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

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

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

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

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

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

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

Abstract: A multi-pin electrical connector including a first connector portion and a second connector portion. Seal retaining rings snapped into the connector portions seal and retain cavity terminal blocks located within each respective connector portion. A locking collar employs a ramped locking feature to snap and secure the first and second connector portions in an interlocked, assembled state. The multi-pin electrical connector can be composed entirely of non-metallic components.

Abstract: A multi-pin electrical connector including a first connector portion and a second connector portion. Seal retaining rings snapped into the connector portions seal and retain cavity terminal blocks located within each respective connector portion. A locking collar employs a ramped locking feature to snap and secure the first and second connector portions in an interlocked, assembled state. The multi-pin electrical connector can be composed entirely of non-metallic components.

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

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: A battery pack is provided that includes a case and at least one battery module disposed within the case. The battery pack further includes a flexible circuit to which the battery module may be electrically coupled. The flexible circuit includes a plurality of airflow openings configured to distribute air throughout the battery pack. In a preferred embodiment, the airflow openings vary in size relative to their proximity to an air source.

Abstract: A battery pack is provided having at least first and second battery modules, and which in one embodiment has ten modules. Each battery module includes a respective first terminal extending from one end of the module and a respective second terminal extending from the other end of the module. The battery pack further includes a conductive interface having a first opening configured to receive the first terminal of the first battery module and a second opening configured to receive the second terminal of the second battery module to thereby provide an electrical series connection. The interface electrically couples the terminals of the two battery modules. The battery pack may further include an electrically non-conductive buss terminal holder configured to receive and position the first and second battery modules and the conductive interface.

Abstract: A power connector system includes a female connector and a male connector. The female connector includes a female terminal in a female housing. The female terminal is in the form of a U-shaped channel defining a recess. A U-shaped contact member in the channel recess forms a second recess. The male connector includes a male terminal in a male housing. The male and female housings are releasably connected together with the male terminal extending into the recess in the contact member.

Abstract: A high power connection system adapted for automotive environments which provides environmental and EMI shielding includes a female connector, a male connector, and a panel mount. The female connector includes a female connector base and a snap fitted female connector cover. The male connector includes a male connector base and a snap fitted male connector cover. The female connector base has at least one female power terminal cavity for seatably receiving a respective female power terminal. The male connector base has at least one male power terminal cavity for seatably receiving a respective male power terminal. The female connector is covered by a cover seal and a conductive shroud. A pair of lock arms protrude outward from the front end of the male connector base, pass through the panel mount and interface with a lever of a lever rotatably connected to the shroud to thereby mechanically assist mating of the male and female connectors.

Abstract: A rescue device for use by an operator on an ice surface and in water. The device has a pair of elongated buoyant bodies which are pivotally connected for movement relative to each other between an operative position in which the bodies are spaced and lie in the same horizontal plane to a folded or inoperative position in which the bottom surfaces of the bodies are abutting. A handle is connected to each body.

Abstract: A high pressure fuel hose for disposition between a tubular stem on a fluid connector on a canister in a fuel tank and tubular stem on a fluid connector on a cover for the fuel tank spaced from the canister. Each of the tubular stems has a fir-tree barb thereon and the high pressure hose includes a convoluted flexible body and a pair of relatively stiff cylindrical ends each of which has a pair of annular inside beads and three annular outside beads between the convoluted body and the inside beads. When the cylindrical ends are press fitted over the fir-tree barbs with force applied at the outside beads, the inside bead seat behind annular shoulders on the barbs for enhanced retention.