Power terminal connector
A power terminal connector includes a flexible conductor having a first mounting portion, a second mounting portion and a flexible section between the first and second mounting portions. The first mounting portion is terminated directly to a power terminal of a first battery module. A female terminal is coupled to the second mounting portion. The female terminal has a terminal body having a receptacle receiving a power terminal of a second battery module. The terminal body is terminated to the second mounting portion to mechanically and electrically connect the terminal body to the flexible conductor. A contact spring is received in the receptacle and is electrically connected to the terminal body. The contact spring has spring beams defining interfaces for the power terminal to create a power path to the power terminal of the second battery module.
1. A power terminal connector comprising:
a flexible conductor having a first mounting portion, a second mounting portion and a flexible section between the first and second mounting portions, the first mounting portion being terminated directly to a power terminal of a first battery module;
a female terminal coupled to the second mounting portion, the female terminal comprising:
a terminal body having a receptacle configured to receive a power terminal of a second battery module, the terminal body being terminated to the second mounting portion to mechanically and electrically connect the terminal body to the flexible conductor, the terminal body having an open front end open to the receptacle and configured to receive the power terminal of the second battery module therethrough; and
a contact spring received in the receptacle and being electrically connected to the terminal body, the contact spring having spring beams defining interfaces for the power terminal of the second battery module to create a power path to the power terminal of the second battery module.
2. The power terminal connector of claim 1 , wherein the flexible conductor is welded directly to the power terminal of the first battery module.
3. The power terminal connector of claim 1 , wherein the terminal body is welded directly to the flexible conductor.
4. The power terminal connector of claim 1 , wherein the terminal body is variably positionable with respect to the power terminal of the first battery module.
5. The power terminal connector of claim 1 , wherein the flexible section allows the first and second mounting portions to move with respect to one another to vary a position of the first mounting portion with respect to the second mounting portion.
6. The power terminal connector of claim 1 , wherein the flexible section comprises a flexible braided wire.
7. The power terminal connector of claim 1 , wherein the flexible section comprises a plurality of flexible metallic strands bundled together.
8. The power terminal connector of claim 1 , wherein the flexible conductor comprises a metal sheet folded over to have multiple layers spanning the flexible section and the first and second mounting portions.
9. The power terminal connector of claim 1 , wherein the flexible section is U-shaped having a first leg and a second leg, the first and second legs movable with respect to one another to change an angle between the first and second legs to change the spacing between the first and second mounting portions.
10. The power terminal connector of claim 1 , wherein the terminal body is box-shaped including a top wall, a bottom wall and opposite side walls defining the receptacle, the bottom wall being welded to the first mounting portion to mechanically and electrically connect the first terminal to the flexible conductor.
11. The power terminal connector of claim 1 , wherein the contact spring includes a first band and a second band, the spring beams extending between the first and second bands, each spring beam having at least two contact bumps between the first and second bands defining interfaces for the power terminal of the second battery module.
12. The power terminal connector of claim 1 , wherein the contact spring includes overstress bumps approximately centrally positioned along each spring beam, the overstress bumps engaging the terminal body to create a power path between the corresponding spring beam and the terminal body.
13. The power terminal connector of claim 1 , wherein the spring beams have contact bumps configured to engage the power terminal of the second battery module, the contact bumps being staggered relative to a front end of the terminal body.
14. The power terminal connector of claim 1 , wherein the terminal body has a series of notches separated by posts at the front end, the contact spring having a series of tabs at a front thereof separated by gaps, the tabs being received in corresponding notches and the gaps receiving corresponding posts to secure the contact spring in the terminal body.
15. The power terminal connector of claim 14 , wherein the tabs are held in the notches and are electrically connected to the terminal body in the notches.
16. The power terminal connector of claim 14 , wherein the posts are held in the gaps and are electrically connected to the contact spring.
17. The power terminal connector of claim 14 , wherein the posts are flared to create flared edges, the flared edges overlap and engage the tabs.
18. The power terminal connector of claim 14 , wherein the terminal body includes a top wall and a bottom wall, the top wall and bottom wall each having notches receiving corresponding tabs.
19. The power terminal connector of claim 14 , wherein the terminal body includes a rear end opposite the front end, the rear end having notches separated by posts, the contact spring having tabs extending from a rear thereof received in corresponding notches in the rear end.
20. The power terminal connector of claim 14 , wherein each tab has multiple points of contact with the terminal body.