Battery pack having flexible circuit connector

• US 6,746,797 B2
• Filed: 07/31/2001
• Issued: 06/08/2004
• Est. Priority Date: 07/31/2001
• Status: Expired due to Fees

• Current Assignee: EnerDel, Inc. (Ener1, Inc.)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Haworth, Dianne L, Benson, Morgan Rey, Wendling, Robert Thomas
• Primary Examiner(s): Kalafut, Stephen
• Assistant Examiner(s): Alejandro, Raymond
• Application Number:
  US09/919,304
• Publication Number:
  US 20030027039A1
• Time in Patent Office: 1,043 Days
• Field of Search: 429/149, 429/156, 429/158, 429/159, 429/160, 429/61, 429/7, 429/178, 429/99
• US Class Current: 429/149
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/38 Construction or manufacture
• CPC Class Codes: H01M 50/178 for pouch or flexible bag cells
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: H01M 50/529 Intercell connections through partitions, e.g. in a battery casing
• CPC Class Codes: H01M 50/548 on opposite sides of the cell
• CPC Class Codes: H01M 50/557 Plate-shaped terminals
• CPC Class Codes: H01M 50/562 characterised by the material
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A battery pack containing a plurality of battery modules, these modules comprising a plurality of individual battery units, these battery units comprising a plurality of bicells with opposing terminals. The battery modules are connected in series by use of a flexible circuit and by opposing positive and negative terminals of each battery unit. The terminals of each battery unit contain a region of apertures which allow the adhesive of the packaging material to seal more effectively, thereby eliminating or reducing the amount of leakage from an individual battery unit.

Claims

1. A battery pack, comprising:

a plurality of battery modules each having at least one positive terminal and one negative terminal associated therewith, wherein at least one of said battery module terminals includes a respective tang that is integral to the terminal; and

a flexible circuit configured to connect said plurality of positive and negative terminals to an output of said battery pack, wherein said flexible circuit further includes windows configured to allow said tangs to pass through, wherein an edge of said window defines a hinged edge for a flap configured such that said flaps are in registry with said tangs and at least one of said battery module terminals is electrically connected to said flap via said tang.

2. The battery pack of claim 1, wherein at least one of said battery modules comprises a plurality of individual battery units, each battery unit including at least one positive terminal and one negative terminal.

3. The battery pack of claim 2, wherein at least one of said battery units includes a plurality of bicells.

4. The battery pack of claim 1, wherein said flexible circuit further comprises a plurality of jumpers.

5. The battery pack of claim 1, wherein said flexible circuit further comprises a controller connector, said controller connector being configured to receive a battery controller, said connector being further configured to be in sensing relation to each battery module.

6. The battery pack of claim 1, wherein said flexible circuit further comprises a fuse.

7. The battery pack of claim 1, wherein said flexible circuit further comprises a pack connector.

8. The battery pack of claim 1, wherein said flexible circuit further comprises a current sensor.

9. The battery pack of claim 1, further comprising at least one living hinge formed along a flex line on said flexible circuit.

10. A battery pack, comprising:

a plurality of battery modules each having at least a positive terminal and a negative terminal associated therewith, wherein at least one of said battery modules comprises a plurality of individual battery units, each battery unit including at least one positive terminal and one negative terminal, wherein at least one of said battery unit terminals includes a respective tang that is integral to the terminal; and

a flexible circuit configured to connect said plurality of positive and negative battery unit terminals to an output of said battery pack, wherein said flexible circuit further includes windows configured to allow said tangs to pass through, wherein an edge of said window defines a hinged edge for a flap configured such that said flaps are in registry with said tangs and at least one of said battery unit terminals is electrically connected to said flap via said tang.

11. The battery pack of claim 10, wherein said flexible circuit further comprises a controller connector, said controller connector being configured to receive a battery controller, said connector being further configured to be in sensing relation to each battery unit.