Traction battery with hurdle-shaped flexible printed circuit

Abstract

The invention provides a traction battery with a hurdle-shaped flexible printed circuit. A traction battery includes a battery array and a flexible printed circuit (FPC). The FPC comprises a hurdle-shaped flexible substrate, the hurdle-shaped flexible substrate is planar and is provided with a first planar surface, a second planar surface, a first edge and a second edge, the first planar surface and the second planar surface are opposite, and the first edge and the second edge extend between the planar surfaces and are opposite. The substrate has a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion. The elbow portion is folded at the first fold and the second fold, respectively, with respect to the intermediate portion such that the first planar surfaces of the first elbow and the second elbow face each other. Circuitry is supported by the substrate and electrically connected between circuit boards supported on opposite sides of the battery array.

Description

Technical Field

[0001] The present application relates to a traction battery for a vehicle, and more particularly to a hurdle-shaped flexible printed circuit for use on a traction battery. Background Art

[0002] Vehicles such as battery electric vehicles and hybrid electric vehicles contain a traction battery assembly to serve as a source of energy for the vehicle. The traction battery may include components and systems that help manage vehicle performance and operation. The traction battery may also include high voltage components and may include an air or liquid thermal management system for controlling the battery temperature. Summary of the invention

[0003] According to one embodiment, a traction battery includes a battery array and a flexible printed circuit (FPC). The FPC includes a cross-bar-shaped flexible substrate that is planar and has opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion. The elbow portion is folded at a first folded portion and a second folded portion, respectively, relative to the middle portion, so that the first planar surfaces of the first elbow and the second elbow face each other. The circuit is supported by the substrate and electrically connected between circuit boards supported on opposite sides of the battery array.

[0004] According to another embodiment, a traction battery includes: a battery array; a first circuit board disposed on a first side of the array and having an associated temperature sensor; a second circuit board disposed on a second side of the array and having an associated sensing module; and a flexible printed circuit (FPC) extending from the first side to the second side of the array. The FPC includes: a cross-bar-shaped flexible substrate that is planar and has opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion, wherein each of the elbow portions is folded relative to the middle portion so that the first planar surfaces of the first elbow and the second elbow face each other; a circuit supported by the substrate; a first connector attached to the circuit and the substrate and connected to the first circuit board; and a second connector attached to the circuit and the substrate and connected to the second circuit board so that the FPC electrically connects the temperature sensor to the sensing module.

[0005] According to yet another embodiment, a flexible printed circuit (FPC) for a traction battery includes a crossbar-shaped flexible substrate that is planar and has opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces. The substrate has a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion. Each of the elbow portions is folded relative to the middle portion so that the first planar surfaces of the first elbow and the second elbow face each other. A circuit is supported by the substrate. A first connector is attached to the circuit at the first end portion, and a second connector is attached to the circuit at the second end portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is a schematic diagram of an exemplary hybrid vehicle.

[0007] Figure 2 is a perspective view of the traction battery assembly.

[0008] Figure 3 is a perspective view of a support structure, a flexible printed circuit (FPC) and a circuit board for a traction battery, with other components omitted for illustrative purposes.

[0009] Figure 4 is a front view of the FPC in the installed configuration.

[0010] Figure 5 is a top view of the FPC in the installed configuration.

[0011] Figure 6 is a side view of the FPC in the installed configuration.

[0012] Figure 7 is a perspective view of the FPC in an installed configuration.

[0013] Figure 8 is a front view of the FPC in a blank configuration. DETAILED DESCRIPTION

[0014] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples, and other embodiments may take on various forms and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show the details of specific components. Therefore, the specific structural details and functional details disclosed herein are not interpreted as restrictive, but only as a representative basis for teaching those skilled in the art to adopt the present invention in various ways. As will be understood by those of ordinary skill in the art, the various features shown and described with reference to any one of the drawings may be combined with the features shown in one or more other drawings to produce embodiments that are not explicitly shown or described. The combination of features shown provides representative embodiments for typical applications. However, for specific applications or embodiments, various combinations and modifications of features consistent with the teachings of the present disclosure may be desirable.

[0015] Figure 1 A schematic diagram of a plug-in hybrid electric vehicle (PHEV) is depicted. However, certain embodiments may also be implemented in the context of non-plug-in hybrid and pure electric vehicles. The vehicle 12 includes one or more electric machines 14 mechanically connected to a hybrid transmission 16. The electric machine 14 may be capable of acting as a motor or a generator. In addition, the hybrid transmission 16 may be mechanically connected to an engine 18. The hybrid transmission 16 may also be mechanically connected to a drive shaft 20, which is mechanically connected to wheels 22. When the engine 18 is turned on or off, the electric machine 14 can provide propulsion and braking capabilities. The electric machine 14 also acts as a generator and can provide fuel economy benefits by recovering energy through regenerative braking. The electric machine 14 reduces pollutant emissions and improves fuel economy by reducing the workload of the engine 18.

[0016] The traction battery or battery pack 24 stores energy that can be used by the electric machine 14. The traction battery 24 generally provides a high voltage direct current (DC) output from one or more battery cell arrays (sometimes referred to as battery cell stacks) within the traction battery 24. A battery cell array includes one or more battery cells.

[0017] A battery cell (such as a prismatic, pouch, cylindrical, or any other type of unit) converts stored chemical energy into electrical energy. A battery cell may include a housing, a positive electrode (cathode), and a negative electrode (anode). An electrolyte allows ions to move between the anode and cathode during discharge and then back during recharge. Terminals may allow current to flow out of the cell for use in a vehicle.

[0018] Different battery pack configurations can be used to meet various vehicle variables, including packaging constraints and power requirements. Thermal management systems can be used to thermally control the battery cells. Examples of thermal management systems include air cooling systems, liquid cooling systems, and combinations of air and liquid systems.

[0019] The traction battery 24 may be electrically connected to one or more power electronics modules 26 via one or more contactors (not shown). The one or more contactors isolate the traction battery 24 from other components when disconnected, and connect the traction battery 24 to other components when closed. The power electronics module 26 may be electrically connected to the motor 14, and may provide the ability to transfer electrical energy bidirectionally between the traction battery 24 and the motor 14. For example, a typical traction battery 24 may provide a DC voltage, while the motor 14 may require a three-phase alternating current (AC) voltage to function. The power electronics module 26 may convert the DC voltage into a three-phase AC voltage according to the needs of the motor 14. In regenerative mode, the power electronics module 26 may convert the three-phase AC voltage from the motor 14 acting as a generator into the DC voltage required by the traction battery 24. The description herein is equally applicable to pure electric vehicles. In pure electric vehicles, the hybrid transmission 16 may be a gearbox connected to the motor 14, without the presence of the engine 18.

[0020] In addition to providing energy for propulsion, the traction battery 24 may also provide energy for other vehicle electrical systems. A typical system may include a DC / DC converter module 28 that converts the high voltage DC output of the traction battery 24 to a low voltage DC supply compatible with other vehicle components. Other high voltage loads (such as compressors and electric heaters) may be connected directly to the high voltage supply without using the DC / DC converter module 28. In a typical vehicle, the low voltage systems are electrically connected to an auxiliary battery 30 (e.g., a 12 volt battery).

[0021] A battery energy control module (BECM) 33 may communicate with the traction battery 24. The BECM 33 may serve as a controller for the traction battery 24 and may also include an electronic monitoring system that manages the temperature and state of charge of each of the battery cells. The traction battery 24 may have a temperature sensor 31, such as a thermistor or other thermometer. The temperature sensor 31 may communicate with the BECM 33 to provide temperature data about the traction battery 24.

[0022] The vehicle 12 may be recharged by a charging station connected to an external power source 36. The external power source 36 may be electrically connected to an electric vehicle supply equipment (EVSE) 38. The external power source 36 may provide DC or AC power to the EVSE 38. The EVSE 38 may have a charging connector 40 for plugging into a charging port 34 of the vehicle 12. The charging port 34 may be any type of port configured to transfer power from the EVSE 38 to the vehicle 12. The charging port 34 may be electrically connected to a charger or an onboard power conversion module 32. The power conversion module 32 may condition the power supplied from the EVSE 38 to provide the appropriate voltage and current levels to the traction battery 24. The power conversion module 32 may interface with the EVSE 38 to coordinate power delivery to the vehicle 12. The EVSE connector 40 may have pins that mate with corresponding recesses of the charging port 34.

[0023] The various components discussed may have one or more associated controllers to control and monitor the operation of the components. The controllers may communicate via a serial bus (eg, a controller area network (CAN)) or via dedicated electrical conduits. Figure 1 The vehicle 12 is merely an example, and the present disclosure is relevant to any vehicle having a traction battery.

[0024] refer to Figure 2 and Figure 3 , the traction battery assembly 50 includes a plurality of battery cells 54 stacked into a battery array 52 (e.g., a linear array). Terminals 61 extend from the cells. Each cell 54 may have two terminals 61, such as a positive terminal and a negative terminal. The positive and negative terminals may be side-by-side or extend from different sides (e.g., opposite sides) of the cell.

[0025] The traction battery 50 may include a support structure 60 having a center plate 62, a bottom plate 64, and a top plate 66. The plates may be arranged in a generally I-shape. The first array 52a may be disposed on a first side 67 of the plate 62, and the second array 52b may be disposed on a second side 68 of the plate 62. The first array and the second array may be electrically connected in series or in parallel.

[0026] One or more circuit boards may be disposed on the end 72 of the battery assembly 50. For example, a first circuit board 70 is disposed on one side of the battery assembly 50, and another circuit board 74 is disposed on the other side of the assembly 50. As shown, the circuit boards 70, 74 are disposed on opposite sides of the board 62. A temperature sensor 76 may be mounted to the first circuit board 70 and electrically connected to the leads of the circuit board 70. The sensor 76 is configured to measure the temperature of one or more of the cells 54. The second circuit board 74 may have another temperature sensor (not visible). In one or more embodiments, each circuit board may include a plurality of associated temperature sensors. The temperature sensor is electrically connected to a sensing module 78, which receives data from the sensor. Each of the circuit boards may also include an associated current and / or voltage sensor (not shown).

[0027] A flexible printed circuit (FPC) 80 is connected between the two circuit boards 70 and 74. This is just one example, and the FPC 80 can be electrically connected between any suitable electronic devices on different sides of the battery 50. The FPC 80 allows data collected from one side of the battery to be transmitted to the circuit board on the other side of the battery. For example, the sensing module 78 may be located on only one of the circuit boards. Thus, data from the temperature sensor 76 can be carried to the sensing module 78 via the FPC 80. This is just one example, and the FPC can carry any number of different data.

[0028] refer to Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 , the FPC 80 has a flexible substrate 82, which is planar and has a first planar surface 84 and a second planar surface 86 opposite to each other and a first edge 88 and a second edge 90 opposite to each other extending between the planar surfaces. The substrate may be hurdle-shaped. The substrate 82 may have a straight middle portion 100, a first end portion 102 joined to the middle portion 100 by a first elbow portion 104, and a second end portion 106 joined to the middle portion 100 by a second elbow portion 108. A connector 110 is attached to the end portion 102, and a connector 112 is attached to the end portion 106. The connectors 110, 112 are configured to be electrically connected to associated electronic components (such as circuit boards 70, 74). For example, the circuit boards 70, 74 may have mating connectors configured to engage with the connectors 110 and 112.

[0029] The elbows 104, 108 may be bent such that the angle defined between the first edge 88 of the first end portion 102 and the first edge 88 of the middle portion 100 is between 80 and 100 degrees, for example, 90 degrees as shown. The circuit 98 is supported by the substrate 82 and electrically connected between the connectors 110 and 112. The circuit 98 includes a plurality of conductors 113, each extending between corresponding pins of the connectors 110, 112. The conductors may be parallel to each other.

[0030] The flexible substrate 82 may be foldable to provide a flexible package. Figure 8 An exemplary hurdle-shaped FPC 80 is shown in its blank shape. In other embodiments, the blank may have other configurations. During assembly, the FPC blank is folded and bent into a mounting configuration as described above (see, e.g., Figure 4 ), and then attached to the support structure 60. The shape of the blank cooperates with the additional folds and bends to be received on the traction battery assembly in an efficient package.

[0031] The FPC 80 may be mounted on the traction battery 50 with the second surface 86 of the middle portion 100 disposed against the first side 90 of the plate 62. The plate 62 may define a concave groove or channel 101 in which the FPC 80 is received. The middle portion 100 may have U-shaped bends 114 and 120 that protrude forward of the surface 84. The bends 114 and 120 provide slack for adjustment during assembly. The bend 114 is formed by folds 116, 118 that may be 90 degrees. The bend 114 causes portions of the planar surface 86 to face each other. The bend 120 is formed by folds 122, 124 that may be 90 degrees. The bend 120 also causes portions of the planar surface 86 to face each other. The end portions 102 and 106 may also include bends to aid in assembly. For example, end portion 102 has a bend 130 that projects from surface 86 and causes portions of surface 84 to face each other, and end portion 106 has a bend 132 that projects from surface 86 and causes portions of surface 84 to face each other.

[0032] Although exemplary embodiments are described above, these embodiments are not intended to describe all possible forms covered by the claims. The words used in the specification are descriptive words rather than restrictive words, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the features of various embodiments can be combined to form other embodiments of the present invention that may not be explicitly described or shown. Although various embodiments may have been described as providing advantages or being superior to other embodiments or prior art implementations in terms of one or more desired characteristics, it will be appreciated by those of ordinary skill in the art that one or more features or characteristics may be compromised to achieve the desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, strength, durability, marketability, appearance, packaging, size, maintainability, weight, manufacturability, ease of assembly, etc. For this reason, embodiments described as less desirable than other embodiments or prior art implementations in terms of one or more characteristics are within the scope of the present disclosure and may be desirable for specific applications.

[0033] According to the present invention, there is provided a traction battery having: a battery array; and a flexible printed circuit (FPC), the FPC comprising: a hurdle-shaped flexible substrate, the hurdle-shaped flexible substrate being planar and having opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion, wherein the elbow portion is folded at first and second folded portions, respectively, relative to the middle portion so that first planar surfaces of the first elbow and the second elbow face each other; and a circuit supported by the substrate and electrically connected between circuit boards supported on opposite sides of the battery array.

[0034] According to one embodiment, a circuit includes a plurality of parallel conductors.

[0035] According to one embodiment, an angle defined between the first edge of the first end portion and the first edge of the middle portion is between 80 degrees and 100 degrees.

[0036] According to one embodiment, the angle is between 87 and 93 degrees.

[0037] According to one embodiment, the straight portion comprises a first bend such that a second planar surface on one side of the bend faces a second planar surface on the other side of the first bend.

[0038] According to one embodiment, the straight portion comprises a second bend such that the second planar surface on one side of the second bend faces the second planar surface on the other side of the second bend.

[0039] According to one embodiment, the first bent portion includes a third folded portion and a fourth folded portion.

[0040] According to one embodiment, the first end portion comprises a third fold and a fourth fold forming a bend such that a first planar surface on one side of the fold faces a first planar surface on the other side of the fold.

[0041] According to one embodiment, the invention also features a support structure having a first plate, wherein the array is mounted to the support structure, and wherein the second planar surface of the intermediate portion is disposed against the plate.

[0042] According to one embodiment, the intermediate portion is sandwiched between the plate and the array.

[0043] According to one embodiment, the board defines a recessed channel, and the FPC is received in the channel.

[0044] According to one embodiment, the FPC includes a first connector and a second connector connected to corresponding connectors of a circuit board.

[0045] According to the present invention, there is provided a traction battery having: a battery array; a first circuit board disposed on a first side of the array and having an associated temperature sensor; a second circuit board disposed on a second side of the array and having an associated sensing module; and a flexible printed circuit (FPC) extending from the first side to the second side of the array, the FPC comprising: a flexible substrate being planar and having opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion, wherein each of the elbow portions is folded relative to the middle portion such that the first planar surfaces of the first elbow and the second elbow face each other; a circuit supported by the substrate; a first connector attached to the circuit and the substrate and connected to the first circuit board; and a second connector attached to the circuit and the substrate and connected to the second circuit board such that the FPC electrically connects the temperature sensor to the sensing module.

[0046] According to one embodiment, the circuit includes a plurality of conductors, each conductor extending from a first connector to a second connector.

[0047] According to one embodiment, the first planar surface of the section of the middle portion faces the first planar surface of the first elbow.

[0048] According to one embodiment, the first planar surface of the other section of the intermediate portion faces the first planar surface of the second elbow.

[0049] According to one embodiment, the invention further features a support structure having a first board, wherein the array is mounted to the support structure, and wherein the second planar surface of the middle portion is disposed against the board such that the FPC is sandwiched between the board and the array.

[0050] According to the present invention, a flexible printed circuit (FPC) for a traction battery is provided, the FPC having: a hurdle-shaped flexible substrate, the hurdle-shaped flexible substrate being planar and having opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion, wherein each of the elbow portions is folded relative to the middle portion so that the first planar surfaces of the first elbow and the second elbow face each other; a circuit supported by the substrate; a first connector attached to the circuit at the first end portion; and a second connector attached to the circuit at the second end portion.

[0051] According to one embodiment, the circuit includes a plurality of conductors, each conductor extending from a first connector to a second connector.

[0052] According to one embodiment, a first planar surface of a segment of the middle portion faces the first planar surface of the first elbow, and wherein a first planar surface of another segment of the middle portion faces the first planar surface of the second elbow.

Claims

1. A traction battery comprising: Battery array; as well as A flexible printed circuit (FPC), the FPC comprising: a hurdle-shaped flexible substrate, the hurdle-shaped flexible substrate being planar and having opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion, wherein the elbow portion is folded relative to the middle portion at the first folded portion and the second folded portion, respectively, so that the first planar surfaces of the first elbow and the second elbow face each other; as well as An electrical circuit is supported by the substrate and electrically connected between circuit boards supported on opposite sides of the battery array.

2. The traction battery of claim 1, wherein the circuit comprises a plurality of parallel conductors.

3. The traction battery of claim 1, wherein an angle defined between the first edge of the first end portion and the first edge of the middle portion is between 80 degrees and 100 degrees.

4. The traction battery of claim 3, wherein the angle is between 87 degrees and 93 degrees.

5. The traction battery of claim 1, wherein the straight portion includes a first bend such that the second planar surface on one side of the bend faces the second planar surface on the other side of the first bend.

6. The traction battery of claim 5, wherein the straight portion includes a second bend such that the second planar surface on one side of the second bend faces the second planar surface on the other side of the second bend.

7. The traction battery of claim 5, wherein the first bend includes a third fold and a fourth fold.

8. The traction battery of claim 1 , wherein the first end portion includes a third fold and a fourth fold, the third fold and the fourth fold forming a bend such that the first planar surface on one side of the fold faces the first planar surface on the other side of the fold.

9. The traction battery of claim 1 further comprising a support structure having a first plate, wherein the array is mounted to the support structure, and wherein the second planar surface of the intermediate portion is disposed against the plate.

10. The traction battery of claim 9, wherein the intermediate portion is sandwiched between the plate and the array.

11. The traction battery of claim 9, wherein the plate defines a recessed channel, and the FPC is received in the channel.

12. The traction battery of claim 1, wherein the FPC includes first and second connectors that connect to corresponding connectors of the circuit board.

13. A traction battery comprising: Battery array; a first circuit board disposed on a first side of the array and having an associated temperature sensor; a second circuit board disposed on a second side of the array and having an associated sensing module; as well as a flexible printed circuit (FPC) extending from the first side to the second side of the array, the FPC comprising: a hurdle-shaped flexible substrate that is planar and has opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion joined to the middle portion by a first elbow portion, and a second end portion joined to the middle portion by a second elbow portion, wherein each of the elbow portions is folded relative to the middle portion so that the first planar surfaces of the first elbow and the second elbow face each other; a circuit supported by the substrate; a first connector attached to the circuit and the substrate and connected to the first circuit board; and A second connector is attached to the circuit and the substrate and connected to the second circuit board so that the FPC electrically connects the temperature sensor to the sensing module.

14. The traction battery of claim 13, wherein the circuit includes a plurality of conductors, each conductor extending from the first connector to the second connector.

15. The traction battery of claim 13, wherein the first planar surface of a segment of the midsection faces the first planar surface of the first bend, and wherein the first planar surface of another segment of the midsection faces the first planar surface of the second bend.

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