Abstract
A contact system for electrically connecting a high current power supply system, in particular a battery unit, is provided. The contact system comprises a busbar, an electrode and a clamp. The clamp has at least two clamp legs, and at least one clamp leg is elastically moveable so as to vary an interspace between the clamp legs, the busbar, and the electrode. At least one of the clamp legs has a respective contact surface contacting a further one of the contact surfaces.
At least one of the clamp leg contact surface, the busbar contact surface, and the electrode contact surface has a protrusion. The protrusion contacts one of the respective other contact surfaces. The protrusion is convex in two mutually vertical sectional planes.
Claims
1. A contact system for electrically connecting a high current power supply system, in particular a battery unit, the contact system comprising: a busbar, an electrode, and a clamp, the clamp having at least two clamp legs, at least one of the at least two clamp legs being elastically moveable so as to vary an interspace between the clamp legs, the busbar and the electrode and at least one of the clamp legs having a respective contact surface contacting a further one of the contact surfaces, at least one of the clamp leg contact surface, the busbar contact surface and the electrode contact surface having a protrusion contacting the respective other one of the contact surfaces, the protrusion being convex in two mutually vertical sectional planes.
2. A contact system for electrically connecting a high current power supply system, the contact system comprising at least two busbars and a clamp, the clamp having at least two clamp legs, at least one of the at least two clamp legs being elastically moveable so as to vary an interspace between the clamp legs, the at least two busbars and at least one of the clamp legs having a respective contact surface contacting a further one of the contact surfaces, at least one of the clamp leg contact surface and the busbar contact surfaces having a protrusion contacting the respective other one of the contact surfaces, the protrusion being convex in two mutually vertical sectional planes.
3. The contact system of claim 1, wherein the protrusion is rounded in the two mutually vertical sectional planes and preferably has radii of curvature of at most 40 mm.
4. The contact system of claim 1, wherein the respective other contact surface has a flat portion, the protrusion and the flat portion contacting each other.
5. The contact system of claim 4, wherein the flat portion has radii of curvature of at least 100 mm.
6. The contact system of claim 4, wherein the protrusion and the flat portion has an average diameter in a projection into a plane perpendicular to the sectional planes of the convexity of the protrusion of at least 10 mm.
7. The contact system of claim 1, wherein the electrode and the busbar are substantially square at least in a portion thereof clamped by the clamp.
8. The contact system of claim 4, wherein the protrusion is provided at one of the electrode contact surface and the busbar contact surface and wherein the flat portion is provided at the other respective electrode contact surface thereof.
9. The contact system of claim 8, wherein one of the clamp legs defines a hole, the protrusion being adapted to penetrate the hole when contacting the flat portion.
10. The contact system of claim 1, wherein at least two of the clamp legs are elastically moveable so as to vary an interspace between the clamp legs.
11. The contact system of claim 4, wherein the at least one busbar defines a direction of longest extension of the busbar and wherein the flat portion is substantially parallel to this direction.
12. The contact system of claim 1, wherein the clamp has at least three clamp legs, two clamp legs thereof on one side and the at least one clamp leg thereof on the other side of the interspace.
13. The contact system of claim 1, wherein the electrode and the clamp are formed integrally with each other.
14. The contact system of claim 1, wherein the respective other one of the contact surfaces has a groove portion being concave in at least one and preferably two mutually vertical sectional planes, the groove portion being adapted such that the protrusion contacts only borders of the groove portion, the contacts at the borders being in the at least one sectional plane of concavity, and the groove portion being adapted such that the protrusion can slide within the groove portion in a direction being in a sectional plane vertical to the sectional plane of the two contacts.
15. A battery set of at least two battery units, each battery unit having at least two electrodes, and at least one busbar electrically connecting the at least two electrodes, one of each battery unit, and having at least one contact system according to claim 1.
16. The battery set of claim 15, wherein the busbar and one of the electrodes of the other battery unit and a further clamp make up a second contact system.
Description
BRIEF DESCRIPTION OF THE DRAWING
[0097] The foregoing aspects and many of the attendant advantages will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts throughout the various views, unless otherwise specified:
[0098] FIG. 1 a schematic perspective view onto an array of battery blocks;
[0099] FIG. 2 a schematic enlarged perspective view of a portion of the array of battery blocks of FIG. 1;
[0100] FIG. 3 a schematic exploded perspective view of the elements of a connector, an electrode and a busbar;
[0101] FIG. 4 a schematic exploded perspective view showing a clamp and a casing of a connector;
[0102] FIG. 5 a schematic perspective view showing the clamp and the casing of FIG. 4 in assembled form;
[0103] FIG. 6 a schematic sectional perspective view showing the clamp and the casing of FIG. 4 in assembled form;
[0104] FIG. 7 a schematic perspective view onto the clamp and the casing of FIG. 4 in assembled form with a spacer;
[0105] FIG. 8 a schematic exploded perspective view onto the clamp and the casing and the spacer of FIG. 7 in assembled form and a lid;
[0106] FIG. 9 a schematic perspective view onto the clamp and the casing and the spacer and the lid of FIG. 8 in assembled form;
[0107] FIG. 10 a schematic perspective view onto a part of a battery block with a connector attached to it from a first perspective;
[0108] FIG. 11 a schematic perspective view onto the part of a battery block with the connector attached to it of FIG. 10 from a second perspective;
[0109] FIG. 12 a schematic perspective view onto a connector and a part of a busbar;
[0110] FIG. 13 a schematic sectional view onto the connector and the part of the busbar of FIG. 12 and an electrode;
[0111] FIG. 14 a schematic top view onto two connectors and a busbar arranged between the two connectors;
[0112] FIG. 15a,b,c a sequence of sectional views onto a connector and a part of a busbar showing assembly steps of the part of the busbar and the connector;
[0113] FIG. 16a a schematic perspective view of an end of a busbar in contact with an electrode;
[0114] FIG. 16b a perspective view of a modified version of the busbar of FIG. 3;
[0115] FIG. 16c a modified version of the schematic sectional view of FIG. 13, but with the busbar of FIG. 16b;
[0116] FIG. 17a a schematic perspective view of an electrode;
[0117] FIG. 17b a schematic side view onto an electrode;
[0118] FIG. 18 a schematic illustration in top view;
[0119] FIG. 19 a schematic perspective view of the electrode of FIG. 18;
[0120] FIG. 20 a schematic side view onto the electrode of FIG. 17 together with a spring clamp;
[0121] FIG. 21 a schematic perspective view onto a part of a battery block;
[0122] FIG. 22 a schematic perspective view onto a part of the battery block of FIG. 21 with a connector and a busbar;
[0123] FIG. 23 a schematic perspective view onto a part of the battery block of FIG. 21 with an end of a busbar in contact with the electrode of the battery block;
[0124] FIG. 24 a schematic perspective view onto the connector of FIG. 22 set on the electrode;
[0125] FIG. 25 a schematic sectional perspective view of the connector of FIG. 22 set on the electrode;
[0126] FIG. 26 a schematic top view onto the connector of FIG. 22 set on the electrode;
[0127] FIG. 27 a schematic perspective view onto the casing of the connector of FIG. 22;
[0128] FIG. 28 a schematic perspective view onto a spacer of the connector of FIG. 22;
[0129] FIG. 29 a schematic perspective view onto the spacer of FIG. 28;
[0130] FIG. 30 a schematic perspective view onto a clamp of the connector of FIG. 22;
[0131] FIG. 31 a schematic perspective view onto the clamp of FIG. 30;
[0132] FIG. 32 a schematic perspective view onto the clamp of FIG. 30;
[0133] FIG. 33 a schematic perspective view onto the clamp of FIG. 30;
[0134] FIG. 34 a schematic view from below onto the connector of FIG. 22;
[0135] FIG. 35 a schematic exploded view onto the casing and the clamp of the connector of FIG. 22;
[0136] FIG. 36 a schematic perspective view onto a part of a battery block with a connector and a busbar;
[0137] FIG. 37 a schematic perspective view onto the spacer and the clamp of the connector of FIG. 36 with the spacer in a second position;
[0138] FIG. 38 a schematic perspective view onto the spacer and the clamp of FIG. 37 with the spacer in a first position;
[0139] FIG. 39 a schematic perspective view onto the casing of the connector of FIG. 36;
[0140] FIG. 40 a schematic perspective view onto the casing of FIG. 39;
[0141] FIG. 41 a schematic perspective view onto the casing of FIG. 39;
[0142] FIG. 42 a schematic perspective view onto the clamp of the connector of FIG. 36, the clamp being in the first state;
[0143] FIG. 43 a schematic perspective view onto the clamp of FIG. 42, the clamp being in the first state;
[0144] FIG. 44 a schematic perspective view onto the clamp of FIG. 42, the clamp being in the second state;
[0145] FIG. 45 a schematic perspective view onto the clamp of FIG. 42, the clamp being in the second state;
[0146] FIG. 46 a schematic perspective view onto the spacer of the connector of FIG. 36;
[0147] FIG. 47 a schematic perspective view onto the axle of a spacer of the connector of FIG. 36;
[0148] FIG. 48 a schematic perspective view of the connector of FIG. 36;
[0149] FIG. 49 a schematic perspective view onto a connector and a busbar and a further busbar;
[0150] FIG. 50 a schematic exploded view of a busbar and two further busbars;
[0151] FIG. 51 a schematic perspective sectional view onto the connector, the busbar and the further busbar of FIG. 49;
[0152] FIG. 52 a schematic perspective sectional view onto the connector and the busbar of FIG. 49 and a further busbar;
[0153] FIG. 53 a schematic perspective view onto the clamp of the connector of FIG. 49;
[0154] FIG. 54 a schematic perspective view onto the first leg of the clamp of FIG. 53;
[0155] FIG. 55 a schematic perspective sectional view onto the second leg of the clamp of FIG. 53;
[0156] FIG. 56 a schematic perspective view onto the second leg of the clamp of FIG. 53;
[0157] FIG. 57 a schematic perspective view onto a connector and a busbar and a further busbar;
[0158] FIG. 58 a schematic exploded view of a busbar and a further busbar;
[0159] FIG. 59 a schematic perspective sectional view onto the connector, the busbar and the further busbar of FIG. 57;
[0160] FIG. 60 a schematic perspective view onto the connector of FIG. 57 in the open state;
[0161] FIG. 61 a schematic perspective view onto an axle used to connect parts of the clamp of the connector of FIG. 57;
[0162] FIG. 62 a schematic perspective view onto a reference part of the first leg of the clamp of the connector of FIG. 57;
[0163] FIG. 63 a schematic perspective sectional view onto the second leg of the clamp of the connector of FIG. 57;
[0164] FIG. 64 a schematic perspective view onto the second leg of the clamp of the connector of FIG. 57;
[0165] FIG. 65 a schematic perspective view onto a connector and a busbar and a further busbar;
[0166] FIG. 66 a schematic exploded view of a busbar and a further busbar;
[0167] FIG. 67 a schematic perspective sectional view onto the connector, the busbar and the further busbar of FIG. 65;
[0168] FIG. 68 a schematic perspective sectional view onto a part of the casing of the connector of FIG. 65;
[0169] FIG. 69 a schematic perspective view onto a part of the casing of the connector of FIG. 65;
[0170] FIG. 70 a schematic perspective sectional view onto a part of the casing of the connector of FIG. 65;
[0171] FIG. 71 a schematic perspective view onto a part of the casing of the connector of FIG. 65;
[0172] FIG. 72 a schematic perspective sectional view onto the clamp of the connector of FIG. 65;
[0173] FIG. 73 a schematic perspective view onto the clamp of the connector of FIG. 65;
[0174] FIG. 74 a schematic perspective view onto a connector and a busbar and a further busbar;
[0175] FIG. 75 a schematic exploded view of a busbar and a further busbar;
[0176] FIG. 76 a schematic perspective sectional view onto the connector, the busbar and the further busbar of FIG. 74;
[0177] FIG. 77 a schematic perspective view onto a piece of the casing of the connector of FIG. 74;
[0178] FIG. 78 a schematic perspective view onto the casing of the connector of FIG. 74 from a first perspective;
[0179] FIG. 79 a schematic perspective view onto the casing of the connector of FIG. 74 from a second perspective;
[0180] FIG. 80 a schematic perspective sectional view onto the clamp of the connector of FIG. 74;
[0181] FIG. 81 a schematic perspective view onto the clamp of the connector of FIG. 74;
[0182] FIG. 82 a schematic perspective view onto a connector and a busbar and a further busbar;
[0183] FIG. 83 a schematic perspective view onto the connector and the busbar and the further busbar of FIG. 82 with the connector in the open state;
[0184] FIG. 84 a schematic perspective view onto the first leg of the clamp of the connector of FIG. 82 and the busbar of FIG. 82;
[0185] FIG. 85 a schematic perspective view onto the second leg of the clamp of the connector of FIG. 82 and the further busbar of FIG. 82;
[0186] FIG. 86 a schematic perspective view onto the second leg of the clamp of the connector of FIG. 82;
[0187] FIG. 87 a schematic perspective view onto the first leg of the clamp of the connector of FIG. 82;
DETAILED DESCRIPTION
[0188] FIG. 1 shows an array 1 of battery blocks 2. In the embodiment shown in FIG. 1, the array 1 has eight battery blocks 2. Four battery blocks 2 each are grouped into one line of battery blocks 2. The two lines of four battery blocks 2 each are arranged in parallel to each other.
[0189] Each battery block 2 can comprise individual battery cells, not visible in the Figures, and connected for example in series. The term battery unit as used herein can relate to such a battery block but also to a battery cell therein whereas the term battery set can relate to the array 1 or to the battery block 2.
[0190] Each battery block has two electrodes (not shown in FIG. 1), an electrode for providing the negative potential and one electrode for providing the positive potential. For each electrode, each battery block 2 is provided with a connector 3. Hence each battery block 2 has two connectors 3 in total. Between a connector 3 of one battery block 2 and a neighboring connector 3 of a neighboring battery block 2, a busbar 4 is arranged. The busbar 4 arranged at the end of the lines of battery blocks 2 is U-shaped. The other busbars 4 are bar-shaped.
[0191] For ease of reference, the connectors 3 shown in FIG. 1 are drawn with their lids 13 open. The same goes for FIG. 2.
[0192] The connector 3 as best seen in FIG. 3 contains a casing 10, a clamp 11, a spacer 12 and a lid 13. FIG. 3 additionally shows an electrode 5 of a battery block and a busbar 4.
[0193] The clamp 11 has a transition section 20 that in the embodiment shown in FIG. 3 is made up of a bridge 21. The clamp 11 has a first leg 22 arranged at one end of the transition section 20. Clamp 11 also has a second leg 23 that is arranged at the opposite end of the transition section 20. The first leg has a reference part 24 that in the embodiment shown in FIG. 3 is a longitudinal tip. The second leg 23 in the embodiment shown in FIG. 3 also has a reference part 25 that in the embodiment shown also is a longitudinal tip. The second leg 23 in the embodiment shown in FIG. 3 has an opening 26. The opening 26 allows the electrode 5 to be arranged on one side of the second leg 23 and for a spherical protrusion 6 of the electrode 5 to protrude through the opening 26 into the space between the first leg 22 and the second leg 23 (see for example FIG. 13).
[0194] It can be seen that protrusion 6 projects on and from a substantially square electrode contact surface and is adapted to lay against and contact a busbar contact surface, namely an end portion of busbar 4. This busbar contact surface is, in contrast to the protrusion, flat.
[0195] Clamp 11 is made by way of cutting and bending from a metal blank and hence is a unitary piece. The transition section 20, the first leg 22 and the second leg 23 are elastically deformable.
[0196] The clamp 11 has a first state shown in FIG. 3, FIG. 4 and FIG. 6 for example. In this first state, the reference part 24 and the reference part 26 are distanced from each other by a first amount. The clamp has a second state (see FIG. 7 for example), in which the reference part 24 and the reference part 25 are distanced from each other by second amount that is different from the first amount, namely larger than the second amount.
[0197] As can be seen when comparing FIG. 6 and FIG. 7, the transition section, the first leg and the second leg are not elastically deformed in the first state. In the first state, the clamp 11 takes up its normal form. At least one of the group of elements containing the transition section 20, the first leg 22 and the second leg 23 are further elastically deformed (more elastically deformed) in the second state than in the first state. As can be seen when comparing FIG. 6 and FIG. 7, the distance between the reference part 24 and the reference part 25 has been increased from the first state shown in FIG. 6 to the second state shown in FIG. 7. This increase in distance is achieved by elastically deforming at least one of the elements of the group that contains the transition section 20, the first leg 22 and the second leg 23.
[0198] The spacer 12 is movable between a first position best shown in FIG. 7 and FIG. 15a and a second position (best shown in FIG. 15c). As can best be seen from FIG. 7, the spacer 12 when it is in the first position is in contact with a part of the first leg 22 when the clamp 11 is in the second state (see FIG. 7).
[0199] As can best be seen from FIG. 15a, FIG. 15b FIG. 15c, the spacer 12 is designed to be rotated from the first position into the second position.
[0200] FIG. 3 and FIG. 7 for example show that two rods 30 extend from the spacer 12 along a rotational axis 31. As can be seen from FIG. 7 and FIG. 8, the rods 30 are arranged in holes 32 of the casing 10 and allow the spacer 12 to rotate relative to the casing 10 about the rotational axis 31.
[0201] FIG. 8, FIG. 9 and FIG. 12 show that the connector 3 has a lid 13. The lid 13 can be arranged in an open position (FIG. 9) on the casing 10. FIG. 12 shows the closed position of the lid 13 on the casing 10. On the casing 10, a knob 14 can be provided that holds the lid 13 in the open position (FIG. 9) and that needs to be overcome by the lid 13 as it is moved from the open position (FIG. 9) to the closed position (FIG. 12). As shown in FIG. 12, the knob 14 can also be used to hold the lid 13 in the closed position. The knob 14 is so to say a part of an elastic latch mechanism, the lid 13 providing for the required elasticity.
[0202] FIGS. 10 and 11 show that the connector 3 can be arranged at an end portion of the battery block 2. On one end, the connector 3 can have a projection 15 that in a form-fit manner engages with a recess on the battery block 2 (see FIG. 11). The casing 10 of the connector 3 can have a through-hole 16 that can be used to bolt the casing 10 to the battery block 2.
[0203] FIG. 12 shows a perspective view onto a connector 3 and a part of a busbar 4. To simplify the view of FIG. 12, the electrode 5 has not been drawn. FIG. 13 shows a sectional view onto the connector 3 and the part of the busbar 4 of FIG. 12 together with the electrode 5.
[0204] FIG. 13 shows that the flat end of the busbar 4 is in contact with the spherical protrusion 6 of the electrode 5. The first leg 22 rests against the busbar 4 from the opposite side compared to the protrusion 6. The first leg 22 hence holds the busbar 4 in contact with the protrusion 6 of the electrode.
[0205] FIG. 13 also shows that the protrusion 6 of the electrode 5 protrudes through the opening 26 in the second leg 23. The main body of the electrode 5 is arranged on the opposite side of the leg 23 compared to the side that the end of the busbar 4 is arranged on.
[0206] Given the shape of the protrusion 6 of the electrode 5, the end of the busbar can swivel about the axis A, the axis B and the axis C (which points out of the plane of the paper) to a certain degree without losing contact to the protrusion 6 or changing the very contact location at the tip of protrusion 6 in an uncontrolled manner (see also FIG. 16). Further, shifts along the directions of axes A and C are possible by a sliding of protrusion 6 on the flat busbar contact surface. The shape of the protrusion 6 and the arrangement of the busbar 4 in contact with the protrusion 6 hence allows for a large degree of tolerance compensation.
[0207] FIG. 14 shows a top view onto two connectors 3 with a busbar 4 arranged between the two connectors 3. FIG. 14 shows, how the busbar 4 has swivelled about the axis A in FIG. 13 in order to compensate a misalignment of the connectors 3.
[0208] The sequence of FIGS. 15a, 15b, 15c shows assembly steps of a system with a connector and a busbar. The electrode that is for example visible in FIG. 13 has been purposefully left out of the FIGS. 15a, 15b, 15c for a better overview. In FIG. 15a, the end of the busbar 4 is arranged outside the connector 3. FIG. 15a shows that there is a clearance between the opening 17 of the casing 10 and a busbar abutment surface 33 on the spacer 12. FIG. 15b shows the situation where the end of the busbar 4 has been inserted through the opening 17 into the casing 10 to the extent that it comes into contact with the busbar contact surface 33. FIG. 15c shows the situation where the end of the busbar 4 has been fully inserted into the casing 10 by being moved from the situation shown in FIG. 15b to the situation shown in FIG. 15c and leading to the spacer 12 being rotated from the first position (FIG. 15a) to the second position (FIG. 15c).
[0209] In a next step in the situation shown in FIG. 15c, lid 13 can be closed. The lid 13 can provide a stopper against the busbar 4 being pulled out of the connector 3.
[0210] FIG. 8 by way of a dotted line shows the extent of the opening 17 into which the end of the busbar 4 can be inserted into the casing 10.
[0211] As can be seen from FIG. 13, part of the busbar 4 is arranged between the reference part 24 and the reference part 25.
[0212] FIG. 16a shows a schematic perspective view of an end of a busbar 4 in contact with an electrode 5. The purpose of FIG. 16a is to highlight that the protrusion 6 as provided on the electrode 5 is a suitable means to allow the busbar 4 and the electrode 5 to perform relative movements, especially rotations about the three perpendicular axes A, B, C without the surface contact between the end of the busbar 4 and the electrode 5 being influenced. The embodiment shown in FIG. 16a shows the busbar 4 and the electrode 5 to be arranged in line, which means that the longitudinal axis of the busbar 4 is parallel to the longitudinal axis of the electrode and/or parallel to the plane from which the protrusion projects. Similar arrangements are shown in FIG. 23, FIG. 52, FIG. 65, FIG. 74, FIG. 82. It is apparent to the person skilled in the art, however, that the ability to keep the good surface contact between the end of the busbar 4 and the electrode 5 by means of the protrusion 6 even in situations, where the end of the busbar 4 and the electrode 5 tilt relative to each other about one of the perpendicular axes A, B, C will also be kept for those embodiments, where the busbar 4 is arranged perpendicular to the electrode 5 for example in the design shown in FIG. 13 or those embodiments, where a busbar and a further busbar are pointing in the same direction as shown in FIG. 49, FIG. 57.
[0213] The protrusion 6 could of course also be an element of the busbar 4 instead of the electrode 5. This would not change the contents and discussion of FIG. 16a. This also applies with regard to FIGS. 3 to 15. Moreover, the protrusion could in some embodiments also be integrally formed in at least one of the clamp legs, for example in both of them, these protrusions contacting the busbar contact surface and the electrode surface, respectively. In such embodiments, the clamp can also serve as an electrically conducting element so that the contact between at least one of the clamp legs and the busbar or the electrode would carry a substantial part of the current.
[0214] Further, the design of the busbar and/or the electrode are generally kept as simple as possible. Such a simple busbar design and electrode design (at least of the electrode portion for making the contact and outside of the battery casing) can be square as shown, wherein shapes with somewhat rounded edges and protrusions as shown are included.
[0215] It goes without saying, that further elements of the connector 3 additional to the clamp, the busbar and the electrode will be adapted to the tolerances (with regard to rotations and shifts) contemplated by means of sufficient clearances. Since the casing predominantly has functions of protecting, insulating and holding the electrically relevant elements, this does not imply substantial differences and is clear to the person skilled in the art.
[0216] The busbar 4 as discussed so far and as shown in FIG. 3 has a flat portion to be contacted by the protrusion 6. FIG. 16b illustrates a modified version of the busbar 4, namely having two oval concave grooves 50 wherein the transition from the flat surface portions there around to the grooves 50 is somewhat rounded. As shown in FIG. 16c which can be compared to FIG. 13 and is a modified version thereof, the protrusion 6 is adapted for engaging into the respective groove 50 but the radius of curvature of the concavity of the groove 50 is substantially smaller than the radius of curvature of the protrusion 6. Therefore, the protrusion 6 contacts the rounded borders of the groove 50.
[0217] This applies to the vertical direction of the Figures. As regards the horizontal direction, the grooves 50 are longer than in the vertical direction by so to say including straight sections (in their profile as seen horizontally). Therefore, the protrusion 6 can shift within the groove 50 in case of horizontal relative movements, for example due to a thermal expansion of the busbar 4.
[0218] Further, the rolling movement in cases illustrated in FIG. 14 is still possible. Articulations around other axis would lead to some shifting movements as well (as in the case of the longitudinal shifting movement).
[0219] The grooves 50 have the advantage of splitting the contact load provided into two points which have a lower overall resistivity than just one contact point. Further, the oblong shape of the groove is particularly adapted for the already described relative movement in the longitudinal direction of the busbar 4 and some sense secures the engagement of the protrusion 6 into the groove 50 therein.
[0220] Beside that, the above explanations also apply to these modifications.
[0221] While in the embodiment shown in FIGS. 3 to 15, the electrode 5 is designed as a separate element from a clamp of a connector, the embodiment shown in the FIGS. 17a to 20 shows that the electrode 5 can have a part that provides the clamp 11. The clamp 11 that is part of the electrode 5, here, has a first leg 22, a second leg 23 and a third leg 27. The clamp 11 has in the embodiment of FIG. 17a two transition sections 20, which in the embodiments of FIG. 17a are made up as two separate bridges 21. In the embodiment shown in FIG. 19, the clamp 11 has one transition section 20 that is made up as one bridge 21. A first leg 22 is arranged at one end of the transition section 20. The second leg 23 is arranged at the opposite end of the transition section 20. The third leg 27 is arranged also at the opposite side of the transition section 21 in comparison to the arrangement of the first leg 22 that is arranged at one end of the transition section 20. Hence, the second leg 23 and the third leg 27 are arranged on one side when compared with the arrangement of the first leg 22 relative to the transition section 20.
[0222] Each of the first leg 22, the second leg 23 and the third leg 27 has a respective protrusion 6 that are intended for coming into contact with an end of the busbar 4. The protrusion 6 of the first leg 22, the second leg 23 and the third leg 27 each allow for tolerance compensation if a busbar 4 (like the busbar shown in FIG. 16) is arranged between the first leg 22, the second leg 23 and the third leg 27. The effect described in conjunction with FIG. 16 will come true for each individual protrusion 6 shown in FIG. 17a.
[0223] It should be mentioned, that any (limited) rotations about a vertical axis in FIGS. 17a to 20 will be compensated also by an elastic response of the second leg 23 and the third leg 27 together with the already described functions of the protrusions 6. This is illustrated in FIG. 18 which is a view of the clamp 11 from above (in relation to FIG. 17a). It shows that the second and third legs 23 and 27 are not aligned any more but have elastically reacted to a rotation of busbar 4 around a rotation axis perpendicular to the drawing in FIG. 18. It can be seen that the protrusions 6 have a rolling function in this reaction.
[0224] It should be noted, however, that the protrusions 6 of the clamp 5 shown in FIGS. 17a to 20 are not mandatory and the same embodiment is contemplated without these protrusions (and thus just bent from a flat sheet metal).
[0225] The electrode 5 shown in FIGS. 17a to 20 has a connection end 7 that is connected, for example welded, to a further section to contact to a battery cell or a parallel arrangement of battery cells.
[0226] The respective bridges 21 and/or the respective first legs 22 and/or the respective second legs 23 and/or the respective third legs 27 are elastically deformable. These parts of the electrode 5 provide the clamp 11, which in the embodiments shown in FIGS. 17a to 20 has a first state, in which a reference part of the first leg 22 (for example the protrusion 6 of the first leg 22) is distanced from a reference part of the second leg 23 (for example the protrusion 6 of the second leg 23) by a first amount and whereby a reference part of the first leg 22 (for example the protrusion 6 of the first leg 22) is distanced from a reference part of the third leg 27 (for example the protrusion 6 of the third leg 23) by a first amount. The clamp 11 also has a second state, in which the same part of the first leg 22 is distanced from the same part of the second leg 23 by a second amount that is different from the first amount and in which the same part of the first leg 22 is distanced from the same part of the third leg 27 by a second amount.
[0227] FIG. 20 shows that in the embodiment shown in FIGS. 17a to 20, a spring clamp 18 is provided. The spring clamp 18 can be used to introduce forces that move the clamp 11 from the second state into the first state into parts of the clamp 11. In particular, spring clamp 18 can be designed in view of its mechanical function and elastic properties and clamp 11, on the other hand, can be designed more in view of its electrical functions such as Ohmic resistances of the clamp as such and of the contact to be made. For example, clamp 11 could be made of a well conducting material as defined above, for example copper, and spring clamp 18 of spring steel. Similar ideas apply to other embodiments as well.
[0228] FIG. 21 shows the end part of a battery block 2 of an array of battery blocks 1. The battery block 2 has an electrode 5 that has a protrusion 6 as already described. It can be seen in FIG. 22 that a connector 3 can be placed at the end of the battery block 2 and used to connect the electrode 5 with a busbar 4 (see FIG. 22). In this connection, the same way of tolerance compensation will be achieved as explained in the context of FIG. 16. FIG. 23 for means of illustration shows (without showing the connector 3) how the end of the busbar 4 is arranged to come into contact with the electrode 5 and the protrusion 6 of the electrode 5. The connector 3 is the means for holding the busbar 4 in contact with the electrode 5.
[0229] The connector 3 used in the embodiment shown in FIGS. 21 to 35 has a casing 10, a clamp 11 and a spacer 12. The spacer 12 has a part that can function as a lid.
[0230] The clamp 11 (see especially FIGS. 30 to 33) has a transition section 20 that is formed as a bridge 21. The transition section 20 connects a first leg 22 that is arranged at one end of the transition section 20 with a second leg 23 that is arranged at the opposite end of the transition section. At least one of the transition section 20, the first leg 22 and the second leg 23 is elastically deformable. The clamp 11 has a first state shown in FIG. 26, 32, 33, 34, in which the reference part 24 of the first leg 22 is distanced from the reference part 25 of the second leg 23 by a first amount. The clamp 11 has a second state best seen in FIGS. 30, 31 and 25, in which reference part 24 is distanced from the reference part 25 by a second amount that is different from the first amount, namely larger. In the second state (FIG. 30,31), the transition section 20 and/or the first leg 22 and/or the second leg 23 is further elastically deformed compared to the first state (FIGS. 32, 33).
[0231] The Figs. show that here clamp 11 has a spherical protrusion, as already discussed earlier.
[0232] The spacer 12 is movable between a first position shown in the FIGS. 24 and 25 to a second position shown in FIG. 22 and FIG. 26. The spacer 12 is in contact with a part of the first leg 22 when the clamp 11 is in the second state and the spacer 12 is in the first position. The spacer 12 is designed to rotate from the first position (FIG. 24, 25) to the second position (FIG. 22, 26). If the spacer 12 is rotated into the second position, the spacer 12 will lose contact with the part of the first leg 22 and will allow the first leg 22 to come into contact with the end of the busbar 4 in order to hold the end of the busbar 4 in contact with the protrusion 6 on the electrode 5 (this arrangement of busbar 4 and electrode 5 being illustrated in FIG. 23 without the connector for illustrative purposes).
[0233] Compared to the embodiment of the connector shown in FIGS. 3 to 15, the spacer 12 in the embodiment shown in FIGS. 21 to 35 has a lever 34 that can be used to manually move the spacer 12 from the first position (FIG. 24, 25) to the second position (FIG. 22, FIG. 26) manually.
[0234] The embodiment shown in FIGS. 36 to 47 also has a spacer 12 that can be operated manually. FIG. 36 shows parts of two battery blocks 2 whereby a connector 3 is provided per battery block 2. A busbar 4 is arranged between the electrodes (not shown in FIG. 36) of the respective battery blocks 2 and held by the respective connectors 3. FIG. 36 shows the connectors 3 in the opened position, which has the spacer 12 in the first position and the clamp 11 in the second state.
[0235] FIGS. 37 and 38 show the spacer 12 and the clamp 11 and indicate, how the spacer 12 is in contact with a part of the first leg 22 of the clamp 11 when the clamp 11 is in the second state and the spacer is in the first position (FIG. 38). FIGS. 37, 38 and 47 show the spacer 12 sits on an axle 35. The axle 35 is arranged in holes 32 in the casing 10 of the connector 3.
[0236] The embodiment shown in the FIGS. 49 to 56 shows a connector 3 that is designed to connect the busbar 4 with a further busbar 4. FIGS. 49 to 56 are explained with the element 4 with the protrusion 6 being a busbar. It will be apparent to the skilled person that the element 4 shown in FIGS. 49 to 56 could likewise be referred to as an electrode 5 with a protrusion 6. The disclosure of FIGS. 49 to 50 is hence being applicable as a disclosure for connecting an electrode with a protrusion 6 to the busbar 4 or to another electrode.
[0237] The connector 3 has the ability to connect the busbar 4 to the further busbar 4 in a manner that busbar 4 and further busbar 4 extend into the same direction away from the connector 3 (see FIG. 49 and FIG. 51). The connector 3 is, however, also designed to be used to connect a busbar 4 to a further busbar 4 that extends away from the busbar 4 in the manner shown in FIG. 52.
[0238] FIG. 50 is used to highlight the two possible scenarios where the connector 3 of FIG. 49 could be used: The connector 3 could be used to connect the busbar 4 shown in the upper part of FIG. 50 with the further busbar 4 shown in the lower left-hand side of FIG. 50. In this scenario, the connector 3 would join the busbar 4 and the further busbar 4 in the manner shown in FIGS. 49 and 51. In the alternative scenario, the busbar 4 shown in the upper part of FIG. 50 can be connected to the further busbar 4 shown in the lower right-hand side of FIG. 50 by the connector 3. In this scenario, the connection would be made as shown in FIG. 52.
[0239] FIG. 50, FIG. 51 and FIG. 52 show that the further busbar 4 has a protrusion 6. Here the same effect of tolerance compensation will occur as explained with reference to FIG. 16.
[0240] The connector shown in FIGS. 49, 51 and 52 has a casing 10 and a clamp 11 arranged inside the casing 10.
[0241] The clamp 11 shown in FIG. 53 has a first leg 22 (see also FIG. 54) and a second leg 23 (see also FIGS. 55 and 56). The first leg 22 has a reference part 24 arranged as part of a flexible portion of the first leg 22. The second leg 23 has four reference parts 25.
[0242] The first leg 22 is joined to the second leg 23 by way of rods 28 protruding from the first leg 22 that are held in holes 29 on the second leg 23 allowing the first leg 22 to swivel relative to the second leg 23. The casing 10 and the clamp 11 can be moved into an open position (not shown, but similar to the position shown in FIG. 60) that allows for the parts of the busbars 4 that are to be connected by way of the connector 3 to be introduced into the connector 3.
[0243] The embodiment shown in the FIGS. 57 to 64 shows a connector 3 that is designed to connect the busbar 4 with a further busbar 4. FIGS. 57 to 64 are explained with the element 4 with the protrusion 6 being a busbar. It will be apparent to the skilled person that the element 4 shown in FIGS. 57 to 64 could likewise be referred to as an electrode 5 with a protrusion 6. The disclosure of FIGS. 57 to 64 is hence being applicable as a disclosure for connecting an electrode with a protrusion 6 to the busbar 4.
[0244] The connector 3 is designed to be used to connect a busbar 4 to a further busbar 4 that extends away from the connector 3 in the same direction as shown in FIG. 57.
[0245] FIG. 58 shows that the connector 3 is to connect the busbar 4 shown in the upper part of FIG. 58 with the further busbar 4 shown in the lower part of FIG. 58.
[0246] FIG. 58 and FIG. 59 show that the further busbar 4 has a protrusion 6. Here the same effect of tolerance compensation will occur as explained with reference to FIG. 16.
[0247] The connector shown in FIGS. 57, 59 and 60 has a casing 10 and a clamp 11. Parts of the casing 10 form part of the clamp 11. The clamp 11 has a first leg 22 that is made up of a first metal part shown in FIG. 62 and by part of the casing 10, namely that part of the casing that the metal part shown in FIG. 62 is attached to. FIG. 60 shows how the upper part of the casing 10 (the opened part) carries the metal part shown in FIG. 62 and thereby forms the first leg of the clamp.
[0248] The first leg 22 has a reference part 24 that is provided by the metal part shown in FIG. 62. The second leg 23 has two reference parts 25.
[0249] The first leg 22 is joined to the second leg 23 by way of an axle 40 shown in FIG. 61 that is held in holes of the plastic part that makes up part of the first leg 22 and that is held in holes 29 on the second leg 23 allowing the first leg 22 to swivel relative to the second leg 23. The casing 10 and the clamp 11 can be moved into an open position (shown in FIG. 60) that allows for the parts of the busbars 4 that are to be connected by way of the connector 3 to be introduced into the connector 3.
[0250] The embodiment shown in the FIGS. 65 to 73 shows a connector 3 that is designed to connect the busbar 4 with a further busbar 4. FIGS. 65 to 73 are explained with the element 4 with the protrusion 6 being a busbar. It will be apparent to the skilled person that the element 4 shown in FIGS. 65 to 73 could likewise be referred to as an electrode 5 with a protrusion 6. The disclosure of FIGS. 65 to 73 is hence being applicable as a disclosure for connecting an electrode with a protrusion 6 to the busbar 4.
[0251] The connector 3 is designed to be used to connect a busbar 4 to a further busbar 4 that extends away from the connector 3 in a different direction as shown in FIG. 65.
[0252] FIG. 66 shows that the connector 3 is to connect the busbar 4 shown in the right-hand side of FIG. 66 with the further busbar 4 shown in the left-hand side of FIG. 66.
[0253] FIGS. 66 and 67 show that the further busbar 4 has a protrusion 6. Here the same effect of tolerance compensation will occur as explained with reference to FIG. 16.
[0254] The connector shown in FIGS. 65, 67 and 60 has a two-part casing 10 and a clamp 11. The lower part 37 of the casing 10 is shown in FIGS. 68 and 69. The upper part 36 of the casing 10 is shown in FIGS. 70 and 71. A lever 38 is arranged at the upper part 36 and serves for providing a clamp load. The clamp load can be produced for example by a spring clamp made of spring steel but also or additionally by a mechanism as here. In the present embodiment, the clamp 11 is naturally open and lever 38 serves to bring it into a closed position (position 1). For this purpose, the lever 38 has an eccentric shape on the turning axis.
[0255] The clamp 11 shown in FIGS. 72 and 73 has a first leg 22 and a second leg 23. The first leg 22 has a reference part 24 arranged as part of a flexible portion of the first leg 22. The second leg 23 has a reference parts 25 by way of a flat wall.
[0256] The first leg 22 is joined to the second leg 23 by way of a transition section 20 that is designed as a bridge 21.
[0257] The embodiment shown in the FIGS. 74 to 81 shows a connector 3 that is designed to connect the busbar 4 with a further busbar 4. FIGS. 74 to 81 are explained with the element 4 with the protrusion 6 being a busbar. It will be apparent to the skilled person that the element 4 shown in FIGS. 74 to 81 could likewise be referred to as an electrode 5 with a protrusion 6. The disclosure of FIGS. 74 to 81 is hence being applicable as a disclosure for connecting an electrode with a protrusion 6 to the busbar 4.
[0258] The connector 3 is designed to be used to connect a busbar 4 to a further busbar 4 that extends away from the connector 3 in a different direction as shown in FIG. 74.
[0259] FIG. 75 shows that the connector 3 is to connect the busbar 4 shown in the right-hand side of FIG. 75 with the further busbar 4 shown in the left-hand side of FIG. 75.
[0260] FIGS. 75 and 76 show that the further busbar 4 has a protrusion 6. Here the same effect of tolerance compensation will occur as explained with reference to FIG. 16.
[0261] The connector shown in FIGS. 74 and 76 has a casing 10 and a clamp 11. A closure piece 39 can be inserted into an opening of the casing 10 as shown in FIGS. 74 and 75.
[0262] The clamp 11 shown in FIGS. 80 and 81 has a first leg 22 and a second leg 23. The first leg 22 has a reference part 24 arranged as part of a flexible portion of the first leg 22. The second leg 23 has a reference parts 25 by way of a flat wall.
[0263] The first leg 22 is joined to the second leg 23 by way of a transition section 20 that is designed as a bridge 21.
[0264] The embodiment shown in FIG. 82 to FIG. 87 shows the connector 3 to connect a first busbar 4 with a further busbar 4. The busbar 4 has a protrusion 6. The embodiment shown in FIGS. 82 to 87 might have an additional casing made of plastic that could be arranged around the elements shown in FIGS. 82 to 87.
[0265] FIGS. 82 to FIG. 87 are explained with the element 4 with the protrusion 6 being a busbar. It will be apparent to the skilled person that the element 4 shown in FIG. 82 to FIG. 87 could likewise be referred to as an electrode 5 with a protrusion 6. The disclosure of FIG. 82 to FIG. 87 is hence being applicable as a disclosure for connecting an electrode with a protrusion 6 to the busbar 4.
[0266] The connector 3 is designed to be used to connect a busbar 4 to a further busbar 4 that extends away from the busbar 4 in the manner shown in FIG. 82.
[0267] FIGS. 83 and 84 show that the busbar 4 has a protrusion 6. Here the same effect of tolerance compensation will occur as explained with reference to FIG. 16.
[0268] The connector shown in FIGS. 82 and 83 has a clamp 11.
[0269] The clamp 11 shown in FIGS. 82 and 83 has a first leg 22 (see also FIGS. 84 and 87) and a second leg 23 (see also FIGS. 85 and 86). The first leg 22 has a reference part 24 arranged as part of a flexible portion of the first leg 22. The second leg 23 has four reference parts 25.
[0270] The first leg 22 is joined to the second leg 23 by way of rods 28 protruding from the first leg 22 that are held in holes 29 on the second leg 23 allowing the first leg 22 to swivel relative to the second leg 23. The clamp 11 can be moved into an open position (see FIG. 83).
