Battery module printed circuit board assembly system and method

• US 9,716,263 B2
• Filed: 03/31/2014
• Issued: 07/25/2017
• 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: Dulle, Ronald J., Gunderson, Mark D., Thieme, Bryan L.
• Primary Examiner(s): Smith, Jeremiah
• Application Number:
  US14/230,915
• Publication Number:
  US 20150070021A1
• Time in Patent Office: 1,212 Days
• 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, a plurality of battery cells disposed in the housing, and a printed circuit board (PCB) assembly disposed in the housing. The PCB assembly includes a PCB and a shunt disposed across a first surface of the PCB. A second surface of the shunt directly contacts the first surface of the PCB, and the shunt is electrically coupled between the battery cells and a terminal of the battery module.

Claims

1. A battery module, comprising:

a housing;

a plurality of battery cells disposed in the housing; and

a printed circuit board (PCB) assembly disposed in the housing, the PCB assembly comprising;

a PCB; and

a shunt disposed across a first surface of the PCB, wherein a second surface of the shunt directly contacts the first surface of the PCB, and wherein the shunt is electrically coupled between the plurality of battery cells and a terminal of the battery module; and

a bus bar that is in electrical communication with one battery cell of the plurality of battery cells and with a connector that is in electrical communication with the terminal of the battery module, wherein the shunt provides a low resistance path between the bus bar of the battery module and the connector of the battery module, and wherein the bus bar comprises an extension that extends over and in contact with the shunt, such that the shunt is disposed between the first surface of the PCB and a bottom surface of the extension of the bus bar.

2. The battery module of claim 1, wherein the connector comprises an integral bladed portion that extends over and in contact with the shunt, such that the shunt is held between the first surface of the PCB and a bottom surface of the bladed portion of the connector.

3. The battery module of claim 1, comprising a lid disposed between the PCB assembly and the plurality of battery cells, wherein the lid is configured to support the PCB assembly, wherein the lid comprises a shunt clip extending upwardly from the lid, and wherein the shunt clip comprises an extension configured to contact a top surface of the shunt, such that the shunt is disposed between the first surface of the PCB and a bottom surface of the extension of the shunt clip.

4. The battery module of claim 3, wherein the shunt clip extends upwardly from the lid through an aperture in the PCB.

5. The battery module of claim 1, wherein the PCB comprises an electrical connection exposed on the first surface, wherein the electrical connection is in contact with the second surface of the shunt, and wherein the electrical connection enables the PCB to monitor characteristics of an electrical flow through the shunt.

6. The battery module of claim 5, wherein the characteristics of the electrical flow comprise voltage output from the battery module.

7. The battery module of claim 1, wherein the second surface of the shunt directly contacts the first surface of the PCB without the shunt extending off the first surface of the PCB.

8. The battery module of claim 1, wherein the shunt is integral with the PCB.

9. A method of manufacturing a battery module, the method comprising:

disposing a printed circuit board (PCB) on top of a lid of the battery module;

disposing a shunt on top of and directly against the PCB;

coupling the shunt to a bus bar on a first end of the shunt and to a connector on a second end of the shunt opposite the first end, wherein the connector is coupled to an output terminal of the battery module;

coupling the bus bar to a terminal of a battery cell of the battery module;

coupling a bottom surface of the shunt with electrical connectors exposed on a top surface of the PCB; and

restraining the shunt on top of the PCB via a shunt clip extending upwardly from the lid and over the shunt, wherein the shunt clip comprises an extension configured to exert a downward force against a top surface of the shunt.

10. The method of claim 9, comprising coupling the shunt to the PCB via adhesive applied between the bottom surface of the shunt and the top surface of the PCB.

11. The method of claim 9, wherein the connector extends from below the lid through an aperture in the lid, wherein a bladed portion of the connector extends over and in contact with a top surface of the shunt.

12. The method of claim 9, wherein an extension of the bus bar extends over and in contact with a top surface of the shunt.

13. The method of claim 9, wherein the shunt is in direct contact with the PCB without extending beyond the top surface of the PCB.

14. The method of claim 9, wherein coupling the shunt to the bus bar and the connector comprises welding the shunt to the bus and to the connector.

15. The method of claim 9, wherein each of the shunt, the bus bar, and the connector are made of copper.

16. The method of claim 9, wherein coupling the shunt to the connector on the second end of the shunt comprises:

disposing the connector proximate the shunt;

disposing a bladed portion over and in contact with the connector and the shunt; and

coupling the bladed portion to the connector and to the shunt.

17. The method of claim 16, wherein coupling the bladed portion to the connector and to the shunt comprises welding the bladed portion to the connector and to the shunt.

18. A battery module, comprising:

a housing;

a plurality of battery cells disposed in the housing; and

a printed circuit board (PCB) assembly disposed in the housing, the PCB assembly comprising;

a PCB; and

a shunt disposed across a first surface of the PCB, wherein a second surface of the shunt directly contacts the first surface of the PCB, and wherein the shunt is electrically coupled between the plurality of battery cells and a terminal of the battery module; and

a lid disposed between the PCB assembly and the plurality of battery cells, wherein the lid is configured to support the PCB assembly, wherein the lid comprises a shunt clip extending upwardly from the lid, and wherein the shunt clip comprises an extension configured to contact a top surface of the shunt, such that the shunt is disposed between the first surface of the PCB and a bottom surface of the extension of the shunt clip, wherein the shunt clip extends upwardly from the lid through an aperture in the PCB.

19. The battery module of claim 18, wherein the PCB comprises an electrical connection exposed on the first surface, wherein the electrical connection is in contact with the second surface of the shunt, and wherein the electrical connection enables the PCB to monitor a characteristic of an electrical flow through the shunt.

20. The battery module of claim 19, wherein the characteristic of the electrical flow comprises voltage output from the battery module.

22. The battery module of claim 18, wherein the second surface of the shunt directly contacts the first surface of the PCB without the shunt extending off the first surface of the PCB.

23. The battery module of claim 18, wherein the shunt is integral with the PCB.

24. The battery module of claim 18, comprising:

a bus bar extending from a terminal of a first battery cell of the plurality of battery cells; and

a module terminal configured to be coupled to a load for powering the load, wherein the shunt is disposed between the bus bar and the module terminal.

25. The battery module of claim 24, comprising a connector extending from the module terminal, wherein the shunt is disposed between, and in direct contact with, the connector and the bus bar.

21. The battery module of 27, wherein the characteristic of the electrical flow comprises a temperature in the shunt, a state of charge of the battery module, or both.