in other suitable formations on the first surface <NUM>, such as in horizontal rows and vertical columns, and/or in a random formation to enable the flange <NUM> to couple to the wall <NUM> via ultrasonic welding in a different manner. The ridges <NUM> may be disposed in a section of the first surface <NUM>, rather than fully surrounding the body portion <NUM>. Although <FIG> depicts the flange <NUM> as having an approximately rectangular shape extending or protruding outwardly from the body portion <NUM>, additionally or alternatively, the flange <NUM> may be of another suitable shape, such as an elliptical, triangular, or another shape extending or protruding outwardly from the body portion <NUM>.

The connector barrel <NUM> may include a notch <NUM> disposed within/on an internal surface <NUM> of the connector barrel <NUM>. That is, the notch <NUM> may extend into a hollow interior <NUM> that extends between the first open end <NUM> and the second open end <NUM> of the body portion <NUM>. Specifically, the notch <NUM> may be utilized to separate the hollow interior <NUM> into one or more sections, thereby providing one or more internal fastening elements or additional guide posts for the connector barrel <NUM>. While the illustrated embodiment only depicts one notch <NUM>, it should be noted that any number (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or more) of notches <NUM> may be disposed throughout the connector barrel <NUM> and may be configured as additional guides. The notches <NUM> may extend along the length <NUM> of the connector barrel <NUM>, and may be configured as guide rails that guide the low voltage signal connector <NUM> and the vehicle control module connector <NUM> into the connector barrel <NUM> in an appropriate orientation.

<FIG> illustrates a front view of the connector barrel <NUM>. In <FIG>, the ridges <NUM> are disposed on the first surface <NUM> of the flange <NUM> elliptically or circumferentially around the body portion <NUM> of the connector barrel <NUM>. That is, the ridges <NUM> generally follow the curvature of the body portion <NUM> around at least a portion of the perimeter of the body portion <NUM> to form a "ring" or "loop" around the body portion <NUM>, or a portion of a ring or loop. In the <FIG>, there are several "loops" that concentrically surround the body portion <NUM>, but additionally or alternatively, the ridges <NUM> may surround the body portion <NUM> in one or more "spiral" formations. The ridges <NUM> may form portions of a ring or loop (e.g., arcuate segments of a ring or loop), each portion being separated via a gap.

A perspective view of a not claimed example of the connector barrel <NUM> is illustrated in <FIG>. As illustrated in <FIG>, the flange <NUM> does not include the ridges or "energy concentrators. " Coupling of the illustrated connector barrel <NUM> may utilize ultrasonic welding in accordance with the description above, but without the ridges or "energy concentrators.

The illustrated connector barrel <NUM> may be configured to be coupled to the wall <NUM> via other methods of applied heat. As an example, the connector barrel <NUM> may be inserted through the opening <NUM> such that the flange <NUM> is adjacent to the wall <NUM>. Heat may be applied between the flange <NUM> and the wall <NUM> to melt the flange <NUM> and/or the wall <NUM> and weld the connector barrel <NUM> to the wall <NUM>.

Additionally or alternatively, heat may be applied via laser transmission. That is, either the flange <NUM> or the wall <NUM> may include absorptive material configured to convert the energy of the laser into heat to melt and weld the components together. The other of the flange <NUM> or the wall <NUM> may include a transmissive material which allows the energy to pass therethrough. For example, the flange <NUM> may include a transmissive material and the wall <NUM> may include an absorptive material. Laser energy may be applied through the flange <NUM> and to the wall <NUM>. The wall <NUM> may absorb the laser energy at the outer surface <NUM> of the wall <NUM>, thereby heating the outer surface <NUM> of the wall <NUM>, which causes the outer surface <NUM> of the wall <NUM> the first surface <NUM> of the flange <NUM> to melt together.

Additionally or alternatively, heat may be applied to the flange <NUM> and the wall <NUM> separately, prior to abutment of the flange <NUM> with the wall <NUM>. When the heat has substantially melted both the flange <NUM> and the wall <NUM>, the surfaces may be mated. The surfaces may be heated while the connector barrel <NUM> is partially disposed within the opening <NUM>, and the flange <NUM> of the connector barrel <NUM> may then be pushed into the wall <NUM> to weld the components together.

<FIG> illustrates a perspective view of a not claimed example of the connector barrel <NUM> that may be coupled to the wall <NUM>. The first surface <NUM> of the flange <NUM> of the connector barrel <NUM> is placed in contact with the outer surface <NUM> of the wall <NUM>. Additionally, a filler material <NUM> (e.g., weld rod) may be positioned around the flange <NUM> and placed in contact with a border surface <NUM> of the flange <NUM> of the connector barrel <NUM> and the outer surface <NUM> of the wall <NUM>. That is, the filler material <NUM> may be positioned at a corner formed by the border surface <NUM> abutting the outer surface <NUM>. A torch <NUM> or other tool may be used to melt the filler material <NUM>. For example, the torch <NUM> may emit heat <NUM> (e.g., via a hot gas) toward the filler material <NUM> to melt the filler material <NUM>, the flange <NUM>, and/or the wall <NUM>. When the filler material <NUM> cools, the filler material <NUM> solidifies the wall <NUM> with the flange <NUM>.

<FIG> each illustrate a block diagram of a method to couple the connector barrel with the wall, in accordance with the present disclosure. It should be understood that the methods may not be exclusive and that steps that are not mentioned may be performed. Additionally, a step of one of the methods may be used in another method such that different methods may be at least partially combined with one another. It should also be understood that there may be additional methods that are not specifically described with respect to <FIG>, but may also be utilized to couple the connector barrel with the wall in accordance with the present disclosure.

<FIG> illustrates a method <NUM> for coupling the connector barrel and the wall of the housing via ultrasonic welding. For example, the connector barrel may be inserted (block <NUM>) through an opening in the wall. As indicated by block <NUM>, the connector barrel is inserted in a manner such that the surface of the flange that includes the ridges, or "energy concentrators," faces the wall.

Further, the connector barrel is maneuvered within the opening to abut (block <NUM>) the ridges of the flange of the connector barrel against the wall. That is, the connector barrel may be inserted through the opening until a substantial number of ridge tips abuts the wall.

Further still, the method <NUM> includes positioning (block <NUM>) the assembly having the connector barrel and the wall on an anvil. The anvil is essentially a substrate on which the assembly is positioned, and against which forces are exerted to couple the assembly. For example, the method <NUM> also includes contacting (block <NUM>) an ultrasonic welding horn with the flange at the surface that does not include the ridges. The method <NUM> then includes transmitting (block <NUM>) ultrasonic vibrations that propagate through the thickness of the flange of the connector barrel, through the ridges on the opposing side of the flange, and towards the wall. The anvil may provide support for the assembly as the ultrasonic welding horn is placed in contact with the flange to facilitate transmission of the ultrasonic vibrations. As previously described, the ultrasonic vibrations may cause local melting along an interface between the flange and the wall. The interface may then be cooled such that the partially molten mixture re-solidifies to couple the flange of the connector barrel with the wall via an ultrasonic weld.

As previously described, the ridges may be on a different surface of the connector barrel, and the different surface of the connector barrel may be ultrasonically welded to a different (e.g., inner) surface of the wall.

<FIG> is a block diagram illustrating a method <NUM> for coupling the connector barrel and the wall by heating the connector barrel and the wall. In block <NUM>, heat is applied to the wall around the opening. The heat may be applied via, for example, a hot plate, with electric current, with a hot fluid, or via another suitable method. The heat then melts a portion of the wall around the opening.

In block <NUM>, heat is similarly applied to the flange and may be applied approximately simultaneously as the heat applied to the wall. Indeed, the heat source for the flange and the wall may be the same. For example, a hot plate may be disposed between the flange of the connector barrel and the wall of the housing of the battery module, and may apply heat to the surfaces intended to be mated. The heat may cause melting of the surfaces intended to be mated.

After heat has been applied to both the wall and the flange to melt the respective components, the flange of the connector barrel may be pressed (block <NUM>) into the wall. The connector barrel may be pre-positioned within the opening in the wall while the wall and the flange of the connector barrel are heated. Alternatively, the flange of the connector barrel and the wall of the housing of the battery module are heated prior to insertion of the connector barrel through the opening in the wall. The abutment of the melted components produce the molten mixture that may re-solidify to couple the connector barrel with the wall.

<FIG> illustrates a method <NUM> for coupling the connector barrel with the wall. In the method <NUM>, one of the connector barrel or the wall includes a laser transmissive material, while the other component includes a laser absorptive material. As used herein, "transmissive" is used to describe materials that are configured permit to laser wavelengths around the infrared spectrum (e.g., between <NUM> nanometers [nm] and <NUM>) to pass through the material without affecting a structure of the material, and "absorptive" is used to describe materials that absorb laser wavelengths around the infrared spectrum to convert infrared radiation energy of the laser into heat. For example, the connector barrel may include a transmissive plastic-based material, while the wall may include an absorptive plastic-based material.

Continuing with the illustrated method <NUM>, the connector barrel is inserted (block <NUM>) through the opening until the flange abuts the wall. Pressure may be applied such that a surface of the flange is substantially flush with a surface of the wall to reduce a gap between the flange and the wall to facilitate coupling the flange and the wall.

In block <NUM>, a laser (e.g., via a semiconductor diode laser) is applied through the component (e.g., of the flange of the connector barrel) that includes the transmissive material towards the component (e.g., the wall of the housing of the battery module) that includes the absorptive material. In this manner, the laser passes through the transmissive component (e.g., the flange of the connector barrel) and is absorbed by the absorptive component (e.g., the wall of the housing of the battery module). The absorptive material then converts infrared energy of the laser into heat, which melts at least a portion of either the transmissive component and/or the absorptive component to create the molten mixture. It should be understood that, although each component may include materials of different absorption levels, the materials may still include similar properties, such as melting points, to enable coupling of the connector barrel <NUM> and the wall <NUM>. That is, as the wall absorbs the energy from the laser and is heated, the flange may receive the heat via conduction, thereby causing the components to melt and solidify together. For example, the connector barrel and the wall of the housing may each be made of the same type of material (e.g., polypropylene), but have different transmissive properties. Additionally, it should be noted that the wavelength of the laser may be based at least in part on the respective materials of the connector barrel and/or the wall, such as absorptive properties of the respective materials.

The absorptive component includes at least one ridge to which the laser is directed. Thus, the laser may be absorbed by the ridge(s) to heat the ridge(s) and cause local melting to couple the flange to the wall at the ridge(s). As an example, the ridge(s) may have an oval, elliptical, rectangular shape, another suitable shape, or any combination thereof, and may follow at least a portion of a perimeter of the flange.

<FIG> illustrates a method <NUM> for coupling the connector barrel with the wall via hot gas welding. In the method <NUM>, the connector barrel is inserted (block <NUM>) through the opening in the wall of the housing of the battery module until the flange abuts the wall and is substantially flush with a surface of the wall. A filler material is positioned (block <NUM>) such that the filler material is in contact with both the flange and the wall. For example, the filler material may be positioned in a corner formed by contacting the flange and the wall. In block <NUM>, heat is applied toward the filler material, which may melt the filler material, the flange, and/or the wall. When the filler material solidifies, the filler material may bond with the flange and the wall. As such, the solidified filler material couples the flange with the wall.

The filler material may be automatically positioned. For example, a torch may be configured to apply heat and also to feed the filler material as heat is applied. As the filler material is fed, the applied heat may at least partially melt the filler material. In this manner, the torch may be directed to output the melted filler material such that the melted filler material is in contact with the flange and the wall, in which solidification of the melted filler material couples the flange and the wall together.

One or more of the disclosed embodiments, alone or on combination, may provide one or more technical effects for the manufacture of battery modules, including coupling a connector barrel to a wall of a housing. In general, embodiments of the present disclosure are directed to a battery module having a housing and a connector barrel at least partially disposed within the housing, where the connector barrel facilitates coupling of internal and external signal connectors or devices. In certain embodiments, the connector barrel is a hollow conduit having a body and two open ends disposed on opposite ends of the body. Specifically, a low voltage signal connector and a vehicle control module connector are communicatively coupled within the connector barrel. For example, the low voltage signal connector is received through the first open end of the connector barrel to mate and connect with the vehicle control module connector received through the second open end of the connector barrel. In this manner, the connectors transmit information from a control module to a vehicle control module within the battery module. The connector barrel may be fixed within an opening of a wall defining an interior of the housing. For example, the connector barrel may include a flange configured to abut the wall. Vibrations and/or heat may be applied to the flange and/or the wall, such that at least a portion of the flange and/or the wall increases in temperature and melts to create a molten mixture of the flange and/or the wall. When the molten mixture re-solidifies, the flange and the wall are coupled to one another. Heat may be applied by a variety of methods, such as via ultrasonic vibrations, a heated fluid, laser transmission, another suitable method, or any combination thereof. The presently disclosed connector barrel simplify the manufacturing/assembly process of the battery module, improve a seal of the housing, and reduce a part count of the battery module. 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.

Claim 1:
A connector barrel (<NUM>) of a battery module (<NUM>), comprising:
- a body (<NUM>) including a first open end (<NUM>), a second open end (<NUM>), and a hollow interior (<NUM>) formed by the body (<NUM>) that extends between the first open end (<NUM>) and the second open end (<NUM>); and
- a flange (<NUM>) disposed on the body (<NUM>) and extending outwardly from the body (<NUM>), characterized in that the flange (<NUM>) comprises a plurality of energy concentrator ridges (<NUM>) disposed on a surface (<NUM>, <NUM>) of the flange (<NUM>), and wherein the plurality of energy concentrator ridges (<NUM>) are configured to facilitate ultrasonic welding of the flange (<NUM>) to a wall (<NUM>) of the battery module (<NUM>).