WO2014066601A1

WO2014066601A1 - Terminal connectors for energy storage system

Info

Publication number: WO2014066601A1
Application number: PCT/US2013/066549
Authority: WO
Inventors: Bruce James SILK; Anthony DIPILLA; Stephen Alford; Philip Andrew STEWART
Original assignee: Enerdel, Inc.
Priority date: 2012-10-24
Filing date: 2013-10-24
Publication date: 2014-05-01

Abstract

Battery assemblies are disclosed including trays and a plurality of battery cells supported by the trays. The battery assemblies include terminal pins and terminal connectors electrically coupled to the terminal pins. The terminal pins may be protected by insulating covers. The terminal connectors may be locked onto the terminal pins.

Description

TERMINAL CONNECTORS FOR ENERGY STORAGE SYSTEM

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority from U.S. Provisional Patent Application Serial No. 61/718,013, filed October 24, 2012, the disclosure of which is hereby expressly incorporated by reference herein in its entirety.

SUMMARY

[0002] The disclosure relates in general to methods and systems for storing and providing energy with a plurality of batteries and, more particularly, to methods and systems for storing and providing energy to a stationary energy storage market with a plurality of batteries.

[0003] Energy storage systems are known. Exemplary energy storage systems are disclosed in PCT Application No. PCT/US2011/52169 (Publication No. WO

2012/158185) filed September 19, 2011, and PCT Application No. PCT/US2012/40776 (Publication No. WO 2012/167269) filed June 4, 2012, both entitled ENERGY

STORAGE SYSTEM, the disclosures of which are expressly incorporated by reference herein in their entirety.

[0004] The present disclosure provides battery assemblies including trays and a plurality of battery cells supported by the trays. The battery assemblies include terminal pins and terminal connectors electrically coupled to the terminal pins. The terminal pins may be protected by insulating covers. The terminal connectors may be locked onto the terminal pins.

[0005] According to an exemplary embodiment of the present disclosure, a battery assembly is provided including a tray, a plurality of battery cells supported by the tray, at least one terminal pin in electrical communication with the plurality of battery cells, the at least one terminal pin having a first locking feature, at least one terminal connector having a socket, the socket being removably coupled to the at least one terminal pin, the socket having a second locking feature that cooperates with the first locking feature to lock the socket onto the at least one terminal pin in electrical communication with the at least one terminal pin, and an insulating cover coupled to the tray, the cover having an outer surface, the at least one terminal pin being located at or behind a plane containing the outer surface of the cover.

[0006] According to another exemplary embodiment of the present disclosure, a battery assembly is provided including a tray, a plurality of battery cells supported by the tray, at least one terminal pin in electrical communication with the plurality of battery cells, at least one terminal connector having a socket, the socket being removably coupled to the at least one terminal pin, a locking means for locking the socket onto the at least one terminal pin in electrical communication with the at least one terminal pin, and an insulating covering means for covering the at least one terminal pin.

[0007] According to yet another exemplary embodiment of the present disclosure, a battery assembly is provided including a tray, a plurality of battery cells supported by the tray, at least one terminal pin in electrical communication with the plurality of battery cells, and at least one terminal connector having a socket and a handle longitudinally aligned with the socket, the socket being removably coupled to the at least one terminal pin for electrical communication with the at least one terminal pin.

[0008] According to still yet another exemplary embodiment of the present disclosure, a battery assembly is provided including a battery support having an outer envelope and at least one battery positioned within the outer envelope, an electrically conductive terminal positioned within the outer envelope, electrically coupled to the at least one battery, and accessible from an exterior of the outer envelope, the electrically conductive terminal defining a first longitudinal axis, and an electrical connector removably coupled to the electrically conductive terminal. The electrical connector includes an electrically conductive portion defining a second longitudinal axis, the electrically conductive portion being received within the outer envelope along the first longitudinal axis into a pocket formed between the electrically conductive terminal and the battery support, an electrical cable electrically coupled to the electrically conductive portion, a housing covering at least a portion of the electrical cable and the electrically conductive portion, and a handle positioned along the second longitudinal axis.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

[0010] FIG. 1 is a top plan view of an exemplary battery assembly of the present disclosure, the battery assembly including a support and a plurality of battery cells supported by the support;

[0011] FIG. 2 illustrates an exemplary battery cell for use in the battery assembly of FIG. 1, the battery cell having a positive terminal and a negative terminal extending from different sides of the battery cell;

[0012] FIG. 2A illustrates another exemplary battery cell for use in the battery assembly of FIG. 1, the battery cell having a positive terminal and a negative terminal extending from a common side of the battery cell;

[0013] FIG. 3 is a partially exploded, perspective view of an exemplary battery module of the present disclosure, a cover, and positive and negative terminal connectors removably coupled to the battery module, the battery module including a plurality of supports in a stacked configuration;

[0014] FIG. 4 is a schematic view of an exemplary electrical arrangement for the battery module of FIG. 3;

[0015] FIG. 5 is a schematic view of an exemplary electrical arrangement for a plurality of battery modules; [0016] FIG. 6 is a partial top plan view of the cover coupled to the battery module of FIG. 3; and

[0017] FIG. 7 is a partial cross-sectional view of the positive terminal connector coupled to the battery module of FIG. 3, taken along line 7-7 of FIG. 3. [0018] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION [0019] While the present disclosure primarily involves storing and providing energy for a stationary energy storage market, it should be understood that the invention may have application to other devices which receive power from batteries. Exemplary applications for a stationary storage market include providing power to a power grid, providing power as an uninterrupted power supply, and other loads which may utilize a stationary power source. In one embodiment, the systems and methods disclosed herein may be implemented to provide an uninterrupted power supply for computing devices and other equipment in data centers. A controller of the data center or other load may switch from a main power source to an energy storage system of the present disclosure based on one or more characteristics of the power being received from the main power source or a lack of sufficient power from the main power source. In one embodiment, the systems and methods disclosed herein may be implemented to provide power to an electric vehicle or a hybrid vehicle.

1. Battery Assembly

[0020] Referring to FIG. 1, a battery assembly 1000 is shown. Battery assembly

1000 includes a support 1002 and a plurality of battery cells 104, illustratively six battery cells 104A-104F. [0021] Support 1002 is a generally tray- shaped, rectangular structure that is also referred to herein as a tray. Support 1002 includes a base 1100, an outer or peripheral wall 1102 extending upward from base 1100, and inner walls 1104 extending upward from base 1100 within peripheral wall 1102. In the illustrated embodiment, base 1100 of support 1002 has a generally solid construction to support cells 104A-104F thereon. Walls 1102, 1104 cooperate to define a plurality of battery pockets for receiving corresponding cells 104A-104F therein atop the supportive base 1100. In this

arrangement, walls 1102, 1104 cooperate to surround and separate adjacent cells 104A- 104F in the pockets. Support 1002 includes first end 1072 on the left side of FIG. 1 and second end 1074 on the right side of FIG. 1.

[0022] The dimensions of support 1002 may vary. However, an exemplary support 1002 has a length measured between first end 1072 and second end 1074 of about 670 mm and a width of about 560 mm. Support 1002 may also have a low thickness or height, giving support 1002 a low profile design that is electrically safe and low in cost with a friendly mass/volume ratio for battery packaging. In one embodiment, the height of support 1002 is up to about 10 percent, 5 percent, 1.5 percent, or 1 percent of the length of support 1002. For example, the height of support 1002 may be less than about 25 mm, 20 mm, or 15 mm.

[0023] In one embodiment, support 1002 is made of a sheet molded composite (SMC) dielectric polymer or another suitable electrically insulating material. Such polymers include fiber-reinforced thermoset polyesters, and more specifically, glass fiber-reinforced thermoset polyesters. An exemplary material for support 1002 is DIELECTRITE E5V-204 SMC, which is available from IDI Composites International of Noblesville, Indiana. Another exemplary material for support 1002 is DIELECTRITE 46-16 BMC, which is also available from IDI Composites International. Additional details regarding DIELECTRITE E5V-204 SMC and DIELECTRITE 46-16 BMC are provided in the above -incorporated US Provisional Patent Application Serial No.

61/543,781. Support 1002 may be manufactured by compression molding or by another suitable molding technique, for example. [0024] Cells 104A-104F are arranged in a generally side-by-side arrangement on support 1002 in FIG. 1. Cells 104A-104F are illustratively arranged in two rows - a first row including three cells 104A-104C and a second row including three cells 104D-104F - although other numbers and arrangements of battery cells 104 are contemplated. [0025] An illustrative battery cell 104 for use in battery assembly 1000 is shown in FIG. 2. Cell 104 is illustratively a soft prismatic cell. Cell 104 includes a cell pouch 120 containing the battery chemistry and anode-cathode pairs. Cell pouch 120 includes a middle portion 126 and a perimeter portion 128. Perimeter portion 128 may be sealed to contain and protect the components inside cell pouch 120. A negative terminal 122 and a positive terminal 124 extend from the interior of cell pouch 120. In the illustrated embodiment, both negative terminal 122 and positive terminal 124 project from perimeter portion 128 of cell pouch 120. Negative terminal 122 and positive terminal 124 may extend from opposite sides of cell 104, as shown in FIG. 2. Alternatively, negative terminal 122 and positive terminal 124 may extend from a common side of cell 104', as shown in FIG. 2A.

[0026] Returning to FIG. 1, cells 104A-104F are electrically coupled together to form a source of power. Terminals 122, 124 of adjacent cells 104 may have an overlapping or partially overlapping arrangement on support 1002. This overlapping arrangement may facilitate electrically and physically coupling adjacent cells 104 together, as discussed further below. By contrast, middle portions 126 (FIG. 2) of the adjacent cells 104 are spaced apart from one another in FIG. 1 such that middle portions 126 of the adjacent cells 104 have a non-overlapping arrangement on support 1002. Cells 104 are illustratively positioned in a single layer having a generally flat configuration on support 1002. Although cells 104 of FIG. 1 form a single layer on support 1002, in one embodiment, multiple layers of cells 104 may be positioned on top of support 1002. In this embodiment, middle portions 126 of cells 104 are still arranged in a non-overlapping arrangement relative to cells 104 within the same layer, but are overlapping with cells 104 of adjacent layers. If a given cell 104 needs replaced, that cell 104 may be removed from support 1002 and replaced with a new cell 104 without disturbing other cells 104 in support 1002.

[0027] Referring still to FIG. 1 , the plurality of cells 104A- 104F are electrically coupled together to form a battery group. In the illustrative embodiment of FIG. 1, cells 104A-104F are electrically coupled together in series to form a single battery group. In one embodiment, the total voltage of the single battery group is less than about 50 volts, which complies with the OSHA HV threshold to provide safe assembly and shipping of battery assembly 1000 and groups of battery assemblies 1000 which are not coupled together. It is also within the scope of the present disclosure that at least two of the cells 104A-104F may be electrically coupled together in parallel. In a further embodiment, the battery cells 104A-104F are divided into multiple battery groups.

[0028] As discussed above, each cell 104A-104F includes a negative terminal 122 and a positive terminal 124. In FIG. 1, the side of each cell 104A-104F corresponding to negative terminal 122 is indicated with a "-" symbol and the side of each cell 104A-104F corresponding to positive terminal 124 is indicated with a "+" symbol.

[0029] Beginning with cell 104A of FIG. 1 and moving in a counter-clockwise direction around support 1002, positive terminal 124 is electrically connected to positive terminal 1004 of battery assembly 1000 through terminal bar 1006. Negative terminal 122 of cell 104 A is electrically connected to positive terminal 124 of the adjacent cell 104B through an overlapping arrangement of the adjacent terminals 122, 124. Negative terminal 122 of cell 104B is electrically connected to positive terminal 124 of the next adjacent cell 104C through an overlapping arrangement, and so on. Compression bars 1008 are placed over overlapping terminals 122, 124 to press terminals 122, 124 together, thereby ensuring electrical and physical contact between the overlapping terminals 122, 124. Between the two rows of battery assembly 1000, cells 104C and 104D are electrically connected through a bussing jumper bar 142 that spans the space between terminals 122, 124 of cells 104C, 104D, without physically overlapping terminals 122, 124 of cells 104C, 104D. Negative terminal 122 of the last cell 104F is electrically connected to negative terminal 1005 of battery assembly 1000 through terminal bar 1006. Terminal bars 1006, cell compression bars 1008, and jumper bar 142 may be tightened against the desired electrical components using suitable fasteners 1086, for example.

[0030] In the illustrated embodiment of FIG. 1, positive terminal 1004 of battery assembly 1000 includes a threaded, positive stud 1066 that is exposed along the first end 1072 of support 1002. In this embodiment, positive stud 1066 of positive terminal 1004 may be electrically coupled to an external connector, as discussed further below. Positive stud 1066 of positive terminal 1004 is illustratively recessed into pocket 1073 on first end 1072 of support 1002 behind peripheral wall 1102, such that positive stud 1066 of positive terminal 1004 is positioned within the outer envelope of support 1002. Negative terminal 1005 of battery assembly 1000 is also located along the first end 1072 of support 1002 in FIG. 1. However, negative terminal 1005 is concealed by peripheral wall 1102 of support 1002. In this embodiment, negative terminal 1005 may be electrically coupled to an adjacent terminal within peripheral wall 1102 of support 1002. Positive terminal 1004 and negative terminal 1005 of battery assembly 1000 are illustratively positioned along the same end 1072 of support 1002. However, the position of positive terminal 1004 and negative terminal 1005 may vary. For example, positive terminal 1004 and negative terminal 1005 may be positioned at opposite ends 1072, 1074 of support 1002.

[0031] The location of positive terminal 1004 and negative terminal 1005 on support 1002 may be reversed by rearranging the orientation of cells 104A-104F in support 1002. For example, if cell 104F takes the place of cell 104A in FIG. 1, negative terminal 122 of cell 104F would take the place of positive terminal 124 of cell 104 A in FIG. 1, and as a result, negative terminal 1005 would take the place of positive terminal 1004 in FIG. 1.

[0032] Battery assembly 1000 further includes a controller 1012. Controller 1012 is operatively coupled to battery cells 104A-104F to monitor voltage and temperature of battery cells 104A-104F, as discussed further below. In one embodiment, controller 1012 is located in a low voltage tray which is provided as part of the battery assembly 1000. [0033] Electrical connections are made at each junction between cells 104 and terminals 1004, 1005 of battery assembly 1000. In FIG. 1, voltage sense connections 1010A-1010G provide voltage readings to controller 1012 through wiring harness 1014 and connector 1016. From connector 1016, the voltage readings may be communicated to controller 1012 via a cable or a wireless network, for example. Assuming battery cells 104 are functioning properly, controller 1012 should read a voltage at the first electrical connection 1010A that corresponds to the voltage of positive terminal 1004. The voltage at the second electrical connection 1010B should generally be offset from the voltage of the first electrical connection 1010A by the expected voltage of the first cell 104A, and so on through the remaining electrical connections 1010C-1010G. In FIG. 1, connector

1016 is illustratively positioned along the same end 1072 of support 1002 as positive and negative terminals 1004, 1005.

[0034] A plurality of thermistors 1020, illustratively thermistors 1020A- 1020D, are also provided on support 1002 of FIG. 1, and are positioned to provide an indication of the temperature of cells 104A-104F. Terminals 122, 124 are generally the warmest portions of cells 104A-104F, and as such, thermistors 1020A-1020D may be positioned near terminals 122, 124. In FIG. 1 , thermistors 1020A-1020D are positioned between adjacent cells 104A-104F in a non-overlapping relationship with cells 104A-104F, but it is also within the scope of the present disclosure that thermistors 1020A-1020D may be positioned above or below cells 104A-104F in an overlapping manner. It is also within the scope of the present disclosure that pockets (not shown) may be provided in support 1002 to receive and hold thermistors 1020A-1020D in place. In FIG. 1, thermistors 1020A-1020D provide temperature readings to controller 1012 through wiring harness 1014 and connector 1016, which may be the same connector 1016 that is associated with voltage sense connections 1010A-1010G or a different connector. From connector 1016, the temperature readings may be communicated to controller 1012 via a cable or a wireless network, for example.

[0035] Support 1002 of FIG. 1 further includes a plurality of handles 1070.

Handles 1070 define the outer envelope of support 1002 along first end 1072 and second end 1074. Because handles 1070 define the outer envelope of support 1002, battery assembly 1000 may be stood on end without stressing positive and negative terminals 1004, 1005, connector 1016, and other electrical components that may be positioned along first end 1072 and/or second end 1074. When a plurality of supports 1002 are stacked together, the handles 1070 of each support 1002 are generally aligned.

2. Modules

[0036] Referring next to FIG. 3, a plurality of battery supports 1002, illustratively eight battery supports 1002A-1002H, may be stacked or layered together to form a battery module 1500. The number of battery supports 1002 in each module 1500 may vary. Each battery support 1002 may include nesting features to facilitate stacking of adjacent battery supports 1002. The illustrative support 1002 includes upper bosses 1050 extending from the top side of support 1002, as shown in FIG. 3, and corresponding lower recesses (not shown) in the bottom side of support 1002. The recesses are positioned to receive bosses 1050 from the adjacent support 1002 to limit movement between adjacent supports 1002, thereby stabilizing the battery module 1500.

[0037] The assembled battery module 1500 may be held together with suitable fasteners. In the illustrated embodiment of FIG. 3, each support 1002 defines a plurality of openings 1054 that align with adjacent openings 1054 to receive fasteners (e.g., bolts, tie rods) through the battery module 1500. It is also within the scope of the present disclosure to wrap fasteners (e.g., bands) around the assembled battery module 1500.

[0038] When adjacent supports 1002 are stacked together to form the module

1500, various regions of support-to-support contact exist where adjacent supports 1002 contact one another. For example, walls 1102, 1104 and handles 1070 of support 1002 may contact adjacent supports 1002. These interfacing regions form a solid material stack in the battery module 1500, thereby increasing the rigidity of the battery module 1500. The solid stack may be spaced apart from cells 104A-104F by being located between adjacent cells 104A-104F and around the outer periphery of the module 1500. [0039] The electrical arrangement of module 1500 is shown schematically in FIG.

4. Each pair of adjacent supports 1002 - a first pair 1502 including supports 1002 A and 1002B, a second pair 1504 including supports 1002C and 1002D, a third pair 1506 including supports 1002E and 1002F, and a fourth pair 1508 including supports 1002G and 1002H - is connected together in series. The four pairs 1502, 1504, 1506, 1508 are connected together in parallel through plate connectors 1510, 1520. This electrical arrangement results in four parallel groups, with each group including twelve cells (on two supports) coupled together in series. Assuming the voltage of each cell 104 is nominally 4 volts, the illustrated electrical arrangement results in a 48 volt system. [0040] The electrical arrangement of module 1500 may vary by adjusting the orientation of cells 104 on respective supports 1002 and/or by adjusting connections between adjacent supports 1002. Another exemplary electrical arrangement includes a single group of batteries, with each group including forty-eight cells (on eight supports) coupled together in series. Assuming the voltage of each cell 104 is nominally 4 volts, this electrical arrangement results in a 192 volt system. Yet another exemplary electrical arrangement includes two parallel groups of batteries, with each group including twenty- four cells (on four supports) coupled together in series. Assuming the voltage of each cell 104 is nominally 4 volts, this electrical arrangement results in a 96 volt system. A further exemplary electrical arrangement includes eight parallel groups of batteries, with each group including six cells (one one support) in series. Assuming the voltage of each cell 104 is nominally 4 volts, this electrical arrangement results in a 24 volt system.

[0041] Referring still to FIG. 4, positive plate connector 1510 is electrically coupled to a positive terminal connector 1516. Similarly, negative plate connector 1520 is electrically coupled to a negative terminal connector 1526. Positive terminal connector 1516 and negative terminal connector 1526 may be electrically coupled to other battery modules, to a load, or to a charger, for example. In the illustrated embodiment of FIG. 5, for example, a plurality of modules 1500, illustratively three modules 1500A-1500C, are electrically coupled together in series through respective positive terminal connectors 1516A- 1516C and negative terminal connectors 1526A- 1526C . Other numbers and arrangements of modules 1500 are within the scope of the present disclosure.

[0042] Returning to FIG. 3, alternating supports 1002A, 1002C, 1002E, 1002G illustratively include positive terminals 1004 with positive studs 1066A, 1066C, 1066E, 1066G, respectively, and alternating supports 1002B, 1002D, 1002F, 1002H illustratively include negative terminals 1005 with negative studs 1068B, 1068D, 1068F, 1068H, respectively. Positive studs 1066A, 1066C, 1066E, 1066G are generally aligned to be coupled together in parallel via positive plate connector 1510 (see also FIG. 4).

Similarly, negative studs 1068B, 1068D, 1068F, 1068H are generally aligned to be coupled together in parallel via negative plate connector 1520 (see also FIG. 4).

Blocking members 1078 may be provided on supports 1002A-1002H to separate and prevent contact between positive studs 1066 and negative studs 1068.

[0043] Positive plate connector 1510 includes a plurality of apertures 1512A,

1512C, 1512E, 1512G that receive positive studs 1066A, 1066C, 1066E, 1066G, respectively. Similarly, negative plate connector 1520 includes a plurality of apertures 1522B, 1522D, 1522F, 1522H that receive negative studs 1068B, 1068D, 1068F, 1068H, respectively. Plate connectors 1510, 1520 are illustratively secured in place by threading fasteners 1514 onto one or more threaded studs 1066, 1068.

[0044] Positive plate connector 1510 is electrically coupled to a positive terminal connector 1516, and negative plate connector 1520 is electrically coupled to a negative terminal connector 1526 (see also FIG. 4). In the illustrated embodiment of FIG. 3, positive plate connector 1510 is electrically coupled to positive terminal connector 1516 via positive pin 1518 on the first positive stud 1066A. Similarly, negative plate connector 1520 is electrically coupled to negative terminal connector 1526 via negative pin 1528 on the last negative stud 1068H.

[0045] Referring still to FIG. 3, the couplings between positive terminal connector 1516 and positive pin 1518 and between negative terminal connector 1526 and negative pin 1528 illustratively occur within an insulating cover 1530 on module 1500. More specifically, the couplings occur through first and second openings 1532, 1534 of cover 1530, respectively. Terminal connectors 1516, 1526 may be keyed to openings 1532, 1534 of cover 1530. In the illustrated embodiment of FIG. 3, each terminal connector 1516, 1526 includes two radial keys 1536 oriented at 12 o'clock and 6 o'clock and each opening 1532, 1534 includes two corresponding radial key slots 1538. Keys 1536 and key slots 1538 cooperate to limit terminal connectors 1516, 1526 to a first, rightward-pointing orientation relative to cover 1530 (shown with respect to positive terminal connector 1516 in FIG. 3) and a second, leftward-pointing orientation relative to cover 1530 (shown with respect to negative terminal connector 1526 in FIG. 3). Limiting the orientation of terminal connectors 1516, 1526 relative to cover 1530 may assist an operator in making accurate electrical connections for module 1500, such as by preventing an external coupling between positive pin 1518 and negative pin 1528 that would cause module 1500 to internally short. Limiting the orientation of terminal connectors 1516, 1526 relative to cover 1530 may also prevent terminal connectors 1516, 1526 from spinning in or separating from cover 1530.

[0046] The coupling between cover 1530 and supports 1002A-1002H of module

1500 is shown in FIG. 6. Cover 1530 is illustratively received within the stacked pockets 1073 of supports 1002A-1002H. Cover 1530 may be held in place within pockets 1073 with rails 1540 on each side of cover 1530 that fit into corresponding grooves or recesses 1542 in supports 1002A-1002H. Fasteners (not shown) may also be used to secure cover 1530 to one or more supports 1002A-1002H. As shown in FIG. 6, a plane P containing the outer surface 1531 of cover 1530 is generally aligned with the outer envelope of module 1500 defined by handles 1070. Also, as discussed further below, tips 1572 of positive pin 1518 and negative pin 1528 are positioned at or behind the plane P, and at or behind the outer envelope of module 1500 defined by handles 1070.

[0047] The coupling between positive terminal connector 1516 and positive pin

1518 through opening 1532 of cover 1530 is shown in FIG. 7. Negative terminal connector 1526 and negative pin 1528 may be identical to positive terminal connector 1516 and positive pin 1518, respectively, so negative terminal connector 1526 and negative pin 1528 are not shown in FIG. 7.

[0048] Positive terminal connector 1516 of FIG. 7 includes socket 1550 that is sized to receive positive pin 1518, as described further below. In one embodiment, socket 1550 utilizes RADSOK^® technology to receive and electrically interact with positive pin 1518. RADSOK^® brand connectors are available from Amphenol of Wallingford, Connecticut. Although socket 1550 is shown herein as having a continuous, solid construction, it is also within the scope of the present disclosure that socket 1550 may include a plurality of spaced-apart fingers arranged in a generally circular pattern, for example. Positive terminal connector 1516 also includes a flexible, internal protrusion 1552. Normally, the internal protrusion 1552 may be biased radially inward from socket 1550 toward positive pin 1518. When necessary, the biasing force of the internal protrusion 1552 may be overcome to move the internal protrusion 1552 radially outward and away from positive pin 1518, as discussed further below. The internal protrusion 1552 may be in the form of one or more flexible wires located inside socket 1550. Similar sockets 1550 are commercially available as SurLok™ type RADSOK^® connectors. The internal protrusion 1552 may also be in the form of a flexible disc (e.g., a mylar disc) or another suitable structure located within socket 1550. The internal protrusion 1552 may be less than about 0.5 mm or 1 mm thick to provide the necessary flexibility.

[0049] Positive terminal connector 1516 further includes lug 1554 electrically coupled to socket 1550 and cable 1556 electrically coupled to lug 1554, such as by crimping lug 1554 around cable 1556. An insulating housing 1558 is provided around socket 1550 and lug 1554. Housing 1558 may cover at least the portions of socket 1550 and lug 1554 that will be exposed outside of cover 1530, for example. According to an exemplary embodiment of the present disclosure, housing 1558 is overmolded onto socket 1550 and lug 1554 to encapsulate portions of socket 1550 and lug 1554 therein, which may improve the ingress protection (IP) rating, creepage, and clearance of positive terminal connector 1516. It is also within the scope of the present disclosure that housing 1558 may be a separate, hinged piece that is closed and locked (e.g., snapped) around socket 1550 and lug 1554.

[0050] In FIG. 7, housing 1558 includes a handle 1560 to facilitate removal of positive terminal connector 1516 from cover 1530. More specifically, handle 1560 facilitates removal of socket 1550 from cover 1530. The illustrative handle 1560 is longitudinally aligned with socket 1550 and with opening 1532 of cover 1530 along axis A. This longitudinal arrangement facilitates the smooth transfer of a user's axial pulling force on handle 1560 along axis A to socket 1550 without having to bend or twist positive terminal connector 1516. The illustrative handle 1560 also includes raised ribs 1562 (FIG. 3) oriented normal to axis A for improved gripping and pulling along axis A, as well as an aperture 1564 for connection to an optional pull ring, for example.

[0051] Positive pin 1518 of FIG. 7 is electrically coupled to socket 1550 of positive terminal connector 1516. Positive pin 1518 includes a first end or base 1570 that is electrically coupled to positive stud 1066A, and a second end or tip 1572 that extends into socket 1550. In FIG. 7, base 1570 of positive pin 1518 is internally threaded to receive and engage the externally threaded positive stud 1066A. Tip 1572 of positive pin 1518 includes an annular groove 1574. Normally, the internal protrusion 1552 from socket 1550 may be biased into groove 1574 of positive pin 1518 to lock socket 1550 onto positive pin 1518. In this embodiment, the internal protrusion 1552 and groove 1574 may serve as a locking means between positive pin 1518 and socket 1550. The user may feel or otherwise sense when the internal protrusion 1552 has engaged groove 1574 to lock socket 1550 onto positive pin 1518. When it becomes necessary to separate positive terminal connector 1516 from positive pin 1518, handle 1560 may be pulled with a sufficient pull-off force to overcome the biasing force of the internal protrusion 1552, thereby freeing the internal protrusion 1552 from groove 1574 of positive pin 1518. The pull-off force may be high enough to avoid accidental separation between positive terminal connector 1516 and positive pin 1518, but low enough to permit manual separation by a user, when desired. For example, the pull-off force may be between about 5 and 20 pounds, and more specifically between about 10 and 15 pounds. [0052] According to an exemplary embodiment of the present disclosure, positive pin 1518 and negative pin 1528 are protected against accidental contact by a user. In FIG. 7, cover 1530 is sufficiently deep to cover tip 1572 of positive pin 1518. In this embodiment, tip 1572 of positive pin 1518 is positioned at or behind a plane P containing the outer surface 1531 of cover 1530. Stated differently, tip 1572 of positive pin 1518 is positioned flush or sub-flush relative to outer surface 1531 of cover 1530. In this embodiment, cover 1530 may serve as a covering means for positive pin 1518. If positive pin 1518 projects about 40 mm from module 1500, for example, outer surface 1531 of cover 1530 may be located more than about 40 mm from module 1500, such as about 42 mm, 44 mm, or 46 mm from module 1500, or more. Because tip 1572 of positive pin 1518 is recessed within cover 1530, the interactions between socket 1550 and positive pin 1518 may also occur within cover 1530. In FIG. 7, for example, the interaction between internal protrusion 1552 of socket 1550 and groove 1574 of positive pin 1518 occur within cover 1530 and behind the plane P containing the outer surface 1531 of cover 1530. Positive terminal connector 1516 is illustratively located on both sides of the plane P - a first portion of positive terminal connector 1516 (e.g., handle 1560) being exposed in front of the plane P for access by a user, and a second portion of positive terminal connector 1516 being concealed behind the plane P for electrical contact with positive pin 1518. [0053] Positive pin 1518 and negative pin 1528 may also be protected against accidental contact by covering tip 1572 with an insulating shield or cover 1576 (e.g., a plastic shield), as shown in FIG. 7. The insulating cover 1576 may deaden tip 1572 of positive pin 1518. In this embodiment, insulating cover 1576 may serve as another covering means for positive pin 1518. However, the insulating cover 1576 may leave the majority of positive pin 1518 exposed (e.g., the portion of positive pin 1518 located between groove 1574 and base 1570) for electrical contact with socket 1550.

[0054] The above-described covers 1530, 1576 may shield positive pin 1518 and negative pin 1528, especially when positive terminal connector 1516 and negative terminal connector 1526 are not in place. Thus, covers 1530, 1576 may facilitate safe interactions with positive pin 1518 and negative pin 1528, such as when attaching and/or removing positive terminal connector 1516 and negative terminal connector 1526, respectively.

[0055] The assembled battery module 1500 may be placed in a suitable enclosure (not shown). Exemplary enclosures are shown and described in US Provisional Patent Application Serial No. 61/678,258, filed August 1, 2012, titled MODULAR ENERGY STORAGE SYSTEM, the disclosure of which is expressly incorporated by reference herein in its entirety. The enclosure may store multiple battery modules, as well as a high voltage module, a low voltage module, and a controller, for example. Exemplary high voltage and low voltage modules are disclosed in the above-incorporated US Provisional Patent Application Serial No. 61/486, 151. It is also within the scope of the present disclosure to place individual battery supports 1002 or grouped battery modules 1500 on racks in the enclosure. Thermal management systems may also be provided to cool the battery modules 1500 with air, liquid, or refrigerant, for example. [0056] The battery arrangements disclosed herein may be coupled together to form battery strings. The processing sequences disclosed in the above -incorporated US Provisional Patent Application Serial No. 61/486, 151 and PCT Application No.

PCT/USl 1/52169 may be used to monitor and control the operation of the battery arrangements disclosed herein. Also, the trays disclosed herein may replace the drawers in the illustrated embodiment disclosed in the above-incorporated US Provisional Patent Application Serial No. 61/486,151 and PCT Application No. PCT/USl 1/52169 to provide the battery power of the energy modules.

[0057] While this invention has been described as having exemplary designs, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A battery assembly comprising:

a tray;

a plurality of battery cells supported by the tray;

at least one terminal pin in electrical communication with the plurality of battery cells, the at least one terminal pin having a first locking feature;

at least one terminal connector having a socket, the socket being removably coupled to the at least one terminal pin, the socket having a second locking feature that cooperates with the first locking feature to lock the socket onto the at least one terminal pin in electrical communication with the at least one terminal pin; and

an insulating cover coupled to the tray, the cover having an outer surface, the at least one terminal pin being located at or behind a plane containing the outer surface of the cover.

2. The battery assembly of claim 1, wherein the plurality of battery cells are arranged in a side-by-side configuration on the tray.

3. The battery assembly of claim 1, wherein the tray extends under a middle portion of each of the plurality of battery cells.

4. The battery assembly of claim 3, wherein the middle portions of the plurality of battery cells are arranged in a non-overlapping configuration.

5. The battery assembly of claim 1, wherein a first portion of the at least one terminal connector is located forward of the plane and a second portion of the at least one terminal connector is located behind the plane.

6. The battery assembly of claim 1, wherein the first and second locking features are located behind the plane.

7. The battery assembly of claim 1, wherein the first and second locking features include a flexible protrusion and a groove.

8. The battery assembly of claim 1, wherein the cover defines at least one opening for removably receiving the at least one terminal connector.

9. The battery assembly of claim 8, wherein the at least one terminal connector is keyed to the at least one opening of the cover.

10. The battery assembly of claim 1, wherein the at least one terminal connector includes a handle, the handle being longitudinally aligned with the socket.

11. A battery assembly comprising:

a tray;

a plurality of battery cells supported by the tray;

at least one terminal pin in electrical communication with the plurality of battery cells;

at least one terminal connector having a socket, the socket being removably coupled to the at least one terminal pin;

a locking means for locking the socket onto the at least one terminal pin in electrical communication with the at least one terminal pin; and

an insulating covering means for covering the at least one terminal pin.

12. The battery assembly of claim 11, wherein the locking means comprises a flexible protrusion and a groove, the flexible protrusion extending radially inward from the socket and into the groove.

13. The battery assembly of claim 11, wherein the locking means is configured to withstand an axial force on the at least one terminal connector of about 10 to 15 pounds.

14. The battery assembly of claim 11, wherein the covering means is coupled to the tray to surround the at least one terminal pin and the at least one terminal connector.

15. The battery assembly of claim 11, wherein the covering means surrounds a tip of the at least one terminal pin.

16. A battery assembly comprising :

a tray;

a plurality of battery cells supported by the tray;

at least one terminal pin in electrical communication with the plurality of battery cells; and

at least one terminal connector having a socket and a handle longitudinally aligned with the socket, the socket being removably coupled to the at least one terminal pin for electrical communication with the at least one terminal pin.

17. The battery assembly of claim 16, wherein the socket is removable from the at least one terminal pin by pulling the handle along a longitudinal axis of the socket.

18. The battery assembly of claim 16, further comprising an insulating cover coupled to the tray to cover the at least one terminal pin, the handle being located outside of the cover when the socket is coupled to the at least one terminal pin.

19. The battery assembly of claim 18, wherein the at least one terminal pin is located inside the cover.

20. The battery assembly of claim 16, wherein the handle is overmolded onto the socket.

21. A battery assembly comprising :

a battery support having an outer envelope and at least one battery positioned within the outer envelope; an electrically conductive terminal positioned within the outer envelope, electrically coupled to the at least one battery, and accessible from an exterior of the outer envelope, the electrically conductive terminal defining a first longitudinal axis; and

an electrical connector removably coupled to the electrically conductive terminal, the electrical connector comprising:

an electrically conductive portion defining a second longitudinal axis, the electrically conductive portion being received within the outer envelope along the first longitudinal axis into a pocket formed between the electrically conductive terminal and the battery support;

an electrical cable electrically coupled to the electrically conductive portion;

a housing covering at least a portion of the electrical cable and the electrically conductive portion; and

a handle positioned along the second longitudinal axis.

22. The battery assembly of claim 21, further comprising an insulating tip supported by the electrically conductive terminal, the insulating tip being positioned within the outer envelope.

23. The battery assembly of claim 21, wherein the second longitudinal axis is parallel with the first longitudinal axis when the electrically conductive portion is received within the outer envelope along the first longitudinal axis.

24. The battery assembly of claim 21, wherein the electrically conductive portion is a socket.

25. The battery assembly of claim 21, wherein the handle is part of the housing.

26. The battery assembly of claim 21, wherein the handle includes ribs oriented generally normal to the second longitudinal axis.