Jumper bus bar

Abstract

In some embodiments, the battery module (104) may include a battery stack having a plurality of battery cells (106), a jumper bus (204) electrically connecting a plurality of non-adjacent battery cells (106) among the plurality of battery cells (106), and a linear bus (206) electrically connecting a plurality of adjacent battery cells (106) among the plurality of battery cells (106). The plurality of adjacent battery cells (106) may be disposed between the plurality of non-adjacent battery cells (106) electrically connected by the jumper bus (204).

Description

Technical Field

[0001] This disclosure generally relates to batteries, and for example to a jumper bus for electrically connecting battery cells and / or battery modules. Background Technology

[0002] Busbars are electrical conductors in a battery pack used to electrically connect battery cells and battery modules. The shape and arrangement of busbars can be used to connect battery terminals in series or parallel. Furthermore, a typical busbar configuration with a prismatic cell layout results in the battery module terminals being located at opposite ends of the battery module, which can make battery pack maintenance difficult, especially in applications where the battery pack is heavy and one or both of the opposite ends of the battery pack are inaccessible.

[0003] U.S. Patent No. 11,677,114 ('114 Patent) discloses a plurality of batteries stacked together and a busbar electrically connecting the plurality of batteries to each other. The busbar has a body extending along an axis along which the batteries are stacked, and a plurality of connectors projecting from the body along an axis intersecting the axis along which the batteries are stacked, and electrically connected to terminals of the batteries, respectively. The plurality of batteries are divided into a plurality of battery cells. Each of the plurality of battery cells includes at least two of the plurality of batteries. The busbar connects at least two of the plurality of batteries in each battery cell in parallel with each other. The busbar also connects the battery cells in series with each other.

[0004] The busbar disclosed in patent '114 places the battery module terminals on opposite sides of the battery module, as discussed above. This makes the battery pack difficult to install and maintain, especially when the battery pack is not easily accessible on one or both of the opposite ends.

[0005] The jumper bus bar disclosed herein solves one or more of the problems set forth above and / or other problems in the art. Summary of the Invention

[0006] A battery module may include a battery stack having a plurality of battery cells; a jumper busbar electrically connecting a plurality of non-adjacent battery cells among the plurality of battery cells; and a linear busbar electrically connecting a plurality of adjacent battery cells among the plurality of battery cells, the plurality of adjacent battery cells being disposed between the plurality of non-adjacent battery cells electrically connected by the jumper busbar.

[0007] A machine may include an electric motor; and a battery module electrically connected to the electric motor, the battery module comprising: a battery stack having a plurality of battery cells; a jumper busbar electrically connected to a plurality of non-adjacent battery cells of the battery stack; and a linear busbar electrically connected to a plurality of adjacent battery cells of the battery stack, the plurality of adjacent battery cells being disposed between the plurality of non-adjacent battery cells electrically connected by the jumper busbar, and the linear busbar being nested within a cutout edge of the jumper busbar.

[0008] A battery pack may include a first battery module; and a second battery module electrically connected to the first battery module, both the first battery module and the second battery module having terminals at the same end of the battery pack, and each of the first battery module and the second battery module includes: a battery stack having a plurality of battery cells, a jumper busbar electrically connecting a plurality of non-adjacent battery cells among the plurality of battery cells, and a linear busbar electrically connecting a plurality of adjacent battery cells among the plurality of battery cells, the plurality of adjacent battery cells being disposed between the plurality of non-adjacent battery cells electrically connected by the jumper busbar. Attached Figure Description

[0009] Figure 1 This is a diagram of an exemplary battery pack.

[0010] Figure 2 This is an isometric view of an exemplary battery module with jumper busbars and linear busbars.

[0011] Figure 3 This is a top view of an exemplary battery module. Detailed Implementation

[0012] This disclosure relates to a jumper busbar suitable for supplying power to any battery module and / or battery pack. For example, the machine may perform operations associated with industries such as mining, construction, agriculture, transportation, or any other sector. The machine may be an electric vehicle, an electric work 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. As used herein, “battery cell,” “battery,” and “cell” are used interchangeably.

[0013] Figure 1This 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.

[0014] 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 power system, and / or a wind power system, and other examples. Machine 114 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.

[0015] 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.

[0016] 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 1As 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.

[0017] 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.

[0018] 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.

[0019] As mentioned above, providing Figure 1 As an example. Other examples can be related to... Figure 1 The examples described are different.

[0020] Figure 2 This is an isometric view of an exemplary battery module 104, each battery module having a module housing 202, a jumper bus 204, a linear bus 206, and module terminals 208. The battery module 104 may include a battery stack having a plurality of battery cells 106. For example, the battery stack may include an odd number of battery cells 106, such as 13 battery cells, 19 battery cells, etc. In other examples, the battery stack may include an even number of battery cells 106.

[0021] Module housing 202 can accommodate the above-mentioned... Figure 1 One or more of the battery cells 106 discussed (e.g., may house a battery stack). The module housing 202 may be formed of plastic, metal, or another rigid material. The module housing 202 may be used 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 through, for example, heat dissipation.

[0022] Jumper bus 204 and linear bus 206 may be formed of a strip or bar of conductive material. Jumper bus 204 and linear bus 206 may act as conduits for allowing current to flow between individual battery cells 106, groups of battery cells 106, and / or battery modules 104. As discussed in more detail below, jumper bus 204 and linear bus 206 may have shape, thickness, or other characteristics that help maintain consistent electrical characteristics (i.e., voltage and / or current) between components. Each jumper bus 204 may electrically connect multiple (e.g., two) non-adjacent battery cells 106 in a battery module. For example, each jumper bus 204 electrically connects two battery cells 106, and two other battery cells 106 (not electrically connected to jumper bus 204) are located between the two battery cells 106 electrically connected by jumper bus 204. Each linear busbar 206 can electrically connect multiple (e.g., two) adjacent battery cells 106 in the battery module 104. For example, each linear busbar 206 can electrically connect battery cells 106 located between battery cells 106 connected by the jumper busbar 204.

[0023] The jumper busbar 204 may have an integral construction formed, for example, by a single plate. The plate of the jumper busbar 204 may have flat edges 210 perpendicular to the two flat sides 212. The flat sides 212 may be parallel to each other at opposite ends of the flat edges 210. Opposite to the flat edges 210 may be a cut edge 214. The cut edge 214 may be profiled to have curved or flat edges. The shape of the cut edge 214 may at least partially match the peripheral shape of the linear busbar 206. Figure 2 In the example, the cut edge 214 has a U-shaped configuration, which makes the jumper bus 204 have an overall U-shape.

[0024] The linear busbar 206 may also have an integral construction formed by a single plate, which may be the same as or different from the jumper busbar 204. Each linear busbar 206 may have a flat edge 216 opposite to the contoured edge 218. The contoured edge 218 may match the contour of the cut-out edge 214 of the jumper busbar 204 to allow the linear busbar 206 to be nested within the cut-out edge 214 of the jumper busbar 204, thereby reducing the overall footprint of the busbars on the battery module 104.

[0025] When assembled onto the battery cell 106, the flat edge 216 of each linear busbar 206 can be parallel to the flat edge 210 of the corresponding jumper busbar 204, such that the linear busbar 206 is nested within the cut edge 214 of the jumper busbar 204 to form a busbar group. Furthermore, when assembled onto the battery cell 106, although the contours of the outlined edge 218 and the cut edge 214 match, an air gap 220 can be defined between each linear busbar 206 and the corresponding jumper busbar 204, which can electrically insulate the jumper busbar 204 from the linear busbar 206. The additional air gap 220 can separate each jumper busbar 204 from each other.

[0026] The jumper bus 204 and linear bus 206 can have various characteristics that improve performance, such as maintaining the accuracy of battery measurements despite, for example, different voltage drops across the terminals of bus 204 and 206. For example, despite different lengths and shapes, the jumper bus 204 and linear bus 206 can have the same (e.g., equal) resistance if at least a portion of the jumper bus 204 and a portion of the linear bus 206 have the same cross-sectional area. For example, the jumper bus 204 and linear bus 206 can have different thicknesses to balance their resistance. Given a specific cross-section, the cross-sectional area can be defined as the height H of the jumper bus 204 or linear bus 206 multiplied by the width W or length L of the jumper bus 204 or linear bus 206, respectively. The height H can be the distance by which the linear bus 206 and / or the jumper bus 204 extend away from the top surface of the battery cell. The width W, perpendicular to the height H, can be the distance between the terminals of the linear busbar 206 and / or the jumper busbar 204 extending within the same battery cell. The length L can be perpendicular to both the width W and the height H. Because... Figure 2 The jumper bus 204 and linear bus 206 shown do not have a uniform width W across all cross sections, so the term "cross-sectional area" can refer to the maximum cross-sectional area, minimum cross-sectional area, median cross-sectional area, average cross-sectional area, or the cross-sectional area taken at, for example, the center of the jumper bus 204 and / or the linear bus 206.

[0027] Furthermore, for battery module 104, jumper bus 204 and linear bus 206 can be arranged on the same surface or plane. For example, jumper bus 204 and linear bus 206 can be disposed on the same surface of printed circuit board 224, which can be disposed on battery module 104.

[0028] The battery module 104 may also include a plurality of terminal busbars 222 (shown as terminal busbars 222A and 222B) at one end of the battery module 104, which form module terminals 208. Module terminals 208 can electrically connect a plurality of battery cells 106 in the battery stack to each other and / or connect a plurality of battery stacks in the battery module 104 to each other. In addition, the module terminals 208 of the plurality of battery modules 104 can be electrically connected to each other to form a battery pack 100. Depending on the position of the terminal busbars 222 relative to the edge of the battery module 104, the terminal busbars 222 may have shapes or configurations that are different from each other and / or different from those of the jumper busbars 204 and the linear busbars 206. For example, the first terminal busbar 222A may be longer than the second terminal busbar 222B, which allows the first terminal busbar 222A and the second terminal busbar 222B to extend from the same end of the battery stack. Terminal 222 may be partially in the shape of the jumper bus 204 or the linear bus 206 described herein.

[0029] As mentioned above, providing Figure 2 As an example. Other examples can be related to... Figure 2 The examples described are different.

[0030] Figure 3This is a top view of an exemplary battery module 104, each battery module having a jumper bus and a linear bus. As shown, each battery module 104 may include a plurality of battery cells 306, 308, 310, 312, and 322 (e.g., corresponding to battery cell 106 described herein), including a pair of adjacent battery cells 302 and a pair of non-adjacent battery cells 304. The pair of adjacent battery cells 302 may include a first battery cell 306 and a second battery cell 308. The pair of non-adjacent battery cells 304 may include a third battery cell 310 and a fourth battery cell 312. The first battery cell 306, the second battery cell 308, the third battery cell 310, and the fourth battery cell 312 may each include a first terminal 314 and a second terminal 316. The first terminal 314 may have the same polarity (e.g., positive), and the second terminal 316 may have the same polarity (e.g., negative). Therefore, the first terminal 314 may be a positive terminal, and the second terminal 316 may be a negative terminal. In some embodiments, the battery module 104 may adopt a polarity configuration opposite to that described herein (e.g., the first terminal 314 may be a negative terminal and the second terminal 316 may be a positive terminal).

[0031] Alternatively, adjacent battery cells can be arranged such that adjacent terminals have opposite polarities. By doing so, groups of linear busbars and jumper busbars can connect the battery cells in series. For example, battery cells 306 and 308 can be arranged such that the first terminal 314 of the first battery cell 306 has a different polarity than the first terminal 314 of the second battery cell 308. Similarly, the second terminal 316 of the first battery cell 306 can have a different polarity than the second terminal 316 of the second battery cell 308. For example, the first terminal 314 of the first battery cell 306 can be a positive terminal, and the first terminal 314 of the second battery cell 308 can be a negative terminal. The second terminal 316 of the first battery cell 306 can be a negative terminal, and the second terminal 316 of the second battery cell 308 can be a positive terminal. When connected by linear busbar 318, the first battery cell 306 and the second battery cell 308 can be connected in series. The first battery cell 306 and the second battery cell 308 can be connected in series with the additional battery cell via additional jumper busbars and / or linear busbars.

[0032] The first linear busbar 318 can electrically connect the first terminal 314 of the first battery cell 306 to the first terminal 314 of the second battery cell 308. As discussed above, the first terminal 314 of the first battery cell 306 and the first terminal of the second battery cell 308 can have the same polarity or different polarities. The first jumper busbar 320 can electrically connect the first terminal 314 of the third battery cell 310 to the first terminal 314 of the fourth battery cell 312. As discussed above, the first terminal 314 of the third battery cell 310 and the first terminal of the fourth battery cell 312 can have the same polarity (i.e., both are positive or both are negative) or different polarities. Furthermore, the first linear busbar 318 can be nested within the first jumper busbar 320 to form a busbar group. The second terminal 316 of the first battery cell 306 can be electrically connected to the second terminal 316 of the fifth battery cell 322 via the second jumper busbar 324. As discussed above, the second terminal 316 of the first battery cell 306 and the second terminal 316 of the fifth battery cell 322 can have the same polarity (i.e., both are positive or both are negative) or different polarities. Different combinations of linear busbars and / or jumper busbars can be connected to the second terminal 316 of the first battery cell 306, the second battery cell 308, the third battery cell 310, and the fourth battery cell 312.

[0033] Furthermore, for each battery cell, one terminal can be electrically connected to a jumper busbar, and another terminal can be electrically connected to a linear busbar in a different busbar group (e.g., a linear busbar not nested within a jumper busbar). For example, if the second terminal 316 of the first battery cell 306 is electrically connected to a jumper busbar 324, then the first terminal 314 of the first battery cell 306 can be electrically connected to the first terminal 314 of an adjacent battery cell 308 via a linear busbar 318. Similarly, if the first terminal 314 of the first battery cell 306 is electrically connected to a linear busbar 318, then the second terminal 316 of the first battery cell 306 can be electrically connected to the second terminal 316 of a non-adjacent battery cell 322 via a jumper busbar 324. In other words, jumper buses and linear buses in different busbar groups can be electrically connected to different terminals of the same battery cell. In this way, jumper busbars and linear busbars can electrically connect battery cells in series (e.g., if adjacent terminals have the same polarity) or in parallel (e.g., if adjacent terminals have different polarities).

[0034] Insulator 326 may be disposed on top of jumper busbar, linear busbar, or both.

[0035] As mentioned above, providing Figure 3 As an example. Other examples can be related to... Figure 3 The examples described are different.

[0036] Industrial applicability

[0037] The jumper bus described herein can be used in any battery module and / or battery pack used to power a machine. For example, the jumper bus can be used in battery modules and / or battery packs used to power the electric motors of electric vehicles or electric work machines. Electric vehicles and electric work machines generally have large battery packs that are difficult to maintain. For example, the battery module of an electric vehicle or electric work machine may have an odd number of battery cells, which results in the terminals of the battery module being located at opposite ends of the battery module. The combination of jumper bus and linear bus described herein can be used to electrically connect an odd number of battery cells. Furthermore, the combination of jumper bus and linear bus allows the terminals of the battery module to be located at the same end of the battery module, which can make the battery pack easier to maintain, especially when the battery pack is very heavy and / or one or more ends of the battery pack are inaccessible.

Claims

1. A battery module (104), comprising: A battery stack with multiple battery cells (106); A jumper busbar (204) electrically connecting multiple non-adjacent battery cells (106) among the plurality of battery cells (106); and A linear busbar (206) electrically connects a plurality of adjacent battery cells (106) among the plurality of battery cells (106), the plurality of adjacent battery cells (106) being disposed between the plurality of non-adjacent battery cells (106) electrically connected by the jumper busbar (204).

2. The battery module (104) according to claim 1, wherein the jumper busbar (204) comprises a plate having a flat edge (210) opposite to the cut edge (214), and The cut edge (214) is outlined according to the peripheral shape of the linear busbar (206).

3. The battery module (104) according to any one of claims 1-2 further includes a plurality of terminal busbars (222) electrically connected to at least one of the plurality of battery cells (106) in the battery stack, the plurality of terminal busbars (222) extending from the same end of the battery stack.

4. A machine (114), comprising: Electric motor (112); as well as A battery module (104) electrically connected to the electric motor (112), the battery module (104) comprising: A battery stack with multiple battery cells (106), A jumper busbar (204) electrically connecting multiple non-adjacent battery cells (106) of the battery stack, and A linear busbar (206) electrically connects a plurality of adjacent battery cells (106) of the battery stack. The plurality of adjacent battery cells (106) are arranged between the plurality of non-adjacent battery cells (106) electrically connected by the jumper bus (204), and The linear busbar (206) is nested within the cut edge of the jumper busbar (204).

5. The machine (114) according to claim 4, wherein the jumper busbar (204) is formed of a plate having a flat edge (210) opposite to the cut edge (214), and The cut edge (214) has a U-shaped configuration.

6. The machine (114) according to any one of claims 4-5 further includes a plurality of terminal busbars (222) electrically connected to at least one of the plurality of battery cells (106) in the battery stack, the plurality of terminal busbars (222) extending from the same end of the battery stack.

7. The machine (114) according to any one of claims 4-5, wherein the first resistance associated with the jumper bus (204) is equal to the second resistance associated with the linear bus (206).

8. The machine (114) according to any one of claims 4-5, wherein the jumper bus (204) is a first jumper bus (204), and the linear bus (206) is a first linear bus (206), and The machine (114) mentioned above also includes: The second jumper connects to the bus bar (204); as well as Second linear busbar (206) The first jumper bus (204), the first linear bus (206), the second jumper bus (204) and the second linear bus (206) are arranged in series and electrically connected to the plurality of battery cells (106).

9. The machine (114) according to claim 8, wherein the first jumper bus (204) is electrically connected to the negative terminal (316) of the battery cell (106) among the plurality of battery cells (106), and the second linear bus (206) is electrically connected to the positive terminal (314) of the battery cell (106).

10. The machine according to claim 9, wherein the first linear busbar (206) is electrically connected to the negative terminal (314) of an additional battery cell (106) among the plurality of battery cells (106), and the second jumper busbar (204) is electrically connected to the positive terminal (316) of the additional battery cell (106).

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