Towing battery pack sensor assembly and sensor providing method

Abstract

The present disclosure provides "Traction battery pack sensor assembly and sensor providing method". A battery pack assembly includes a sensor tab configured to be secured to a component of a traction battery pack and a wire. The wire has a compressed portion providing the sensor tab and an uncompressed portion providing a sense lead extending from the sensor tab.

Description

Technical Field

[0001] This disclosure generally relates to a sensor assembly for a traction battery pack, and more specifically to a sensor assembly having compressed sensor tabs and sensing leads, said sensing leads being stranded wires. Background Technology

[0002] Electrified vehicles include a traction battery pack that powers the vehicle's motor and other electrical loads. The traction battery pack may include multiple battery cells and various other internal battery components that support the propulsion of the electric vehicle. A sensor assembly is used to monitor various parameters associated with the traction battery pack. Summary of the Invention

[0003] In some aspects, the technology described herein relates to a battery pack assembly comprising: a sensor tab configured to be attached to a component of a traction battery pack; and a stranded wire having a compressed portion providing the sensor tab and an uncompressed portion providing sensing leads extending from the sensor tab.

[0004] In some respects, the technology described herein relates to a battery pack assembly in which the sensor tabs are ultrasonically compressed sensor tabs.

[0005] In some respects, the technology described herein relates to a battery pack assembly in which the sensor tabs are provided by ultrasonically compressed stranded wire.

[0006] In some respects, the technology described herein relates to a battery pack assembly in which the sensor tabs are secured to the component by at least one solder joint.

[0007] In some respects, the technology described herein relates to a battery pack assembly, wherein the at least one welded portion is at least one laser-welded portion.

[0008] In some respects, the technology described herein relates to a battery pack assembly, wherein the components are the terminal blocks of battery cells.

[0009] In some respects, the technology described herein relates to a battery pack assembly that further includes a control module, wherein the sensing leads extend from the sensor tabs to a connector connected to the control module.

[0010] In some respects, the technology described herein relates to a battery pack assembly, wherein the control module is a battery pack sensor module.

[0011] In some respects, the technology described herein relates to a battery pack assembly in which the stranded wires providing the sensing leads comprise a plurality of individual strands.

[0012] In some aspects, the technology described herein relates to a battery pack assembly comprising: a cell stack including a plurality of battery cells disposed along an axis of the cell stack; a compression sensor tab attached to a portion of at least one of the battery cells within the plurality of battery cells; and a stranded wire extending from the compression sensor tab to a connector.

[0013] In some respects, the technology described herein relates to a battery pack assembly, wherein said portion is a terminal piece of at least one of the battery cells within the plurality of battery cells.

[0014] In some respects, the technology described herein relates to a battery pack assembly in which at least one of the battery cells is welded to the plurality of battery cells via a compression sensor tab.

[0015] In some respects, the technology described herein relates to a battery pack assembly that further includes a connector with stranded wires extending from the compressed sensor tab to the connector, the connector being configured to engage a battery pack sensor module.

[0016] In some respects, the technology described herein relates to a battery pack assembly in which the compressed sensor tab is provided by an area of ​​ultrasonic compression of the stranded wire.

[0017] In some respects, the technology described herein relates to a battery pack assembly that further includes an insulating coating, and the stranded wires include a plurality of individual conductive strands bundled within the insulating coating.

[0018] In some respects, the technology described herein relates to a method of providing a battery pack sensor, the method comprising: sensing parameters of a component by means of a sensor tab attached to a component within a traction battery pack, the sensor tab being provided by a compressed region of stranded wire.

[0019] In some aspects, the technology described herein relates to a method of providing a battery pack sensor, the method further comprising attaching the sensor tab to the component by soldering the sensor tab to the component.

[0020] In some respects, the technology described herein relates to a method of providing a battery pack sensor, the method further comprising compressing a portion of the stranded wire to provide the compressed region of the stranded wire prior to the sensing and the attachment.

[0021] In some respects, the technology described herein relates to a method for providing a battery pack sensor, wherein the compression is ultrasonic compression.

[0022] In some aspects, the technology described herein relates to a method for providing a battery pack sensor, the method further comprising transmitting data from the sensor patch to a control module of the traction battery pack via the stranded wire during the sensing process.

[0023] Embodiments, examples, and alternatives, including any of their various aspects or respective individual features, may be adopted independently or in any combination of the foregoing paragraphs, claims, or the following description and drawings. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible. Attached Figure Description

[0024] According to the specific embodiments, various features and advantages of the disclosed examples will become apparent to those skilled in the art. The accompanying drawings of the specific embodiments can be briefly described as follows:

[0025] Figure 1 A side view of an electrified vehicle with a battery pack according to an exemplary embodiment of the present disclosure is shown.

[0026] Figure 2 Showing from Figure 1 An unfolded diagram of the battery pack.

[0027] Figure 3 It shows Figure 2 A close-up view of the area shows a sensor assembly with sensing leads, where sensor tabs are attached to the traction battery pack.

[0028] Figure 4 Showing from Figure 2 A perspective view of the battery cells in the battery pack.

[0029] Figure 5 Showing from Figure 2 The sensor assembly of the battery pack.

[0030] Figure 6 It shows in Figure 5 The cross-sectional view taken at line 6–6 in the diagram. Detailed Implementation

[0031] This disclosure details an exemplary sensor assembly for a traction battery pack. The sensor assembly may incorporate sensing leads and sensor tabs with stranded wires, the sensor tabs being provided by a compressed region of the stranded wires. After the region of the stranded wires is compressed to establish the compressed region, it is not necessary to attach the sensing leads to the sensor tabs.

[0032] refer to Figure 1The electrified vehicle 10 includes a battery pack 14, a motor 18, and wheels 22. The battery pack 14 supplies power to the motor 18, which converts electrical energy into mechanical power to drive the wheels 22. Therefore, the battery pack 14 is a traction battery pack.

[0033] In an exemplary embodiment, the battery pack 14 is fixed to the bottom of the electric vehicle 10. In other examples, the battery pack 14 may be located elsewhere on the electric vehicle 10.

[0034] Electrified vehicle 10 is a purely electric vehicle. In other examples, electrified vehicle 10 is a hybrid electric vehicle that selectively uses torque provided by an internal combustion engine (as a replacement or supplement to the electric motor) to drive the wheels. In general, electrified vehicle 10 can be any type of vehicle with a traction battery pack.

[0035] Although specific component relationships are shown in the accompanying drawings of this disclosure, the illustrations are not intended to limit the scope of this disclosure. The placement and orientation of the various components of the electrified vehicle 10 are shown schematically and may vary within the scope of this disclosure. Furthermore, the various drawings accompanying this disclosure are not necessarily drawn to scale, and some features may be enlarged or minimized to emphasize certain details of a particular component, assembly, or system.

[0036] Now for reference Figure 2 – Figure 4 In an exemplary embodiment, the traction battery pack 14 includes a plurality of cell stacks 26, a control module 30, a sensor assembly 34, and other battery pack components held within the interior 38 of the housing assembly 42. In this example, the housing tray 46 and the housing cover 50 are joined together to provide the interior 38.

[0037] Each of the cell stacks 26 includes a plurality of individual battery cells 54 arranged along the respective cell stack axis A. The battery cells 54 store and supply electricity to power various components of the electrified vehicle 10.

[0038] In an exemplary embodiment, battery cell 54 is a lithium-ion pouch cell. However, within the scope of this disclosure, battery cells having other geometries (cylindrical, prismatic, etc.) and / or chemical properties (nickel-metal hydride, lead-acid, etc.) may be used alternatively.

[0039] Each battery cell 54 includes a contact terminal 58 extending from the housing 60. Within the cell stack 26, the contact terminal 58 extends through the side frame 62 and is folded to and attached to a corresponding busbar 64. The side frame 62 holds the busbar 64. The contact terminal 58 can be attached to the busbar 64 via a solder joint.

[0040] In this example, sensor assembly 34 is attached to a corresponding contact terminal 58. Sensor assembly 34 operatively connects contact terminals 58 to one of control modules 30. Sensor assembly 34 can collect voltage information from the associated contact terminals 58. The voltage information is transmitted as a signal to control module 30, which then monitors the voltage of the battery cells 54 within battery pack 14.

[0041] In another example, sensor assembly 34 can collect information other than voltage information. For example, sensor assembly 34 can collect temperature information and transmit that temperature information back to control module 30.

[0042] Furthermore, the sensor assembly 34 can be connected to components other than the contact terminal 58. The sensor assembly 34 can be attached to the housing 60 of one of the battery cells 54, or to another component of the busbar or battery pack 14.

[0043] Therefore, although the example sensor assembly 34 is described as being operatively connected to the tab terminal 58 and used for monitoring voltage, in other examples, the sensor assembly 34 may be operatively connected to any other component of the battery pack 14 and may be used to monitor a variety of other parameters (e.g., temperature, current, state of charge, state of power, resistance, gas or pressure level, humidity, vibration, etc.).

[0044] Now for reference Figure 5 and Figure 6 And continue to refer to Figure 2 and Figure 3 The example sensor assembly 34 includes a sensor patch 66, a sensing lead 70, and a connector 74.

[0045] The sensor tab 66 is directly attached to the component of the battery pack 14—here, the tab terminal 58. The sensor tab 66 can be attached to the tab terminal 58 via a soldering part (such as a laser soldering part 78). Soldering the sensor tab 66 to the tab terminal 58 operatively connects the sensor tab 66 to the tab terminal 58, allowing the sensor tab 66 to collect data from the tab terminal 58.

[0046] Sensing lead 70 extends from sensor tab 66 to connector 74, which connects to connector 82 in one of the control modules 30. Connectors 74 and 82 may be plug-in pin-type connectors.

[0047] Data collected by sensor patch 66 is transmitted as a signal to control module 30 via sensing leads 70 and connectors 74, 82. Control module 30 may be a battery pack sensor module (BPSM). Data provided by sensor assembly 34 can be analyzed by control module 30 to facilitate monitoring of battery pack 14. Control module 30 can identify problems based on the data.

[0048] The sensor patch 66 and sensing lead 70 are provided by stranded wire 88. To establish the sensor patch 66, the insulating coating 92 is removed from region R of the stranded wire 88, which exposes multiple individual conductive strands 96 of the stranded wire 88. These exposed individual conductive strands 96 are then compressed to provide the sensor patch 66.

[0049] In this example, the compression is ultrasonic compression, where the exposed individual conductive strands 96 within region R are compressed within an ultrasonic welding machine. The ultrasonic compression of the exposed individual conductive strands 96 bonds the exposed individual strands together to provide the sensor tab 66. Other types of compression may be used in other examples.

[0050] The remainder of the stranded wire 88 remains attached to the sensor tab 66 and is not compressed. The remainder of the stranded wire 88 may remain uncompressed and bundled within the insulating coating 92 to provide the sensing lead 70. The stranded wire consists of a plurality of individual strands 96 twisted together to form a larger conductor, which particularly enhances flexibility. Those skilled in the art will understand that stranded wire differs from solid wire.

[0051] The designated sensor tab 66 is compressed or ultrasonically compressed to structurally distinguish it from other types of sensor tabs, such as those cut from a solid sheet of material. Those skilled in the art, and who benefit from this disclosure, will be able to structurally distinguish a sensor tab constructed by compressing multiple individual conductive strands together from one not compressed in this manner. Therefore, the designation of sensor tab 66 as a compressed sensor tab structurally distinguishes it from other types of sensor tabs.

[0052] Connector 74 can be connected to the end of stranded wire 88 opposite to sensor tab 66 to complete sensor assembly 34. In the completed sensor assembly 34, stranded wire 88 extends from connector 74 of sensor assembly 34 to sensor tab 66 of sensing lead. Stranded wire 84 includes a plurality of individual strands 96.

[0053] The area of ​​the compressed stranded wire 88 provided to enable the sensor tab 66 to provide a relatively solid tab suitable for direct attachment to the tab terminal 58 without leaving stray strands that could provide unwanted conductive paths. Furthermore, since the sensor tab 66 is established by compressing the area of ​​the stranded wire 88 without separating the area, it is not necessary to attach the sensing lead to the sensor tab 66 after ultrasonically compressing the area.

[0054] In the past, traces on flexible printed circuit boards were operatively connected to patch terminals and other components for monitoring purposes. Sensor assemblies 34, which primarily rely on stranded wires, can be used to replace flexible printed circuit boards. This, as can be understood, reduces complexity.

[0055] The foregoing description is exemplary in nature and not restrictive. Variations and modifications made to the disclosed examples will become apparent to those skilled in the art, and such variations and modifications do not necessarily depart from the spirit of this disclosure. Therefore, the scope of protection accorded to this disclosure can only be determined by studying the following claims.

[0056] According to the present invention, a battery pack assembly is provided, comprising: a cell stack including a plurality of battery cells disposed along an axis of the cell stack; a compression sensor tab attached to a portion of at least one of the battery cells within the plurality of battery cells; and a stranded wire extending from the compression sensor tab to a connector.

[0057] According to an embodiment, the portion is a terminal of at least one of the battery cells within the plurality of battery cells.

[0058] According to an embodiment, at least one of the battery cells is welded to the plurality of battery cells via a compression sensor patch.

[0059] According to an embodiment, the invention is further characterized by a connector in which the stranded wire extends from the compressed sensor tab to the connector, the connector being configured to engage the battery pack sensor module.

[0060] According to an embodiment, the compressed sensor patch is provided by the ultrasonically compressed region of the stranded wire.

[0061] According to an embodiment, the invention is further characterized by an insulating coating, wherein the stranded wire comprises a plurality of individual conductive strands bundled within the insulating coating.

Claims

1. A battery pack assembly comprising: A sensor connector, the sensor connector being configured to be attached to a component of a traction battery pack; as well as A stranded wire having a compressed portion providing the sensor tab and an uncompressed portion providing sensing leads extending from the sensor tab.

2. The battery pack assembly as claimed in claim 1, wherein the sensor patch is an ultrasonically compressed sensor patch.

3. The battery pack assembly of claim 1, wherein the sensor tab is provided by ultrasonically compressed stranded wire.

4. The battery pack assembly of claim 1, wherein the sensor patch is fixed to the component by at least one solder joint.

5. The battery pack assembly of claim 4, wherein the at least one welded portion is at least one laser-welded portion.

6. The battery pack assembly as claimed in claim 1, wherein the component is a terminal block of the battery cell.

7. The battery pack assembly of claim 1, further comprising a control module, wherein the sensing lead extends from the sensor patch to a connector connected to the control module.

8. The battery pack assembly as claimed in claim 7, wherein the control module is a battery pack sensor module.

9. The battery pack assembly of claim 1, wherein the stranded wire providing the sensing lead comprises a plurality of individual strands.

10. A method for providing a battery pack sensor, comprising: The parameters of the component are sensed by sensor tabs attached to the component within the traction battery pack, the sensor tabs being provided by the compressed portion of stranded wire.

11. The method of providing a battery pack sensor as claimed in claim 10, further comprising attaching the sensor tab to the component by soldering the sensor tab to the component.

12. The battery pack sensor providing method of claim 11, further comprising, prior to the sensing and the attachment, compressing a portion of the stranded wire to provide the compressed region of the stranded wire.

13. The method of providing a battery pack sensor as claimed in claim 12, wherein the compression is ultrasonic compression.

14. The battery pack sensor providing method of claim 10, further comprising, during the sensing, transmitting data from the sensor patch to the traction battery pack via the stranded wire, a control module.

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