Abstract: A pack for batteries or other electrical storage devices, such as capacitors, is designed for ease of manufacture and installation of components in the case with vertical motions to provide an efficient and cost effective assembly. An exemplary embodiment has a molded case and cover in which all of the internal components are installed in the case through the open top without requiring fasteners, tools or additional supporting parts. The components include a flexible circuit on a flexible plastic sheet carrying control and sensor circuitry and temperature sensors together with internal and external connectors. Buss bars and connecting terminals mount in vertical slots and include prongs that extend through flexible flap connectors into guide recesses to provide connections to the flexible circuit. Batteries with vertical blade terminals are received in slots of the buss bars. An electronic control module and current sensor are also provided.

Abstract: Disclosed is an intercell buss system 10 comprising:at least a pair of electrical cells 12, 14, each having an electrical terminal 12A, 14B thereon;a lid 18 having an up and a down position, such that in the down position, the lid covers at least a portion of the terminals of the cells; further, the lid has a projection 20 thereon; anda current carrying member 16 located on the projection 20 of the lid 18 such that when the lid is in the down position electrical current can pass from one cell to the other through the current carrying member which acts as an intercell buss and when the lid is in the up position, no current can pass through the current carrying member.

Abstract: A battery pack has a plurality of batteries connected in series to provide a high voltage energy source and energy storage. The battery pack has a high voltage receptacle in which a high voltage harness is connected when power is to be distributed or stored. a cover guard prevents inadvertent access to the harness connector. The cover guard has integral therewith an electrical disconnect mechanism and latch mechanism which must be manipulated prior to exposing the harness connector. The disconnect mechanism eliminates the electrical connection of the batteries to a receptacle in which the harness connector is installed. The latch mechanism prevents removal of the cover guard prior to manual disconnection and also prevents reconnection prior to the cover guard being properly positioned.

Abstract: A battery pack for easy access to, and uniform cooling/heating of, the individual battery modules thereof. The pack comprises stackable housing parts (i.e., top and bottom) housing multiple tiers of battery modules supported by underlying trays having openings/holes therein aligned with gaps/spaces between adjacent battery modules through which cooling/heating air is uniformly flowed in parallel between the modules from an underlying plenum. The battery modules are compressively immobilized in the housing by resilient foam pads which bear down on the tops of the modules.