Sensing assembly with a control module for a battery interconnection assembly of

Abstract

A battery pack interconnect assembly (50) for electrically connecting cell terminals (24, 26) of battery cells (20) in a battery pack (10) includes a bus bar interconnect (100) having bus bars (200) arranged in rows (204) and columns (206). The battery pack interconnect assembly includes a sensing assembly (500) coupled to the bus bar for sensing at least one parameter of the bus bar. The sensing assembly includes a control assembly (400) and a sensing harness (300) coupled to the control assembly, the sensing harness having a sensing cable (350) with a sensing conductor (360) coupled to the bus bar at a sensing point. The control assembly includes a control circuit board (410) and a control module (450) coupled to control circuitry of the control circuit board. Each control module includes a module terminal (480) coupled between a control circuit and a respective sensing conductor.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 723,233, filed November 21, 2024, the subject of which is incorporated herein by reference in its entirety. Technical Field

[0003] The main topic of this article is battery packs, such as those used in electric vehicles. Background Technology

[0004] Electric vehicles include battery systems comprising battery packs with a large number of battery cells. Typical battery systems require connectivity solutions to transfer / distribute power between the battery cell packs and have specifications for sensing battery parameters such as voltage and temperature. To transfer power, busbars (aluminum or copper) are typically soldered to the cell terminals in series and / or parallel electrical configurations. With the proliferation of electric vehicle applications, the indirect cost ($ / kWh) of components is carefully examined, and cost minimization is desired, for example, by minimizing the number of parts and components. For electric vehicle battery systems, the battery cell stack size is very large. Typically, assembling a battery system requires many components that are individually assembled to the corresponding cell terminals, which is time-consuming and increases the cost of the assembly process. Operating parameters of components need to be monitored, such as voltage, temperature, state of charge, or other operating characteristics at each busbar. Some systems use wiring harnesses with sensors to monitor the components of the battery system. Wiring harnesses add weight, cost, and assembly time.

[0005] There is still a need for a method to assemble battery packs, such as those used in electric vehicles, in a cost-effective and reliable manner. Summary of the Invention

[0006] In one embodiment, a battery pack interconnect assembly is provided for electrically connecting cell terminals of battery cells in a battery pack. The battery pack interconnect assembly includes a busbar interconnect comprising a plurality of busbars arranged in a matrix, the matrix having multiple rows and columns of busbars and busbar carriers for holding the busbars. Each busbar includes a first mating end for mating with a corresponding cell terminal of a corresponding battery cell and a second mating end for mating with an adjacent cell terminal of an adjacent corresponding battery cell. The busbars electrically connect to the battery cells in the battery pack. The battery pack interconnect assembly includes a sensing component coupled to the busbars for sensing at least one parameter of the busbars. The sensing component includes a control component and a sensing harness coupled to the control component. The sensing harness has a sensing cable having a sensing conductor coupled to the busbar at a sensing point. The control component includes a control board and control modules of control circuitry coupled to the control board. Each control module includes a module terminal coupled between the control circuitry and a corresponding sensing conductor. Attached Figure Description

[0007] The invention will be described by way of example with reference to the accompanying drawings, in which:

[0008] Figure 1 This is a perspective view of a battery pack including battery pack interconnect components according to an exemplary embodiment.

[0009] Figure 2 This is a top view of a battery pack interconnect assembly according to an exemplary embodiment.

[0010] Figure 3 This is a top view of a sensing module according to an exemplary embodiment.

[0011] Figure 4 This is a side view of a sensing module according to an exemplary embodiment.

[0012] Figure 5 This is a top view of a sensing cable according to an exemplary embodiment.

[0013] Figure 6 This is a cross-sectional view of a sensing cable according to an exemplary embodiment.

[0014] Figure 7 A sensing component according to an exemplary embodiment is shown.

[0015] Figure 8 This is a perspective view of a control module according to an exemplary embodiment.

[0016] Figure 9 This is a bottom perspective view of a portion of a control assembly according to an exemplary embodiment, showing a control module ready to mate with a control circuit board.

[0017] Figure 10 This is a bottom view of a control component according to an exemplary embodiment.

[0018] Figure 11 This is a top view of a control component according to an exemplary embodiment.

[0019] Figure 12 This is a cross-sectional view of a control component according to an exemplary embodiment.

[0020] Figure 13 This is a cross-sectional view of a control component according to an exemplary embodiment.

[0021] Figure 14 This is a cross-sectional view of a control component according to an exemplary embodiment, showing a sensing conductor terminated to a module terminal via an ultrasonic welding process.

[0022] Figure 15 This is a cross-sectional view of a control component according to an exemplary embodiment, showing a sensing conductor terminated to a module terminal via a laser welding process.

[0023] Figure 16 This is a cross-sectional view of a control component according to an exemplary embodiment, showing a sensing conductor terminated to a module terminal via a resistance welding process.

[0024] Figure 17 This is a cross-sectional view of a control component according to an exemplary embodiment, showing a sensing conductor terminated to a module terminal via a resistance welding process. Detailed Implementation

[0025] Figure 1 This is a perspective view of a battery pack 10 including a battery pack interconnect assembly 50 according to an exemplary embodiment. The battery pack interconnect assembly 50 includes a busbar interconnect 100 having a plurality of busbars 200. The battery pack interconnect assembly 50 includes a sensing assembly 500, which includes a sensing harness 300 and a control assembly 400 coupled to the sensing harness 300. The sensing harness 300 senses one or more operating parameters of the battery pack 10, such as the voltage, temperature, state of charge, or other operating characteristics of the battery pack 10. The control assembly 400 receives sensor data from the sensing harness 300 and can control one or more operations associated with the battery pack 10, such as a charging operation. For example, the control assembly 400 can be communicatively coupled to a battery control module, a battery distribution unit, or other control devices for a battery system. The control assembly 400 can aggregate sensor data, for example, for each busbar 200.

[0026] Battery pack 10 may be a battery pack for a vehicle (e.g., an electric vehicle). However, in alternative embodiments, battery pack 10 may be used in other applications. In one exemplary embodiment, battery pack 10 is a high-voltage battery pack. For example, battery pack 10 may be a 400V or 800V battery pack. Busbar interconnects 100 are used to electrically connect a matrix of battery cells 20 of battery pack 10. For example, busbar interconnects 100 may electrically connect battery cells 20 in series and / or parallel.

[0027] Battery cell 20 can be held in battery pack housing 12. Battery pack 10 includes positive battery interconnect terminal 14 and negative battery interconnect terminal 16. Battery interconnect terminals 14, 16 can be connected to other power distribution components of battery pack 10, such as contactors and fuses for connecting to a charging system and / or load (e.g., an electric motor).

[0028] Each battery cell 20 includes a cell housing 22, a first cell terminal 24, and a second cell terminal 26. In various embodiments, the battery cell 20 may be a prismatic battery cell. The first cell terminal 24 and the second cell terminal 26 may be a cathode terminal and an anode terminal. In an exemplary embodiment, the battery cells 20 are rectangular and arranged in a stacked configuration. For example, the battery cells 20 may be stacked in rows and columns in a matrix. The battery cell matrix may have a large surface area, for example, greater than two square meters (2m²). 2 (or larger). For example, the matrix can have a length between approximately 1.0m and 2.0m and a width between approximately 1.0m and 1.5m. Adjacent battery cells 20 in a row are interconnected via corresponding busbars 200 of the busbar interconnect 100. Adjacent rows of battery cells 20 are interconnected via corresponding busbars 200 of the busbar interconnect 100. For example, end battery cells 20 can be connected row by row.

[0029] The busbar interconnect 100 includes a busbar carrier 110 that holds the busbars 200. The busbar carrier 110 holds the busbars 200 in relative positions to mate with the cell terminals 24, 26 of the respective battery cells 20. The busbars 200 electrically connect adjacent battery cells 20, for example, in series and / or in parallel. In various embodiments, the busbar carrier 110 integrates all the busbars 200 into a single unit or structure for mounting to a matrix of battery cells 20. For example, a single busbar carrier 110 may be used to hold all the busbars 200. In other various embodiments, the busbar carrier 110 may include multiple frames or units, each frame or unit holding multiple busbars 200, such as a row of busbars 200. The frames / units may be connected together by other elements of the busbar carrier 110 to form a connection structure.

[0030] In various embodiments, the busbar carrier 110 may be a structural foam lead frame that holds the busbar 200. For example, the busbar carrier 110 may be manufactured using a structural foam molding process. In alternative embodiments, the busbar carrier may be made of other materials, such as molded plastic structures. The busbar carrier 110 may be molded or formed on the busbar matrix. For example, the busbar carrier 110 may be in situ overmolded onto a portion of the busbar 200 to form the busbar interconnect 100. The busbar carrier 110 may be formed around a portion of the busbar 200 to hold the busbars 200 relative to each other and relative to the cell terminals 24, 26 of the battery cell 20.

[0031] In one exemplary embodiment, the busbar carrier 110 includes a frame or grid 120. The grid 120 is formed around a portion of the busbar 200 to hold the busbar 200 in relative position. In one exemplary embodiment, the busbar carrier 110 holds all the busbars 200 for the battery pack 10 to reduce the number of components required for final assembly into the battery pack 10. For example, a single busbar interconnect 100 is assembled into the battery pack 10. The busbar carrier 110 is used to position the busbars 200 for electrical connection to the cell terminals 24, 26 of the battery cells 20. In one exemplary embodiment, sensing components 500 (such as sensing harness 300 and / or control components 400) are coupled to the busbar carrier 110. The busbar carrier 110 can be used to position the sensing components 500 on the battery cells 20.

[0032] The grid 120 includes frame members 122 configured to engage with the busbar 200 to maintain the relative position of the busbar 200. Frame members 122 include an outer frame member 130 surrounding the periphery of the grid 120, and an inner frame member 140 spanning the interior of the grid 120 to abut against the busbar 200. The inner frame member 140 extends between the outer frame members 130. For example, the inner frame member 140 includes a longitudinal element 142 and a transverse element 144. The longitudinal element 142 extends longitudinally through the grid 120 between opposite ends. The transverse element 144 extends laterally through the grid 120 between opposite sides. The longitudinal element 142 and / or the transverse element 144 can be used to support portions of the busbar 200. The transverse element 144 interconnects the longitudinal element 142 to provide support for the longitudinal element 142 and vice versa. In one exemplary embodiment, the inner frame member 140 is integrally formed with the outer frame member 130. For example, the inner frame member 140 is formed together with the outer frame member 130 during the structural molding process. The lattice 120 forms a single, integral structure.

[0033] In one exemplary embodiment, a lateral element 144 spans a column of busbar 200. The lateral element 144 engages the busbar 200 to support it. The lateral element 144 supports each busbar 200 in a corresponding column. In one exemplary embodiment, a longitudinal element 142 is located in the gaps between rows of busbar 200. The longitudinal element 142 may be used to support at least some of the busbars 200. However, in alternative embodiments, the longitudinal element 142 may additionally or alternatively be used to support some or all of the busbars 200.

[0034] In one exemplary embodiment, the sensing harness 300 has sensing points 302 for monitoring the busbar 200 and / or unit terminals 24, 26. For example, the sensing harness 300 is electrically connected to the busbar 200 at sensing points 302 to monitor the voltage, temperature, charge status, or other operating characteristics of the busbar 200 and / or unit terminals 24, 26. The sensing harness 300 is configured to be electrically connected to a control component 400. The sensing harness 300 transmits sensing signals from sensing points 302 to the control component 400, which can be used to control the operation of the vehicle and / or the charging operation of the vehicle.

[0035] The battery pack interconnect assembly 50 provides a large-size battery cell interconnect assembly configured to be mounted to the battery pack 10 (e.g., each battery cell 20), such as a single cell. The busbar carrier 110 holds the busbars 200 in place to terminate to the cell terminals 24, 26 of each battery cell 20 of the battery pack 10. By holding the busbars 200 to be assembled to the battery cells 20 of the battery pack 10, the assembly process, such as in conventional battery systems where each busbar is individually assembled to the battery cell through multiple assembly steps, can be eliminated. The busbar interconnect 100 reduces the total number of parts count and the number of parts handled during the assembly of the battery pack 10. The busbar carrier 110 can have a large format and surface area. For example, the structural process of manufacturing the lattice frame for the busbar carrier 110 allows the busbar carrier 110 to have a large footprint. The structural material of the grid frame used for the busbar carrier 110 is dimensionally stable and does not tend to warp, making assembly and termination to the battery cell simpler, faster, and less costly compared to conventional assembly processes.

[0036] Figure 2 This is a top view of a portion of a battery pack interconnect assembly 50 according to an exemplary embodiment. Figure 2A matrix 202 of busbars 200 and a sensing component 500 coupled to the busbars 200 are shown. The busbars 200 are arranged in rows 204 and columns 206 in the matrix 202. The arrangement of the busbars 200 corresponds to the arrangement of the battery cells 20 for connection to the corresponding cell terminals 24, 26. A sensing harness 300 traverses the rows 204 and columns 206 of the busbars 200 to be electrically connected to each busbar 200 to sense the characteristics (e.g., voltage) of each busbar 200. A control component 400 may be integrated into the matrix of busbars 200, for example, between some columns 206 or some rows 204, or may be located outside the matrix 202, for example, along one side of the matrix 202 of the busbars 200.

[0037] Each busbar 200 includes a metal plate 210 having a body 212, a first mating pad 214 at a first mating end 215, and a second mating pad 216 at a second mating end 217. The first mating pad 214 is configured to connect to a cell terminal 24 of one of the battery cells 20. The second mating pad 216 is configured to connect to a cell terminal 26 of an adjacent battery cell 20. The busbar 200 electrically connects adjacent battery cells 20. The mating pads 214, 216 may include openings 218 therethrough, for example for positioning the busbar 200 relative to the cell terminals 24, 26. The openings 218 can be used for pick-and-place operations. The openings 218 can be used to hold the position of the busbar 200 during the overmolding process that forms the busbar carrier 110.

[0038] In one exemplary embodiment, each busbar 200 is generally rectangular. For example, a busbar 200 includes a first end 220, a second end 222, a first side 224, and a second side 226. The busbar 200 may be elongated, for example, having ends 220, 222 that are longer than the sides 224, 226. In one exemplary embodiment, the busbar is generally planar. For example, the first and second mating pads 214, 216 may be coplanar for attachment to unit terminals 24, 26. Optionally, the body 212 may be offset relative to the first mating pad 214 and the second mating pad 216 or out of plane, for example, located above or below the plane of the first mating pad 214 and the second mating pad 216. The busbar 200 may include mounting features for mounting the busbar 200 to the busbar carrier 110, such as mounting tabs, posts, brackets, clips, notches, openings, etc.

[0039] In one exemplary embodiment, the matrix 202 of busbars 200 includes busbars 200 with eighteen rows 204 and busbars 200 with seven columns 206. In alternative embodiments, more or fewer busbars 200 may be provided in rows 204 and / or columns 206. In one exemplary embodiment, the busbars 200 include external busbars 240 and internal busbars 242. External busbars 240 are arranged along opposite sides (e.g., right and left) of the busbar matrix 202. External busbars 240 are used to connect two different rows of battery cells 20. Internal busbars 242 extend between external busbars 240. Internal busbars 242 are used to connect adjacent battery cells 20 within the same column. External busbars 240 are oriented perpendicular to the internal busbars 242. For example, the internal busbars 242 are oriented longitudinally, and the external busbars 240 are oriented laterally. In alternative embodiments, other orientations are possible.

[0040] The sensing harness 300 includes sensing modules 310 and sensing cables 350 coupled to each of the sensing modules 310. The sensing modules 310 are used to electrically connect the sensing cables 350 to corresponding busbars 200. However, in an alternative embodiment, the sensing harness 300 may be provided without sensing modules 310. Instead, the sensing cables 350 may be directly coupled to the busbars 200. The sensing modules 310 and sensing cables 350 form a cover structure overlapping a matrix 202 of the busbars 200. The sensing modules 310 may extend generally in the Y direction, and the sensing cables 350 may extend generally in the X direction. In an exemplary embodiment, the sensing cable 350 is a flat, flexible cable having a plurality of flat conductors disposed in an insulator, the plurality of flat conductors being configured to be electrically connected to corresponding rows of the sensing modules 310.

[0041] In one exemplary embodiment, a sensing module 310 extends along column 206 of busbar 200 and is electrically connected at a corresponding sensing point 302 to a corresponding busbar 200 in column 206. The sensing module 310 senses characteristics, such as voltage, of each corresponding busbar 200. A sensing cable 350 crosses each sensing module 310 and is electrically connected to the sensing module 310 to aggregate signals from the sensing module 310. The sensing cable 350 is electrically connected to a control component 400.

[0042] The control assembly 400 includes a control circuit board 410 and a control module 450 coupled to the control circuit board 410. In an exemplary embodiment, an electrical connector 440 is coupled to the control circuit board 410 and configured to be electrically connected to another component of the battery system, such as a vehicle's battery distribution unit or battery control module.

[0043] Each control module 450 is coupled to a corresponding sensing cable 350. A control circuit board 410 aggregates signals from the control modules 450 and the corresponding sensing cables 350. The control circuit board 410 may be a rigid printed circuit board. In various other embodiments, the control circuit board 410 may be a flexible circuit board. In one exemplary embodiment, the control assembly 400 is a low-profile interconnect solution to connect the sensing harness 300 to the electrical connector 440. The sensing cables 350 may be electrically connected to the control modules 450, for example, via soldering processes (e.g., ultrasonic soldering, resistance soldering, laser soldering, etc.).

[0044] Figure 3 This is a top view of a sensing module 310 according to an exemplary embodiment. Figure 4 This is a side view of a sensing module 310 according to an exemplary embodiment. In one exemplary embodiment, the sensing module 310 includes a sensing housing 320 and one or more sensing circuits. In the illustrated embodiment, the sensing module 310 includes a pair of sensing circuits, namely a first sensing circuit 312 and a second sensing circuit 314. In alternative embodiments, the sensing module 310 may include more or fewer sensing circuits 312, 314. In various embodiments, the sensing circuits 312, 314 may be electrically connected to different busbars 200. In other various embodiments, the sensing circuits 312, 314 may be connected to the same busbar 200 to define multiple contacts with the same busbar 200, and thus define redundant connections to improve reliability.

[0045] In one exemplary embodiment, the sensing housing 320 is made of an electrically insulating material, such as a dielectric material, such as a plastic material. The sensing housing 320 may be a molded part. In various embodiments, the sensing housing 320 is formed at appropriate locations on the sensing circuits 312, 314. For example, the sensing housing 320 may overlay a portion of the sensing circuits 312, 314. The sensing module 310 may be an overlay molded lead frame. In alternative embodiments, the sensing housing 320 may be pre-formed, and the sensing circuits 312, 314 may be coupled to the sensing housing 320. In the illustrated embodiment, the sensing housing 320 includes a top 322, a bottom 324, and a side edge 326 between the top 322 and the bottom 324. The sensing housing 320 may be generally rectangular. However, in alternative embodiments, the sensing housing 320 may have other shapes. The bottom 324 may be mounted to one or more of the busbar 200 and / or busbar carrier 110. In one exemplary embodiment, sensing circuits 312, 314 may extend along top 322, for example, for connection to sensing cable 350.

[0046] The first sensing circuit 312 and the second sensing circuit 314 may be similar to each other and include similar structures. The same reference numerals may be used herein to identify the same elements. Sensing circuit 312 includes a sensing contact 330 extending between a first end 332 and a second end 334. In an exemplary embodiment, the sensing contact 330 is a stamped contact, which is formed by stamping and bending or shaping a sheet of metal into a predetermined shape. Sensing contact 330 may include a busbar. In an alternative embodiment, sensing circuit 312 may include flexible circuitry, such as a flat flexible cable, a flexible printed circuit board, a ribbon cable, or other types of flexible circuitry.

[0047] The sensing contact 330 includes a first mating tab 336 at a first end 332 and a second mating tab 338 at a second end 334. In the illustrated embodiment, the first and second mating tabs 336 and 338 are at different vertical heights. For example, the first mating tab 336 may be substantially coplanar with the bottom 324 of the second housing 320, and the second mating tab 338 may be substantially coplanar with the top 322 of the second housing 320. The first mating tab 336 is configured to be electrically connected to the busbar 200. For example, the first mating tab 336 may be connected to the busbar 200 by welding, conductive bonding, riveting, or conductive adhesive bonding. In the illustrated embodiment, the second mating tab 338 extends along the top 322 of the transmitting housing 320. The second mating tab 338 is configured to be electrically connected to the sensing cable 350. For example, the second mating tab 338 may be connected to the sensing cable 350 by welding, conductive bonding, riveting, or conductive adhesive bonding.

[0048] In one exemplary embodiment, the second mating tabs 338 of the first sensing circuit 312 and the second sensing circuit 314 may overlap at the top 322. For example, the second mating tabs 338 may wrap around each other on opposite sides of the sensing housing 320. The second mating tabs 338 may be spaced apart from each other by gaps. The second mating tabs 338 are electrically isolated from each other for electrical connection to different busbars 200.

[0049] Figure 5 This is a top view of a sensing cable 350 according to an exemplary embodiment. Figure 6 This is a cross-sectional view of a sensing cable 350 according to an exemplary embodiment. In an exemplary embodiment, the sensing cable 350 is a flat, flexible cable. The sensing cable 350 extends between a first end 352 and a second end 354. The sensing cable 350 includes a connection region 304 configured for connection to a control assembly 400. The connection region 304 may be located at one of the ends, such as the first end 352, or it may be located at a central location, such as away from the first end 352 and the second end 354.

[0050] The sensing cable 350 includes an insulator 356 holding a plurality of sensing conductors 360. The insulator 356 may include one or more flexible plastic films 358, such as an upper film, a lower film, and may include one or more intermediate films between the upper and lower films. These layers may be bonded together by an adhesive. The insulator 356 may be a laminated structure. In various other embodiments, the insulator 356 may be extruded around the sensing conductors 360. The sensing conductors 360 are sandwiched between the layers of the flexible plastic film 358. The film 358 may be made of a polyester-based material, a polyethylene-based material, a polyamide-based material, a polyurethane-based material, a PVC material, etc. The film 358 may be laminated to the sensing conductors 360, for example, using one or more adhesive layers, to form a single flexible unit.

[0051] The sensing conductor 360 is a flat, parallel conductor. The sensing conductor 360 can be made of copper, aluminum, or other metallic materials. Each sensing conductor 360 includes an upper surface 362 and a lower surface 364. The sensing conductor 360 includes side surfaces 366 between the upper surface 362 and the lower surface 364. In an exemplary embodiment, the sensing conductor 360 has a rectangular cross-section. A membrane 358 covers the upper surface 362 and the lower surface 364. The membrane 358 can be located between the side surfaces 366 of adjacent sensing conductors 360.

[0052] In the illustrated embodiment, the sensing cable 350 includes fifteen sensing conductors 360. In alternative embodiments, the sensing cable 350 may include more or fewer sensing conductors 360, for example, to accommodate the number of bus voltage signals to be measured or other components such as temperature sensors, which may depend on the number of battery cells. In one exemplary embodiment, the sensing conductors 360 each have the same dimensions (e.g., height and width). However, in alternative embodiments, the sensing conductors 360 may have different dimensions. In one exemplary embodiment, the sensing cable 350 may have a common spacing or interval between the sensing conductors 360. However, in alternative embodiments, the sensing cable 350 may have different spacing between the sensing conductors 360.

[0053] In one exemplary embodiment, the sensing cable 350 includes a connection access window 372 that exposes a corresponding sensing conductor 360 at a connection point 378. For example, a portion of the insulator 356 may be selectively removed to form the connection access window 372 and expose the corresponding sensing conductor 360. In various embodiments, the insulator 356 may be removed by ablation, scraping, cutting, or other removal processes. The connection access window 372 provides access to the sensing conductor 360 at the connection point 378 for electrical connection to sensing circuits 312, 314 of the sensing module 310. For example, the sensing conductor 360 may be electrically connected to the corresponding sensing circuits 312, 314 by one of welding, conductive bonding, staking, or conductive adhesive bonding. In one exemplary embodiment, the sensing conductor 360 is connected to the corresponding sensing circuits 314, 314 by ultrasonic welding, resistance welding, laser welding, or other similar welding processes. In one exemplary embodiment, the connection access window 374 exposes different sensing conductors 360 along different segments of the sensing cable 350 for connection to different sensing modules 310. For example, each sensing conductor 360 may be exposed at different locations along the length of the sensing cable 350 to connect to different sensing modules 310.

[0054] In one exemplary embodiment, the sensing cable 350 (in) Figure 7 (Further illustrated) This includes a module access window 376 that exposes corresponding sensing conductors 360, such as all sensing conductors 360, at a junction 378. For example, a portion of insulator 356 may be removed to form the module access window 376 and expose the corresponding sensing conductors 360. In various embodiments, insulator 356 may be removed by ablation, scraping, cutting, or other removal processes. The module access window 376 provides access to the sensing conductors 360 at the junction 378 for electrical connection to a control module 450 of the control assembly 400. For example, the sensing conductors 360 may be electrically connected to the control module 450 by one of the following methods: welding, conductive bonding, riveting, or conductive adhesive bonding. In an exemplary embodiment, the sensing conductors 360 are connected to the control module 450 by ultrasonic welding, resistance welding, laser welding, or other similar welding processes.

[0055] Figure 7 A sensing component 500 according to an exemplary embodiment is shown. Figure 7A sensing harness 300 and a control assembly 400 are shown. The sensing harness 300 includes a sensing module 310 and a sensing cable 350 coupled to the sensing module 310. The sensing cable 350 is coupled to a control circuit board 410 via a control module 450. The sensing cable 350 extends laterally through the sensing modules 310, for example along rows of the sensing modules 310, to overlap with and be electrically connected to each sensing module 310 in the corresponding row. The sensing cable 350 is a flat, flexible cable having a plurality of flat conductors electrically connected to the corresponding sensing module 310.

[0056] The sensing module 310 is connected to the busbar 200. For example, the sensing circuits 312 and 314 can be electrically connected to the corresponding busbar 200 by one of the following methods: soldering, conductive bonding, riveting, or conductive adhesive bonding. The sensing circuits 312 and 314 can be soldered to the busbar 200 at the same time as the busbar 200 is soldered to the battery cell, thus eliminating the need for pre-soldering and simplifying assembly.

[0057] During assembly, sensing conductors 360 are electrically connected to sensing circuits 312, 314 at corresponding junctions 378. For example, connection access window 372 exposes sensing conductors 360 for electrical connection to sensing circuits 312, 314. Sensing conductors 360 can be electrically connected to corresponding sensing circuits 312, 314 via soldering, conductive bonding, riveting, or conductive adhesive bonding. Connection access window 374 exposes different sensing conductors 360 along different segments of sensing cable 350 for connection to different sensing modules 310.

[0058] During assembly, the sensing conductor 360 is electrically connected to the control module 450 at a corresponding junction 378. For example, the module access window 376 exposes the sensing conductor 360 for electrical connection to the control module 450. The sensing conductor 360 can be electrically connected to the module terminals of the control module 450 via a method of soldering, conductive bonding, riveting, or conductive adhesive bonding.

[0059] Figure 8 This is a perspective view of a control module 450 according to an exemplary embodiment. In an exemplary embodiment, the control module 450 is an electrical connector configured to be electrically connected to a control circuit board 410. The control module 450 is configured to be electrically connected to a sensing conductor 360 of a sensing cable 350.

[0060] The control module 450 includes a module housing 452 having a wall 454 supporting module terminals 480. The module housing 452 extends between a top 456 and a bottom 458. The module housing 452 includes a first side 460 and a second side 462 opposite to the first side 460. The module housing 452 includes a first end 464 and a second end 466 opposite to the first end 464. The wall 454 may be provided at the sides 460, 462 and / or the ends 464, 466. In an exemplary embodiment, the module housing 452 includes an opening 468 between the sides 460, 462 and / or the ends 464, 466. The opening 468 may open at the top 456 and / or the bottom 458. Module terminals 480 are exposed in the opening 468, such as sensing conductors 360 for termination to sensing cable 350. In the illustrated embodiment, the module housing 452 is generally rectangular in shape. In alternative embodiments, the module housing 452 may have other shapes. In one exemplary embodiment, the module housing 452 includes one or more mounting brackets 470, for example at ends 464, 466, for mounting the control module 450 to the control circuit board 410. Other types of mounting features may be used in alternative embodiments.

[0061] Module terminal 480 is conductive. For example, module terminal 480 may be made of a metallic material such as copper or aluminum. In an exemplary embodiment, module terminal 480 is a stamped and formed terminal. In various embodiments, module terminal 480 may be a stamped lead frame overmolded from an overmolded body forming module housing 452. For example, module housing 452 may be formed in appropriate locations around module terminal 480. In alternative embodiments, module terminal 480 may be formed separately and inserted into module housing 452.

[0062] Each module terminal 480 extends between a first end 482 and a second end 484. The module terminal 480 includes a body 486 located between the first end 482 and the second end 484. In an exemplary embodiment, the module terminal 480 includes a mating pad 490 along the body 486 or at the first end 482, configured to mate with a corresponding sensing conductor 360 of the sensing cable 350. For example, the sensing conductor 360 may be soldered to the mating pad 490 to electrically connect the sensing conductor 360 to the module terminal 480. In an alternative embodiment, the sensing conductor 360 may be coupled to the mating pad 490 by other processes. In the illustrated embodiment, the mating pad 490 is located at or near the top 456 of the module housing 452. Other locations are also possible in alternative embodiments. The mating pad 490 may extend across the top of the opening 468. The mating pad 490 may be accessed from above and / or from below, for example, for soldering to the sensing conductor 360.

[0063] In one exemplary embodiment, module terminal 480 includes a termination pad 492 along body 486 or at a second end 484. Termination pad 492 is configured to terminate to control circuit board 410. For example, termination pad 492 may be soldered or brazed to circuitry or conductors of control circuit board 410. For example, termination pad 492 may be a solder pad or solder tail for soldering to control circuit board 410. In the illustrated embodiment, termination pad 492 extends from module housing 452. For example, termination pad 492 may extend from a first side 460 or a second side 462, for example, near bottom 458. In alternative embodiments, termination pad 492 may be at other locations. In various embodiments, module terminals 480 may be arranged within module housing 452 such that adjacent module terminals 480 are inverted 180°, with their termination pads 492 extending in opposite directions from the first side 460 and the second side 462, respectively. By extending every other termination pad 492 in opposite directions, the module terminals 480 are positioned relative to each other and have good voltage separation (e.g., creepage performance) at the termination point on the control board 410.

[0064] Figure 9 This is a bottom perspective view of a portion of the control assembly 400, showing a control module 450 ready to mate with a control circuit board 410. The control circuit board 410 includes a substrate 412, which may be a layered circuit board. The control circuit board 410 includes an upper surface 414 and a lower surface 416. The control circuit board 410 includes a slot 418 between the upper surface 414 and the lower surface 416. The slot 418 is sized and shaped to receive the control module 450. For example, the slot 418 may have a rectangular shape. The control module 450 is received in the slot 418 to form an in-board component, which reduces the overall height of the control assembly 400. In an alternative embodiment, the control circuit board 410 may be configured without the slot 418, and the control module 450 may be surface-mounted to either the upper surface 414 or the lower surface 416.

[0065] The control circuit board 410 includes control circuitry 420 (also referred to as control circuitry termination) configured to mate with corresponding module terminals 480 of the control module 450. Control circuitry 420 may be a pad, trace, via, or other circuitry of the control circuit board 410. In the illustrated embodiment, control circuitry 420 is located at the lower surface 416. In alternative embodiments, other locations are possible, such as at the upper surface 414. In the illustrated embodiment, control circuitry 420 is arranged on opposite sides of slot 418 for mates with termination pads 492 of module terminals 480 extending from opposite sides of the control module 450. By having every other control circuitry 420 on opposite sides of slot 418, control circuitry 420 has good voltage separation (e.g., creepage performance) relative to each other. In alternative embodiments, other arrangements of control circuitry 420 are possible, such as arranging all control circuitry 420 on the same side of slot 418.

[0066] Figure 10 This is a bottom view of a control component 400 according to an exemplary embodiment. Figure 11 This is a top view of a control component 400 according to an exemplary embodiment. Figure 10 and Figure 11 A control module 450 connected to a control circuit board 410 is shown. Figure 11 A sensing cable 350 connected to the control module 450 is also shown. In an exemplary embodiment, the control module 450 is received in a slot 418 of a control circuit board 410. Module terminals 480 are connected to the control circuit 420, such as by soldering. The sensing conductor 360 of the sensing cable 350 is connected to the module terminal 480. For example, the sensing conductor 360 may be soldered to a mating pad 490 of the corresponding module terminal 480.

[0067] Figure 12 This is a cross-sectional view of a control component 400 according to an exemplary embodiment. Figure 13 This is a cross-sectional view of a control component 400 according to an exemplary embodiment. Figure 12 and Figure 13 Cut open by different module terminals 480, the module terminals 480 have end pads 492 extending in opposite directions on opposite sides of the module housing 452. Figure 12 and Figure 13 A control module 450 connected to a control circuit board 410 is shown. Figure 12 and Figure 13 The sensing cable 350 connected to the control module 450 is shown.

[0068] During assembly, the control module 450 is received in a slot 418 of the control circuit board 410. In an exemplary embodiment, the top 456 of the module housing 452 is located above the upper surface 414 of the control circuit board 410, and the bottom 458 of the module housing 452 is located below the lower surface 416 of the control circuit board 410. In an exemplary embodiment, termination pads 492 of the module terminals 480 extend from the module housing 452 near the bottom 458. Termination pads 492 of different adjacent module terminals 480 extend from different sides 460, 462 of the module housing 452. The termination pads 492 are coupled to the control circuit 420 at the lower surface 416 of the control circuit board 410, for example, by soldering.

[0069] A mating pad 490 of module terminal 480 is located at top 456. The mating pad 490 is positioned above control circuit board 410. The sensing conductor 360 of sensing cable 350 terminates at mating pad 490. For example, sensing conductor 360 may be soldered to the outer surface of mating pad 490. In an exemplary embodiment, opening 468 provides access to mating pad 490, for example from above and / or below mating pad 490, for soldering sensing conductor 360 to mating pad 490. In an exemplary embodiment, sensing cable 350 extends along upper surface 414 of control circuit board 410. In various embodiments, sensing cable 350 may be positioned at a height above upper surface 414, for example, slightly elevated above control circuit board 410. However, sensing cable 350 may be positioned close to control circuit board 410, resulting in a low overall profile height for control assembly 400.

[0070] Figure 14 This is a cross-sectional view of a control assembly 400 according to an exemplary embodiment, showing a sensing conductor 360 terminated to a module terminal 480 via an ultrasonic welding process. An opening 468 provides bilateral proximity of the ultrasonic welding head 600 and anvil 602 in the mating region to a mating pad 490 of the module terminal 480 to perform the ultrasonic welding process.

[0071] Figure 15 This is a cross-sectional view of a control assembly 400 according to an exemplary embodiment, showing a sensing conductor 360 terminated to a module terminal 480 via a laser welding process. An opening 468 allows a top clamp 610 and a bottom clamp 612 to bring the mating pad 490 of the module terminal 480 into close proximity in the mating area to perform the laser welding process.

[0072] Figure 16This is a cross-sectional view of a control assembly 400 according to an exemplary embodiment, showing a sensing conductor 360 terminated to a module terminal 480 via a resistance welding process. An opening 468 provides bilateral proximity of the upper resistance welding nozzle 620 and the lower resistance welding nozzle 622 in the mating region to a mating pad 490 of the module terminal 480 to perform the resistance welding process.

[0073] Figure 17 This is a cross-sectional view of a control assembly 400 according to an exemplary embodiment, showing a sensing conductor 360 terminated to a module terminal 480 via a resistance welding process. An opening 468 provides access in the mating region to a mating pad 490 of the module terminal 480 via resistance welding tips 630, 632, which can be from above or below, depending on the type of resistance welding.

Claims

1. A battery pack interconnect assembly (50) for electrically connecting the cell terminals (24, 26) of battery cells (20) in a battery pack (10), the battery pack interconnect assembly comprising: A busbar interconnect (100) includes a plurality of busbars (200) arranged in a matrix (202) and a busbar carrier (110) holding the busbars. The matrix (202) has a plurality of rows (204) and a plurality of columns (206) of the busbars. Each busbar includes a first mating end (215) for mating with a corresponding cell terminal of a corresponding battery cell and a second mating end (217) for mating with an adjacent cell terminal of an adjacent corresponding battery cell. The busbars are electrically connected to the battery cells in the battery pack. and A sensing component (500) is connected to the busbar for sensing at least one parameter of the busbar. The sensing component includes a control component (400) and a sensing harness (300) connected to the control component. The sensing harness has a sensing cable (350) with a sensing conductor (360) connected to the busbar at a sensing point (302). The control component includes a control circuit board (410) and control modules (450) of a control circuit connected to the control circuit board. Each control module includes a module terminal (480) connected between the control circuit and the corresponding sensing conductor.

2. The battery pack interconnect assembly (50) according to claim 1, wherein the control circuit board (410) aggregates signals from each of the control modules (450) and the corresponding sensing cables (350), the signals representing parameters from all of the sensing conductors (360).

3. The battery pack interconnect assembly (50) according to claim 1, wherein the control circuit board (410) includes a slot (418) for receiving the control module (450).

4. The battery pack interconnect assembly (50) according to claim 1, wherein the control circuit board (410) has an upper surface (362) and a lower surface (364), the control circuit board including a slot (418) between the upper surface and the lower surface, the slot receiving the control module (450).

5. The battery pack interconnect assembly (50) according to claim 4, wherein the module terminal (480) of the control module (450) is connected to the control circuit of the control circuit board (410) at the lower surface (364), and the sensing cable (350) extends along the upper surface (362) of the control circuit board.

6. The battery pack interconnect assembly (50) according to claim 5, wherein the sensing conductor (360) of the sensing cable (350) is terminated at a height above the upper surface (362) to the module terminal (480).

7. The battery pack interconnect assembly (50) of claim 1, wherein each control module includes a module housing for holding the module terminals (480), the module housing having a top (322) and a bottom (324), the top being above the upper surface (364) of the control circuit board (410) and the bottom being below the lower surface (362) of the control circuit board.

8. The battery pack interconnect assembly (50) of claim 7, wherein the module housing includes a first side (224) extending between the top (322) and the bottom (324) and a second side (226) opposite to the first side, the module terminals (480) including mating pads (490) and termination pads (492), the mating pads being located on the top and configured to connect to a sensing conductor (360) of a corresponding sensing cable (350), the termination pads of a first subset of the module terminals being located on the first side of the module housing, and the termination pads of a second subset of the module terminals being located on the second side of the module housing.

9. The battery pack interconnect assembly (50) of claim 1, wherein each control module includes a module housing for holding the module terminal (480), the module housing having a top (322) and a bottom (324), the module housing having a first wall (454), a second wall and a cavity between the first wall and the second wall, the first wall supporting a first end (220) of the module terminal, the second wall supporting a second end (222) of the module terminal, and the module housing being open above and below the module terminal between the first wall and the second wall to expose an upper surface and a lower surface (362, 364) of the module terminal.

10. The battery pack interconnect assembly (50) according to claim 1, wherein the sensing conductors (360) of the sensing cable (350) extend parallel to each other with a conductor spacing, and the module terminals (480) of the control module (450) extend parallel to each other with a terminal spacing equal to the conductor spacing.

11. The battery pack interconnect assembly (50) of claim 1, wherein the sensing cable (350) includes a module window (376) that exposes all of the sensing conductors (360) in the module window, the module window being aligned with a corresponding control module, wherein the exposed portions of the sensing conductors in the module window are terminated to corresponding module terminals (480) in the module window.

12. The battery pack interconnect assembly (50) according to claim 1, wherein the module terminal (480) includes a mating pad (490) and the sensing conductor (360) is soldered to the corresponding mating pad.

13. The battery pack interconnect assembly (50) of claim 1, wherein the sensing harness (300) includes a sensing module (310) coupled to the sensing cable (350), the sensing module including sensing circuits (312, 314) electrically connected at the sensing point (302) to a corresponding busbar (200) to sense parameters of each of the corresponding busbars, the sensing cable spanning between rows (204) of sensing modules, wherein the sensing conductor (360) is electrically connected to a corresponding sensing circuit of the corresponding sensing module.

14. The battery pack interconnect assembly (50) of claim 1, wherein the sensing cable (350) is a flat flexible cable having a flat conductor defining the sensing conductor (360), the sensing conductors extending parallel to each other and surrounded by an insulator (356), a portion of which is removed to form an access window (372, 374) at a junction (378) to the sensing conductor.

15. The battery pack interconnect assembly (50) of claim 14, wherein the access windows (372, 374) expose different sensing conductors (360) at each of the respective busbars (200) for electrical connection to the different busbars.

16. A sensing assembly (500) for sensing parameters of a busbar (200), the busbar being electrically connected to cell terminals (24, 26) of a battery cell (20) in a battery pack (10), the sensing assembly comprising: A sensing harness (300) includes a sensing module (310) and a sensing cable (350) connected to the sensing module (302). The sensing module is configured to be electrically connected at a sensing point (302) to a corresponding busbar to sense sensing parameters of each of the corresponding busbars. Each sensing module includes a sensing housing and sensing circuits (312, 314) held by the sensing housing. The sensing circuits are configured to be electrically connected to the corresponding busbar. The sensing cables extend in rows (204) parallel to each other. The sensing cables are flat, flexible cables with a plurality of sensing conductors (360) that span each of the sensing modules. The sensing conductors are electrically connected to the corresponding sensing circuit of each of the sensing modules. and A control component (400) is connected to a sensing cable of the sensing harness. The control component includes a control circuit board (410) and a control module (450) connected to the control circuit board. Each control module includes a module terminal (480) connected to a control circuit of the control circuit board. The module terminal includes a mating portion of a sensing conductor connected to the corresponding sensing cable. The control module (450) electrically connects the corresponding sensing cable to the control circuit board.

17. The sensing harness (300) of claim 16, wherein the control circuit board (410) has an upper surface (362) and a lower surface (364), the control circuit board including a slot (418) between the upper surface and the lower surface, the slot receiving the control module (450).

18. The sensing harness (300) of claim 16, wherein the sensing cable (350) includes a module window (376) exposing all sensing conductors (360) within the module window, the module window being aligned with a corresponding control module, wherein the exposed portions of the sensing conductors within the module window are terminated to corresponding module terminals (480) within the module window.

19. The sensing harness (300) according to claim 16, wherein the module terminal (480) includes a mating pad (490) and the sensing conductor (360) is soldered to the corresponding mating pad.

20. A battery pack (10), comprising: Battery cells (20) are arranged in a matrix having a plurality of rows (204) and a plurality of columns (206) of the battery cells, each battery cell including a first cell terminal (24) and a second cell terminal (26). and A battery pack interconnect assembly (50) is electrically connected to a first cell terminal and a second cell terminal of the battery cell. The battery pack interconnect assembly (10) includes a busbar interconnect (100) and a sensing assembly (500) electrically connected to the busbar interconnect. The busbar interconnection includes a plurality of busbars (200) arranged in a matrix (202) and a busbar carrier (110) holding the busbars. The matrix (202) has a plurality of rows and a plurality of columns of the busbars. Each busbar includes a first mating end (215) for mating with a first cell terminal of a corresponding battery cell and a second mating end (217) for mating with a second cell terminal of an adjacent corresponding battery cell. The busbars are electrically connected to the battery cells in the battery pack. The sensing component includes a sensing harness (300) and a control component (400) connected to the sensing harness. The sensing harness includes a sensing module (310) and a sensing cable (350) connected to the sensing module. The sensing module is electrically connected at a sensing point to a corresponding busbar to sense the sensing parameters of each of the corresponding busbars. Each sensing module includes a sensing housing (320) and a sensing circuit (312) held by the sensing housing (320). The sensing circuit is configured to be electrically connected to the corresponding busbar. The sensing cables extend in rows parallel to each other. The sensing cables are flat, flexible cables with a plurality of sensing conductors (360) that cross each of the sensing modules. The sensing conductors are electrically connected to the corresponding sensing circuit of each of the sensing modules. and The control component is connected to the sensing cable of the sensing harness. The control component includes a control circuit board (410) and a control module (450) connected to the control circuit board. Each control module includes a module terminal (480) connected to the control circuit of the control circuit board. The module terminal includes a mating portion of the sensing conductor connected to the corresponding sensing cable. The control module electrically connects the corresponding sensing cable to the control circuit board.

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