Rechargeable energy storage system with radio frequency signal directing components and method of manufacture

Abstract

A rechargeable energy storage system and method of manufacture includes: a battery pack having a battery cell module assembly, wherein an interconnect board is disposed between the battery cells and the battery cell monitoring unit and physically connects them; and a module cover that at least partially encloses the battery cells, the battery cell monitoring unit, and the interconnect board. The battery pack has relatively high and relatively low loss regions for radio frequency signal communication. A radio frequency manager is wirelessly connectable to the battery cell monitoring unit via radio frequency signal communication. A signal directing component is operable to transmit and / or receive radio frequency signals between the battery cell monitoring unit and the radio frequency manager, is configured to direct the radio frequency signals to the relatively low loss region, and is integrated into one of the module cover, the interconnect board, or the radio frequency manager.

Description

BACKGROUND OF THE INVENTION

[0001] The present disclosure generally relates to rechargeable energy storage systems having signal-directing components, such as antennas, reflectors, or lenses, for guiding radio frequency signals between battery cell monitoring units and radio frequency managers with low loss and improved packaging space, and the present disclosure also relates to methods of manufacturing rechargeable energy storage systems.

[0002] A rechargeable energy storage system, such as an electrical energy storage system for powering an electric or hybrid vehicle, includes a battery pack having a battery cell module assembly, which can be one of a plurality of battery cell module assemblies. The battery cell module assembly includes a plurality of battery cells and a battery cell monitoring unit. The battery pack also includes a radio frequency manager (also referred to as a battery radio frequency manager). Battery cell data, such as individual battery cell voltages and charge and discharge currents, are monitored by the battery cell monitoring unit and wirelessly transmitted via radio frequency communication to the battery radio frequency manager. The battery radio frequency manager is typically wired to an electronic control device (which can be referred to as a controller) that controls the operation (charging and discharging) of the battery cells related to various operating modes of the vehicle powertrain.

[0003] The reliability of wireless communication between one or more battery cell module assemblies and the battery radio frequency manager depends on signal strength and signal losses inherent in electrically complex systems. SUMMARY OF THE INVENTION

[0004] A rechargeable energy storage system is provided that utilizes a radio frequency signal-directing component that is specifically configured to guide wireless signals through relatively low-loss regions of the battery pack to enhance radio frequency signal communication. Performing radio frequency analysis on the rechargeable energy storage system can inform relatively high-loss regions and relatively low-loss regions from the main radiation surface of the antenna. The radio frequency directing component disclosed herein utilizes the relatively low-loss regions to achieve high signal strength. Additionally, the signal-directing component can be integrated in a matrix composed of a high dielectric loss material having a low loss tangent to reduce packaging space requirements and assembly process steps.

[0005] A rechargeable energy storage system includes a battery pack that may have a plurality of battery cell module assemblies. Each battery cell module assembly has a plurality of battery cells and a battery cell monitoring unit. The battery cell monitoring unit includes a printed circuit board configured to monitor one or more parameters of the battery cells. The battery cell module assembly also includes an interconnect board that is disposed between the plurality of battery cells and the battery cell monitoring unit and physically connects the plurality of battery cells to the battery cell monitoring unit. The battery cell module assembly includes a module cover that at least partially encloses the plurality of battery cells, the battery cell monitoring unit, and the interconnect board, wherein the battery cell monitoring unit is disposed adjacent to the module cover. The battery pack has a relatively high loss region for radio frequency signal communication and a relatively low loss region for radio frequency signal communication. A radio frequency manager is wirelessly connectable via radio frequency signal communication to the battery cell monitoring unit of the battery cell module assembly. A signal directing component is operable to transmit and / or receive radio frequency signals between the battery cell monitoring unit of the battery cell module assembly and the radio frequency manager and is configured to direct the radio frequency signals to the relatively low loss region, thereby increasing signal strength or reducing signal loss compared to other paths of the radio frequency signal and enabling more reliable wireless communication. The signal directing component is integrated in one of the module cover, the interconnect board, or the radio frequency manager. Apparently, the signal directing component is not in the printed circuit board of the battery cell monitoring unit, and customizing or reconfiguring the signal directing component may be relatively expensive and complex compared to other components. By placing the signal directing unit elsewhere, the same printed circuit board can be used in different applications, such as in different vehicle powertrain layouts, without having to modify the printed circuit board to account for different radio frequency signal patterns of different applications.

[0006] In some embodiments, the signal directing component is an antenna. For example, the signal directing component can be a directional antenna integrated in the module cover. A directional antenna radiates and receives radio frequency signal power with greater intensity in one direction than in any other direction, which is different from an omnidirectional antenna that radiates and receives radio frequency signal power with substantially equal intensity in all directions. Although omnidirectional antennas can be used in many different configured systems, a directional antenna can provide a stronger radio frequency signal, even when having a smaller physical size than an omnidirectional antenna, if its high-intensity direction is oriented in the relatively low loss region.

[0007] In other embodiments, the signal directing component can be a pair of directional antennas that are oriented in opposite high-gain directions and integrated in the radio frequency manager. Since a radio frequency manager of a given design is typically used with battery packs of different configurations, any embodiment where the signal directing component is integrated in the radio frequency manager herein can attempt to provide greater design flexibility and economies of scale.

[0008] In some other embodiments, the signal directing component can be a pair of directional antennas oriented in opposite high-gain directions with respect to each other, where one of the directional antennas is the enabled directional antenna and the other is the idle directional antenna, and the enabled directional antenna results in a stronger RF signal between the battery cell monitoring unit and the RF manager. For example, the battery cell module assemblies within a battery pack can be arranged in different orientations relative to the position of the RF manager, or can be arranged in different orientations in different applications (such as on different vehicles). One of the antennas can produce a stronger RF signal when the battery cell module assembly is in one orientation, while the other produces a stronger RF signal when the battery cell module assembly is in another orientation. Thus, by activating the correct antenna (e.g., the one that results in a stronger RF signal) in each application, a pair of identically constructed directional antennas and packaging locations can be used for a variety of different battery pack configurations or vehicle applications. In some embodiments, a pair of directional antennas where only one of them is activated can be integrated in the module cover, while in other embodiments, they can be integrated in the RF manager.

[0009] In some other embodiments, the signal directing component can be a bi-directional antenna integrated in the module cover or the RF manager. The bi-directional antenna has two high-gain directions opposite to each other. Although only one direction can be oriented along the path of RF signal communication between the battery cell monitoring unit and the RF manager, the identically designed bi-directional antenna can be used in different applications because it provides the design flexibility of having two high-gain directions.

[0010] Instead of an antenna, the signal directing component can be a reflector. In one embodiment, the reflector can be integrated in the interconnect board. For example, the printed circuit board of the battery cell monitoring unit can include an antenna, such as an omnidirectional antenna not specifically configured to provide high gain in the low RF signal loss region of the system. However, the reflector can be oriented to direct the RF signal from the antenna of the printed circuit board of the battery cell monitoring unit to a relatively low RF signal loss region. Thus, more complex printed circuit board antennas (whether directional or omnidirectional) can be used in many applications with different signal loss patterns, while the reflector in the interconnect board is customized to direct the RF signal based on the specific RF signal loss pattern of the application. In another embodiment, the signal directing component can be a reflector integrated in the housing of the RF manager and oriented to direct the RF signal from the antenna of the printed circuit board of the RF manager to a relatively low RF signal loss region.

[0011] As another alternative, the signal directing component can be a lens integrated in the module cover, and the lens can be oriented to direct the RF signal from the antenna of the printed circuit board of the battery cell monitoring unit to a relatively low RF signal loss region.

[0012] Other features can be implemented to further enhance signal strength and manufacturing convenience. For example, a signal directing component can be integrated into a substrate, which is then embedded into a module cover, an interconnect board, or a radio frequency manager. This enables the signal directing component to be pre-packaged in a substrate with a known encapsulation space, and this can be more easily achieved in a suitable larger component (e.g., a module cover, an interconnect board, or a radio frequency manager) by, for example, overmolding. The substrate can be a first material that is embedded into a second material of the module cover, the interconnect board, or the radio frequency manager, and the first material can have a higher dielectric constant and a lower loss tangent than the second material. This enables the signal directing component to be miniaturized (e.g., reduced in size) and encapsulated closer to the surface of the substrate to maintain radio frequency signal gain. Additionally, the substrate can have retention features that are operable to hold the substrate in a fixed position during embedding of the substrate (with the signal directing component integrated therewith) into the module cover, the interconnect board, or the radio frequency manager. A specific orientation of the signal directing component that results in a low radio frequency signal loss path can thus be more easily and precisely achieved.

[0013] In some embodiments, an electrical connector can extend from the signal directing component out of the substrate and can be embedded with the substrate into the module cover or the interconnect board such that an end of the electrical connector extends out of the module cover or the interconnect board and can be connected to or pass through a battery cell monitoring unit. Thus, the signal directing component, the substrate, and the electrical connector can be provided as a pre-assembled module to be more easily overmolded in the module cover or the interconnect board and connection to the larger footprint of the battery cell monitoring unit.

[0014] In some implementations, multiple signal directing components of the above-described signal directing components can be used for high signal strength and low loss. For example, directional antennas can be used in each battery cell module assembly (e.g., in the module cover or the interconnect board) and in the radio frequency manager, such as in the housing of the radio frequency manager.

[0015] A method of manufacturing a rechargeable energy storage system includes integrating a signal directing component operable to transmit and / or receive radio frequency signals between a cell monitoring unit of a battery cell module assembly of a battery pack and a radio frequency manager into one of a module cover of the cell module assembly, an interconnect board of the battery cell module assembly, or the radio frequency manager. The interconnect board is configured to be disposed between battery cells of the battery cell module and the cell monitoring unit and physically connect them, and the cell monitoring unit is configured to be disposed between the interconnect board and the module cover. Integrating the signal directing component includes orienting the signal directing component in the module cover, interconnect board, or radio frequency manager to direct radio frequency signals through a relatively low loss region for radio frequency signal communication of the battery pack. For example, the method may include performing a radio frequency analysis to determine the relatively low loss region of the battery pack before integrating the signal directing component. The radio frequency analysis may be done, for example, by using an omnidirectional antenna.

[0016] In some embodiments, the method may include integrating the signal directing component with a substrate before integrating the signal directing component into the module cover, interconnect board, or radio frequency manager. Subsequently integrating the signal directing component into the module cover, interconnect board, or radio frequency manager may include embedding the substrate into the module cover, interconnect board, or radio frequency manager. The substrate may be a first material, and the module cover, interconnect board, or radio frequency manager into which the substrate is embedded may be a second material. The first material may have a higher dielectric constant and a lower loss tangent than the second material.

[0017] An integrated electrical connector may extend from the signal directing component, and the method may include connecting the integrated electrical connector to the cell monitoring unit or the interconnect board after integrating the signal directing component.

[0018] In some embodiments, the signal directing component may be a pair of directional antennas oriented in opposite high gain directions, the pair including a first antenna and a second antenna, and the method may include: determining which of the first antenna and the second antenna results in a stronger radio frequency signal between the cell monitoring unit and the radio frequency manager; and enabling a radio frequency path between the cell monitoring unit and the radio frequency manager only for the one of the first antenna and the second antenna that results in the stronger radio frequency signal between the cell monitoring unit and the radio frequency manager.

[0019] The present disclosure also includes the following solutions:

[0020] Solution 1. A rechargeable energy storage system, comprising:

[0021] A battery pack including a battery cell module assembly and a radio frequency manager, the battery cell module assembly having:

[0022] A plurality of battery cells,

[0023] A battery cell monitoring unit having a printed circuit board configured to monitor one or more parameters of the battery cell

[0024] An interconnection board disposed between the plurality of battery cells and the battery cell monitoring unit and physically connecting the plurality of battery cells to the battery cell monitoring unit, and

[0025] A module cover at least partially enclosing the plurality of battery cells, the battery cell monitoring unit, and the interconnection board, wherein the battery cell monitoring unit is disposed adjacent to the module cover;

[0026] Wherein the radio frequency manager is wirelessly connectable to the battery cell monitoring unit via radio frequency signal communication; wherein the battery cell module assembly has a relatively high loss region for radio frequency signal communication and a relatively low loss region for radio frequency signal communication; and

[0027] A signal directing component operable to transmit and / or receive radio frequency signals between the battery cell monitoring unit and the radio frequency manager and configured to direct the radio frequency signals to the relatively low loss region, the signal directing component being integrated into one of the module cover, the interconnection board, or the radio frequency manager.

[0028] Solution 2. The rechargeable energy storage system according to Solution 1, further comprising:

[0029] A substrate; wherein the signal directing component is integrated with the substrate;

[0030] Wherein the substrate is embedded in one of the module cover, the interconnection board, or the radio frequency manager.

[0031] Solution 3. The rechargeable energy storage system according to Solution 2, wherein the substrate has a retention feature operable to hold the substrate in a fixed position during embedding the substrate in one of the module cover, the interconnection board, or the radio frequency manager.

[0032] Solution 4. The rechargeable energy storage system according to Solution 2, wherein the substrate is a first material, one of the module cover, the interconnection board, or the radio frequency manager in which the substrate is embedded is a second material, and the first material has a higher dielectric constant and a lower loss tangent than the second material.

[0033] Solution 5. The rechargeable energy storage system according to Solution 2, further comprising:

[0034] An electrical connector that extends from the signal-directing component out of the base body and is embedded with the base body into the module cover or the interconnect board, such that an end of the electrical connector extends out of the module cover or the interconnect board and is capable of connecting to or passing through the battery cell monitoring unit.

[0035] Aspect 6. The rechargeable energy storage system according to Aspect 1, wherein the signal-directing component is a directional antenna integrated in the module cover.

[0036] Aspect 7. The rechargeable energy storage system according to Aspect 1, wherein the signal-directing component is a pair of directional antennas that are oriented in opposite high-gain directions with respect to each other and are integrated in the RF manager.

[0037] Aspect 8. The rechargeable energy storage system according to Aspect 1, wherein the signal-directing component is a pair of directional antennas that are oriented in opposite high-gain directions with respect to each other, and the pair of directional antennas includes an active directional antenna and an idle directional antenna.

[0038] Aspect 9. The rechargeable energy storage system according to Aspect 8, wherein the pair of directional antennas is integrated into the module cover.

[0039] Aspect 10. The rechargeable energy storage system according to Aspect 8, wherein the pair of directional antennas is integrated into the RF manager.

[0040] Aspect 11. The rechargeable energy storage system according to Aspect 1, wherein the signal-directing component is a bi-directional antenna integrated in the module cover.

[0041] Aspect 12. The rechargeable energy storage system according to Aspect 1, wherein the signal-directing component is a bi-directional antenna integrated in the RF manager.

[0042] Aspect 13. The rechargeable energy storage system according to Aspect 1, wherein:

[0043] the signal-directing component is a reflector integrated in the interconnect board;

[0044] the printed circuit board of the battery cell monitoring unit includes an antenna; and

[0045] the reflector is oriented to direct the RF signal from the antenna of the printed circuit board of the battery cell monitoring unit to the relatively low-loss region.

[0046] Aspect 14. The rechargeable energy storage system according to Aspect 1, wherein:

[0047] The RF manager includes a printed circuit board having an antenna and a housing disposed adjacent to the printed circuit board of the RF manager; and

[0048] The signal directing component is a reflector, the reflector being integrated in the housing of the RF manager and oriented to direct the RF signal from the antenna of the printed circuit board of the RF manager to the relatively low-loss region.

[0049] Aspect 15. The rechargeable energy storage system according to Aspect 1, wherein:

[0050] The signal directing component is a lens integrated in the module cover;

[0051] The printed circuit board of the battery cell monitoring unit includes an antenna; and

[0052] The lens is oriented to direct the RF signal from the antenna of the printed circuit board to the relatively low-loss region.

[0053] Aspect 16. A method of manufacturing a rechargeable energy storage system, the method comprising:

[0054] Integrating a signal directing component operable to transmit and / or receive RF signals between a battery cell monitoring unit of a battery cell module assembly of a battery pack and an RF manager of the battery pack into one of the module cover of the battery cell module assembly, an interconnect board of the battery cell module assembly, or the RF manager; wherein the interconnect board is configured to be disposed between battery cells of the battery cell module assembly and the battery cell monitoring unit and physically connect the battery cells of the battery cell module assembly and the battery cell monitoring unit, and the battery cell monitoring unit is configured to be disposed between the interconnect board and the module cover;

[0055] Wherein integrating the signal directing component includes orienting the signal directing component in one of the module cover, the interconnect board, or the RF manager to direct the RF signal through a relatively low-loss region of the battery pack for RF signal communication.

[0056] Aspect 17. The method according to Aspect 16, further comprising:

[0057] Performing an RF analysis to determine the relatively low-loss region of the battery pack before integrating the signal directing component.

[0058] Aspect 18. The method according to Aspect 16, further comprising:

[0059] Integrate the signal directing component with the substrate; and

[0060] Integrating the signal directing component into one of the module cover, the interconnect board, or the RF manager is performed after integrating the signal directing component with the substrate and includes embedding the substrate into the one of the module cover, the interconnect board, or the RF manager; wherein the substrate is a first material, the module cover, the interconnect board, or the RF manager into which the substrate is embedded is a second material, and the first material has a higher dielectric constant and a lower loss tangent than the second material.

[0061] Scheme 19. The method according to Scheme 16, wherein an integrated electrical connector extends from the signal directing component; and the method further comprises:

[0062] After integrating the signal directing component, connecting the integrated electrical connector to the battery cell monitoring unit or the interconnect board.

[0063] Scheme 20. The method according to Scheme 16, wherein the signal directing component is a pair of directional antennas, the pair of directional antennas are oriented in opposite high-gain directions to each other, the pair of directional antennas includes a first antenna and a second antenna, and the method further comprises:

[0064] Determining which of the first antenna and the second antenna results in a stronger RF signal between the battery cell monitoring unit and the RF manager; and

[0065] Enabling an RF path between the battery cell monitoring unit and the RF manager only for the one of the first antenna and the second antenna that results in a stronger RF signal between the battery cell monitoring unit and the RF manager.

[0066] From the following detailed description of the best mode for carrying out the present disclosure in conjunction with the drawings, the above and other features and advantages of the present disclosure are apparent. Description of the Drawings

[0067] Figure 1 is a diagram of a vehicle powertrain having a rechargeable energy storage system (RESS) including a battery pack, the battery pack having a battery cell module assembly (BCMA) and an RF manager configured to wirelessly communicate with the BCMA.

[0068] Figure 2 is included in Figure 1 a plan view of a battery cell module assembly (BCMA) in a battery pack.

[0069] Figure 3 A plan view of a first embodiment of a signal directing component, the signal directing component being configured to direct an antenna, the directional antenna being integrated into a substrate and an integrated flexible electrical connector extending from the directional antenna and extending outside the substrate.

[0070] Figure 4 Is in such as Figure 1 Of BCMA's BCMA Figure 5 Partial cross-sectional view taken at line 4-4 of, the modified to have Figure 3 The directional antenna, substrate, and integrated flexible electrical connector and embedded in the module cover.

[0071] Figure 5 Is Figure 4 Partial bottom view of BCMA of.

[0072] Figure 6 A plan view of a radio frequency manager, similar to Figure 1 Of the radio frequency manager, modified to include a pair of directional antennas integrated into a substrate embedded in the housing of the radio frequency manager, wherein the radio frequency manager is shown mounted on a battery pack enclosure.

[0073] Figure 7 Is similar to Figure 1 Partial bottom view of BCMA of, modified to include a pair of directional antennas integrated into a substrate embedded in the module cover and an integrated flexible electrical connector extending from the pair of directional antennas.

[0074] Figure 8 Is at Figure 7 Of line 8-8 Figure 7 Partial cross-sectional view of BCMA of, which includes the pair of directional antennas and a switch that connects each directional antenna to the printed circuit board of the battery cell monitoring unit, respectively.

[0075] Figure 9 Is similar to Figure 1 Partial bottom view of BCMA of, modified to include a bi-directional antenna integrated into a substrate embedded in the module cover and an integrated flexible electrical connector extending from the bi-directional antenna.

[0076] Figure 10 Is similar to Figure 1 Plan view of a radio frequency manager of a radio frequency manager, modified to include a bi-directional antenna integrated into a substrate embedded in the housing of the radio frequency manager.

[0077] Figure 11 A cross-sectional side view of a signal directing component configured as a reflector, the reflector being integrated in a substrate.

[0078] Figure 12 is similar to Figure 1 a partial cross-sectional view of BCMA similar to Figure 11 which is modified to include a reflector of

[0079] Figure 13 is similar to Figure 1 a plan view of a radio frequency manager similar to Figure 10 which is modified to include a plurality of reflectors integrated into a substrate of

[0080] Figure 14 is similar to Figure 1 a partial cross-section of BCMA similar to DETAILED DESCRIPTION

[0081] Figure 1 FIG. 1 is a schematic diagram of a vehicle powertrain 10 that includes a rechargeable energy storage system (RESS) 12. The vehicle powertrain 10 can be for an electric vehicle (e.g., the powertrain includes only a power source for motive power, such as an electric motor / generator) or a hybrid electric vehicle (e.g., the powertrain includes both a power source for propulsion and another power source for propulsion, such as an internal combustion engine or a fuel cell). The RESS 12 includes a battery pack and a radio frequency manager 16. The battery pack includes a plurality of battery cell module assemblies (BCMAs) 14 (one shown). The radio frequency manager 16 is configured to communicate wirelessly with the BCMA 14, as shown by wireless radio frequency signal S. Although only one BCMA 14 is shown for discussion purposes, other similar BCMAs can be arranged side by side in rows, for example, in the battery pack 15. For example, there can be sixteen, twenty-eight, or other numbers of BCMAs in the battery pack 15. Additionally, in some embodiments, the RESS 12 can include multiple battery packs. In most such wireless communications, the BCMA 14 transmits radio frequency signals (e.g., acts as a transmitter), while the radio frequency manager 16 receives the signals (e.g., acts as a receiver), although in some cases, the radio frequency manager 16 sends wireless signals to the BCMA 14 (e.g., acts as a transmitter while the BCMA 14 acts as a receiver).

[0082] The battery pack 15 supplies electrical energy to one or more power sources, such as the motor - generator 18 that supplies motive torque to a load 26 (such as a vehicle driveline). More specifically, the motor controller 20 controls the reception (or emission therefrom) of electrical energy by the stator 22, which powers the rotor 24 operatively connected to the load 26 and can act as a generator, such as during regenerative braking. The battery pack 15 is rechargeable, such as by capturing braking energy while operating the motor - generator 18 as a generator to convert rotational torque into electrical energy. The controller 28 receives data indicating the operating parameters of the BCMA 14, such as cell voltage and charge and discharge current, via signals from the radio - frequency manager 16 and can be physically connected thereto (e.g., wired to the radio - frequency manager 16). Although shown as a single controller 28, there may be multiple controllers interconnected to form a control system. The same or different controllers 28 can also receive other vehicle information, such as acceleration and braking requirements, and can command the operation of the motor - generator 18 by sending control signals to the motor controller 20.

[0083] Figure 2 is included in Figure 1 A plan view of one of the BCMA 14s included in the RESS 12. The BCMA 14 includes a plurality of battery cells 30. The battery cells 30 can be connected to each other in series to an interconnect board 32. Adjacent battery cells 30 can be stacked on top of each other or can be separated, for example, by a gap or foam 34. The BCMA 14 includes a cell monitoring unit 36 having a printed circuit board 38 (shown in dashed lines) configured to monitor one or more parameters of the battery cells 30. The interconnect board 32 is disposed between the plurality of battery cells 30 and the cell monitoring unit 36 and includes electronic components that physically connect the plurality of battery cells 30 to the cell monitoring unit 36 and the printed circuit board 38 thereon. End plates 40 can enclose the battery cells 30 at opposite sides of the BCMA 14. An outer retainer 42 can extend around the bottom and the remaining sides (the sides of the retainer 42 are shown in Figure 5 but not shown in Figure 2 to show the battery cells 30). The end plates 40 are not shown in Figure 1 The retainer 62 of the battery pack 15 supports and encloses a plurality of BCMAs.

[0084] The module cover 44 is arranged to be adjacent to the battery cell monitoring unit 36 and at least partially enclose the plurality of battery cells 30, the battery cell monitoring unit 36, and the interconnecting board 32. The module cover 44 can be fixed to the end plate 40 and a portion of the outer cage 42, such as a portion that extends orthogonally to the end plate 40. The standoff 46 integrally formed with the module cover 44 can slightly separate the inner side of the module cover 44 from the outer side of the battery cell monitoring unit 36, where the printed circuit board 38 can be disposed on the outer side.

[0085] One or more antennas are used to transfer data from the battery cell monitoring unit 36 of the BCMA 14 to the radio frequency manager 16. In most cases, the wireless signal is transmitted from the battery cell monitoring unit 36 to the radio frequency manager 16 via the one or more antennas of the BCMA 14, so that the BCMA 14 operates as a transmitter and the radio frequency manager 16 operates as a receiver. In some modes, the antenna included in the radio frequency manager 16 can also transmit a control signal from the controller 28 to the battery cell monitoring unit 36, so that the radio frequency manager 16 operates as a transmitter and the BCMA 14 operates as a receiver. In other words, the radio frequency manager 16 is a wireless manager capable of both receiving a wireless signal from the battery cell monitoring unit 36 and providing a corresponding wired signal to the controller 28 and transmitting a wireless signal to the battery cell monitoring unit 36 according to the instruction of the wired control signal from the controller 28. Similarly, the battery cell monitoring unit 36 is capable of both transmitting a wireless signal to the radio frequency manager 16 and receiving a wireless signal from the radio frequency manager 16.

[0086] During the initial design of the RESS 12, a radio frequency analysis can be performed to determine one or more relatively high-loss regions and one or more relatively low-loss regions of the battery pack 15. For example, the radiation pattern of the main radiation plane of the omnidirectional antenna included in the printed circuit board 38 of the battery cell monitoring unit 36 of the BCMA 14 can be studied to determine the relative signal strength at different parts of the pattern. The relatively high-loss region of the battery pack 15 for radio frequency signal communication corresponds to the relatively strong signal part of the radiation pattern, and the relatively low-loss region of the battery pack 15 for radio frequency signal communication corresponds to the relatively weak signal part of the radiation pattern. Interference from the electronic components of the battery cell monitoring unit 36 or the structural components of the battery pack 15 can affect the radiation pattern and ultimately the relatively high-loss region and the relatively low-loss region.

[0087] In addition, the placement of the radio frequency manager 16 in the battery pack 15 relative to the BCMA 14 can be based on the available packaging space or other considerations, so that the relative position of the radio frequency manager 16 relative to the BCMA 14 and the transmitting components therein is different in different vehicles. For example, in some embodiments, the radio frequency manager 16 can be relative to, such asFigure 1 The BCMA 14 shown in is positioned. In other embodiments, the BCMA 14 can be arranged in an orientation that is 180 degrees different from Figure 1 the orientation shown, such as where the module cover 44 faces the opposite direction. In addition to the relatively high and relatively low loss regions determined by radio frequency analysis, the relative positioning of the BCMA 14 and the radio frequency manager 16 also affects how to optimize the BCMA 14 and / or the radio frequency manager 16 to achieve a strong radio signal for radio frequency signal communication.

[0088] At least in part based on these factors and considerations, the battery pack 15, as disclosed in various embodiments herein, is equipped with a signal directing component that is operable to transmit and / or receive radio frequency signals between the battery cell monitoring unit 36 and the radio frequency manager 16 and is configured to direct the radio frequency signals to a relatively low loss region. In the embodiments disclosed herein, the signal directing component is integrated into the module cover, the interconnect board, or the radio frequency manager. Apparently, the signal directing component is not integrated into the battery cell monitoring unit 36 or the printed circuit board 38 included thereon. This allows a given printed circuit board design to be used for more than just battery pack configurations. In other words, the cost of fabricating and generating different printed circuit boards for each battery pack configuration can be avoided, and instead, due in part to customizing the battery pack through the signal directing components discussed herein, the same printed circuit board can be used for different battery pack configurations.

[0089] Figure 3 A first embodiment of a signal directing component that is a directional antenna 50 is shown. The directional antenna 50 is shown as being integrated with a substrate 52 as an integral component and is configured as a log periodic dipole antenna having a series of dipole elements 51 (also referred to as arms) and wires 53 interconnecting the elements. The radiation pattern produced when the antenna 50 is electrically excited results in the strongest radio frequency signal in the direction of arrow A. Although a log periodic dipole antenna is shown, other types of directional antennas that result in the maximum radio frequency signal intensity in a single direction, such as other surface-mounted antennas, can alternatively be used, which is different from an omnidirectional antenna that radiates and receives radio frequency signal power at substantially the same intensity in substantially all directions or a bi-directional antenna that produces substantially the same radio frequency signal intensity in opposite directions.

[0090] The directional antenna 50 can be printed on the surface of the substrate 52 or embedded within the substrate 52 (e.g., secondarily molded therein) to integrate the directional antenna 50 with the substrate 52. The directional antenna 50 is integrated within the substrate 52 such that the electrical connector 54 extends out of the substrate 52 from the directional antenna 50. The electrical connector 54 can also be referred to as a feeder line and is shown extending from the wire 53. In other words, the electrical connector 54 is integrated with the antenna 50 and the substrate 52 and is also flexible, allowing it to be bent or turned such that the end 55 of the electrical connector 54 can be connected to an adjacent (e.g., upper or lower layer) electrical component as discussed herein. The material of the antenna 50 is a good conductor, such as copper or aluminum, for emitting radio frequency signals. The substrate 52 is an electrostatic discharge protection material having a high dielectric constant and a low loss tangent, which helps to miniaturize the size of the antenna 50. For example, the material of the substrate 52 can be silicone rubber or a ceramic laminate (e.g., alumina, polytetrafluoroethylene (PTFE) ceramic, or others).

[0091] The substrate 52 is configured to have a retention feature 56. In the illustrated embodiment, the retention feature 56 is a hole molded, drilled, or otherwise provided in the substrate 52. The retention feature 56 is used to hold the substrate 52 in a fixed position during embedding of the substrate 52 within the module cover 44, the interconnect board 32, or the radio frequency manager 16 to ensure that the signal directing component (e.g., antenna 50) is oriented to achieve the strongest radio frequency signal directed to and through the relatively low loss region of the battery pack 15. For example, in various embodiments of the substrates 52, 52A, 52E, 52F, and 52G having the retention features 56 disclosed herein, pins or dowels can extend through the holes 56 during molding of the material of the housing of the module cover 44, the interconnect board 32, or the radio frequency manager 16 over the substrate 52. In other embodiments, the retention feature can include heat stakes routed through the holes or can include fasteners attached to the substrate 52, 52A, 52E, 52F, or 52G.

[0092] Figure 4 and Figure 5Shown is a directional antenna 50 integrated into a substrate 52, which in turn is integrated in a module cover 44. In other embodiments, the directional antenna 50 may alternatively be integrated in an interconnect board 32 or in the housing of a radio frequency manager 16. The BCMA of the RESS 12 including such an embodiment of the directional antenna 50 is referred to as BCMA 14A. The substrate 52 is embedded in the module cover 44, which is a material different from the substrate. For example, the substrate 52 is a first material and the module cover 44 is a second material, and the first material has a higher dielectric constant and a lower loss tangent than the second material. The first material may be, for example, silicone rubber or a ceramic laminate (e.g., alumina, polytetrafluoroethylene (PTFE) ceramic, or others). The second material may be, for example, polypropylene, nylon, or polycarbonate. In order to embed the substrate 52 in the module cover 44 by secondary molding the second material, the substrate 52 is held in a mold of the module cover 44 by pins at the retention features 56 so as to orient the directional antenna 50 in a direction that achieves high gain and guides radio frequency signals through a low-loss region of the BCMA 14A. Since the package envelope of the directional antenna 50 within the substrate 52 is known and relatively small compared to the module cover 44 (e.g., the outer dimensions of the substrate 52 are known), its position for achieving the desired signal within the mold of the module cover 44 is design-flexible and the implementation cost is relatively low. In contrast, if the directional antenna 50 is incorporated into a printed circuit board 38 of a battery cell monitoring unit 36, this may require more expense to reconfigure the printed circuit board 38 for different positions of the directional antenna 50 when used in different layouts of a battery pack 15 within a powertrain (e.g., different relative orientations of the battery cell monitoring unit 36 and the radio frequency manager 16).

[0093] As Figure 4 shown, an electrical connector 54 extends out of the substrate 52 from a wire 53 and is embedded in the module cover 44 with the substrate 52 such that an end 55 of the electrical connector 54 extends out of the module cover 44 and is connectable to the battery cell monitoring unit 36. For example, the electrical connector 54 may be a flexible connector such as a soldering pin, a jumper wire cable (sometimes referred to as a Dupont connector), a micro coaxial connector (MMCX), or a microstrip to a coplanar connection. Thus, data from the battery cells 30 is relayed via an electrical signal from the battery cell monitoring unit 36 through the electrical connector 54 and output as a radio frequency signal S ( Figure 1 shown) via the antenna 50 by a wireless connection to the radio frequency manager 16.

[0094] Figure 6is a plan view of a radio frequency manager 16A having a pair of directional antennas 50A, 50B. Antennas 50A and 50B are referred to as a pair of directional antennas or dual directional antennas, and are integrated into a substrate 52A, which is the same as substrate 5 described in reference Figure 3 except having a different shape to accommodate the two directional antennas 50A, 50B. Substrate 52A is embedded in the housing 60 of the radio frequency manager, such as by overmolding. In this implementation of the directional antennas 50A, 50B in the housing 60, Figure 1 the radio frequency manager 16 is referred to as radio frequency manager 16A. The housing 60 can be a different material from the substrate 52A. For example, the substrate 52A is a first material, and the housing 60 is a second material, which can be the same or different from the material of the module cover 44. The first material has a higher dielectric constant and a lower loss tangent than the second material. The first material can be silicone rubber or a ceramic laminate (such as alumina, polytetrafluoroethylene (PTFE) ceramic, or others). The second material can be, for example, polypropylene, nylon, or polycarbonate. The directional antennas 50A, 50B are shown as being integrated in a single substrate 52A having a pair of retention features 56, which are configured as holes and can be used to simultaneously orient the two directional antennas 50A, 50B. Alternatively, each antenna 50A, 50B can be integrated into a separate substrate 52, each substrate having a retention feature 56 (such as a total of four retention features 56), and the substrates 52 can be placed adjacent to each other when the substrates 52 are embedded in the housing 60.

[0095] The radio frequency manager 16A is shown as being mounted structurally, such as on the cage 62 of the battery pack 15. The bolt 63 is shown as securing the housing 60 to the cage 62. The radio frequency manager 16A can be located in an area that is accessible for maintenance. The radio frequency manager 16A can be designed to communicate with battery cell module assemblies of different configurations used on different battery packs. Because it can be a common device used with different battery cell module assemblies architectures, economies of scale can be achieved if it can be adapted to communicate via radio frequency signals guided over low-loss regions to different battery packs. Thus, the radio frequency manager 16A can be in different positions relative to components of the battery cell monitoring unit with which it communicates on different battery pack platforms. By configuring the signal directing components as a pair of directional antennas 50A, 50B in the radio frequency manager 16A whose high gain directions are oriented opposite to each other, one of the directional antennas can effect communication over the low-loss region even when the radio frequency manager 16A is positioned on one side of the BCMA 14, 14A, 14B, 14C, 14D, or 14E in one application and on the opposite side of the BCMA 14, 14A, 14B, 14C, 14D, or 14E or on a different one of the BCMA 14, 14A, 14B, 14C, 14D, or 14E in another application. The bi-directional antennas 50A, 50B may not be as efficient as a single directional antenna in some embodiments because half of the signal (the signal pattern of one of the two antennas) may be effectively wasted. However, it may be easier to implement compared to producing two different radio frequency modules (each radio frequency module having a single directional antenna, one pointing in a first direction and the other pointing in the opposite direction for use with different arrangements of the battery pack). Additionally, it may be useful in a dual manager system (e.g., a battery pack having two separate radio frequency managers) because each antenna 50A, 50B can be configured to communicate via radio frequency with a different one of the BCMA in the BCMA.

[0096] Figure 7 is a partial bottom view of the BCMA 14B, which is similar to Figure 1 the BCMA 14 and includes a pair of directional antennas 50C, 50D integrated into a substrate 52A of a substrate such as Figure 6 shown. For purposes of description, the directional antenna 50C will be referred to as the first directional antenna, and the directional antenna 50D will be referred to as the second directional antenna. The directional antennas 50C, 50D are oriented to have high gain directions opposite to each other, as Figure 6antennas 50A, 50B, but different from the directional antennas 50A, 50B is that only one of the directional antennas 50C, 50D is activated to save signal strength. More specifically, the directional antenna 50C or 50D that results in a stronger radio frequency signal between the battery cell monitoring unit 36 and the radio frequency manager 16 (or radio frequency managers 16A, 16B, or 16C if used therewith) is the enabled directional antenna, and the other directional antenna 50C or 50D is the idle directional antenna.

[0097] Activate the correct directional antenna among the directional antennas 50C, 50D in one of a variety of different ways. For example, as Figure 8 shown, the integrated switch 68 can be disposed on the printed circuit board 38 of the battery cell monitoring unit 36. For purposes of explanation, the switch 68 is schematically shown in the gap between the printed circuit board 38 and the module cover 44 (the gap is shown enlarged for illustration purposes), and can be on the surface 67 of the printed circuit board 38 (e.g., horizontally disposed within the paper). The switch 68 has a first position (shown in solid lines) where the switch 68 closes the circuit between certain electrical components of the printed circuit board 38 and the first directional antenna 50C, but when the switch 68 is in the first position, no power is supplied to the second directional antenna 50D. The switch 68 can alternatively be moved to a second position 68A (shown in dashed lines) to close the circuit between other electrical components of the printed circuit board 38 and the second directional antenna 50D, but when the switch 68 is in the second position 68A, no power is supplied to the first directional antenna 50C. To determine the position of the switch 68, a controller such as the controller 28 can be programmed to, when the vehicle powertrain 10 is first started, select the switch position to power the directional antenna 50C or 50D that produces a stronger signal at the radio frequency manager 16, 16A, 16B, or 16C. The program stored on the controller 28 can move the switch 68 to each position to temporarily test the strength of the signal from each directional antenna 50C, 50D. Alternatively, the stored program can select the switch position based on other data, such as data indicating the relative positions of the BCMA 14B and the radio frequency manager 16, 16A, 16B, or 16C.

[0098] As another alternative, instead of switch 68, a zero-ohm resistor can be provided which can be manually connected to close only the circuit that activates the directional antenna 50C or 50D closer to the RF manager 16, 16A, 16B, or 16C, while another zero-ohm resistor can be removed to disconnect the circuit to the other directional antenna 50C or 50D, thereby disabling (deactivating) that antenna. In yet another alternative, corresponding different traces can be provided to different directional antennas 50C, 50D, and then power only needs to be provided along the trace to the one of the directional antennas 50C, 50D that provides a stronger RF signal with lower loss (e.g., the RF signal is guided over a relatively low-loss region).

[0099] The connection via the switch or zero-ohm resistor can be done before or simultaneously with the integration of the directional antennas 50C, 50D and the substrate 52A in the module cover 44. For example, the inventory of BCMA 14B can be modified such that in half, the directional antenna 50C is activated and the directional antenna 50D is idle, while in the other half, the directional antenna 50D is activated and the directional antenna 50C is idle. Then each type of inventory is ready to be assembled in the battery pack 15 with different relative positions of the BCMA 14B and the RF managers 16, 16A, 16B, or 16C.

[0100] Figure 9 is similar to Figure 1 Partial bottom view of BCMA 14C, which is similar to BCMA 14, and is modified to include a signal-directing component configured with a bi-directional antenna 50E having bi-directional beams. The bi-directional antenna 50E is integrated in a substrate 52E, which is similar to substrate 52 but has a different external shape. The integrated flexible electrical connector 54 ( Figure 9 not shown in Figure 4 but similar to the electrical connector shown in Figure 4 can extend from the bi-directional antenna 50E and out of the substrate 52E such that it has a portion embedded in the substrate 52E and an end connected to a printed circuit board 38 similar to that shown in Figure 6 . The bi-directional antenna 50E is called a bi-directional antenna because it radiates or receives most of its energy only in two opposite directions (e.g., opposite beams in two opposite high-gain directions). These two opposite beams are shown as the first beam B1 and the second beam B2 in dashed lines. Similar to the dual-directional antennas 50A and 50B of

[0101] Figure 10 is a plan view of a radio frequency manager 16B of a bi-directional antenna 50E including Figure 9 The bi-directional antenna 50E has bi-directional beams B1, B2 and is integrated into a substrate 52E embedded in a housing 60 of the radio frequency manager 16B. Integrating the bi-directional antenna 50E in the housing 60 can result in improved packaging because the radio frequency manager 16B can be placed in a more accessible area of the vehicle. The advantage of using the bi-directional antenna 50E on the radio frequency manager 16B is that the reception of radio frequency signals from the nodes of the battery cell monitoring unit 36 is improved regardless of the layout of the battery pack 15. Additionally, the bi-directional antenna 50E would be useful in a dual manager system (e.g., a rechargeable energy storage system having two battery radio frequency managers) because each beam B1 and B2 can be in radio frequency communication with a different set of battery cell module assemblies.

[0102] Figure 11 is a cross-sectional side view of a signal directing component of a reflector 150 configured to be integrated in a substrate 52F. More specifically, the reflector 150 is embedded in the substrate 52F. Retention features such as holes 56 are provided in the substrate 52F to maintain the desired orientation of the substrate 52F and the reflector 150 when the substrate 52F is secondarily molded in Figure 12 the interconnect board 32 of the BCMA 14D. In this position, the reflector 150 is inside an antenna 50F embedded in a printed circuit board 38 of the battery cell monitoring unit 36 and is oriented such that radio frequency signal S to or from the antenna 50F is reflected by the reflector 150 through a relatively low-loss region of the battery pack 15 to communicate with the radio frequency managers 16, 16A, 16B or 16C.

[0103] Figure 13 is a plan view of a radio frequency manager 16C similar to Figure 1 the radio frequency manager 16, which is modified to have a plurality of reflectors 150, each reflector being integrated in a substrate 52F such as substrate 52, which is then embedded in a housing 60 of the radio frequency manager 16C, such that each reflector 150 is below an antenna in the housing 60 of the radio frequency manager 16C (e.g., each reflector 150 is closer to the lower cover of the housing 60 below the antenna). By providing two separate reflectors 150 at different positions on the housing 60, radio frequency managers 16C of the same construction can be used for different battery pack 15 configurations, where multiple BCMA 14, 14A, 14B, 14C, 14D or 14E are arranged at different positions relative to the radio frequency manager 16C, such that radio frequency signals can be transmitted to the radio frequency manager 16C along different low-loss regions of different battery pack configurations. As another alternative, a single reflector can be provided inside the housing 60 of the radio frequency manager 16 and along the incoming Figure 13The line 150A in the plane of the paper surface is arranged diagonally. In this arrangement, a single diagonal reflector can direct the signals from the two antennas within the housing 60 along a relatively low-loss path.

[0104] Figure 14 is a partial cross-sectional view of the BCMA 14E, which includes a signal-directing component that is configured as a lens 250 integrated in the matrix 52G of the material of the matrix 52, and the matrix 52G has retention features 56 used, for example, when embedding the matrix 52G in the module cover 44. The lens 250 can be, for example, Luneburg lenses. The lens 250 is oriented and has a geometric configuration determined by radio frequency analysis to allow it to direct the radio frequency signal S from the antenna 50F in the printed circuit board 38 of the embedded battery cell monitoring unit 36 to the radio frequency managers 16, 16A, 16B, or 16C in a predetermined low-loss region of the BCMA 14E.

[0105] It should be understood that any signal-directing component (e.g., the directional antenna 50, a pair of directional antennas 50A, 50B, the bi-directional antenna 50E, the reflector 150, or the lens 250) described as being integrated in a component of the BCMA 14, 14A, 14B, 14C, 14D, or 14E can be used in combination with any signal-directing component (e.g., the directional antenna 50, a pair of directional antennas 50A, 50B, the bi-directional antenna 50E, the reflector 150, or the lens 250) described as being integrated into the radio frequency managers 16, 16A, 16B, or 16C in order to further increase the radio frequency communication signal strength and reduce the signal loss in the battery pack 15.

[0106] The method 300 for manufacturing the rechargeable energy storage system RESS 12 as described herein is shown in Table I.

[0107] Table I

[0108]

[0109] The method 300 can include step 310: performing a radio frequency analysis to determine the relatively low-loss regions of the battery pack 15. For example, an off-the-shelf omnidirectional antenna included in the printed circuit board 38 can be used for this purpose.

[0110] In some embodiments, the method 300 can include step 312: integrating the signal-directing components 50, 50A, 50B, 50C, 50D, 50E, 150, or 250 into the matrix 52, 52A, 52E, 52F, or 52G, which is a material having a relatively high dielectric constant and a relatively low loss tangent (e.g., compared to the material of the component into which it is later integrated).

[0111] After step 312, method 300 includes step 314: integrating a signal directing component 50, 50A, 50B, 50C, 50D, 50E, 150, or 250 operable to transmit and / or receive radio frequency signals between the battery cell monitoring units 36 of BCMA 14, 14A, 14B, 14C, 14D, or 14E and the radio frequency managers 16, 16A, 16B, or 16C into one of the module cover 44 of BCMA, the interconnect board 32 of BCMA, or the radio frequency managers 16, 16A, 16B, or 16C. Step 314 may include sub-step 316: orienting the signal directing component 50, 50A, 50B, 50C, 50D, 50E, 150, or 250 in the module cover 44, the interconnect board 32, or the radio frequency managers 16, 16A, 16B, or 16C to direct radio frequency signals through a relatively low-loss region for radio frequency signal communication for the battery pack 15. For example, the retention features 56 of the substrate 52, 52A, 52E, 52F, or 52G may be held to orient the signal directing component 50, 50A, 50B, 50C, 50D, 50E, 150, or 250. Step 314 may also include sub-step 318: embedding the substrate 52, 52A, 52E, 52F, or 52G into the one of the module cover 44, the interconnect board 32, or the radio frequency managers 16, 16A, 16B, or 16C. The substrate 52, 52A, 52E, 52F, or 52G may be a first material, and the module cover 44, the interconnect board 32, or the radio frequency managers 16, 16A, 16B, or 16C into which the substrate is embedded may be a second material, and the first material may have a higher dielectric constant and a lower loss tangent than the second material.

[0112] The integrated flexible electrical connector 54 may extend from the signal directing component 50, 50A, 50B, 50C, 50D, 50E, and method 300 may include step 320: connecting the integrated flexible electrical connector 54 to the printed circuit board 38 of the battery cell monitoring unit 36 after integrating the signal directing component.

[0113] In some embodiments, the signal-directing component can be a pair of directional antennas 50C, 50D oriented in high-gain directions opposite to each other, the pair including a first directional antenna 50C and a second directional antenna 50D, and method 300 can include step 322: determining which of the first directional antenna 50C and the second directional antenna 50D results in a stronger radio frequency signal between the battery cell monitoring unit 36 and the radio frequency manager 16, 16A, 16B, or 16C. Thereafter, method 300 can include step 324: enabling the radio frequency path between the battery cell monitoring unit 36 and the radio frequency manager 16, 16A, 16B, or 16C only for the one of the first directional antenna 50C and the second directional antenna 50D that results in the stronger radio frequency signal, such as by closing a switch or connecting a zero-ohm resistor.

[0114] Accordingly, the rechargeable energy storage systems and manufacturing methods disclosed herein utilize one or more signal-directing components, such as antennas, reflectors, or lenses, to direct radio frequency signals between the battery cell monitoring unit and the radio frequency manager with greater signal strength, relatively low loss, improved package space, and the ability to be used in different battery pack configurations and layouts.

[0115] While the best mode for carrying out the disclosure has been described in detail, those familiar with the art to which this disclosure pertains will recognize various alternative designs and embodiments for practicing the teachings within the scope of the appended claims.

Claims

1. A rechargeable energy storage system, comprising: A battery pack including a battery cell module assembly and a radio frequency manager, wherein the battery cell module assembly has: A plurality of battery cells, A cell monitoring unit having a printed circuit board configured to monitor one or more parameters of the battery cells, An interconnect board disposed between the plurality of battery cells and the cell monitoring unit and physically connecting the plurality of battery cells to the cell monitoring unit, and A module cover at least partially enclosing the plurality of battery cells, the cell monitoring unit, and the interconnect board, wherein the cell monitoring unit is disposed adjacent to the module cover; Wherein the radio frequency manager is wirelessly connectable to the cell monitoring unit via radio frequency signal communication; wherein the battery cell module assembly has a relatively high loss region for radio frequency signal communication and a relatively low loss region for radio frequency signal communication; And A signal directing component operable to transmit and / or receive radio frequency signals between the cell monitoring unit and the radio frequency manager and configured to direct the radio frequency signals to the relatively low loss region, the signal directing component being integrated into one of the module cover, the interconnect board, or the radio frequency manager.

2. The rechargeable energy storage system according to claim 1, further Comprising: A substrate; Wherein the signal directing component is integrated with the substrate; Wherein the substrate is embedded in one of the module cover, the interconnect board, or the radio frequency manager.

3. The rechargeable energy storage system according to claim 2, wherein the substrate has a retention feature operable to hold the substrate in a fixed position during embedding of the substrate in one of the module cover, the interconnect board, or the radio frequency manager.

4. The rechargeable energy storage system according to claim 2, wherein the substrate is a first material, the one of the module cover, the interconnect board, or the radio frequency manager in which the substrate is embedded is a second material, and the first material has a higher dielectric constant and a lower loss tangent than the second material.

5. The rechargeable energy storage system according to claim 2, further Comprising: An electrical connector extending from the signal directing component out of the substrate and being embedded with the substrate in the module cover or the interconnect board such that an end of the electrical connector extends out of the module cover or the interconnect board and is capable of connecting to or passing through the cell monitoring unit.

6. The rechargeable energy storage system according to claim 1, wherein the signal directing component is a directional antenna integrated in the module cover.

7. The rechargeable energy storage system according to claim 1, wherein the signal directing component is a pair of directional antennas oriented in opposite high gain directions and integrated in the radio frequency manager.

8. The rechargeable energy storage system according to claim 1, wherein the signal directing component is a pair of directional antennas, the pair of directional antennas being oriented in opposite high-gain directions with respect to each other, and the pair of directional antennas comprising an enabling directional antenna and an idle directional antenna.

9. The rechargeable energy storage system according to claim 8, wherein the pair of directional antennas is integrated into the module cover.

10. The rechargeable energy storage system according to claim 8, wherein the pair of directional antennas is integrated into the RF manager.

11. The rechargeable energy storage system according to claim 1, wherein the signal directing component is a bi-directional antenna integrated in the module cover.

12. The rechargeable energy storage system according to claim 1, wherein the signal directing component is a bi-directional antenna integrated in the RF manager.

13. The rechargeable energy storage system according to claim 1, wherein: the signal directing component is a reflector integrated in the interconnect board; the printed circuit board of the battery cell monitoring unit includes an antenna; and the reflector is oriented to direct the RF signal from the antenna of the printed circuit board of the battery cell monitoring unit to the relatively low-loss region.

14. The rechargeable energy storage system according to claim 1, wherein: the RF manager includes a printed circuit board having an antenna and a housing disposed adjacent to the printed circuit board of the RF manager; and the signal directing component is a reflector integrated in the housing of the RF manager and oriented to direct the RF signal from the antenna of the printed circuit board of the RF manager to the relatively low-loss region.

15. The rechargeable energy storage system according to claim 1, wherein: the signal directing component is a lens integrated in the module cover; the printed circuit board of the battery cell monitoring unit includes an antenna; and the lens is oriented to direct the RF signal from the antenna of the printed circuit board to the relatively low-loss region.

16. A method of manufacturing a rechargeable energy storage system, the method comprising: integrating a signal directing component operable to transmit and / or receive RF signals between a battery cell monitoring unit of a battery cell module assembly of a battery pack and an RF manager of the battery pack into one of the module cover of the battery cell module assembly, the interconnect board of the battery cell module assembly, or the RF manager; wherein the interconnect board is configured to be disposed between battery cells of the battery cell module assembly and the battery cell monitoring unit and physically connect the battery cells of the battery cell module assembly and the battery cell monitoring unit, and the battery cell monitoring unit is configured to be disposed between the interconnect board and the module cover. Integrating the signal-directing component includes orienting the signal-directing component in one of the module cover, the interconnect board, or the RF manager to direct the RF signal through a relatively low-loss region of the battery pack for RF signal communication.

17. The method according to claim 16, further comprising: performing an RF analysis to determine the relatively low-loss region of the battery pack before integrating the signal-directing component.

18. The method according to claim 16, further comprising: integrating the signal-directing component with a substrate; and wherein integrating the signal-directing component into one of the module cover, the interconnect board, or the RF manager is performed after integrating the signal-directing component with the substrate and includes embedding the substrate into one of the module cover, the interconnect board, or the RF manager; wherein the substrate is a first material, the module cover, the interconnect board, or the RF manager into which the substrate is embedded is a second material, and the first material has a higher dielectric constant and a lower loss tangent than the second material.

19. The method according to claim 16, wherein an integrated electrical connector extends from the signal-directing component; and the method further comprising: connecting the integrated electrical connector to the battery cell monitoring unit or the interconnect board after integrating the signal-directing component.

20. The method according to claim 16, wherein the signal-directing component is a pair of directional antennas oriented in opposite high-gain directions with respect to each other, the pair of directional antennas includes a first antenna and a second antenna, and the method further comprising: determining which of the first antenna and the second antenna results in a stronger RF signal between the battery cell monitoring unit and the RF manager; and enabling an RF path between the battery cell monitoring unit and the RF manager only for the one of the first antenna and the second antenna that results in a stronger RF signal between the battery cell monitoring unit and the RF manager.

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