Rigid printed circuit board busbar carrier and cell interconnect

Abstract

In some embodiments, the battery module (104) may include: a battery stack including a plurality of battery cells (106); one or more module interconnect busbars (208); and a printed circuit board (PCB) (204) disposed on the battery stack and defining a plurality of openings (214). The PCB (204) may be configured as a carrier for the one or more module interconnect busbars (208). The plurality of openings (214) may be arranged such that each of the plurality of openings (214) is aligned with a terminal of each of the plurality of battery cells (106). The one or more module interconnect busbars (208) may be attached to the PCB (204) in alignment with the plurality of openings (214) and electrically connected to the plurality of battery cells (106) of the battery stack.

Description

Technical Field

[0001] This disclosure generally relates to batteries and, for example, rigid printed circuit board (PCB) busbar carriers and cell interconnects. Background Technology

[0002] The machine may include one or more battery packs to provide power to its components, such as lights, computer systems, and / or motors, among other examples. The battery pack may be associated with a modular design that includes multiple battery modules. A battery module may include multiple battery cells. The battery cells may be connected in series or parallel via busbars and cell interconnect circuitry placed on an injection-molded carrier. Manufacturing battery modules typically requires placing the carrier separately from other components on the battery cells, which increases manufacturing complexity. Furthermore, the carrier is an additional component that can increase the manufacturing cost of the battery module. In addition, the carrier serves as a fixture for assembling the battery cells and increases the size of the battery module, while being largely ineffective or useless after assembly.

[0003] Chinese Patent No. 214176206 ('206 Patent) discloses a battery module connection and acquisition structure, which includes an integrated busbar base film, multiple busbar cells, and multiple acquisition circuit boards. The multiple busbar cells and multiple acquisition circuit boards are arranged on the integrated busbar base film. The integrated busbar base film is provided with multiple hollow electrode avoidance holes, which allow the battery electrodes of the battery module to pass through the busbar cells and then be connected to the busbar cells by welding. Assembling the battery module of the '206 Patent involves placing a buffer layer between the top of the battery cells and the busbar base film. The electrodes and acquisition circuit boards are then placed on top of the busbar base film. However, the '206 Patent does not disclose a carrier that prevents the battery module acquisition structure from being assembled separately from the rest of the battery module. Furthermore, without a carrier, the battery module acquisition structure of the '206 Patent may require increased manufacturing complexity.

[0004] The rigid PCB carrier disclosed herein solves one or more of the above-mentioned problems and / or other problems in the art. Summary of the Invention

[0005] A battery module may include: a battery stack including a plurality of battery cells; one or more module interconnect busbars; a printed circuit board (PCB) disposed on the battery stack and defining a plurality of openings, the PCB being configured as a carrier for the one or more module interconnect busbars, and the plurality of openings being arranged such that each of the plurality of openings is aligned with a terminal of each of the plurality of battery cells, the one or more module interconnect busbars being attached to the PCB aligned with the plurality of openings and electrically connected to the plurality of battery cells of the battery stack.

[0006] A machine may include: an electric motor; and a battery pack electrically connected to the electric motor, the battery pack including a plurality of battery cells and a PCB, the PCB being configured as a carrier for one or more busbars, the PCB defining a plurality of openings spaced apart from each other and forming a first row and a second row parallel to the first row in the PCB, the plurality of openings being arranged such that each of the plurality of openings is aligned with a terminal of each of the plurality of battery cells, and the one or more busbars are attached to the PCB aligned with the plurality of openings and electrically connected to the plurality of battery cells.

[0007] A carrier for a battery stack may include: a printed circuit board defining a plurality of openings arranged to align with terminals of battery cells of the battery stack, the PCB configured to be attached to one or more busbars, and the plurality of openings configured to enable electrical connection between the battery cells and the one or more busbars; and tabs electrically connecting the busbars to the PCB. Attached Figure Description

[0008] Figure 1 This is a diagram of an exemplary battery pack.

[0009] Figure 2 This is a perspective view of an exemplary battery module.

[0010] Figure 3 yes Figure 2 A close-up view of a portion of an exemplary battery module.

[0011] Figure 4 yes Figure 2 A side view of an exemplary battery module.

[0012] Figure 5 Is with Figure 2 Top view of an exemplary PCB and busbar used in conjunction with a battery module.

[0013] Figure 6 yes Figure 5 Bottom view of an exemplary PCB and busbar. Detailed Implementation

[0014] This disclosure relates to a rigid PCB busbar carrier and cell interconnects suitable for any machine that uses power supplied by a battery. For example, the machine may perform operations associated with industries such as mining, construction, agriculture, transportation, or any other sector. The machine may be a locomotive, an electric vehicle, an electric working machine (e.g., a compactor, paver, cold milling machine, grader, backhoe loader, wheel loader, harvester, excavator, automatic grader, skid steer loader, tractor, and / or bulldozer), or an energy storage system, among other examples. The concepts described herein apply to battery cells, battery modules, and / or battery packs. As used herein, “battery cell,” “battery,” and “cell” are used interchangeably.

[0015] Figure 1 This is a diagram of an exemplary battery pack 100. The battery pack 100 may include a battery pack housing 102, one or more battery modules 104, and one or more battery cells 106. The battery pack 100 includes a battery pack controller 108 associated with storing information and / or controlling one or more operations associated with the battery pack 100. Each battery module 104 includes a module controller 110 associated with storing information and / or controlling one or more operations associated with the battery module 104.

[0016] Battery pack 100 may be associated with component 112. Component 112 may be powered by battery pack 100. For example, component 112 may be a load that consumes energy supplied by battery pack 100, such as an electric motor, and other examples. As another example, component 112 supplies energy to battery pack 100 (e.g., stored by battery cells 106). In such examples, component 112 may be a generator, a solar system and / or a wind power system, and other examples. Machine 116 may include battery pack 100 and component 112 (e.g., an electric motor). For example, battery pack 100 (e.g., one or more battery modules 104 thereof) may be electrically connected to component 112. Machine 114 may be an electric vehicle (e.g., a car, train, or boat) or an electric work machine.

[0017] The battery pack housing 102 may include a metallic shield (e.g., steel, aluminum, etc.) to protect components located within the battery pack housing 102 (e.g., battery modules 104, battery cells 106, battery pack controller 108, module controller 110, wires, circuit boards, etc.). Each battery module 104 includes one or more (e.g., multiple) battery cells 106 (e.g., located within the housing of the battery module 104). The battery cells 106 may be connected in series and / or in parallel within the battery module 104 (e.g., soldered to busbars via terminals). Each battery cell 106 is associated with a chemical type. Chemical types may include lithium-ion (Li-ion), nickel metal hydride (NiMH), nickel cadmium (NiCd), lithium-ion polymer (Li-ion polymer), lithium iron phosphate (LFP), and / or nickel manganese cobalt (NMC), among other examples.

[0018] Battery modules 104 can be arranged in one or more strings within the battery pack 100. For example, battery modules 104 are connected via electrical connections, such as... Figure 1 As shown in the diagram. Electrical connections may be removable, such as via bolts and / or nuts at one or more terminals on the housing of battery module 104. Battery modules 104 may be connected in series and / or in parallel. For example, multiple battery modules 104 may be connected in series to (e.g., to component 112) provide a specific voltage. Alternatively, multiple battery modules 104 may be connected in parallel to increase the current and / or power output of battery pack 100. The number of battery cells 106 included in each battery module 104 and the number of battery modules 104 included in battery pack 100 (e.g., and the relative series and / or parallel connections of battery cells 106 and / or battery modules 104) may be associated with the desired output power and intended use of battery pack 100. For example, any number of battery cells 106 may be included in battery module 104. Similarly, any number of battery modules 104 may be included in battery pack 100.

[0019] Battery pack controller 108 is communicatively connected (e.g., via a communication link) to each module controller 110. Battery pack controller 108 may be associated with receiving, generating, storing, processing, providing, and / or routing information associated with battery pack 100. Battery pack controller 108 may also be referred to as a battery pack management device or system. Battery pack controller 108 may communicate with component 112 and / or the controller of component 112, may control the start-up and / or shutdown procedures of battery pack 100, may monitor (e.g., the current and / or voltage of the string of battery modules 104), and / or may monitor and / or control the current and / or voltage supplied by battery pack 100, among other examples. Module controller 110 may be associated with receiving, generating, storing, processing, providing, and / or routing information associated with battery module 104. Module controller 110 may communicate with battery pack controller 108.

[0020] The battery pack controller 108 and / or module controller 110 may be associated with monitoring and / or determining the state of charge (SOC), state of health (SOH), depth of discharge (DOD), output voltage, temperature, and / or internal resistance and impedance, among other examples, associated with the battery module 104 and / or the battery pack 100. Alternatively or additionally, the battery pack controller 108 and / or module controller 110 may be associated with monitoring, controlling, and / or reporting one or more parameters associated with the battery cell 106. One or more parameters may include cell voltage, temperature, chemistry type, cell energy throughput, cell internal resistance, and / or the number of charge / discharge cycles of the battery module 104, among other examples.

[0021] The battery pack 100 may also include one or more circuits 114 for protecting against spikes in current, voltage, or both. For example, as discussed in more detail below, circuit 114 may include one or more trace fuses or surface mount fuses and / or provide transient voltage suppression.

[0022] As mentioned above, providing Figure 1 As an example. Other examples can be related to... Figure 1 The examples described are different.

[0023] Figure 2 and 3 An exemplary battery module 104 is shown. Specifically, Figure 2 This is a perspective view of battery module 104, and Figure 3 This is a close-up view of a portion of battery module 104. Battery module 104 includes module housing 202, PCB 204 (shown as semi-transparent in the figure for clarity), tabs 206, and busbar 208 (also known as "module interconnect busbar").

[0024] Module housing 202 can accommodate the above-mentioned... Figure 1 The discussion concerns one or more battery cells 106 arranged in a battery stack. The module housing 202 may be formed of plastic, metal, or another rigid material. The module housing 202 serves to generally protect the battery cells 106 from external forces and potential contaminants. In some scenarios, the module housing 202 may further help maintain the temperature of the battery cells 106, for example, through heat dissipation.

[0025] PCB 204 may be a thin, monolithic rigid board made of a composite material and configured as a retainer for busbar 208. For example, PCB 204 may serve the dual purpose of providing electrical connections for the battery stack and aligning busbar 208 with battery cell 106. PCB 204 may be formed of a rigid material. For example, the board of PCB 204 may be made of a material such as flame retardant 4 (FR4) (e.g., PCB 204 may be formed of FR4), which may include woven fiberglass cloth and epoxy resin adhesive. PCB 204 may be an electrical insulator and include traces printed onto the board. The traces may be used to connect various electrical components of battery module 104. PCB 204 may be formed of a single layer or multiple layers (e.g., multilayer PCB) to provide, for example, consistent trace resistance across different traces (e.g., trace resistance balancing). PCB 204 may be at least partially disposed on the top surface of module housing 202 and / or on top of battery cell 106. PCB 204 can be disposed over one or more conductive areas of each of the plurality of battery cells 106, thereby reducing the risk of accidental contact with conductive areas. For example, PCB 204 can extend over the terminals of each of the plurality of battery cells 106. As discussed in more detail below, PCB 204 may include alignment holes 210, access holes 212, and openings 214.

[0026] The tab 206 may be formed of nickel or another metal. The tab 206 can directly electrically connect the busbar 208 to the PCB 204 to, for example, facilitate voltage measurement of one or more battery cells 106 covered by the PCB 204. The tab 206 may contact the busbar 208 and is accessible via traces in the PCB 204 and / or through access holes 212 in the PCB 204. In some embodiments, wire bonding may be used as an alternative to or supplement to the tab 206.

[0027] Busbar 208 may be formed from a strip or bar of conductive material. Busbar 208 may act as a conduit for allowing current to flow between individual battery cells 106, groups of battery cells 106, and / or between battery modules 104. For example, two or more busbars in busbar 208 may act as terminals of battery module 104, such as positive and negative terminals. Busbar 208 may have similar shapes, thicknesses, cross-sectional areas, or other characteristics relative to each other to help maintain consistent electrical connections between battery cells 106 in battery module 104. Busbar 208 may be disposed between the PCB 204 and the top surface of the battery cell terminals, such that the PCB 204 provides an insulating layer between busbar 208 and the battery module 104 housing 202. Busbar 208 may be attached to PCB 204 via fasteners 216 (such as rivets) or via adhesive. For example, PCB 204 can serve as a carrier for busbar 208, enabling pre-alignment of busbar 208 with battery cell 106. When fastener 216 is used to attach busbar 208 to PCB 204, both busbar 208 and PCB 204 can include alignment holes 210 defined therein, and fastener 216 can extend through alignment holes 210. Therefore, alignment holes 210 can aid in aligning busbar 208 with PCB 204, battery cell 106, or both. Since busbar 208 can be disposed between PCB 204 and module housing 202, and since PCB 204 can be formed of a non-conductive material, PCB 204 can insulate busbar 208 from other electrical components in battery module 104.

[0028] One or more openings in opening 214 can be aligned with one or more busbars 208 and one or more battery cells 106, allowing each busbar 208 to be attached (e.g., bolted or welded) to the battery cell 106. Examples of welding techniques for attaching busbars 208 to battery cells 106 may include laser welding, acoustic welding, metal inert gas (MIG) welding, tungsten inert gas (TIG) welding, and / or combinations thereof, among others. Additional openings, such as opening 220 (see...) Figure 3 This allows the PCB 204 to be aligned with the module housing 202 of the battery module 104. Alternatively or additionally, an opening along the center of the PCB 204 can facilitate cell ventilation by allowing gas to escape.

[0029] Additional components, such as one or more trace fuses or surface mount fuses 218, may be disposed on or incorporated into the PCB 204. For example, a trace fuse may be incorporated into one or more traces of the PCB 204. A trace fuse may be a trace segment designed to fail when supplied with a current exceeding a certain value. For example, a trace fuse may have a width, thickness, or cross-sectional area that cannot support a current exceeding a certain value, causing the trace fuse to fail, thereby disconnecting the electrical connection and providing a degree of protection to other electronic components. Alternatively, one or more surface mount fuses 218 may be disposed on the PCB 204, and each of the surface mount fuses 218 may be electrically connected to at least one busbar in the busbar 208. For example, a surface mount fuse 218 may be a discrete component electrically connected to one or more traces of the busbar 208 and the PCB 204. A surface mount fuse 218 may be configured to intentionally fail when the current in the busbar 208 exceeds a predetermined value. For example, when subjected to a current exceeding a certain value, the surface mount fuse 218 can melt, thereby disconnecting the electrical connection. The surface mount fuse 218, accessible from the surface of the PCB 204, is easier to repair and replace compared to a trace fuse.

[0030] PCB 204 may include components related to transient voltage suppression (e.g., transient voltage suppressors) to shunt or clamp transient voltages, for example, before they could damage other electronic components of battery module 104. Examples of components related to transient voltage suppression may include diodes, rheostats, temperature sensors (e.g., thermistors), liquid sensors, gas detection sensors, and / or combinations thereof, as well as one or more of other examples. Other electronic components that may be integrated into the PCB may include one or more connectors. In some cases, PCB 204 may include one or more components of a battery management system (e.g., those mentioned above regarding...). Figure 1 The battery pack controller 108 and / or module controller 110 are discussed. Furthermore, the PCB can electrically connect one or more components of the battery management system to one or more battery cells within the battery cells.

[0031] As mentioned above, providing Figure 2 and 3 As an example. Other examples can be related to... Figure 2-3 The examples described are different.

[0032] Figure 4 The above is about Figure 2 and 3 A side view of an exemplary battery module 104 is shown and discussed. The battery module 104 may include a battery stack comprising a plurality of battery cells 106 within a module housing 202. Furthermore, as... Figure 4As shown, PCB 204 can be disposed above the conductive area of ​​each battery cell 106 and / or above the busbar 208, thereby acting as an electrical insulator.

[0033] As mentioned above, providing Figure 4 As an example. Other examples can be related to... Figure 4 The examples described are different.

[0034] Figure 5 and 6 Top and bottom views of the exemplary PCB 204 and busbar 208 are shown respectively. Figure 5 As shown, PCB 204 includes alignment holes 210 and 220, an access hole 212, and openings 214 (shown as 214A and 214B), as described above regarding Figure 2 and 3 As discussed. For example... Figure 6 As shown, busbars 208 can be attached to the bottom surface of PCB 204 via fasteners 216 (via, for example, alignment holes 210) and / or adhesive, such that each busbar 208 is aligned with at least one of the openings 214. For example, if a busbar 208 attached to the bottom surface of PCB 204 is accessible from the top surface of the PCB via, for example, an opening 214, then the busbar 208 can be aligned with at least one of the openings 214. Alignment of the busbar 208 with the opening 214 allows the busbar 208 to be soldered to the battery cell 106 via the opening 214 (e.g., the opening 214 can be configured to provide an electrical connection between the battery cell 106 and the busbar 208). The openings 214 can be spaced apart from each other and together form at least a first row 502 and a second row 504 in PCB 204. The first row 502 and the second row 504 can be parallel to each other. The openings 214 can be arranged in pairs, wherein each opening 214 in the pair originates from a different row. For example, the first opening 214A of a pair of openings 214 may be in the first row 502, and the second opening 214B of the pair of openings 214 may be in the second row 504. Each pair of openings 214 may correspond to one battery cell of the battery cell 106. For example, the first opening 214A and the second opening 214B may be aligned with different terminals of the same battery cell 106. Therefore, one or more busbars 208 may be aligned with and soldered to the terminals of the battery cell 106 via a pair of openings 214.

[0035] As mentioned above, providing Figure 5 and 6 As an example. Other examples can be related to... Figure 5 and 6 The examples described are different.

[0036] Industrial applicability

[0037] The rigid PCB carrier described herein can be used to connect battery cells together to form battery modules, and to facilitate the connection of multiple battery modules in a battery pack. Battery packs with rigid PCB carriers can be used in any machine that uses power supplied by batteries. For example, the battery pack can be installed in locomotives, electric vehicles, electric work machines (e.g., compactors, pavers, cold milling machines, graders, backhoe loaders, wheel loaders, harvesters, excavators, automatic graders, skid steer loaders, tractors, and / or bulldozers), or energy storage systems, among other examples.

[0038] By using the PCB as both a busbar carrier and a cell interconnect, as discussed above, the PCB, busbars, tabs, and potentially other components can be pre-assembled before being attached to the module housing, reducing manufacturing time and complexity. Furthermore, using a rigid PCB carrier as disclosed herein combines the functionality of the circuitry and the carrier (which could otherwise be provided as separate components) into a single unit, thereby simplifying the battery module, reducing its size, simplifying its manufacturing, and lowering its cost. For example, the rigid PCB described herein can eliminate the need for additional wiring harnesses or flexible structures. Additionally, the rigid PCB carrier can provide extra insulation between the busbars and other components of the battery module and / or battery pack, thereby improving the electrical performance and resilience of the battery module and / or battery pack.

Claims

1. A battery module (104), comprising: A battery stack including multiple battery cells (106); One or more module interconnect busbars (208); A printed circuit board (PCB) (204) is disposed on the battery stack and defines a plurality of openings (214). The PCB (204) is configured as a carrier for the interconnect busbars (208) of the one or more modules, and The plurality of openings (214) are arranged such that each of the plurality of openings (214) is aligned with a terminal of each of the plurality of battery cells (106); and One or more busbars (208) are attached to the PCB (204) in alignment with the plurality of openings (214) and are electrically connected to the plurality of battery cells (106) of the battery stack.

2. The battery module (104) according to claim 1, wherein the one or more module interconnecting busbars (208) are attached to the plurality of battery cells (106) via the plurality of openings (214).

3. The battery module (104) according to any one of claims 1-2, wherein the one or more module interconnecting busbars (208) are attached to the PCB (204) via fasteners (216) or adhesives.

4. The battery module (104) according to claim 3, wherein the fastener (216) extends through an alignment hole (210) defined in the one or more module interconnect busbars (208) and the PCB (204).

5. The battery module (104) according to any one of claims 1-2, wherein the PCB (204) is formed of a rigid material.

6. The battery module (104) according to any one of claims 1-2, wherein the plurality of openings (214) are spaced apart from each other and together form at least a first row (502) and a second row (504) parallel to the first row (502) in the PCB (204).

7. The battery module (104) according to claim 6, wherein two of the plurality of openings (214) are arranged in pairs, the pair including one of the plurality of openings (214) in the first row (502) and the other of the plurality of openings (214) in the second row (504), and each pair corresponds to one of the plurality of battery cells (106) in the battery stack.

8. A machine (114), comprising: Electric motor; as well as A battery pack electrically connected to the electric motor, the battery pack including a plurality of battery cells (106) and a printed circuit board (PCB) (204) configured as a carrier for one or more busbars (208), The PCB (204) defines a plurality of openings (214) that are spaced apart from each other and together form a first row (502) and a second row (504) parallel to the first row (502) in the PCB (204). The plurality of openings (214) are arranged such that each of the plurality of openings (214) is aligned with a terminal of each of the plurality of battery cells (106), and The one or more busbars (208) are attached to the PCB (204) in alignment with the plurality of openings (214) and are electrically connected to the plurality of battery cells (106).

9. The machine (114) according to claim 8, wherein the plurality of openings (214) are arranged in pairs, the pair comprising one of the plurality of openings (214) in the first row (502) and another of the plurality of openings (214) in the second row (504), and each pair corresponds to one of the plurality of battery cells (106).

10. The machine (114) according to any one of claims 8-9, wherein the PCB (204) is electrically connected to one or more battery cells (106) and the module controller (110).

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