Modular flexible circuit integration for different series configurations for a battery

Abstract

A method is disclosed which may include providing an application-specific integrated circuit for detecting battery cells, wherein the circuit has at least a first channel and a second channel, a first connecting line connected to the first channel and a second connecting line connected to the second channel, a first weld pad connected to the first connecting line, a second weld pad connected to the second connecting line, and connecting a first shunt to the first weld pad and the second weld pad.

Description

[0001] The technical field generally refers to batteries, their components, and methods for their manufacture.

[0002] Until now, mechanical connectors have been used in batteries to connect detection leads.

[0003] US Patent 2012 / 0286794A1 describes systems and methods for scalable battery cell control. A printed circuit board connected to a battery cell stack is designed to monitor and balance individual cells within the stack. The battery cell control system configures software commands based on the voltage applied to a battery cell stack.

[0004] EP 3 316 348 A1 describes a busbar for a battery system, comprising a first busbar element and a second busbar element spaced apart from each other, and a third busbar element that structurally and electrically connects the first busbar element and the second busbar element to form a common busbar. The third busbar element is configured to electrically connect the first busbar element and the second busbar element as a shunt resistor, defining an ohmic resistance.

[0005] DE 10 2022 112 979 A1 describes a battery monitoring device for monitoring the operating state of battery cells of a battery module for a motor vehicle, comprising connection contacts for connecting one battery cell each of a maximum number of battery cells in a first cell configuration, wherein at least one of the connection contacts has an auxiliary contact point electrically connected to it, which is configured to alternatively connect a second cell configuration with a smaller number than the maximum number of battery cells by placing a bridge between an occupied connection contact and the auxiliary contact point.

[0006] It is desirable to provide a design and method for manufacturing batteries without using a mechanical connector to connect sensing line assemblies to each other.

[0007] A method according to the invention comprises: providing an application-specific integrated circuit for detecting battery cells, comprising at least a first channel and a second channel, a first connecting line connected to the first channel, a second connecting line connected to the second channel, a first weld pad connected to the first connecting line, a second weld pad connected to the second connecting line, and a first extension comprising a first flexible circuit with a first detection line trace; welding a first shunt to the first weld pad and the second weld pad; and connecting a first wire bond to the first detection line trace and the first shunt.

[0008] In one embodiment, the application-specific integrated circuit for detecting battery cells further comprises a third channel and a fourth channel, a third connecting line connected to the third channel, a fourth connecting line connected to the fourth channel, a third weld pad connected to the third connecting line, and a fourth weld pad connected to the fourth connecting line; and the method comprises welding a second shunt to the third weld pad and the fourth weld pad.

[0009] In one embodiment, the method further comprises connecting a first wire bond to the first welding pad and the first connecting lead, and connecting a second wire bond to the second welding pad and the second connecting lead.

[0010] In one embodiment, the application-specific integrated circuit for detecting battery cells comprises a third channel and a fourth channel, a third connecting line connected to the third channel, and a fourth connecting line connected to the fourth channel, a third weld pad connected to the fourth connecting line, and a fourth weld pad connected to the fourth connecting line; and the method comprises welding a second shunt to the third weld pad and the fourth weld pad.

[0011] In one embodiment, the application-specific integrated circuit for detecting battery cells further comprises a second extension comprising a second flexible circuit with a second detection line trace.

[0012] In one embodiment, the method further comprises connecting a second wire bond to the second detection line trace and to a second shunt.

[0013] In one embodiment, the method further comprises connecting a third wire bond to the third welding pad and the third connecting lead, and connecting a fourth wire bond to the fourth welding pad and the fourth connecting lead.

[0014] In one embodiment, the application-specific integrated circuit for detecting battery cells further comprises at least a third channel, a third connecting line connected to a third weld pad, a second detection line trace connected to a second cell or cell group, and the method further comprises welding the first shunt to the third weld pad.

[0015] In one embodiment, the application-specific integrated circuit for detecting battery cells further comprises at least a fifth channel, a fifth connecting line connected to a fifth welding pad, and the method further comprises welding the second shunt to the fifth welding pad.

[0016] A product according to the invention comprises: an application-specific integrated circuit for detecting battery cells, comprising at least a first channel and a second channel, a first connecting line connected to the first channel and a second connecting line connected to the second channel, a first welding pad connected to the first connecting line and a second welding pad connected to the second connecting line, and a first shunt welded to the first welding pad and the second welding pad, a first extension comprising a first flexible circuit with a first detection line trace, and a first wire bond connected to the first detection line trace and to the first shunt.

[0017] A series of embodiments are described below in conjunction with the following drawings, where identical numbers denote identical elements and where: Fig. Figure 1 shows a product that may include part of a battery management system; Fig. Figure 2 shows a product that may include a detection line assembly with a first shunt and a second shunt, which is used to reconfigure a modular detection line assembly; Fig. Figure 3 illustrates a product that may include a detection line assembly with a first shunt and a second shunt, which is used to reconfigure a modular detection line assembly; Fig. Figure 4 illustrates a product that may include a modular central integrated circuit board and a sensing line assembly module and a pair of extensions, each extension having a shunt that reconfigures the modular central integrated circuit board and the sensing line assembly; Fig. Figure 5 illustrates a product that may include a central integrated circuit bus and sensing line module and a pair of extensions, each extension having a shunt that reconfigures a modular central integrated circuit board and a sensing line assembly; and Fig. Figure 6 is a side view showing a product that may include a first flexible circuit and a first wire bond connecting the first flexible circuit and a first shunt, as well as a second flexible circuit and a second wire bond connecting the second flexible circuit and a welding pad.

[0018] A variety of sensing lines, which are low-voltage lines between cells and a battery management system, can be used to control a battery cell or a group of cells within a battery. If one or more cells have a peak voltage and other cells have lower voltages, a relay can be closed to discharge the cell (or group of cells) with the peak voltage through a balancing resistor. This reduces the voltage to that of the next highest-voltage cell.

[0019] In Fig. Figure 1 shows a range of variants that can comprise a product 100, which can be part of a battery management system and can include a variety of battery cells or cell groups, comprising a first cell or cell group 102, a second cell or cell group 104, a third cell or cell group 106, and so on. The first cell or cell group 102 can have a first terminal 108, which can be a positive terminal, and a second terminal 110, which can be a negative terminal. Similarly, the second cell or cell group 104 can have a first terminal 112, which can be a positive terminal, and a second terminal 114, which can be a negative terminal, and the third cell group 106 can have a first terminal 116, which can be a positive terminal, and a second terminal 118, which can be a negative terminal.A busbar 121 can comprise a variety of sections, each connected to a cell or cell group. In several variations, a first section 122 of the busbar 121 can be connected to the first terminal 108 of the first cell or cell group 102. A second section 124 of the busbar 121 can be connected to the second terminal 110 of the first cell or cell group 102 and to the first terminal 112 of the second cell or cell group 104. Similarly, a third section 126 of the busbar 121 can be connected to the second terminal 114 of the second cell or cell group and to the first terminal 116 of the third cell or cell group 106. The busbar 121 can also include a fourth section 128, which can be connected to the second terminal 118 of the third cell or cell group 106.

[0020] A first detection line 130 can be connected to the first section 122 of the busbar 121, and a second detection line 138 can be connected to the second section 124 of the busbar 121. The first detection line 130 and the second detection line 138 can be selectively connected to each other by a first relay 134 and a first balancing resistor 136, which is arranged to operate when the first relay 134 closes. A third detection line 139 can be connected to the third section 126 of the busbar 121. The third detection line 139 and the second detection line 138 can be selectively connected to each other by a second relay 140 and a second balancing resistor 142, which are arranged to operate when the second relay 140 closes. A fourth detection line 144 can be connected to the fourth section 128 of the busbar 121.The fourth detection line 144 and the third detection line 139 can be selectively connected to each other by a third relay 146 and a third balancing resistor 148, which are arranged to operate when the third relay 146 closes.

[0021] Fig. Figure 2 illustrates a number of variants that a product 100 may include, which may have a cell sensing device 150 of the battery management system, which may include a cell sensing application-specific integrated circuit (cell sensing ASIC) 153. The cell sensing ASIC 153 may have a variety of channels for sensing lines, to which, for example, an ASIC ground channel 152 and an ASIC power channel 154 may be connected. A variety of other channels may be provided, such as channel 0, represented by reference 156, channel 1, represented by reference 158, channel N, represented by reference 160, channel N-1, represented by reference 162, and a variety of other channels, such as a first channel 164 and a second channel 166.

[0022] A detection line connection device 151 can be provided, which can include a plurality of connection lines or paths. A first connection line 168 can be connected to the ASIC ground channel 152 and the first solder pad 182. A second connection line 170 can be connected to channel 0, designated by reference 156, and a second solder pad 184. A third connection line 172 can be connected to channel 1, designated by reference 158, and the third solder pad 186. A fourth connection line 174 can be connected to the first channel 164 and a fourth solder pad 188. A fifth connection line 176 can be connected to the second channel 166 and a fifth solder pad 190. A sixth connection line 178 can be connected to channel N-1 162 and a sixth solder pad 192.A seventh connecting line 180 can be connected to channel N 160 and a seventh solder pad 194. An eighth connecting line 181 can be connected to the ASIC power channel and an eighth solder pad 196.

[0023] In a similar way to in Fig. As shown in Figure 1, a variety of sensing traces can be connected to the terminals of a cell or cell group. For example, a first sensing trace 198 can be connected directly or indirectly to the second weld pad 184 and a first cell or cell group 200. A second sensing trace 202 can be connected directly or indirectly to the third weld pad 186 and to the first cell or cell group 200 and a second cell or cell group 204. A third sensing trace 206 can be connected directly or indirectly to the fourth weld pad 188 and to the second cell or cell group 204 and a third cell or cell group 208. A fourth sensing trace 210 can be connected directly or indirectly to the fifth weld pad 190 and to the third cell or cell group 208 and a fourth cell or cell group 212.A fifth detection line trace 214 can be connected directly or indirectly to the sixth weld pad 192 and to the fourth cell or cell group 212 and a fifth cell or cell group 216. A sixth detection line trace 28 can be connected directly or indirectly to the seventh weld pad 194 and to the fifth cell or cell group 216. A first shunt 220 can be connected to the first weld pad 182, the second weld pad 184, and the third weld pad 186. Adding the first shunt 220 leaves the first cell or cell group unoccupied, and it is ignored during cell balancing by the battery management system. A second shunt 222 can be connected to the eighth weld pad 196, the seventh weld pad 194, and the sixth weld pad 192. The addition of the second shunt 222 results in the fifth cell or cell group being unoccupied and ignored during cell balancing by the battery management system.For each cell or group of cells, a relay and a balancing resistor can be provided and selectively connected to two detection lines, as shown in . Fig. 1 shown.

[0024] In Fig. 3 shows a series of variants that may be structured similarly to those in Fig. 2, except that no detection line connection device is provided and the first shunt 220 can be connected to the first solder pad 182 and the second solder pad 184 to short-circuit the ASIC power channel 154 and channel 0 152. The second shunt 222 can be connected to the eighth solder pad 196 and the seventh solder pad 194 to short-circuit the ASIC power channel 154 and channel N 160. As can be seen from the in the Fig. As can be seen from the variants shown in 1-2, at least one shunt can be used to short-circuit at least two sweat pads and / or to discharge at least one cell or cell group.

[0025] In Fig. Figure 4 shows a number of variants that may include a first modular component comprising a central integrated circuit board and a detection line assembly 157, which may include the cell detection device 150 of the battery management system, the cell detection ASIC 153, a plurality of connecting lines, a plurality of solder pads, and / or a plurality of detection lines. At least one extension, for example, a first extension 224 and / or a second extension 226, may be provided. The first extension 224 and / or the second extension 226 may be arranged in the same plane as the central integrated circuit board and the detection line assembly 157, or at least part of the first extension 224 and / or the second extension 226 may be located above the central integrated circuit board and the detection line assembly 157.The first extension 224 and / or the second extension 226 may have at least one detection line, or at least one shunt, or at least one shunt may be provided as a separate part.

[0026] The cell sensing ASIC 153 can have a variety of channels to which the sensing lines can be connected, e.g., an ASIC ground channel 152 and an ASIC power channel 154. A variety of other channels can be provided, e.g., channel 0, represented by reference 156, channel 1, represented by reference 158, channel N, represented by reference 160, channel N-1, represented by reference 162, and a variety of other channels, e.g., a first channel 164 and a second channel 166.

[0027] A first connecting wire 168 can be connected to the ASIC ground channel 152 and the first solder pad 182. A second connecting wire 170 can be connected to channel 0, designated by reference 156, and to a second solder pad 184. A third connecting wire 172 can be connected to channel 1, designated by reference 158, and the third solder pad 186. A fourth connecting wire 174 can be connected to the first channel 164 and the fourth solder pad 188. A fifth connecting wire 176 can be connected to the second channel 166 and to a fifth solder pad 190. A sixth connecting wire 178 can be connected to channel N-1 162 and to a sixth solder pad 192. A seventh connecting wire 180 can be connected to channel N 160 and to a seventh solder pad 194. And an eighth connecting line 181 can be connected to the ASIC power channel and an eighth solder pad 196.

[0028] In a similar way to in Fig. As shown in Figure 1, a variety of sensing leads can be connected to the terminals of a cell or cell group. The first extension 224 can include a first sensing lead trace 198, which can be connected directly or indirectly to the second weld pad 184 or the first shunt 220 and a first cell or cell group 200. A second sensing lead trace 202 can be connected directly or indirectly to the third weld pad 186 and to the first cell or cell group 200 and a second cell or cell group 204. A third sensing lead trace 206 can be connected directly or indirectly to the fourth weld pad 188 and to the second cell or cell group 204 and a third cell or cell group 208. A fourth sensing lead trace 210 can be connected directly or indirectly to the fifth weld pad 190 and to the third cell or cell group 208 and a fourth cell or cell group 212.A fifth detection line trace 214 can be connected directly or indirectly to the sixth weld pad 192 and to the fourth cell or cell group 212 and a fifth cell or cell group 216. The second extension 226 can have a sixth connection line trace 218, which can be connected directly or indirectly to the seventh weld pad 194 or to the second shunt 222 and to the fifth cell or cell group 216. A first shunt 220 can be connected to the first weld pad 182, the second weld pad 184, and the third weld pad 186. The addition of the first shunt 220 results in the first cell or cell group being unoccupied and ignored during cell balancing by the battery management system. A second shunt 222 can be connected to the eighth weld pad 196, the seventh weld pad 194, and the sixth weld pad 192.The addition of the second shunt 222 results in the fifth cell or cell group being unoccupied and ignored during cell balancing by the battery management system. A relay and a balancing resistor can be provided for each cell or cell group and selectively connected to two sensing lines, e.g., as shown in [reference]. Fig. 1 shown.

[0029] Fig. Figure 5 shows a number of variants that may be structured similarly to those in Fig. 4, except that the second shunt 222 can be connected to the eighth weld pad 196 and the seventh weld pad 194 to short-circuit the ASIC power channel 154 and channel N 160, and the first shunt 220 can be connected to the first weld pad 182 and the second weld pad 184 to short-circuit the ASIC power channel 154 and channel O 152. As can be seen from the in the Fig. As can be seen from the variants shown in 4-5, at least one shunt can be used to short-circuit at least two sweat pads and / or to leave at least one cell or cell group unoccupied.

[0030] A number of variants are in Fig.Figure 6 shows a product 100 that can include a first extension 224, which can include a first detection line track 198 connected to a first shunt 220 by a first wire bond 232. The first detection line track 198 can be supported or enclosed by a first polymer material 228, such as a polyamide. The first detection line track 198 and the first polymer material 228 can form a first flexible circuit 238. The first polymer material 228 and the first detection line track 198 can be supported by a first substrate 230, which can be a non-conductive substrate such as a glass fiber sheet. A first modular component can be a central integrated circuit board, and the detection line assembly 157 can have a first connecting line 168 that can be supported or enclosed by a second polymer material 236.The first connecting line 168 can be connected to a first welding pad 182 by a second wire bond 234. A first shunt 220 can be welded to a first welding pad 182, and a first connecting line 168 can be connected to the first welding pad 182 by a second wire bond 234. The first welding pad 182 can be part of the central integrated circuit board, and the detection line assembly 157 can be a separate part.

Claims

[1] Procedure, encompassing: Providing an application-specific integrated circuit (153) for detecting battery cells, comprising at least a first channel (152) and a second channel (156), a first connecting line (168) connected to the first channel (152), a second connecting line (170) connected to the second channel (156), a first solder pad (182) connected to the first connecting line (168), a second solder pad (184) connected to the second connecting line (170), and a first extension (224) comprising a first flexible circuit (238) with a first detection line trace (198); Welding a first shunt (220) to the first welding pad (182) and the second welding pad (184); and Connecting a first wire bond (232) to the first detection line trace (198) and to the first shunt (220). [2] Method according to claim 1, wherein the application-specific integrated circuit (153) for detecting battery cells further comprises a third channel (158) and a fourth channel (164), a third connecting line (172) connected to the third channel (158), a fourth connecting line (174) connected to the fourth channel (164), a third weld pad (186) connected to the third connecting line (172), and a fourth weld pad (188) connected to the fourth connecting line (174); and welding a second shunt (222) to the third weld pad (186) and the fourth weld pad (188). [3] Method according to claim 1, further comprising connecting a first wire bond (232) to the first welding pad (182) and the first connecting line (168), and connecting a second wire bond (234) to the second welding pad (184) and the second connecting line (170). [4] Method according to claim 1, further comprising a second extension (226) comprising a second flexible circuit with a second detection line track (202). [5] Method according to claim 4, further comprising connecting a second wire bond (234) to the second detection line trace (202) and to a second shunt (222). [6] Method according to claim 5, further comprising connecting a third wire bond to the third welding pad (186) and the third connecting line (172), and connecting a fourth wire bond to the fourth welding pad (188) and the fourth connecting line (174). [7] Product, comprising: an application-specific integrated circuit (153) for detecting battery cells, comprising at least a first channel (152) and a second channel (156), a first connecting line (168) connected to the first channel (152), and a second connecting line (170) connected to the second channel (156), a first welding pad (182) connected to the first connecting line (168), and a second welding pad (184) connected to the second connecting line (170); a first shunt (220) which is welded to the first welding pad (182) and the second welding pad (184) a first extension (224) comprising a first flexible circuit (238) with a first detection line track (198); and a first wire bond (232) which is connected to the first detection line track (198) and to the first shunt (220).

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