U.S. patent application number 17/598440 was filed with the patent office on 2022-06-09 for flexible circuit having a fuse, bus bar holder including a lead-in structure, electrical conduction assembly having a bus bar and battery including the same.
The applicant listed for this patent is CPS Technology Holdings LLC. Invention is credited to Christopher M. Bonin, Nicholas E. Elison, Fredrick C. Ellner, Jason D. Fuhr, Rajesh Kurnar, Ken Nakayama, Judson W. Riggins, Abed Al Fattah Isam Shafie, Xugang Zhang.
Application Number | 20220181708 17/598440 |
Document ID | / |
Family ID | 1000006224710 |
Filed Date | 2022-06-09 |
United States Patent
Application |
20220181708 |
Kind Code |
A1 |
Ellner; Fredrick C. ; et
al. |
June 9, 2022 |
FLEXIBLE CIRCUIT HAVING A FUSE, BUS BAR HOLDER INCLUDING A LEAD-IN
STRUCTURE, ELECTRICAL CONDUCTION ASSEMBLY HAVING A BUS BAR AND
BATTERY INCLUDING THE SAME
Abstract
An electrical conduction assembly comprising a flexible layer,
an interface being associated with and electrically coupled to a
terminal of an external electrical element, and a circuit trace
coupled to the flexible layer and to the interface. The circuit
trace includes a fuse as part of the trace, and the fuse is
associated with the interface. Also disclosed is a battery
including the electrical conduction assembly. Further disclosed is
a bus bar holder for a battery. The bus bar holder includes a
lead-in structure coupled with a main body on a first side. The
lead in structure includes a first lead-in wall to be disposed
between a first plurality of battery cells and a second lead-in
wall orthogonal to the first lead-in wall. The bus bar holder can
also include a plurality of pockets, each or which includes a
respective aperture and a respective recess.
Inventors: |
Ellner; Fredrick C.;
(Bayside, WI) ; Shafie; Abed Al Fattah Isam;
(Shorewood, WI) ; Kurnar; Rajesh; (Bartlesville,
OK) ; Elison; Nicholas E.; (Mequon, WI) ;
Bonin; Christopher M.; (South Milwaukee, WI) ; Fuhr;
Jason D.; (Sussex, WI) ; Nakayama; Ken;
(Racine, WI) ; Zhang; Xugang; (Burlington, WI)
; Riggins; Judson W.; (Milwaukee, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CPS Technology Holdings LLC |
New York |
NY |
US |
|
|
Family ID: |
1000006224710 |
Appl. No.: |
17/598440 |
Filed: |
March 27, 2020 |
PCT Filed: |
March 27, 2020 |
PCT NO: |
PCT/US2020/025329 |
371 Date: |
September 27, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62825590 |
Mar 28, 2019 |
|
|
|
62838749 |
Apr 25, 2019 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M 50/519 20210101;
H05K 1/028 20130101; H05K 1/0296 20130101; H01M 2010/4271 20130101;
H05K 2201/10037 20130101; H01M 50/505 20210101; H01M 2220/20
20130101; H01M 50/583 20210101; H01M 10/425 20130101; H05K
2201/10181 20130101 |
International
Class: |
H01M 10/42 20060101
H01M010/42; H01M 50/505 20060101 H01M050/505; H01M 50/519 20060101
H01M050/519; H01M 50/583 20060101 H01M050/583; H05K 1/02 20060101
H05K001/02 |
Claims
1. A flexible circuit comprising: a flexible layer; an interface
being associate with and electrically coupled to a terminal of an
external electrical element; and a circuit trace coupled to the
flexible layer and to the interface, the circuit trace including a
fuse as part of the trace, the fuse being associated with the
interface.
2. The flexible circuit according to claim 1, further comprising a
trace cover layer at least covering a portion of the circuit trace,
the trace cover including a fuse coating encapsulating the
fuse.
3. The flexible circuit according to claim 1, wherein the fuse
coating includes a plurality of layers of polyimide.
4. The flexible circuit according to claim 1, wherein the fuse
includes a non-straight trace.
5. The flexible circuit according to claim 1, wherein the fuse
includes a plurality of fuses as part of the trace, wherein the
plurality of fuses work in conjunction.
6. The flexible circuit according to claim 1, wherein the fuse
being associated with the interface includes the fuse being in
spaced relation to the interface.
7. The flexible circuit according to claim 1, wherein the flexible
layer includes a flexible film dielectric.
8-22. (canceled)
23. A battery comprising: a housing; a plurality of battery cells
housed by the housing, the plurality of battery cells including a
battery cell having a cell terminal; an electrical conduction
assembly housed by the housing and electrically coupled to the
plurality of battery cells, the electrical conduction assembly
comprising: a flexible layer; a cell interface being associate with
and electrically coupled to the cell terminal; a circuit trace
supported by the flexible layer and coupled to the cell interface,
the circuit trace including a fuse as part of the trace, the fuse
being associated with the cell interface.
24. The battery according to claim 23, wherein the electrical
conduction assembly further comprises a fuse coating encapsulating
the fuse.
25. The battery according to claim 23, having fuse coating includes
a plurality of layers of polyimide.
26. The battery according to claim 23, wherein the fuse includes a
non-straight trace.
27. The battery according to claim 26, wherein the fuse includes a
sinusoidal-shaped trace.
28. The battery according to claim 23, wherein the fuse includes a
plurality of fuses as part of the trace, wherein the plurality of
fuses work in conjunction.
29. The battery according to claim 23, wherein the fuse being
associated with the cell interface includes the fuse being in
spaced relation to the cell interface.
30. The battery according to claim 23, wherein the flexible layer
includes a flexible film dielectric.
31. The battery according to claim 23, wherein the electrical
conduction assembly further comprises a trace cover layer.
32. The battery according to claim 23 and further comprising a
battery control module housed by the housing, and wherein the
electrical conduction assembly further includes a control module
interface coupled to the circuit trace, and wherein the control
module interface electrically couples the circuit trace to the
battery control module.
33. The battery according to claim 23, wherein the electrical
conduction assembly further comprises a holder supporting the
flexible layer and the cell interface.
34. The battery according to claim 33, wherein the holder further
includes a bus bar coupling the cell terminal to the cell
interface.
35. The battery according to claim 23, wherein the plurality of
battery cells includes a plurality of lithium-ion battery cells
36. A vehicle having the battery according to claim 23.
37. A bus bar holder for a battery comprising a housing having a
wall, a first plurality of battery cells and a second plurality of
battery cells housed by the housing, the bus bar holder comprising:
a main body comprising: a first side to be disposed next to the
first plurality of battery cells and the second plurality of
battery cells; and a second side opposite the first side and to be
disposed away from the first plurality of battery cells and the
second plurality of battery cells; and a lead-in structure coupled
with the main body on the first side, the lead-in structure
comprising: a first lead-in wall to be disposed between the first
plurality of battery cells and the second plurality of battery
cells; and a second lead-in wall orthogonal to the first lead-in
wall, the second lead-in wall to be disposed between the wall of
the housing, and the first plurality of battery cells and the
second plurality of battery cells.
38-63. (canceled)
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of US Patent Application
No. 62/838,749; filed on Apr. 25, 2019; entitled "EMBEDDED FUSE
DESIGN IN LITHIUM ION VOLTAGE AND TEMPERATURE SENSING COMPONENT";
the content of which is incorporated herein by reference.
[0002] This application also claims the benefit of US Patent
Application No. 62/825,590; filed on Mar. 28, 2019; entitled
"EMBEDDED FUSE DESIGN IN LITHIUM ION VOLTAGE AND TEMPERATURE
SENSING COMPONENT"; the content of which is incorporated herein by
reference.
BACKGROUND
[0003] This disclosure relates to the field of batteries. Aspects
of the disclosure relate to the field of battery safety for
batteries. Aspects of the disclosure relate to bus bar holders for
batteries.
[0004] Generally, a battery system may include one or more
batteries that store electrical energy. Thus, battery systems are
often implemented in electrical systems. In particular, using
stored electrical energy, a battery may supply electrical power to
an electrical load in the electrical system, thereby discharging
the battery. Additionally, the battery may capture electrical power
from an electrical source (e.g., a generator) in the electrical
system, thereby storing it as electrical energy and charging the
battery.
[0005] In advanced batteries, for example but not limited to,
lithium ion batteries, a battery control module (BCM), which may
also be referred to as a battery management unit (BMU), may be
provided to regulate battery function of the battery, which may
also be referred to as a battery module. The BCM or BMU
(collectively referred to hereinafter as the BCM) may comprise one
or more printed circuit boards (PCBs) which may include a processor
and memory programmed to monitor and control the battery. The BCM
may perform load balancing and control charging and discharging of
the battery.
[0006] Known PCBs for BCMs may be prone to internal and external
short circuits. Further, the BCMs may be insufficient to protect
the battery management system and battery from undesirable currents
from the cells. An improved BCM with an improved PCB is
desired.
[0007] In traditional configurations, advanced batteries may
include electrochemical cells disposed in a housing through an
opening in the housing. Traditional configurations may also include
a holder or carrier disposed over the electrochemical cells and
within the opening of the housing. It is now recognized that it is
desirable to facilitate placing and maintaining the carrier in the
opening of the housing and over the electrochemical cells for
quickly and readily electrically connecting a PCB to the
electrochemical cells.
SUMMARY
[0008] Disclosed herein is an apparatus which may address one or
more deficiencies known above. In one or more constructions, the
apparatus may aid in the interruption of high currents generated
from short circuits in or through a flexible circuit. Alternatively
or additionally in one or more constructions, the apparatus may
quickly and readily place an electrical conduction assembly next to
a plurality of battery cells for easing electrical connection. Also
or additionally in one or more implementations, a method of
assembling a battery module may help address one or more
deficiencies known above.
[0009] In one embodiment, disclosed is a flexible circuit, which
can be used with a battery control module (BCM). The flexible
circuit may comprise embedded traces which may connect battery
cells to the BCM. The traces may further comprise one or more
fusable links, which may also be referred to herein as fuses. The
flexible circuit may further comprise a coating such as but not
limited to one or more layers of polyimide.
[0010] In another embodiment, disclosed is an electrical conduction
assembly, which can have a flexible circuit. The flexible circuit
comprises a flexible layer, an interface being associate with and
electrically coupled to a terminal of an external electrical
element, and a circuit trace coupled to the flexible layer and to
the interface. The circuit trace includes a fuse as part of the
trace, and the fuse is associated with the interface. Consequently,
the fuse is further associated with the external electrical
element.
[0011] The electrical conduction assembly can be used in a battery
(or battery module). The battery may include a housing, a plurality
of battery cells housed by the housing, and the electrical
conduction assembly housed by the housing and electrically coupled
to the plurality of battery cells. The plurality of battery cells
can include a battery cell having a cell terminal, and the
interface of the electrical conduction assembly may be a cell
interface associated with and electrically coupled to the cell
terminal.
[0012] The disclosed apparatus may have a number of advantages
regarding safety and consistency, for example but not limited to in
the automotive environment. The advantages may be realized by
features including fuse shape, fuse location within the trace and
with reference to the bus bars, the coating layers and material
type, event encapsulation, fusing time consistency, and use of
embedded fuses.
[0013] In a further embodiment, disclosed is a bus bar holder (or
carrier) comprising a main body and a lead-in structure coupled
with the main body. The main body includes a first side to be
disposed next to a first plurality of battery cells and a second
plurality of battery cells, and a second side opposite the first
side and to be disposed away from the first plurality of battery
cells and the second plurality of battery cells. The lead-in
structure includes a first lead-in wall to be disposed between the
first plurality of battery cells and the second plurality of
battery cells, and a second lead-in wall orthogonal to the first
lead-in wall. The second lead-in wall is to be disposed between a
wall of a battery housing, and the first plurality of battery cells
and the second plurality of battery cells. The lead-in structure
can facilitate placing and maintaining the holder with respect to
the battery housing and the plurality of battery cells.
[0014] In a yet further embodiment, disclosed is an electrical
conduction assembly for a battery. The electrical conduction
assembly can include a bus bar holder, a plurality of bus bars held
by the bus bar holder, and an electrical circuit is coupled to the
plurality of bus bars. The bus bar holder has a first plurality of
apertures, a first side to be disposed next to the plurality of
battery cells, and a second side opposite the first side and to be
disposed away from the plurality of battery cells. The second side
comprises a plurality of pockets, each pocket of the plurality of
pockets including at least one of the first plurality of apertures
and a recess. Each bus bar of the plurality of bus bars is disposed
in a respective pocket of the plurality of pockets. Each bus bar of
the plurality of bus bars has a tab disposed in the recess of the
respective pocket. The tab can be a placement tab and/or an
interface tab. The receptables and tabs can facilitate properly and
quickly connecting the plurality of bus bars to the electrochemical
cells.
[0015] These and other features and advantages of devices, systems,
and methods according to this invention are described in, or are
apparent from, the following detailed descriptions of various
examples of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] One or more examples of embodiments of the apparatus and
methods according to this invention will be described in detail,
with reference to the following figures, wherein:
[0017] FIG. 1 is a cut-away block diagram of a vehicle showing
portions of an electrical system;
[0018] FIG. 2 is an exploded view of a battery (or battery module)
capable of being used in the vehicle of FIG. 1;
[0019] FIG. 3 is an isometric view of an electrical conduction
assembly of the battery of FIG. 2;
[0020] FIG. 4 is a top view of a flexible circuit of the electrical
conduction assembly of FIG. 3;
[0021] FIG. 5 is a top view of a fuse of the flexible circuit of
FIG. 4;
[0022] FIG. 6 is a top view of fuses of the flexible circuit of
FIG. 4;
[0023] FIG. 7 is a top view of a fuse capable of being used with
the flexible circuit of FIG. 4;
[0024] FIG. 8 is a top view of a fuse capable of being used with
the flexible circuit of FIG. 4; and
[0025] FIG. 9 is a top view of the fuse of FIG. 8 in an environment
and being blown.
[0026] FIG. 10 is an isometric view of a housing of the battery of
FIG. 2.
[0027] FIG. 11 is a partial isometric, exposed view of the
electrical conduction assembly of FIG. 3 in the battery of FIG.
2.
[0028] FIG. 12 is a section view of a portion of the battery along
line 12-12 of FIG. 11.
[0029] FIG. 13 is a first isometric view of the bottom side of a
bus bar holder of the electrical conduction assembly of FIG.
11.
[0030] FIG. 14 is a second isometric view of the bottom side of the
bus bar holder of FIG. 13.
[0031] FIG. 15 is a side view of the bus bar holder of FIG. 13.
[0032] FIG. 16 is a second side view of the bus bar holder of FIG.
13.
[0033] FIG. 17 is a first isometric view of the top side of a bus
bar holder of FIG. 13.
[0034] FIG. 18 is a second isometric view of the top side of the
bus bar holder of FIG. 13.
[0035] FIG. 19 is a plan view of the electrical conduction assembly
of FIG. 11.
[0036] It should be understood that the drawings are not
necessarily to scale. In certain instances, details that are not
necessary to the understanding of the invention or render other
details difficult to perceive may have been omitted. It should be
understood, of course, that the invention is not necessarily
limited to the particular embodiments illustrated herein.
DESCRIPTION
[0037] The disclosure may be understood to relate to (but not be
limited to) use of a battery in a vehicle environment. In various
embodiments, the battery may be a lithium ion or other advanced
battery. FIG. 1 shows a cut-away of a vehicle 100 having an
electrical system 105 for electrical infrastructure in the vehicle
100. The electrical system 105 may include an energy storage
component 110 which may comprise one or more battery modules
115/120. The vehicle 100 may further comprise an engine 125,
alternator 130, ignition system 135, and control module 140 which
may have a processor 145 and memory 150. The energy storage
component 110 may electrically couple to the vehicle's electrical
system 105 by way of a bus 155. This may allow for powering of
vehicle functionality including electrical devices such as the
vehicle display 160 and advanced vehicle functionality.
[0038] A vehicle electrical system 105 may be included in an
automotive vehicle or the like. In some embodiments, the control
module 140 may control operation of the electrical system 105
and/or the electrical devices. For example, in an automotive
vehicle, the control module 140 may include a battery management
system (BMS) and/or a vehicle control unit (VCU).
[0039] FIG. 2 shows an example battery (or battery module) 165 for
understanding the apparatus and process herein, according to
various embodiments. In FIG. 2, an exploded view of portions of the
battery 165 is shown. The battery 165 is seen to comprise a housing
170 which may likewise comprise a number of covers 175 and 180.
Cells 185 may be provided in the housing 170, which may be
connected for use with a lid assembly 190. An electrical conduction
assembly (or printed circuit board (PCB) assembly) 195 may likewise
be provided. The electrical conduction assembly 195 can couple to
the battery control module (BCM) 197 and may be considered part of
the BCM 197. One or more terminals 200 may be provided to allow for
access to battery power.
[0040] In FIG. 3, the electrical conduction assembly 195 is shown
in greater detail. The electrical conduction assembly 195 may be
used, for example, with a battery (such as, but not limited to, the
example battery 165 disclosed in FIG. 2). The electrical conduction
assembly 190 may comprise a flexible circuit 205 in electrical
communication with one or more bus bar interfaces 210. The bus bar
interfaces 210 may serve to connect the flexible circuit 205 with
one or more bus bars 215 (which may then couple to one or more
battery terminals). The flexible circuit 205 may further be coupled
to a control module interface 220. The control module interface 220
may connect the electrical conduction assembly 195 with a load
source (for example, but not limited to, a vehicle) via the BCM
197. Further discussion regarding the electrical conduction
assembly 195 is provided below in connection with FIGS. 10-19.
[0041] A detailed view of the flexible circuit 205 may be seen in
FIG. 4, according to various embodiments. A number of bus bar
interfaces 210 may be seen coupled to a trace 225. The trace 225
may comprise, in various embodiments, copper. While copper is
disclosed, suitable conductive alternatives should be understood as
within the scope of this disclosure. The flexible circuit 205 may
further comprise a trace cover 230, thereby embedding the trace.
The trace cover 230 may comprise, for example, but not limited to,
a layer of polyimide. In various embodiments, the trace cover 230
may comprise multiple layers. As one non-limiting example, the
trace cover 230 may comprise two layers of polyimide. While
polyimide is disclosed, alternative compositions, should be
contemplated as within the scope of this disclosure. Other example
flexible plastic substrates include PEEK and transparent conductive
polyester films. The trace cover 230 comprising multiple layers may
provide advantages to encapsulation in the event of flows blowing,
as described further herein. In various embodiments, the trace
cover 230 may cover the entire or substantially all of the flexible
circuit 205.
[0042] Further, as shown as part of a non-limiting example in FIG.
4, a number of fuses 235 (only four are labelled) can be seen
spaced away from the bus bar interfaces 210. One or more fuses 235
may be provided on each trace in spaced relation to the bus bar
interface 210. As a non-limiting example, the one or more fuses may
be positioned approximately one-half inch to four inches from a bus
bar interface 210 on the trace. While one half inch to four inches
are provided, more or less distance should be contemplated as
within the scope of this disclosure. The number of fuses in the
circuit may vary based on the trace. As a non-limiting example, the
number of fuses may be the same or more than the number of bus bars
provided, in various examples of embodiments. For example, in FIG.
4, nine fuses are shown in the trace.
[0043] The fuses 235 and fuse locations may allow for a number of
advantages. For example, the fuses 235 may allow for protection
from catastrophic failure, for example, by isolating a cell (e.g.,
cell 240; FIG. 2). Therefore, the fuse 235D may advantageously be
located close to a cell terminal (e.g., cell terminal 245; FIG. 2)
but also isolated from heat. This may advantageously prevent the
main trace 225 from fusing before the fuse 235D. The location may
have further advantages, including if failure occurs, knowledge of
where the failure has taken place. Further the location between
fuses 235 and the trace 225 may prevent fusing of neighboring
traces. In various constructions, fuse location may prevent
exposure to debris or smoke from a tripped fuse. In other words,
the fuse location may advantageously prevent a secondary fault or
cascading failure.
[0044] Additionally, the disclosed battery 165 and flexible circuit
205 may advantageously allow for fuse time consistency. For
example, by having a disclosed shape and location, fusing current
may be consistent. For example, if a certain amperage flows through
a fuse, it may consistently fuse in a certain time.
[0045] The disclosed flexible circuit 205 may comprise embedded
fuses 235. In addition to the disclosed advantages, embedding the
fuses 235 into the circuit 205 may allow for advantages in
manufacturing. For example, the flexible circuit 205 may not
require additional steps for battery assembly. Alternatively, the
fuses 235 could be provided on the BCM or through a surface mount
process in final assembly manufacture.
[0046] The disclosed flexible circuit 205 may provide particular
advantages in the automotive environment. For example, the
disclosed flexible circuit 205 having fuses (for example, embedded
fuses 235) may be used in a twelve-volt, lithium-ion application
exposed to the automotive environment. While such a battery is
described as a non-limiting example; it should be understood the
disclosed flexible circuit 205 may be used in a variety of other
batteries. Therefore, the disclosed battery 165 and flexible
circuit 205 may advantageously be robust enough to withstand the
requirements of the automotive environment.
[0047] FIGS. 5-8 show a plurality of fuses. In various embodiments,
the fuses may be copper. While copper is disclosed, alternative
conductive materials should be understood as within the scope of
this disclosure.
[0048] FIG. 7 shows a fuse 250, according to various embodiments.
The fuse 250 may be seen to have a straight shape and is connected
to a trace 255 on each end 260, 265. The fuse may further comprise
a cover 270 (or coating). The cover 270 may allow for encapsulation
should the fuse 250 blow.
[0049] FIG. 8 shows another fuse 275, according to various
embodiments. The fuse 270 may be seen to have a sinusoidal-type
shape and be connected to a trace 255 on each end 260, 265. Again,
the fuse 275 may further comprise a cover 270 (or coating), which
may allow for encapsulation should the fuse blow.
[0050] In various embodiments, the cover 270 may be flat and
unnoticeable until the fuse is tripped. The cover 270 may be the
same or similar to the coating 230 provided over the flexible
circuit 205 as described above.
[0051] The fuse 275 having a substantially sinusoidal shape may be
understood to have an amplitude which may increase the coverage
area. In various embodiments, the fuse 275 and coating 270 (for
example, multiple layers of polyimide as described above) may allow
for additional volume for any smoke or residue upon fusing of the
fuse 275 over a straight fuse 250. Therefore, a sinusoidal fuse 275
may allow for more volume of encapsulation due to the height and
width of the fuse.
[0052] The use of a sinusoidal fuse 275 may likewise allow for
advantages to isolation of heat. In various embodiments, the fuse
275 may allow for concentration of heat in the middle of the fuse,
isolating the heat from neighboring traces. Isolation of the fuse
may therefore allow for a single isolated short.
[0053] FIG. 9 shows a fuse 280 having a sinusoidal shape in its
environment 285. The fuse 280 is shown as a blown fuse. In various
embodiments, the bubble 290 around the fuse 285 is caused by the
heat and the encapsulation of the smoke.
[0054] The disclosed flexible circuit 205 including the discussed
fuses, coating, and trace, has a number of advantages. For example,
as seen in FIG. 9 when tripped, the fuse 280 can create the bubble
290. This bubble 290 may be understood to be comprised of material
and smoke created from the heat from tripping. The bubble 290 may
be comprised of the coating, leading to safe encapsulation of the
fuse event. While straight and sinusoidal fuses are disclosed, a
variety of other fuse shapes and sizes (e.g., non-straight,
curving, angular, irregular) should be understood as within the
scope of this disclosure.
[0055] Moving now to FIGS. 10-19, the figures disclose further
drawings related to an improved bus bar holder (may also be
referred to in the art as a bus bar carrier). FIG. 10 shows the
housing 170 of the battery 165. The shown housing 170 has four
compartments: first cell compartment 300, second cell compartment
305, electrical conduction assembly compartment 310 (also seen in
FIG. 11), and BCM compartment 315 (best shown in FIG. 2). FIG. 11
shows the electrical conduction assembly 195 disposed in the
electrical conduction assembly compartment 310. While four
compartments are shown and described herein, the number of
compartments and arrangement of compartments can be different from
what is shown and described herein.
[0056] With reference to FIGS. 10 and 11, a partition (or partition
wall) 320 separates the first cell compartment 300 and the second
cell compartment 305, a first wall 325 separates the cell
compartments 300 and 305 and the BCM compartment 315, and a second
wall 330 separates the electrical conduction assembly compartment
310 and the BCM compartment 315. As best shown in FIG. 11, a bus
bar holder 335 separates the electrical conduction assembly
compartment 310 from the cell compartments 300 and 305. The bus bar
holder 335 can be an injection molded part and can be formed of
polypropylene. The second wall 330 may include one or more
apertures between the electrical conduction assembly compartment
310 and the BCM compartment 315. In the shown construction of FIG.
11, the aperture 340 allows a portion of the flexible circuit 205,
including the control module interface 220 (FIG. 3), to go from the
electrical conduction assembly compartment 310 to the BCM
compartment 315. The second wall 330 also includes a second
aperture 345 and a third aperture 350, which allow for cell stack
to system bus.
[0057] With reference to FIGS. 10-12, the second wall 330 includes
a shelf 355 to receive a jutting segment (or simply jut) 360 of the
bus bar holder 335. The second wall 330 (and similarly the first
wall 325) includes an indentation (or chamfer) 365 having a surface
370 angled between the shelf 355 and the cell compartments 300 and
305. The indentation 365 receives a lead-in structure (discuss
below) of the bus bar holder 335. The second wall 330 also includes
a first platform 375 having the second aperture 345 and a second
platform 380 having the third aperture 350. The platforms 375 and
380 are raised to receive respective bus bars (discussed below) of
the electrical conduction assembly 310.
[0058] The bus bar holder 335 includes posts (one post 381 is
labeled in detail) projecting out from a surface (referred to
herein as the top surface 382) of the bus bar holder 335. Each post
381 includes a base (or stem) 385 having a plug 390. When the bus
bar holder 335 is placed in the electrical conduction assembly
compartment 310, the post 375 can make contact with the cover 175
(FIG. 2) helping to hold the electrical conduction assembly 310 in
place. Prior to assembly, the plug 390 can mate with a socket 395
(FIG. 13). The socket is a cavity in the post 381, which allows the
bus bar holders 335 and electrical conduction assemblies 195 to be
stackable prior to insertion in the battery module 165.
[0059] FIGS. 13 and 14 are isometric views showing the bottom side
of the bus bar holder 335 from two different angles. FIGS. 15 and
16 are side views of the bus bar holder 335. With reference to
FIGS. 13-16, the bus bar holder 335 includes a plurality of spacers
(two spacers 400 are labelled). The spacers 400 can be of varying
sizes and at varying locations. For the shown construction, the
spacers 400 are located on opposite sides of the apertures
(discussed below) for the cell terminals.
[0060] The bus bar holder 335 further includes a lead-in structure
405 extending from the bottom surface 410 of the bus bar holder
main body 415. The shown lead-in structure 405 includes two walls
420 and 425 extending from the bottom surface 410. The first wall
420 is orthogonal to the second wall 425. The first wall 420 is
wedge shaped and acts as a divider between the battery cells in the
first cell compartment 300 and the battery cells in the second cell
compartment 335. The wedge shape of the first wall 420 allows the
bus bar holder to more easily enter and divide the battery cell
stacks among the two compartments.
[0061] The second wall 425 includes a two-tiered wall. The first
tier 430 of the second wall 425 is sized to be smaller than the
length of the angled surface 370. The first tier 430 creates
separation between the chamfer 360 and the cell stack and pushes
the cells 185 toward the housing bottom. The second tier 435 of the
second wall 425 is sized to be larger than the length of the angled
surface 370. The second tier 435 provides a broader surface to push
the cells 185 back after the first tier 435 has created separation
to the housing 170. During manufacturing of the battery module 165,
the forces are typically only applied as the bus bar holder 335 is
inserted into the housing 170 and only if the battery cells 185 are
not naturally in their desired final position. That is, the lead-in
structure 405 can provide a fixing force for the battery cells 185
during manufacturing. The lead-in structure 405 can also provide a
placement with the battery cells 185 that can help reduce the gap
between the cell stacks and can help reduce the potential movement
of the battery cells 185 during vibration and shock to the battery
module 165.
[0062] When the bus bar holder 335 is placed with respect to the
battery cells 185, the jutting segment 360 sits on the shelf 355,
and the spacers 400 abut the battery cells 185 on either side of
the cell terminals 245. The cell terminal 245 enters corresponding
apertures and make contact with the bus bars 215. Also, vent
apertures align with vents of the battery cells 185 to allow gas to
vent from the cells 185 through the electrical conduction assembly
195.
[0063] FIGS. 17 and 18 are isometric views showing the top surface
382 of the bus bar holder 335 from two different angles. For the
construction shown in FIGS. 15-18, the bus bar holder includes a
plurality of pockets 450A-G in the main body 415. The plurality of
pockets 450A-G hold a plurality of bus bars 215A-G (FIG. 19),
respectively. In the shown construction, the plurality of pockets
450A-G includes seven pockets for seven bus bars.
[0064] Each pocket of the plurality of pockets 450A-G includes at
least one respective recess 460A-G and 465A-G. For pockets 450 A
and G, these pockets have two recesses 460A and G and 465A and G.
For pockets 450B and F, these pockets have a recess 460B and F and
a wall defining a portion of a second recess 465B and F. For
pockets 450C and F, the pockets includes a wall forming the recess
460C and F and two walls forming in part the recesses 465C and F.
For pocket 450D, the pocket includes two recesses 460D1 and 460D2
and two walls forming a portion of the recess 465D.
[0065] The recess 460A-G and 465A-G receive tabs of the bus bar
215A-G. A tab can be a placement tab (e.g., placement tabs 470A-G)
or an interface tab (interface tabs 475A-G). The placement tabs
470A-G, in combination with recesses 460A-G, help properly align
each bus bar 455A-G in its respective pocket 450A-G. The interface
tabs 475A-G, in combination with bus bar interfaces 210A-G, help
couple the respective bus bars 215A-G to the flexible circuit 205.
The interface tabs 475A-G, in combination with recesses 465A-G, can
also be used to properly align each bus bar 455A-G in its
respective pocket 450A-G.
[0066] Referring again to FIGS. 17 and 18, the bus bar holder 335
includes one or more vertical walls (wall 480 is labelled) to avoid
accident shorts during assembly, normal operation, or under abuse
conditions. The top surface 382 further includes heat staking posts
(post 485 is labelled). The heat staking posts 485 receive the
flexible circuit 205 and are heated to secure the flexible circuit
205 in place. The heat staking posts 485 can also be situated to
help align and place the flexible circuit 205.
[0067] The bus bar 215D, which may be referred to as the bridge
busbar, includes a fold or multiple bends (best seen in FIGS. 3 and
19). The bridge bus bar 215D includes extra matter or width so that
it has sufficient cross-sectional area to prevent the bar 215D from
heating up. The additional cross-sectional area helps reduce the
effective resistance. However, if the interface tab 475D was flat,
then it would be too large to fit in the given space. To help with
the extra material in existing space, the interface tab 275D
includes folds/bends in the material in order to package. For
electrons, they do not see the bends--only see the larger cross
section.
[0068] The bus bar holder 335 provides the following additional
features in addition to the features already discussed above. The
following may be in addition or alternative to the above
features.
[0069] The bus bar holder 335 helps locate and align the cell
terminals and cell-to-cell bus bars for welding. For example, the
bus bar holder 335 can provide final vertical positioning of the
two cell stacks relative to the housing 170. The second wall (or
rib) 425 of the bus bar holder 335 wedges between the chamfer in
the housing 170 and the cells 185. This wedging biases the cells
175 towards the bottom of the housing 170 to allow insertion of the
bus bar holder 335, final positioning of the cells 185, and serves
to limit the amount of available space between the cell stacks and
the housing opening. This makes the pack less sensitive to
vibration and mechanical shock loading. The first wall (or rib) 420
that is perpendicular to the second wall 425 wedges between the two
stacks of cells 240, moving them out from the center of the cell
compartments.
[0070] Therefore, the bus bar holder 335 can help align all cell to
cell bus bars 215A-G relative to the twelve cell terminals
simultaneously. With one operation placing bus bar holder 335, all
seven bus bars 215A-G are placed and located simultaneously, rather
than having to precisely place all seven one at a time. The bus bar
holder 335 can also maximize the size of the weld area on top of
the cell terminals 245 by reducing the amount of positional
misalignment the cells 185 have relative to the bus bars 215A-G and
the housing. For example, the bus bar holder 335 biases the cells
185 to the bottom of the housing with the first wall 420. This
reduces the positional misalignment of the cell terminals 245
relative to the bus bars 215 by more than half, which allows for a
larger weld zone. Also, the bus bar holder 335 can provide final
horizontal positioning of the two cell stacks relative to the
housing 170 with the first wall 430 wedging between the two stacks
of cells, moving them out from the center of the pack. This reduces
the positional misalignment of the cell terminals 245 relative to
the bus bars 215 horizontally, which allows for a larger weld zone.
Further, the bus bar holder 335 can provide a limited amount of
movement to the bus bars side-to-side and top-to-bottom (with the
pack in its normal operating orientation), so that the bus bar
holder 335 can be a loose fit inside the housing.
[0071] The bus bar holder 335 can also help with contact between
bus bars 225 and cell terminals 245. The raised rectangular pads
(or spacers 400) contact the top surface of the cells 185 and stop
the bus bar holder 335 from going down any further. The spacers set
the functional height between the cell terminals 245 and the bus
bars 215. If this distance was too large, the bus bar 215 would be
pulled at an angle by the flexible circuit 205, and the gap between
the terminal 245 and bus bar 215 may result in no weld or a weld of
inadequate strength. If this distance is too small, due to
variations in the height of components, the bus bar 215 may not
come down to be in contact with the cell terminal 245, which may
result in no weld or a weld of inadequate strength.
[0072] As utilized herein, the terms "approximately," "about,"
"substantially," and similar terms are intended to have a broad
meaning in harmony with the common and accepted usage by those of
ordinary skill in the art to which the subject matter of this
disclosure pertains. It should be understood by those of skill in
the art who review this disclosure that these terms are intended to
allow a description of certain features described and claimed
without restricting the scope of these features to the precise
numerical ranges provided. Accordingly, these terms should be
interpreted as indicating that insubstantial or inconsequential
modifications or alterations of the subject matter described and
claimed are considered to be within the scope of the invention as
recited in the appended claims.
[0073] It should be noted that references to relative positions
(e.g., "top" and "bottom") in this description are merely used to
identify various elements as are oriented in the Figures. It should
be recognized that the orientation of particular components may
vary greatly depending on the application in which they are
used.
[0074] For the purpose of this disclosure, the term "coupled" means
the joining of two members directly or indirectly to one another.
Such joining may be stationary in nature or moveable in nature.
Such joining may be achieved with the two members or the two
members and any additional intermediate members being integrally
formed as a single unitary body with one another or with the two
members or the two members and any additional intermediate members
being attached to one another. Such joining may be permanent in
nature or may be removable or releasable in nature.
[0075] It is also important to note that the construction and
arrangement of the system, methods, and devices as shown in the
various examples of embodiments is illustrative only. Although only
a few embodiments have been described in detail in this disclosure,
those skilled in the art who review this disclosure will readily
appreciate that many modifications are possible (e.g., variations
in sizes, dimensions, structures, shapes and proportions of the
various elements, values of parameters, mounting arrangements, use
of materials, colors, orientations, etc.) without materially
departing from the novel teachings and advantages of the subject
matter recited. For example, elements shown as integrally formed
may be constructed of multiple parts or elements show as multiple
parts may be integrally formed, the operation of the interfaces may
be reversed or otherwise varied, the length or width of the
structures and/or members or connector or other elements of the
system may be varied, the nature or number of adjustment positions
provided between the elements may be varied (e.g. by variations in
the number of engagement slots or size of the engagement slots or
type of engagement). The order or sequence of any process or method
steps may be varied or re-sequenced according to alternative
embodiments. Other substitutions, modifications, changes and
omissions may be made in the design, operating conditions and
arrangement of the various examples of embodiments without
departing from the spirit or scope of the present inventions.
[0076] While this invention has been described in conjunction with
the examples of embodiments outlined above, various alternatives,
modifications, variations, improvements and/or substantial
equivalents, whether known or that are or may be presently
foreseen, may become apparent to those having at least ordinary
skill in the art. Accordingly, the examples of embodiments of the
invention, as set forth above, are intended to be illustrative, not
limiting. Various changes may be made without departing from the
spirit or scope of the invention. Therefore, the invention is
intended to embrace all known or earlier developed alternatives,
modifications, variations, improvements and/or substantial
equivalents.
[0077] 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.
* * * * *