System and method for establishing connections of a battery module

• US 9,660,244 B2
• Filed: 03/31/2014
• Issued: 05/23/2017
• Est. Priority Date: 09/06/2013
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Dinkelman, John P., DeKeuster, Richard M., Soleski, Edward J., Balk, Mikhail S., Winders, Lisa L.
• Primary Examiner(s): Slifka, Sarah A
• Assistant Examiner(s): Sheikh, Haroon S
• Application Number:
  US14/231,013
• Publication Number:
  US 20150072176A1
• Time in Patent Office: 1,149 Days
• Field of Search: None
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/02 to electric heating circuits
• CPC Class Codes: B60L 1/14 to electric lighting circuits
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/34 Cabin temperature
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• 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 58/15 : Preventing overcharging
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: B60L 58/24 : for controlling the temperature of batteries
• CPC Class Codes: B60L 58/26 : by cooling
• CPC Class Codes: B60R 16/03 : for supply of electrical power to vehicle subsystems or for circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: B60R 16/033 : characterised by the use of electrical cells or batteries for propulsion puposes B60K1/04; supplying batteries to, or removing batteries from, vehicles B60S5/06; testing of charge state G01R31/36
• CPC Class Codes: G01R 31/3835 : involving only voltage measurements
• CPC Class Codes: G01R 31/385 : Arrangements for measuring battery or accumulator variables for monitoring G01R31/382
• CPC Class Codes: G01R 31/52 : Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: H01H 47/325 : by switching regulator
• 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 10/058 : Construction or manufacture
• 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 10/4257 : Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/482 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/486 : for measuring temperature
• CPC Class Codes: H01M 10/6551 : Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• 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 2200/103 : Fuse
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 2250/20 : Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 4/661 : Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/665 : Composites
• CPC Class Codes: H01M 50/20 : Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders structural combination of accumulators with charging apparatus H01M10/46
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/264 : for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 : Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/287 : Fixing of circuit boards to lids or covers
• CPC Class Codes: H01M 50/291 : characterised by their shape
• CPC Class Codes: H01M 50/30 : Arrangements for facilitating escape of gases
• CPC Class Codes: H01M 50/308 : Detachable arrangements, e.g. detachable vent plugs or plug systems
• CPC Class Codes: H01M 50/342 : Non-re-sealable arrangements
• CPC Class Codes: H01M 50/35 : Gas exhaust passages comprising elongated, tortuous or labyrinth-shaped exhaust passages
• CPC Class Codes: H01M 50/358 : External gas exhaust passages located on the battery cover or case
• CPC Class Codes: H01M 50/367 : Internal gas exhaust passages forming part of the battery cover or case; Double cover vent systems
• CPC Class Codes: H01M 50/50 : Current conducting connections for cells or batteries
• CPC Class Codes: H01M 50/502 : Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
• 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 50/528 : Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: H01M 50/529 : Intercell connections through partitions, e.g. in a battery casing
• CPC Class Codes: H01M 50/543 : Terminals
• CPC Class Codes: H01M 50/569 : Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: H01M 50/571 : Methods or arrangements for affording protection against corrosion; Selection of materials therefor
• CPC Class Codes: H01M 50/572 : Means for preventing undesired use or discharge
• CPC Class Codes: H01M 50/583 : in response to current, e.g. fuses
• CPC Class Codes: H01M 50/597 : Protection against reversal of polarity
• CPC Class Codes: H01R 12/716 : Coupling device provided on the PCB
• CPC Class Codes: H02H 7/18 : for batteries; for accumulators
• CPC Class Codes: H05K 1/0218 : by printed shielding conductors, ground planes or power plane H05K1/0236 takes precedence
• CPC Class Codes: H05K 1/0262 : Arrangements for regulating voltages or for using plural voltages
• CPC Class Codes: H05K 1/0263 : High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board H05K1/0293 takes precedence
• CPC Class Codes: H05K 1/0298 : Multilayer circuits
• CPC Class Codes: H05K 1/18 : Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 2201/0715 : provided by an outer layer of PCB
• CPC Class Codes: H05K 2201/09327 : Special sequence of power, ground and signal layers in multilayer PCB
• CPC Class Codes: H05K 2201/10492 : Electrically connected to another device mounted components directly electrically connected to each other H05K2201/1053
• CPC Class Codes: H05K 2201/1053 : Mounted components directly electrically connected to each other, i.e. not via the PCB
• CPC Class Codes: H05K 2201/10545 : Related components mounted on both sides of the PCB
• CPC Class Codes: H05K 3/32 : electrically connecting electric components or wires to printed circuits
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• 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 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 29/4911 : including sealing
• CPC Class Codes: Y10T 29/49114 : including adhesively bonding

Abstract

A battery module includes a housing and battery cells disposed in the housing, each of the battery cells including two terminals. The battery module also includes bus bar cell interconnects including a first material, where each bus bar cell interconnect is configured to electrically couple two adjacent battery cells via an electrical coupling with a first terminal of one of the adjacent battery cells and a second terminal of the other adjacent battery cell, where at least one of the first and second terminals includes the first material. The battery module includes welds, each weld being disposed at a corresponding welding point to directly couple one of the bus bar cell interconnects with the corresponding at least one terminal including the first material. Each welding point is accessible for welding from a position above the battery cells when the interconnects are disposed over the battery cells.

Claims

1. A battery module, comprising:

a housing;

a plurality of battery cells disposed in the housing, wherein each battery cell of the plurality of battery cells comprises a first terminal having a first material, and a second terminal;

a plurality of bus bar cell interconnects comprising the first material, wherein each bus bar cell interconnect of the plurality of bus bar cell interconnects is configured to electrically couple two adjacent battery cells of the plurality of battery cells via an electrical coupling with the first terminal of one of the adjacent battery cells and the second terminal of the other adjacent battery cell;

a plurality of first welds, wherein each first weld of the plurality of first welds is disposed at a corresponding first welding point and directly couples a corresponding bus bar cell interconnect of the plurality of bus bar cell interconnects with a corresponding one of the first terminals comprising the first material;

a terminal post connector for outputting a voltage from the plurality of battery cells, the terminal post connector comprising the first material;

a printed circuit board (PCB) installed in the battery module proximate to the first and second terminals of the plurality of battery cells; and

a shunt disposed on the PCB of the battery module for carrying current from the plurality of battery cells to the terminal post connector, wherein the terminal post connector is welded to the shunt at a first shunt welding point, and wherein the first shunt welding point and each first welding point of the plurality of first welds is accessible for welding from a position above the plurality of battery cells and unencumbered by the installed PCB.

2. The battery module of claim 1, comprising a plurality of second welds, wherein all of the first and second terminals of the plurality of battery cells comprise the first material, wherein each second weld of the plurality of second welds is disposed at a corresponding second welding point and directly couples the corresponding bus bar cell interconnect with a corresponding one of the second terminals comprising the first material, and wherein each second welding point of the plurality of second welds is accessible for welding from the position above the plurality of battery cells and unencumbered by the installed PCB.

3. The battery module of claim 1, wherein the second terminal of each battery cell of the plurality of battery cells comprises a second material different from the first material.

4. The battery module of claim 3, comprising a plurality of adapters, wherein each adapter of the plurality of adapters is disposed over a corresponding second terminal comprising the second material, wherein each adapter comprises:

a first end comprising the second material, wherein the first end is configured to contact the second terminal comprising the second material; and

a second end comprising the first material, wherein the adapter transitions from the second material in the first end to the first material in the second end, wherein the second end is welded directly to the corresponding bus bar cell interconnect of the plurality of bus bar cell interconnects at an adapter welding point, and wherein each of the adapter welding points is accessible for welding from the position above the plurality of battery cells unencumbered by the installed PCB.

5. The battery module of claim 4, comprising a first bus bar of the battery module coupled between one battery cell of the plurality of battery cells and the shunt, the first bus bar comprising the first material, wherein the shunt is welded directly to the first bus bar of the battery module at a second shunt welding point, and wherein the second shunt welding point is accessible for welding from the position above the battery module and unencumbered by the installed PCB.

6. The battery module of claim 5, wherein the first bus bar is welded directly to one of the first terminals comprising the first material at a first bus bar welding point, and wherein the first bus bar welding point is accessible for welding from the position above the plurality of battery cells and unencumbered by the installed PCB.

7. The battery module of claim 1, wherein the PCB comprises one or more voltage sense connection tabs, wherein each of the one or more voltage sense connection tabs is coupled via a tab weld to one of the plurality of bus bar cell interconnects at a tab welding point, and wherein each tab welding point is accessible for welding from the position above the plurality of battery cells and unencumbered by the installed PCB.

8. The battery module of claim 1, comprising a second bus bar of the battery module, wherein the second bus bar comprises the first material and is electrically coupled between one battery cell of the plurality of battery cells and a second terminal post connector of the battery module.

9. The battery module of claim 8, wherein the second bus bar of the battery module is welded directly to the first terminal of the one battery cell of the plurality of battery cells at a second bus bar welding point, and wherein the second bus bar welding point is accessible for welding from the position above the plurality of battery cells and unencumbered by the installed PCB.

10. The battery module of claim 8, comprising an adapter, wherein the adapter comprises:

a first end comprising a second material different from the first material, wherein the first end contacts the second terminal of the one battery cell of the plurality of battery cells; and

a second end comprising the first material, wherein the adapter transitions from the second material in the first end to the first material in the second end, wherein the second end is welded directly to the second bus bar at a second bus bar welding point, and wherein the second bus bar welding point is accessible for welding from the position above the plurality of battery cells and unencumbered by the installed PCB.

11. The battery module of claim 1, wherein the first material is copper, and wherein each first weld of the plurality of first welds comprises a copper-to-copper weld.

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

disposing a plurality of battery cells in a housing of the battery module, wherein each battery cell of the plurality of battery cells comprises first and second terminals disposed on a terminal end of the battery cell;

disposing a plurality of bus bar cell interconnects comprising a first material over the plurality of battery cells;

electrically coupling each bus bar cell interconnect of the plurality of bus bar cell interconnects with two adjacent battery cells of the plurality of battery cells via an electrical coupling with the first terminal of one of the adjacent battery cells and the second terminal of the other adjacent battery cell, wherein at least one of the first or second terminals comprises the first material;

installing a printed circuit board (PCB) over the plurality of battery cells and proximate to the terminals of the plurality of battery cells such that a first surface of the PCB faces the terminal ends of the plurality of battery cells; and

then

welding each bus bar cell interconnect of the plurality of bus bar cell interconnects directly to a corresponding one of the first or second terminals at a corresponding welding point, wherein each welding point is accessible for welding from a position above the plurality of battery cells when the plurality of bus bar cell interconnects are disposed over the plurality of battery cells;

welding a terminal post connector comprising the first material to a shunt comprising the first material at a first shunt welding point, wherein the shunt is coupled to a second surface of the PCB opposite the first surface of the PCB, wherein the shunt is configured to provide an electrical path between the plurality of battery cells and the terminal post connector, and wherein the terminal post connector is configured to output a voltage from the plurality of battery cells; and

welding the shunt to a first bus bar comprising the first material at a second shunt welding point, wherein the first bus bar is configured to electrically couple the shunt with the first or the second terminal of one battery cell of the plurality of battery cells;

wherein the first shunt welding point and the second shunt welding point are both accessible for welding from the position above the plurality of battery cells and the PCB.

13. The method of claim 12, comprising welding, after installing the PCB over the plurality of battery cells and proximate to the terminals of the plurality of battery cells, each bus bar cell interconnect of the plurality of bus bar cell interconnects directly to the corresponding first and second terminals at the welding points accessible for welding from the position above the plurality of battery cells, wherein all of the first and second terminals of the plurality of battery cells comprise the first material.

14. The method of claim 12, wherein one of the first or second terminals of each battery cell of the plurality of battery cells comprises a second material different from the first material, and wherein the method comprises:

disposing a plurality of adapters over the first or second terminals comprising the second material, wherein each adapter comprises;

a first end comprising the second material, wherein the first end is configured to contact the corresponding terminal comprising the second material; and

a second end comprising the first material, wherein the adapter transitions from the second material in the first end to the first material in the second end; and

after installing the PCB over the plurality of battery cells and proximate to the terminals of the plurality of battery cells, welding each bus bar cell interconnect of the plurality of bus bar cell interconnects directly to a corresponding adapter of the plurality of adapters at a corresponding adapter welding point, wherein each of the adapter welding points is accessible for welding from the position above the plurality of battery cells.

15. The method of claim 12, comprising welding, after installing the PCB over the plurality of battery cells and proximate to the terminals of the plurality of battery cells, the first bus bar directly to the first or the second terminal of the one battery cell of the plurality of battery cells at a first bus bar welding point, wherein the first or the second terminal to which the first bus bar is directly welded comprises the first material, and wherein the first bus bar welding point is accessible for welding from the position above the plurality of battery cells.

16. The method of claim 12, comprising:

disposing the PCB over the plurality of battery cells, wherein the PCB comprises one or more voltage sense connection tabs, such that each of the one or more voltage sense connection tabs is aligned with one of the plurality of bus bar cell interconnects; and

after installing the PCB over the plurality of battery cells and proximate to the terminals of the plurality of battery cells, welding each of the one or more voltage sense connection tabs to a corresponding bus bar cell interconnect of the plurality of bus bar cell interconnects at a tab welding point, wherein each tab welding point is accessible for welding from the position above the plurality of battery cells.

17. The method of claim 12, comprising electrically coupling a second bus bar between the plurality of battery cells and a second terminal post connector of the battery module, wherein the second bus bar comprises the first material.

18. The method of claim 17, comprising welding, after installing the PCB over the plurality of battery cells and proximate to the terminals of the plurality of battery cells, the second bus bar directly to one of the first or second terminals comprising the first material from the position above the plurality of battery cells.

19. A method of establishing connections of a battery module, the method comprising:

disposing a printed circuit board (PCB) over a plurality of battery cells and proximate to terminal ends of the plurality of battery cells, wherein terminals of the plurality of battery cells extend from the terminal ends, wherein the terminal ends face a first surface of the PCB, and wherein the PCB comprises one or more voltage sense tabs extending from a second surface of the PCB opposite to the first surface; and

then;

electrically coupling each bus bar cell interconnect of a plurality of bus bar cell interconnects with two adjacent battery cells of the plurality of battery cells via an electrical coupling with a first terminal of one of the adjacent battery cells and a second terminal of the other adjacent battery cell, wherein at least one of the first or second terminals comprises a first material;

welding each bus bar cell interconnect of the plurality of bus bar cell interconnects directly to the at least one of the first or second terminals at a corresponding welding point via a single welding tool from a position above the plurality of battery cells;

welding a terminal post connector comprising the first material to a shunt comprising the first material at a first shunt welding point, wherein the shunt is coupled to the PCB of the battery module, wherein the shunt is configured to provide an electrical path between the plurality of battery cells and the terminal post connector, and wherein the terminal post connector is configured to output a voltage from the plurality of battery cells;

welding the shunt to a first bus bar comprising the first material at a second shunt welding point such that the first bus bar electrically couples the shunt with a terminal of one of plurality of battery cells; and

welding the one or more voltage sense tabs to a corresponding one or more bus bar cell interconnects of the plurality of bus bar cell interconnects at corresponding one or more tab welding points, wherein the one or more tab welding points, the first shunt welding point, and the second shunt welding point are accessible for welding from the position above the plurality of battery cells.

20. The method of claim 19, comprising welding each bus bar cell interconnect of the plurality of bus bar cell interconnects directly to the corresponding first terminal and the corresponding second terminal at the welding points accessible for welding from the position above the plurality of battery cells, wherein all of the terminals of the plurality of battery cells comprise the first material.

21. The method of claim 19, wherein the first material is copper, and wherein each weld generated by the welding comprises a copper-to-copper weld.