BUSBAR SUPPORTS AND METHODS OF THEIR USE FOR BATTERY SYSTEMS

• US 20100247998A1
• Filed: 12/01/2009
• Published: 09/30/2010
• Est. Priority Date: 01/12/2009
• Status: Active Grant

• Current Assignee: A123 Systems Incorporated
• Original Assignee: A123 Systems Incorporated
• Inventors: BUTT, Shazad M., IJAZ, Mujeeb, HOSTLER, Jonathan E.
• Granted Patent: US 8,815,429 B2
• Time in Patent Office: Days
• US Class Current: 429/120
• CPC Class Codes: H01H 2085/025 Structural association with a binding post of a storage battery
• CPC Class Codes: H01H 85/0241 Structural association of a fuse and another component or apparatus switches with built-in fuses H01H9/10, spark-gap arresters H01H85/44, transformers and inductances H01F27/402, capacitors H01G2/14, lamps H01K1/66, semiconductors H01L23/5256 or H01L23/62
• CPC Class Codes: H01H 85/044 General constructions or structure of low voltage fuses, i.e. below 1000 V, or of fuses where the applicable voltage is not specified H01H85/046 - H01H85/048 take precedence
• CPC Class Codes: H01H 85/10 with constriction for localised fusing H01H85/11 takes precedence
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/0468 Compression means for stacks of electrodes and separators
• CPC Class Codes: H01M 10/42 Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• 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 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/653 characterised by electrically insulating or thermally conductive materials
• CPC Class Codes: H01M 10/6551 Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6553 Terminals or leads
• CPC Class Codes: H01M 10/6555 arranged between the cells
• CPC Class Codes: H01M 2004/027 Negative electrodes
• CPC Class Codes: H01M 2200/00 Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2200/103 Fuse
• CPC Class Codes: H01M 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/193 Organic material
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/258 : Modular batteries; Casings provided with means for assembling
• CPC Class Codes: H01M 50/3425 : in the form of rupturable membranes or weakened parts, e.g. pierced with the aid of a sharp member
• CPC Class Codes: H01M 50/507 : comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules
• CPC Class Codes: H01M 50/516 : by welding, soldering or brazing
• CPC Class Codes: H01M 50/522 : Inorganic material
• CPC Class Codes: H01M 50/55 : on the same side of the cell
• CPC Class Codes: H01M 50/553 : Terminals adapted for prismatic, pouch or rectangular cells
• CPC Class Codes: H01M 50/562 : characterised by the material
• CPC Class Codes: H01M 50/566 : by welding, soldering or brazing
• CPC Class Codes: H01M 50/581 : in response to temperature
• CPC Class Codes: H01M 50/588 : outside the batteries, e.g. incorrect connections of terminals or busbars
• CPC Class Codes: H01M 6/42 : Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making

Abstract

A battery system comprises a plurality of battery subunits, each subunit comprising a heatsink and at least one battery cell with a positive terminal and a negative terminal; where each heatsink has a respective busbar support mounted to it, and each busbar support includes first and second slots through which, respectively, a positive and a negative terminal of the at least one battery cell for that subunit passes, wherein a first busbar is located above and held at least in part by the first busbar support and is electrically connected to the negative terminal passing through the first slot in the first busbar support; and a second busbar is located above and held at least in part by the first busbar support and electrically connected to the positive terminal passing through the second slot in the first busbar support.

Claims

1. A battery system comprising:

a plurality of battery subunits, each subunit comprising a heatsink and at least one battery cell with a positive terminal and a negative terminal;

a plurality of busbar supports equal in number to the plurality of battery subunits and each of which is mounted on the heatsink of a corresponding different one of the plurality of subunits, each busbar support including a first slot through which the positive terminal of the at least one battery cell for that subunit passes and a second slot though which the negative terminal for the at least one battery cell for that subunit passes, said plurality of busbar supports including a first busbar support;

a first busbar located above and held at least in part by the first busbar support and electrically connected to the negative terminal passing through the first slot in the first busbar support; and

a second busbar located above and held at least in part by the first busbar support and electrically connected to the positive terminal passing through the second slot in the first busbar support.

2. The battery system of claim 1 wherein the first busbar support includes a latch to grip a slot in a heatsink.

3. The battery system of claim 1 wherein the first busbar support includes a thermistor and a port in which a thermistor at least partially situated.

4. The battery system of claim 1 further comprising a busbar cover wherein the first busbar support includes a receptacle to which the busbar cover is attached.

5. The battery system of claim 1 wherein the first busbar support includes a channel in which wiring is situated and a flexible finger that at least partially retains the wiring within the channel.

6. The battery system of claim 1 wherein the first busbar support includes two latches between which a busbar is at least partially held.

7. The battery system of claim 1 wherein the first busbar support includes a main body situated between the first busbar and the positive terminal of the battery of the corresponding subunit.

8. The battery system of claim 1 wherein the battery cell is a prismatic battery cell.

9. A method of manufacturing a battery comprising:

mounting a first battery cell on a heatsink wherein the battery cell has a first terminal;

attaching a busbar support to the heatsink wherein the busbar support includes a first slot through which the first terminal passes;

supplying a busbar having a U-shaped portion defining a channel and characterized by a bend corner at one end of the U-shaped portion, said busbar also having a reduced reflectivity treatment at least in the vicinity of the bend corner;

mounting the busbar to the busbar support, the busbar support securing the busbar so that the first battery terminal is positioned in the channel formed by the U-shaped portion so that the top end of the terminal is proximate to the bend corner;

directing a laser beam at the bend corner of the U-shaped portion; and

with the laser beam, melting the busbar at the bend corner and forming a metallurgical bond between the busbar and the top end of the first battery terminal.

10. The method of claim 9 wherein the laser beam is directed at an angle substantially head-on to the end of the battery cell terminal.

11. The method of claim 10 wherein the laser beam moves in a direction of travel parallel to the channel.

12. The method of claim 11 wherein the laser beam is directed at an angle slightly less than perpendicular to the direction of travel.

13. The method of claim 9, wherein the treatment comprises a coating of one or more of nickel and tin.

14. The method of claim 9 further comprising forming the busbar by joining a first busbar segment to a second busbar segment, wherein the first segment is made of a first metal and the second segment is made of a second metal that is different from the first metal.

15. The method of claim 14, wherein the first busbar segment is ultrasonically welded to the second busbar segment prior to attaching the busbar to the terminal.