Detection cover assemblies with integrated heat barrier for traction battery banks

Abstract

Battery banks for traction battery packs are provided. An example battery bank may include a sensing cover assembly with integrated thermal barriers. Each thermal barrier can be secured to a top cover of the sensing cover assembly using a combination of one or more slots on the top cover and one or more thermal barrier flat connectors, thus reducing parts and complexity.

Description

AREA OF TECHNOLOGY

[0001] This disclosure generally relates to traction battery packs and, in particular, battery banks that include detection cover assemblies having integrated thermal barriers. GENERAL STATE OF THE ART

[0002] Electrified vehicles include a traction battery pack to supply power to electric motors and other electrical components within the vehicle. The traction battery pack comprises a variety of battery cells and various other internal components that support the electric vehicle's propulsion system. SUMMARY

[0003] A battery bank for a battery pack according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells and a busbar module assembly configured to electrically connect the plurality of battery cells. The busbar module assembly includes a first busbar module, a second busbar module, and a capture cover assembly connected to the first and second busbar modules. The capture cover assembly includes a plurality of integrated thermal barriers.

[0004] In a further non-restrictive embodiment of the preceding battery bank, the plurality of integrated thermal batteries is secured to an upper cover of the detection cover assembly.

[0005] In a further non-restrictive embodiment of one of the preceding battery banks, the detection cover assembly also includes a flexible printed circuit board.

[0006] In a further non-restrictive embodiment of any of the preceding battery banks, the detection cover assembly further includes a foam barrier arranged between the top cover and the flexible printed circuit board.

[0007] In a further non-restrictive embodiment of any of the preceding battery banks, a first thermal barrier of the plurality of integrated thermal batteries includes a flat plug which is received within a slot in the top cover to secure the first thermal barrier to the top cover.

[0008] In a further non-restrictive embodiment of any of the preceding battery banks, a first thermal barrier of the plurality of integrated thermal batteries comprises a plurality of flat plugs which are received within a plurality of slots in the top cover to secure the first thermal barrier to the top cover.

[0009] In a further non-restrictive embodiment of any of the preceding battery banks, the plurality of integrated heat barriers consists of a heat-resistant material and the top cover consists of a plastic material.

[0010] In a further non-restrictive embodiment of any of the preceding battery banks, an upper cover of the detection cover assembly includes a first support received through a first opening of the first busbar module and a second support received through a second opening of the second busbar module.

[0011] In a further non-restrictive embodiment of any of the preceding battery banks, a frame of each of the first busbar module and the second busbar module includes an opening dimensioned to accommodate a cell flat connector of at least one battery cell of the plurality of battery cells.

[0012] In another non-restrictive embodiment of any of the preceding battery banks, a busbar is mounted on the frame.

[0013] A battery bank for a traction battery pack according to another exemplary aspect of the present disclosure includes, among other things, a cell stack assembly comprising a plurality of battery cells and a busbar module assembly. The busbar module assembly includes a capture cover assembly comprising a top cover and a first thermal barrier secured to the top cover.

[0014] In a further non-restrictive embodiment of the preceding battery bank, the detection cover assembly also includes a flexible printed circuit board.

[0015] In a further non-restrictive embodiment of one of the preceding battery banks, the detection cover assembly further includes a foam barrier arranged between the top cover and the flexible printed circuit board.

[0016] In a further non-restrictive embodiment of any of the preceding battery banks, the detection cover assembly is connected to a first busbar module and a second busbar module of the busbar module assembly.

[0017] In a further non-restrictive embodiment of any of the preceding battery banks, the upper cover of the detection cover assembly includes a first support that is received through a first opening of the first busbar module and a second support that is received through a second opening of the second busbar module.

[0018] In a further non-restrictive embodiment of any of the preceding battery banks, the first thermal barrier includes a first flat connector which is received within a first slot in the top cover to secure the first thermal barrier to the top cover.

[0019] In a further non-restrictive embodiment of any of the preceding battery banks, a second thermal barrier of the detection cover assembly includes a second flat connector which is received within a second slot in the top cover to secure the second thermal barrier to the top cover.

[0020] In a further non-restrictive embodiment of any of the preceding battery banks, a third thermal barrier of the detection cover assembly includes a third flat connector which is received within a third slot of the top cover to secure the third thermal barrier to the top cover.

[0021] In a further non-restrictive embodiment of any of the preceding battery banks, the first thermal barrier of the detection cover assembly comprises a plurality of flat connectors which are received within a plurality of slots in the top cover to secure the first thermal barrier to the top cover.

[0022] In a further non-restrictive embodiment of any of the preceding traction battery packs, the first heat barrier consists of a heat-resistant material and the top cover consists of a plastic material.

[0023] The embodiments, examples, and alternatives described in the preceding paragraphs, the claims, or the following description and drawings, including their various aspects or individual features, may be used independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, provided such features are not incompatible.

[0024] The various features and advantages of this disclosure will become apparent to the person skilled in the art from the following detailed description. The drawings accompanying the detailed description can be summarized as follows. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 schematically illustrates an electrified vehicle. Fig. Figure 2 illustrates a battery bank of a traction battery pack. Fig. 3 is a partially disassembled view of a cell stack assembly of the battery bank made of Fig. 2. Fig. Figure 4 illustrates a detection cover assembly of a battery bank. Fig. 5 is a cross-sectional view through section 5-5 from Fig. 4. Fig. Figure 6 illustrates an upper cover of the capture cover assembly made of Fig. 4-5. Fig. Figure 7 illustrates another exemplary capture cover assembly of a battery bank. DETAILED DESCRIPTION

[0025] This disclosure details battery banks for traction battery packs. An exemplary battery bank may include a sensing cover assembly that incorporates thermal barriers. Each thermal barrier may be secured to a top cover of the sensing cover assembly using a combination of one or more slots on the top cover and one or more thermal barrier flat connectors, thereby reducing parts and complexity. These and other features are discussed in more detail in the following paragraphs of this detailed disclosure.

[0026] Fig. Figure 1 schematically illustrates an electrified vehicle 10. The electrified vehicle 10 can include any type of electrified powertrain. In one embodiment, the electrified vehicle 10 is a battery electric vehicle (BEV). However, the concepts described in this document are not limited to BEVs and could extend to other electrified vehicles, including, but not limited to, hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, etc. Therefore, although not specifically shown in the exemplary embodiment, the powertrain of the electrified vehicle 10 could be equipped with an internal combustion engine, which can be used either alone or in combination with other power sources to propel the electrified vehicle 10.

[0027] In the illustrated embodiment, the electrified vehicle 10 is depicted as an automobile. However, the electrified vehicle 10 could alternatively be a sport utility vehicle (SUV), a van, a pickup truck, or any other vehicle configuration. Although a specific relationship of the components is illustrated in the figures of this disclosure, the illustrations in this disclosure are not intended to be limiting. The placement and orientation of the various components of the electrified vehicle 10 are shown schematically and could vary within the scope of this disclosure. Furthermore, the various figures accompanying this disclosure are not necessarily drawn to scale, and some features may be enlarged or reduced to highlight certain details of a particular component or system.

[0028] In one embodiment, the electrified vehicle 10 is a fully electric vehicle powered exclusively by electrical power, such as from one or more electric machines 12, without any assistance from an internal combustion engine. The electric machine 12 can operate as an electric motor, an electric generator, or both. The electric machine 12 receives electrical power and can convert this power into torque to drive one or more wheels 14 of the electrified vehicle 10.

[0029] A voltage bus 16 can electrically couple the electric machine 12 to a traction battery pack 18. The traction battery pack 18 is an exemplary battery of an electrified vehicle. The traction battery pack 18 can be a high-voltage traction battery pack assembly comprising a variety of battery cell groupings capable of outputting electrical power to supply the electric machine 12 and / or other electrical consumers of the electrified vehicle 10. Alternatively or additionally, other types of energy storage devices and / or output devices could also be used to supply the electrified vehicle 10 with electrical power.

[0030] The traction battery pack 18 may be secured to an underbody 20 of the electrified vehicle 10. However, within the scope of this disclosure, the traction battery pack 18 could be located at a different location on the electrified vehicle 10.

[0031] Fig. 2 and Fig. Figure 3 illustrates features assigned to an exemplary battery bank 22 for use within a traction battery pack, such as the traction battery pack 18 of the electrified vehicle 10. Fig. 1. One or more battery banks, having a design similar to battery bank 22, could be installed within the traction battery pack 18.

[0032] The battery bank 22 can include one or more cell stack assemblies 28 housed within a bank housing 26. The bank housing 26 can include an upper cover 30, a lower cover 32, and a pair of end plates 34. The upper cover 30 can be positioned vertically above the lower cover 32. Various terms, such as "above," "below," "top," and "bottom," are used in the different drawings in relation to the arrangement of the components of the traction battery pack 18 and should not otherwise be considered restrictive. These terms refer to the general orientation of the traction battery pack 18 when installed in the electrified vehicle 10. Fig. 1 is installed. In the context of this disclosure, vertical also refers to the ground and how the traction battery pack 18 is oriented when installed in the electrified vehicle 10.

[0033] The upper cover 30 can be secured to the lower cover 32 (e.g., screwed, welded, glued, etc.). Furthermore, the upper cover 30 and / or the lower cover 32 can be secured to the end plates 34 (e.g., screwed, welded, glued, etc.). The upper cover 30, the lower cover 32, and the end plates 34 can be arranged together to provide a sealed enclosure for housing the cell stack assembly 28. However, other configurations of the bank enclosure 26 are considered within the scope of this disclosure. Accordingly, the size, shape, and configuration of the bank enclosure 26 could vary within the scope of this disclosure.

[0034] Each cell stack assembly 28 can contain a plurality of battery cells 24 arranged together along a cell stack axis A (see Fig. 3) In one embodiment, the battery cells are 24 lithium-ion pouch cells. However, within the scope of this disclosure, alternatively, battery cells with other geometries (cylindrical, prismatic, etc.) and / or chemical compositions (nickel-metal hydride, lead-acid, etc.) could be used. The total number of battery cells 24 provided within the battery bank 22 can vary and is not intended to limit this disclosure.

[0035] A cell expansion pad 36 can be arranged between adjacent battery cells 24 of the cell stack assembly 28. The cell expansion pads 36 can comprise a material (e.g., polyurethane foam, silicone foam, etc.) that is adapted to accommodate swelling of battery cells.

[0036] The cell stack assembly 28 can additionally include a busbar module assembly 38, which is configured to electrically connect the battery cells 24 of the cell stack assembly 28. Once electrically coupled, the battery cells 24 can supply at least part of the electrical power required to achieve electric propulsion of the electrified vehicle 10.

[0037] The busbar module assembly 38 can include a first busbar module 40, a second busbar module 42, and a capture cover assembly 44. The first busbar module 40 and the second busbar module 42 can each include a plurality of busbars 46 held within a busbar frame 48. The total number of busbars 46 provided within each of the first busbar module 40 and the second busbar module 42 is not limited by this disclosure.

[0038] The busbars 46 can be metallic components of the first and second busbar modules 40, 42, and the busbar frames 48 can be plastic components of the first and second busbar modules 40, 42. In one embodiment, the busbars 46 are made of copper or aluminum, and the busbar frames 48 are made of polypropylene or polyethylene. However, other materials are considered within the scope of this disclosure.

[0039] Each busbar frame 48 can include openings 50 (e.g., elongated slots), each dimensioned to receive a cell connector 52 of one or more of the battery cells 24 of the cell stack 28. The cell connector terminals 52 can extend through the openings 50 for connection to the busbars 46. The busbars 46 can connect the connector terminals 52 of adjacent battery cells 24 for electrical connection of the battery cells 24 of the cell stack assembly 28.

[0040] Now mainly with reference to Fig. 3-6 The detection cover assembly 44 of the busbar module assembly 38 can include a top cover 54, a flexible printed circuit board 56, and a foam barrier 60 located between the top cover 54 and the flexible printed circuit board 56. The top cover 54 can be made of any plastic material. The flexible printed circuit board 56 can include detection leads and other circuitry necessary for monitoring voltage and temperature information associated with the battery cells 24 of the cell stack assembly 28. The foam barrier 60 can be secured to the underside of the top cover 54 or formed integrally with it and can be configured to protect various circuits of the flexible printed circuit board 56.

[0041] Each opposite side of the upper cover 54 can include one or more brackets 58. The first busbar module 40 and the second busbar module 42 can be secured to the detection cover assembly 44 via the brackets 58 to assemble the busbar module assembly 38. In one embodiment, each bracket 58 is located within an opening 59 (see Fig. 3) included, which is formed either in the first busbar module 40 or the second busbar module 42. However, within the scope of this disclosure, other configurations for securing the busbar modules 40, 42 to the detection cover assembly 44 are considered.

[0042] The capture cover assembly 44 can further include a variety of thermal barriers 62. The thermal barriers 62 and the top cover 54 can be integrated together to reduce parts and provide an optimized installation configuration for the battery bank 22. In this disclosure, the term "integrated" means that the thermal barriers 62 are pre-assembled (glued, friction-fit, clamped, etc.) and thus physically connected to the top cover 54 to form a single, integrated component. In some implementations, the thermal barriers 62 can be provided as a "part-in-assembly" (PIA) of the capture cover assembly 44.

[0043] The heat barriers 62 can be made of heat-resistant materials, such as mica, aerogels, etc. However, other materials or combinations of materials could also be used to construct the heat barriers 62 within the scope of this disclosure.

[0044] The top cover 54 can include a plurality of slots 64. The slots 64 can extend through a material thickness of the top cover 54. Each slot 64 can be dimensioned to accommodate an integrated flat connector 66 of one of the thermal barriers 62. The integrated flat connectors 66 can be securely held within the slots 64 by a friction fit, adhesive, or other suitable attachment methods to integrate the thermal barriers 62 as part of the detection cover assembly 44. Although not specifically shown, the flexible printed circuit board 56 and the foam barrier 60 can each include corresponding slots aligned with the slots 64 of the top cover 54 to accommodate the flat connectors 66 of the thermal barriers 62.

[0045] In one embodiment, a plurality of the slots 64 and a plurality of the integrated flat connectors 66 work together to secure each heat barrier 62 to the upper cover 54 (see e.g. Fig. 4-6). In another embodiment, a single slot 64 and a single integrated flat connector 66 work together to secure each thermal barrier 62 to the upper cover 54 (see e.g. Fig. 7).

[0046] The thermal barriers 62 can be used as guides to slide the battery cells 24 into place during the assembly of the cell stack assembly 28. The thermal barriers 62 serve to hold the battery cells 24 in a vertical orientation before the cell stack assembly 28 is inserted into the lower cover 32 during the battery bank 22 assembly process.

[0047] In the assembled state of the battery bank 22, the thermal barriers 62 can divide the battery bank 22 into two or more groupings or compartments of the battery cells 24. In one embodiment, the groups of four individual battery cells 24 are separated by the thermal barriers 62. However, other configurations are considered within the scope of this disclosure. For example, should a battery thermal event occur in one or more of the battery cells 24, the thermal barriers 62 can reduce or prevent the thermal energy associated with the thermal event from moving from cell to cell along the length of the battery bank 22, thereby inhibiting the transfer of thermal energy within the traction battery pack 18.

[0048] The exemplary battery banks presented in this disclosure incorporate thermal barriers and integrated capture cover assemblies for electrically connecting a stacked grouping of battery cells. The thermal barriers and the top cover of the integrated capture cover assembly are, among other advantages, integrated to reduce parts, simplify logistics, optimize bank assembly and efficiency, and provide increased energy density.

[0049] Although the different non-restrictive embodiments are illustrated by showing specific components or steps, the embodiments of this disclosure are not limited to these specific combinations. It is possible to use some of the components or features from any of the non-restrictive embodiments in combination with features or components from any of the other non-restrictive embodiments.

[0050] It is understood that identical reference numerals denote corresponding or similar elements in the multiple views. It is understood that although a specific component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the lessons of this disclosure.

[0051] The foregoing description is to be interpreted as illustrative and not as limiting. A person skilled in the art will understand that certain modifications may fall within the scope of this disclosure. For these reasons, the following patent claims should be read carefully to determine the true scope and content of this disclosure.

Claims

[1] Battery bank for a traction battery pack, comprising: a large number of battery cells; and a busbar module assembly configured to electrically connect the plurality of battery cells, wherein the busbar module assembly comprises a first busbar module, a second busbar module and a detection cover assembly connected to the first busbar module and the second busbar module, the capture cover assembly includes a variety of integrated thermal barriers. [2] Battery bank according to claim 1, wherein the plurality of integrated thermal batteries is secured to an upper cover of the detection cover assembly. [3] Battery bank according to claim 2, wherein the detection cover assembly further includes a flexible printed circuit board and wherein the detection cover assembly optionally includes a foam barrier arranged between the upper cover and the flexible printed circuit board of the detection cover assembly. [4] Battery bank according to claim 2, wherein a first thermal barrier of the plurality of integrated thermal batteries includes a flat plug which is received within a slot of the top cover to secure the first thermal barrier to the top cover. [5] Battery bank according to claim 2, wherein a first thermal barrier of the plurality of integrated thermal batteries comprises a plurality of flat connectors which are received within a plurality of slots of the top cover to secure the first thermal barrier to the top cover. [6] Battery bank according to claim 2, wherein the plurality of integrated heat barriers consists of a heat-resistant material and the top cover consists of a plastic material. [7] Battery bank according to a preceding claim, wherein an upper cover of the detection cover assembly includes a first holder which is received through a first opening of the first busbar module and a second holder which is received through a second opening of the second busbar module. [8] Battery bank according to a preceding claim, wherein a frame of each of the first busbar module and the second busbar module includes an opening dimensioned to accommodate a cell flat connector of at least one battery cell of the plurality of battery cells, and optionally comprising a busbar mounted on the frame. [9] Battery bank for a traction battery pack, comprising: a cell stack assembly comprising a plurality of battery cells and a busbar module assembly, wherein the busbar module assembly includes a capture cover assembly comprising a top cover and a first thermal barrier secured to the top cover. [10] Battery bank according to claim 9, wherein the detection cover assembly further includes a flexible printed circuit board and wherein the detection cover assembly optionally includes a foam barrier arranged between the upper cover and the flexible printed circuit board. [11] Battery bank according to claim 9 or 10, wherein the detection cover assembly is connected to a first busbar module and a second busbar module of the busbar module assembly and wherein the upper cover of the detection cover assembly optionally includes a first holder which is received through a first opening of the first busbar module and a second holder which is received through a second opening of the second busbar module. [12] Battery bank according to any one of claims 9 to 11, wherein the first thermal barrier includes a first flat connector which is received within a first slot of the upper cover to secure the first thermal barrier to the upper cover. [13] Battery bank according to claim 12, wherein a second thermal barrier of the detection cover assembly includes a second flat connector which is received within a second slot of the upper cover to secure the second thermal barrier to the upper cover, and wherein optionally a third thermal barrier of the detection cover assembly includes a third flat connector which is received within a third slot of the upper cover to secure the third thermal barrier to the upper cover. [14] Battery bank according to any one of claims 9 to 13, wherein the first thermal barrier of the detection cover assembly comprises a plurality of flat connectors which are received within a plurality of slots of the top cover to secure the first thermal barrier to the top cover. [15] Battery bank according to any one of claims 9 to 14, wherein the first heat barrier is made of a heat-resistant material and the top cover is made of a plastic material.

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