WO2024072277A1 - Electrical connector, pair of electrical connectors, battery pack, and vehicle - Google Patents

Electrical connector, pair of electrical connectors, battery pack, and vehicle Download PDF

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Publication number
WO2024072277A1
WO2024072277A1 PCT/SE2023/050871 SE2023050871W WO2024072277A1 WO 2024072277 A1 WO2024072277 A1 WO 2024072277A1 SE 2023050871 W SE2023050871 W SE 2023050871W WO 2024072277 A1 WO2024072277 A1 WO 2024072277A1
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WO
WIPO (PCT)
Prior art keywords
electrical connector
electrical
contact surface
contact
pair
Prior art date
Application number
PCT/SE2023/050871
Other languages
French (fr)
Inventor
Achraf Dirhoussi
Original Assignee
Scania Cv Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Scania Cv Ab filed Critical Scania Cv Ab
Publication of WO2024072277A1 publication Critical patent/WO2024072277A1/en

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02Contact members
    • H01R13/22Contacts for co-operating by abutting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00Electric propulsion with power supplied within the vehicle
    • B60L50/50Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64Constructional details of batteries specially adapted for electric vehicles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/62Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
    • H01R13/6205Two-part coupling devices held in engagement by a magnet
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00Connectors or connections adapted for particular applications
    • H01R2201/26Connectors or connections adapted for particular applications for vehicles

Definitions

  • the present disclosure relates to an electrical connector configured to electrically connect to a second electrical connector when pressed against the second electrical connector along an engagement axis.
  • the present disclosure further relates to a pair of electrical connectors comprising a first electrical connector and a second electrical connector.
  • the present disclosure relates to a battery pack comprising a pair of electrical connectors, as well as a vehicle comprising an electrical connector.
  • Assembly lines are commonly used in industry when assembling complex items, such as for example vehicles and other transportation equipment, household appliances, electronic goods, and the like.
  • An assembly line is a process in which components, arrangements, and systems are assembled to a semi-finished assembly which is transported between different working stations at which components, arrangements, and systems are mounted in sequence to the semi-finished assembly to eventually form the final product.
  • Many vehicle manufacturers utilize assembly lines when assembling vehicles, and in the vehicle industry, such an assembly line is sometimes referred to as a final assembly line.
  • Assembly lines can significantly reduce assembling costs and assembly times of products, such as vehicles. Assembly steps at an assembly line may be performed manually by an assembler or by an assembling machine, such as an industrial robot. Assembling machines, such as industrial robots, are usually preferred over manual assembly by assemblers, because of the speed and precision of assembling machines, and because they can replace burdensome tasks.
  • Modern vehicles comprise numerous electrical devices and subsystems. Moreover, the current trend of electrification has increased the number of electrical devices and subsystems considerably. Such electrical devices and subsystems are commonly connected to an electrical system of the vehicle using a pair of electrical connectors.
  • one electrical connector of the pair of electrical connectors comprises a number of metal pins configured to be inserted into small recessed holes provided with metal parts, such as metal sleeves, or the like, arranged in the other electrical connector.
  • the electrical connector comprising the number of metal pins is commonly referred to as a male connector whereas the electrical connector comprising the number of recessed holes is commonly referred to as a female connector.
  • the error margin of an assembling machine is usually a too high for electrically connecting electrical connectors in a reliable and consistent manner.
  • an industrial robot may have an error margin of about one millimetre which is usually enough to hinder a reliable and consistent connection of two electrical connectors.
  • the tolerances of electrical connectors are usually too high for allowing a more precise assembling machine, such as an industrial robot, to connect two electrical connectors in a reliable and consistent manner. Therefore, electrical connectors are usually connected to each other manually by an assembler at working stations of modern assembly lines. This adds assembling costs to the final product and increases the assembly time thereof.
  • a further problem associated with electrical connectors is to ensure that the electrical connection provided by an electrical connector is reliable when the electrical connector is connected to another electrical connector. If the electrical connection fails, it may have a critical impact on the functionality of the product.
  • the object is achieved by an electrical connector configured to electrically connect to a second electrical connector when pressed against the second electrical connector along an engagement axis.
  • the electrical connector comprises a connector body, and a number of contact elements attached to the connector body.
  • Each contact element of the number of contact elements comprises a contact surface configured to abut against a respective contact surface of the second electrical connector.
  • each contact surface is movably arranged relative to the connector body in directions perpendicular to the engagement axis and each contact element of the number of contact elements comprises a magnetised portion at the contact surface.
  • an electrical connector having conditions to be connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface is movably arranged relative to the connector body in directions perpendicular to the engagement axis and because each contact element of the number of contact elements comprises a magnetised portion at the contact surface.
  • the electrical connector can be electrically connected to the second electrical connector by being pressed against the second electrical connector at a slight offset from an engagement axis of the second electrical connector. This is because each contact surface can move relative to the connector body in directions perpendicular to the engagement axis of the electrical connector to compensate for the offset while the magnetised portions at the contact surfaces can provide an attractive force with contact surfaces of the second electrical connector to ensure an abutting contact between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector.
  • an electrical connector having conditions to be connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, the electrical connector has conditions for reducing manufacturing and assembling costs of products, such as vehicles. Furthermore, an electrical connector is provided having conditions for reducing manufacturing times of products, such as manufacturing times of vehicles.
  • the electrical connector since the electrical connector has conditions for being connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, an electrical connector is provided allowing less free space around the electrical connector in a product comprising the electrical connector. Accordingly, in this manner, the electrical connector provides conditions for more space for other components or parts of the product comprising the electrical connector, which also facilitates the design of the product comprising the electrical connector.
  • each contact element of the number of contact elements comprises the magnetised portion at the contact surface, a stronger and more reliable electrical connection can be ensured between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector also when the electrical connectors are connected to each other. This is because the magnetised portions can increase the normal forces between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector. In this manner, the electrical connector has conditions for improving reliability of a product, such as a vehicle, comprising the electrical connector.
  • an electrical connector is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.
  • the contact surface of each contact element is biased in a direction coinciding with a surface normal of the contact surface.
  • an electrical connector is provided having conditions for being connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, while an even stronger and more reliable electrical connection can be ensured between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector when the electrical connectors are connected to each other. This is because the normal forces between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector are increased when the electrical connectors are connected to each other.
  • each contact element is configured to abut against a contact surface of the second electrical connector along a plane being substantially parallel to the engagement axis.
  • an electrical connector is provided having conditions for being connected to the second electrical connector in an even more reliable and consistent manner by an assembling machine, such as an industrial robot.
  • each contact surface can be moved in an efficient manner relative to the connector body by an abutting contact against a contact surface of a second electrical connector to compensate for an offset during a connection procedure between the electrical connectors.
  • each contact element comprises an attachment portion and a connecting portion connecting the contact surface to the attachment portion, and wherein each contact element is attached to the connector body via the attachment portion thereof.
  • an electrical connector is provided having conditions for being connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, while having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner.
  • each contact element biases the contact surface in a direction coinciding with a surface normal of the contact surface.
  • an electrical connector is provided having conditions for being connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, while an even stronger and more reliable electrical connection can be ensured between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector when the electrical connectors are connected to each other. This is because the normal forces between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector are increased when the electrical connectors are connected to each other.
  • an electrical connector is provided having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner.
  • the attachment portion, the connecting portion, and the contact surface are formed by one piece of continuous material.
  • an electrical connector is provided having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner.
  • an electrical connector is provided having conditions for a strong and reliable electrical connection when the electrical connector is connected to a second electrical connector.
  • the attachment portion, the connecting portion, and the contact surface are formed by bending of one piece of a sheet metal material.
  • an electrical connector is provided having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner.
  • an electrical connector is provided having conditions for a strong and reliable electrical connection when the electrical connector is connected to a second electrical connector.
  • each contact element is substantially flat.
  • an electrical connector is provided having conditions for being connected to the second electrical connector in an even more reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface can be moved in an efficient manner relative to the connector body by an abutting contact against a contact surface of a second electrical connector to compensate for an offset during a connection procedure between the electrical connectors.
  • each contact element since the contact surface of each contact element is substantially flat, it can be ensured that a large proportion of each contact surface abuts against a contact surface of the second electrical connector when the electrical connector is connected to the second electrical connector. It this manner, a strong and reliable electrical connection can be ensured when the electrical connector is connected to the second electrical connector.
  • the electrical connector comprises two or more contact elements arranged in a row, and wherein the magnetised portion of each adjacent pair of contact elements has opposite polarity.
  • an electrical connector is provided capable of providing an attractive force between each contact surface and a matching contact surface of a second electrical connector intended for connection, while providing a repelling force between each the contact surface and one or two adjacent non-matching contact surfaces of the second electrical connector.
  • an electrical connector is provided having conditions for being connected to the second electrical connector in an even more reliable and consistent manner by an assembling machine, such as an industrial robot.
  • an electrical connector is provided having conditions for a strong and reliable electrical connection when the electrical connector is connected to the second electrical connector.
  • the electrical connector is configured to provide an electrical connection between different components of a vehicle when connected to the second electrical connector.
  • an electrical connector is provided having conditions to be connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, for providing an electrical connection between different components of a vehicle.
  • an electrical connector is provided having conditions for reducing manufacturing and assembling costs of vehicles.
  • an electrical connector is provided having conditions for reducing manufacturing times of vehicle.
  • an electrical connector is provided allowing less free space around the electrical connector in a vehicle comprising the electrical connector. Accordingly, in this manner, the electrical connector provides conditions for more space for other components or parts of the vehicle comprising the electrical connector.
  • each contact element of the number of contact elements comprises the magnetised portion at the contact surface
  • the electrical connector has conditions for improving reliability of the vehicle.
  • the object is achieved by a pair of electrical connectors comprising a first electrical connector and a second electrical connector, wherein the first electrical connector is configured to electrically connect to the second electrical connector when the first and second electrical connectors are pressed against each other along an engagement axis to an engagement position.
  • Each of the first and second electrical connectors comprises a connector body, and a number of contact elements attached to the connector body, wherein each contact element of the first electrical connector comprises a contact surface configured to abut against a respective contact surface of the contact elements of the second electrical connector.
  • each contact surface of the first electrical connector is movably arranged relative to the connector body in directions perpendicular to the engagement axis, each contact element of the first electrical connector comprises a magnetised portion at the contact surface.
  • each contact surface of the first electrical connector is movably arranged relative to the connector body in directions perpendicular to the engagement axis and because each contact element of the first electrical connector comprises a magnetised portion at the contact surface.
  • the first and second electrical connectors can be connected by being pressed against each other at a slight offset from the engagement axis. This is because each contact surface of the first electrical connector can move relative to the connector body in directions perpendicular to the engagement axis to compensate for the offset while the magnetised portions at the contact surfaces of the first electrical connector can provide an attractive force with contact surfaces of the second electrical connector to ensure an abutting contact between the contact surfaces of the contact elements of the first electrical connector and the contact surfaces of the second electrical connector.
  • the pair of electrical connectors has conditions to be connected in a reliable and consistent manner by an assembling machine, such as an industrial robot, a pair of electrical connectors is provided having conditions for reducing manufacturing and assembling costs of products, such as vehicles. Furthermore, a pair of electrical connectors is provided having conditions for reducing manufacturing times of products, such as manufacturing times of vehicles.
  • the pair of electrical connectors since the pair of electrical connectors has conditions to be connected in a reliable and consistent manner by an assembling machine, such as an industrial robot, a pair of electrical connectors is provided allowing less free space around the pair of electrical connectors in a product comprising the pair of electrical connectors. Accordingly, in this manner, the pair of electrical connectors provides conditions for more space for other components or parts of the product comprising the pair of electrical connectors, which also facilitates the design of the product.
  • the pair of electrical connectors has conditions for improving reliability of a product, such as a vehicle, comprising the pair of electrical connectors.
  • a pair of electrical connectors is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above- mentioned object is achieved.
  • each contact element of the second electrical connector comprises a magnetised portion at the contact surface thereof.
  • a pair of electrical connectors is provided having conditions for being connected in an even more reliable and consistent manner by an assembling machine, such as an industrial robot, while an even stronger and more reliable electrical connection can be ensured between the contact surfaces of the pair of electrical connectors when the pair of electrical connectors is in the engaged position.
  • the magnetised portion at the contact surfaces of the contact elements of the second electrical connector can increase the attractive force between the contact surfaces of the pair of electrical connectors.
  • the polarity of the magnetised portions of the pair of electrical connectors are oriented such that an attractive force is obtained between each pair of opposing of magnetised portions when the pair of electrical connectors is in the engagement position.
  • a pair of electrical connectors having conditions for being connected in an even more reliable and consistent manner by an assembling machine, such as an industrial robot, while an even stronger and more reliable electrical connection can be ensured between the contact surfaces of the pair of electrical connectors when the pair of electrical connectors is in the engaged position.
  • each contact surface of the second electrical connector is movably arranged relative to the connector body of the second electrical connector in directions perpendicular to the engagement axis.
  • a pair of electrical connectors is provided having conditions for being connected in an even more reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface of the second electrical connector can move relative to the connector body of the second electrical connector in directions perpendicular to the engagement axis to compensate for an offset when the first and second electrical connectors are pressed against each other to the engagement position.
  • the object is achieved by a battery pack configured to provide electricity to an electric propulsion motor of a vehicle, wherein the battery pack comprises at least two layers of battery cells and a pair of electrical connectors according to some embodiments of the present disclosure, and wherein the pair of electrical connectors is configured to electrically connect components arranged in two different layers of battery cells of the battery pack.
  • the battery pack comprises a pair of electrical connectors according to some embodiments
  • a battery pack is provided in which the pair of electrical connectors can be connected, i.e., pressed to the engaged position, in a reliable and consistent manner by an assembling machine, such as an industrial robot.
  • a battery pack is provided having conditions for reduced manufacturing and assembling costs. Furthermore, a battery pack is provided having conditions for reduced manufacturing times thereof.
  • the battery pack comprises a pair of electrical connectors according to some embodiments, a battery pack is provided allowing less free space around the pair of electrical connectors. Accordingly, in this manner, more space is available for other components or parts in the battery pack, which also facilitates the design of the battery pack.
  • the battery pack comprises a pair of electrical connectors according to some embodiments, a battery pack is provided having conditions for being reliable.
  • a battery pack is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.
  • the object is achieved by a vehicle comprising an electrical connector according to some embodiments of the present disclosure, a pair of electrical connectors according to some embodiments of the present disclosure, or a battery pack according to some embodiments of the present disclosure.
  • the vehicle comprises an electrical connector according to some embodiments of the present disclosure, a pair of electrical connectors according to some embodiments of the present disclosure, or a battery pack according to some embodiments of the present disclosure, a vehicle is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.
  • Fig. 1 schematically illustrates a pair of electrical connectors according to some embodiments
  • Fig. 2 schematically illustrates a cross section through an electrical connector illustrated in Fig. 1
  • Fig. 3 schematically illustrates a perspective view of a number of contact elements of a first electrical connector and a number of contact elements of a second electrical connector
  • Fig. 4 schematically illustrates a cross section through a pair of electrical connectors in an engaged position
  • FIG. 5 schematically illustrates magnetised portions of a pair of electrical connectors explained with reference to Fig. 1 - Fig. 4,
  • Fig. 6 schematically illustrates a vehicle according to some embodiments
  • Fig. 7 schematically illustrates a battery pack of the vehicle illustrated in Fig. 6.
  • Fig. 1 schematically illustrates a pair of electrical connectors 1, 2 according to some embodiments.
  • the pair of electrical connectors 1, 2 comprises a first electrical connector 1 and a second electrical connector 2.
  • the first electrical connector 1 is in some places therein referred to “the electrical connector 1”.
  • the first electrical connector 1 is configured to electrically connect to the second electrical connector 2 when the first and second electrical connectors 1, 2 are pressed against each other along an engagement axis to an engagement position.
  • the first and second electrical connectors 1 , 2 are configured to electrically connect to each other when the first and second electrical connectors 1 , 2 are pressed against each other along an engagement axis to an engagement position.
  • the first and second electrical connectors 1 , 2 are illustrated in a disengaged position.
  • Each of the first and second electrical connectors 1 , 2 comprises a connector body 3, 3’ and a number of contact elements e1 , e2, e3, e4, eT, e2’, e3’, e4’ attached to the connector body 3, 3’.
  • the reference signs for the contact elements e1 , e2, e3, e4 of the first electrical connector 1 are abbreviated “e1 - e4” in some places herein for reasons of brevity and clarity.
  • the reference signs for the contact elements eT, e2’, e3’, e4’ of the second electrical connector 2 are abbreviated “e - e4”’ in some places herein for reasons of brevity and clarity.
  • each of the first and second electrical connectors is configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to be configured to the first and second electrical connectors
  • each of the first and second electrical connectors 1 , 2 may comprise another number of contact elements e1 - e4, eT - e4’, such as a number between one and forty, a number between one and twenty, or the like.
  • Fig. 2 schematically illustrates a cross section through the first electrical connector 1 illustrated in Fig. 1.
  • the cross section is made through a portion of the first electrical connector 1 at which one contact element e1 of the number of contact elements is arranged.
  • the engagement axis Ex of the first electrical connector 1 is indicated.
  • the cross section of Fig. 2 is made in a plane parallel to the engagement axis Ex.
  • Fig. 3 schematically illustrates a perspective view of a number of contact elements e1 - e4 of the first electrical connector and a number of contact elements eT - e4’ of the second electrical connector explained with reference to Fig. 1 and Fig. 2.
  • Fig. 1 - Fig. 3 if not indicated otherwise.
  • all contact elements e1 - e4 of the first electrical connector 1 have equal structural design.
  • all contact elements eT - e4’ of the second electrical connector 2 have equal structural design.
  • the contact elements e - e4’ of the second electrical connector 2 have equal but mirrored structural design as the contact elements e1 - e4 of the first electrical connector 1.
  • each contact element e1 - e4 of the first electrical connector 1 comprises a contact surface s1 , s2, s3, s4.
  • each contact element eT - e4’ of the second electrical connector 2 comprises a contact surface sT, s2’, s3’, s4’.
  • the reference signs for the contact surface s1 , s2, s3, s4 of the contact elements e1 - e4 of the first electrical connector 1 are abbreviated “s1 - s4” in some places herein for reasons of brevity and clarity.
  • the reference signs for the contact surfaces sT, s2’, s3’, s4’ of the contact elements eT - e4’ of the second electrical connector 2 are abbreviated “sT - s4”’ in some places herein for reasons of brevity and clarity.
  • each contact element e1 - e4 of the first electrical connector 1 is configured to abut against a respective contact surface sT - s4’ of the contact elements eT - e4’ of the second electrical connector 2 when the first and second electrical connectors 1, 2 are pressed against each other along an engagement axis Ex to an engagement position.
  • each contact surface s1 - s4 of the first electrical connector 1 is movably arranged relative to the connector body 3 in directions d2, d3 perpendicular to the engagement axis Ex.
  • each contact element e1 - e4 of the first electrical connector 1 is flexible to allow movement of the contact surface s1 - s4 relative to the connector body 3 in directions d2, d3 perpendicular to the engagement axis Ex.
  • the contact surface s1 - s4, s1 ’ - s4’ of each contact element e1 - e4, eT - e4’ of the first and second electrical connectors 1 , 2 is substantially flat.
  • the contact surface s1 - s4, sT - s4’ of each contact element e1 - e4, eT - e4’ of the first and second electrical connectors 1 , 2 may have another shape, such as a rounded shape.
  • Fig. 4 schematically illustrates a cross section through a pair of electrical connectors 1 , 2 in an engaged position.
  • the cross section is made through a portion of the pair of electrical connectors 1, 2 at which one contact element e1 of the first electrical connector 1 is arranged and at which one contact element e of the second electrical connector 2 is arranged.
  • the engagement axis Ex of the first electrical connector 1 is indicated.
  • the cross section of Fig. 4 is made in a plane parallel to the engagement axis Ex.
  • the contact surface s1 of the contact element e1 of the first electrical connector 1 has been moved in the direction d3 perpendicular to the engagement axis Ex upon movement of the first electrical connector 1 relative to the second electrical connector 2 to the engaged position.
  • the first electrical connector 1 has been moved in the direction d3 by an abutting contact between the contact element e1 , e2 of the first and second electrical connectors 1, 2.
  • the direction d3 is opposite to a surface normal N of the contact surface s1 of the contact element e1 of the first electrical connector 1.
  • the surface normal N of the contact surface s1 of the contact element e1 of the first electrical connector 1 is indicated in Fig. 2.
  • each contact element e1 - e4 of the first electrical connector 1 comprises a magnetised portion ml, m2, m3, m4 at the contact surface s1 - s4.
  • the reference signs for the magnetised portions ml, m2, m3, m4 of the contact elements e1 - e4 of the first electrical connector 1 are abbreviated “ml - m4” in some places herein for reasons of brevity and clarity.
  • each contact element e1 - e4 of the first electrical connector 1 comprises a magnetised portion ml - m4 at the contact surface s1 - s4, an electrical connector 1 is provided having conditions to be connected to the second electrical connector 2 in a reliable and consistent manner by an assembling machine, such as an industrial robot.
  • an assembling machine such as an industrial robot.
  • each contact surface s1 - s4 is movably arranged relative to the connector body 3 in directions d2, d3 perpendicular to the engagement axis Ex and because each contact element e1 - e4 comprises a magnetised portion ml - m4 at the contact surface s1 - s4 of the contact element e1 - e4.
  • the magnetised portions ml - m4 of the contact elements e1 - e4 of the first electrical connector 1 can provide an attractive force between each contact surface s1 - s4 and a matching contact surface sT - s4’ of the second electrical connector 2. In this manner, the magnetised portions ml - m4 of the first electrical connector 1 can guide the contact surfaces s1 - s4 of the contact elements e1 - e4 into correct positions also when the first and second electrical connectors 1 , 2 are pressed against each other at a slight offset from the engagement axis Ex.
  • the magnetised portions ml - m4 at the contact surfaces s1 - s4 are formed by magnets attached to the respective contact element e1 - e4 at a side opposite to the respective contact surface s1 - s4 of the contact element e1 - e4. As defined herein, such magnets may form part of the contact element e1 - e4. Moreover, according to some embodiments, the magnetised portions ml - m4 at the contact surfaces s1 - s4 may be formed by a magnetised portion of the material of the contact element e1 - e4.
  • the contact surface s1 - s4 of each contact element e1 - e4 is configured to abut against a contact surface sT - s4’ of the second electrical connector 2 along a plane P being substantially parallel to the engagement axis Ex.
  • each contact element e1 - e4 comprises an attachment portion 7 and a connecting portion 9 connecting the contact surface s1 - s4 to the attachment portion 7.
  • each contact element e1 - e4 is attached to the connector body 3 via the attachment portion 7 thereof.
  • the attachment portion 7 is connected to a conductor 15.
  • the conductor 15 may be connected to a wire of a cable, or the like.
  • the contact surface s1 - s4 are formed by one piece of continuous material.
  • the magnetised portions ml - m4 at the contact surfaces s1 - s4 of the contact elements e1 - e4 may thus be formed by a magnetised portion of such a piece of continuous material.
  • the attachment portion 7, the connecting portion 9, and the contact surface s1 - s4 are formed by bending of one piece of a sheet metal material.
  • the magnetised portions ml - m4 at the contact surfaces s1 - s4 of the contact elements e1 - e4 may be formed by a magnetised portion of such one piece of a sheet metal material.
  • the attachment portion 7, the connecting portion 9, and the contact surface s1 - s4 may be formed by two or more separate pieces of material which may be attached or joined together to form a respective contact element e1 - e4.
  • the conductor 15 may form part of the contact element e1 as referred to herein.
  • the contact surface s1 - s4 of each contact element e1 - e4 is biased in a direction d2 coinciding with a surface normal N of the contact surface s1 - s4.
  • the connecting portion 9 of each contact element e1 - e4 biases the contact surface s1 - s4 in the direction d2 coinciding with the surface normal N of the contact surface s1 - s4.
  • each contact element e1 - e4 may be biased in a direction d2 coinciding with a surface normal N of the contact surface s1 - s4 in another manner, such as by a separate resilient member, for example a spring member, a rubber element, or the like.
  • each contact element eT - e4’ of the second electrical connector 2 comprises a magnetised portion mT, m2’, m3’, m4’ at the contact surface sT - s4’ thereof.
  • the reference signs for the magnetised portions mT, m2’, m3’, m4’ of the contact elements e - e4’ of the second electrical connector 2 are abbreviated “mT - m4’” in some places herein for reasons of brevity and clarity.
  • Each contact element eT - e4’ of the second electrical connector 2 may comprise the same features, functions, and advantages as the first electrical connector 1 described herein.
  • each contact surface sT - s4’ of the second electrical connector 2 is movably arranged relative to the connector body 3’ of the second electrical connector 2 in directions d2, d3 perpendicular to the engagement axis Ex.
  • each contact element eT - e4’ of the second electrical connector 2 is flexible to allow movement of the contact surface s1’ - s4’ relative to the connector body 3’ of the second electrical connector 2 in directions d2, d3 perpendicular to the engagement axis Ex.
  • each contact element e1’ - e4’ of the second electrical connector 2 comprises an attachment portion 7’ and a connecting portion 9’ connecting the contact surface s1’ - s4’ to the attachment portion 7’. Furthermore, according to the illustrated embodiments, each contact element e1’ - e4’ of the second electrical connector 2 is attached to the connector body 3’ of the second electrical connector 2 via the attachment portion 7’. Moreover, the attachment portion 7’ is connected to a conductor 15’, wherein the conductor 15’ may be connected to a wire of a cable, or the like.
  • connection portion 9, 9’ of the contact elements e1 - e4, eT - e4’ of the first and second electrical connectors 1, 2 is inclined relative to the engagement axis Ex. In this manner, a connection of the first and second electrical connectors 1, 2 by an assembling machine, such as an industrial robot, can be further facilitated.
  • Fig. 5 schematically illustrates the magnetised portions ml - m4, ml’ - m4’ of the pair of electrical connectors 1, 2 explained with reference to Fig. 1 - Fig. 4.
  • the magnetised portions ml - m4, mT - m4’ of the pair of electrical connectors 1 , 2 are schematically illustrated at relative positions obtained when the pair of electrical connectors 1, 2, is in the engaged position.
  • the polarity of the magnetised portions ml - m4, ml’ - m4’ of the pair of electrical connectors 1, 2 are oriented such that an attractive force is obtained between each pair p1 - p4 of opposing of magnetised portions ml - m4, ml’ - m4’ when the first and second electrical connectors 1 , 2 is in the engagement position.
  • a first pair p1 opposing of magnetised portions ml , ml’ of the first and second electrical connectors 1, 2 can be seen.
  • the magnetised portion ml of the contact element e1 of the first electrical connector 1 superimposes the magnetised portion ml’ of the contact element e1’ of the second electrical connector 2 as seen in a direction d2 perpendicular to the engagement axis Ex.
  • the contact elements e1 , e1’ of the first and second electrical connectors 1, 2 are configured such that the contact surfaces s1 , s1’ thereof are located between the pair p1 opposing of magnetised portions ml, ml’.
  • pair p1 - p4 of opposing of magnetised portions ml - m4, mT - m4’ is intended to encompass a pair of magnetised portions ml - m4, mT - m4’ of two contact elements e1 - e4, eT - e4’ configured to abut against each other when the first and second electrical connectors 1, 2 are in the engaged position.
  • the contact elements e1 - e4 of the first electrical connector 1 are arranged in one row r1. According to further embodiments, the contact elements e1 - e4 of the first electrical connector 1 may be arranged in two or more rows. Likewise, the contact elements eT - e4’ of the second electrical connector 2 are arranged in one row r2. Like above, according to further embodiments, the contact elements eT - e4’ of the second electrical connector 2 may be arranged in two or more rows.
  • the magnetised portion ml - m4 of each adjacent pair a1 - a3 of contact elements e1 - e4 of the row r1 of contact elements e1 - e4 of the first electrical connector 1 of has opposite polarity.
  • the magnetised portion mT - m4’ of each adjacent pair a1 - a3 of contact elements eT - e4’ of the row r2 of contact elements eT - e4’ of the second electrical connector 2 has opposite polarity.
  • an attractive force is obtained between magnetised portions m2, m2’ of a second pair p2 of opposing magnetised portions m2, m2’ due to the opposite polarity of the magnetised portions m2, m2’.
  • an attractive force is obtained between a second magnetised portion m2 of a contact element e2 of the first electrical connector 1 and a second magnetised portion m2’ of a contact element e2’ of the second electrical connector 2.
  • the second magnetised portion m2 of the contact element e2 of the first electrical connector 1 is comprised in a first adjacent pair a1 of contact elements e1, e2 of the first electrical connector 1 as well as in a second adjacent pair a2 of contact elements e2, e3 of the first electrical connector 1 .
  • the second magnetised portion m2 of the contact element e2 of the first electrical connector 1 will thus apply a repelling force onto a first magnetised portion mT of a contact element eT of the second electrical connector 2 as well as a third magnetised portion m3’ of a contact element e3’ of the second electrical connector 2.
  • the first and second electrical connectors 1 , 2 have conditions for being connected in an even more reliable and consistent manner by an assembling machine, such as an industrial robot, having some error margin.
  • the magnetised portions ml - m4, mT - m4’ of the first and second electrical connectors 1 , 2 can guide the contact surfaces s1 - s4, sT - s4’ of the contact elements e1 - e4, eT - e4’ into correct positions also when the first and second electrical connectors 1, 2 are pressed against each other at a slight offset from the engagement axis Ex.
  • a stronger and more reliable electrical connection can be provided when the first and second electrical connectors 1 , 2 are in the engaged position.
  • Fig. 6 schematically illustrates a vehicle 20, according to some embodiments of the present disclosure.
  • the vehicle 20 is a truck, i.e., a type of heavy vehicle.
  • the vehicle 20, as referred to herein may be another type of heavy or lighter type of manned or unmanned vehicle for land or waterbased propulsion such as a lorry, a bus, a construction vehicle, a tractor, a car, a ship, a boat, or the like.
  • the vehicle 20 comprises an electric powertrain 42.
  • the electric powertrain 42 is configured to provide motive power to the vehicle 20 via wheels 57 of the vehicle 20.
  • the electric powertrain 42 comprises an electric propulsion motor 33.
  • the electric propulsion motor 33 is capable of providing motive power to the vehicle 20 via wheels 57 of the vehicle 20 as well as providing regenerative braking of the vehicle 20.
  • the electric propulsion motor 33 is capable of operating as an electric motor as well as an electric generator.
  • the electric propulsion motor 33 of the vehicle 20 may also be referred to as a vehicle propulsion motor/generator.
  • the electric powertrain 42 of the vehicle 20 is a pure electric powertrain, i.e., a powertrain comprising no internal combustion engine.
  • the electric powertrain 42 of the vehicle 20 may be a so- called hybrid electric powertrain comprising a combustion engine in addition to the electric propulsion motor 33 for providing motive power to the vehicle 20.
  • the vehicle 20 comprises a battery pack 10 and an electric system 40.
  • the battery pack 10 is operably connected to the electric propulsion motor 33 via the electric system 40.
  • the battery pack 10 is configured to provide electricity to the electric propulsion motor 33 via the electric system 40.
  • the battery pack 10 is configured to receive electricity from the electric propulsion motor 33 via the electric system 40 during regenerative braking of the vehicle 20.
  • the battery pack 10 comprises a number of battery cells.
  • the vehicle 20 is illustrated as comprising one battery pack 10. However, the vehicle 20 may comprise more than one battery pack 10.
  • the vehicle 20 is illustrated as positioned onto a flat horizontal surface H in an intended use position.
  • a vertical direction vd of the vehicle 20 is indicated.
  • the vertical direction vd of the vehicle 20 is perpendicular to the flat horizontal surface H when the vehicle 20 is positioned thereon in the intended use position.
  • the vertical direction vd of the vehicle 20 coincides with a local gravity vector at the location of the vehicle 20 when the vehicle 20 positioned onto a flat horizontal surface H in an intended use position.
  • a horizontal direction hd of the vehicle 20 is indicated.
  • the horizontal direction hd of the vehicle 20 is parallel to the flat horizontal surface H when the vehicle 20 is positioned thereon in the intended use position.
  • the vehicle 20 has a longitudinal direction Id.
  • the longitudinal direction Id of the vehicle 20 is parallel to the flat horizontal surface Hs when the vehicle 20 is positioned in the intended upright use position thereon.
  • the longitudinal direction Id of the vehicle 20 is parallel to a forward moving direction fd of the vehicle 20 as well as to a reverse moving direction rd of the vehicle 20.
  • the reverse moving direction rd of the vehicle 20 is opposite to the forward moving direction fd of the vehicle 20.
  • Fig. 7 schematically illustrates the battery pack 10 of the vehicle 20 illustrated in Fig. 6.
  • the battery pack 10 comprises a casing 17 and a number of layers L1 , L2, L3, L4 of battery cells 5 arranged inside the casing 17.
  • the reference sign for the layers L1, L2, L3, L4 of battery cells 5 is abbreviated “L1 - L4” in some places herein for reasons of brevity and clarity.
  • the battery pack 10 comprises four layers L1 - L4 of battery cells 5 arranged inside the casing 17.
  • the battery pack 10 may comprise another number of layers L1 - L4 of battery cells 5 arranged inside the casing 17, such as a number between two and twelve, or a number between two and eight.
  • Fig. 7 the vertical direction vd, the longitudinal direction Id, and the horizontal direction hd of the vehicle 2 illustrated in Fig. 6 are indicated.
  • the battery pack 10 is illustrated in an intended mounting orientation relative to these directions vd, Id, hd in Fig. 2 and Fig. 3.
  • the layers L1 - L4 of battery cells 5, as well as the casing sections 7.1 - 7.4, of the battery pack 1 have greater dimensions measured in directions parallel to the horizontal direction hd than the dimensions measured in directions parallel to the vertical direction vd.
  • the layers L1 - L4 of battery cells, as well as the casing sections 7.1 - 7.4, of the battery packs 1 , T are stacked on top of each other along the vertical direction vd.
  • the layers L1 - L4 of battery cells 5, as well as the casing sections 7.1 - 7.4, of the battery pack 1 may have other types of dimensions and may be stacked on top of each other in another manner.
  • each layer L1 - L4 of battery cells 5 of the battery pack 10 may comprise a higher number of battery cells, such as for example a number between four and one hundred fifty battery cells 5.
  • the casing 17 forms a protective outer shell for battery cells 5 inside the casing 17.
  • Each layer L1 - L4 of battery cells 5 may comprise a number of battery modules, wherein each battery module may comprise a number of battery cells 5 arranged in one or more rows.
  • the casing 17 is formed by a number of casing sections 7.1 , 7.2, 7.3, 7.4.
  • the reference sign for the casing sections 7.1 , 7.2, 7.3, 7.4 of the casing 17 is abbreviated “7.1 - 7.4” in some places herein for reasons of brevity and clarity.
  • each casing section 7.1 - 7.4 is configured to accommodate one layer L1 - L4 of battery cells 5.
  • the battery pack 10 comprises the same number of casing sections 7.1 - 7.4 as the number of layers L1 - L4 of battery cells 5 of the battery pack 10.
  • two adjacent casing sections 7.1 - 7.4 of the number of casing sections 7.1 - 7.4 are attached to each other via a number of fastening elements.
  • the battery pack 10 comprises a component c1 arranged in a first layer L1 and a second component c2 arranged in a second layer L2 of the number of layers L1 - L4 of the battery pack 10.
  • Each of the components c1, c2 may be configured for diagnosing battery cells 5 of the layers L1, L2.
  • each of the components c1, c2 may be configured for communicating an operational status of battery cells 5, or groups of battery cells 5 of the layers L1, L2, to another device or system, such as a battery monitoring system, or the like.
  • the battery pack 10 comprises a pair of electrical connectors 1, 2 according to the embodiments explained with reference to Fig. 1 - Fig. 5.
  • the pair of electrical connectors 1 , 2 is configured to electrically connect the components c1 , c2 arranged in the two different layers L1 , L2 of battery cells 5 of the battery pack 10.
  • the pair of electrical connectors 1 , 2 is configured to electrically connect the first component c1 arranged in the first layer L1 and the second component c2 arranged in the second layer L2 of the battery pack 10.
  • the pair of electrical connectors 1 , 2 is arranged inside a compartment covered by a lid 48. Since the first and second electrical connectors 1, 2 of the pair of electrical connectors 1, 2 have conditions for being connected in a reliable and consistent manner by an assembling machine, such as an industrial robot, the compartment in which the first and second electrical connectors 1 , 2 are arranged can be made smaller than would be the case otherwise. This is because the compartment in which the first and second electrical connectors 1 , 2 are arranged is not required to be sufficiently sized for accommodating fingers and/or hands of an assembler. As a further result, more space can be provided inside the layers L1 , L2 of the battery pack 10 for accommodating other types of objects or structures, such as battery cells 5.
  • the battery pack 10 is illustrated as comprising one pair of electrical connectors 1, 2.
  • the battery pack 10 may comprise another number of pairs of electrical connectors.
  • a second and third layer L2, L3 of battery cells 5 may each comprise a pair of electrical connectors.
  • the pair of electrical connectors arranged in the second layer L2 may configured to electrically connect the second component c2 arranged in the second layer L2 and a third component c3 arranged in a third layer L3 of the battery pack 10.
  • the pair of electrical connectors arranged in the third layer L3 may configured to electrically connect the third component c3 arranged in the third layer L3 and a fourth component c4 arranged in a fourth layer L4 of the battery pack 10.
  • Each of such pair of electrical connectors may be arranged inside a compartment of the respective layer L2, L3 covered by a respective lid 48’, 48”.
  • each of the first and second electrical connectors 1 , 2 is configured to provide an electrical connection between different components c1, c2, c3, c4 of a vehicle 20 when connected, i.e., when being in the engaged position as referred to herein.
  • the first and second electrical connectors 1, 2 according to the present disclosure may be used for other purposes, such as forming an electrical connection between parts of another type of device, circuit, or system.
  • the components c1 , c2, c3, c4 of the vehicle 20 have a nominal voltage within the so-called Voltage Class A, usually abbreviated VCA, namely a nominal voltage lower than 60 volts. Therefore, the components c1, c2, c3, c4 of the vehicle 20 may also be referred to as low voltage components, or VCA components.
  • the first and second electrical connectors 1 , 2 are configured to electrically connects parts of a low voltage electrical circuit, i.e., an electrical circuit having a nominal voltage lower than 60 volts.
  • the first and second electrical connectors 1 , 2, as referred to herein, may be configured to electrically connects parts of a high voltage electrical circuit, i.e., an electrical circuit having a nominal voltage within the so-called Voltage Class B, usually abbreviated VCB, namely a nominal voltage equal to, or higher than, 60 volts.
  • VCB Voltage Class B
  • the vehicle 2 illustrated in Fig. 6 comprises an electrical connector 1, a pair of electrical connectors 1, 2, as well as a battery pack 10 comprising a pair of electrical connectors 1, 2.
  • substantially parallel to may encompass that the angle between the objects referred to is less than 10 degrees, or is less than 7 degrees.
  • substantially flat may encompass that the object referred to deviates less than 10% from the shape of a flat plane.

Abstract

An electrical connector (1) is disclosed configured to electrically connect to a second electrical connector (2) when pressed against the second electrical connector (2) along an engagement axis (Ex). The electrical connector (1) comprises a connector body (3), and a number of contact elements (e1 - e4) attached to the connector body (3). Each contact element (e1 - e4) comprises a contact surface (s1 - s4) configured to abut against a respective contact surface (s1' - s4') of the second electrical connector (2). Moreover, each contact surface (s1 - s4) is movably arranged relative to the connector body (3) in directions (d2, d3) perpendicular to the engagement axis (Ex) and comprises a magnetised portion (m1 - m4) at the contact surface (s1 - s4). The present disclosure further relates to a pair of electrical connectors (1, 2), a battery pack (10), and a vehicle (20).

Description

Electrical Connector, Pair of Electrical Connectors, Battery Pack, and Vehicle
TECHNICAL FIELD
The present disclosure relates to an electrical connector configured to electrically connect to a second electrical connector when pressed against the second electrical connector along an engagement axis. The present disclosure further relates to a pair of electrical connectors comprising a first electrical connector and a second electrical connector. Moreover, the present disclosure relates to a battery pack comprising a pair of electrical connectors, as well as a vehicle comprising an electrical connector.
BACKGROUND
Assembly lines are commonly used in industry when assembling complex items, such as for example vehicles and other transportation equipment, household appliances, electronic goods, and the like. An assembly line is a process in which components, arrangements, and systems are assembled to a semi-finished assembly which is transported between different working stations at which components, arrangements, and systems are mounted in sequence to the semi-finished assembly to eventually form the final product. Many vehicle manufacturers utilize assembly lines when assembling vehicles, and in the vehicle industry, such an assembly line is sometimes referred to as a final assembly line.
Assembly lines can significantly reduce assembling costs and assembly times of products, such as vehicles. Assembly steps at an assembly line may be performed manually by an assembler or by an assembling machine, such as an industrial robot. Assembling machines, such as industrial robots, are usually preferred over manual assembly by assemblers, because of the speed and precision of assembling machines, and because they can replace burdensome tasks.
Modern vehicles comprise numerous electrical devices and subsystems. Moreover, the current trend of electrification has increased the number of electrical devices and subsystems considerably. Such electrical devices and subsystems are commonly connected to an electrical system of the vehicle using a pair of electrical connectors. Typically, one electrical connector of the pair of electrical connectors comprises a number of metal pins configured to be inserted into small recessed holes provided with metal parts, such as metal sleeves, or the like, arranged in the other electrical connector. The electrical connector comprising the number of metal pins is commonly referred to as a male connector whereas the electrical connector comprising the number of recessed holes is commonly referred to as a female connector.
The error margin of an assembling machine, such as an industrial robot, is usually a too high for electrically connecting electrical connectors in a reliable and consistent manner. As an example, an industrial robot may have an error margin of about one millimetre which is usually enough to hinder a reliable and consistent connection of two electrical connectors. Moreover, the tolerances of electrical connectors are usually too high for allowing a more precise assembling machine, such as an industrial robot, to connect two electrical connectors in a reliable and consistent manner. Therefore, electrical connectors are usually connected to each other manually by an assembler at working stations of modern assembly lines. This adds assembling costs to the final product and increases the assembly time thereof.
Moreover, at a design stage of the product, it must be ensured that sufficient free space is available so that an assembler can connect the electrical connectors to each other, i . e. , so that hands and/or fingers of the assembler can reach the electrical connectors to perform a manual connection of the electrical connectors. This required free space usually restricts the design of products and usually restricts the size, design, and placement of other components or parts in the product around a pair of electrical connectors.
A further problem associated with electrical connectors is to ensure that the electrical connection provided by an electrical connector is reliable when the electrical connector is connected to another electrical connector. If the electrical connection fails, it may have a critical impact on the functionality of the product.
In addition, generally, on today’s consumer market, it is an advantage if products comprise different features and functions while the products have conditions and/or characteristics suitable for being manufactured and assembled in a cost- efficient manner.
SUMMARY
It is an object of the present invention to overcome, or at least alleviate, at least some of the above-mentioned problems and drawbacks.
According to a first aspect of the invention, the object is achieved by an electrical connector configured to electrically connect to a second electrical connector when pressed against the second electrical connector along an engagement axis. The electrical connector comprises a connector body, and a number of contact elements attached to the connector body. Each contact element of the number of contact elements comprises a contact surface configured to abut against a respective contact surface of the second electrical connector. Moreover, each contact surface is movably arranged relative to the connector body in directions perpendicular to the engagement axis and each contact element of the number of contact elements comprises a magnetised portion at the contact surface.
Thereby, an electrical connector is provided having conditions to be connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface is movably arranged relative to the connector body in directions perpendicular to the engagement axis and because each contact element of the number of contact elements comprises a magnetised portion at the contact surface.
Accordingly, due to these features, the electrical connector can be electrically connected to the second electrical connector by being pressed against the second electrical connector at a slight offset from an engagement axis of the second electrical connector. This is because each contact surface can move relative to the connector body in directions perpendicular to the engagement axis of the electrical connector to compensate for the offset while the magnetised portions at the contact surfaces can provide an attractive force with contact surfaces of the second electrical connector to ensure an abutting contact between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector.
Moreover, since an electrical connector is provided having conditions to be connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, the electrical connector has conditions for reducing manufacturing and assembling costs of products, such as vehicles. Furthermore, an electrical connector is provided having conditions for reducing manufacturing times of products, such as manufacturing times of vehicles.
In addition, since the electrical connector has conditions for being connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, an electrical connector is provided allowing less free space around the electrical connector in a product comprising the electrical connector. Accordingly, in this manner, the electrical connector provides conditions for more space for other components or parts of the product comprising the electrical connector, which also facilitates the design of the product comprising the electrical connector.
Furthermore, since each contact element of the number of contact elements comprises the magnetised portion at the contact surface, a stronger and more reliable electrical connection can be ensured between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector also when the electrical connectors are connected to each other. This is because the magnetised portions can increase the normal forces between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector. In this manner, the electrical connector has conditions for improving reliability of a product, such as a vehicle, comprising the electrical connector.
Accordingly, an electrical connector is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.
Optionally, the contact surface of each contact element is biased in a direction coinciding with a surface normal of the contact surface. Thereby, an electrical connector is provided having conditions for being connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, while an even stronger and more reliable electrical connection can be ensured between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector when the electrical connectors are connected to each other. This is because the normal forces between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector are increased when the electrical connectors are connected to each other.
Optionally, the contact surface of each contact element is configured to abut against a contact surface of the second electrical connector along a plane being substantially parallel to the engagement axis. Thereby, an electrical connector is provided having conditions for being connected to the second electrical connector in an even more reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface can be moved in an efficient manner relative to the connector body by an abutting contact against a contact surface of a second electrical connector to compensate for an offset during a connection procedure between the electrical connectors. Optionally, each contact element comprises an attachment portion and a connecting portion connecting the contact surface to the attachment portion, and wherein each contact element is attached to the connector body via the attachment portion thereof. Thereby, an electrical connector is provided having conditions for being connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, while having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner.
Optionally, the connecting portion of each contact element biases the contact surface in a direction coinciding with a surface normal of the contact surface. Thereby, an electrical connector is provided having conditions for being connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, while an even stronger and more reliable electrical connection can be ensured between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector when the electrical connectors are connected to each other. This is because the normal forces between the contact surfaces of the electrical connector and the contact surfaces of the second electrical connector are increased when the electrical connectors are connected to each other. Moreover, due to these features, an electrical connector is provided having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner.
Optionally, the attachment portion, the connecting portion, and the contact surface are formed by one piece of continuous material. Thereby, an electrical connector is provided having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner. Moreover, an electrical connector is provided having conditions for a strong and reliable electrical connection when the electrical connector is connected to a second electrical connector.
Optionally, the attachment portion, the connecting portion, and the contact surface are formed by bending of one piece of a sheet metal material. Thereby, an electrical connector is provided having conditions and characteristics suitable for being manufactured and assembled in a cost-efficient manner. Moreover, an electrical connector is provided having conditions for a strong and reliable electrical connection when the electrical connector is connected to a second electrical connector.
Optionally, the contact surface of each contact element is substantially flat. Thereby, an electrical connector is provided having conditions for being connected to the second electrical connector in an even more reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface can be moved in an efficient manner relative to the connector body by an abutting contact against a contact surface of a second electrical connector to compensate for an offset during a connection procedure between the electrical connectors.
Moreover, since the contact surface of each contact element is substantially flat, it can be ensured that a large proportion of each contact surface abuts against a contact surface of the second electrical connector when the electrical connector is connected to the second electrical connector. It this manner, a strong and reliable electrical connection can be ensured when the electrical connector is connected to the second electrical connector.
Optionally, the electrical connector comprises two or more contact elements arranged in a row, and wherein the magnetised portion of each adjacent pair of contact elements has opposite polarity. Thereby, an electrical connector is provided capable of providing an attractive force between each contact surface and a matching contact surface of a second electrical connector intended for connection, while providing a repelling force between each the contact surface and one or two adjacent non-matching contact surfaces of the second electrical connector. Thus, due to these features, an electrical connector is provided having conditions for being connected to the second electrical connector in an even more reliable and consistent manner by an assembling machine, such as an industrial robot. Moreover, due to these features, an electrical connector is provided having conditions for a strong and reliable electrical connection when the electrical connector is connected to the second electrical connector.
Optionally, the electrical connector is configured to provide an electrical connection between different components of a vehicle when connected to the second electrical connector. Thereby, an electrical connector is provided having conditions to be connected to the second electrical connector in a reliable and consistent manner by an assembling machine, such as an industrial robot, for providing an electrical connection between different components of a vehicle. As a result, an electrical connector is provided having conditions for reducing manufacturing and assembling costs of vehicles. Furthermore, an electrical connector is provided having conditions for reducing manufacturing times of vehicle.
In addition, an electrical connector is provided allowing less free space around the electrical connector in a vehicle comprising the electrical connector. Accordingly, in this manner, the electrical connector provides conditions for more space for other components or parts of the vehicle comprising the electrical connector.
Furthermore, since each contact element of the number of contact elements comprises the magnetised portion at the contact surface, the electrical connector has conditions for improving reliability of the vehicle.
According to a second aspect of the invention, the object is achieved by a pair of electrical connectors comprising a first electrical connector and a second electrical connector, wherein the first electrical connector is configured to electrically connect to the second electrical connector when the first and second electrical connectors are pressed against each other along an engagement axis to an engagement position. Each of the first and second electrical connectors comprises a connector body, and a number of contact elements attached to the connector body, wherein each contact element of the first electrical connector comprises a contact surface configured to abut against a respective contact surface of the contact elements of the second electrical connector. Moreover, each contact surface of the first electrical connector is movably arranged relative to the connector body in directions perpendicular to the engagement axis, each contact element of the first electrical connector comprises a magnetised portion at the contact surface.
Thereby, a pair of electrical connectors is provided having conditions to be connected, i.e. , pressed to the engaged position, in a reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface of the first electrical connector is movably arranged relative to the connector body in directions perpendicular to the engagement axis and because each contact element of the first electrical connector comprises a magnetised portion at the contact surface.
Accordingly, due to these features, the first and second electrical connectors can be connected by being pressed against each other at a slight offset from the engagement axis. This is because each contact surface of the first electrical connector can move relative to the connector body in directions perpendicular to the engagement axis to compensate for the offset while the magnetised portions at the contact surfaces of the first electrical connector can provide an attractive force with contact surfaces of the second electrical connector to ensure an abutting contact between the contact surfaces of the contact elements of the first electrical connector and the contact surfaces of the second electrical connector. Moreover, since the pair of electrical connectors has conditions to be connected in a reliable and consistent manner by an assembling machine, such as an industrial robot, a pair of electrical connectors is provided having conditions for reducing manufacturing and assembling costs of products, such as vehicles. Furthermore, a pair of electrical connectors is provided having conditions for reducing manufacturing times of products, such as manufacturing times of vehicles.
In addition, since the pair of electrical connectors has conditions to be connected in a reliable and consistent manner by an assembling machine, such as an industrial robot, a pair of electrical connectors is provided allowing less free space around the pair of electrical connectors in a product comprising the pair of electrical connectors. Accordingly, in this manner, the pair of electrical connectors provides conditions for more space for other components or parts of the product comprising the pair of electrical connectors, which also facilitates the design of the product.
In addition, due to the magnetised portion at the contact surfaces of the first electrical connector, a stronger and more reliable electrical connection can be ensured between the contact surfaces of the first electrical connector and the contact surfaces of the second electrical connector also when the pair of electrical connectors is in the engaged position. This is because the magnetised portions can increase the normal forces between the contact surfaces of the first electrical connector and the contact surfaces of the second electrical connector. In this manner, the pair of electrical connectors has conditions for improving reliability of a product, such as a vehicle, comprising the pair of electrical connectors.
Accordingly, a pair of electrical connectors is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above- mentioned object is achieved.
Optionally, each contact element of the second electrical connector comprises a magnetised portion at the contact surface thereof. Thereby, a pair of electrical connectors is provided having conditions for being connected in an even more reliable and consistent manner by an assembling machine, such as an industrial robot, while an even stronger and more reliable electrical connection can be ensured between the contact surfaces of the pair of electrical connectors when the pair of electrical connectors is in the engaged position. This is because the magnetised portion at the contact surfaces of the contact elements of the second electrical connector can increase the attractive force between the contact surfaces of the pair of electrical connectors. Optionally, the polarity of the magnetised portions of the pair of electrical connectors are oriented such that an attractive force is obtained between each pair of opposing of magnetised portions when the pair of electrical connectors is in the engagement position. Thereby, a pair of electrical connectors is provided having conditions for being connected in an even more reliable and consistent manner by an assembling machine, such as an industrial robot, while an even stronger and more reliable electrical connection can be ensured between the contact surfaces of the pair of electrical connectors when the pair of electrical connectors is in the engaged position.
Optionally, each contact surface of the second electrical connector is movably arranged relative to the connector body of the second electrical connector in directions perpendicular to the engagement axis. Thereby, a pair of electrical connectors is provided having conditions for being connected in an even more reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface of the second electrical connector can move relative to the connector body of the second electrical connector in directions perpendicular to the engagement axis to compensate for an offset when the first and second electrical connectors are pressed against each other to the engagement position.
According to a third aspect of the invention, the object is achieved by a battery pack configured to provide electricity to an electric propulsion motor of a vehicle, wherein the battery pack comprises at least two layers of battery cells and a pair of electrical connectors according to some embodiments of the present disclosure, and wherein the pair of electrical connectors is configured to electrically connect components arranged in two different layers of battery cells of the battery pack.
Since the battery pack comprises a pair of electrical connectors according to some embodiments, a battery pack is provided in which the pair of electrical connectors can be connected, i.e., pressed to the engaged position, in a reliable and consistent manner by an assembling machine, such as an industrial robot.
Moreover, since the pair of electrical connectors has conditions to be connected in a reliable and consistent manner by an assembling machine, such as an industrial robot, a battery pack is provided having conditions for reduced manufacturing and assembling costs. Furthermore, a battery pack is provided having conditions for reduced manufacturing times thereof. In addition, since the battery pack comprises a pair of electrical connectors according to some embodiments, a battery pack is provided allowing less free space around the pair of electrical connectors. Accordingly, in this manner, more space is available for other components or parts in the battery pack, which also facilitates the design of the battery pack.
Furthermore, since the battery pack comprises a pair of electrical connectors according to some embodiments, a battery pack is provided having conditions for being reliable.
Accordingly, a battery pack is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.
According to a fourth aspect of the invention, the object is achieved by a vehicle comprising an electrical connector according to some embodiments of the present disclosure, a pair of electrical connectors according to some embodiments of the present disclosure, or a battery pack according to some embodiments of the present disclosure.
Since the vehicle comprises an electrical connector according to some embodiments of the present disclosure, a pair of electrical connectors according to some embodiments of the present disclosure, or a battery pack according to some embodiments of the present disclosure, a vehicle is provided overcoming, or at least alleviating, at least some of the above-mentioned problems and drawbacks. As a result, the above-mentioned object is achieved.
Further features of, and advantages with, the present invention will become apparent when studying the appended claims and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Various aspects of the invention, including its particular features and advantages, will be readily understood from the example embodiments discussed in the following detailed description and the accompanying drawings, in which:
Fig. 1 schematically illustrates a pair of electrical connectors according to some embodiments,
Fig. 2 schematically illustrates a cross section through an electrical connector illustrated in Fig. 1, Fig. 3 schematically illustrates a perspective view of a number of contact elements of a first electrical connector and a number of contact elements of a second electrical connector, Fig. 4 schematically illustrates a cross section through a pair of electrical connectors in an engaged position,
Fig. 5 schematically illustrates magnetised portions of a pair of electrical connectors explained with reference to Fig. 1 - Fig. 4,
Fig. 6 schematically illustrates a vehicle according to some embodiments, and Fig. 7 schematically illustrates a battery pack of the vehicle illustrated in Fig. 6.
DETAILED DESCRIPTION
Aspects of the present invention will now be described more fully. Like numbers refer to like elements throughout. Well-known functions or constructions will not necessarily be described in detail for brevity and/or clarity.
Fig. 1 schematically illustrates a pair of electrical connectors 1, 2 according to some embodiments. The pair of electrical connectors 1, 2 comprises a first electrical connector 1 and a second electrical connector 2. The first electrical connector 1 is in some places therein referred to “the electrical connector 1”.
As is further explained herein, the first electrical connector 1 is configured to electrically connect to the second electrical connector 2 when the first and second electrical connectors 1, 2 are pressed against each other along an engagement axis to an engagement position. In other words, the first and second electrical connectors 1 , 2 are configured to electrically connect to each other when the first and second electrical connectors 1 , 2 are pressed against each other along an engagement axis to an engagement position. In Fig. 1, the first and second electrical connectors 1 , 2 are illustrated in a disengaged position.
Each of the first and second electrical connectors 1 , 2 comprises a connector body 3, 3’ and a number of contact elements e1 , e2, e3, e4, eT, e2’, e3’, e4’ attached to the connector body 3, 3’. The reference signs for the contact elements e1 , e2, e3, e4 of the first electrical connector 1 are abbreviated “e1 - e4” in some places herein for reasons of brevity and clarity. Likewise, the reference signs for the contact elements eT, e2’, e3’, e4’ of the second electrical connector 2 are abbreviated “e - e4”’ in some places herein for reasons of brevity and clarity.
According to the illustrated embodiments, each of the first and second electrical connectors
1, 2 comprises four contact elements e1 - e4, eT - e4’. However, each of the first and second electrical connectors 1 , 2 may comprise another number of contact elements e1 - e4, eT - e4’, such as a number between one and forty, a number between one and twenty, or the like.
Fig. 2 schematically illustrates a cross section through the first electrical connector 1 illustrated in Fig. 1. In Fig. 2, the cross section is made through a portion of the first electrical connector 1 at which one contact element e1 of the number of contact elements is arranged. In Fig. 2, the engagement axis Ex of the first electrical connector 1 is indicated. The cross section of Fig. 2 is made in a plane parallel to the engagement axis Ex.
Fig. 3 schematically illustrates a perspective view of a number of contact elements e1 - e4 of the first electrical connector and a number of contact elements eT - e4’ of the second electrical connector explained with reference to Fig. 1 and Fig. 2. Below, simultaneous reference is made to Fig. 1 - Fig. 3, if not indicated otherwise. According to these embodiments, all contact elements e1 - e4 of the first electrical connector 1 have equal structural design. Likewise, according to these embodiments, all contact elements eT - e4’ of the second electrical connector 2 have equal structural design. Moreover, according to these embodiments, the contact elements e - e4’ of the second electrical connector 2 have equal but mirrored structural design as the contact elements e1 - e4 of the first electrical connector 1.
As indicated in Fig. 3, each contact element e1 - e4 of the first electrical connector 1 comprises a contact surface s1 , s2, s3, s4. Likewise, each contact element eT - e4’ of the second electrical connector 2 comprises a contact surface sT, s2’, s3’, s4’. The reference signs for the contact surface s1 , s2, s3, s4 of the contact elements e1 - e4 of the first electrical connector 1 are abbreviated “s1 - s4” in some places herein for reasons of brevity and clarity. Likewise, the reference signs for the contact surfaces sT, s2’, s3’, s4’ of the contact elements eT - e4’ of the second electrical connector 2 are abbreviated “sT - s4”’ in some places herein for reasons of brevity and clarity.
As is further explained herein, each contact element e1 - e4 of the first electrical connector 1 is configured to abut against a respective contact surface sT - s4’ of the contact elements eT - e4’ of the second electrical connector 2 when the first and second electrical connectors 1, 2 are pressed against each other along an engagement axis Ex to an engagement position.
In Fig. 2, a number of the directions d1 - d4 are indicated. According to embodiments herein, each contact surface s1 - s4 of the first electrical connector 1 is movably arranged relative to the connector body 3 in directions d2, d3 perpendicular to the engagement axis Ex. In more detail, according to the illustrated embodiments, each contact element e1 - e4 of the first electrical connector 1 is flexible to allow movement of the contact surface s1 - s4 relative to the connector body 3 in directions d2, d3 perpendicular to the engagement axis Ex.
According to the illustrated embodiments, the contact surface s1 - s4, s1 ’ - s4’ of each contact element e1 - e4, eT - e4’ of the first and second electrical connectors 1 , 2 is substantially flat. However, according to further embodiments, the contact surface s1 - s4, sT - s4’ of each contact element e1 - e4, eT - e4’ of the first and second electrical connectors 1 , 2 may have another shape, such as a rounded shape.
Fig. 4 schematically illustrates a cross section through a pair of electrical connectors 1 , 2 in an engaged position. In Fig. 4, the cross section is made through a portion of the pair of electrical connectors 1, 2 at which one contact element e1 of the first electrical connector 1 is arranged and at which one contact element e of the second electrical connector 2 is arranged. In Fig. 4, the engagement axis Ex of the first electrical connector 1 is indicated. The cross section of Fig. 4 is made in a plane parallel to the engagement axis Ex.
As can be seen when comparing Fig. 2 and Fig. 4, the contact surface s1 of the contact element e1 of the first electrical connector 1 has been moved in the direction d3 perpendicular to the engagement axis Ex upon movement of the first electrical connector 1 relative to the second electrical connector 2 to the engaged position. In more detail, the first electrical connector 1 has been moved in the direction d3 by an abutting contact between the contact element e1 , e2 of the first and second electrical connectors 1, 2. According to the illustrated embodiments, the direction d3 is opposite to a surface normal N of the contact surface s1 of the contact element e1 of the first electrical connector 1. The surface normal N of the contact surface s1 of the contact element e1 of the first electrical connector 1 is indicated in Fig. 2.
Moreover, as indicated in Fig. 2 - Fig. 4, according to embodiments herein, each contact element e1 - e4 of the first electrical connector 1 comprises a magnetised portion ml, m2, m3, m4 at the contact surface s1 - s4. The reference signs for the magnetised portions ml, m2, m3, m4 of the contact elements e1 - e4 of the first electrical connector 1 are abbreviated “ml - m4” in some places herein for reasons of brevity and clarity.
Since each contact element e1 - e4 of the first electrical connector 1 comprises a magnetised portion ml - m4 at the contact surface s1 - s4, an electrical connector 1 is provided having conditions to be connected to the second electrical connector 2 in a reliable and consistent manner by an assembling machine, such as an industrial robot. This is because each contact surface s1 - s4 is movably arranged relative to the connector body 3 in directions d2, d3 perpendicular to the engagement axis Ex and because each contact element e1 - e4 comprises a magnetised portion ml - m4 at the contact surface s1 - s4 of the contact element e1 - e4. The magnetised portions ml - m4 of the contact elements e1 - e4 of the first electrical connector 1 can provide an attractive force between each contact surface s1 - s4 and a matching contact surface sT - s4’ of the second electrical connector 2. In this manner, the magnetised portions ml - m4 of the first electrical connector 1 can guide the contact surfaces s1 - s4 of the contact elements e1 - e4 into correct positions also when the first and second electrical connectors 1 , 2 are pressed against each other at a slight offset from the engagement axis Ex. As a further result, a stronger and more reliable electrical connection can be ensured between the contact surfaces s1 - s4 of the electrical connector 1 and the contact surfaces sT - s4’ of the second electrical connector 2 also when the electrical connectors 1, 2 are in the engaged position.
According to the illustrated embodiments, the magnetised portions ml - m4 at the contact surfaces s1 - s4 are formed by magnets attached to the respective contact element e1 - e4 at a side opposite to the respective contact surface s1 - s4 of the contact element e1 - e4. As defined herein, such magnets may form part of the contact element e1 - e4. Moreover, according to some embodiments, the magnetised portions ml - m4 at the contact surfaces s1 - s4 may be formed by a magnetised portion of the material of the contact element e1 - e4.
According to the illustrated embodiments, the contact surface s1 - s4 of each contact element e1 - e4 is configured to abut against a contact surface sT - s4’ of the second electrical connector 2 along a plane P being substantially parallel to the engagement axis Ex.
Furthermore, according to the illustrated embodiments, each contact element e1 - e4 comprises an attachment portion 7 and a connecting portion 9 connecting the contact surface s1 - s4 to the attachment portion 7. Moreover, according to the illustrated embodiments, each contact element e1 - e4 is attached to the connector body 3 via the attachment portion 7 thereof. The attachment portion 7 is connected to a conductor 15. The conductor 15 may be connected to a wire of a cable, or the like.
Moreover, according to these embodiments, the attachment portion 7, the connecting portion
9, and the contact surface s1 - s4 are formed by one piece of continuous material. The magnetised portions ml - m4 at the contact surfaces s1 - s4 of the contact elements e1 - e4 may thus be formed by a magnetised portion of such a piece of continuous material.
In more detail, according to the illustrated embodiments, the attachment portion 7, the connecting portion 9, and the contact surface s1 - s4 are formed by bending of one piece of a sheet metal material. Like above, the magnetised portions ml - m4 at the contact surfaces s1 - s4 of the contact elements e1 - e4 may be formed by a magnetised portion of such one piece of a sheet metal material.
According to further embodiments, the attachment portion 7, the connecting portion 9, and the contact surface s1 - s4 may be formed by two or more separate pieces of material which may be attached or joined together to form a respective contact element e1 - e4. Furthermore, the conductor 15 may form part of the contact element e1 as referred to herein.
According to the illustrated embodiments, the contact surface s1 - s4 of each contact element e1 - e4 is biased in a direction d2 coinciding with a surface normal N of the contact surface s1 - s4. In more detail, according to these embodiments, the connecting portion 9 of each contact element e1 - e4 biases the contact surface s1 - s4 in the direction d2 coinciding with the surface normal N of the contact surface s1 - s4. However, according to further embodiments, each contact element e1 - e4 may be biased in a direction d2 coinciding with a surface normal N of the contact surface s1 - s4 in another manner, such as by a separate resilient member, for example a spring member, a rubber element, or the like.
As can be seen in Fig. 3 and Fig. 4, according to the illustrated embodiments, each contact element eT - e4’ of the second electrical connector 2 comprises a magnetised portion mT, m2’, m3’, m4’ at the contact surface sT - s4’ thereof. The reference signs for the magnetised portions mT, m2’, m3’, m4’ of the contact elements e - e4’ of the second electrical connector 2 are abbreviated “mT - m4’” in some places herein for reasons of brevity and clarity. Each contact element eT - e4’ of the second electrical connector 2 may comprise the same features, functions, and advantages as the first electrical connector 1 described herein.
As an example, according to the illustrated embodiments, each contact surface sT - s4’ of the second electrical connector 2 is movably arranged relative to the connector body 3’ of the second electrical connector 2 in directions d2, d3 perpendicular to the engagement axis Ex. In this manner, a connection of the first and second electrical connectors 1, 2 by an assembling machine, such as an industrial robot, can be further facilitated. As understood from the above, according to the illustrated embodiments, each contact element eT - e4’ of the second electrical connector 2 is flexible to allow movement of the contact surface s1’ - s4’ relative to the connector body 3’ of the second electrical connector 2 in directions d2, d3 perpendicular to the engagement axis Ex.
Moreover, according to the illustrated embodiments, each contact element e1’ - e4’ of the second electrical connector 2 comprises an attachment portion 7’ and a connecting portion 9’ connecting the contact surface s1’ - s4’ to the attachment portion 7’. Furthermore, according to the illustrated embodiments, each contact element e1’ - e4’ of the second electrical connector 2 is attached to the connector body 3’ of the second electrical connector 2 via the attachment portion 7’. Moreover, the attachment portion 7’ is connected to a conductor 15’, wherein the conductor 15’ may be connected to a wire of a cable, or the like.
Each connection portion 9, 9’ of the contact elements e1 - e4, eT - e4’ of the first and second electrical connectors 1, 2 is inclined relative to the engagement axis Ex. In this manner, a connection of the first and second electrical connectors 1, 2 by an assembling machine, such as an industrial robot, can be further facilitated.
Fig. 5 schematically illustrates the magnetised portions ml - m4, ml’ - m4’ of the pair of electrical connectors 1, 2 explained with reference to Fig. 1 - Fig. 4. In more detail, in Fig. 5, the magnetised portions ml - m4, mT - m4’ of the pair of electrical connectors 1 , 2 are schematically illustrated at relative positions obtained when the pair of electrical connectors 1, 2, is in the engaged position.
As can be seen in Fig. 5, according to these embodiments, the polarity of the magnetised portions ml - m4, ml’ - m4’ of the pair of electrical connectors 1, 2 are oriented such that an attractive force is obtained between each pair p1 - p4 of opposing of magnetised portions ml - m4, ml’ - m4’ when the first and second electrical connectors 1 , 2 is in the engagement position.
In Fig. 4, a first pair p1 opposing of magnetised portions ml , ml’ of the first and second electrical connectors 1, 2 can be seen. According to these embodiments, the magnetised portion ml of the contact element e1 of the first electrical connector 1 superimposes the magnetised portion ml’ of the contact element e1’ of the second electrical connector 2 as seen in a direction d2 perpendicular to the engagement axis Ex. Moreover, the contact elements e1 , e1’ of the first and second electrical connectors 1, 2 are configured such that the contact surfaces s1 , s1’ thereof are located between the pair p1 opposing of magnetised portions ml, ml’. In this manner, the contact surfaces s1, s1’ of the contact elements e1, e1’ 1 of the first and second electrical connectors 1, 2 are pressed against each other by the attractive force obtained between the first pair p1 opposing of magnetised portions ml, mT.
As understood from the above, since the polarity of the magnetised portions ml - m4, mT - m4’ are oriented such that an attractive force is obtained between each pair p1 - p4 of opposing of magnetised portions ml - m4, mT - m4’ when the pair of electrical connectors 1, 2 is in the engagement position, the contact surfaces s1 - s4, sT - s4’ of the first and second electrical connectors 1, 2 are pressed against each other by the attractive force obtained between the pairs p1 - p4 of opposing of magnetised portions ml - m4, ml’ - m4’. The wording pair p1 - p4 of opposing of magnetised portions ml - m4, mT - m4’, as used herein, is intended to encompass a pair of magnetised portions ml - m4, mT - m4’ of two contact elements e1 - e4, eT - e4’ configured to abut against each other when the first and second electrical connectors 1, 2 are in the engaged position.
As is indicated in Fig. 3, the contact elements e1 - e4 of the first electrical connector 1 are arranged in one row r1. According to further embodiments, the contact elements e1 - e4 of the first electrical connector 1 may be arranged in two or more rows. Likewise, the contact elements eT - e4’ of the second electrical connector 2 are arranged in one row r2. Like above, according to further embodiments, the contact elements eT - e4’ of the second electrical connector 2 may be arranged in two or more rows.
As indicated in Fig. 5, according to these embodiments, the magnetised portion ml - m4 of each adjacent pair a1 - a3 of contact elements e1 - e4 of the row r1 of contact elements e1 - e4 of the first electrical connector 1 of has opposite polarity. Likewise, the magnetised portion mT - m4’ of each adjacent pair a1 - a3 of contact elements eT - e4’ of the row r2 of contact elements eT - e4’ of the second electrical connector 2 has opposite polarity. Due to these features, an attractive force is obtained between each pair p1 - p4 of opposing of magnetised portions ml - m4, mT - m4’ when the pair of electrical connectors 1, 2 is in the engagement position, while a repelling force is obtained between magnetised portions ml - m4, mT - m4’ at adjacent contact surfaces s1 - s4, sT - s4’ not intended for connection.
That is, as an example, an attractive force is obtained between magnetised portions m2, m2’ of a second pair p2 of opposing magnetised portions m2, m2’ due to the opposite polarity of the magnetised portions m2, m2’. In other words, an attractive force is obtained between a second magnetised portion m2 of a contact element e2 of the first electrical connector 1 and a second magnetised portion m2’ of a contact element e2’ of the second electrical connector 2. The second magnetised portion m2 of the contact element e2 of the first electrical connector 1 is comprised in a first adjacent pair a1 of contact elements e1, e2 of the first electrical connector 1 as well as in a second adjacent pair a2 of contact elements e2, e3 of the first electrical connector 1 . The second magnetised portion m2 of the contact element e2 of the first electrical connector 1 will thus apply a repelling force onto a first magnetised portion mT of a contact element eT of the second electrical connector 2 as well as a third magnetised portion m3’ of a contact element e3’ of the second electrical connector 2.
Thus, due to these features, the first and second electrical connectors 1 , 2 have conditions for being connected in an even more reliable and consistent manner by an assembling machine, such as an industrial robot, having some error margin. This is because the magnetised portions ml - m4, mT - m4’ of the first and second electrical connectors 1 , 2 can guide the contact surfaces s1 - s4, sT - s4’ of the contact elements e1 - e4, eT - e4’ into correct positions also when the first and second electrical connectors 1, 2 are pressed against each other at a slight offset from the engagement axis Ex. Moreover, due to these features, a stronger and more reliable electrical connection can be provided when the first and second electrical connectors 1 , 2 are in the engaged position.
Fig. 6 schematically illustrates a vehicle 20, according to some embodiments of the present disclosure. According to the illustrated embodiments, the vehicle 20 is a truck, i.e., a type of heavy vehicle. According to further embodiments, the vehicle 20, as referred to herein, may be another type of heavy or lighter type of manned or unmanned vehicle for land or waterbased propulsion such as a lorry, a bus, a construction vehicle, a tractor, a car, a ship, a boat, or the like.
The vehicle 20 comprises an electric powertrain 42. According to the illustrated embodiments, the electric powertrain 42 is configured to provide motive power to the vehicle 20 via wheels 57 of the vehicle 20. The electric powertrain 42 comprises an electric propulsion motor 33. The electric propulsion motor 33 is capable of providing motive power to the vehicle 20 via wheels 57 of the vehicle 20 as well as providing regenerative braking of the vehicle 20. Thus, according to the illustrated embodiments, the electric propulsion motor 33 is capable of operating as an electric motor as well as an electric generator. The electric propulsion motor 33 of the vehicle 20 may also be referred to as a vehicle propulsion motor/generator. According to the illustrated embodiments, the electric powertrain 42 of the vehicle 20 is a pure electric powertrain, i.e., a powertrain comprising no internal combustion engine. According to further embodiments, the electric powertrain 42 of the vehicle 20 may be a so- called hybrid electric powertrain comprising a combustion engine in addition to the electric propulsion motor 33 for providing motive power to the vehicle 20.
Moreover, as is indicated in Fig. 6, the vehicle 20 comprises a battery pack 10 and an electric system 40. The battery pack 10 is operably connected to the electric propulsion motor 33 via the electric system 40. In other words, the battery pack 10 is configured to provide electricity to the electric propulsion motor 33 via the electric system 40. Moreover, according to the illustrated embodiments, the battery pack 10 is configured to receive electricity from the electric propulsion motor 33 via the electric system 40 during regenerative braking of the vehicle 20. As is further explained herein, the battery pack 10 comprises a number of battery cells. In Fig. 6, the vehicle 20 is illustrated as comprising one battery pack 10. However, the vehicle 20 may comprise more than one battery pack 10.
In Fig. 6, the vehicle 20 is illustrated as positioned onto a flat horizontal surface H in an intended use position. Moreover, in Fig. 6, a vertical direction vd of the vehicle 20 is indicated. The vertical direction vd of the vehicle 20 is perpendicular to the flat horizontal surface H when the vehicle 20 is positioned thereon in the intended use position. Moreover, the vertical direction vd of the vehicle 20 coincides with a local gravity vector at the location of the vehicle 20 when the vehicle 20 positioned onto a flat horizontal surface H in an intended use position. In Fig. 6, a horizontal direction hd of the vehicle 20 is indicated. The horizontal direction hd of the vehicle 20 is parallel to the flat horizontal surface H when the vehicle 20 is positioned thereon in the intended use position.
As can be seen in Fig. 6, the wheels 57 of the vehicle 20 are abutting against the flat horizontal surface Hs when the vehicle 20 is positioned in the intended upright use position on the flat horizontal surface Hs. The vehicle 20 has a longitudinal direction Id. The longitudinal direction Id of the vehicle 20 is parallel to the flat horizontal surface Hs when the vehicle 20 is positioned in the intended upright use position thereon. Moreover, the longitudinal direction Id of the vehicle 20 is parallel to a forward moving direction fd of the vehicle 20 as well as to a reverse moving direction rd of the vehicle 20. The reverse moving direction rd of the vehicle 20 is opposite to the forward moving direction fd of the vehicle 20.
Fig. 7 schematically illustrates the battery pack 10 of the vehicle 20 illustrated in Fig. 6. The battery pack 10 comprises a casing 17 and a number of layers L1 , L2, L3, L4 of battery cells 5 arranged inside the casing 17. The reference sign for the layers L1, L2, L3, L4 of battery cells 5 is abbreviated “L1 - L4” in some places herein for reasons of brevity and clarity.
According to the embodiments illustrated in Fig. 7, the battery pack 10 comprises four layers L1 - L4 of battery cells 5 arranged inside the casing 17. As is further explained herein, the battery pack 10 may comprise another number of layers L1 - L4 of battery cells 5 arranged inside the casing 17, such as a number between two and twelve, or a number between two and eight.
In Fig. 7, the vertical direction vd, the longitudinal direction Id, and the horizontal direction hd of the vehicle 2 illustrated in Fig. 6 are indicated. The battery pack 10 is illustrated in an intended mounting orientation relative to these directions vd, Id, hd in Fig. 2 and Fig. 3.
As seen in Fig. 7, the layers L1 - L4 of battery cells 5, as well as the casing sections 7.1 - 7.4, of the battery pack 1 have greater dimensions measured in directions parallel to the horizontal direction hd than the dimensions measured in directions parallel to the vertical direction vd. Moreover, the layers L1 - L4 of battery cells, as well as the casing sections 7.1 - 7.4, of the battery packs 1 , T are stacked on top of each other along the vertical direction vd. However, according to further embodiments, the layers L1 - L4 of battery cells 5, as well as the casing sections 7.1 - 7.4, of the battery pack 1, may have other types of dimensions and may be stacked on top of each other in another manner.
In Fig. 7, only one battery cell 5 is indicated in a first layer L1 of battery cells 5 for reasons of brevity and clarity. However, each layer L1 - L4 of battery cells 5 of the battery pack 10 may comprise a higher number of battery cells, such as for example a number between four and one hundred fifty battery cells 5. The casing 17 forms a protective outer shell for battery cells 5 inside the casing 17. Each layer L1 - L4 of battery cells 5 may comprise a number of battery modules, wherein each battery module may comprise a number of battery cells 5 arranged in one or more rows.
According to the illustrated embodiments, the casing 17 is formed by a number of casing sections 7.1 , 7.2, 7.3, 7.4. The reference sign for the casing sections 7.1 , 7.2, 7.3, 7.4 of the casing 17 is abbreviated “7.1 - 7.4” in some places herein for reasons of brevity and clarity. According to the illustrated embodiments, each casing section 7.1 - 7.4 is configured to accommodate one layer L1 - L4 of battery cells 5. In other words, the battery pack 10 comprises the same number of casing sections 7.1 - 7.4 as the number of layers L1 - L4 of battery cells 5 of the battery pack 10. According to the illustrated embodiments, two adjacent casing sections 7.1 - 7.4 of the number of casing sections 7.1 - 7.4 are attached to each other via a number of fastening elements.
The battery pack 10 comprises a component c1 arranged in a first layer L1 and a second component c2 arranged in a second layer L2 of the number of layers L1 - L4 of the battery pack 10. Each of the components c1, c2 may be configured for diagnosing battery cells 5 of the layers L1, L2. Moreover, each of the components c1, c2 may be configured for communicating an operational status of battery cells 5, or groups of battery cells 5 of the layers L1, L2, to another device or system, such as a battery monitoring system, or the like.
According to the illustrated embodiments, the battery pack 10 comprises a pair of electrical connectors 1, 2 according to the embodiments explained with reference to Fig. 1 - Fig. 5. The pair of electrical connectors 1 , 2 is configured to electrically connect the components c1 , c2 arranged in the two different layers L1 , L2 of battery cells 5 of the battery pack 10. In other words, according to the illustrated embodiments, the pair of electrical connectors 1 , 2 is configured to electrically connect the first component c1 arranged in the first layer L1 and the second component c2 arranged in the second layer L2 of the battery pack 10.
As schematically illustrated in Fig. 7, the pair of electrical connectors 1 , 2 is arranged inside a compartment covered by a lid 48. Since the first and second electrical connectors 1, 2 of the pair of electrical connectors 1, 2 have conditions for being connected in a reliable and consistent manner by an assembling machine, such as an industrial robot, the compartment in which the first and second electrical connectors 1 , 2 are arranged can be made smaller than would be the case otherwise. This is because the compartment in which the first and second electrical connectors 1 , 2 are arranged is not required to be sufficiently sized for accommodating fingers and/or hands of an assembler. As a further result, more space can be provided inside the layers L1 , L2 of the battery pack 10 for accommodating other types of objects or structures, such as battery cells 5.
In Fig. 7, the battery pack 10 is illustrated as comprising one pair of electrical connectors 1, 2. However, the battery pack 10 may comprise another number of pairs of electrical connectors. As an example, a second and third layer L2, L3 of battery cells 5 may each comprise a pair of electrical connectors. According to such embodiments, the pair of electrical connectors arranged in the second layer L2 may configured to electrically connect the second component c2 arranged in the second layer L2 and a third component c3 arranged in a third layer L3 of the battery pack 10. Likewise, the pair of electrical connectors arranged in the third layer L3 may configured to electrically connect the third component c3 arranged in the third layer L3 and a fourth component c4 arranged in a fourth layer L4 of the battery pack 10. Each of such pair of electrical connectors may be arranged inside a compartment of the respective layer L2, L3 covered by a respective lid 48’, 48”.
As understood from the above, according to the illustrated embodiments, each of the first and second electrical connectors 1 , 2 is configured to provide an electrical connection between different components c1, c2, c3, c4 of a vehicle 20 when connected, i.e., when being in the engaged position as referred to herein. However, the first and second electrical connectors 1, 2 according to the present disclosure may be used for other purposes, such as forming an electrical connection between parts of another type of device, circuit, or system.
According to the illustrated embodiments, the components c1 , c2, c3, c4 of the vehicle 20 have a nominal voltage within the so-called Voltage Class A, usually abbreviated VCA, namely a nominal voltage lower than 60 volts. Therefore, the components c1, c2, c3, c4 of the vehicle 20 may also be referred to as low voltage components, or VCA components. In other words, the first and second electrical connectors 1 , 2 according to the illustrated embodiments are configured to electrically connects parts of a low voltage electrical circuit, i.e., an electrical circuit having a nominal voltage lower than 60 volts.
However, according to further embodiments, the first and second electrical connectors 1 , 2, as referred to herein, may be configured to electrically connects parts of a high voltage electrical circuit, i.e., an electrical circuit having a nominal voltage within the so-called Voltage Class B, usually abbreviated VCB, namely a nominal voltage equal to, or higher than, 60 volts.
Moreover, as understood from the above, according to the illustrated embodiments, the vehicle 2 illustrated in Fig. 6 comprises an electrical connector 1, a pair of electrical connectors 1, 2, as well as a battery pack 10 comprising a pair of electrical connectors 1, 2.
The wording “substantially parallel to”, as used herein, may encompass that the angle between the objects referred to is less than 10 degrees, or is less than 7 degrees.
The wording “substantially flat”, as used herein, may encompass that the object referred to deviates less than 10% from the shape of a flat plane.
It is to be understood that the foregoing is illustrative of various example embodiments and that the invention is defined only by the appended independent claims. A person skilled in the art will realize that the example embodiments may be modified, and that different features of the example embodiments may be combined to create embodiments other than those described herein, without departing from the scope of the present invention, as defined by the appended independent claims.
As used herein, the term "comprising" or "comprises" is open-ended, and includes one or more stated features, elements, steps, components, or functions but does not preclude the presence or addition of one or more other features, elements, steps, components, functions, or groups thereof.

Claims

1. An electrical connector (1) configured to electrically connect to a second electrical connector (2) when pressed against the second electrical connector (2) along an engagement axis (Ex), wherein the electrical connector (1) comprises: a connector body (3), and a number of contact elements (e1 - e4) attached to the connector body (3), wherein each contact element (e1 - e4) of the number of contact elements (e1 - e4) comprises a contact surface (s1 - s4) configured to abut against a respective contact surface (s1 ’ - s4’) of the second electrical connector (2), wherein each contact surface (s1 - s4) is movably arranged relative to the connector body (3) in directions (d2, d3) perpendicular to the engagement axis (Ex), and wherein each contact element (e1 - e4) of the number of contact elements (e1 - e4) comprises a magnetised portion (ml - m4) at the contact surface (s1 - s4).
2. The electrical connector (1) according to claim 1 , wherein the contact surface (s1 - s4) of each contact element (e1 - e4) is biased in a direction (d2) coinciding with a surface normal (N) of the contact surface (s1 - s4).
3. The electrical connector (1) according to claim 1 or 2, wherein the contact surface (s1 - s4) of each contact element (e1 - e4) is configured to abut against a contact surface (sT - s4’) of the second electrical connector (2) along a plane (P) being substantially parallel to the engagement axis (Ex).
4. The electrical connector (1) according to any one of the preceding claims, wherein each contact element (e1 - e4) comprises an attachment portion (7) and a connecting portion (9) connecting the contact surface (s1 - s4) to the attachment portion (7), and wherein each contact element (e1 - e4) is attached to the connector body (3) via the attachment portion (7) thereof.
5. The electrical connector (1) according to claim 4, wherein the connecting portion (9) of each contact element (e1 - e4) biases the contact surface (s1 - s4) in a direction (d2) coinciding with a surface normal (N) of the contact surface (s1 - s4).
6. The electrical connector (1) according to claim 4 or 5, wherein the attachment portion (7), the connecting portion (9), and the contact surface (s1 - s4) are formed by one piece of continuous material.
7. The electrical connector (1) according to any one of the claims 4 - 6, wherein the attachment portion (7), the connecting portion (9), and the contact surface (s1 - s4) are formed by bending of one piece of a sheet metal material.
8. The electrical connector (1) according to any one of the preceding claims, wherein the contact surface (s1 - s4) of each contact element (e1 - e4) is substantially flat.
9. The electrical connector (1) according to any one of the preceding claims, wherein the electrical connector (1) comprises two or more contact elements (e1 - e4) arranged in a row (r1 ), and wherein the magnetised portion (ml - m4) of each adjacent pair (a1 - a3) of contact elements (e1 - e4) has opposite polarity.
10. The electrical connector (1) according to any one of the preceding claims, wherein the electrical connector (1) is configured to provide an electrical connection between different components (c1 , c2) of a vehicle (20) when connected to the second electrical connector (2).
11. A pair of electrical connectors (1, 2) comprising a first electrical connector (1) and a second electrical connector (2), wherein the first electrical connector (1) is configured to electrically connect to the second electrical connector (2) when the first and second electrical connectors (1, 2) are pressed against each other along an engagement axis (Ex) to an engagement position, wherein each of the first and second electrical connectors (1, 2) comprises: a connector body (3, 3’), and a number of contact elements (e1 - e4, eT - e4’) attached to the connector body (3, 3’), wherein each contact element (e1 - e4) of the first electrical connector (1) comprises a contact surface (s1 - s4) configured to abut against a respective contact surface (sT - s4’) of the contact elements (eT - e4’) of the second electrical connector (2), wherein each contact surface (s1 - s4) of the first electrical connector (1) is movably arranged relative to the connector body (3) in directions (d2, d3) perpendicular to the engagement axis (Ex), and wherein each contact element (e1 - e4) of the first electrical connector (1) comprises a magnetised portion (ml - m4) at the contact surface (s1 - s4).
12. The pair of electrical connectors (1 , 2) according to claim 11 , wherein each contact element (eT - e4’) of the second electrical connector (2) comprises a magnetised portion (mT - m4’) at the contact surface (sT - s4’) thereof. The pair of electrical connectors (1 , 2) according to claim 12, wherein the polarity of the magnetised portions (ml - m4, m - m4’) of the pair of electrical connectors (1 , 2) are oriented such that an attractive force is obtained between each pair (p1 - p4) of opposing of magnetised portions (ml - m4, mT - m4’) when the pair of electrical connectors (1 , 2) is in the engagement position. The pair of electrical connectors (1 , 2) according to any one of the claims 11 - 13, wherein each contact surface (sT - s4’) of the second electrical connector (2) is movably arranged relative to the connector body (3’) of the second electrical connector (2) in directions (d2, d3) perpendicular to the engagement axis (Ex). A battery pack (10) configured to provide electricity to an electric propulsion motor (33) of a vehicle (20), wherein the battery pack (10) comprises at least two layers (L1 - L4) of battery cells (5) and a pair of electrical connectors (1, 2) according to any one of the claims 11 - 14, and wherein the pair of electrical connectors (1 , 2) is configured to electrically connect components (c1, c2) arranged in two different layers (L1 , L2) of battery cells (5) of the battery pack (10). A vehicle (20) comprising an electrical connector (1) according to any one of the claims 1 - 10, a pair of electrical connectors (1, 2) according to any one of the claims 11 - 14, or a battery pack (10) according to claim 15.
PCT/SE2023/050871 2022-09-26 2023-09-01 Electrical connector, pair of electrical connectors, battery pack, and vehicle WO2024072277A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE2251111A SE546067C2 (en) 2022-09-26 2022-09-26 Electrical Connector, Pair of Electrical Connectors, Battery Pack, and Vehicle
SE2251111-7 2022-09-26

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WO2024072277A1 true WO2024072277A1 (en) 2024-04-04

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US20100144209A1 (en) * 2006-09-29 2010-06-10 Adc Gmbh Connection element for communications and data technology
US20150188254A1 (en) * 2013-12-30 2015-07-02 Foxconn Interconnect Technology Limited Magnetic connector for electronic device
US20150244105A1 (en) * 2014-02-25 2015-08-27 Lotes Co., Ltd Electrical connector assembly with magnetic element
WO2019018620A1 (en) * 2017-07-20 2019-01-24 Materion Corporation Electronic connectors with magnetic copper alloys
EP3471213A1 (en) * 2017-10-10 2019-04-17 Shenzhen Prime Logic Technology Co., Ltd. Apparatus and methods for vehicle battery charging or voltage monitoring
CN112600032A (en) * 2020-12-24 2021-04-02 南京苏美达智能技术有限公司 Magnetic charging butt joint structure for automatic walking equipment

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100144209A1 (en) * 2006-09-29 2010-06-10 Adc Gmbh Connection element for communications and data technology
US20150188254A1 (en) * 2013-12-30 2015-07-02 Foxconn Interconnect Technology Limited Magnetic connector for electronic device
US20150244105A1 (en) * 2014-02-25 2015-08-27 Lotes Co., Ltd Electrical connector assembly with magnetic element
WO2019018620A1 (en) * 2017-07-20 2019-01-24 Materion Corporation Electronic connectors with magnetic copper alloys
EP3471213A1 (en) * 2017-10-10 2019-04-17 Shenzhen Prime Logic Technology Co., Ltd. Apparatus and methods for vehicle battery charging or voltage monitoring
CN112600032A (en) * 2020-12-24 2021-04-02 南京苏美达智能技术有限公司 Magnetic charging butt joint structure for automatic walking equipment

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SE546067C2 (en) 2024-05-07

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