Battery pack interconnection assembly for battery pack

Abstract

A battery pack interconnect assembly (50) for electrically connecting cell terminals (24, 26) of cells (20) in a battery pack (10) includes a busbar interconnect (100) having a busbar carrier (110) holding a plurality of busbars (200), each busbar having a first mating end (215) and a second mating end (217) for mating with a respective adjacent cell terminal. The battery interconnect assembly includes a sensing harness (300) having a sensing module (310) and a sensing cable (350) having a sensing conductor (360) coupled to the sensing module. The sensing module includes sensing circuitry (312, 314) electrically connected to the respective busbars at a sensing point (302) to sense a voltage of each of the respective busbars. The sensing cable spans between the sensing modules, wherein the sensing conductors are electrically connected to respective sensing circuits of respective sensing modules. The sensing conductor of the sensing cable is electrically connected to a control module (400).

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Application No. 63 / 710,357, filed October 22, 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 cells. A typical battery system requires connectivity solutions to transfer / distribute power between the cell packs and has 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 overhead cost ($ / kWh) of components is being carefully examined, and cost minimization is desired, for example, by minimizing the number and size of components. For electric vehicle battery systems, the cell stacks are 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 busbar. 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 cells in a battery pack. The battery pack interconnect assembly includes a bus interconnect comprising a plurality of buses arranged in a matrix, the matrix having multiple rows and columns of buses and bus carriers holding the buses. Each bus includes a first mating end for mating with a corresponding cell terminal of a corresponding cell and a second mating end for mating with an adjacent cell terminal of an adjacent corresponding cell. The bus electrically connects to the cells in the battery pack. The battery pack interconnect assembly includes a sensing harness having sensing points coupled to the bus. The sensing harness includes a sensing module and a sensing cable coupled to the sensing module. The sensing cable includes a sensing conductor. The sensing module includes sensing circuitry electrically connected at the sensing points to the respective bus to sense the voltage of each of the respective bus. Sensing cables traverse between sensing modules, wherein the sensing conductors are electrically connected to the corresponding sensing circuitry of the respective sensing module. The sensing conductors of the sensing cables are electrically connected to a 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 the sensing module according to an exemplary embodiment.

[0011] Figure 4 This is a side view of the sensing module according to an exemplary embodiment.

[0012] Figure 5 This is a top view of a sensing cable according to an exemplary embodiment.

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

[0014] Figure 7 A sensing harness according to an exemplary embodiment is shown.

[0015] Figure 8 A portion of a battery pack interconnect assembly according to an exemplary embodiment is shown, illustrating a sensing module connected to a busbar.

[0016] Figure 9 A portion of a battery pack interconnect assembly according to an exemplary embodiment is shown, illustrating a sensing harness connected to a busbar.

[0017] Figure 10 A portion of a battery pack interconnect assembly according to an exemplary embodiment is shown, illustrating a sensing harness connected to a busbar.

[0018] Figure 11 According to the exemplary embodiments, along Figure 10 The image shows a cross-sectional view of the battery pack interconnect components, taken from line AA.

[0019] Figure 12 According to the exemplary embodiments, along Figure 10 The image shows a cross-sectional view of the battery pack interconnect components taken from line BB.

[0020] Figure 13 According to the exemplary embodiments, along Figure 10 The image shows a cross-sectional view of the battery pack interconnect components taken by line CC.

[0021] Figure 14 A portion of a battery pack interconnect assembly according to an exemplary embodiment is shown, illustrating a sensing harness connected to a busbar. Detailed Implementation

[0022] 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 bus interconnect 100 and a sensing harness 300. The bus interconnect 100 has a plurality of buses 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.

[0023] Battery pack 10 may be a battery pack for a vehicle, such as 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. Bus interconnect 100 is used to electrically connect the matrix of cells 20 of battery pack 10. For example, bus interconnect 100 may connect the cells 20 in series and / or in parallel.

[0024] The battery cell 20 can be held in the battery pack housing 12. The battery pack 10 includes a positive battery interconnect terminal 14 and a negative battery interconnect terminal 16. The battery interconnect terminals 14 and 16 can be connected to other power distribution components of the battery pack 10, such as contactors and fuses for connecting to a charging system and / or a load (e.g., an electric motor).

[0025] Each cell 20 includes a battery casing 22, a first cell terminal 24, and a second cell terminal 26. In various embodiments, the cell 20 may be a prismatic 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 cells 20 are rectangular and arranged in a stacked configuration. For example, the cells 20 may be stacked as rows and columns of 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 cells 20 in a row are interconnected via corresponding buses 200 of the bus interconnect 100. Adjacent rows of cells 20 are interconnected via corresponding buses 200 of the bus interconnect 100. For example, end cells 20 may be connected row by row.

[0026] The bus interconnect 100 includes a bus carrier 110 that holds the bus 200. The bus carrier 110 holds the bus 200 in a relative position for mating with the cell terminals 24, 26 of the respective cells 20. The bus 200 electrically connects adjacent cells 20, for example, in series and / or in parallel. In various embodiments, the bus carrier 110 integrates all the bus 200s into a single unit or structure for mounting to a matrix of cells 20. For example, a single bus carrier 110 may be used to hold all the bus 200s. In other various embodiments, the bus carrier 110 may include multiple frames or units, each frame or unit holding multiple bus 200s, such as a row of bus 200s. The frames / units may be connected together by other elements of the bus carrier 110 to form a connection structure.

[0027] In various embodiments, the bus carrier 110 may be a structural foam lead frame that holds the bus 200. For example, the bus carrier 110 may be manufactured using a structural foam molding process. In alternative embodiments, the bus carrier may be made of other materials, such as molded plastic structures. The bus carrier 110 may be molded or formed on a bus matrix. For example, the bus carrier 110 may be in-situ overmolded onto a portion of the bus 200 to form the bus interconnect 100. The bus carrier 110 may be formed around a portion of the bus 200 to hold the bus 200 relative to each other and relative to the cell terminals 24, 26 of the cell 20.

[0028] In an exemplary embodiment, the bus carrier 110 includes a frame or grid 120. The grid 120 is formed around portions of the bus 200 to hold the bus 200 in relative position. In an exemplary embodiment, the bus carrier 110 holds all the bus 200s for the battery pack 10 to reduce the number of components required for final assembly into the battery pack 10. For example, a single bus interconnect 100 is assembled into the battery pack 10. The bus carrier 110 is used to position the bus 200 for electrical connection to the cell terminals 24, 26 of the cell 20. In an exemplary embodiment, a sensing harness 300 is coupled to the bus carrier 110. The bus carrier 110 can be used to position the sensing harness on the cell 20.

[0029] The trellis 120 includes frame members 122 configured to connect to busbars 200 to maintain the relative position of the busbars 200. Frame members 122 include outer frame members 130 and inner frame members 140, the outer frame members 130 surrounding the periphery of the trellis 120 and the inner frame members 140 spanning the interior of the trellis 120 to connect to the busbars 200. The inner frame members 140 extend between the outer frame members 130. For example, the inner frame members 140 include longitudinal elements 142 and transverse elements 144. The longitudinal elements 142 extend longitudinally through the trellis 120 between opposite ends. The transverse elements 144 extend laterally through the trellis 120 between opposite sides. The longitudinal elements 142 and / or the transverse elements 144 can be used to support portions of the busbars 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 a single, integral structure.

[0030] In an exemplary embodiment, the lateral element 144 spans a column of 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 rows of 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.

[0031] In an exemplary embodiment, the sensing harness 300 has sensing points 302 for monitoring the bus 200 and / or cell terminals 24, 26. For example, the sensing harness 300 is electrically connected to the bus 200 at sensing points 302 to monitor the voltage, temperature, state of charge, or other operating characteristics of the bus 200 and / or cell 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.

[0032] Battery pack interconnect assembly 50 provides a large cell interconnect assembly configured to be mounted to battery pack 10 (e.g., each cell 20), such as a single unit. Bus carrier 110 holds bus 200 in place to terminate to cell terminals 24, 26 of each cell 20 of battery pack 10. By holding bus 200 to be assembled to the cells 20 of battery pack 10, assembly processes, such as those in conventional battery systems where each bus is individually assembled to the cell through multiple assembly steps, can be omitted. Bus interconnect assembly 100 reduces the total number of parts and the number of parts handled during assembly of battery pack 10. Bus carrier 110 can have a large format and surface area. For example, the structural process of manufacturing the lattice frame for bus carrier 110 achieves a large footprint for bus carrier 110. The structural material of the lattice frame for bus carrier 110 is dimensionally stable and does not tend to warp, thus making assembly and termination to the cells simpler, faster, and less costly compared to conventional assembly processes.

[0033] 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 busbar 200 and sensing harness 300 connected to busbar 200. Busbar 200 is arranged in rows 204 and columns 206 of matrix 202. The arrangement of busbar 200 corresponds to the arrangement of battery cells 20 for connection to corresponding battery cell terminals 24, 26. Sensing harness 300 traverses rows 204 and columns 206 of busbar 200 to be electrically connected to each of busbar 200 for sensing the characteristics (e.g., voltage) of each of busbar 200.

[0034] 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 cells 20. The second mating pad 216 is configured to connect to a cell terminal 26 of an adjacent cell 20. The busbar 200 electrically connects adjacent 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.

[0035] 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 that are 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 cell 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.

[0036] In an exemplary embodiment, the matrix 202 of busbars 200 includes eighteen rows 204 and seven columns 206 of busbars 200. In alternative embodiments, more or fewer busbars 200 may be provided in rows 204 and / or columns 206. In an exemplary embodiment, the busbars 200 include outer busbars 240 and inner busbars 242. The outer busbars 240 are arranged along opposite sides (e.g., right and left) of the busbar matrix 202. The outer busbars 240 are used for connecting cells 20 in two different rows. The inner busbars 242 extend between the outer busbars 240. The inner busbars 242 are used for connecting adjacent cells 20 in the same column. The outer busbars 240 are oriented perpendicular to the inner busbars 242. For example, the inner busbars 242 are oriented longitudinally, and the outer busbars 240 are oriented laterally. In alternative embodiments, other orientations are possible.

[0037] The sensing harness 300 includes sensing modules 310 and sensing cables 350 coupled to each of the sensing modules 310. The sensing modules 310 and sensing cables 350 form a cover structure overlapping a matrix 202 of the busbar 200. The sensing modules 310 may extend generally in the Y direction, and the sensing cables 350 may extend generally in the X direction. In an exemplary embodiment, the sensing cables 350 are flat, flexible cables having a plurality of flat conductors disposed in an insulator configured to be electrically connected to corresponding rows of the sensing modules 310.

[0038] In an exemplary embodiment, a sensing module 310 extends along column 206 of busbars 200 and is electrically connected to a corresponding busbar 200 in column 206 at a corresponding sensing point 302. The sensing module 310 senses characteristics, such as voltage, of each corresponding busbar 200. A sensing cable 350 crosses each of the sensing modules 310 and is electrically connected to the sensing module 310 to aggregate signals from the sensing module 310. The sensing cable 350 is electrically connected to a control module 400.

[0039] Figure 3 This is a top view of the sensing module 310 according to an exemplary embodiment. Figure 4 This is a side view of a sensing module 310 according to an exemplary embodiment. In the exemplary embodiment, the sensing module 310 includes a sensing housing 320 and one or more sensing circuits. In the illustrated embodiment, the sensing module 310 includes a pair of sensing circuits, namely a first sensing circuit 312 and a second sensing circuit 314. In alternative embodiments, the sensing module 310 may include more or fewer sensing circuits 312, 314. In various embodiments, the sensing circuits 312, 314 may be electrically connected to different buses 200. In other various embodiments, the sensing circuits 312, 314 may be connected to the same bus 200 to define multiple contact points with the same bus 200, and thus define redundant connections to improve reliability.

[0040] In an exemplary embodiment, the sensing housing 320 is made of a dielectric material, such as a plastic material. The sensing housing 320 may be a molded part. In various embodiments, the sensing housing 320 is formed at appropriate locations on the sensing circuits 312, 314. For example, the sensing housing 320 may overlay a portion of the sensing circuits 312, 314. The sensing module 310 may be an overlay molded lead frame. In alternative embodiments, the sensing housing 320 may be pre-formed, and the sensing circuits 312, 314 may be coupled to the sensing housing 320. In the illustrated embodiment, the sensing housing 320 includes a top 322, a bottom 324, and a side edge 326 between the top 322 and the bottom 324. The sensing housing 320 is generally rectangular. However, in alternative embodiments, the sensing housing 320 may have other shapes. The bottom 324 may be mounted to one or more of the busbar 200 and / or busbar carrier 110. In an exemplary embodiment, the sensing circuits 312, 314 may extend along the top 322, for example for connection to the sensing cable 350.

[0041] The first sensing circuit 312 and the second sensing circuit 314 may be similar to each other and include similar structures. The same reference numerals may be used herein to identify the same elements. Sensing circuit 312 includes a sensing contact 330 extending between a first end 332 and a second end 334. In an exemplary embodiment, the sensing contact 330 is a stamped contact, which is formed by stamping and bending or shaping a sheet of metal into a predetermined shape. Sensing contact 330 may include a busbar. In an alternative embodiment, sensing circuit 312 may include flexible circuitry, such as a flat flexible cable, a flexible printed circuit board, a ribbon cable, or other types of flexible circuitry.

[0042] The sensing contact 330 includes a first mating tab 336 at a first end 332 and a second mating tab 338 at a second end 334. In the illustrated embodiment, the first mating tab 336 and the second mating tab 338 are at different vertical heights. For example, the first mating tab 336 may be substantially coplanar with the bottom 324 of the second housing 320, and the second mating tab 338 may be substantially coplanar with the top 322 of the second housing 320. The first mating tab 336 is configured to be electrically connected to the busbar 200. For example, the first mating tab 336 may be connected to the busbar 200 by welding, conductive bonding, riveting, or conductive adhesive bonding. In the illustrated embodiment, the second mating tab 336 extends along the top 322 of the transmitting housing 320. The second mating tab 336 is configured to be electrically connected to the sensing cable 350. For example, the second mating tab 338 may be connected to the sensing cable 350 by welding, conductive bonding, riveting, or conductive adhesive bonding.

[0043] In an exemplary embodiment, the second mating tabs 338 of the first sensing circuit 312 and the second sensing circuit 314 may overlap at the top 322. For example, the second mating tabs 338 may bypass each other on opposite sides of the sensing housing 320. The second mating tabs 338 may be spaced apart from each other by gaps. The second mating tabs 338 are electrically isolated from each other for electrical connection to different busbars 200.

[0044] Figure 5 This is a top view of the sensing cable 350 according to an exemplary embodiment. Figure 6 This is a cross-sectional view of a sensing cable 350 according to an exemplary embodiment. In the exemplary embodiment, the sensing cable 350 is a flat, flexible cable. The sensing cable 350 extends between a first end 352 and a second end 354. In the 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.

[0045] The sensing cable 350 includes an insulator 356 holding a plurality of sensing 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 sensing conductors 360. The sensing conductors 360 are sandwiched between the 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 sensing conductors 360 using one or more adhesive layers to form a single flexible unit.

[0046] The sensing conductor 360 is a flat, parallel conductor. The sensing conductor 360 can be made of copper, aluminum, or other metallic materials. Each sensing conductor 360 includes an upper surface 362 and a lower surface 364. The sensing conductor 360 includes side surfaces 366 between the upper surface 362 and the lower surface 364. In an exemplary embodiment, the sensing 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 sensing conductors 360.

[0047] In the illustrated embodiment, the sensing cable 350 includes fifteen sensing conductors 360. In alternative embodiments, the sensing cable 350 may include more or fewer sensing conductors 360, such as the number to accommodate a bus voltage signal to be measured or other components such as a temperature sensor, which may depend on the number of cells. In the exemplary embodiment, the sensing conductors 360 each have the same dimensions (e.g., height and width). However, in alternative embodiments, the sensing conductors 360 may have different dimensions. In the exemplary embodiment, the sensing cable 350 may have a common pitch or spacing between the sensing conductors 360. However, in alternative embodiments, the sensing cable 350 may have different spacing between the sensing conductors 360.

[0048] In an exemplary embodiment, the sensing cable 350 includes a connection access window 372 that exposes a corresponding sensing 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 sensing 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 at the junction 374 to the sensing conductor 360 for electrical connection to sensing circuits 312, 314 of the sensing module 310. For example, the sensing conductor 360 may be electrically connected to the corresponding sensing circuits 312, 314 by one of soldering, conductive bonding, riveting, or conductive adhesive bonding. In an exemplary embodiment, the connection access window 374 exposes different sensing conductors 360 along different segments of the sensing cable 350 for connection to different sensing modules 310. For example, each sensing conductor 360 may be exposed at different locations along the length of the sensing cable 350 for connection to different sensing modules 310.

[0049] Figure 7 A sensing harness 300 according to an exemplary embodiment is shown. The sensing harness 300 includes sensing modules 310 and sensing cables 350 coupled to each of the sensing modules 310. The sensing modules 310 are arranged in rows and columns. The sensing cables 350 extend laterally across the sensing modules 310, such as along rows of sensing modules 310, to overlap with and be electrically connected to each sensing module 310 in the respective row. The sensing cables 350 are flat, flexible cables having a plurality of flat conductors electrically connected to the respective sensing modules 310. In an exemplary embodiment, the sensing cables 350 are electrically connected to the sensing modules 310 to form a cable harness configured to be coupled to a busbar 200. For example, the sensing cables 350 are electrically connected to the sensing modules 310 before the sensing modules 310 are coupled to the busbar 200. In an alternative embodiment, the sensing modules 310 may be coupled to the busbar 200 before the sensing cables 350 are coupled to the sensing modules 310.

[0050] Figure 8 A portion of the battery pack interconnect assembly 50 is shown, including a sensing module 310 connected to bus 200. In various embodiments, the sensing module 310 may be connected to bus 200 before the sensing cable 350 is connected to the sensing module 310.

[0051] During assembly, sensing module 310 is coupled to busbar 200. Sensing module 310 may be coupled to busbar carrier 110, such as to frame member 122. For example, sensing module 310 may be coupled to longitudinal element 142 and / or transverse element 144. Sensing circuits 312, 314 may be electrically connected to the respective busbar 200 via one of the following methods: soldering, conductive bonding, riveting, or conductive adhesive bonding. Sensing circuits 312, 314 can be soldered to busbar 200 simultaneously with soldering to the battery cell, thus eliminating the need for pre-soldering and simplifying assembly. In an alternative embodiment, sensing circuits 312, 314 may be pre-soldered or bonded to each other and / or busbar 200 before soldering busbar 200 to the battery cell. In an exemplary embodiment, sensing circuits 312, 314 are electrically connected to adjacent busbars 200, such as buses in adjacent rows.

[0052] Figure 9 A portion of the battery pack interconnect assembly 50 is shown, including a sensing harness 300 connected to bus 200. A sensing module 310 is connected to bus 200. During assembly, the sensing module 310 may be connected to bus carrier 110, such as to frame member 122. During assembly, a sensing cable 350 may be connected to bus carrier 110, such as to frame member 122. For example, the sensing cable 350 may be connected to longitudinal element 142 and / or transverse element 144.

[0053] During assembly, sensing conductors 360 are electrically connected to sensing circuits 312, 314 at corresponding junctions. For example, connection access window 372 exposes sensing conductors 360 for electrical connection to sensing circuits 312, 314. Sensing conductors 360 can be electrically connected to corresponding sensing circuits 312, 314 via soldering, conductive bonding, riveting, or conductive adhesive bonding. Connection access window 374 exposes different sensing conductors 360 along different sections of sensing cable 350 for connection to different sensing modules 310.

[0054] Figure 10 A portion of the battery pack interconnect assembly 50 is shown, along with a sensing harness connected to the bus 200. Figure 11 It is along Figure 10 The cross-sectional view of the battery pack interconnect assembly 50 taken by line AA. Figure 12 It is along Figure 10 The cross-sectional view of the battery pack interconnect assembly 50 taken by line BB. Figure 13 It is along Figure 10 The cross-sectional view of the battery pack interconnect assembly 50 is taken by line CC.

[0055] Sensing module 310 is connected to bus 200. During assembly, sensing module 310 may be connected to bus carrier 110. For example, sensing housing 320 may be connected to one of frame members 122. Sensing housing 320 may be secured to frame member 122 by adhesives, fasteners, clips, latches, or other fixing devices. Sensing housing 320 and / or frame member 122 may include positioning features to align and / or position sensing housing 320 relative to frame member 122. Sensing housing 320 positions sensing circuits 312, 314 relative to bus 200. For example, a first sensing circuit 312 may be connected to one of bus 200, and a second sensing circuit 314 may be connected to an adjacent bus 200.

[0056] When assembled, the sensing cable 350 is coupled to the sensing module 310. For example, sensing conductors 360 are electrically connected to sensing circuits 312, 314 at corresponding junctions. In an exemplary embodiment, different sensing conductors 360 are coupled to mating tabs 338 of the first sensing circuit 312 and the second sensing circuit 314. For example, a connection access window 372 exposes different sensing conductors 360 for electrical connection to different sensing circuits 312, 314. The sensing conductors 360 can be electrically connected to the respective sensing circuits 312, 314 by one of soldering, conductive bonding, riveting, or conductive adhesive bonding. The sensing conductors 360 can be directly soldered to each other and / or the busbar 200 or an intermediate material (e.g., solder, conductive adhesive, etc.) can be disposed therebetween.

[0057] Figure 14 A portion of the battery pack interconnect assembly 50 is shown, along with a sensing harness 300 connected to the bus 200. Figure 14 A sensing harness 300 is shown, which includes a temperature sensor 306 and a fuse 308 connected to a sensing cable 350. The temperature sensor 306 and the fuse 308 can be connected to a corresponding sensing conductor 360. The temperature sensor 306 can be an NTC thermistor or other type of temperature sensor.

Claims

1. A battery pack interconnect assembly (50) for electrically connecting cell terminals (24, 26) of cells (20) in a battery pack (10), the battery pack interconnect assembly comprising: A bus interconnect (100) includes a plurality of buses (200) arranged in a matrix (202) and a bus carrier (110) holding the buses. The matrix (202) has multiple rows (204) of the buses and multiple columns (206) of the buses. Each bus includes a first mating end (215) and a second mating end (217). The first mating end (215) is used to mate with a corresponding cell terminal of a corresponding cell, and the second mating end (217) is used to mate with an adjacent cell terminal of an adjacent corresponding cell. The bus is electrically connected to the cells in the battery pack. and A sensing harness (300) has sensing points (302) connected to the busbars. The sensing harness includes a sensing module (310) and a sensing cable (350) connected to the sensing module. The sensing cable includes a sensing conductor (360). The sensing module includes sensing circuits (312, 314) electrically connected at the sensing points to the respective busbars to sense the voltage of each of the respective busbars. The sensing cable spans between the sensing modules, wherein the sensing conductor is electrically connected to the respective sensing circuit of the respective sensing module. The sensing conductor of the sensing cable is electrically connected to a control module (400).

2. The battery pack interconnect assembly (50) according to claim 1, wherein, The sensing cable (350) is a flat, flexible cable having a flat conductor defining the sensing conductor (360).

3. The battery pack interconnect assembly (50) according to claim 2, wherein, The sensing conductors (360) extend parallel to each other and are surrounded by an insulator (356), a portion of which is removed to form an access window (372) to the sensing conductor at a junction point, where the sensing conductor is electrically connected to the sensing circuit (312, 314).

4. The battery pack interconnect assembly (50) according to claim 3, wherein, The sensing conductor (360) is electrically connected to the corresponding sensing circuit (312, 314) by one of the following methods: welding connection, conductive bonding connection, riveting connection or conductive adhesive connection.

5. The battery pack interconnect assembly (50) according to claim 3, wherein, The access window (372) exposes different sensing conductors (360) at each corresponding sensing module (310).

6. The battery pack interconnect assembly (50) according to claim 1, wherein, The sensing module (310) includes a sensing housing (320), and the sensing circuit (312) is held by the sensing housing.

7. The battery pack interconnect assembly (50) according to claim 6, wherein, The sensing circuit is a first sensing circuit (312), and the sensing module (310) includes a second sensing circuit (314) held by the sensing housing (320).

8. The battery pack interconnect assembly (50) according to claim 7, wherein, The first sensing circuit (312) and the second sensing circuit (314) are electrically connected to different buses (200).

9. The battery pack interconnect assembly (50) according to claim 7, wherein, The first sensing circuit (312) and the second sensing circuit (314) are electrically connected to the same bus (200), thereby forming a redundant electrical connection to the bus.

10. The battery pack interconnect assembly (50) according to claim 7, wherein, Different signal conductors are electrically connected to the first sensing circuit (312) and the second sensing circuit (314).

11. The battery pack interconnect assembly (50) according to claim 1, wherein, The sensing circuit (312, 314) includes stamped sensing contacts (330).

12. The battery pack interconnect assembly (50) according to claim 1, wherein, The sensing module (310) is connected to the bus (200) before the sensing cable (350) is electrically connected to the sensing module.

13. The battery pack interconnect assembly (50) according to claim 1, wherein, Before the sensing module is electrically connected to the bus (200), the sensing cable (350) is electrically connected to the sensing module (310).

14. The battery pack interconnect assembly (50) according to claim 1, wherein, The sensing harness (300) includes one or more temperature sensors (306) coupled to the sensing conductor (360).

15. The battery pack interconnect assembly (50) according to claim 1, wherein, The sensing harness (300) includes one or more fuses (308) connected to the sensing conductor (360).

16. A sensing harness (300) for sensing the voltage of a bus (200), the bus (200) being electrically connected to cell terminals (24, 26) of cells (20) in a battery pack (10), the sensing harness comprising: A sensing module (310) is configured to be electrically connected at a sensing point (302) to a corresponding bus to sense the voltage of each of the corresponding buses. Each sensing module includes a sensing housing (320) and a sensing circuit (312) held by the sensing housing, the sensing circuit being configured to be electrically connected to the corresponding bus. and Sensing cables (350) extend parallel to each other in rows (204). The sensing cables are flat, flexible cables with a plurality of sensing conductors (360) that cross each of the sensing modules. The sensing conductors are electrically connected to the corresponding sensing circuits of each of the sensing modules. The sensing conductors of the sensing cables are electrically connected to the control module (400).

17. The sensing harness (300) according to claim 16, wherein, The sensing cable (350) is a flat, flexible cable with a flat conductor defining the sensing conductor (360) surrounded by an insulator (356), a portion of which is removed to form an access window (372) to the sensing conductor at a junction, the sensing conductor being electrically connected to the sensing circuit (312, 314) at the junction, wherein the access window exposes a different sensing conductor at each respective sensing module (310).

18. The sensing harness (300) according to claim 16, wherein, The sensing circuit is a first sensing circuit (312), and the sensing module (310) includes a second sensing circuit (314) held by the sensing housing (320). The first sensing circuit and the second sensing circuit are electrically connected to different busbars (200), wherein different signal conductors are electrically connected to the first sensing circuit and the second sensing circuit.

19. A battery pack (10), comprising: The battery cell (20) is arranged in a matrix (202) having a plurality of rows (204) and a plurality of columns (206) of the battery cell, each battery cell including a first battery cell terminal (24) and a second battery cell terminal (26). and A battery pack interconnect assembly (50) electrically connected to the first cell terminal and the second cell terminal of the battery cell, the battery pack interconnect assembly including a bus interconnect (100) and a sensing harness (300) electrically connected to the bus interconnect. The bus interconnect includes a plurality of buses (200) arranged in a matrix and a bus carrier (110) holding the buses. The matrix has multiple rows and multiple columns of the buses. Each bus includes a first mating end (215) and a second mating end (217). The bus is electrically connected to the cells in the battery pack. The first mating end (215) is used to mate with the first cell terminal of the corresponding cell, and the second mating end (217) is used to mate with the second cell terminal of the adjacent corresponding cell. The sensing harness has sensing points (302) connected to the busbars. The sensing harness includes a sensing module (310) and a sensing cable (350). The sensing cable includes a sensing conductor (360). The sensing module includes sensing circuits (312, 314). The sensing circuits (312, 314) are electrically connected to the respective busbars at the sensing points to sense the voltage of each respective busbar. The sensing cable spans between the sensing modules, wherein the sensing conductors are electrically connected to the respective sensing circuits of the respective sensing modules, and the sensing conductors of the sensing cable are electrically connected to the control module (400).

20. The battery pack (10) according to claim 19, wherein, The sensing cable (350) is a flat, flexible cable with a flat conductor defining the sensing conductor (360) surrounded by an insulator (356), a portion of which is removed to form an access window (372) to the sensing conductor at a junction point, the sensing conductor being electrically connected to the sensing circuit (312, 314) at the junction point, wherein the access window exposes a different sensing conductor at each respective sensing module (310).

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