Method for interconnection of battery packs and battery assembly containing interconnected battery packs

• US 7,667,432 B2
• Filed: 04/27/2006
• Issued: 02/23/2010
• Est. Priority Date: 04/27/2006
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Berdichevsky, Eugene, Kohn, Scott, West, Dorian
• Primary Examiner(s): Assouad; Patrick J
• Assistant Examiner(s): WILLIAMS, ARUN C
• Application Number:
  US11/414,050
• Publication Number:
  US 20070252556A1
• Time in Patent Office: 1,398 Days
• Field of Search: 320/104, 320/107, 320/112, 320/120, 320/116, 320/117, 320/126, 307/10.7, 307/71, 439/500
• US Class Current: 320/112
• CPC Class Codes: B60L 2270/145 Structure borne vibrations
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: H01M 50/505 comprising a single busbar
• CPC Class Codes: H01M 50/509 characterised by the type of connection, e.g. mixed connections
• CPC Class Codes: H01M 50/517 by fixing means, e.g. screws, rivets or bolts
• 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

A system and method interconnects battery packs using a flexible bus bar to prevent vibration from breaking or damaging the connections therebetween.

Claims

1. A method of electrically coupling a plurality of battery packs to one another, comprising:

coupling a plurality of sets of batteries in series, each set comprising a plurality of batteries coupled in parallel, to produce each of the plurality of battery packs;

providing at least two terminals at least near one face of each of the plurality of battery packs; and

electrically coupling to one another each of the plurality of battery packs by electrically coupling each of at least one of the terminals of each of the battery packs to at least one of the terminals of at least one other of the battery packs, at least one of the couplings being made via at least one flexible mesh conductor capable of carrying a current in excess of 30 amps.

2. The method of claim 1, wherein:

the at least two terminals of each of the plurality of battery packs extend from at least near a different face of said pack to a location substantially adjacent to the face of said pack; and

the conductors are connected to the flexible bus bar via a screw terminal in which the head of the screw is parallel to the face of the pack.

3. The method of claim 1, wherein the flexible conductor comprises a metal mesh.

4. The method of claim 3, wherein the flexible mesh conductor comprises a flexible bus bar comprising at least two terminals.

5. The method of claim 1, additionally comprising locating each of the packs in the plurality substantially adjacent to one another.

6. The method of claim 1, wherein at least two of the at least two terminals are located at a substantially same height relative to an edge of the battery pack.

7. The method of claim 1, wherein for a first battery pack of the plurality of battery packs:

the at least two terminals comprises at least three terminals;

a first at least one of the three terminals couples the first battery pack in series to a second battery pack of the plurality of battery packs; and

a second and third terminal of the at least three terminals couples the first battery pack in parallel to a third battery pack of the plurality of battery packs.

8. The method of claim 1, additionally comprising the step of coupling the plurality of battery packs to a vehicle.

9. The method of claim 8, wherein the vehicle comprises an automobile.

10. The method of claim 8 comprising an electric power source.

11. The method of claim 8 comprising a hybrid-electric power source.

12. A battery assembly comprising:

a plurality of battery packs each comprising a plurality of sets of batteries coupled in series, each set comprising a plurality of batteries coupled in parallel, each battery pack additionally comprising at least two terminals at least near one face of each said battery pack; and

at least one flexible mesh conductor capable of carrying a current in excess of 30 amps, each flexible mesh conductor electrically coupling at least one of the terminals of at least one of the plurality of battery packs to at least one of the terminals of at least one other of the plurality of battery packs.

13. The battery assembly of claim 12 wherein each of the battery packs comprise a plurality of terminals, the terminals extending from one side of said battery pack and adjacent to another side of said battery pack.

14. The battery assembly of claim 12, wherein each battery pack comprises a plurality of sets of batteries, each of the batteries in a set being coupled to one another in parallel, each of the sets being coupled in series.

15. The battery assembly of claim 12, wherein the battery assembly is coupled to a power source of an electric vehicle.

16. The battery assembly of claim 12, wherein the battery assembly is coupled to a power source of a hybrid-electric vehicle.

17. The battery assembly of claim 15, wherein the vehicle comprises an automobile.

18. The battery assembly of claim 15, where in the vehicle comprises a rocket.

19. The battery assembly of claim 16, wherein the vehicle comprises an automobile.

20. The battery assembly of claim 16, where in the vehicle comprises a rocket.

21. The battery assembly of claim 12, wherein the electrical connection is made via two terminals at substantially the same height relative to an edge of each of the at least two battery packs.

22. The battery assembly of claim 12, wherein:

the electrical interconnection is made between a first battery pack, a second battery pack, and a third battery pack;

the electrical interconnection comprises a series connection between the first battery pack and the second battery pack;

the electrical interconnection comprises a parallel connection between the second battery pack and the third battery pack; and

said electrical connections are made via at least three flexible metal meshes.