Power battery assembly

Abstract

Provided is a power battery assembly including: a battery cell having a positive terminal and a negative terminal; the electronic unit comprises a measuring device and a wireless transmitter; a support structure configured to be attached to the battery cell and arranged to receive the electronic unit, the support structure comprising at least one conductive element arranged to electrically couple the electronic unit to the positive terminal and the negative terminal, the power supply device supplies power to the wireless transmitter and the measuring device; and wherein the measurement device is configured to measure a property of the battery cell, and the wireless transmitter is configured to wirelessly transmit the measured property.

Description

[0001] This application is a divisional application of the Chinese invention patent application with application date of January 13, 2020, application number 2020800204572, and invention name “Power Battery Assembly”. Technical Field

[0002] The invention relates to an electric power battery assembly comprising a battery cell and an electronic unit comprising a measuring device for measuring a property of the battery cell. The invention also relates to a method of forming and operating such an electric power battery assembly. Summary of the invention

[0003] According to one aspect of the invention, there is provided an electric battery assembly, comprising: a battery cell having a positive terminal and a negative terminal; an electronic unit including a measuring device and a wireless transmitter; a support structure for attachment to the battery cell and arranged to accommodate the electronic unit, the support structure comprising at least one conductive element, the at least one conductive element being arranged to electrically couple the electronic unit to the positive terminal and the negative terminal, thereby providing power to the wireless transmitter and the measuring device; and wherein the measuring device is configured to measure a property of the battery cell, and the wireless transmitter is configured to wirelessly transmit the measured property. The measuring device of the electronic unit may be configured to measure a property of a prismatic battery cell, such as current, voltage or temperature, and the wireless transmitter may be configured to wirelessly transmit the measured property. Advantageously, the support structure may be retrofitted to a separate battery cell after manufacture without requiring any modification to the existing manufacturing process of the battery cell. Furthermore, in some embodiments, two or more battery assemblies may be combined to form a battery, which may be interchangeably referred to as a battery pack, wherein each battery cell is associated with an electronic unit including a measuring device and a wireless transmitter. In this way, the individual properties of each battery cell included in the battery pack can be measured. The battery management system (BMS) can use the measured battery cell information to control the operation of the individual battery cells. In some embodiments, the support structure can be attached to two or more battery cells. In such an embodiment, the electronic unit, specifically the measuring device, can be configured to measure the properties of the two or more battery cells to which the support structure is attached. Alternatively, the support structure may include two or more electronic units, each of which includes a measuring device configured to measure the properties of a different battery cell in the multiple battery cells to which the support structure is attached. In another embodiment, it is envisioned that the electronic unit may include two or more measuring devices, each of which is configured to measure the properties of different battery cells. The electronic unit may include a single wireless transmitter configured to wirelessly transmit the measured properties measured by each of the two or more measuring devices. In order to facilitate the receiving device (e.g., BMS) to identify the battery cell associated with the received measured properties, a unique identifier may be associated with each data transmission from the wireless transmitter. The unique identifier enables unique identification of a specific battery cell associated with the measured property. This facilitates the management of individual battery cells.

[0004] According to some embodiments, the wireless transmitter is a near field communication (NFC) device configured for short-range communication. The signal transmitted by the wireless transmitter complies with the relevant NFC standard, details of which are known in the art. Using an NFC device as a wireless transmitter helps to reduce the risk of signal interference between different battery assemblies that are in close proximity. In the case where multiple battery assemblies are combined together in a battery pack (where multiple wireless transmitters send measurement data very close to each other), reducing signal interference is particularly important. In such applications, there is a significant risk of signal interference. The use of short-range communication signals mitigates this interference. In addition, the use of short-range communication signals improves security and reduces the risk of unauthorized third parties accessing the transmitted data signals.

[0005] In some embodiments, the support structure may be removably attached to the battery unit. This may be advantageous for maintenance purposes, where access to the battery unit is required for maintenance purposes, and / or where access to the support structure and / or the electronic unit is required for maintenance reasons.

[0006] The support structure may include a bracket formed toward a first end and a second end thereof. The bracket may define a support surface between the first end and the second end, and the support surface may be configured to at least partially secure the electronic unit within the bracket. The battery assembly may include a cover. The cover and the bracket may have cooperating surface profiles that attach the cover to the bracket to enclose the electronic unit and thereby limit movement of the electronic unit relative to the surface of the battery cell. This configuration of the bracket and the cover provides an advantageous mechanism for accommodating the electronic unit while enabling access to the electronic unit. This is advantageous for maintenance purposes.

[0007] According to certain embodiments, the power battery assembly may include a cylindrical battery cell. The positive terminal and the negative terminal may be located on opposite end faces of the cylindrical battery cell, and the support structure may be located on the cylindrical surface of the battery cell. The support structure may extend in one direction along at least a portion of the height of the cylindrical battery cell. In particular, the length of the support structure may extend in a direction parallel to the height of the cylindrical battery cell. The support structure may include a contact surface configured to contact the cylindrical surface of the cylindrical battery cell. The contact surface may have a surface profile complementary to the profile of the cylindrical surface of the cylindrical battery cell. This results in improved ergonomic attachment of the support structure to the cylindrical battery cell. In some embodiments, the contact surface profile may be arc-shaped. In some embodiments, the width of the support structure may extend in a plane orthogonal to the longitudinal axis of symmetry of the cylindrical battery cell. The cross-section of the cylindrical battery may be taken in a direction orthogonal to the longitudinal axis of symmetry, and the width of the support structure may extend along a portion of the circumference of the circular cross-section of the cylindrical battery cell, forming an arc length relative to the central angle θ of the circular cross-section, the angle θ being less than 90°. The central angle θ is centered about the center of the circular cross section. Advantageously, this enables two or more battery assemblies comprising cylindrical cells to be combined and arranged so that the support structures of each assembly do not interfere with each other.

[0008] According to some embodiments, the contact surface may include an attachment member for attaching the support structure to the cylindrical surface of the cylindrical battery cell. The attachment member may include a fastener. The attachment member may include an adhesive that enables the support structure to be attached to the cylindrical surface of the cylindrical battery cell. In some embodiments, the adhesive may enable the support structure to be repeatedly removed and reattached to the cylindrical support surface.

[0009] In some embodiments, the support structure may include gripping arms extending outwardly from the support structure and arranged to grip the positive and negative terminals of the cylindrical battery cell, thereby attaching the support structure to the cylindrical battery cell by forming an interference fit with the terminals of the cylindrical battery cell. The gripping arms may be configured at a distal end of the support structure.

[0010] In some embodiments, the gripping arms can be configured to extend in a plane orthogonal to the length of the support structure to facilitate gripping of the battery terminals.

[0011] In some embodiments, the power battery assembly may include a prismatic battery cell. The positive terminal and the negative terminal may protrude from the end face at positions spaced apart on the same end face of the prismatic battery cell. The end face of the prismatic battery cell may be substantially flat. The positive terminal and the negative terminal may be positioned on the end face toward opposite sides of the prismatic battery cell. The positive terminal and the negative terminal may protrude from the flat end face of the prismatic battery cell. The cross-sections of the positive terminal and the negative terminal may be rectangular or circular. The inter-terminal space may be defined and defined between the positive terminal and the negative terminal in a direction across the end face, and defined between the end face of the prismatic battery cell and the distal surfaces of the positive terminal and the negative terminal in a direction orthogonal to the end face.

[0012] The first end and the second end of the bracket can be configured to be attached to the positive terminal and the negative terminal of the prismatic battery cell, respectively. The bracket defines a support surface between the first end and the second end, and the electronic unit can be supported on the support surface. The support surface can be received in the inter-terminal space. The electronic unit can be electrically connected to each of the positive terminal and the negative terminal to provide power for the wireless transmitter. According to some embodiments in which the battery cell includes a prismatic battery cell, when the cover is attached to the bracket, the bracket and the cover enclose the electronic unit, thereby limiting the movement of the electronic unit across the end face of the prismatic battery cell and the movement in a direction orthogonal to the end face. The movement of the electronic unit across the end face is limited in a direction orthogonal to the direction in which the positive terminal and the negative terminal are separated across the end face: a direction orthogonal to the direction in which the positive terminal and the negative terminal are separated across the end face; and in the direction in which the positive terminal and the negative terminal are separated across the end face.

[0013] The bracket and the cover can cooperate to hold the electronic unit in the inter-terminal space and limit the movement of the electronic unit relative to the prismatic battery cell. Thus, the electronic unit can be held relative to the prismatic battery cell on which it operates. In addition, and as described below, the electronic unit can be held to provide improved operation of the electronic unit itself and to provide improved operation of the electronic unit using additional electronic devices that wirelessly communicate with the electronic unit. In addition, the electronic unit can be attached to the prismatic battery cell without modifying the prismatic battery cell itself. In addition, the position of the electronic unit in the inter-terminal space can minimize the extent to which the occupied space of the prismatic battery cell is increased. Therefore, it is easy to accommodate power battery assemblies in larger battery structures (for example, in electric vehicles or in battery packs).

[0014] In certain embodiments, when the support structure is attached to the prismatic battery cell, the bracket may not extend above the positive and negative terminals. An exception to this may be with respect to portions of the surface profile that protrude beyond the distal ends of the positive and negative terminals and define a surface profile that engages with a cooperating surface profile of the cover. Thus, the extent to which the footprint of the prismatic battery cell is increased by the support structure is minimized.

[0015] In certain embodiments, when the support structure is attached to the prismatic battery cell, the bracket may not extend beyond the perimeter of the end face of the prismatic battery cell from which the positive and negative terminals protrude. Thus, the footprint of the prismatic battery cell may not increase beyond the perimeter of the end face, whereby the prismatic battery cell with the support structure attached may be accommodated in a space sufficient to accommodate a prismatic battery cell without the support structure.

[0016] Each of the first and second ends of the bracket can be shaped to fit around a respective one of the positive and negative terminals of the prismatic battery cell. More specifically, each of the first and second ends of the bracket can define a hole, and more specifically define a closed hole through which the respective one of the positive and negative terminals extends. The hole can be defined by a boundary wall. The boundary wall can extend no further than the distal end of the terminal.

[0017] According to some embodiments, each of the first and second ends of the bracket can define a profile that interlocks with a profile defined by a corresponding one of the positive terminal and the negative terminal. This interlock provides resistance to removing the bracket from the terminal. Wherein the profile defined by the terminal includes a recess, such as a recess toward the base of the terminal, the profile defined by the end of the bracket can be shaped to be received in the recess in the terminal. The end of the bracket can be shaped to provide a snap-fit ​​attachment to the terminal.

[0018] The support may include a support base defining a support surface for supporting the electronic unit. The shaped first and second ends of the support may extend from opposite ends of the support base. The support base may define a vent aperture therethrough that aligns with a vent in an end face of the prismatic battery cell when the support is attached to the prismatic battery cell. Prismatic battery cells typically have vents to allow the prismatic battery cell to be decompressed in the event of a prismatic battery cell failure, which causes an increase in pressure inside the prismatic battery cell. The vent aperture in the support base allows the vent in the prismatic battery cell to function by assisting ventilation. In addition, the support base presents a continuous surface to the end face of the prismatic battery cell.

[0019] In some embodiments, the support may further include a first wall and a second wall extending upward from respective opposite edges of the support base, and such that each of the first wall and the second wall extends between the positive terminal and the negative terminal. The height of the first wall and the second wall may be such that their distal ends extend no further than the distal ends of the positive terminal and the negative terminal. In an embodiment in which the terminal receiving hole is defined by a boundary wall, as described above, the boundary wall may be substantially the same height as the first wall and the second wall. The support base and the first wall and the second wall may define a support space for receiving an electronic unit. The electronic unit may be shaped so that it is a snug fit between the first wall and the second wall. Thus, the movement of the electronic unit across the end face of the prismatic battery cell may be limited in a direction orthogonal to the direction of separation of the positive terminal and the negative terminal.

[0020] In some embodiments, the bracket may further include a transverse wall extending upward from the bracket base and extending between the first wall and the second wall. The transverse wall may be spaced apart from an end of the bracket base adjacent to the first or second end of the bracket. The transverse wall may provide an obstacle to the movement of the electronic unit across the end face of the prismatic battery cell in the direction of separation of the positive terminal and the negative terminal. Therefore, the first wall, the second wall and the transverse wall may limit the movement of the electronic unit across the end face in two mutually orthogonal directions. In the case where the terminal receiving hole is defined by a boundary wall, as described above, the boundary wall may provide a further obstacle to the movement of the electronic unit across the end face in the direction of separation of the positive terminal and the negative terminal.

[0021] As described above, the electronics unit can be electrically coupled to each of the positive terminal and the negative terminal via at least one conductive element to provide power to the wireless transmitter and the measuring device. In some embodiments, the at least one conductive element can include a first electrical conductor and a second electrical conductor extending from the electronics unit, the first electrical conductor and the second electrical conductor providing electrical conduction from the positive conductor and the negative conductor, respectively. In some embodiments, the first electrical conductor and the second electrical conductor can extend from opposite ends of the electronics unit.

[0022] In some embodiments, when housing the electronics unit, the support structure may define a formation that holds the first electrical conductor and the second electrical conductor.

[0023] The first electrical conductor and the second electrical conductor may be electrically coupled to the positive terminal and the negative terminal by different means. According to some embodiments, the distal end of at least one of the first electrical conductor and the second electrical conductor may include a wire terminal located above a corresponding one of the positive terminal and the negative terminal. In some embodiments, the wire terminal may be welded to the terminal. In some embodiments, the wire terminal may only be in contact with the terminal without being welded to the terminal. In use, the wire terminal may be clamped between the terminal and a busbar, whereby power may be drawn from the terminal by the electronic unit.

[0024] According to one embodiment, each of the first electrical conductor and the second electrical conductor can be electrically coupled to a conductive fastener that is fastened to the terminal. The conductive fastener can be located at a distal end of each of the first electrical conductor and the second electrical conductor. The conductive fastener can be shaped to fit around the terminal, and the cross-section of the terminal can be rectangular or circular. In addition, the conductive fastener can define teeth that abut against the terminal in use. The shape and size of the conductive fastener can be set to provide an interference fit with the terminal, thereby forming a good conductive path from the terminal.

[0025] According to one embodiment, the conductive fastener may form a part of the bracket and, in addition to providing electrical conduction, may attach the bracket to the positive terminal and the negative terminal. As described above, each of the first end and the second end of the bracket may define a profile that interlocks with a profile defined by a corresponding one of the positive terminal and the negative terminal. According to some embodiments, each conductive fastener may be included in a corresponding one of the first end and the second end of the bracket and may define a profile that interlocks with a profile defined by a corresponding one of the positive terminal and the negative terminal. The bracket may be formed, for example, of a plastic material as described below, wherein the conductive fastener is assembled to the bracket after it is formed. Alternatively, the conductive fastener may be incorporated into the bracket during the formation of the bracket. In some embodiments, the electronic unit may be electrically connected to the conductive fastener of the bracket by welding or soldering each first electrical conductor and the second electrical conductor to a corresponding one of the two conductive fasteners.

[0026] According to some embodiments, the cover may have such a size that when it is attached to the bracket, the cover does not extend beyond the periphery of the end face of the prismatic battery cell from which the positive terminal and the negative terminal protrude. Therefore, the occupied space of the prismatic battery cell may not be increased beyond the end face, whereby the prismatic battery cell with the cover attached may be accommodated in a space sufficient to accommodate a prismatic battery cell without the cover.

[0027] In some embodiments, the cover can be sized so that when it is attached to the holder, the cover extends to the positive terminal at a first end and to the negative terminal at an opposite second end. Thus, the positive and negative terminals may not be covered by the cover, whereby the positive and negative terminals may be electrically coupled to a busbar or the like. In addition, the cover may cover the holder space except for at least one hole extending through the cover to allow the vent of the prismatic battery cell to function.

[0028] As described above, the cover and the bracket may have cooperating surface profiles for attaching the cover to the bracket. The surface profile in the cover may be defined by holes toward the periphery of the cover and shaped to receive corresponding protrusions extending upward from the bracket. Each hole and corresponding protrusion may interlock to provide a snap-fit ​​attachment of the cover to the bracket.

[0029] In some embodiments, the cover may define a first surface facing the support when the cover is attached to the support and a second flat surface away from the support when the cover is attached to the support. At least one antenna formation may be defined on the second flat surface. The antenna formation may be shaped to hold an antenna for wireless communication with a wireless transmitter of the electronic unit. The antenna may be included in the battery assembly. The wireless transmitter may include an electronic unit antenna. Therefore, the support and the cover may cooperate to hold the electronic unit and provide a suitable relative arrangement of the wireless transmitter and the antenna held by the cover in the antenna formation. The antenna formation may define a slot for receiving the antenna. In some embodiments, the slot may extend across the cover in a direction orthogonal to the separation direction of the positive terminal and the negative terminal. In the presence of multiple power battery assemblies as described herein, the multiple power battery assemblies may be positioned adjacent to each other, whereby their antenna receiving slots may be aligned, whereby a single antenna (such as a transmission line that may work as an antenna) may be received in these slots, so that the single antenna extends over the multiple power battery assemblies. Therefore, the cover of each of the power battery assemblies may provide wireless communication between each wireless transmitter and the single antenna, and provide a suitable arrangement of the single antenna relative to each wireless transmitter in terms of separation, isolation, and orientation.

[0030] The electronic unit may include a printed circuit board, more particularly a rigid printed circuit board. In some embodiments, the printed circuit board may be flexible. The wireless transmitter may consist of electronic components mounted on the printed circuit board. Further electronic components may be mounted on the printed circuit board. Such further electronic components may form at least a part of the measuring device and may include similar components of a microprocessor.

[0031] According to some embodiments, the support structure may be integrally formed of a plastic material, such as polypropylene, which may be glass filled to an extent of 10%-20%.The cover may be integrally formed of a plastic material, such as polypropylene.

[0032] The battery cell may include a container, more specifically a rigid container. In those embodiments including prismatic battery cells, the container may include one or more pouch cells. In the case where the container includes a plurality of pouch cells, the positive terminals of the plurality of pouch cells may be electrically connected, and the negative terminals of the plurality of pouch cells may be electrically connected. In those embodiments including prismatic battery cells, the container may be generally, and more specifically substantially, a rectangular cuboid form. The container may define a first end face and a second end face oriented oppositely and a side extending between the first end face and the second end face and extending around the container. The positive terminal and the negative terminal may protrude from one and the same of the first end face and the second end face. In the case where the container is in the form of a cuboid and more specifically in the form of a rectangular cuboid, the side may include a first side surface to a fourth side surface, wherein the first surface and the third surface are oriented oppositely, and the second surface and the fourth surface are oriented oppositely. The first surface and the third surface may be much larger than the second surface and the fourth surface. In those embodiments including cylindrical battery cells, the container is cylindrical in shape, including a cylindrical surface having two end faces, each end face representing a different one of a positive battery terminal or a negative battery terminal. The two end faces are generally arranged in parallel with the cylindrical surface extending longitudinally between them.

[0033] The battery cell may include at least one electrochemical arrangement. The electrochemical arrangement may include a lithium ion electrochemical arrangement, more specifically, a lithium ion polymer electrochemical arrangement. In the case where the battery cell includes a prismatic battery cell, the at least one electrochemical arrangement may each be contained within a pouch cell container, more specifically, a sealed pouch cell container, which may be flexible, thereby allowing expansion of the pouch cell container.

[0034] According to another aspect of the invention, an electric vehicle is provided, which includes at least one power battery assembly according to the above aspect of the invention and any one or more embodiments thereof, and an electric motor that drives the electric vehicle based on power received from the at least one power battery assembly.

[0035] According to another aspect of the invention, there is provided a fixed or portable generator, such as an uninterruptible power supply, comprising at least one power battery assembly according to the above aspects of the invention and any one of its multiple embodiments, and a charger input for charging the at least one power battery assembly.

[0036] According to another aspect of the present invention, there is provided a method for forming and operating an electric power battery assembly, the electric power battery assembly comprising a battery cell having a positive terminal and a negative terminal, an electronic unit comprising a measuring device and a wireless transmitter, and a support structure configured to be attached to the battery cell, the method comprising: attaching the support structure to the battery cell via a first end and a second end of the support structure, the support structure being formed to be attached to the positive terminal and the negative terminal, respectively; supporting the electronic unit on a support surface defined by the support structure between the first end and the second end, the electronic unit being electrically connected to each of the positive terminal and the negative terminal when so supported, thereby providing power to the wireless transmitter and the measuring device; measuring properties of the battery cell with the measuring device; and wirelessly transmitting the measured properties via the wireless transmitter.

[0037] In some embodiments, the support structure may include a bracket formed toward a first end and a second end thereof, the bracket defining a support surface between the first end and the second end, and the method may include: attaching a cover to the bracket via cooperative surface contours of the cover and the bracket to enclose the electronic unit and thereby limit movement of the electronic unit relative to a surface of the battery cell.

[0038] Embodiments of any aspect of the invention may include one or more features of the other aspects of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Other features and advantages of the present invention will become apparent from the following detailed description, given by way of example only and with reference to the accompanying drawings, in which:

[0040] Figure 1 is an exploded perspective view of a power battery assembly according to one embodiment wherein an electronics unit is attached to a prismatic battery cell via a removable support structure;

[0041] Figure 2 A removable support structure with a power battery assembly attached Figure 1 A perspective view of a prismatic battery cell;

[0042] Figure 3A is an illustration of a prismatic battery cell with a removable support structure attached and an electronics unit in place on the support structure;

[0043] Figure 3B It is around Figure 3A A detailed view of one terminal of an arrangement of prismatic battery cells;

[0044] Figure 4A shows how electrical connections are made between the terminals of a prismatic battery cell and an electronic unit according to one embodiment;

[0045] Figure 4Bshows how to make electrical connections between round terminals of a prismatic battery cell and an electronic unit according to another embodiment;

[0046] Figure 4C shows how to make electrical connections between terminals and electronic units according to yet another embodiment;

[0047] Figure 5 A prismatic battery cell is shown with a cover of a power cell assembly attached to a support structure;

[0048] Fig. 6A is a perspective view of a power cell assembly according to one embodiment, wherein an electronics unit is attached to a cylindrical cell via a removable support structure;

[0049] Figure 6B yes Fig. 6A An exploded perspective view of a battery assembly;

[0050] Figure 6C yes Fig. 6A A cross-sectional view of a battery assembly taken on a plane orthogonal to a longitudinal axis of the battery cell;

[0051] Fig. 7A is a perspective view of a battery assembly including a plurality of cylindrical battery cells;

[0052] Figure 7B yes Fig. 7A A plan perspective view of a battery assembly; and

[0053] Figure 8 is a perspective view of a battery including a plurality of cylindrical battery cells sharing a single support structure according to one embodiment. DETAILED DESCRIPTION

[0054] The present inventors have designed a power battery that may include a plurality of power battery cells and a plurality of electronic units, wherein each of the plurality of electronic units measures the properties of a corresponding one of the plurality of power battery cells. In such a power battery, it is desirable to attach each electronic unit to the power battery cell on which it operates. Furthermore, it is desirable to attach each electronic unit to its corresponding power battery cell in a manner that provides for the correct operation of the electronic unit while reducing the impact on the ease of use of the power battery cell. Moreover, it is desirable to attach each electronic unit to its corresponding power battery cell without changing the power battery cell.

[0055] Therefore, it is an object of at least some of the embodiments disclosed herein to provide a power battery assembly comprising a battery cell and an electronic unit, the electronic unit comprising a measuring device for measuring a property of the battery cell, wherein the electronic unit is attached to the battery cell. Another object of at least some of the embodiments disclosed herein is to provide a method of forming and operating such a power battery assembly.

[0056] According to an embodiment of the invention, a support structure for attaching to a battery cell is provided. The support structure may be configured to be removable and retrofittable to the battery cell. The support structure may be configured to accommodate an electronic unit and include at least one conductive element arranged to electrically couple the electronic unit to the positive terminal and the negative terminal of the power battery cell, so that power can be provided to the electronic unit. The electronic unit includes a measuring device configured to measure the properties of the battery cell and a wireless transmitter configured to wirelessly transmit the measured properties. The wireless transmitter may include a near field communication (NFC) device configured for short-range wireless communication. Since the operating characteristics of NFC devices are well known in the art, further details are not provided herein, except that the wireless transmitter complies with all relevant NFC operating standards. The use of near field communication reduces the risk of signal interference between wireless transmitters that are located very close to each other.

[0057] The removable support structure may include different ways of attaching itself to the battery cell, which may depend on the form factor of the battery cell. Specifically, according to certain embodiments, the support structure may be configured with components for attaching to a battery cell having a prismatic form factor, which is generally referred to in the art as a prismatic battery cell. Similarly, in alternative embodiments, the support structure may be configured with components for attaching to a cylindrical battery cell. In the context of the present disclosure, the terms prismatic and cylindrical refer only to the geometry of the battery cell as dictated by its housing, and not to its internal chemistry.

[0058] To facilitate the reader's understanding of the present invention, embodiments in which the support structure is configured to be attached to a prismatic battery cell and a cylindrical battery cell will be described in turn. In both cases, reducing the impact of the attachment of the support structure on the occupied space of the battery cell helps to minimize the impact on the existing occupied space of the battery cell. In this context, the term battery occupied space is used to represent the volume of the space occupied by the battery cell. Reducing the impact of the attachment of the support structure on the occupied space of the battery cell helps to ensure that the support structure is retrofittable and can be incorporated into existing applications of the battery cell. In particular, the disclosed support structure does not provide any geometric and / or volume barriers to combining multiple battery cells together to form a battery or battery pack. This is achieved by positioning the support structure in the spatial volume of the adjacent battery cell, which does not have any substantial impact on the existing useful geometric occupied space of the battery cell. For example, with respect to a prismatic battery cell including spaced positive and negative terminals extending from a shared battery surface, such a spatial volume can be defined between the terminals. Further details according to this embodiment are given below. In most practical applications, the space between the terminals of the prismatic battery cell is not used for any purpose. In particular, this space is not used when multiple prismatic battery cells are packaged together to form a battery pack. Therefore, by positioning the support structure in this spatial volume, the ability to combine prismatic battery cells together is not affected. With respect to cylindrical battery cells, a similar effect can be achieved by positioning the support structure on a portion of the cylindrical surface so that the support structure is positioned in the gap formed between adjacent cylindrical cells when multiple cylindrical cells are combined to form a battery pack. Again, further details of this embodiment are also disclosed below. Another advantage of the embodiments disclosed herein is that no modification to the existing battery cell manufacturing process is required to accommodate the support structure.

[0059] Figure 1An exploded view of a power battery assembly 10 according to an embodiment of the invention is shown. The power battery assembly includes a prismatic battery cell 12, a support structure 14, an electronic unit 16, and a cover 18. The support structure 14 may be shaped like a bracket and will be interchangeably referred to simply as the bracket 14 in the subsequent description. Bracket forming means that the support structure includes a spatial volume, such as a recess, suitable for receiving the electronic unit 16. The prismatic battery cell 12 has a known form and function and thus includes a rigid container that can accommodate a plurality of soft-pack batteries, each of which can include a lithium-ion polymer electrochemical arrangement. The positive terminals of the plurality of soft-pack batteries can be connected together and led out to the positive terminal 20 of the prismatic battery cell, and the negative terminals of the plurality of soft-pack batteries can be connected together and led out to the negative terminal 20 of the prismatic battery cell. The positive and negative terminals 20 protrude upward from the same end surface of the prismatic battery cell 12. An inter-terminal space is defined and delimited between the positive and negative terminals 20 in a direction across the end faces and between the end faces of the prismatic battery cell and the distal sides of the positive and negative terminals in a direction orthogonal to the end faces. A vent 22 may be provided in the end faces of the prismatic battery cell 12 between the positive and negative terminals 20. In summary, the bracket 14 is attached to the prismatic battery cell 12 and the electronic unit 16 is placed on the bracket 14. The electronic unit 16 is electrically coupled to the positive and negative terminals 20. The cover 18 may be attached to the bracket 14 such that the electronic unit 16 is enclosed between the cover and the bracket.

[0060] A perspective view of a prismatic battery cell 12 with a holder 14 of an electronic battery assembly attached is shown in FIG. Figure 2 . The bracket includes a bracket base 32 that defines a support surface 34 that supports the electronic unit 16. The bracket base 32 defines a vent 36 therethrough, which can be aligned with the vent 22 in the end surface of the prismatic battery cell 12 to assist in venting the prismatic battery cell. The bracket 14 can also include first and second walls 38 that extend upward from respective opposite edges of the bracket base 32 and such that each of the first and second walls extends between the positive and negative terminals 20. The height of the first and second walls 38 is such that their distal ends extend no further than the distal ends of the positive and negative terminals 20. The bracket 14 can also include a transverse wall 40 extending upward from the bracket base 32 and extending between the first and second walls 38. The transverse wall 40 can be spaced apart from each end of the bracket base 32.

[0061] Each of the first and second ends of the bracket 14 can be shaped to fit around a corresponding one of the positive and negative terminals 20. Further considering the first and second ends of the bracket 14, each of the first and second ends of the bracket can define a hole through which a corresponding one of the positive and negative terminals can extend. The hole is defined by a boundary wall 42, the height of which is such that it does not extend beyond the distal end of the terminal 20 and is the same as the first and second walls 38. The bracket base 32, the first and second walls 38, and a portion of the boundary wall 42 at each of the first and second ends define a recess, equivalently referred to as a bracket space, for receiving the electronic unit 16. In addition, as can be clearly seen from the following description, a portion of the boundary wall 42 at one of the first and second ends and the lateral wall 40 constitute an obstacle to the movement of the electronic unit 16 across the end face of the prismatic battery cell in the separation direction of the positive and negative terminals 20.

[0062] A view of a prismatic battery cell 12 with a bracket 14 attached and an electronic unit 16 in place on the bracket is shown in FIG. Figure 3A The electronic unit 16 includes a measuring device and a wireless transmitter, which are composed of electronic components mounted on a rigid printed circuit board 44. The measuring device of the electronic unit is configured to measure the properties of the prismatic battery cell, such as current, voltage or temperature, and the wireless transmitter transmits the measured properties wirelessly. For example, in some embodiments, the measured properties can be transmitted wirelessly to a battery management system (BMS). According to some embodiments, the wireless transmitter is a near field communication (NFC) device configured for short-range communication. This helps to reduce interference between closely located wireless transmitters, which may occur when multiple battery assemblies (each of which includes a separate wireless transmitter) operate in close proximity, such as when operating in a battery including multiple battery assemblies. In such applications, it is necessary to reduce interference in order to ensure the faithful transmission of data. The measurement of current, voltage or temperature is performed in accordance with conventional practice. The form and function of the wireless transmitter may be as described in WO2018 / 002667A1, which is incorporated herein by reference. The printed circuit board 44 further includes a microprocessor and supporting circuits having conventional form and function. The microprocessor processes the measurements made by the measuring device and forms data packets for wireless transmission of the data from the electronics unit 16 .

[0063] like Figure 3AAs shown, the printed circuit board 44 is received in the support space defined by the support 14, and the printed circuit board is a snug fit between the first and second walls 38 and between a portion of the boundary wall 42 at one end of the support and the lateral wall 40. Therefore, the movement of the electronic unit 16 across the end face of the prismatic battery cell 12 is restricted in two mutually orthogonal directions. The first and second electrical conductors 46 extend from opposite ends of the printed circuit board 44. The support 14 can define first and second configurations for holding the first electrical conductor and the second electrical conductor, respectively. Each of the first and second configurations has the form of a simple beam 48, which is spaced apart from the support base 32 and is supported by the first or second wall 38 at the first end and supported by the support base at the second end. The electrical conductor 46 can be assembled below the simple beam 48 to hold the electrical conductor in place and guide it toward its corresponding terminal 20.

[0064] Figure 3A A detailed view of the arrangement of one of the terminals of a prismatic battery cell is shown in Figure 3B In. From Figure 3B As can be seen, the boundary wall 42 defines a lip 50 on its inner surface and at its lower edge. In addition, the terminal 20 defines a recess 52 around its perimeter and toward its base. The bracket 14 is attached to the prismatic cell 12 by positioning the bracket 14 on the prismatic cell 12 so that the positive and negative terminals 20 are received through corresponding holes defined by the boundary wall 42. The bracket 14 is then pressed down against the resistance presented by the lip 50 to their respective terminals 20 until the lip is received in the recess 52 in the terminal 20. Thus, the lip 50 and the recess 52 provide a snap fit that attaches the bracket 14 to the prismatic cell 12.

[0065] The first and second electrical conductors 46 may be electrically coupled to the positive and negative terminals 20 by one of a variety of means. Figure 3B and Figure 4A (It is Figure 3B 180 degrees), and according to one embodiment, the distal end of each of the first and second electrical conductors 46 includes a lead terminal 54 located above and in contact with a corresponding one of the positive and negative terminals 20. In order to keep the electrical conductors 46 in contact with the corresponding terminals 20, the lead terminals 54 can be welded to the terminals 20. In use, when the power battery assembly is electrically connected to an external device, the lead terminals 54 can be sandwiched between the terminals 20 and the busbar. When both the first and second electrical conductors 46 are electrically connected to the positive and negative terminals 20, power for the electronic unit 16 is drawn from the prismatic battery cell 12 through the positive and negative terminals 20.

[0066] It should be understood that the use of welding represents a non-limiting way to maintain the electrical conductors in contact with the respective terminals. Alternative means for maintaining the electrical conductors in contact with the respective terminals are also contemplated. For example, with reference to Figure 4B According to another embodiment, a conductive fastener 62 may be provided at the end of each of the first and second electrical conductors 46. The conductive fastener 62 is shaped to fit around the terminal 20 and maintain contact with the terminal 20. This can be achieved by sizing the conductive fastener 20 to be complementary in shape and size to the cross-sectional shape and size of the terminal 2 so that an interference fit can be formed with the terminal 20 when the conductive fastener 62 is placed around the terminal 20. The cross-section of the terminal 20 may be rectangular or circular, but other cross-sectional shapes are also contemplated. In certain embodiments where the terminal 20 has a circular cross-section, the conductive fastener 62 may include a push-on fixing washer, such as a push-on fixing washer provided by Springmasters Ltd. of Arthur Street, Redditch, B98 8LF, United Kingdom. In certain embodiments, the conductive fastener 62 for a terminal of rectangular or circular cross-section may define teeth that abut against the terminal 20 in use, wherein the conductive fastener is shaped and sized to provide an interference fit with the terminal 20, thereby forming a good conductive path from the terminal.

[0067] According to another embodiment, and with reference to Figure 4C In addition to providing electrical conduction, the conductive fasteners 72 may form part of the bracket 14 and attach the bracket to the positive and negative terminals 20. Figure 3B As described in the embodiment of the present invention, the lip 50 defined by the boundary wall 42 interlocks with the recess 52 in the positive and negative terminals 20. According to the present embodiment, each conductive fastener 72 can be included in a corresponding one of the first end and the second end of the bracket 14 and defines a protrusion that interlocks with the recess 52 in the corresponding one of the positive terminal and the negative terminal. Figure 4C The bracket 14 can be used in the same manner as described above with reference to the aforementioned embodiments (particularly with reference to Figure 3A The electronic unit 16 can be attached to the prismatic battery cell 12 in the same manner as described in the embodiment of the present invention, whereby the protrusion defined by the conductive fastener 72 provides a snap fit with the recess 52 in the positive and negative terminals 20. The bracket 14 can be formed, for example, by molding from a plastic material as described below, wherein the conductive fastener 72 is assembled to the bracket after it is formed. Alternatively, the conductive fastener 72 can be incorporated into the bracket during molding of the bracket. The electronic unit 16 can be electrically coupled to the conductive fastener of the bracket by welding or soldering each first electrical conductor and second electrical conductor to the exposed portion 74 of a corresponding one of the two conductive fasteners 72.

[0068] According to one embodiment, a prismatic battery cell 12 having a cover 18 of a power cell assembly attached to a support is provided. Figure 5 . The cover 18 can be sized such that when it is attached to the bracket 14, the cover extends no further than the perimeter of the end faces of the prismatic battery cell 12 and above the first and second walls 38. In addition, the cover 18 can be sized such that when it is attached to the bracket 14, the cover extends to the positive terminal at a first end and to the negative terminal at an opposite second end. Thus, the positive and negative terminals 20 are not covered by the cover 18, whereby the positive and negative terminals can be electrically coupled to a busbar or the like. In the interim, the cover 18 can be configured to cover the bracket space except for at least one hole 82 extending through the cover to allow the vent 22 of the prismatic battery cell 12 to function.

[0069] The cover 18 and the bracket 14 may include cooperating surface profiles that attach the cover to the bracket. The surface profile in the cover 18 is defined by holes 84 that face the periphery of the cover and are shaped to receive corresponding protrusions 86 included in and extending upward from the bracket. Each hole 84 and the corresponding protrusion 86 interlock to provide a snap-fit ​​attachment of the cover to the bracket. The cover 18 defines a first surface facing the bracket when the cover is attached to the bracket 14 and a second flat surface 88 away from the bracket when the cover is attached to the bracket. Two parallel grooves 90 are defined on the second flat surface 88. The grooves 90 extend across the cover in a direction orthogonal to the separation direction of the positive and negative terminals 20. Each groove 90 receives and holds a corresponding cable of a dual cable antenna (not shown). In use, the dual cable antenna wirelessly communicates with the electronic unit antenna contained in the wireless transmitter of the electronic unit 16.

[0070] According to some embodiments, the support may be integrally formed from 10%-20% glass filled polypropylene. The cover may be integrally formed from polypropylene.

[0071] As previously mentioned, according to alternative embodiments, the support structure 100 may be configured to be attached to a cylindrical battery cell 102, such as Fig. 6A 103. Unlike prismatic battery cells, the terminals of cylindrical battery cells are included on opposite end surfaces of the cylindrical battery cells. Figure 6B yes Fig. 6A102 is an exploded perspective view of a battery assembly 103 of the embodiment. The support structure 100 of the present embodiment can be bracket-shaped as in the previously described embodiments, and as with the previously described embodiments, will be interchangeably referred to as a bracket. A significant difference between the bracket 100 of the present embodiment and the previously disclosed embodiments is that each of the first and second ends of the bracket includes a gripping arm 104, which is arranged to grip a corresponding one of the positive and negative terminals 106 of the cylindrical battery cell so that the bracket 100 can be attached to the cylindrical battery cell 102. The bracket 100 is arranged to support the electronic unit 16 in substantially the same manner as previously described with respect to the previous embodiments.

[0072] It should be understood that, unless otherwise noted, support structures contemplated for use with cylindrical battery cells share the same features as previously disclosed support structures described for use with prismatic battery cells. For example, the support structure may include a cover and antenna configuration as previously described. To avoid repetition, not all shared features will be described, but rather the following description of embodiments including cylindrical battery cells will focus on describing significant differences relative to prismatic battery cell embodiments.

[0073] According to some embodiments, the bracket 100 may include a contact surface that is arranged to contact at least a portion of the cylindrical surface 108 of the cylindrical battery cell 102 when attached to the battery cell 102. The contact surface may have a surface profile that is complementary to at least a portion of the profile of the cylindrical surface 108. In particular, the surface profile of the contact surface may include a radius of curvature that is complementary to the radius of curvature of the cylindrical surface 108 of the cylindrical battery cell 102. When attached to the cylindrical battery cell 102, the bracket 100 extends in one direction along at least a portion of the height of the battery cell, such as Fig. 6A shown.

[0074] Figure 6C yes Fig. 6A The cross-sectional plan view of the battery assembly 103 is taken from a plane orthogonal to the longitudinal axis z of the cylindrical battery cell 102. The longitudinal axis z is symmetrical to the longitudinal axis of the cylindrical battery cell 102. The contact surface 110 is Figure 6C . The width of the contact surface 110 defines an arc length that is proportional to the radius r of the cylindrical battery cell 102 and the angle θ. The angle θ represents the angle subtended by the arc length, which represents the width of the contact surface and is equivalent to the width of the bracket 100. According to an embodiment of the present disclosure, the width of the bracket 100 is selected to ensure that the angle θ it subtends is less than 90°. This helps to minimize any obstruction to other adjacent cylindrical battery cells when multiple cylindrical battery cells are combined into a battery pack.

[0075] like Fig. 6A and 6BAs shown, the gripping arms 104 extend in a direction orthogonal to the length of the support structure 100. According to some embodiments, the spacing distance d between the gripping arms 104 is selected to be Figure 6B ) to ensure that each gripping arm 104 grips its corresponding battery cell terminal 106 with sufficient force to form a tight interference fit with the terminal 106 of the cylindrical battery cell 102. One way this can be achieved is to size the spacing distance d to be slightly less than the height h of the cylindrical battery. The gripping arms 104 can be constructed of a material that allows the arms to bend somewhat. When the gripping arms 104 bend to fit around the corresponding battery terminal, the restoring force opposes the bending direction and helps ensure a tight interference fit with the corresponding terminal 106.

[0076] In alternative embodiments, it is contemplated that the support structure 100 may be provided with an attachment member for attaching the support structure 100 to the cylindrical surface 108 of the cylindrical battery cell 102. For example, one such attachment member may include an adhesive tape. The adhesive tape may be placed on the contact surface 110 so that the support structure 100 can be bonded to the cylindrical surface 108 of the battery cell 102. Alternative attachment members are also contemplated that enable the support structure 100 to be fixed to the cylindrical surface 108 of the battery cell 102.

[0077] As with previously disclosed embodiments, the support structure 100 may include at least one conductive element configured to electrically couple the electronic unit 16 to the battery cell terminal 106. Fig. 6A and 6B In the illustrated embodiment, the at least one conductive element includes first and second electrical conductors 110 extending from opposite ends of the electronic unit 16, and specifically from opposite ends of a printed circuit board included in the electronic unit 16, in a manner similar to that described in the previous embodiment. The first and second electrical conductors 110 extend to the gripping arms 104, and the gripping arms 104 are arranged so that at least a portion of the distal ends of the first and second electrical conductors 110 can make electrical contact with the corresponding battery terminals 106. In some embodiments, the distal ends of the first and second electrical conductors 110 can be located on the inner surface of the gripping arms 104 that contacts the corresponding battery terminals 106. In this way, the interference fit formed between the gripping arms 104 and the battery terminals also helps to establish an electrical connection between the first and second electrical conductors 104 and the battery terminals 106. For example, the gripping arms can each include a cavity (not shown) through which the first and second electrical conductors 110 can pass so that the distal ends of the first and second electrical conductors 110 can be located on the inner surface of the gripping arms 104. In certain embodiments, the gripping arm 104 may be provided with holes configured to receive distal ends of the first and second electrical conductors 104 and to establish electrical connections with corresponding battery terminals 106 through the holes.

[0078] Fig. 7A is a perspective view of a battery pack 112, interchangeably referred to simply as a battery, which includes Figures 6A-6C A plurality of battery assemblies 103 are shown. Figure 7B yes Fig. 7A 1. A plan view of a battery pack 112. Each battery assembly 103 includes a support structure 100 attached to a cylindrical battery cell 102. Fig. 7A and 7B It is easy to highlight how, by limiting the width of the support structure to an arc length subtended by an angle less than 90°, it is ensured that the battery assemblies 103 can be arranged relative to each other without causing the support structures 100 of adjacent assemblies to interfere with each other. This can be achieved by considering Figure 7B The illustrated gaps 114 are naturally formed between the cylindrical battery cells when the cylindrical battery cells are brought together and in contact on their cylindrical surfaces.

[0079] Figure 8 is an alternative configuration of the support structure 100 in which three different cylindrical battery cells 102 share the same support structure 116 to form a battery pack 115. One cylindrical battery cell 102 is shown as transparent so as to better enable the shape of the shared support structure 116 to be visible. In such an embodiment, it is contemplated that the shared support structure 116 may include a plurality of electronic units (not shown), each electronic unit being assigned to measure a property of a different one of the cylindrical battery cells attached to the shared support structure 116. Alternatively, it is contemplated that the shared support structure 116 may include a single electronic unit arranged to measure a property of each of the coupled cylindrical battery cells 102.

[0080] Although illustrative embodiments have been described herein, the scope of the present application includes any and all embodiments based on the present disclosure with equivalent elements, modifications, omissions, combinations (e.g., across various aspects of various embodiments), adaptations or changes. The elements described in the claims will be interpreted broadly based on the language used in the claims, without limitation to the examples described in this specification or during the application process, which will be interpreted as non-exclusive. In addition, the steps of the disclosed method can be modified in any way, including by reordering the steps in the insertion and deletion steps. Therefore, this specification and embodiments are considered to be embodiments only, and the true scope and spirit are indicated by the following claims and their full equivalent scope.

Claims

1. A power battery assembly, comprising: a cylindrical battery cell having a positive terminal and a negative terminal, the positive terminal and the negative terminal being located on opposite end faces of the cylindrical battery cell; an electronic unit comprising a measuring device and a wireless transmitter; a support structure configured for attachment to a cylindrical surface of the cylindrical battery cell and arranged to house the electronic unit, the support structure comprising at least one conductive element arranged to electrically couple the electronic unit to the positive terminal and the negative terminal, the at least one conductive element comprising a first electrical conductor and a second electrical conductor extending from opposite ends of the electronic unit, the first electrical conductor and the second electrical conductor providing electrical conduction from the positive terminal and the negative terminal, respectively, thereby providing power to the wireless transmitter and the measuring device; at least one of the first electrical conductor and the second electrical conductor is electrically coupled to a conductive fastener shaped to fit around and thereby be secured to a respective one of the positive terminal and the negative terminal, the conductive fastener defining teeth that abut against the terminal whereby the conductive fastener provides an interference fit with the terminal; and The measuring device is configured to measure a property of the cylindrical battery cell, and the wireless transmitter is configured to wirelessly transmit the measured property.

2. The power battery assembly according to claim 1, wherein: The wireless transmitter is a near field communication device, which is configured for short-range communication.

3. The power battery assembly according to claim 1, wherein: The support structure is removably attached to the battery cell.

4. The power battery assembly according to claim 1, wherein: The support structure includes a bracket formed toward a first end and a second end of the support structure, the bracket defining a support surface between the first end and the second end, and the support surface is configured to at least partially secure the electronic unit within the bracket.

5. The power cell assembly of claim 4, comprising a cover, the cover and the bracket having cooperating surface contours that attach the cover to the bracket to enclose the electronic unit and thereby limit movement of the electronic unit relative to a surface of the battery cell.

6. The power battery assembly according to claim 1, wherein: The support structure extends in one direction along at least a portion of the height of the cylindrical battery cell.

7. The power battery assembly according to claim 1, wherein: The support structure includes a contact surface configured to contact the cylindrical surface of the cylindrical battery cell, the contact surface having a surface profile that is complementary to a profile of the cylindrical surface of the cylindrical battery cell.

8. The power battery assembly according to claim 7, wherein: The contact surface includes an attachment member for attaching the support structure to the cylindrical surface of the cylindrical battery cell.

9. The power battery assembly according to claim 8, wherein: The attachment member includes an adhesive.

10. The power battery assembly according to claim 1, wherein: The support structure includes gripping arms extending outwardly from the support structure and arranged to grip the positive and negative terminals of the cylindrical battery cell, thereby attaching the support structure to the cylindrical battery cell by forming an interference fit with the terminals of the cylindrical battery cell.

11. The power battery assembly according to claim 1, wherein: The support structure includes a beam that holds the first electrical conductor and the second electrical conductor when housing the electronics unit.

12. The power battery assembly according to claim 1, wherein: A distal end of at least one of the first electrical conductor and the second electrical conductor includes a lead terminal positioned above a respective one of the positive terminal and the negative terminal.

13. The power battery assembly according to claim 4, wherein: Each of the conductive fasteners is included in a respective one of the first end and the second end of the bracket, and each of the conductive fasteners defines a profile that interlocks with a profile defined by a respective one of the positive terminal and the negative terminal, whereby the conductive fasteners attach the bracket to the positive terminal and the negative terminal to further provide electrical conduction.

14. The power battery assembly according to claim 1, wherein: The cover defines a first surface and a second planar surface, wherein the first surface faces the bracket when the cover is attached to the bracket, and the second planar surface faces away from the bracket when the cover is attached to the bracket, and at least one antenna structure is defined on the second planar surface, the antenna structure retaining an antenna, and the antenna is configured to wirelessly communicate with an electronic unit antenna included in the wireless transmitter of the electronic unit.

15. A power battery, comprising a plurality of power battery assemblies, each of the plurality of power battery assemblies being according to claim 14, the antenna structure of each of the power battery assemblies defining an antenna retaining slot extending across the cover and retaining the antenna, the plurality of power battery assemblies being positioned adjacent to each other, whereby the antenna retaining slots of the plurality of power battery assemblies are aligned, thereby receiving a single antenna in the plurality of antenna retaining slots and allowing the single antenna to extend over the plurality of power battery assemblies.

16. The power cell according to claim 15, wherein: The antenna holding groove extends across the cover in a direction orthogonal to a separation direction of the positive electrode terminal and the negative electrode terminal.

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