Battery module printed circuit board assembly system and method

• US 10,468,654 B2
• Filed: 07/24/2017
• Issued: 11/05/2019
• Est. Priority Date: 09/06/2013
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: CPS Technology Holdings, LLC
• Inventors: Dulle, Ronald J., Gunderson, Mark D., Thieme, Bryan L.
• Primary Examiner(s): Smith, Jeremiah R
• Application Number:
  US15/658,239
• Publication Number:
  US 20170324075A1
• Time in Patent Office: 834 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, wherein the PCB assembly comprises a PCB having an upper PCB surface through which an electrical connector of the PCB is exposed, and wherein the PCB assembly comprises a shunt having a bottom shunt surface in direct contact with the upper PCB surface and with the electrical connector exposed through the upper PCB surface, such that the shunt is in electrical communication with the electrical connector of the PCB.

2. The battery module of claim 1, comprising a processor or measurement device, wherein the electrical connector is electrically coupled between the shunt and the processor or measurement device.

3. The battery module of claim 2, wherein an additional electrical connector is exposed through the upper PCB surface of the PCB, wherein the additional electrical connector is electrically coupled between the shunt and either the processor, the measurement device, or an additional measurement device.

4. The battery module of claim 2, wherein the processor or measurement device is configured to measure a voltage output of the battery module, a current of the battery module, or both.

5. The battery module of claim 1, comprising a bus bar electrically coupled between an end battery cell of the plurality of battery cells and the shunt of the PCB assembly.

6. The battery module of claim 5, comprising:

a battery module terminal configured to be coupled to a load powered by the battery module; and

a connector electrically coupled between the battery module terminal and the shunt.

7. The battery module of claim 6, wherein the bus bar directly contacts an upper shunt surface that is opposite the bottom shunt surface, and wherein the connector directly contacts the upper shunt surface.

8. The battery module of claim 7, wherein the bus bar directly contacts the upper shunt surface on a first end of the shunt, and wherein the connector directly contacts the upper shunt surface on a second end of the shunt opposing the first end of the shunt.

9. The battery module of claim 6, wherein the shunt is configured to provide a low resistance path between the bus bar of the battery module and the battery module terminal.

10. The battery module of claim 1, wherein the electrical connector is configured to enable the PCB to monitor characteristics of an electrical flow through the shunt.

11. The battery module of claim 1, comprising:

a battery module terminal configured to be coupled to a load powered by the battery module; and

a bus bar electrically coupled between an end battery cell of the plurality of battery cells and the shunt of the PCB assembly, wherein the shunt is configured to provide a low resistance path between the bus bar of the battery module and the battery module terminal.

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

exposing an electrical connector through an upper printed circuit board (PCB) surface of a PCB of a PCB assembly;

disposing a shunt on and above the upper PCB surface such that a bottom shunt surface of the shunt directly contacts the upper PCB surface of the PCB and the electrical connector exposed through the upper PCB surface, and such that the shunt is in electrical communication with the electrical connector;

coupling a bus bar to the shunt, wherein the bus bar is configured to be coupled to a plurality of battery cells of the battery module; and

coupling a connector to the shunt, wherein the connector is configured to be coupled to a battery module terminal of the battery module;

wherein the bus bar is coupled directly to a first end of the shunt along an upper shunt surface that is opposite the bottom shunt surface of the shunt, wherein the connector is coupled directly to a second end of the shunt along the upper shunt surface of the shunt.

13. A battery module having a printed circuit board (PCB) assembly, comprising:

a plurality of battery cells;

a PCB of the PCB assembly, wherein the PCB includes an upper PCB surface through which an electrical connector is exposed; and

a shunt having a bottom shunt surface in direct contact with the upper PCB surface and with the electrical connector exposed through the upper PCB surface such that the shunt is in electrical communication with the electrical connector, wherein the shunt is configured to provide a low resistance path between an end cell of the plurality of battery cells and a battery module terminal configured to be coupled to a load powered by the battery module.

14. The PCB assembly of claim 13, comprising a processor or measurement device of the PCB assembly, wherein the electrical connector is electrically coupled between the shunt and the processor or measurement device of the PCB assembly.

15. The PCB assembly of claim 14, wherein an additional electrical connector is exposed through the upper PCB surface of the PCB, and wherein the additional electrical connector is electrically coupled between the shunt and either the processor, the measurement device, or an additional measurement device.

16. The PCB assembly of claim 14, wherein the processor or measurement device is configured to measure a voltage output of the battery module, a current of the battery module, or both.

17. The PCB assembly of claim 13, wherein the shunt is in direct contact with both the electrical connector and the upper PCB surface.