Battery module with integrated RF communication and cell sensing board

• US 10,411,306 B2
• Filed: 09/01/2016
• Issued: 09/10/2019
• Est. Priority Date: 04/19/2016
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Kim, Theodore T., Johnson, Jeffrey, Wang, Tao
• Primary Examiner(s): Jimenez, Anthony R
• Application Number:
  US15/254,662
• Publication Number:
  US 20170301961A1
• Time in Patent Office: 1,104 Days
• Field of Search: 429 61
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 2010/4271 Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
• CPC Class Codes: H01M 2010/4278 Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/284 with incorporated circuit boards, e.g. printed circuit boards [PCB]
• CPC Class Codes: H01M 50/503 characterised by the shape of the interconnectors
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: H01M 50/522 Inorganic material
• CPC Class Codes: H01M 50/524 Organic material
• CPC Class Codes: H01M 50/526 having a layered structure
• CPC Class Codes: H04B 1/48 in circuits for connecting transmitter and receiver to a common transmission path, e.g. by energy of transmitter H04B1/46 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations

Abstract

A battery module for use with a controller includes a printed circuit board assembly (PCBA) mounted to a plurality of battery cells. The PCBA includes a substrate, a radio frequency (RF) communications circuit, a cell sensing circuit, and a conductive interconnecting member. The cell sensing circuit is operable for measuring a respective cell voltage of each of the battery cells. The conductive interconnect member forms an electrical connection between the battery cells. The RF communications circuit is in wireless communication with the controller and is operable for wirelessly transmitting the measured cell voltages to the controller. A battery system includes a master battery controller and the battery pack. A vehicle includes an electric machine operable for generating output torque for propelling the vehicle, as well as the battery system noted above.

Claims

1. A battery module for use with a controller, the battery module comprising:

a plurality of battery cells; and

a printed circuit board assembly (PCBA) mounted with respect to the battery cells, and having;

a substrate defining a conductive interconnect member having a plurality of conductive tabs, wherein the plurality of conductive tabs are oriented parallel to a plane of orientation of the substrate and form a serial electrical connection between the battery cells within the battery module;

a radio frequency (RF) communications circuit connected to a surface of the substrate; and

a cell sensing circuit connected to the surface of the substrate, and to the RF communications circuit via the substrate, wherein the cell sensing circuit is operable for determining a respective cell voltage of each of the battery cells;

wherein the RF communications circuit is in wireless communication with the controller and is operable for wirelessly transmitting the determined cell voltages to the controller.

2. The battery module of claim 1, wherein the RF communications circuit is in wireless communication with the controller via a 2.4 GHz protocol.

3. The battery module of claim 1, wherein the substrate is constructed of molded plastic.

4. The battery module of claim 1, wherein the plurality of conductive tabs includes first and second strips of conductive tabs in the form of alternating pads or squares of different conductive materials arranged along different edges of the substrate, and wherein the RF communications circuit and the cell sensing circuit are both mounted to the surface of the substrate between the first and second strips of conductive tabs.

5. The battery module of claim 1, wherein the RF communications circuit communicates with the controller using Time Synchronized Channel Hopping.

6. The battery module of claim 1, further comprising a module cover spanning the PCBA and the plurality of battery cells.

7. The battery module of claim 6, wherein the controller is positioned at least 0.1 m from the module cover.

8. A battery system comprising:

a master battery controller; and

a battery pack having a plurality of battery modules each including;

a plurality of battery cells; and

a printed circuit board assembly (PCBA) mounted with respect to the plurality of battery cells and having;

a substrate defining a conductive interconnect member having a plurality of conductive tabs, wherein the plurality of conductive tabs are oriented parallel to a plane of orientation of the substrate and form a serial electrical connection between the battery cells within the battery module;

a radio frequency (RF) communications circuit connected to a surface of the substrate; and

a cell sensing circuit connected to the surface of the substrate, and to the RF communications circuit through the substrate, wherein the cell sensing circuit is operable for determining a respective cell voltage of each of the battery cells;

wherein the RF communications circuit is in wireless communication with the master battery controller and is operable for wirelessly transmitting the cell voltages to the master battery controller, and wherein the master battery controller is programmed to execute a control action with respect to the battery pack using the cell voltages.

9. The battery system of claim 8, wherein the master battery controller is positioned at least about 0.1 m away from the battery modules.

10. The battery system of claim 8, wherein the RF communications circuit is in wireless communication with the master battery controller via a 2.4 GHz protocol.

11. The battery system of claim 8, wherein the conductive interconnect member includes first and second strips of conductive tabs in the form of alternating pads or squares of different conductive materials arranged along different edges of the substrate, and the RF communications circuit and the cell sensing circuit are both mounted to the surface of the substrate between the first and second strips.

12. The battery system of claim 8, wherein the RF communications circuit communicates with the controller using Time Synchronized Channel Hopping.

13. The battery system of claim 8, further comprising a module cover spanning the PCBA and the plurality of battery cells.

14. A vehicle comprising:

an electric machine operable for generating output torque for propelling the vehicle; and

a battery system electrically connected to the electric machine, and having;

a master battery controller; and

a battery pack having a plurality of battery modules, with each battery module including;

a plurality of battery cells; and

a printed circuit board assembly (PCBA) mounted to the plurality of battery cells, the PCBA including;

a substrate defining a conductive interconnect member having a plurality of conductive tabs, wherein the plurality of conductive tabs are oriented parallel to a plane of orientation of the substrate and form a serial electrical connection between the battery cells within the battery module;

a radio frequency (RF) communications circuit connected to a surface of the substrate; and

a cell sensing circuit connected to the surface of the substrate, and to the RF communications circuit through the substrate, wherein the cell sensing circuit is operable for measuring a respective cell voltage of each of the battery cells;

wherein the RF communications circuit is in wireless communication with the master battery controller and is operable for wirelessly transmitting the measured cell voltages to the master battery controller, and the controller is programmed to execute a control action with respect to the vehicle using the measured cell voltages.

15. The vehicle of claim 14, wherein the substrate has a plurality of conductive tabs oriented parallel to the plane of orientation of the substrate, and wherein the conductive interconnect member includes the conductive tabs.

16. The vehicle of claim 14, wherein the conductive interconnect member includes first and second strips of conductive tabs arranged along different edges of the substrate, and the RF communications circuit and the cell sensing circuit are both mounted to the surface of the substrate between the first and second strips.

17. The vehicle of claim 14, wherein the RF communications circuit communicates with the controller using Time Synchronized Channel Hopping.

18. The vehicle of claim 14, further comprising a module cover spanning the PCBA and the plurality of battery cells.

19. The vehicle of claim 14, wherein the RF communications circuit is in wireless communication with the master battery controller via a 2.4 GHz protocol.