Battery pack interconnection assembly for battery pack

Abstract

A battery pack interconnection assembly (50) is provided for electrically connecting cell terminals (24, 26) of battery cells in a battery pack (10). A battery pack interconnect assembly includes a bus bar interconnect (100) and a bus bar carrier (110) holding a bus bar. Each bus bar includes a first mating end (215) and a second mating end (217). The battery pack interconnect assembly includes a sensing harness (300) having a sensing point (302) coupled to the bus bar. The sensing harness includes a bus bar sensing cable (310) and a connection cable (350). The bus bar sensing cable and the connection cable are both flat flexible cables. A bus bar sensing cable extends along a column of bus bars, wherein a sensing flat conductor is electrically connected to a corresponding bus bar in a corresponding column. A connection cable spans each of the bus bar sensing cables, with a connection flat conductor electrically connected to a corresponding sensing flat conductor. The connection flat conductor of the connection cable is electrically connected to the control module (400).

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Application No. 63 / 709,703, filed October 21, 2024, the subject of which is incorporated herein by reference in its entirety. Technical Field

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

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

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

[0006] In one embodiment, a battery pack interconnect assembly is provided for electrically connecting cell terminals of battery cells in a battery pack. The battery pack interconnect assembly includes a busbar interconnect comprising a plurality of busbars arranged in a matrix having multiple rows and columns of busbars, and a busbar carrier holding the busbars. Each busbar includes a first mating end for mating with a corresponding cell terminal of a corresponding battery cell and a second mating end for mating with an adjacent cell terminal of an adjacent corresponding battery cell. The busbars electrically connect to the battery cells in the battery pack. The battery pack interconnect assembly includes a sensing harness having sensing points coupled to the busbars. The sensing harness includes busbar sensing cables and connecting cables coupled to each of the busbar sensing cables. The busbar sensing cables are flat, flexible cables having a plurality of sensing flat conductors. The connecting cables are flat, flexible cables having a plurality of connecting flat conductors. The busbar sensing cables extend along columns of busbars, wherein the sensing flat conductors are electrically connected at corresponding sensing points to corresponding busbars in corresponding columns to sense the voltage of each corresponding busbar. The connecting cable spans each of the busbar sensing cables, wherein the connecting flat conductor is electrically connected to the corresponding sensing flat conductor of each of the busbar sensing cables. The connecting flat conductor of the connecting cable is electrically connected to the control module. Attached Figure Description

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

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

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

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

[0011] Figure 4 This is an enlarged view of a portion of a busbar sensing cable according to an exemplary embodiment.

[0012] Figure 5 This is a cross-sectional view of a busbar sensing cable according to an exemplary embodiment.

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

[0014] Figure 7 This is a top view of a busbar sensing cable according to an exemplary embodiment.

[0015] Figure 8This is a cross-sectional view of a busbar sensing cable according to an exemplary embodiment.

[0016] Figure 9 This is a top view of the connecting cable according to an exemplary embodiment.

[0017] Figure 10 This is an enlarged view of a portion of the connecting cable according to an exemplary embodiment.

[0018] Figure 11 This is an enlarged view of another portion of the connecting cable according to an exemplary embodiment.

[0019] Figure 12 This is a cross-sectional view of the connecting cable according to an exemplary embodiment.

[0020] Figure 13 This is a cross-sectional view of the connecting cable at another location according to an exemplary embodiment.

[0021] Figure 14 This is an enlarged view of a portion of a battery pack interconnect assembly according to an exemplary embodiment, showing four rows and two columns of busbars.

[0022] Figure 15 This is an enlarged view of a portion of a battery pack interconnect assembly according to an exemplary embodiment, showing two rows and two columns of busbars. Detailed Implementation

[0023] Figure 1 This is a perspective view of a battery pack 10 including a battery pack interconnect assembly 50 according to an exemplary embodiment. The battery pack interconnect assembly 50 includes a busbar interconnect 100 and a sensing harness 300. The busbar interconnect 100 has a plurality of busbars 200, and the sensing harness 300 is used to sense parameters of the battery pack, such as the voltage, temperature, state of charge, or other operating characteristics of the battery pack 10.

[0024] Battery pack 10 may be a battery pack for a vehicle (e.g., an electric vehicle). However, in alternative embodiments, battery pack 10 may be used in other applications. In an exemplary embodiment, battery pack 10 is a high-voltage battery pack. For example, battery pack 10 may be a 400V or 800V battery pack. Busbar interconnects 100 are used to electrically connect a matrix of battery cells 20 of battery pack 10. For example, busbar interconnects 100 may connect battery cells 20 in series and / or in parallel.

[0025] Battery cell 20 can be held within battery pack housing 12. Battery pack 10 includes positive battery interconnect terminal 14 and negative battery interconnect terminal 16. Battery interconnect terminals 14, 16 can interface with other power distribution components of battery pack 10, such as contactors and fuses for connecting to charging systems and / or loads (e.g., electric motors).

[0026] Each battery cell 20 includes a cell housing 22, a first cell terminal 24, and a second cell terminal 26. In various embodiments, the battery cell 20 may be a prismatic battery cell. The first cell terminal 24 and the second cell terminal 26 may be a cathode terminal and an anode terminal. In an exemplary embodiment, the battery cells 20 are rectangular and arranged in a stacked configuration. For example, the battery cells 20 may be stacked into rows and columns of battery cells 20 in a matrix. The cell matrix may have a large surface area, for example, greater than two square meters (2m²). 2 (or more). For example, the matrix may have a length between approximately 1.0 m and 2.0 m and a width between approximately 1.0 m and 1.5 m. Adjacent battery cells 20 in a row are interconnected via corresponding busbars 200 of the busbar interconnect 100. Adjacent rows of battery cells 20 are interconnected via corresponding busbars 200 of the busbar interconnect 100. For example, end battery cells 20 may be connected row-to-row.

[0027] The busbar interconnect 100 includes a busbar carrier 110 that holds the busbars 200. The busbar carrier 110 holds the busbars 200 in a relative position for mating with the cell terminals 24, 26 of the respective battery cells 20. The busbars 200 electrically connect adjacent battery cells 20, for example, in series and / or in parallel. In various embodiments, the busbar carrier 110 integrates all the busbars 200 into a single unit or structure for mounting to a matrix of battery cells 20. For example, a single busbar carrier 110 may be used to hold all the busbars 200. In other various embodiments, the busbar carrier 110 may include multiple frames or units, each holding multiple busbars 200, such as a row of busbars 200, and the frames / units may be connected together by other elements of the busbar carrier 110 to form a connection structure.

[0028] In various embodiments, the busbar carrier 110 may be a structural foam lead frame that holds the busbar 200. For example, the busbar carrier 110 may be manufactured using a structural foam molding process. In alternative embodiments, the busbar carrier may be made of other materials, such as molded plastic structures. The busbar carrier 110 may be molded or formed on the busbar matrix. For example, the busbar carrier 110 may be in-situ overmolded onto a portion of the busbar 200 to form the busbar interconnect 100. The busbar carrier 110 may be formed around a portion of the busbar 200 to hold the busbar 200 relative to each other and relative to the cell terminals 24, 26 of the battery cell 20.

[0029] In an exemplary embodiment, the busbar carrier 110 includes a frame or grid 120. The grid 120 is formed around a portion of the busbar 200 to hold the busbar 200 in relative position. In an exemplary embodiment, the busbar carrier 110 holds all the busbars 200 for the battery pack 10 to reduce the number of components required for final assembly into the battery pack 10. For example, a single busbar interconnect 100 is assembled into the battery pack 10. The busbar carrier 110 is used to position the busbars 200 for electrical connection to the cell terminals 24, 26 of the battery cells 20. In an exemplary embodiment, a sensing harness 300 is coupled to the busbar carrier 110. The busbar carrier 110 can be used to position the sensing harness on the battery cells 20.

[0030] The grid 120 includes frame members 122 configured to connect to the busbar 200 to maintain the relative position of the busbar 200. Frame members 122 include an outer frame member 130 surrounding the periphery of the grid 120, and an inner frame member 140 spanning the interior of the grid 120 to abut against the busbar 200. The inner frame member 140 extends between the outer frame members 130. For example, the inner frame member 140 includes longitudinal elements 142 and transverse elements 144. The longitudinal elements 142 extend longitudinally through the grid 120 between opposite ends. The transverse elements 144 extend laterally through the grid 120 between opposite sides. The longitudinal elements 142 and / or the transverse elements 144 can be used to support portions of the busbar 200. The transverse elements 144 interconnect the longitudinal elements 142 to provide support for the longitudinal elements 142, and vice versa. In an exemplary embodiment, the inner frame member 140 and the outer frame member 130 are integrally formed. For example, the inner frame member 140 is formed together with the outer frame member 130 during the structural molding process. The lattice 120 forms an integral monolithic structure.

[0031] In an exemplary embodiment, the lateral element 144 spans a column of the busbar 200. The lateral element 144 engages the busbar 200 to support it. The lateral element 144 supports each of the busbars 200 in a corresponding column. In an exemplary embodiment, the longitudinal element 142 is located in the gaps between the rows of the busbars 200. In the illustrated embodiment, the longitudinal element 142 is not used to support the busbars 200. However, in alternative embodiments, the longitudinal element 142 may additionally or alternatively be used to support some or all of the busbars 200.

[0032] In an exemplary embodiment, the sensing harness 300 has sensing points 302 for monitoring the busbar 200 and / or unit terminals 24, 26. For example, the sensing harness 300 is electrically connected to the busbar 200 at sensing points 302 to monitor the voltage, temperature, charge status, or other operating characteristics of the busbar 200 and / or unit terminals 24, 26. The sensing harness 300 is configured to be electrically connected to a control module 400, such as a battery control module. The sensing harness 300 transmits sensing signals from sensing points 302 to the control module 400, which can be used to control the operation of the vehicle and / or the charging operation of the vehicle.

[0033] The battery pack interconnect assembly 50 provides a large-format battery cell interconnect assembly configured to be mounted as a single unit to the battery pack 10 (e.g., each battery cell 20). The busbar carrier 110 holds all busbars 200 in place to terminate to the cell terminals 24, 26 of each battery cell 20 of the battery pack 10. By holding all busbars 200 to be assembled to all battery cells 20 of the battery pack 10, assembly processes, such as those for conventional battery systems where each busbar is individually assembled to a battery cell through multiple assembly steps, are eliminated. The busbar interconnect 100 reduces the total number of parts count and the number of parts handled during the assembly of the battery pack 10. The busbar carrier 110 can have a large format and surface area. For example, the structural process of manufacturing the lattice framework for the busbar carrier 110 achieves a large footprint for the busbar carrier 110. The structural material of the lattice framework used for the busbar carrier 110 is dimensionally stable and does not tend to warp, thus making the assembly and termination of the battery cells simpler, faster, and less costly compared to conventional assembly processes.

[0034] Figure 2 This is a top view of the battery pack interconnect assembly 50 according to an exemplary embodiment. Figure 2 A matrix 202 is shown showing busbars 200 and sensing harnesses 300 connected to the busbars 200. The busbars 200 are arranged in rows 204 and columns 206 of the matrix 202. The arrangement of the busbars 200 corresponds to the arrangement of the battery cells 20 for connection to the respective cell terminals 24, 26. The sensing harnesses 300 traverse the rows 204 and columns 206 of the busbars 200 to be electrically connected to each of the busbars 200 for sensing the characteristics (e.g., voltage) of each of the busbars 200.

[0035] Each busbar 200 includes a metal plate 210 having a body 212, a first mating pad 214 at a first mating end 215, and a second mating pad 216 at a second mating end 217. The first mating pad 214 is configured to connect to a cell terminal 24 of one of the battery cells 20. The second mating pad 216 is configured to connect to a cell terminal 26 of an adjacent battery cell 20. The busbar 200 electrically connects adjacent battery cells 20. The mating pads 214, 216 may include openings 218 therethrough, for example for positioning the busbar 200 relative to the cell terminals 24, 26. The openings 218 can be used for pick-and-place operations. The openings 218 can be used to hold the position of the busbar 200 during the overmolding process that forms the busbar carrier 110.

[0036] In an exemplary embodiment, each busbar 200 is generally rectangular. For example, a busbar 200 includes a first end 220, a second end 222, a first side 224, and a second side 226. The busbar 200 may be elongated, for example, having ends 220, 222 longer than the sides 224, 226. In an exemplary embodiment, the busbar is generally planar. For example, the first and second mating pads 214, 216 may be coplanar for attachment to unit terminals 24, 26. Optionally, the body 212 may be offset relative to or out of plane with respect to the first and second mating pads 214, 216, for example, located above or below the plane of the first and second mating pads 214, 216. The busbar 200 may include mounting features for mounting the busbar 200 to the busbar carrier 110, such as mounting tabs, posts, brackets, clips, notches, openings, etc.

[0037] In an exemplary embodiment, the matrix 202 of the busbars 200 includes eighteen rows 204 and seven columns 206 of the busbars 200. In an alternative embodiment, more or fewer busbars 200 may be arranged in rows 204 and / or columns 206. In an exemplary embodiment, the busbars 200 include external busbars 240 and internal busbars 242. External busbars 240 are arranged along opposite sides (e.g., right and left) of the busbar matrix 202. External busbars 240 are used to connect battery cells 20 in two different rows. Internal busbars 242 extend between the external busbars 240. Internal busbars 242 are used to connect adjacent battery cells 20 in the same column. External busbars 240 are oriented perpendicular to the internal busbars 242. For example, the internal busbars 242 are oriented vertically, and the external busbars 240 are oriented laterally. In alternative embodiments, other orientations are possible.

[0038] The sensing harness 300 includes busbar sensing cables 310 and connecting cables 350 coupled to each of the busbar sensing cables 310. The busbar sensing cables 310 and connecting cables 350 form a lattice structure overlapping the matrix 202 of the busbar 200. For example, the busbar sensing cables 310 and connecting cables 350 may be oriented perpendicular to each other. In the illustrated embodiment, the busbar sensing cables 310 extend in the Y direction, and the connecting cables 350 extend in the X direction. In an exemplary embodiment, the busbar sensing cables 310 are flat flexible cables (FFC). y It has multiple flat conductors arranged in an insulator. In an exemplary embodiment, the connecting cable 350 is a flat flexible cable (FFC). x It has multiple flat conductors arranged in an insulator.

[0039] In an exemplary embodiment, a busbar sensing cable 310 extends along column 206 of busbars 200 and is electrically connected at a corresponding sensing point 302 to each busbar 200 in the corresponding column 206 to sense characteristics, such as voltage, of each corresponding busbar 200. A connecting cable 350 spans each of the busbar sensing cables 310 and is electrically connected to the busbar sensing cables 310 to aggregate signals from the busbar sensing cables 310. The connecting cable 350 is electrically connected to the control module 400.

[0040] Figure 3 This is a top view of the busbar sensing cable 310 according to an exemplary embodiment. Figure 4 This is an enlarged view of a portion of a busbar sensing cable 310 according to an exemplary embodiment. Figure 5 This is a cross-sectional view of the busbar sensing cable 310 according to an exemplary embodiment. Figure 6 This is a cross-sectional view of the busbar sensing cable 310 at another location according to an exemplary embodiment.

[0041] In an exemplary embodiment, the busbar sensing cable 310 is a flat, flexible cable. The busbar sensing cable 310 extends between a first end 312 and a second end 314. The busbar sensing cable 310 includes an insulator 316 holding a plurality of sensing flat conductors 320. The insulator 316 may include one or more flexible plastic films 318, such as an upper film, a lower film, and may include one or more intermediate films between the upper and lower films. These layers may be bonded by an adhesive. The insulator 316 may be a laminated structure. In various other embodiments, the insulator 316 may be extruded around the sensing flat conductors 320. The sensing flat conductors 320 are sandwiched between layers of the flexible plastic film 318. The film 318 may be made of a polyester-based material, a polyethylene-based material, a polyamide-based material, a polyurethane-based material, a PVC material, etc. The film 318 may, for example, be laminated to each other and / or laminated to the sensing flat conductors 320 using one or more adhesive layers to form a single flexible unit.

[0042] The sensing flat conductor 320 is a flat, parallel conductor. The sensing flat conductor 320 can be made of copper, aluminum, or other metallic materials. Each sensing flat conductor 320 includes an upper surface 322 and a lower surface 324. The sensing flat conductor 320 includes a side surface 326 between the upper surface 322 and the lower surface 324. In an exemplary embodiment, the sensing flat conductor 320 has a rectangular cross-section. A membrane 318 covers the upper surface 322 and the lower surface 324. The membrane 318 can be located between the side surfaces 326 of adjacent sensing flat conductors 320.

[0043] In the illustrated embodiment, the busbar sensing cable 310 includes six of the sensing flat conductors 320. In alternative embodiments, the busbar sensing cable 310 may include more or fewer sensing flat conductors 320. In the exemplary embodiment, the sensing flat conductors 320 each have the same dimensions (e.g., height and width). However, in alternative embodiments, the sensing flat conductors 320 may have different dimensions. In the exemplary embodiment, the busbar sensing cable 310 may have a common pitch or spacing between the sensing flat conductors 320. However, in alternative embodiments, the busbar sensing cable 310 may have different spacing between the sensing flat conductors 320.

[0044] In an exemplary embodiment, the busbar sensing cable 310 includes a sensing entry window 330 ( Figure 5The sensing access window 330 exposes the corresponding sensing flat conductor 320 at sensing point 302. For example, a portion of the insulator 316 may be selectively removed to form a sensing access window 330 and expose the sensing flat conductor 320. In various embodiments, the insulator 316 may be removed by ablation, scraping, cutting, or other removal processes. The sensing access window 330 provides access to the sensing flat conductor 320 at sensing point 302 for electrically connecting the sensing flat conductor 320 to the busbar 200. For example, the sensing flat conductor 320 may be electrically connected to the corresponding busbar 200 by one of the following methods: soldering, conductive bonding, riveting, or conductive adhesive bonding.

[0045] In an exemplary embodiment, a plurality of sensing flat conductors 320 may be exposed in each of the sensing access windows 330. Exposing a plurality of sensing flat conductors 320 in each sensing access window 330 allows for multiple contact points between the busbar sensing cable 310 and the corresponding busbar 200. The redundant electrical connections of the plurality of sensing flat conductors 320 to the corresponding busbar 200 improve reliability and / or limit warranty costs, recalls, and material scrap.

[0046] In an exemplary embodiment, the busbar sensing cable 310 includes a connection access window 332 that exposes a corresponding sensing flat conductor 320 at a junction 334. For example, a portion of the insulator 316 may be selectively removed to form the connection access window 332 and expose the sensing flat conductor 320. In various embodiments, the insulator 316 may be removed by ablation, scraping, cutting, or other removal processes. The connection access window 332 provides access to the sensing flat conductor 320 at the junction 334 for electrically connecting the sensing flat conductor 320 to the connecting cable 350. For example, the sensing flat conductor 320 may be electrically connected to the corresponding connecting flat conductor of the connecting cable 350 via a welding connection, a conductive bonding connection, a riveting connection, or a conductive adhesive connection.

[0047] In an exemplary embodiment, the busbar sensing cable 310 includes a conductor separation window 340 passing through the busbar sensing cable 310. Figure 6 For example, portions of the insulator 316 and the sensing flat conductor 320 can be selectively removed to form a conductor separation window 330. In various embodiments, the conductor separation window 340 is formed by cutting, punching, ablation, or other removal processes used to remove portions of the insulator 316 and the sensing flat conductor 320. This removal allows the sensing flat conductor 320 to be separated into electrically isolated segments. Electrically isolated segments of the sensing flat conductor 320 allow the same sensing flat conductor 320 to be connected to different busbars 200 without short-circuiting or damaging the sensing flat conductor 320.

[0048] In an exemplary embodiment, some of the sensing flat conductors 320 are not removed, but instead pass along the side of the conductor separation window 340. For example, the outermost sensing flat conductor 320 may remain intact along the length of the busbar sensing cable 310, and only the inner sensing flat conductors 320 are removed at the conductor separation window 340. Such sensing flat conductors 320 can be used to provide structural cohesion for the busbar sensing cable 310 along its length, allowing the sensing cable 310 to remain a single or integral component. For example, such sensing flat conductors 320 are not used as sensing conductors and are not electrically connected to any busbar in the busbar 200. For example, such sensing flat conductors 320 are not exposed in any sensing entry window 330.

[0049] Figure 7 This is a top view of the busbar sensing cable 310 according to an exemplary embodiment. Figure 8 This is a cross-sectional view of the busbar sensing cable 310 according to an exemplary embodiment. Figure 7 and Figure 8 Busbar sensing cable 310 with sensing flat conductors 320 of different sizes is shown. For example, two of the sensing flat conductors 320 used to connect to the busbar 200 to sense parameters of the busbar 200 are wider than the other sensing flat conductors 320. The two wide sensing flat conductors 320 may be at least twice as wide as the other sensing flat conductors 320.

[0050] In an exemplary embodiment, the busbar sensing cable 310 may include other mounting locations 342, such as for mounting other sensors or components 344, such as temperature sensors, fuses, or other components. Components 344 may be electrically connected to one or more of the sensing flat conductors 320.

[0051] Figure 9 This is a top view of the connecting cable 350 according to an exemplary embodiment. Figure 10 This is an enlarged view of a portion of the connecting cable 350 according to an exemplary embodiment. Figure 11 This is an enlarged view of another portion of the connecting cable 350 according to an exemplary embodiment. Figure 12 This is a cross-sectional view of the connecting cable 350 according to an exemplary embodiment. Figure 13 This is a cross-sectional view of the connecting cable 350 at another location according to an exemplary embodiment.

[0052] In an exemplary embodiment, the connecting cable 350 is a flat, flexible cable. The connecting cable 350 extends between a first end 352 and a second end 354. In an exemplary embodiment, an electrical connector 304 is disposed at the first end 352. The electrical connector 304 is configured to be electrically connected to the control module 400.

[0053] The connecting cable 350 includes an insulator 356 that holds a plurality of connecting flat conductors 360. The insulator 356 may include one or more flexible plastic films 358, such as an upper film, a lower film, and may include one or more intermediate films between the upper and lower films. These layers may be bonded together by an adhesive. The insulator 356 may be a laminated structure. In various other embodiments, the insulator 356 may be extruded around the connecting flat conductors 360. The connecting flat conductors 360 are sandwiched between layers of the flexible plastic film 358. The film 358 may be made of a polyester-based material, a polyethylene-based material, a polyamide-based material, a polyurethane-based material, a PVC material, etc. The film 358 may, for example, be laminated to each other and / or laminated to the connecting flat conductors 360 using one or more adhesive layers to form a single flexible unit.

[0054] The connecting flat conductor 360 is a flat, parallel conductor. The connecting flat conductor 360 can be made of copper, aluminum, or other metallic materials. Each sensing flat conductor 360 includes an upper surface 362 and a lower surface 364. The sensing flat conductor 360 includes a side surface 366 between the upper surface 362 and the lower surface 364. In an exemplary embodiment, the connecting flat conductor 360 has a rectangular cross-section. A membrane 358 covers the upper surface 362 and the lower surface 364. The membrane 358 can be located between the side surfaces 366 of adjacent connecting flat conductors 360.

[0055] In the illustrated embodiment, the connecting cable 350 includes fifteen of the connecting flat conductors 360. In an alternative embodiment, the connecting cable 350 may include more or fewer connecting flat conductors 360 to accommodate the number of bus voltage signals to be measured or other components (such as temperature sensors), depending on the number of battery cells. In the exemplary embodiment, the connecting flat conductors 360 each have the same dimensions (e.g., height and width). However, in an alternative embodiment, the connecting flat conductors 360 may have different dimensions. In the exemplary embodiment, the connecting cable 350 may have a common pitch or spacing between the connecting flat conductors 360. However, in an alternative embodiment, the connecting cable 350 may have different spacing between the connecting flat conductors 360.

[0056] In an exemplary embodiment, the connecting cable 350 includes a connection access window 372 that exposes a corresponding connecting flat conductor 360 at a junction 374. For example, a portion of the insulator 356 may be selectively removed to form the connection access window 372 and expose the connecting flat conductor 360. In various embodiments, the insulator 356 may be removed by ablation, scraping, cutting, or other removal processes. The connection access window 372 provides access to the connecting flat conductor 360 at the junction 374 for electrical connection to the sensing flat conductor 320 of the busbar sensing cable 310. For example, the connecting flat conductor 360 may be electrically connected to the corresponding sensing flat conductor 320 by one of soldering, conductive bonding, riveting, or conductive adhesive bonding. In an exemplary embodiment, the connection access window 374 exposes different connecting flat conductors 360 along different sections of the connecting cable 350 for connection to different busbar sensing cables 310. For example, each connecting flat conductor 360 may be exposed at different locations along the length of the connecting cable 350 for connection to different busbar sensing cables 310.

[0057] Figure 14 This is an enlarged view of a portion of the battery pack interconnect assembly 50 according to an exemplary embodiment, showing four rows 204 and two columns 206 of the busbar 200. Figure 15 This is an enlarged view of a portion of a battery pack interconnect assembly 50 according to an exemplary embodiment, showing two rows 204 and two columns 206 of busbars 200. Sensing harnesses 300 traverse the rows 204 and columns 206 of the busbars 200 to be electrically connected to each of the busbars 200 for sensing the characteristics (e.g., voltage) of each of the busbars 200.

[0058] During assembly, the sensing harness 300 is connected to the busbar 200. The sensing harness 300 may be connected to the busbar carrier 110, such as to the frame member 122. For example, the busbar sensing cable 310 may be connected to the longitudinal element 142 and / or the transverse element 144. The connecting cable 350 may be connected to the longitudinal element 142 and / or the transverse element 144.

[0059] During assembly, the exposed portion of the sensing flat conductor 320 of the busbar sensing cable 310 at the sensing entry window 330 is electrically connected to the corresponding busbar 200. The sensing flat conductor 320 can be electrically connected to the corresponding busbar 200 via a method of soldering, conductive bonding, riveting, or conductive adhesive bonding. In an exemplary embodiment, multiple sensing flat conductors 320 are exposed in each of the sensing entry windows 330 to allow multiple contact points with each busbar 200 and to form redundant electrical connections with the respective busbar 200 to improve reliability.

[0060] During assembly, the connecting flat conductor 360 is electrically connected to the sensing flat conductor 320 at corresponding junctions. For example, connection access windows 332 and 372 expose the sensing flat conductor 320 and the connecting flat conductor 360 for electrical connection between them. The connecting flat conductor 360 can be electrically connected to the corresponding sensing flat conductor 320 via a welding connection, conductive bonding connection, riveting connection, or conductive adhesive connection. The connection access window 374 exposes different connecting flat conductors 360 along different sections of the connecting cable 350 for connection to different busbar sensing cables 310.

Claims

1. A battery pack interconnect assembly (50) for electrically connecting cell terminals (24, 26) of battery cells (20) in a battery pack (10), the battery pack interconnect assembly comprising: A busbar interconnect (100) includes a plurality of busbars (200) arranged in a matrix (202) and a busbar carrier (110) holding the busbars. The matrix (202) has multiple rows (204) and multiple columns (206) of the busbars. Each busbar includes a first mating end (215) for mating with a corresponding cell terminal of a corresponding battery cell and a second mating end (217) for mating with an adjacent cell terminal of an adjacent corresponding battery cell. The busbars are electrically connected to the battery cells in the battery pack. and A sensing harness (300) having sensing points (302) connected to the busbar, the sensing harness including a busbar sensing cable (310) and a connecting cable (350) connected to each of the busbar sensing cables, the busbar sensing cable being a flat flexible cable having a plurality of sensing flat conductors (320), the connecting cable being a flat flexible cable having a plurality of connecting flat conductors (360), the busbar sensing cable extending along a column of the busbar, wherein the sensing flat conductors are electrically connected at corresponding sensing points to corresponding busbars in corresponding columns to sense the voltage of each of the corresponding busbars, the connecting cable spanning each of the busbar sensing cables, wherein the connecting flat conductors are electrically connected to the corresponding sensing flat conductors of each of the busbar sensing cables, and the connecting flat conductors of the connecting cable being electrically connected to a control module (400).

2. The battery pack interconnect assembly (50) according to claim 1, wherein the busbar sensing cable (310) and the connecting cable (350) form a grid structure.

3. The battery pack interconnect assembly (50) according to claim 1, wherein the busbar sensing cable (310) includes sensing access windows (330, 332) that expose a corresponding sensing flat conductor (320) at the sensing point (302).

4. The battery pack interconnect assembly (50) according to claim 1, wherein the sensing flat conductor (320) is electrically connected to the corresponding busbar (200) by one of welding connection, conductive bonding connection, riveting connection or conductive adhesive connection.

5. The battery pack interconnect assembly (50) of claim 1, wherein the busbar sensing cable (310) includes a first connection entry window (330) exposing a corresponding sensing flat conductor (320) at a junction (334), and the connecting cable (350) includes a second connection entry window (332) exposing the connecting flat conductor (360) at a junction, the second connection entry window being aligned with the corresponding first connection entry window to electrically connect the connecting flat conductor to the corresponding sensing flat conductor at the junction.

6. The battery pack interconnect assembly (50) according to claim 5, wherein the second connection access window (332) exposes different connection flat conductors (320) at each of the corresponding busbar sensing cables (310).

7. The battery pack interconnect assembly (50) according to claim 5, wherein the connecting flat conductor (360) is electrically connected to the corresponding sensing flat conductor (320) by one of welding connection, conductive bonding connection, riveting connection or conductive adhesive connection.

8. The battery pack interconnect assembly (50) of claim 1, wherein the busbar sensing cable (310) includes a conductor separation window (340) passing through the busbar sensing cable, the conductor separation window (340) separating the sensing flat conductor (320) into electrically isolated segments.

9. The battery pack interconnect assembly (50) of claim 1, wherein a plurality of sensing flat conductors (320) are connected to each busbar (200) to define a plurality of contact points (334) between the busbar sensing cable (310) and the corresponding busbar.

10. The battery pack interconnect assembly (50) of claim 1, wherein the sensing harness (300) includes an electrical connector at the end of the connecting cable (350) connected to the control module (400).

11. The battery pack interconnect assembly (50) of claim 1, wherein the busbar carrier (110) includes a frame coupled to the busbar (200) to hold the busbar in the column (206), and the busbar sensing cable (310) is coupled to the frame.

12. A sensing harness (300) for sensing the voltage of a busbar (200), the busbar (200) being electrically connected to cell terminals (24, 26) of a battery cell (20) in a battery pack (10), the sensing harness comprising: Busbar sensing cable (310) extends parallel to each other in columns (206), the busbar sensing cable is a flat flexible cable (310) having a plurality of sensing flat conductors (320), the busbar sensing cable extends along columns of the busbars (200), the sensing flat conductors being configured to be electrically connected at sensing points (302) to the corresponding busbars in the corresponding columns to sense the voltage of each of the corresponding busbars; and A connecting cable (350) extends parallel to each other in rows (204), the connecting cable being a flat flexible cable having a plurality of connecting flat conductors (360) that cross each of the busbar sensing cables, the connecting flat conductors being electrically connected to a corresponding sensing flat conductor of each of the busbar sensing cables, and the connecting flat conductors of the connecting cable being electrically connected to a control module (400).

13. The sensing harness (300) according to claim 12, wherein the busbar sensing cable (310) and the connecting cable (350) form a grid structure.

14. The sensing harness (300) according to claim 12, wherein the busbar sensing cable (310) includes sensing access windows (330, 332) that expose the corresponding sensing flat conductor (320) at the sensing point (302).

15. The sensing harness (300) of claim 12, wherein the busbar sensing cable (310) includes a first connection entry window (330) exposing a corresponding sensing flat conductor (320) at a junction (334), and the connecting cable (350) includes a second connection entry window (332) exposing the connecting flat conductor (360) at a junction, the second connection entry window being aligned with the corresponding first connection entry window to electrically connect the connecting flat conductor to the corresponding sensing flat conductor at the junction.

16. The sensing harness (300) according to claim 15, wherein the second connection entry window (332) exposes different connection flat conductors (360) at each of the corresponding busbar sensing cables (310).

17. The sensing harness (300) according to claim 15, wherein the connecting flat conductor (360) is electrically connected to the corresponding sensing flat conductor (320) by one of welding connection, conductive bonding connection, riveting connection or conductive adhesive connection.

18. The sensing harness (300) of claim 12, wherein a plurality of sensing flat conductors (320) are configured to be connected to each busbar (200) to define a plurality of contact points (334) between the busbar sensing cable (310) and the corresponding busbar.

19. A battery pack (10), comprising: The battery cells (20) are arranged in a matrix having a plurality of rows (204) and a plurality of columns (206) of the battery cells, each battery cell including a first cell terminal (24) and a second cell terminal (26). and A battery pack interconnect assembly (50) is electrically connected to a first cell terminal and a second cell terminal of the battery cell. The battery pack interconnect assembly includes a busbar interconnect (100) and a sensing harness (300) electrically connected to the busbar interconnect. The busbar interconnection includes a plurality of busbars (200) arranged in a matrix (202) and a busbar carrier (110) holding the busbars. The matrix (202) has multiple rows and multiple columns of the busbars. Each busbar includes a first mating end (215) for mating with a first cell terminal of a corresponding battery cell and a second mating end (217) for mating with a second cell terminal of an adjacent corresponding battery cell. The busbars are electrically connected to the battery cells in the battery pack. The sensing harness has sensing points (302) connected to the busbar. The sensing harness includes a busbar sensing cable (310) and a connecting cable (350). The busbar sensing cable is a flat flexible cable with multiple sensing flat conductors (320). The connecting cable is a flat flexible cable with multiple connecting flat conductors (360). The busbar sensing cable extends along a column of the busbar. The sensing flat conductors are electrically connected at corresponding sensing points to the corresponding busbars in the corresponding column to sense the voltage of each of the corresponding busbars. The connecting cable spans each of the busbar sensing cables. The connecting flat conductors are electrically connected to the corresponding sensing flat conductors of each of the busbar sensing cables. The connecting flat conductors of the connecting cable are electrically connected to the control module (400).

20. The battery pack of claim 19, wherein a plurality of sensing flat conductors (320) are connected to each busbar (200) to define a plurality of contact points (334) between the busbar sensing cable (310) and the corresponding busbar.

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