A battery connector system includes a tray assembly configured to be mounted to a battery module made from a plurality of battery cells. The tray assembly includes a tray and a plurality of busbars held by the tray. The tray having a base with channels extending through the base. The channels receiv
A battery connector system includes a tray assembly configured to be mounted to a battery module made from a plurality of battery cells. The tray assembly includes a tray and a plurality of busbars held by the tray. The tray having a base with channels extending through the base. The channels receive cell tabs from corresponding battery cells. The tray has a tray connector configured to mate with an electrical connector. The busbars are aligned with corresponding channels and configured to be electrically connected to corresponding cell tabs. The busbars are coupled to the tray. The busbars have pins positioned in the tray connector for direct connection with the electrical connector. Optionally, the battery connector system may include a wire harness connector configured to be coupled to the tray connector that includes a housing holding a plurality of terminals being terminated to corresponding wires configured to be routed to a centralized battery management system and the battery connector system may include a circuit board connector configured to be coupled to the tray connector that has a housing holding a circuit board with a plurality of terminals mounted thereto. Either the wire harness connector or the circuit board connector is selectively coupled to the tray connector to define a centralized or decentralized battery management system, respectively.
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1. A battery connector system comprising: a tray assembly configured to be mounted to a battery module made from a plurality of battery cells, the tray assembly comprising a tray and a plurality of busbars held by the tray such that the tray and busbars are mounted to the battery module together as
1. A battery connector system comprising: a tray assembly configured to be mounted to a battery module made from a plurality of battery cells, the tray assembly comprising a tray and a plurality of busbars held by the tray such that the tray and busbars are mounted to the battery module together as a unit;the tray having a base with channels extending through the base, the channels receiving cell tabs from corresponding battery cells, the tray having a tray connector configured to mate with an electrical connector;the busbars being aligned with corresponding channels and configured to be electrically connected to corresponding cell tabs, the busbars being coupled to the tray, the busbars having pins positioned in the tray connector for direct connection with the electrical connector. 2. The battery connector system of claim 1, wherein the busbars include plates, the plates being oriented parallel to the cell tabs and being configured to be directly electrically connected to corresponding cell tabs, the pins extending from the plates and being generally coplanar with the plates, the plates being positioned exterior of the tray connector, the pins being positioned interior of the tray connector. 3. The battery connector system of claim 1, wherein the busbars include plates, the plates being received in the channels, the plates being welded to the cell tabs. 4. The battery connector system of claim 1, wherein the tray connector includes shroud walls defining chambers, the chambers having open tops configured to receive the electrical connector, the shroud walls having slots therethrough, the busbars extending through corresponding slots to position the pins in corresponding chambers. 5. The battery connector system of claim 1, wherein the tray has a first side and a second side, the tray connector being positioned between the first and second sides, the busbars extending from both sides of the tray connector such that some of the busbars are positioned between the tray connector and the first side and some of the busbars are positioned between the tray connector and the second side. 6. The battery connector system of claim 5, wherein the tray connector is approximately centrally located between the first and second sides. 7. The battery connector system of claim 1, wherein the tray has a mounting platform, at least one busbar includes a mounting base seated on the mounting platform, the mounting base having a post extending therefrom defining an external battery connection for the battery connector system. 8. The battery connector system of claim 1, further comprising a thermistor assembly having a thermistor sensor for measuring a temperature of at least one battery cell, the thermistor assembly including a thermistor contact coupled to the thermistor sensor and extending into the tray connector for electrical connection to the electrical connector. 9. The battery connector system of claim 1, wherein the busbars include at least one locating feature for locating the busbar with respect to the tray. 10. The battery connector system of claim 1, further comprising: a wire harness connector configured to be coupled to the tray connector, the wire harness connector having a housing holding a plurality of terminals, the terminals being terminated to corresponding wires configured to be routed to a centralized battery management system; anda circuit board connector configured to be coupled to the tray connector, the circuit board connector having a housing holding a circuit board, the circuit board having a plurality of terminals mounted thereto;wherein either the wire harness connector or the circuit board connector is selectively coupled to the tray connector to define a centralized or decentralized battery management system, respectively. 11. A battery connector system comprising: a tray assembly configured to be mounted to a battery module made from a plurality of battery cells, the tray assembly comprising a tray and a plurality of busbars held by the tray such that the tray and busbars are mounted to the battery module together as a unit, the tray having a base with channels extending through the base, the channels receiving cell tabs from corresponding battery cells, the tray having a tray connector, the busbars being aligned with corresponding channels and configured to be electrically connected to corresponding cell tabs, the busbars being coupled to the tray, the busbars having pins positioned in the tray connector;a wire harness connector configured to be coupled to the tray connector, the wire harness connector having a housing holding a plurality of terminals, the terminals being terminated to corresponding wires configured to be routed to a centralized battery management system; anda circuit board connector configured to be coupled to the tray connector, the circuit board connector having a housing holding a circuit board, the circuit board having a plurality of terminals mounted thereto;wherein either the wire harness connector or the circuit board connector is selectively coupled to the tray connector to define a centralized or decentralized battery management system, respectively. 12. The battery connector system of claim 11, wherein the busbars include plates, the plates being configured to be directly electrically connected to corresponding cell tabs, the pins extending from the plates, the plates being positioned exterior of the tray connector, the pins being positioned interior of the tray connector. 13. The battery connector system of claim 11, wherein the busbars include plates, the plates being received in the channels, the plates being welded or jointed to the cell tabs. 14. The battery connector system of claim 11, wherein the tray connector includes shroud walls defining chambers, the chambers having open tops configured to receive the wire harness connector or the circuit board connector, the shroud walls having slots therethrough, the busbars extending through corresponding slots to position the pins in corresponding chambers. 15. The battery connector system of claim 11, wherein the tray has a first side and a second side, the tray connector being positioned between the first and second sides, the busbars extending from both sides of the tray connector such that some of the busbars are positioned between the tray connector and the first side and some of the busbars are positioned between the tray connector and the second side. 16. The battery connector system of claim 15, wherein the tray connector is approximately centrally located between the first and second sides. 17. The battery connector system of claim 11, wherein the tray has a mounting platform, at least one busbar includes a mounting base seated on the mounting platform, the mounting base having a post extending therefrom defining an external battery connection for the battery connector system. 18. The battery connector system of claim 11, wherein the busbars include at least one locating feature for locating the busbar with respect to the tray. 19. A battery connector system comprising: a tray assembly configured to be mounted to a battery module made from a plurality of battery cells, the tray assembly comprising a tray and a plurality of busbars held by the tray such that the tray and busbars are mounted to the battery module together as a unit, the busbars being electrically connected to corresponding battery cells, the tray having a tray connector and the busbars having pins positioned in the tray connector; andan electrical connector coupled to the tray connector, the electrical connector having terminals coupled to corresponding pins of the busbars, each terminal comprises a body having a mating end with deflectable beams opposing one another, the mating end having open sides between the beams, the pins being received between the beams to resiliently deflect the beams and extending through the open sides. 20. The battery connector system of claim 19, wherein the beams engage opposite sides of the corresponding pins, the pins extending from the terminals through at least one of the open sides thereof. 21. The battery connector system of claim 19, wherein the busbars include plates, the plates being configured to be directly electrically connected to corresponding cell tabs, the pins extending from the plates, the plates being positioned exterior of the tray connector, the pins being positioned interior of the tray connector. 22. The battery connector system of claim 19, wherein the electrical connector comprises at least one of a wire harness connector or a circuit board connector, the wire harness connector having a housing holding the terminals, the terminals being terminated to corresponding wires configured to be routed to a centralized battery management system, and the circuit board connector has a housing holding a circuit board, the terminals being mounted to the circuit board, wherein either the wire harness connector or the circuit board connector is selectively coupled to the tray connector to define a centralized or decentralized battery management system, respectively.
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