Delphi Technologies, Inc.

Enerdel, Inc.

Aptiv Technologies Limited

Delphi Technologies IP Limited

Robert C Beer

Duane D Kruger

Brad T Hanauer

Christopher E Schaefer

Kevin J Hawes

Thomas Hubert Van Steenkiste

Christopher Adrian Margrave

Dominic Anthony Messuri

Robert Anthony Lawrence

Michael L Mellott

Leslie L Jones

Mark D McCall

Raymond J Blasko

Hoi Lui

Jerry Wendling

John L Wicks

Dane E Carter

Jeffrey J Ronning

Ryan K Rossiter

Adam M Kemp

Robert Thomas Wendling

James P Cykon

John M Sova

David L Brown

Ajay Bhargava

Michael C Wolczak

James Okrucky

Richard E Teets

Michael L Phifer

Joseph Gregory Tackett

Scott A Keener

Matthew S Carrell

Mark A Ebenhart

Timothy N Pulliam

A radar unit includes a printed circuit board (PCB) supporting an integrated circuit (IC) chip. A radome is arranged over the IC chip. A spring engages the IC chip and the radome. The spring is configured to transfer thermal energy between the IC chip and the radome.

Radar unit with thermal transfer via radome

A framed lithium battery cell group includes a first frame member () and a second frame member (). The frame members are locked together, clamping the lithium battery cell pack () on the seal edge surfaces (), thereby providing structural rigidity and protection from damage due to handling and vibration. Each of the frame members () has multiple pins () and sockets () on the side opposite the clamping surface () to facilitate aligning and stacking multiple lithium battery cell pack and frame assemblies to form a lithium battery cell group (). Each of the frame members () include a buss bar capture feature () having a bus bar () inserted therein for electrically connecting all of the terminals for a given lithium battery pack group to the buss bar ().

Apparatus and method for securing battery cell packs

An electronics module that includes a printed circuit board (PCB), a connector, a housing with a shroud, and an interposer. The PCB defines a plane of the PCB. The connector is coupled to the PCB to form a circuit board assembly (CBA). The connector includes a plurality of header pins oriented perpendicular to the plane. The housing is configured to receive the CBA. The housing is configured to define an opening in a wall of the housing proximate to the connector when the CBA is installed. The wall is characterized as perpendicular to the plane. The interposer is configured to couple to the housing. The interposer includes a plurality of mating pins oriented parallel to the plane. Each of the mating pins defines a forked end configured to make electrical contact with each of the header pins when the interposer is inserted into the opening.

Electronics module with a side entry connection

A complex wave spring, or Beer Spring&#x2122;, for electrically coupling opposed electrical contact surfaces or generating a relatively constant force. The spring includes a first wave portion shaped to define a first upward undulation and a first downward undulation, and a second wave portion fixedly arranged relative to the first wave portion. The second wave portion is shaped to define a second upward undulation proximate to the first downward undulation, and a second downward undulation proximate to the first upward undulation. The spring may be formed of electrically conductive material suitable for electrically coupling electrical contact surfaces when the spring is in contact between the surfaces. The complex spring provides unusually constant spring forces over a relatively wide range of compression distances.

Complex wave spring

A printed circuit board supported over the top surface of a multi-cell battery module for battery cell voltage and temperature monitoring has an array of openings in alignment with selected battery cells for receiving temperature-sensing units that electrically couple with contacts formed on the printed circuit board and resiliently engage the cases of the selected battery cells. Each such temperature-sensing unit includes a printed circuit board mountable lamp socket and a lamp socket insert including a thermistor and a compressible element that maintains the thermistor in thermal proximity to the battery cell case when the temperature-sensing unit is installed in a respective printed circuit board opening.

Cell temperature sensing apparatus for a battery module

A prismatic-cell battery pack is provided with integral coolant passages including an intake plenum, an exhaust plenum, and a distributed array of coolant channels coupled between the intake plenum and the exhaust plenum. Coolant medium forced into the intake plenum enters the coolant channels in parallel, draws heat away from the battery cells, and then enters the exhaust plenum for expulsion into the atmosphere. The battery pack is configured as a set of stackable interlocking battery cell modules including at least one battery cell in thermal proximity to an array of coolant channels distributed over the profile of the battery cell, and a pair of peripheral chambers joined to opposite ends of the coolant channels to form the intake and exhaust plenums when the modules are arranged and interlocked in a lineal stack.

Prismatic-cell battery pack with integral coolant passages

A process for physically bonding two parts to each other is disclosed. In addition, a process for forming electrical connections have a low resistance is disclosed. The process is generally applicable to the joining of two parts each formed from a metal, an alloy, or a combination thereof. The process finds special use in the formation of multi-celled batteries. The process involves placing two parts or electrical conductors in contact with each other and then bonding them to each other using a kinetic spray process and powder particles. In formation of a multi-celled battery the particles are preferably electrically conductive. The process enables for rapid and cost effective formation of a physical connection. In addition, the connection can have an electrical resistance of less than about 0.5 milli Ohms and strength equal or greater than ultrasonic welding. The process has the advantage of being a low temperature process thereby lowering the risk of thermal damage to the parts or cells of a multi-cell battery during formation of the connection.

Secure physical connections formed by a kinetic spray process

An interlock plate slidably affixed to a multi-bay connector header ensures a preordained connection sequence of multiple plug-in connectors. The interlock plate covers portions of the connector header, and can move with respect to the connector header to prevent access to selected bays of the header. When in a base position, the interlock plate allows insertion of one or more make-first/break-last connector plugs, but blocks insertion of one or more make-last/break-first connector plugs. When in a shifted position, the interlock plate prevents removal of the inserted make-first/break-last connector plug(s), and allows insertion of the make-last/break-first connector plug(s). Insertion of the make-last/break-first connector plug(s) locks the interlock plate in the shifted position, so that the make-last/break-first connector plug(s) must be removed prior to the make-first/break-last connector plug(s).

Multi-connector apparatus with connection-sequencing interlock mechanism

A pressure connection apparatus includes a conductive spring member having first and second end portions that are curved, and first and second retaining members having curved pockets that are oppositely oriented for receiving the first and second curved ends of the conductive spring member. An aluminum foil terminal of one battery is sandwiched between the conductive spring and the pocket of the first retaining member, while a copper foil terminal of another battery is sandwiched between the conductive spring and the pocket of the second retaining member. The spring member is clad with aluminum on one side and copper on the other, and the end portions are oppositely curved so that the aluminum-clad side contacts the aluminum foil terminal within the pocket of the first retaining member, and the copper-clad side contacts the copper foil terminal within the pocket of the second retaining member.

Terminal connection apparatus for battery cells having foil terminals

A voltage tap apparatus functions as both a voltage tap and a cell isolator for conductive case battery cells that are joined end-to-end in a series chain. The apparatus includes conductive leadframe elements partially encased in a plastic frame that engages the joined cells about their juncture, with portions of the lead-frame elements exposed to electrically contact the conductive cases of the cells. In a first embodiment, the plastic frame is in the form of a hinged clamp that closes about the juncture of the cells, and the lead-frame elements are routed to terminals formed on one end of the frame. In a second embodiment, the plastic frame and a connector are mounted on a printed circuit board and the leadframe elements in the plastic frame couple the battery cells to the connector.

Voltage tap apparatus for series connected conductive case battery cells

A filtered electrical connector for a power module comprises a connector body having a back wall partly defining a chamber at one end of the connector body. An alternating current filter is retained in the chamber, and a terminal extends through the back wall, the chamber, and the alternating current filter disposed in the chamber. The filtered electrical connector is attached to a housing having a metal portion with the chamber disposed in a pass-through hole of the housing. The terminal is attached to an electrical circuit inside the housing and the alternating current filter is grounded on the metal portion of the housing to filter alternating current flowing outside of the housing from the electrical circuit inside the housing via the terminal.

Filtered electrical connector and combination having same

An electrical connector has a connect or shroud. A pin block disposed in the connector body supports a plurality of terminal pins that have head portions projecting out a forward end of the pin block and tail portions projecting out a rearward end of the pin block. The connector shroud has a socket at a forward end that receives a terminal stabilizer that is locked to the pin block to hold the terminal stabilizer and the pin block in assembly with the connector shroud to form a module. The module may include a block seal that can be sandwiched between the terminal stabilizer and the pin block during assembly of the module. The rear end of the connector shroud is truncated at an angle for a direct top down assembly of the module to a housing that has an attachment collar that is truncated at the same angle. The pin terminal tail portions are bent at a right angle and project through holes in a pin alignment member and a printed circuit board that are mounted inside the housing.

Electrical connector

A battery assembly is designed to include a plurality of cells positioned parallel to each other. A frame including end supports position the cells appropriately. Each of the cells includes a first terminal and a second terminal. Two buses are positioned over all of the first terminals and all of the second terminals. Each of the buses includes slots allowing the terminals to extend therethrough. Once through, the terminals are bent over the bus bar. A slide is then positioned over the terminals protecting the terminals and maintaining the terminals in electrical contact with each other. This battery assembly allows more than three cells to be connected to each other and is versatile enough to allow the removal of certain cells to enhance the airflow through the battery assembly.

Battery assembly and method of making same

The present invention includes a low insertion force connector assembly capable of providing an electrical interface to a circuit board. The connector assembly includes a housing and electrically conductive terminals mounted in the housing. The connector assembly further includes slide and wedge members which are inserted into the housing along with a connective end portion of a flexible flat cable pressing exposed conductors on the flexible flat cable against terminal contact arms.

Low insertion force connector

A high current circuit disconnect system includes a fuse, current limiting resistor, a manual disconnection unit, and a holder having a pair of connections for connecting the high current disconnect system to an electrical circuit. The manual disconnection unit is wired in series with the fuse and provides a user selectable circuit interrupt. A first portion of the manual disconnection unit is located in the holder, while a second portion thereof is selectively connectable to the first portion, wherein when in the connected state the path therethrough is closed, but when in the disconnected state, the path therethrough is open. The current limiting resistor is wired in parallel with the manual disconnection unit, and also in series with the fuse.

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Noblesville, IN, United States of America

Robert C Beer