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

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

Abstract: A framed lithium battery cell group includes a first frame member (20) and a second frame member (30). The frame members are locked together, clamping the lithium battery cell pack (10) on the seal edge surfaces (13, 16), thereby providing structural rigidity and protection from damage due to handling and vibration. Each of the frame members (20, 30) has multiple pins (25) and sockets (26) on the side opposite the clamping surface (33) to facilitate aligning and stacking multiple lithium battery cell pack and frame assemblies to form a lithium battery cell group (50). Each of the frame members (20, 30) include a buss bar capture feature (22, 32) having a bus bar (40) inserted therein for electrically connecting all of the terminals for a given lithium battery pack group to the buss bar (40).

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

Abstract: A battery assembly internal connection device for making an electrical connection within a battery assembly that includes a plurality of cells. The device is operable from a pre-stage position where no electrical connection is made to a final position where an electrical connection is made. The device includes a terminal configured to make electrical contact with a first electrode of a cell when the device is operated to the final position. The terminal may optionally include a sharp portion configured to cut through dielectric material covering the first electrode as the device is operated from the pre-stage position to the final position.

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

Abstract: A battery pack containing a plurality of battery cells having a housing and defining an opening within the housing and a battery control module configured to be disposed within the opening of the battery pack. The battery control module may contain circuitry for controlling a connection between the battery pack and an electric load or electric source and for controlling the charging of the battery cells. The circuitry within the battery control module is connected by rigid conductors, such as conductive traces on a circuit board or bus bars rather than flexible wire cables. The battery control module may be configured to be removed for serving the battery pack without removing the battery pack housing. The battery pack may further include a battery voltage monitor configured to monitor a terminal voltage of each battery cell and send a digital signal representing the voltage to the battery control module.

Abstract: An electrical connector assembly and a battery pack system utilizing the electrical connector assembly are described. The electrical connector assembly includes a first connector body defining a first locating pin and a second connector body defining a first location socket. The first connector body may also define a second locating socket and the second connector body may define a second locating pin having the same shape as the first locating pin and first locating socket. The electrical connection between the first and second connector bodies is established by a conductor connected between the terminals. The locating pins and locating sockets provide lateral location of the terminals relative to each other. The terminals or the conductor may define a U-shaped portion that provides longitudinal and vertical assembly tolerance of the terminals in the first connector body relative to the terminals in the second connector body.

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

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

Abstract: A battery suitable for hybrid vehicle use that includes coolant flow channels overlying a surface of each battery cell forming the battery, and a plenum that provides structural integrity to the battery. The plenum also defines an intake plenum having an intake cross section area that decreases as a distance from an intake opening increases and an exhaust plenum having an exhaust cross section area that increases as a distance from an exhaust opening decreases. The arrangement of battery cells and the plenum provide for a scalable battery design that can be readily adapted to various battery power ratings and cooling capabilities such as forced air cooling.

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

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

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

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

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

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

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

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

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