RECESSED TERMINAL IN MODULE BODY

• US 20160064722A1
• Filed: 07/17/2015
• Published: 03/03/2016
• Est. Priority Date: 08/26/2014
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Mack, Robert J., DeKeuster, Richard M., Lobert, Jonathan P., Nakayama, Ken
• Granted Patent: US 10,056,598 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/10 for monitoring or controlling batteries
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 2200/20 Pressure-sensitive devices
• CPC Class Codes: H01M 2220/10 Batteries in stationary systems, e.g. emergency power source in plant
• 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 50/227 Organic material
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 50/505 comprising a single busbar
• 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 50/561 Hollow metallic terminals, e.g. terminal bushings
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

The present disclosure includes a group of electrically interconnected battery cells disposed within a housing. The disclosure also includes a major terminal of a battery module configured to be coupled to a load for powering the load. One or more portions of the major terminal are disposed within a recess in a surface of the housing. The present disclosure also includes a bus bar that provides an electrical pathway between the group of electrically interconnected battery cells and the major terminal. The bus bar is disposed within the housing.

Claims

1. A battery module, comprising:

a group of electrically interconnected battery cells;

a housing, wherein the group of electrically interconnected battery cells are disposed within the housing;

a major terminal of the battery module configured to be coupled to a load for powering the load, wherein one or more portions of the major terminal are disposed within a recess in a surface of the housing; and

a bus bar that provides an electrical pathway between the group of electrically interconnected battery cells and the major terminal, wherein the bus bar is disposed within the housing.

2. The battery module of claim 1, wherein the major terminal comprises a base and a post disposed within the housing.

3. The battery module of claim 2, wherein the base is molded into the recess, and wherein the base is configured to receive the post within the recess.

4. The battery module of claim 2, wherein a first conductive material of the base is different than a second conductive material of the post.

5. The battery module of claim 4, wherein the first conductive material is copper or the second conductive material is stainless steel.

6. The battery module of claim 1, wherein the housing comprises a lower housing portion and a housing cover.

7. The battery module of claim 6, wherein the housing cover is disposed at least partially over the recess to secure the one or more portions of the major terminal molded into the recess within the housing.

8. The battery module of claim 7, wherein the housing comprises a housing collar configured to secure the housing cover to the lower housing portion.

9. The battery module of claim 1, wherein the one or more portions of the major terminal are secured within the recess of the housing with an attachment mechanism, and wherein the attachment mechanism comprises one or more of a sealant, a glue, an o-ring, a resin, an adhesive, a foam, or a combination thereof.

10. The battery module of claim 1, wherein a body of the bus bar extends from the group of electrically interconnected battery cells to the major terminal.

11. The battery module of claim 10, wherein the body comprises an aperture that aligns with an opening of the recess disposed through the surface of the housing.

12. The battery module of claim 1, wherein the group of electrically interconnected battery cells comprises a group of electrically interconnected prismatic lithium-ion (Li-ion) electrochemical cells.

13. A battery module, comprising:

a housing comprising a recess disposed in a surface of the housing;

an electrochemical cell having a minor terminal disposed within the housing;

a major terminal electrically coupled to the electrochemical cell, wherein the major terminal comprises a base and a post engaged within the base, and wherein the base of the major terminal is disposed within the recess; and

a bus bar that provides an electrical path between the minor terminal of the electrochemical cell and the major terminal of the battery module.

14. The battery module of claim 13, wherein the base of the major terminal is configured to receive the post of the major terminal completely within the recess.

15. The battery module of claim 13, wherein the electrochemical cell or the bus bar are disposed within the housing.

16. The battery module of claim 13, wherein the bus bar is at least partially disposed on the surface of the housing, and wherein the bus bar comprises an aperture that receives the post of the major terminal.

17. The battery module of claim 13, wherein the bus bar is disposed within the recess of the housing.

18. The battery module of claim 13, wherein the base comprises a first material and the post comprises a second material different than the first material.

19. The battery module of claim 18, wherein the first material is copper or the second material is stainless steel.

20. The battery module of claim 13, wherein the base is configured to receive the post without integrally coupling with the post.

21. A method of manufacturing a battery module, comprising:

disposing a base of a major terminal within a recess in a surface of a housing, wherein a group of electrically interconnected battery cells are disposed within the housing; and

inserting a post of a major terminal through an opening of the recess such that the base of the major terminal engages with the post of the major terminal; and

coupling the major terminal to the group of electrically interconnected battery cells via a major bus bar disposed within the housing to provide an electrical pathway that powers a load.

22. The method of claim 21, comprising molding the base of the major terminal within the recess.

23. The method of claim 21, comprising disposing the base of the major terminal within the recess in a premolded state.

24. The method of claim 21, comprising securing the base of the major terminal within the recess with an attachment mechanism, wherein the attachment mechanism comprises one or more of a sealant, a glue, an o-ring, a resin, an adhesive, a foam, or a combination thereof.

25. The method of claim 21, comprising embedding the base of the major terminal into the recess of the housing.

26. The method of claim 21, comprising embedding the base of the major terminal, a portion of the bus bar, or a combination thereof, within a wall of a housing of the battery module.