Thermal barrier integrated sensing cover assembly for traction battery array

Abstract

The present disclosure provides a thermal barrier integrated sensing cover assembly for a traction battery array. A battery array for a traction battery pack is provided. An exemplary battery array may include a sensing cover assembly with an integrated thermal barrier. Each thermal barrier may be secured to a top cover of the sensing cover assembly using a combination of one or more top cover slots and one or more thermal barrier tabs, thereby reducing parts and complexity.

Description

Technical Field

[0001] This disclosure generally relates to traction battery packs, and more specifically to battery arrays including a sensing cover assembly with an integrated thermal barrier. Background Technology

[0002] Electrified vehicles include a traction battery pack that powers the vehicle's motor and other electrical loads. The traction battery pack comprises multiple battery cells and various other internal battery components that support the propulsion of the electric vehicle. Summary of the Invention

[0003] A battery array for a traction battery pack according to an exemplary aspect of this disclosure particularly includes: a plurality of battery cells; and a busbar module assembly configured to electrically connect the plurality of battery cells. The busbar module assembly includes a first busbar module, a second busbar module, and a sensing cover assembly connected to the first busbar module and the second busbar module. The sensing cover assembly includes a plurality of integrated thermal barriers.

[0004] In another non-limiting embodiment of the aforementioned battery array, the plurality of integrated thermal barriers are fixed to the top cover of the sensing cover assembly.

[0005] In another non-limiting embodiment of any of the aforementioned battery arrays, the sensing cover assembly further includes a flexible printed circuit board.

[0006] In another non-limiting embodiment of any of the aforementioned battery arrays, the sensing cover assembly further includes a foam barrier disposed between the top cover and the flexible printed circuit board.

[0007] In another non-limiting embodiment of any of the aforementioned battery arrays, the first thermal barrier of the plurality of integrated thermal barriers includes a tab that is received within a slot in the top cover to secure the first thermal barrier to the top cover.

[0008] In another non-limiting embodiment of any of the aforementioned battery arrays, the first thermal barrier of the plurality of integrated thermal barriers includes a plurality of tabs received within a plurality of slots in the top cover to secure the first thermal barrier to the top cover.

[0009] In another non-limiting embodiment of any of the aforementioned battery arrays, the plurality of integrated thermal barriers are made of heat-resistant material, and the top cover is made of plastic material.

[0010] In another non-limiting embodiment of any of the aforementioned battery arrays, the top cover of the sensing cover assembly includes a first mounting member received through a first opening of the first busbar module and a second mounting member received through a second opening of the second busbar module.

[0011] In another non-limiting embodiment of any of the aforementioned battery arrays, the frame of each of the first busbar module and the second busbar module includes an opening sized to receive a cell terminal of at least one of the plurality of battery cells.

[0012] In another non-limiting embodiment of any of the aforementioned battery arrays, a busbar is mounted to the frame.

[0013] A battery array for a traction battery pack according to another exemplary aspect of this disclosure particularly includes: a cell stack assembly comprising a plurality of battery cells and a busbar module assembly. The busbar module assembly includes a sensing cover assembly comprising a top cover and a first thermal barrier fixed to the top cover.

[0014] In another non-limiting embodiment of the aforementioned battery array, the sensing cover assembly further includes a flexible printed circuit board.

[0015] In another non-limiting embodiment of any of the aforementioned battery arrays, the sensing cover assembly further includes a foam barrier disposed between the top cover and the flexible printed circuit board.

[0016] In another non-limiting embodiment of any of the aforementioned battery arrays, the sensing cover assembly is connected to a first busbar module and a second busbar module of the busbar module assembly.

[0017] In another non-limiting embodiment of any of the aforementioned battery arrays, the top cover of the sensing cover assembly includes a first mounting member received through a first opening of the first busbar module and a second mounting member received through a second opening of the second busbar module.

[0018] In another non-limiting embodiment of any of the aforementioned battery arrays, the first thermal barrier includes a first tab that is received within a first slot in the top cover to secure the first thermal barrier to the top cover.

[0019] In another non-limiting embodiment of any of the aforementioned battery arrays, the second thermal barrier of the sensing cover assembly includes a second tab that is received within a second slot in the top cover to secure the second thermal barrier to the top cover.

[0020] In another non-limiting embodiment of any of the aforementioned battery arrays, the third thermal barrier of the sensing cover assembly includes a third tab that is received within a third slot in the top cover to secure the third thermal barrier to the top cover.

[0021] In another non-limiting embodiment of any of the aforementioned battery arrays, the first thermal barrier of the sensing cover assembly includes a plurality of tabs received within a plurality of slots in the top cover to secure the first thermal barrier to the top cover.

[0022] In another non-limiting embodiment of any of the aforementioned battery arrays, the first thermal barrier is made of a heat-resistant material, and the top cover is made of a plastic material.

[0023] The embodiments, examples, and alternatives (including any of their various aspects or corresponding features) described in the foregoing paragraphs, claims, or the following description and drawings may be used independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.

[0024] Various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The accompanying drawings, which briefly describe the specific embodiments, are as follows. Attached Figure Description

[0025] Figure 1 An electric vehicle is shown schematically.

[0026] Figure 2 The battery array of the traction battery pack is shown.

[0027] Figure 3 yes Figure 2 A partial exploded view of the battery array cell stack assembly.

[0028] Figure 4 The sensor cover assembly for the battery array is shown.

[0029] Figure 5 Is it through Figure 4 Section 5-5 is a cross-sectional view.

[0030] Figure 6 It shows Figures 4-5 The top cover of the sensor cover assembly.

[0031] Figure 7 Another exemplary sensing cover assembly for the battery array is shown. Detailed Implementation

[0032] This disclosure details a battery array for a traction battery pack. An exemplary battery array may include a sensing cover assembly with integrated thermal barriers. Each thermal barrier can be secured to the top cover of the sensing cover assembly using a combination of one or more top cover slots and one or more thermal barrier tabs, thereby reducing parts and complexity. These and other features are discussed in more detail in the following paragraphs of this specific embodiment.

[0033] Figure 1 An electrified vehicle 10 is schematically illustrated. The electrified vehicle 10 may include any type of electrified powertrain. In this embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). However, the concepts described herein are not limited to BEVs and can be extended to other electrified vehicles, including but not limited to hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, etc. Therefore, although not specifically shown in the exemplary embodiments, the powertrain of the electrified vehicle 10 may be equipped with an internal combustion engine, which may be used alone or in combination with other power sources to propel the electrified vehicle 10.

[0034] In the illustrated embodiment, the electrified vehicle 10 is depicted as an automobile. However, the electrified vehicle 10 may alternatively be a sports utility vehicle (SUV), van, pickup truck, or any other vehicle configuration. Although specific component relationships are shown in the accompanying drawings of this disclosure, the illustrations are not intended to limit the scope of this disclosure. The placement and orientation of the various components of the electrified vehicle 10 are schematically shown and may vary within the scope of this disclosure. Furthermore, the various drawings accompanying this disclosure are not necessarily drawn to scale, and some features may be enlarged or minimized to emphasize certain details of particular components or systems.

[0035] In this embodiment, the electrified vehicle 10 is a purely electric vehicle propelled solely by electricity (such as by one or more motors 12) without any assistance from an internal combustion engine. The motor 12 may operate as an electric motor, a generator, or both. The motor 12 receives electricity and may convert it into torque for driving one or more wheels 14 of the electrified vehicle 10.

[0036] Voltage bus 16 can electrically connect motor 12 to traction battery pack 18. Traction battery pack 18 is an exemplary electric vehicle battery. Traction battery pack 18 can be a high-voltage traction battery pack assembly including multiple groups of battery cells capable of outputting power to power motor 12 and / or other electrical loads of electric vehicle 10. Other types of energy storage devices and / or output devices may alternatively or additionally be used to power electric vehicle 10.

[0037] The traction battery pack 18 can be fixed to the bottom 20 of the electric vehicle 10. However, within the scope of this disclosure, the traction battery pack 18 can be located elsewhere on the electric vehicle 10.

[0038] Figure 2 and Figure 3 Features associated with the exemplary battery array 22 are shown for use in traction battery packs (e.g., such as...) Figure 1The battery pack 18 is used in the electric vehicle 10. One or more battery arrays with a similar design to the battery array 22 can be encapsulated within the traction battery pack 18.

[0039] The battery array 22 may include one or more cell stack assemblies 28 housed within an array housing 26. The array housing 26 may include a top cover 30, a bottom cover 32, and a pair of end plates 34. The top cover 30 may be vertically positioned above the bottom cover 32. Various terms such as “above,” “below,” “top,” and “bottom” are used in the various figures relative to the arrangement of components of the traction battery pack 18 and should not be considered limiting in any other way. These terms are for reference only when the traction battery pack 18 is installed... Figure 1 The general orientation of the electric vehicle 10. For the purposes of this disclosure, vertical reference is also made to the ground and how the traction battery pack 18 is oriented when mounted on the electric vehicle 10.

[0040] The top cover 30 can be secured (e.g., bolted, welded, adhered, etc.) to the bottom cover 32. Furthermore, the top cover 30 and / or the bottom cover 32 can be secured (e.g., bolted, welded, adhered, etc.) to the end plate 34. The top cover 30, bottom cover 32, and end plate 34 can be arranged together to provide a sealed housing for receiving the cell stack assembly 28. However, other array housing 26 configurations are contemplated within the scope of this disclosure. Therefore, the size, shape, and configuration of the array housing 26 can vary within the scope of this disclosure.

[0041] Each cell stack assembly 28 may include multiple battery cells 24 arranged together along the cell stack axis A (see Figure 3 In this embodiment, battery cell 24 is a lithium-ion pouch cell. However, within the scope of this disclosure, battery cells having other geometries (cylindrical, prismatic, etc.) and / or chemical properties (nickel-metal hydride, lead-acid, etc.) may be used alternatively. The total number of battery cells 24 provided in the battery array 22 may vary and is not intended to limit this disclosure.

[0042] Cell expansion pads 36 can be disposed between adjacent battery cells 24 in the cell stack assembly 28. Cell expansion pads 36 may include materials suitable for accommodating the expansion of the battery cells (e.g., polyurethane foam, silicone foam, etc.).

[0043] The cell stack assembly 28 may further include a busbar module assembly 38 configured to electrically connect the battery cells 24 of the cell stack assembly 28. Once electrically connected, the battery cells 24 can supply at least a portion of the power necessary to enable the electric propulsion of the electrified vehicle 10.

[0044] The busbar module assembly 38 may include a first busbar module 40, a second busbar module 42, and a sensing cover assembly 44. The first busbar module 40 and the second busbar module 42 may each include a plurality of busbars 46 held within a busbar frame 48. Providing the total number of busbars 46 within each of the first busbar module 40 and the second busbar module 42 is not intended to limit this disclosure.

[0045] The busbar 46 may be a metal component of the first busbar module 40 and the second busbar module 42, and the busbar frame 48 may be a plastic component of the first busbar module 40 and the second busbar module 42. In embodiments, the busbar 46 is made of copper or aluminum, and the busbar frame 48 is made of polypropylene or polyethylene. However, other materials are contemplated within the scope of this disclosure.

[0046] Each busbar frame 48 may include an opening 50 (e.g., an elongated slot), each opening being sized to receive a cell contact terminal 52 of one or more of the battery cells 24 of the cell stack assembly 28. The cell contact terminal 52 may extend through the opening 50 to connect to the busbar 46. The busbar 46 may engage the contact terminals 52 of adjacent battery cells 24 together to electrically connect the battery cells 24 of the cell stack assembly 28.

[0047] Currently, the main reference is... Figures 3-6 The sensing cover assembly 44 of the busbar module assembly 38 may include a top cover 54, a flexible printed circuit board 56, and a foam barrier 60 disposed between the top cover 54 and the flexible printed circuit board 56. The top cover 54 may be made of any suitable plastic material. The flexible printed circuit board 56 may include sensing leads and other circuitry necessary for monitoring voltage and temperature information associated with the battery cells 24 of the cell stack assembly 28. The foam barrier 60 may be fixed to or integrally formed with the underside of the top cover 54 and may be configured to protect the various circuitry of the flexible printed circuit board 56.

[0048] Each opposite side of the top cover 54 may include one or more mounting members 58. The first busbar module 40 and the second busbar module 42 may be secured to the sensing cover assembly 44 via the mounting members 58 to assemble the busbar module assembly 38. In an embodiment, each mounting member 58 is received in an opening 59 formed in the first busbar module 40 or the second busbar module 42 (see [link to original document]). Figure 3 However, other configurations for securing the busbar modules 40, 42 to the sensing cover assembly 44 are conceivable within the scope of this disclosure.

[0049] The sensing cover assembly 44 may additionally include multiple thermal barriers 62. The thermal barriers 62 and the top cover 54 may be integrated together to reduce parts and provide an optimized packaging configuration for the battery array 22. In this disclosure, the term "integrated" means that the thermal barriers 62 are pre-assembled (adhesive, friction-fitted, clamped, etc.) and thus physically connected to the top cover 54 to establish an integral integrated component. In some implementations, the thermal barriers 62 may be provided to the sensing cover assembly 44 as a "part in assembly" (PIA).

[0050] The thermal barrier 62 can be made of heat-resistant materials (such as mica, aerogel, etc.). However, within the scope of this disclosure, other materials or combinations of materials can be used to construct the thermal barrier 62.

[0051] The top cover 54 may include a plurality of slots 64. The slots 64 may be formed through the material thickness of the top cover 54. Each slot 64 may be sized to receive an integrated tab 66 of one of the thermal barriers 62. The integrated tab 66 may be securely held within the slot 64 by friction engagement, adhesive, or other suitable attachment method to integrate the thermal barrier 62 as part of the sensing cover assembly 44. Although not specifically shown, the flexible printed circuit board 56 and the foam barrier 60 may each include a corresponding slot aligned with the slots 64 of the top cover 54 to receive the tab 66 of the thermal barrier 62.

[0052] In one embodiment, a plurality of slots 64 and a plurality of integrated tabs 66 cooperate to secure each thermal barrier 62 to the top cover 54 (see example). Figures 4-6 In another embodiment, a single slot 64 and a single integrated tab 66 cooperate to secure each thermal barrier 62 to the top cover 54 (see, for example...). Figure 7 ).

[0053] When assembling the cell stack assembly 28, the thermal barrier 62 can be used as a guide for sliding the battery cells 24 into place. The thermal barrier 62 is used to hold the battery cells 24 in a vertical orientation during the battery array 22 assembly process before inserting the cell stack assembly 28 into the bottom cover 32.

[0054] In the assembled state of the battery array 22, the thermal barrier 62 can divide the battery array 22 into two or more groups or compartments of battery cells 24. In an embodiment, groups of four individual battery cells 24 are separated by the thermal barrier 62. However, other configurations are contemplated within the scope of this disclosure. If, for example, a battery thermal event occurs in one or more of the battery cells 24, the thermal barrier 62 can reduce or even prevent the movement of heat associated with the thermal event across the length of the battery array 22 between cells, thereby suppressing the transfer of heat within the traction battery pack 18.

[0055] The exemplary battery array disclosed herein includes a stacked grouped thermal barrier integrated sensing cover assembly for electrically connecting battery cells. The thermal barrier and top cover of the integrated sensing cover assembly are integrated together to reduce parts, simplify logistics, optimize array packaging and efficiency, and provide increased energy density and other benefits.

[0056] While different non-limiting embodiments are shown having specific components or steps, the embodiments disclosed herein are not limited to those particular combinations. Some of the components or features from any of the non-limiting embodiments may be used in combination with features or components from any of the other non-limiting embodiments.

[0057] It should be understood that the same reference numerals identify corresponding or similar elements throughout all the figures. It should be understood that although particular arrangements of components are disclosed and shown in these exemplary embodiments, other arrangements may also benefit from the teachings of this disclosure.

[0058] The foregoing description should be interpreted as illustrative and not restrictive. Those skilled in the art will understand that certain modifications may be made within the scope of this disclosure. For these reasons, the appended claims should be examined to determine the true scope and content of this disclosure.

Claims

1. A battery array for a traction battery pack, comprising: a plurality of battery cells; and a busbar module assembly configured to electrically connect the plurality of battery cells, the busbar module assembly comprising a first busbar module, a second busbar module, and a sensing cover assembly connected to the first busbar module and the second busbar module, wherein the sensing cover assembly comprises a plurality of integrated thermal barriers.

2. The battery array of claim 1, wherein the plurality of integrated thermal barriers are secured to a top cover of the sensing cover assembly.

3. The battery array of claim 2, wherein the sensing cover assembly further comprises a flexible printed circuit board, and optionally wherein the sensing cover assembly comprises a foam barrier disposed between the top cover and the flexible printed circuit board of the sensing cover assembly.

4. The battery array of claim 2, wherein a first thermal barrier of the plurality of integrated thermal barriers comprises a tab received within a slot of the top cover to secure the first thermal barrier to the top cover.

5. The battery array of claim 2, wherein a first thermal barrier of the plurality of integrated thermal barriers comprises a plurality of tabs received within a plurality of slots of the top cover to secure the first thermal barrier to the top cover.

6. The battery array of claim 2, wherein the plurality of integrated thermal barriers are constructed of a heat resistant material, and the top cover is constructed of a plastic material.

7. The battery array of any preceding claim, wherein a top cover of the sensing cover assembly comprises a first mount received through a first opening of the first busbar module, and a second mount received through a second opening of the second busbar module.

8. The battery array of any preceding claim, wherein a frame of each of the first busbar module and the second busbar module comprises an opening sized to receive a cell tab terminal of at least one battery cell of the plurality of battery cells, and optionally comprises a busbar mounted to the frame.

9. A battery array for a traction battery pack, comprising: a cell stack assembly comprising a plurality of battery cells and a busbar module assembly, wherein the busbar module assembly comprises a sensing cover assembly comprising a top cover and a first thermal barrier secured to the top cover.

10. The battery array of claim 9, wherein the sensing cover assembly further comprises a flexible printed circuit board, and optionally wherein the sensing cover assembly comprises a foam barrier disposed between the top cover and the flexible printed circuit board.

11. The battery array of claim 9 or 10, wherein the sensing cover assembly is connected to a first busbar module and a second busbar module of the busbar module assembly, and optionally wherein the top cover of the sensing cover assembly comprises a first mount received through a first opening of the first busbar module, and a second mount received through a second opening of the second busbar module.

12. The battery array of any of claims 9-11, wherein the first thermal barrier includes a first tab that is received within a first slot of the top cover to secure the first thermal barrier to the top cover.

13. The battery array of claim 12, wherein a second thermal barrier of the sensing cover assembly includes a second tab that is received within a second slot of the top cover to secure the second thermal barrier to the top cover, and optionally wherein a third thermal barrier of the sensing cover assembly includes a third tab that is received within a third slot of the top cover to secure the third thermal barrier to the top cover.

14. The battery array of any of claims 9-13, wherein the first thermal barrier of the sensing cover assembly includes a plurality of tabs that are received within a plurality of slots of the top cover to secure the first thermal barrier to the top cover.

15. The battery array of any of claims 9-14, wherein the first thermal barrier is composed of a heat-resistant material, and the top cover is composed of a plastic material.

Images