U.S. patent application number 14/704614 was filed with the patent office on 2016-07-07 for snap-in extensions and guide walls for bus bar bridges of a battery module.
The applicant listed for this patent is Johnson Controls Technology Company. Invention is credited to Christopher M. Bonin, Jennifer L. Czarnecki, Richard M. DeKeuster, Jason D. Fuhr, Robert J. Mack, Ken Nakayama, Dale B. Trester, Matthew R. Tyler, Xugang Zhang.
Application Number | 20160197320 14/704614 |
Document ID | / |
Family ID | 56286968 |
Filed Date | 2016-07-07 |
United States Patent
Application |
20160197320 |
Kind Code |
A1 |
Mack; Robert J. ; et
al. |
July 7, 2016 |
SNAP-IN EXTENSIONS AND GUIDE WALLS FOR BUS BAR BRIDGES OF A BATTERY
MODULE
Abstract
The present disclosure includes a battery module having a group
of electrically interconnected electrochemical cells, a battery
module terminal configured to be coupled to a load for powering the
load, and an electrical path extending between the group of
electrically interconnected electrochemical cells and the battery
module terminal, where the electrical path includes a bus bar
bridge. The battery module also includes a housing, where the group
of electrically interconnected electrochemical cells is disposed
within the housing, and the housing includes a pair of extensions
positioned along sides of the bus bar bridge and configured to
retain the bus bar bridge and to block movement of the bus bar
bridge in at least one direction.
Inventors: |
Mack; Robert J.; (Milwaukee,
WI) ; DeKeuster; Richard M.; (Racine, WI) ;
Czarnecki; Jennifer L.; (Franklin, WI) ; Nakayama;
Ken; (Franklin, WI) ; Tyler; Matthew R.;
(Brown Deer, WI) ; Bonin; Christopher M.; (South
Milwaukee, WI) ; Zhang; Xugang; (Milwaukee, WI)
; Trester; Dale B.; (Milwaukee, WI) ; Fuhr; Jason
D.; (Sussex, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson Controls Technology Company |
Holland |
MI |
US |
|
|
Family ID: |
56286968 |
Appl. No.: |
14/704614 |
Filed: |
May 5, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62100001 |
Jan 5, 2015 |
|
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|
Current U.S.
Class: |
429/158 |
Current CPC
Class: |
H01M 2/206 20130101;
H01M 10/0525 20130101; H01M 2/22 20130101; H01M 2/305 20130101;
H01M 10/613 20150401; H01M 2/1205 20130101; H01M 2/1077 20130101;
G01R 31/3835 20190101; H01M 2/1241 20130101; H01M 10/052 20130101;
H01M 10/0413 20130101; H01M 10/647 20150401; H01M 2220/10 20130101;
H01M 2/1005 20130101; H01M 2/30 20130101; H01M 10/058 20130101;
G01R 31/396 20190101; H01M 2/10 20130101; H01M 2/32 20130101; H01M
2/12 20130101; H01M 2/1217 20130101; H01M 2010/4271 20130101; H01M
2/1083 20130101; H01M 10/6551 20150401; H01M 10/6557 20150401; H01M
2/1016 20130101; H01M 10/65 20150401; H01M 10/653 20150401; H01M
2/04 20130101; H01M 2220/20 20130101; H01M 2/02 20130101; H01M
2/1252 20130101; H01M 2/1294 20130101; H01M 2/24 20130101; H01M
10/4257 20130101; H01M 2/1072 20130101; H01M 2/18 20130101; H01M
2/34 20130101; H01M 10/4207 20130101; H01M 10/482 20130101; H01M
2/1211 20130101; H01M 2/20 20130101; H01M 10/02 20130101; H01M
10/60 20150401; H01M 10/625 20150401; Y02E 60/10 20130101 |
International
Class: |
H01M 2/10 20060101
H01M002/10; H01M 2/20 20060101 H01M002/20; H01M 10/0525 20060101
H01M010/0525 |
Claims
1. A lithium-ion (Li-ion) battery module, comprising: a group of
electrically interconnected electrochemical cells; a battery module
terminal configured to be coupled to a load for powering the load;
an electrical path extending between the group of electrically
interconnected electrochemical cells and the battery module
terminal, wherein the electrical path comprises a bus bar bridge;
and a housing, wherein the group of electrically interconnected
electrochemical cells is disposed within the housing, and wherein
the housing comprises a pair of extensions positioned along sides
of the bus bar bridge and configured to retain the bus bar bridge
and to block movement of the bus bar bridge in at least one
direction.
2. The Li-ion battery module of claim 1, wherein the pair of
extensions is configured to block movement of the bus bar bridge
only along a transverse axis of the bus bar bridge.
3. The Li-ion battery module of claim 1, wherein the pair of
extensions is configured to block movement of the bus bar bridge
only along a transverse axis of the bus bar bridge and a
longitudinal axis of the bus bar bridge perpendicular to the
transverse axis.
4. The Li-ion battery module of claim 1, wherein the pair of
extensions is configured to block movement of the bus bar bridge
only along a transverse axis of the bus bar bridge, a longitudinal
axis of the bus bar bridge perpendicular to the transverse axis,
and an axis along a thickness of the bus bar bridge perpendicular
to both the transverse and longitudinal axes.
5. The Li-ion battery module of claim 1, wherein the bus bar bridge
comprises an S-shape having a first base, a second base, and an
S-bend extending between the first base and the second base.
6. The Li-ion battery module of claim 5, wherein the first base of
the bus bar bridge extends between the extensions of the pair of
extensions.
7. The Li-ion battery module of claim 5, wherein the S-bend extends
between the extensions of the pair of extensions.
8. The Li-ion battery module of claim 5, wherein the housing
comprises an additional pair of extensions positioned along the
sides of the bus bar bridge and configured to retain the bus bar
bridge and to block movement of the bus bar bridge in at least one
direction, wherein the first base of the bus bar bridge extends
between the extensions of the pair of extensions, wherein the
second base of the bus bar bridge extends between the additional
extensions of the additional pair of extensions, and wherein the
pair of extensions and the additional pair of extensions extend in
a first vertical direction substantially parallel to at least the
portion of the S-bend of the bus bar bridge.
9. The Li-ion battery module of claim 1, wherein each extension of
the pair of extensions comprises a hook that extends toward the
other extension of the pair of extensions and over at least a
portion of the bus bar bridge.
10. The Li-ion battery module of claim 9, wherein the hook of each
extension comprises a corresponding right triangle having a base
facing a first portion of the bus bar bridge and parallel with the
first portion of the bus bar bridge.
11. The Li-ion battery module of claim 1, wherein the group of
electrically interconnected electrochemical cells comprises a group
of electrically interconnected prismatic lithium-ion (Li-ion)
electrochemical cells.
12. The Li-ion battery module of claim 1, wherein the bus bar
bridge is positioned proximate to the pair of extensions such that
a first weld point of the bus bar bridge is exposed with sufficient
clearance for access via a welding tool on a first side of the pair
of extensions, and a second weld point of the bus bar bridge is
exposed with sufficient clearance for access via the welding tool
on a second side of the pair of extensions opposite to the first
side.
13. The Li-ion battery module of claim 1, wherein the battery
module comprises a shunt, and the bus bar bridge is welded to the
shunt.
14. The Li-ion battery module of claim 1, wherein the pair of
extensions extend above a first surface of a first base of the bus
bar bridge.
15. The Li-ion battery module of claim 1, wherein the battery
module comprises a relay switch mechanism and the bus bar bridge is
coupled to a component of the relay switch mechanism.
16. The Li-ion battery module of claim 1, wherein the housing and
the pair of extensions are plastic, and the pair of extensions is
integrally formed with the housing.
17. A lithium-ion (Li-ion) battery module, comprising: a housing; a
plurality of electrochemical cells disposed in the housing; a major
terminal of the battery module; and an electrical path extending
between the plurality of electrochemical cells and the major
terminal of the battery module, wherein the electrical path
comprises an S-shaped bus bar bridge having a first base, a second
base, and an S-bend extending between the first and second bases,
wherein the housing comprises a first extension extending upwardly
and proximate to a first side of the S-shaped bus bar bridge and a
second extension extending upwardly and proximate to a second side
of the S-shaped bus bar bridge opposite to the first side, and
wherein the first and second extensions are configured to block
movement of the S-shaped bus bar bridge along at least one axis of
the S-shaped bus bar bridge.
18. The Li-ion battery module of claim 17, wherein the first and
second extensions are together configured to block movement of the
S-shaped bus bar bridge along at least a first axis of the S-shaped
bus bar bridge and a second axis of the S-shaped bus bar bridge
perpendicular to the first axis.
19. The Li-ion battery module of claim 17, wherein the first and
second extensions are together configured to block movement of the
S-shaped bus bar bridge along at least a first axis of the S-shaped
bus bar bridge, a second axis of the S-shaped bus bar bridge
perpendicular to the first axis, and a third axis of the S-shaped
bus bar bridge perpendicular to the first and second axes.
20. The Li-ion battery module of claim 17, wherein the first
extension comprises a first pointed edge extending toward the
second extension, and the second extension comprises a second
pointed edge extending toward the first extension.
21. A lithium-ion (Li-ion) battery module, comprising: an
electrical path extending between a group of electrically
interconnected electrochemical cells and a terminal of the battery
module, wherein the terminal is configured to be coupled to a load
for powering the load; a bus bar bridge of the electrical path; and
at least one snap-in extension integrally formed with a housing of
the battery module and disposed immediately adjacent the bus bar
bridge, wherein the at least one snap-in extension comprises a hook
extending over the bus bar bridge and the at least one snap-in
extension is configured to at least temporarily block movement of
the bus bar bridge in at least one direction.
22. The Li-ion battery module of claim 21, wherein the hook
comprises a first right triangle having a lower flat surface facing
a base of the bus bar bridge and parallel with the base.
23. The Li-ion battery module of claim 21, wherein the bus bar
bridge is an S-shaped bus bar bridge having a first base, a second
base, and an S-bend extending between the first base and the second
base.
24. The Li-ion battery module of claim 21, wherein the at least one
snap-in extension is disposed immediately adjacent the base of the
bus bar bridge such that the hook extends over the base of the bus
bar bridge.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from and the benefit of
U.S. Provisional Application Ser. No. 62/100,001, filed Jan. 5,
2015, entitled "MECHANICAL AND ELECTRICAL ASPECTS OF LITHIUM ION
BATTERY MODULE WITH VERTICAL AND HORIZONTAL CONFIGURATIONS," which
is hereby incorporated by reference in its entirety for all
purposes.
BACKGROUND
[0002] The present disclosure relates generally to the field of
batteries and battery modules. More specifically, the present
disclosure relates to positioning and retention of bus bar bridges
of a battery module.
[0003] This section is intended to introduce the reader to various
aspects of art that may be related to various aspects of the
present disclosure, which are described below. This discussion is
believed to be helpful in providing the reader with background
information to facilitate a better understanding of the various
aspects of the present disclosure. Accordingly, it should be
understood that these statements are to be read in this light, and
not as admissions of prior art.
[0004] A vehicle that uses one or more battery systems for
providing all or a portion of the motive power for the vehicle can
be referred to as an xEV, where the term "xEV" is defined herein to
include all of the following vehicles, or any variations or
combinations thereof, that use electric power for all or a portion
of their vehicular motive force. For example, xEVs include electric
vehicles (EVs) that utilize electric power for all motive force. As
will be appreciated by those skilled in the art, hybrid electric
vehicles (HEVs), also considered xEVs, combine an internal
combustion engine propulsion system and a battery-powered electric
propulsion system, such as 48 Volt (V) or 130V systems. The term
HEV may include any variation of a hybrid electric vehicle. For
example, full hybrid systems (FHEVs) may provide motive and other
electrical power to the vehicle using one or more electric motors,
using only an internal combustion engine, or using both. In
contrast, mild hybrid systems (MHEVs) disable the internal
combustion engine when the vehicle is idling and utilize a battery
system to continue powering the air conditioning unit, radio, or
other electronics, as well as to restart the engine when propulsion
is desired. The mild hybrid system may also apply some level of
power assist, during acceleration for example, to supplement the
internal combustion engine. Mild hybrids are typically 96V to 130V
and recover braking energy through a belt or crank integrated
starter generator. Further, a micro-hybrid electric vehicle (mHEV)
also uses a "Stop-Start" system similar to the mild hybrids, but
the micro-hybrid systems of a mHEV may or may not supply power
assist to the internal combustion engine and operates at a voltage
below 60V. For the purposes of the present discussion, it should be
noted that mHEVs typically do not technically use electric power
provided directly to the crankshaft or transmission for any portion
of the motive force of the vehicle, but an mHEV may still be
considered as an xEV since it does use electric power to supplement
a vehicle's power needs when the vehicle is idling with internal
combustion engine disabled and recovers braking energy through an
integrated starter generator. In addition, a plug-in electric
vehicle (PEV) is any vehicle that can be charged from an external
source of electricity, such as wall sockets, and the energy stored
in the rechargeable battery packs drives or contributes to drive
the wheels. PEVs are a subcategory of EVs that include all-electric
or battery electric vehicles (BEVs), plug-in hybrid electric
vehicles (PHEVs), and electric vehicle conversions of hybrid
electric vehicles and conventional internal combustion engine
vehicles.
[0005] xEVs as described above may provide a number of advantages
as compared to more traditional gas-powered vehicles using only
internal combustion engines and traditional electrical systems,
which are typically 12V systems powered by a lead acid battery. For
example, xEVs may produce fewer undesirable emission products and
may exhibit greater fuel efficiency as compared to traditional
internal combustion vehicles and, in some cases, such xEVs may
eliminate the use of gasoline entirely, as is the case of certain
types of EVs or PEVs.
[0006] As technology continues to evolve, there is a need to
provide improved power sources, particularly battery modules, for
such vehicles. For example, in traditional configurations, battery
modules may include components configured to provide electrical
communication between one or more terminals of the battery module
and a group of electrically interconnected electrochemical cells of
the battery module. Unfortunately, traditional configurations may
include expensive components to provide the electrical
communication (e.g., electrical path) between the group of
electrically interconnected electrochemical cells and the one or
more terminals of the battery module. Further, manufacturing
processes to position said components and to enable the electrical
communication may be expensive and inefficient. Accordingly, it is
now recognized that improved components and manufacturing processes
for electrically coupling electrochemical cells and terminals of a
battery module are desired.
SUMMARY
[0007] A summary of certain embodiments disclosed herein is set
forth below. It should be understood that these aspects are
presented merely to provide the reader with a brief summary of
certain embodiments and that these aspects are not intended to
limit the scope of this disclosure. Indeed, this disclosure may
encompass a variety of aspects that may not be set forth below.
[0008] The present disclosure relates to a battery module having a
group of electrically interconnected electrochemical cells, a
battery module terminal configured to be coupled to a load for
powering the load, and an electrical path extending between the
group of electrically interconnected electrochemical cells and the
battery module terminal, where the electrical path includes a bus
bar bridge. The battery module also includes a housing, where the
group of electrically interconnected electrochemical cells is
disposed within the housing, and the housing includes a pair of
extensions positioned along sides of the bus bar bridge and
configured to retain the bus bar bridge and to block movement of
the bus bar bridge in at least one direction.
[0009] The present disclosure also relates a battery module having
a housing, electrochemical cells disposed in the housing, a major
terminal, and an electrical path extending between the
electrochemical cells and the major terminal. The electrical path
includes an S-shaped bus bar bridge having a first base, a second
base, and an S-bend extending between the first and second bases.
The housing includes a first extension extending upwardly and
proximate to a first side of the S-shaped bus bar bridge, and a
second extension extending upwardly and proximate to a second side
of the S-shaped bus bar bridge opposite to the first side. The
first and second extensions are configured to block movement of the
S-shaped bus bar bridge along at least one axis of the S-shaped bus
bar bridge.
[0010] The present disclosure also relates to a battery module
having an electrical path extending between a group of electrically
interconnected electrochemical cells and a terminal of the battery
module, where the terminal is configured to be coupled to a load
for powering the load. The battery module also includes a bus bar
bridge of the electrical path. Further, the battery module includes
at least one snap-in extension integrally formed with a housing of
the battery module and disposed immediately adjacent the bus bar
bridge, wherein the at least one snap-in extension comprises a hook
extending over the bus bar bridge and the at least one snap-in
extension is configured to at least temporarily block movement of
the bus bar bridge in at least one direction.
DRAWINGS
[0011] Various aspects of this disclosure may be better understood
upon reading the following detailed description and upon reference
to the drawings in which:
[0012] FIG. 1 is a perspective view of a vehicle having a battery
system configured in accordance with present embodiments to provide
power for various components of the vehicle;
[0013] FIG. 2 is a cutaway schematic view of an embodiment of the
vehicle and the battery system of FIG. 1;
[0014] FIG. 3 is an overhead exploded perspective view of an
embodiment of a battery module for use in the vehicle of FIG. 1, in
accordance with an aspect of the present disclosure;
[0015] FIG. 4 is a perspective view of an embodiment of the battery
module of FIG. 3, in accordance with an aspect of the present
disclosure;
[0016] FIG. 5 is a front view of an embodiment of the battery
module of FIG. 3, in accordance with an aspect of the present
disclosure;
[0017] FIG. 6 is a front schematic view of an embodiment of snap-in
extensions and a bus bar bridge, taken along line 6-6 in FIG. 5,
for use in the battery module of FIG. 3, in accordance with an
aspect of the present disclosure;
[0018] FIG. 7 is a side schematic view of an embodiment of snap-in
extensions, a bus bar bridge, and other components for use in the
battery module of FIG. 3, in accordance with an aspect;
[0019] FIG. 8 is a front schematic view of an embodiment of guide
walls and a bus bar bridge for use in the battery module of FIG. 3,
in accordance with an aspect of the present disclosure;
[0020] FIG. 9 is a side schematic view of an embodiment of guide
walls, a bus bar bridge, and other components for use in the
battery module of FIG. 3, in accordance with an aspect of the
present disclosure;
[0021] FIG. 10 is a top schematic view of an embodiment of a bus
bar bridge, in accordance with an aspect of the present disclosure;
and
[0022] FIG. 11 is a schematic view of an embodiment of an
electrical path for use in the battery module of FIG. 3, in
accordance with an aspect of the present disclosure; and
[0023] FIG. 12 is a process flow diagram of an embodiment of a
method of securing a bus bar bridge of the battery module of FIG.
3, in accordance with an aspect of the present disclosure.
DETAILED DESCRIPTION
[0024] One or more specific embodiments will be described below. In
an effort to provide a concise description of these embodiments,
not all features of an actual implementation are described in the
specification. It should be appreciated that in the development of
any such actual implementation, as in any engineering or design
project, numerous implementation-specific decisions must be made to
achieve the developers' specific goals, such as compliance with
system-related and business-related constraints, which may vary
from one implementation to another. Moreover, it should be
appreciated that such a development effort might be complex and
time consuming, but would nevertheless be a routine undertaking of
design, fabrication, and manufacture for those of ordinary skill
having the benefit of this disclosure.
[0025] The battery systems described herein may be used to provide
power to various types of electric vehicles (xEVs) and other high
voltage energy storage/expending applications (e.g., electrical
grid power storage systems). Such battery systems may include one
or more battery modules, each battery module having a number of
battery cells (e.g., lithium-ion (Li-ion) electrochemical cells)
arranged and electrically interconnected to provide particular
voltages and/or currents useful to power, for example, one or more
components of an xEV. As another example, battery modules in
accordance with present embodiments may be incorporated with or
provide power to stationary power systems (e.g., non-automotive
systems).
[0026] In accordance with embodiments of the present disclosure,
the battery module may include a group of electrically
interconnected electrochemical cells disposed in a housing of the
battery module. The battery module may also include two terminals
(e.g., module terminals or major terminals) extending outwardly
from the housing and configured to be coupled to a load for
powering the load. Two corresponding electrical paths may be
defined between the group of electrically interconnected
electrochemical cells and the two corresponding terminals of the
battery module. For example, a first electrical path may be
established between the group of electrically interconnected
electrochemical cells and a first terminal (e.g., a first major
terminal) of the battery module. A second electrical path may be
established between the group of electrically interconnected
electrochemical cells and a second terminal (e.g., a second major
terminal) of the battery module.
[0027] In certain embodiments, the electrical paths between the
group of electrically interconnected electrochemical cells and the
two terminals of the battery module may include corresponding
transitions between a first and second material. For example, the
electrochemical cells may be electrically interconnected via bus
bars that include the first material (e.g., aluminum). The two
major terminals (and/or other components of the battery module,
such as a shunt) that are configured to be coupled to the load may
include the second material (e.g., copper), which may cost less
than the first material but may not be compatible with the
electrochemical cells and thus, may not be used for the bus bars.
Accordingly, components that enable the transition between the
first and second materials (e.g., of the bus bars and of the major
terminals, respectively) may be included in both of the first and
second electrical paths. For example, a bi-metal bus bar may be
disposed in both the first and second electrical paths to enable
the transition from the first material (of the bus bars) to the
second material (of the major terminals) in each of the paths. The
bi-metal bus bars may be bi-metallic, and may each include a first
end having the first material and coupled to a first component
(e.g., a terminal of one of the electrochemical cells or a bus bar
extending from one of the terminals of one of the electrochemical
cells) of the electrical path having the first material, and a
second end having the second material and coupled to a second
component (e.g., a bus bar bridge) of the electrical path having
the second material. The bus bar bridges of each electrical path
may extend between the corresponding bi-metal bus bar and another
corresponding component of the battery module (e.g., a shunt or
relay having the second material). Additional bus bar bridges
having the second material may also be included in each electrical
path, as set forth below with reference to the figures, to couple
the electrical paths with the major terminals having the second
material.
[0028] To couple the bus bar bridges to the appropriate components
of the electrical paths, the bus bar bridges may be welded at
either end (e.g., to the bi-metal bus bar on a first end and to the
shunt or relay on a second end, as described above). However, to
enable efficient manufacturing of the battery module, in accordance
with present embodiments, the housing of the battery module may
include snap-in extensions or guide walls that enable temporary
retention of the bus bar bridges or support for the bus bar bridges
in one or more directions. For example, the snap-in extensions or
guide walls may be integrally formed with the housing of the
battery module, and may be configured to receive the bus bar
bridges and to enable retention of the bus bar bridges (e.g., by
blocking movement of the bus bar bridges in one or more
directions), while facilitating exposure of weld points of the bus
bar bridges to a welding tool. In other words, in certain
embodiments, the snap-in extensions or guide walls may enable
retention of the bus bar bridges while the battery module is
oriented in the one or more directions. Thus, the bus bar bridges
may be held in place while the battery module is oriented
complimentary to the retention capabilities of the snap-in
extensions or guide posts and complimentary to the positioning of a
welding tool along the weld points of the bus bar bridges for
welding the bus bar bridges to appropriate components of the
electrical paths. Further, the retention mechanisms (e.g., the
snap-in features) may be minimally invasive (e.g., via sizing
and/or positioning of the retention mechanisms), such that a
welding tool may access weld points on the bus bar bridges to more
permanently secure the bus bar bridges in the electrical
path(s).
[0029] To help illustrate, FIG. 1 is a perspective view of an
embodiment of a vehicle 10, which may utilize a regenerative
braking system. Although the following discussion is presented in
relation to vehicles with regenerative braking systems, the
techniques described herein are adaptable to other vehicles that
capture/store electrical energy with a battery, which may include
electric-powered and gas-powered vehicles.
[0030] As discussed above, it would be desirable for a battery
system 12 to be largely compatible with traditional vehicle
designs. Accordingly, the battery system 12 may be placed in a
location in the vehicle 10 that would have housed a traditional
battery system. For example, as illustrated, the vehicle 10 may
include the battery system 12 positioned similarly to a lead-acid
battery of a typical combustion-engine vehicle (e.g., under the
hood of the vehicle 10). Furthermore, as will be described in more
detail below, the battery system 12 may be positioned to facilitate
managing temperature of the battery system 12. For example, in some
embodiments, positioning a battery system 12 under the hood of the
vehicle 10 may enable an air duct to channel airflow over the
battery system 12 and cool the battery system 12.
[0031] A more detailed view of the battery system 12 is described
in FIG. 2. As depicted, the battery system 12 includes an energy
storage component 13 coupled to an ignition system 14, an
alternator 15, a vehicle console 16, and optionally to an electric
motor 17. Generally, the energy storage component 13 may
capture/store electrical energy generated in the vehicle 10 and
output electrical energy to power electrical devices in the vehicle
10.
[0032] In other words, the battery system 12 may supply power to
components of the vehicle's electrical system, which may include
radiator cooling fans, climate control systems, electric power
steering systems, active suspension systems, auto park systems,
electric oil pumps, electric super/turbochargers, electric water
pumps, heated windscreen/defrosters, window lift motors, vanity
lights, tire pressure monitoring systems, sunroof motor controls,
power seats, alarm systems, infotainment systems, navigation
features, lane departure warning systems, electric parking brakes,
external lights, or any combination thereof. Illustratively, in the
depicted embodiment, the energy storage component 13 supplies power
to the vehicle console 16 and the ignition system 14, which may be
used to start (e.g., crank) the internal combustion engine 18.
[0033] Additionally, the energy storage component 13 may capture
electrical energy generated by the alternator 15 and/or the
electric motor 17. In some embodiments, the alternator 15 may
generate electrical energy while the internal combustion engine 18
is running. More specifically, the alternator 15 may convert the
mechanical energy produced by the rotation of the internal
combustion engine 18 into electrical energy. Additionally or
alternatively, when the vehicle 10 includes an electric motor 17,
the electric motor 17 may generate electrical energy by converting
mechanical energy produced by the movement of the vehicle 10 (e.g.,
rotation of the wheels) into electrical energy. Thus, in some
embodiments, the energy storage component 13 may capture electrical
energy generated by the alternator 15 and/or the electric motor 17
during regenerative braking. As such, the alternator 15 and/or the
electric motor 17 are generally referred to herein as a
regenerative braking system.
[0034] To facilitate capturing and supplying electric energy, the
energy storage component 13 may be electrically coupled to the
vehicle's electric system via a bus 19. For example, the bus 19 may
enable the energy storage component 13 to receive electrical energy
generated by the alternator 15 and/or the electric motor 17.
Additionally, the bus 19 may enable the energy storage component 13
to output electrical energy to the ignition system 14 and/or the
vehicle console 16. Accordingly, when a 12 volt battery system 12
is used, the bus 19 may carry electrical power typically between
8-18 volts.
[0035] Additionally, as depicted, the energy storage component 13
may include multiple battery modules. For example, in the depicted
embodiment, the energy storage component 13 includes a lithium ion
(e.g., a first) battery module 20 and a lead-acid (e.g., a second)
battery module 22, which each includes one or more battery cells.
In other embodiments, the energy storage component 13 may include
any number of battery modules. Additionally, although the lithium
ion battery module 20 and lead-acid battery module 22 are depicted
adjacent to one another, they may be positioned in different areas
around the vehicle. For example, the lead-acid battery module 22
may be positioned in or about the interior of the vehicle 10 while
the lithium ion battery module 20 may be positioned under the hood
of the vehicle 10.
[0036] In some embodiments, the energy storage component 13 may
include multiple battery modules to utilize multiple different
battery chemistries. For example, when the lithium ion battery
module 20 is used, performance of the battery system 12 may be
improved since the lithium ion battery chemistry generally has a
higher coulombic efficiency and/or a higher power charge acceptance
rate (e.g., higher maximum charge current or charge voltage) than
the lead-acid battery chemistry. As such, the capture, storage,
and/or distribution efficiency of the battery system 12 may be
improved.
[0037] To facilitate controlling the capturing and storing of
electrical energy, the battery system 12 may additionally include a
control module 24. More specifically, the control module 24 may
control operations of components in the battery system 12, such as
relays (e.g., switches) within energy storage component 13, the
alternator 15, and/or the electric motor 17. For example, the
control module 24 may regulate amount of electrical energy
captured/supplied by each battery module 20 or 22 (e.g., to de-rate
and re-rate the battery system 12), perform load balancing between
the battery modules 20 and 22, determine a state of charge of each
battery module 20 or 22, determine temperature of each battery
module 20 or 22, control voltage output by the alternator 15 and/or
the electric motor 17, and the like.
[0038] Accordingly, the control unit 24 may include one or more
processor 26 and one or more memory 28. More specifically, the one
or more processor 26 may include one or more application specific
integrated circuits (ASICs), one or more field programmable gate
arrays (FPGAs), one or more general purpose processors, or any
combination thereof. Additionally, the one or more memory 28 may
include volatile memory, such as random access memory (RAM), and/or
non-volatile memory, such as read-only memory (ROM), optical
drives, hard disc drives, or solid-state drives. In some
embodiments, the control unit 24 may include portions of a vehicle
control unit (VCU) and/or a separate battery control module.
[0039] An overhead exploded perspective view of an embodiment of
the battery module 20 for use in the vehicle 10 of FIG. 2 is shown
in FIG. 3. In the illustrated embodiment, the battery module 20
(e.g., lithium-ion [Li-ion] battery module) includes a housing 30
and electrochemical cells 32 (e.g., prismatic lithium-ion [Li-ion]
electrochemical cells) disposed inside the housing 30. In the
illustrated embodiment, six prismatic Li-ion electrochemical cells
32 are disposed in two stacks 34 within the housing 30, three
electrochemical cells 32 in each stack 34. However, in other
embodiments, the battery module 20 may include any number of
electrochemical cells 32 (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more
electrochemical cells), any type of electrochemical cell 32 (e.g.,
Li-ion, lithium polymer, lead-acid, nickel cadmium, or nickel metal
hydride, prismatic, and/or cylindrical), and any arrangement of the
electrochemical cells 32 (e.g., stacked, separated, or
compartmentalized).
[0040] As shown, the electrochemical cells 32 may include terminals
36 (e.g., cell terminals, minor terminals) extending upwardly
(e.g., in direction 37). Accordingly, the terminals 36 may extend
into an opening 38 disposed in an upper side 40 or face of the
housing 30. For example, the electrochemical cells 32 may be
inserted into the housing 30 through the opening 38 in the upper
side 40, and positioned within the housing 30 such that the
terminals 36 of the electrochemical cells 32 are disposed in the
opening 38. A bus bar carrier 42 may be disposed into the opening
38 and may retain bus bars 44 disposed thereon and configured to
interface with the terminals 36 of the electrochemical cells 32.
For example, the bus bars 44 may interface with the terminals 36 to
electrically couple adjacent electrochemical cells 32 together
(e.g., to form a group of electrically interconnected
electrochemical cells 32). The bus bars 44 may be mounted or
disposed on or proximate to a top or a bottom face or surface of
the bus bar carrier 42 (e.g., facing away from the electrochemical
cells 32 or facing the electrochemical cells 32). However, in other
embodiments, the battery module 20 may not include the bus bar
carrier 42 and the bus bars 44 may be disposed directly onto the
terminals 36.
[0041] Depending on the embodiment, the bus bars 44 may couple the
electrochemical cells 32 in series, in parallel, or some of the
electrochemical cells 32 in series and some of the electrochemical
cells 32 in parallel. In general, the bus bars 44 enable a group of
electrically interconnected electrochemical cells 32. Further,
certain of the bus bars 44 may be configured to enable electrical
coupling of the group of electrically interconnected
electrochemical cells 32 with major terminals 46 (e.g., module
terminals) of the battery module 20, where the major terminals 46
are configured to be coupled to a load (e.g., component(s) of the
vehicle 10) to power the load. A cover 54 may be disposed over the
bus bar carrier 42 to seal the opening 38 in the housing 30 of the
battery module 20 and/or to protect the bus bars 44, other
components disposed on the bus bar carrier 42, and/or other
components of the battery module 20.
[0042] In accordance with present embodiments, the bus bars 44
(e.g., disposed on the bus bar carrier 42) may include two major
bus bars 56 configured to enable electrical communication between
the group of electrically interconnected electrochemical cells 32
and the major terminals 46. For example, the two major bus bars 56
may extend beyond a perimeter 58 of the bus bar carrier 42 (e.g.,
in direction 61) and may each define at least a portion of a
corresponding electrical path between the group of electrically
interconnected electrochemical cells 32 and the major terminals 46.
The major bus bars 56 may include a first material (e.g., aluminum)
corresponding with a material of the terminals 36 of the
electrochemical cells 32 and with the bus bars 44 (e.g., minor bus
bars or cell bus bars). In accordance with present embodiments,
each major bus bar 56 may extend from the group of electrically
interconnected electrochemical cells 32 toward another component of
the corresponding electrical path extending between the group of
electrically interconnected electrochemical cells 32 and the
corresponding major terminal 46.
[0043] For example, the major bus bars 56 may each extend toward a
corresponding bi-metal bus bar 59 that facilitates transition of
the electrical path from the first material (e.g., aluminum) to a
second material (e.g., copper), which will be described in detail
with reference to later figures. In the illustrated embodiment,
only one bi-metal bus bar 59 is shown in one of the electrical
paths, although it should be noted that the other of the electrical
paths may also include the bi-metal bus bar 59. As shown, the
bi-metal bus bar 59 may be coupled on a first end to the major bus
bar 56, and on a second end to another component of the electrical
path. For example, in the illustrated embodiment, one of the
electrical paths (e.g., having the illustrated bi-metal bus bar 59)
includes a shunt 60 coupled to a printed circuit board (PCB) 62 of
the battery module 20, where the shunt 60 includes the second
material (e.g., copper) and the PCB 62 detects in the shunt 60 a
voltage, a temperature, and/or other important parameters of the
electrical path and the battery module 20 in general. In accordance
with present embodiments, bus bar bridges 64 having the second
material (e.g., copper) may be included in the electrical path on
either end of the shunt 60. For example, one bus bar bridge 64
extends between, and couples to, the second end (e.g., copper end)
of the bi-metal bus bar 59 and the shunt 60. It should be noted
that the coupling of the bus bar bridge 64 to the bi-metal bus bar
59 is blocked from view in the illustrated embodiment by the
housing 30. Another bus bar bridge 64 extends between, and couples
to, the shunt 60 and another component of the electrical path
(e.g., the major terminal 46 or a connecting piece between the bus
bar bridge 64 and the major terminal 46). It should be noted that
the coupling of the bus bar bridge 64 and the other component of
the electrical path (e.g., the major terminal 46 or connecting
piece between the major terminal 46 and the bus bar bridge 64) is
blocked from view in the illustrated embodiment by the housing
30.
[0044] In accordance with the present disclosure, the bus bar
bridges 64 may be at least temporarily retained (e.g., before being
welded to the components of the electrical path described above)
via snap-in extensions or guide walls extending from the housing 30
(e.g., integrally formed with the housing 30), where the snap-in
extensions or guide walls block movement of the bus bar bridges 64
in at least one direction or along one axis (e.g., along axis 37
[longitudinal axis with respect to the bus bar bridges 64], axis 61
[axis along a thickness of the bus bar bridges 64], or axis 66
[axis along the width of the bus bar bridges 64]). It should be
noted that the bus bar bridges 64 may couple to a component of the
battery module 20 other than the PCB 62 (e.g., to a relay or
switch). For example, in the illustrated embodiment, the bus bar
bridges 64 are only shown for one of the electrical paths, but the
other electrical path may include bus bar bridges 64 coupled to a
relay or switch. It should also be noted that, in other
embodiments, the electrical paths may include other components that
facilitate transition between the first and the second materials,
and that the bus bar bridges 64 may couple to such other
components.
[0045] Turning now to FIGS. 4 and 5, a perspective view and a front
view, respectively, of an embodiment of the battery module 20 of
FIG. 3 is shown. In the illustrated embodiments, as previously
described, the shunt 60 of one of the electrical paths may be
coupled to the PCB 62, where the PCB 62 (or signals of the PCB 62
or of the battery module 20) detects and/or analyzes operating
parameters or conditions of the battery module 20 (e.g., of the
electrical path having the shunt 60). The electrical path also
includes the bus bar bridges 64, which electrically couple the
shunt 60 to the electrically interconnected electrochemical cells
32 within the housing 30 of the battery module 20 and to the major
terminal 46 of the battery module 20 (e.g., the major terminal 46
configured to be coupled to a load). Further, as previously
described, the housing 30 may include snap-in extensions 70 (or
guide walls) through which the bus bar bridges 64 extend, where the
snap-in extensions 70 retain the bus bar bridges 64 (e.g., block
movement of the bus bar bridges 64) in one or more directions
(e.g., along axis 37, axis 61, axis 66, or a combination
thereof).
[0046] As shown in the illustrated embodiments, the battery module
20 may include one electrical path for each major terminal 46. For
example, as shown, one electrical path extends through the shunt 60
coupled to the PCB 62, while the other electrical path extends
through a relay 71 of the battery module 20. The relay 71 may be a
switch (or include a switch mechanism) that enables coupling and
decoupling of the electrical path. For example, the switch
mechanism of the relay 71 may be opened to disconnect the circuit
between the two major terminals 46 (and having the group of
electrically interconnected electrochemical cells 32 and two
electrical paths) of the battery module 20. The switch mechanism of
the relay 71 may be closed to connect the circuit between the two
major terminals 46 of the battery module 20. The electrical path
having the relay 71 (or coupled to the relay 71) may also include
bus bar bridges 64, where the bus bar bridges 64 extend from either
end of the relay 71 or component of the relay 71. Thus, the
electrical path extends from the electrochemical cells 32, through
the bi-metal bus bar 59, through one of the bus bar bridges 64,
through the relay 71 (or component thereof), through the other one
of the bus bar bridges 64, and to the major terminal 46.
[0047] It should be noted that the snap-in extensions 70 may
include hooks 72 that extend inwardly and over the bus bar bridge
64. For example, a cross-sectional schematic view of an embodiment
of a pair of snap-in extensions 70, taken along line 6-6 in FIG. 5
and for use in the battery module 20 of FIG. 3, is shown in FIG. 6.
In the illustrated embodiment, each snap-in extension 70 includes a
hook 72 (e.g., triangle, right triangle, triangular prism, point,
pointed hook) extending toward the other extension 70 of the pair.
For example, each hook 72 may include a point 73 that points toward
the other extension 70. Put differently, each hook 72 may be
triangular (e.g., a right triangle) having a downwardly and
inwardly sloping surface 74 that slopes toward the point 73. The
surface 74 may enable pushing of the bus bar bridge 64 through the
surface 74 and into place under a lower flat surface 77 of each
hook 72, where the lower flat surface 77 of each hook 72 may be
substantially parallel with a top surface 79 of the bus bar bridge
64. Further, the hooks 72 may facilitate retention of the bus bar
bridge 64 (e.g., by blocking movement of the bus bar bridge 64), at
least temporarily, in direction 61. Wall posts 75 of the snap-in
extensions 70 may facilitate retention of the bus bar bridge 64
(e.g., by blocking movement of the bus bar bridge 64), at least
temporarily, along direction 66.
[0048] A side schematic view of an embodiment of the snap-in
extensions 70, bus bar bridge 64, shunt 60, and PCB 62 is shown in
FIG. 7. In the illustrated embodiment, the bus bar bridge 64 is
S-shaped and includes a first base 80, a second base 82, and an
S-bend 84 extending between the first base 80 and the second base
82. The first base 80 is configured to be coupled (e.g., welded) to
a component (not shown) of the electrical path (e.g., as described
with reference to FIGS. 3-5). The second base 82, as previously
described, may be configured to be coupled (e.g., welded) to the
shunt 60. In the illustrated embodiment, the snap-in extensions 70
are generally disposed proximate to (e.g., in-line with) the first
base 80 along direction 37. However, in other embodiments, the
snap-in extensions 70 may be disposed proximate to (e.g., in-line
with) the S-bend 84 of the bus bar bridge 64, the second base 82 of
the bus bar bridge 64, the first base 80 (as described above), or a
combination thereof. In general, the snap-in extensions 70 retain
(e.g., block at least some movement of) the bus bar bridge 64 in at
least one direction (e.g., direction 66, direction 37, direction
61, or a combination thereof). For example, the snap-in extensions
70 may block at least some movement of the bus bar bridge 64 via
the hooks 72 (shown in FIG. 6) contacting the upper surface 79
(shown in FIG. 7) of the bus bar bridge 64 (e.g., along direction
61), via the hooks 72 (shown in FIG. 6) contacting the S-bend 84
(shown in FIG. 7) of the bus bar bridge 64 (e.g., along direction
37), and via the snap-in extensions 70 contacting sides of the bus
bar bridge 64 (e.g., along direction 66). However, in some
embodiments, as indicated by arrow 99 (shown in FIG. 7), the
snap-in extensions 70 may extend above the upper surface 79 of the
bus bar bridge 64 and above the S-bend 84, such that the S-bend 84
would not contact the hooks 72 (shown in FIG. 6) if slid along
direction 37. In such embodiments, the snap-in extensions 70 may
only block movement of the bus bar bridge 64 in directions 66 and
61.
[0049] It should be noted that, in some embodiments, guide walls 90
(e.g., extensions) may be included in place of, or in addition to,
snap-in extensions 70. For example, a cross-sectional schematic
view of the guide walls 90 and a portion of the bus bar bridge 64
is shown in FIG. 8. In the illustrated embodiment, the guide walls
90 include only the wall posts 75 (e.g., without the hooks). Thus,
the guide walls 90 may only block movement (at least temporarily)
of the bus bar bridge 64 in direction 66. However, in another
embodiment, the guide walls 90 may include the hooks (e.g., the
hooks 72 in FIGS. 3-7), and, thus, may be referred to as snap-in
extensions in embodiments having the hooks. Further, it should be
noted that "extensions" encompasses both the snap-in extensions 70
and the guide walls 90.
[0050] A side schematic view of the guide walls 90 is shown in FIG.
9. In the illustrated embodiment, the guide walls 90 are disposed
proximate to (e.g., in-line with) the S-bend 84. However, the guide
walls 90 may be disposed proximate to (e.g., in-line with) any
portion of the bus bar bridge 64, including the S-bend 84, the
first base 80, the second base 82, or a combination thereof.
[0051] It should also be noted that, in certain embodiments, the
guide walls 90 (or snap-in extensions 70) may not be included in
pairs and/or may be included along other surfaces of the bus bar
bridge 64. For example, a schematic top view of the bus bar bridge
64 is shown in FIG. 10. In the illustrated embodiment, the bus bar
bridge 64 includes two longitudinal sides 100, 102 extending along
the first base 80, the S-bend 84, and the second base 82 of the bus
bar bridge 64. The bus bar bridge also includes two transverse
sides 104, 106 extending between the longitudinal sides 100, 102,
where the first transverse side 104 extends along the first base 80
of the bus bar bridge 64 and the second transverse side 106 extends
along the second base 82 of the bus bar bridge 64. One or more
guide walls 90 or snap-in extensions 70 may be included along any
one of the longitudinal sides 100, 102 and/or transverse sides 104,
106.
[0052] It should be noted that, in the illustrated embodiment, the
bus bar bridge 64 is sized and shaped such that the bus bar bridge
64, if rotated 180 degrees about axis 66, is substantially
positioned the same and capable of its same intended function and
connectibility as it was prior to rotating the bus bar bridge 64
180 degrees about axis 66. In other words, because of the S-shaped
nature of the bus bar bridge 64, the bus bar bridge 64 may be
flipped 180 degrees about axis 66 and would still fit into place in
the electrical path. This feature increases ease of manufacturing
and interchangeability of parts. It should also be noted that, in
accordance with present embodiments, all of the bus bar bridge 64
of one electrical path may be substantially the same in shape and
size. This feature also enables increased ease of manufacturing and
interchangeability of parts. In some embodiments, all of the bus
bar bridges 64 of the entire battery module 20 may be
interchangeable.
[0053] A schematic view of an embodiment of an electrical path 120
of the battery module 20 is shown in FIG. 11. The electrical path
120 extends between one electrochemical cell 32 or two or more
electrically interconnected electrochemical cells 32 (e.g.,
illustrated optionally as dashed lines) and one major terminal 76
(e.g., module terminal) of the battery module 20. In the
illustrated embodiment, the electrical path 120 includes the bus
bar bridge 64, and may include any number of other components. The
illustrated embodiment also includes one or more snap-in extensions
70 and/or guide walls 90. As shown, the snap-in extensions 70
and/or guide walls 90 may be disposed along any side or surface of
the bus bar bridge 64. It should also be noted that more than one
bus bar bridge 64 and corresponding snap-in extensions 70 and/or
guide walls 90 may be included, as previously described. The
snap-in extensions 70 and/or guide walls 90 provide at least
temporary retention of the bus bar bridge(s) 64 before, during,
and/or after welding of the bus bar bridge(s) into place in the
electrical path 120.
[0054] A process flow diagram of an embodiment of a method 150 of
securing the bus bar bridge 64 of the battery module 20 of FIG. 3
is shown in FIG. 12. The method 150 includes positioning the bus
bar bridge 64 proximate to one or more extensions (e.g., the
snap-in extensions 70 or the guide walls 90) (block 152). For
example, the bus bar bridge 64 may be positioned between a pair of
extensions, where the extensions block movement of the bus bar
bridge 64 in at least one direction.
[0055] The method 150 also includes positioning the bus bar bridge
64 within the electrical path 120 (block 154). For example, the bus
bar bridge 64 may be positioned within the electrical path 120 such
that the bus bar bridge 64 is in position to be welded to one or
more components (e.g., the bi-metal bus bar 59, the shunt 60, the
relay 71, or some other component of the electrical path 120).
Indeed, the bus bar bridge 64 may be positioned in contact with the
one or more components of the electrical path 120.
[0056] Further, the method 150 includes orienting the battery
module 20 such that weld points of the bus bar bridge 64 are
accessible by a welding tool (block 156). For example, as
previously described, the extensions (e.g., the snap-in extensions
70 and/or the guide walls 90) may be positioned such that weld
points of the bus bar bridge 64 are accessible by the welding tool,
and such that the bus bar bridge 64 remains in position during the
welding process. Thus, the battery module 20 may be moved such that
the welding tool can access the weld points, while the extensions
retain the bus bar bridge 64 in place.
[0057] Further still, the method 150 includes welding the bus bar
bridge 64 to the appropriate components of the electrical path 120
(block 158). For example, the welding tool may heat weld points of
the bus bar bridge 64 and/or press against the bus bar bridge 64 to
weld the bus bar bridge 64 to the appropriate components of the
electrical path 120. Additionally or alternatively, other welding
processes may be used to weld the bus bar bridge 64 into place. Any
welding process (e.g., ultrasonic welding, laser welding, diffusion
welding) suitable for welding the bus bar bridge 64 to the
appropriate components of the electrical path 120 is within the
scope of present embodiments.
[0058] One or more of the disclosed embodiments, alone or in
combination, may provide one or more technical effects useful in
the manufacture of battery modules, and portions of battery
modules. In general, embodiments of the present disclosure include
a battery module having electrical paths extending between a group
of electrically interconnected electrochemical cells and major
terminals (e.g., module terminals) of the battery module. The
electrical paths may each include one or more bus bar bridges.
Snap-in extensions or guide walls of the housing may enable at
least temporary retention of the bus bar bridge(s) before, during,
and/or after the bus bar bridge(s) is/are welded into place in the
electrical paths. The technical effects and technical problems in
the specification are exemplary and are not limiting. It should be
noted that the embodiments described in the specification may have
other technical effects and can solve other technical problems.
[0059] The specific embodiments described above have been shown by
way of example, and it should be understood that these embodiments
may be susceptible to various modifications and alternative forms.
It should be further understood that the claims are not intended to
be limited to the particular forms disclosed, but rather to cover
all modifications, equivalents, and alternatives falling within the
spirit and scope of this disclosure.
* * * * *