Sensor arrangement with control modules for a battery pack - interconnection arrangement for a battery pack

Abstract

A battery pack interconnection arrangement (50) for electrically connecting cell terminals (24, 26) of battery cells (20) in a battery pack (10) comprises a busbar interconnection (100) with busbars (200) having rows (204) and columns (206). The battery pack interconnection arrangement includes a sensor arrangement (500) coupled to the busbars for detecting at least one parameter of the busbars. The sensor arrangement comprises a control arrangement (400) and a sensor wiring harness (300) coupled to the control arrangement, comprising sensor cables (350) with sensor conductors (360) that are coupled to the busbars at sensor points. The control arrangement comprises a control board (410) and control modules (450) that are connected to the control circuits of the control board. Each control module comprises module terminals (480) that are connected between the control circuits and the corresponding sensor conductors.

Description

[0001] This application claims priority over Provisional U.S. Application No. 63 / 723,233, filed on November 21, 2024, the subject matter of which is hereby incorporated in its entirety by reference.

[0002] The subject matter of this application generally relates to battery packs, such as battery packs for electric vehicles.

[0003] Electric vehicles have a battery system that includes a battery pack with a large number of battery cells. A typical battery system requires a connectivity solution to transfer / distribute energy between groups of battery cells and includes devices for sensing battery parameters such as voltage and temperature. For energy transfer, busbars (made of aluminum or copper) are typically welded to the cell terminals in a series and / or parallel electrical configuration. As electric vehicle applications become more widespread, the overhead costs of components ($ / kWh) are closely scrutinized, and there is a desire to minimize costs, for example, by minimizing the number of parts and part numbers. In battery systems for electric vehicles, the battery cell stacks are very large.Typically, assembling a battery system requires many parts that are individually mounted to the corresponding cell terminals, which is time-consuming and increases the assembly cost. There is a need to monitor the operating parameters of the components, such as the voltages at each busbar, the temperature, the state of charge, and other operating characteristics. Some systems use wiring harnesses with sensors to monitor the battery system components. These wiring harnesses increase the weight, cost, and assembly time.

[0004] There is still a need for a method for the cost-effective and reliable assembly of battery packs, for example for electric vehicles.

[0005] In one embodiment, a battery pack interconnection arrangement is provided for electrically connecting the cell terminals of battery cells in a battery pack. The battery pack interconnection arrangement comprises a busbar interconnection consisting of a plurality of busbars arranged in a matrix with multiple rows and multiple columns of busbars, and a busbar support that holds the busbars. Each busbar comprises a first mating end for connecting to the corresponding cell terminal of the corresponding battery cell and a second mating end for connecting to the adjacent cell terminal of the adjacent corresponding battery cell. The busbars electrically connect the battery cells in the battery pack.The battery pack interconnection assembly comprises a sensor assembly coupled to the busbars for sensing at least one busbar parameter. The sensor assembly includes a control assembly and a sensor wiring harness connected to the control assembly. The sensor wiring harness has sensor cables with sensor conductors that are connected to the busbars at sensor points. The control assembly comprises a control board and control modules connected to the control circuits of the control board. Each control module includes module terminals that are connected between the control circuits and the corresponding sensor conductors.

[0006] The invention is described by way of example with reference to the attached figures, which show the following: Fig. Figure 1 shows a perspective view of a battery pack comprising a battery pack interconnection arrangement, according to an exemplary embodiment. Fig. Figure 2 shows a top view of the battery pack interconnection arrangement according to an exemplary embodiment. Fig. Figure 3 is a top view of the sensor module according to an exemplary embodiment. Fig. Figure 4 is a side view of the sensor module according to an exemplary embodiment. Fig. Figure 5 is a top view of the sensor cable according to an exemplary embodiment. Fig. Figure 6 is a cross-sectional view of the sensor cable according to an exemplary embodiment. Fig. Figure 7 shows the sensor arrangement according to an exemplary embodiment. Fig. Figure 8 is a perspective view of the control module according to an exemplary embodiment. Fig. Figure 9 is a perspective bottom view of part of the control arrangement, showing the control module which, according to an exemplary embodiment, is ready to be assembled with the control board. Fig. Figure 10 is a bottom view of the control arrangement according to an exemplary embodiment. Fig. Figure 11 is a top view of the control arrangement according to an exemplary embodiment. Fig. Figure 12 is a cross-sectional view of the control arrangement according to an exemplary embodiment. Fig. Figure 13 is a cross-sectional view of the control arrangement according to an exemplary embodiment. Fig. Figure 14 is a cross-sectional view of the control arrangement according to an exemplary embodiment, showing how the sensor conductor is connected to the module terminal by an ultrasonic welding process. Fig. Figure 15 is a cross-sectional view of the control arrangement according to an exemplary embodiment, showing how the sensor conductor is connected to the module terminal by a laser welding process. Fig. Figure 16 is a cross-sectional view of the control arrangement according to an exemplary embodiment, showing how the sensor conductor is connected to the module terminal by a resistance welding process. Fig. Figure 17 is a cross-sectional view of the control arrangement according to an exemplary embodiment, showing how the sensor conductor is connected to the module terminal by a resistance welding process.

[0007] Fig. Figure 1 is a perspective view of a battery pack 10 with a battery pack interconnection arrangement 50 according to an exemplary embodiment. The battery pack interconnection arrangement 50 comprises a busbar interconnection 100 having a plurality of busbars 200. The battery pack interconnection arrangement 50 includes a sensor arrangement 500 with a sensor wiring harness 300 and a control arrangement 400 coupled to the sensor wiring harness 300. The sensor wiring harness 300 detects one or more operating parameters of the battery pack 10, such as voltage, temperature, state of charge, or other operating characteristics of the battery pack 10. The control arrangement 400 receives the sensor data from the sensor wiring harness 300 and can control one or more processes associated with the battery pack 10, such as the charging process.For example, the control arrangement 400 can be communicatively coupled with a control module, a battery distribution unit, or another control device for the battery system. The control arrangement 400 can aggregate the sensor data, for example, for each of the busbars 200.

[0008] The battery pack 10 can be a battery pack for a vehicle, for example, an electric vehicle. However, in alternative embodiments, the battery pack 10 can also be used in other applications. In one exemplary embodiment, the battery pack 10 is a high-voltage battery pack. The battery pack 10 can, for example, be a 400 V or 800 V battery pack. The busbar interconnection 100 is used to electrically connect a matrix of battery cells 20 of the battery pack 10. For example, the busbar interconnection 100 can electrically connect the battery cells 20 in series and / or parallel.

[0009] The battery cells 20 can be held in a battery pack housing 12. The battery pack 10 comprises a positive battery interconnection terminal 14 and a negative battery interconnection terminal 16. The battery interconnection terminals 14 and 16 can be connected to other power distribution components of the battery pack 10, such as contactors and fuses, for connection to a charging system and / or a load, such as an electric motor.

[0010] Each battery cell 20 comprises a housing 22, a first cell terminal 24, and a second cell terminal 26. The battery cell 20 can be a prismatic battery cell in various embodiments. The first and second cell terminals 24, 26 can be cathode and anode connections, respectively. In one exemplary embodiment, the battery cells 20 are rectangular and arranged in a stacked configuration. For example, the battery cells 20 can be stacked in rows and columns within the matrix. The cell matrix can have a large surface area, for example, greater than two square meters (2 m²). 2or more). For example, the matrix can have a length between approximately 1.0 m and 2.0 m and a width between approximately 1.0 m and 1.5 m. Adjacent battery cells 20 in the rows are connected to each other by the corresponding busbars 200 of the busbar interconnection 100. Adjacent rows of battery cells 20 are connected to each other by the corresponding busbars 200 of the busbar interconnection 100. For example, final battery cells 20 can be connected row by row.

[0011] The busbar interconnection 100 comprises a busbar support 110 that holds the busbars 200. The busbar support 110 holds the busbars 200 in relative positions to connect them to the cell terminals 24, 26 of the corresponding battery cells 20. The busbars 200 electrically connect adjacent battery cells 20, for example, in series and / or parallel. In various embodiments, the busbar support 110 integrates all the busbars 200 into a single unit or structure for attachment to the matrix of battery cells 20. For example, a single busbar support 110 can be used to hold all the busbars 200. In other various embodiments, the busbar support 110 can comprise several frames or units, each of which holds a plurality of the busbars 200, for example, a column of busbars 200.The frames / units can be connected to each other by other elements of the busbar support 110 to form a connected structure.

[0012] In various embodiments, the busbar support 110 can be a structural foam ladder frame that holds the busbars 200. For example, the busbar support 110 can be manufactured by a structural foam molding process. In alternative embodiments, the busbar support can be manufactured from other materials, for example, from a molded plastic structure. The busbar support 110 can be molded or formed on the busbar matrix. For example, the busbar support 110 can be overmolded in situ over portions of the busbars 200 to form the busbar interconnection 100. The busbar support 110 can be formed around portions of the busbars 200 to hold the busbars 200 relative to each other and relative to the cell terminals 24, 26 of the battery cells 20.

[0013] In an exemplary embodiment, the busbar support 110 comprises a frame or grid 120. The grid 120 is formed around portions of the busbars 200 to hold the busbars 200 in relative positions. In an exemplary embodiment, the busbar support 110 holds all the busbars 200 for the battery pack 10 to reduce the number of parts required for the final assembly of the battery pack 10. For example, the individual busbar interconnection 100 is mounted on the battery pack 10. The busbar support 110 is used to position the busbars 200 for electrical connection to the cell terminals 24, 26 of the battery cells 20. In an exemplary embodiment, the sensor arrangement 500, such as the sensor wiring harness 300 and / or the control arrangement 400, is coupled to the busbar support 110.The busbar support 110 can be used to position the sensor arrangement 500 on the battery cells 20.

[0014] The grid 120 comprises frame elements 122 configured to couple with the busbars 200 to maintain their relative positions. The frame elements 122 include outer frame elements 130, which surround a perimeter of the grid 120, and inner frame elements 140, which extend across an interior space of the grid 120 to connect with the busbars 200. The inner frame elements 140 extend between the outer frame elements 130. For example, the inner frame elements 140 include longitudinal elements 142 and transverse elements 144. The longitudinal elements 142 extend lengthwise across the grid 120 between opposite ends. The transverse elements 144 extend transversely across the grid 120 between opposite sides. The longitudinal elements 142 and / or the transverse elements 144 can be used to support parts of the busbars 200.The transverse elements 144 form an interconnection of the longitudinal elements 142, for example to support them, and vice versa. In an exemplary embodiment, the inner frame elements 140 are integrally formed with the outer frame elements 130. For example, the inner frame elements 140 are formed together with the outer frame elements 130 during a structural forming process. The grid 120 forms a uniform, monolithic structure.

[0015] In one exemplary embodiment, the transverse elements 144 extend across the gaps of the busbars 200. The transverse elements 144 engage with the busbars 200 to support them. The transverse elements 144 support each of the busbars 200 in the corresponding gaps. In another exemplary embodiment, the longitudinal elements 142 are located in the gaps between the rows of busbars 200. The longitudinal elements 142 can be used to support at least some of the busbars 200. In alternative embodiments, however, the longitudinal elements 142 can be used additionally or alternatively to support some or all of the busbars 200.

[0016] In an exemplary embodiment, the sensor wiring harness 300 has sensor points 302 for monitoring the busbars 200 and / or the cell terminals 24, 26. For example, the sensor wiring harness 300 is electrically connected to the busbars 200 at the sensor points 302 to monitor the voltage, temperature, state of charge, or other operating characteristics of the busbars 200 and / or the cell terminals 24, 26. The sensor wiring harness 300 is configured to be electrically connected to the control arrangement 400. The sensor wiring harness 300 sends sensor signals from the sensor points 302 to the control arrangement 400, which can be used to control the operation of the vehicle and / or a charging process of the vehicle.

[0017] The battery pack interconnection assembly 50 provides a large-format battery cell interconnection assembly configured to be attached to the battery pack 10 (for example, to each of the battery cells 20) as a single unit. The busbar support 110 holds the busbars 200 in the correct positions for connection to the cell terminals 24, 26 of each of the battery cells 20 of the battery pack 10. By holding the busbars 200 for mounting on the battery cells 20 of the battery pack 10, assembly processes such as those found in conventional battery systems, where each busbar is individually mounted to the battery cells in multiple assembly steps, are eliminated. The busbar interconnection assembly 100 reduces the overall number of parts and the number of components to be handled during the assembly of the battery pack 10.The busbar support 110 can have a large format and surface area. For example, the structural process used to manufacture the grid frame for the busbar support 110 allows for a large footprint. The structural material of the grid frame for the busbar support 110 is dimensionally stable and does not warp, making assembly and connection to the battery cells simpler, faster, and more cost-effective compared to conventional assembly processes.

[0018] Fig. Figure 2 is a top view of part of the battery pack interconnection arrangement 50 according to an exemplary embodiment. Fig. Figure 2 shows a matrix 202 of busbars 200 and the sensor arrangement 500 connected to the busbars 200. The busbars 200 are arranged in rows 204 and columns 206 in the matrix 202. The arrangement of the busbars 200 corresponds to the arrangement of the battery cells 20 to establish a connection to the corresponding cell terminals 24, 26. The sensor wiring harness 300 traverses the rows 204 and columns 206 of the busbars 200 to establish an electrical connection to each of the busbars 200 and to detect the properties (e.g., voltages) of each busbar 200. The control arrangement 400 can be integrated into the matrix of busbars 200, for example, between some of the columns 206 or some of the rows 204, or it can be arranged outside the matrix 202, for example, along one side of the matrix 202 of busbars 200.

[0019] Each busbar 200 comprises a metal plate 210 with a main body 212, a first mating pad 214 at a first mating end 215, and a second mating pad 216 at a second mating end 217. The first mating pad 214 is configured to connect to a cell terminal 24 of one of the battery cells 20. The second mating pad 216 is configured to connect to a cell terminal 26 of an adjacent battery cell 20. The busbar 200 electrically connects the adjacent battery cells 20. The mating pads 214 and 216 may include through openings 218, for example, to position the busbars 200 relative to the cell terminals 24 and 26. The openings 218 may be used for a pick-up and placement operation.The openings 218 can be used to hold the positions of the busbars 200 during the forming process to create the busbar support 110.

[0020] In an exemplary embodiment, each busbar 200 is generally rectangular. For example, the busbar 200 comprises a first end 220, a second end 222, a first side 224, and a second side 226. The busbar 200 can be elongated, for example, by having ends 220, 222 that are longer than sides 224, 226. In an exemplary embodiment, the busbar is generally planar. For example, the first and second mating pads 214, 216 can be coplanar to be attached to the cell terminals 24, 26. Optionally, the main body 212 can be offset relative to the first and second mating pads 214, 216 or arranged out of plane, for example, above or below the plane of the first and second mating pads 214, 216.The busbar 200 can include fastening elements such as mounting tabs, pins, brackets, clamps, notches, openings and the like for fastening the busbar 200 to the busbar support 110.

[0021] In one exemplary embodiment, the busbar matrix 202 comprises eighteen rows 204 of busbars 200 and seven columns 206 of busbars 200. In alternative embodiments, more or fewer busbars 200 may be provided in the rows 204 and / or the columns 206. In one exemplary embodiment, the busbars 200 comprise outer busbars 240 and inner busbars 242. The outer busbars 240 are arranged along opposite sides of the busbar matrix 202 (for example, the right side and the left side). The outer busbars 240 are used to connect two different rows of battery cells 20. The inner busbars 242 extend between the outer busbars 240. The inner busbars 242 serve to connect adjacent battery cells 20 within the same column.The outer busbars 240 are aligned perpendicular to the inner busbars 242. For example, the inner busbars 242 are aligned longitudinally and the outer busbars 240 transversely. Other orientations are possible in alternative embodiments.

[0022] The sensor wiring harness 300 comprises sensor modules 310 and sensor cables 350, each connected to a sensor module 310. The sensor modules 310 serve to electrically connect the sensor cables 350 to the corresponding busbars 200. In alternative embodiments, however, the sensor wiring harness 300 can be provided without the sensor modules 310. Instead, the sensor cables 350 can be directly connected to the busbars 200. The sensor modules 310 and the sensor cables 350 form a cover structure that overlaps the busbar matrix 202 of the busbars 200. The sensor modules 310 generally extend in the Y direction, and the sensor cables 350 generally extend in the X direction.In an exemplary embodiment, the sensor cables 350 have flat flexible cables in which a plurality of flat conductors are arranged, configured in an insulator such that they are electrically connected to corresponding rows of the sensor modules 310.

[0023] In an exemplary embodiment, the sensor modules 310 extend along the columns 206 of the busbars 200 and are electrically connected to the corresponding busbars 200 in the column 206 at the corresponding sensor points 302. The sensor modules 310 detect properties, such as the voltage, of each of the corresponding busbars 200. The sensor cables 350 extend over each of the sensor modules 310 and are electrically connected to the sensor modules 310 to aggregate the signals from the sensor modules 310. The sensor cables 350 are electrically connected to the control arrangement 400.

[0024] The control arrangement 400 comprises a control board 410 and control modules 450 connected to the control board 410. In an exemplary embodiment, an electrical connector 440 is connected to the control board 410 and configured to be electrically connected to another component of the battery system, such as a battery distribution unit or a battery control module of the vehicle.

[0025] Each control module 450 is connected to the corresponding sensor cable 350. The control board 410 aggregates the signals from the control modules 450 and the corresponding sensor cables 350. The control board 410 can be a rigid printed circuit board. In other embodiments, the control board 410 can be a flexible printed circuit board. In one exemplary embodiment, the control arrangement 400 is a flat connection solution for connecting the sensor cable harness 300 to the electrical connector 440. The sensor cables 350 can be electrically connected to the control modules 450, for example, by a welding process (such as ultrasonic welding, resistance welding, laser welding, and the like).

[0026] Fig. Figure 3 is a top view of the sensor module 310 according to an exemplary embodiment. Fig. Figure 4 is a side view of the sensor module 310 according to an exemplary embodiment. In one exemplary embodiment, the sensor module 310 comprises a sensor housing 320 and one or more sensor circuits. In the illustrated embodiment, the sensor module 310 comprises a pair of sensor circuits, namely a first sensor circuit 312 and a second sensor circuit 314. In alternative embodiments, the sensor module 310 may comprise more or fewer sensor circuits 312, 314. In various embodiments, the sensor circuits 312, 314 may be electrically connected to different busbars 200. In other various embodiments, the sensor circuits 312, 314 may be connected to the same busbar 200 to define multiple contact points with the same busbar 200 and thus define a redundant connection for improved reliability.

[0027] In one exemplary embodiment, the sensor housing 320 is made of an electrically insulating material, for example, a dielectric material such as a plastic. The sensor housing 320 can be a molded part. In various embodiments, the sensor housing 320 is formed in place on the sensor circuits 312, 314. For example, the sensor housing 320 can be overmolded over parts of the sensor circuits 312, 314. The sensor module 310 can be an overmolded conductor frame. In alternative embodiments, the sensor housing 320 can be pre-molded, and the sensor circuits 312, 314 can be connected to the sensor housing 320. In the illustrated embodiments, the sensor housing 320 comprises a top surface 322, a bottom surface 324, and side edges 326 between the top surface 322 and the bottom surface 324. The sensor housing 320 can generally be rectangular.In alternative embodiments, the sensor housing 320 can also have other shapes. The underside 324 can be attached to one or more of the busbars 200 and / or the busbar support 110. In an exemplary embodiment, the sensor circuits 312, 314 can extend along the top side 322, for example, for connection to the sensor cable 350.

[0028] The first and second sensor circuits 312, 314 can be similar to each other and have similar structures. Identical elements can be designated here with the same reference numerals. The sensor circuit 312 comprises a sensor contact 330 extending between a first end 332 and a second end 334. In an exemplary embodiment, the sensor contact 330 is a stamped and formed contact, which is stamped from a sheet of metal and bent or formed into a predetermined shape. The sensor contact 330 can include a busbar. In alternative embodiments, the sensor circuit 312 can comprise a flexible circuit, such as a flat flexible cable, a flexible printed circuit board, a ribbon cable, or another type of flexible circuit.

[0029] The sensor contact 330 comprises a first counter tab 336 at the first end 332 and a second counter tab 338 at the second end 334. In the illustrated embodiment, the first and second counter tabs 336, 338 are located at different vertical heights. For example, the first counter tab 336 can generally be coplanar with the bottom 324 of the second housing 320, and the second counter tab 338 can generally be coplanar with the top 322 of the second housing 320. The first counter tab 336 is configured to be electrically connected to the busbar 200. For example, the first counter tab 336 can be connected to the busbar 200 by a weld, a conductive adhesive bond, a rivet, or a conductive adhesive bond. In the illustrated embodiments, the second counter tab 338 extends along the top 322 of the transmitting housing 320.The second counter tab 338 is configured to be electrically connected to the sensor cable 350. For example, the second counter tab 338 can be connected to the sensor cable 350 by a weld, a conductive adhesive connection, a rivet connection, or a conductive adhesive connection.

[0030] In an exemplary embodiment, the second counter tabs 338 of the first and second sensor circuits 312, 314 can overlap on the top surface 322. For example, the second counter tabs 338 can overlap each other on opposite sides of the sensor housing 320. The second counter tabs 338 can be spaced apart from each other by a gap. The second counter tabs 338 are electrically insulated from each other to establish an electrical connection to different busbars 200.

[0031] Fig. Figure 5 is a top view of the sensor cable 350 according to an exemplary embodiment. Fig. Figure 6 is a cross-sectional view of the sensor cable 350 according to an exemplary embodiment. In an exemplary embodiment, the sensor cable 350 is a ribbon cable. The sensor cable 350 extends between a first end 352 and a second end 354. The sensor cable 350 includes a connection area 304 configured to connect to the control arrangement 400. The connection area 304 can be located at one of the ends, for example, at the first end 352, or at a central location, for example, remote from the first and second ends 352, 354.

[0032] The sensor cable 350 comprises an insulator 356 that holds a plurality of sensor conductors 360. The insulator 356 can comprise one or more layers of flexible plastic film 358, for example, a top film, a bottom film, and one or more intermediate films between the top and bottom films. The layers can be bonded together by adhesive. The insulator 356 can be a laminated structure. In other embodiments, the insulator 356 can be extruded around the sensor conductors 360. The sensor conductors 360 are arranged between layers of the flexible plastic film 358. The films 358 can be made of a polyester-based material, a polyethylene-based material, a polyamide-based material, a polyurethane-based material, a PVC material, and the like.The foils 358 can be laminated together and / or with the sensor conductors 360, for example using one or more adhesive layers to form a single flexible unit.

[0033] The sensor conductors 360 are flat, parallel conductors. The sensor conductors 360 can be made of copper, aluminum, or another metallic material. Each sensor conductor 360 comprises a top surface 362 and a bottom surface 364. The sensor conductor 360 includes sides 366 between the top surface and the bottom surface 362, 364. In an exemplary embodiment, the sensor conductors 360 have a rectangular cross-section. The foils 358 cover the top and bottom surfaces 362, 364. The foils 358 can be arranged between the sides 366 of adjacent sensor conductors 360.

[0034] In the illustrated embodiment, the sensor cable 350 comprises fifteen sensor conductors 360. In alternative embodiments, the sensor cable 350 may comprise more or fewer sensor conductors 360, for example, to accommodate the number of busbar voltage signals to be measured or other components such as temperature sensors, which may depend on the number of battery cells. In one exemplary embodiment, the sensor conductors 360 each have the same dimensions (for example, height and width). In alternative embodiments, however, the sensor conductors 360 may have different dimensions. In one exemplary embodiment, the sensor cable 350 may have a common spacing between the sensor conductors 360. In alternative embodiments, however, the sensor cable 350 may have different spacings between the sensor conductors 360.

[0035] In one exemplary embodiment, the sensor cable 350 comprises connection access windows 372 that expose the corresponding sensor conductors 360 at connection points 378. For example, portions of the insulator 356 can be selectively removed to form the connection access windows 372 and expose the corresponding sensor conductors 360. In various embodiments, the insulator 356 can be removed by ablation, scraping, cutting, or other removal methods. The connection access windows 372 provide access to the sensor conductors 360 at the connection points 378 for electrical connection to the sensor circuits 312, 314 of the sensor modules 310. For example, the sensor conductors 360 can be electrically connected to the corresponding sensor circuits 312, 314 by a weld, a conductive adhesive bond, a crimp connection, or a conductive adhesive bond.In an exemplary embodiment, the sensor conductors 360 are connected to the corresponding sensor circuits 314 by ultrasonic welding, resistance welding, laser welding, or another similar welding process. In an exemplary embodiment, the connection access windows 374 expose different sensor conductors 360 along different segments of the sensor cable 350 to establish a connection to different sensor modules 310. For example, each sensor conductor 360 can be exposed at a different location along the length of the sensor cable 350 to establish a connection to a different sensor module 310.

[0036] In an exemplary embodiment, the sensor cable comprises 350 (furthermore in Fig. (Figure 7) a module access window 376 that exposes the corresponding sensor conductors 360, for example, all sensor conductors 360, at connection points 378. For example, parts of the insulator 356 can be removed to form the module access window 376 and expose the corresponding sensor conductors 360. In various embodiments, the insulator 356 can be removed by ablation, peeling, cutting, or other removal methods. The access window 376 allows access to the sensor conductors 360 at the connection points 378 for electrical connection to the control module 450 of the control arrangement 400. For example, the sensor conductors 360 can be electrically connected to the control module 450 by a weld, a conductive adhesive connection, a rivet connection, or a conductive adhesive connection.In an exemplary embodiment, the sensor conductors 360 are connected to the control module 450 by ultrasonic welding, resistance welding, laser welding or another similar welding process.

[0037] Fig. Figure 7 shows the sensor arrangement 500 according to an exemplary embodiment. Fig. Figure 7 shows the sensor wiring harness 300 and the control assembly 400. The sensor wiring harness 300 comprises the sensor modules 310 and the sensor cables 350 connected to the sensor modules 310. The sensor cables 350 are connected to the control board 410 via the control modules 450. The sensor cables 350 extend laterally over the sensor modules 310, for example, along the rows of sensor modules 310, to overlap the sensor modules 310 and be electrically connected to each sensor module 310 in the corresponding row. The sensor cables 350 are flat, flexible cables comprising a multitude of flat conductors that are electrically connected to the corresponding sensor modules 310.

[0038] The sensor modules 310 are coupled to the busbars 200. For example, the sensor circuits 312 and 314 can be electrically connected to the corresponding busbars 200 by means of a weld, a conductive bond, a plug connection, or a conductive adhesive connection. The sensor circuits 312 and 314 can be welded to the busbars 200 simultaneously with the welding of the busbars 200 to the battery cells, thus eliminating the need for pre-welding and simplifying assembly.

[0039] During assembly, the sensor conductors 360 are electrically connected to the sensor circuits 312, 314 at the corresponding connection points 378. For example, the access windows 372 expose the sensor conductors 360 for electrical connection to the sensor circuits 312, 314. The sensor conductors 360 can be electrically connected to the corresponding sensor circuits 312, 314 by a weld, a conductive adhesive connection, a rivet connection, or a conductive adhesive connection. The connection access windows 374 expose various sensor conductors 360 along different segments of the sensor cable 350 for connection to various sensor modules 310.

[0040] During assembly, the sensor conductors 360 are electrically connected to the control module 450 at the corresponding connection points 378. For example, the access window 376 exposes the sensor conductors 360 for electrical connection to the control module 450. The sensor conductors 360 can be electrically connected to the module terminals of the control module 450 by a weld, a conductive adhesive bond, a rivet, or a conductive adhesive bond.

[0041] Fig. Figure 8 is a perspective view of the control module 450 according to an exemplary embodiment. In an exemplary embodiment, the control module 450 is an electrical connector configured to be electrically connected to the control board 410. The control module 450 is configured to be electrically connected to the sensor conductors 360 of the sensor cable 350.

[0042] The control module 450 comprises a module housing 452 with walls 454 that support module terminals 480. The module housing 452 extends between a top 456 and a bottom 458. The module housing 452 comprises a first side 460 and a second side 462, which is opposite the first side 460. The module housing 452 comprises a first end 464 and a second end 466, which is opposite the first end 464. The walls 454 can be provided on the sides 460, 462 and / or the ends 464, 466. In an exemplary embodiment, the module housing 452 includes an opening 468 between the sides 460, 462 and / or the ends 464, 466. The opening 468 can be open on the top 456 and / or the bottom 458. The module terminals 480 are exposed in the opening 468, for example for connection to the sensor conductors 360 of the sensor cable 350. In the illustrated embodiment, the module housing 452 is generally rectangular in shape.The module housing 452 can have other shapes in alternative embodiments. In one exemplary embodiment, the module housing 452 includes one or more mounting brackets 470, for example at the ends 464, 466, to attach the control module 450 to the control board 410. In alternative embodiments, other types of mounting devices can be used.

[0043] The module terminals 480 are electrically conductive. For example, the module terminals 480 can be made of a metallic material, such as copper or aluminum. In one exemplary embodiment, the module terminals 480 are stamped and formed terminals. In various embodiments, the module terminals 480 can be a stamped conductor frame overmolded by a body forming a module housing 452. For example, the module housing 452 can be formed in place around the module terminals 480. In alternative embodiments, the module terminals 480 can be formed separately and inserted into the module housing 452.

[0044] Each module terminal 480 extends between a first end 482 and a second end 484. The module terminal 480 comprises a main body 486 between the first and second ends 482, 484. In an exemplary embodiment, the module terminal 480 includes a mating pad 490 along the main body 486 or at the first end 482, configured to connect to the corresponding sensor wire 360 ​​of the sensor cable 350. For example, the sensor wire 360 ​​can be welded to the mating pad 490 to electrically connect the sensor wire 360 ​​to the module terminal 480. In alternative embodiments, the sensor wire 360 ​​can be connected to the mating pad 490 by other methods. In the illustrated embodiment, the counterpart pad 490 is located on or near the top surface 456 of the module housing 452. Other positions are possible in alternative embodiments.The counterpart pad 490 can extend over the top of the opening 468. The counterpart pad 490 can be accessible from above and / or below, for example for welding with the sensor conductor 360.

[0045] In one exemplary embodiment, the module terminal 480 includes a termination pad 492 along the main body 486 or at the second end 484. The termination pad 492 is configured to connect to the control board 410. For example, the termination pad 492 can be welded or soldered to a circuit or conductor of the control board 410. For example, the termination pad 492 can be a solder pad or a solder lug for soldering to the control board 410. In the illustrated embodiment, the termination pad 492 extends from the module housing 452. For example, the termination pad 492 can extend from the first side 460 or the second side 462, for example, near the bottom 458. In alternative embodiments, the termination pad 492 can be located at other positions.In various embodiments, the module terminals 480 can be arranged within the module housing 452 such that adjacent module terminals 480 are rotated by 180°, with their termination pads 492 extending in opposite directions from the first side 460 and the second side 462, respectively. Because every second termination pad 492 extends in opposite directions, the module terminals 480 exhibit good voltage separation (e.g., creepage distance performance) relative to each other and at the connection to the control board 410.

[0046] Fig. Figure 9 is a perspective bottom view of a portion of the control assembly 400, showing the control module 450 ready for assembly with the control board 410. The control board 410 comprises a substrate 412, which may be a multilayer printed circuit board. The control board 410 comprises a top surface 414 and a bottom surface 416. The control board 410 includes a slot 418 between the top surface and the bottom surface 414, 416. The slot 418 is dimensioned and shaped to accommodate the control module 450. For example, the slot 418 may have a rectangular shape. The control module 450 is inserted into the slot 418 to form an internal component, thus reducing the overall height of the control assembly 400. In alternative embodiments, the control board 410 can be provided without the slot 418 and the control module 450 can be surface-mounted on the top 414 or the bottom 416.

[0047] The control board 410 comprises control circuits 420 (also referred to as control circuit terminations) configured to connect to the corresponding module terminals 480 of the control module 450. The control circuits 420 can be pads, traces, vias, or other circuitry of the control board 410. In the illustrated embodiment, the control circuits 420 are located on the underside 416. Alternative positions are possible, for example, on the top side 414. In the illustrated embodiment, the control circuits 420 are arranged on opposite sides of the slot 418 to connect to the termination pads 492 of the module terminals 480, which extend from opposite sides of the control module 450.Since every second control circuit 420 is located on opposite sides of the slot 418, the control circuits 420 have good voltage separation (e.g., tracking performance) from each other. In alternative embodiments, other arrangements of the control circuits 420 are possible; for example, all control circuits 420 can be arranged on the same side of the slot 418.

[0048] Fig. Figure 10 is a bottom view of the control arrangement 400 according to an exemplary embodiment. Fig. Figure 11 is a top view of the control arrangement 400 according to an exemplary embodiment. Fig. 10 and Fig. Figure 11 shows the control module 450, which is connected to the control board 410. Fig. Figure 11 also shows the sensor cable 350, which is connected to the control module 450. In an exemplary embodiment, the control module 450 is accommodated in the slot 418 of the control board 410. The module terminals 480 are connected to the control circuits 420, for example by soldering. The sensor conductors 360 of the sensor cable 350 are connected to the module terminals 480. For example, the sensor conductors 360 can be soldered to the mating pads 490 of the corresponding module terminals 480.

[0049] Fig. Figure 12 is a cross-sectional view of the control arrangement 400 according to an exemplary embodiment. Fig. Figure 13 is a cross-sectional view of the control arrangement 400 according to an exemplary embodiment. Fig. 12 and Fig. Figure 13 shows sections through various module terminals 480, which have the termination pads 492 facing in opposite directions on the opposite sides of the module housing 452. Fig. 12 and Fig. Figure 13 shows the control module 450, which is connected to the control board 410. Fig. 12 and Fig. Figure 13 shows the sensor cable 350, which is connected to the control module 450.

[0050] After assembly, the control module 450 is inserted into the slot 418 of the control board 410. In an exemplary embodiment, the top 456 of the module housing 452 is located above the top 414 of the control board 410, and the bottom 458 of the module housing 452 is located below the bottom 416 of the control board 410. In an exemplary embodiment, the termination pads 492 of the module terminals 480 extend from the module housing 452 near the bottom 458. The termination pads 492 of different adjacent module terminals 480 extend from the different sides 460, 462 of the module housing 452. The termination pads 492 are connected to the control circuits 420, for example by soldering them to the control circuits 420 on the bottom 416 of the control board 410.

[0051] The mating pads 490 of the module terminals 480 are located on the top surface 456. The mating pads 490 are located above the control board 410. The sensor conductors 360 of the sensor cable 350 are connected to the mating pads 490. For example, the sensor conductors 360 can be welded to the outer surfaces of the mating pads 490. In an exemplary embodiment, the opening 468 allows access to the mating pads 490, for example, from above and / or below the mating pads 490, in order to weld the sensor conductors 360 to the mating pad 490. In an exemplary embodiment, the sensor cable 350 extends along the top surface 414 of the control board 410. In various embodiments, the sensor cable 350 can be located at a height above the top surface 414, for example, slightly raised above the control board 410.However, the sensor cable 350 can be located in close proximity to the control board 410, so that the control assembly 400 has a low overall height.

[0052] Fig. Figure 14 is a cross-sectional view of the control arrangement 400 according to an exemplary embodiment, showing how the sensor conductor 360 is connected to the module terminal 480 by an ultrasonic welding process. The opening 468 allows access from both sides to the mating pad 490 of the module terminal 480 in the connection area, so that an ultrasonic horn 600 and an anvil 602 can perform the ultrasonic welding process.

[0053] Fig. Figure 15 is a cross-sectional view of the control arrangement 400 according to an exemplary embodiment, showing how the sensor conductor 360 is connected to the module terminal 480 by a laser welding process. The opening 468 provides access from both sides to the mating pad 490 of the module terminal 480 in the connection area for an upper clamping device 610 and a lower clamping device 612 to perform the laser welding process.

[0054] Fig. Figure 16 is a cross-sectional view of the control arrangement 400 according to an exemplary embodiment, showing how the sensor conductor 360 is connected to the module terminal 480 by a resistance welding process. The opening 468 provides access from both sides to the mating pad 490 of the module terminal 480 in the connection area for an upper resistance welding tip 620 and a lower resistance welding tip 622 to perform the resistance welding process.

[0055] Fig.Figure 17 is a cross-sectional view of the control arrangement 400 according to an exemplary embodiment, showing how the sensor conductor 360 is connected to the module terminal 480 by a resistance welding process. The opening 468 allows access to the mating pad 490 of the module terminal 480 in the connection area for the resistance welding tips 630, 632, which can come from above or below depending on the type of resistance welding. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 723,233

[0001]

Claims

[1] Battery pack interconnection arrangement (50) for electrically connecting cell terminals (24, 26) of battery cells (20) in a battery pack (10), the battery pack interconnection arrangement comprising: a busbar interconnection (100) comprising a plurality of busbars (200) arranged in a matrix (202) with multiple rows (204) and multiple columns (206), and a busbar support (110) holding the busbars, each busbar comprising a first mating end (215) for connecting to the corresponding cell terminal of the corresponding battery cell and a second mating end (217) for connecting to the adjacent cell terminal of the adjacent corresponding battery cell, the busbars electrically connecting the battery cells in the battery pack; and a sensor arrangement (500) connected to the busbars for measuring at least one parameter of the busbars, wherein the sensor arrangement comprises a control arrangement (400) and a sensor wiring harness (300) connected to the control arrangement, wherein the sensor wiring harness has sensor cables (350) with sensor conductors (360) which are connected to the busbars at the sensor points (302), wherein the control arrangement comprises a control board (410) and control modules (450) which are connected to control circuits of the control board, wherein each control module comprises module terminals (480) which are connected between the control circuits and the corresponding sensor conductors. [2] Battery pack interconnection arrangement (50) according to claim 1, wherein the control board (410) aggregates signals from each of the control modules (450) and corresponding sensor cables (350) representing the parameters of all sensor conductors (360). [3] Battery pack interconnection arrangement (50) according to claim 1, wherein the control board (410) comprises slots (418) which accommodate the control modules (450). [4] Battery pack interconnection arrangement (50) according to claim 1, wherein the control board (410) has a top (362) and a bottom (364), wherein the control board comprises slots (418) between the top and the bottom, the slots accommodating the control modules (450). [5] Battery pack interconnection arrangement (50) according to claim 4, wherein the module terminals (480) of the control modules (450) are connected to the control circuits of the control board (410) on the underside (364) and the sensor cables (350) extend along the top side (362) of the control board. [6] Battery pack interconnection arrangement (50) according to claim 5, wherein the sensor cables (350) with their sensor conductors (360) are connected to the module terminals (480) at a height above the top (362). [7] Battery pack interconnection arrangement (50) according to claim 1, wherein each control module comprises a module housing that holds the module terminals (480), the module housing having a top (322) and a bottom (324), the top being located above a top surface (364) of the control board (410) and the bottom being located below a bottom surface (362) of the control board. [8] Battery pack interconnection arrangement (50) according to claim 7, wherein the module housing comprises a first side (224) and a second side (226) opposite the first side, extending between the top (322) and the bottom (324), wherein the module terminals (480) comprise mating pads (490) and end pads (492), wherein the mating pads are arranged on the top side and are configured to be connected to the sensor conductors (360) of the corresponding sensor cable (350), wherein the end pads of a first subset of the module terminals are arranged on the first side of the module housing and the end pads of a second subset of the module terminals are arranged on the second side of the module housing. [9] Battery pack interconnection arrangement (50) according to claim 1, wherein each control module comprises a module housing that holds the module terminals (480), the module housing having a top (322) and a bottom (324), the module housing having a first wall (454), a second wall and a cavity between the first and the second wall, the first wall supporting first ends (220) of the module terminals, the second wall supporting second ends (222) of the module terminals, and the module housing being open above and below the module terminals between the first and the second wall to expose the upper and lower surfaces (362, 364) of the module terminals. [10] Battery pack interconnection arrangement (50) according to claim 1, wherein the sensor cables (350) extend parallel to each other and the conductor spacing and the module terminals (480) of the control modules (450) extend parallel to each other with a terminal spacing corresponding to the conductor spacing. [11] Battery pack interconnection arrangement (50) according to claim 1, wherein the sensor cable (350) comprises a module window (376) that exposes all sensor conductors (360) in the module window, wherein the module window is aligned with the corresponding control module, wherein exposed sections of the sensor conductors in the module window are connected to the corresponding module terminals (480) in the module window. [12] Battery pack interconnection arrangement (50) according to claim 1, wherein the module terminals (480) comprise counterpart pads (490), wherein the sensor conductors (360) are welded to the corresponding counterpart pads. [13] Battery pack interconnection arrangement (50) according to claim 1, wherein the sensor cable harness (300) comprises sensor modules (310) connected to the sensor cables (350), the sensor modules comprising sensor circuits (312, 314) electrically connected to the corresponding busbars (200) at the sensor points (302) to detect the parameters of each of the corresponding busbars, the sensor cables extending between the sensor modules in a row (204), the sensor conductors (360) being electrically connected to the corresponding sensor circuits of the corresponding sensor modules. [14] Battery pack interconnection arrangement (50) according to claim 1, wherein the sensor cables (350) are flat ribbon cables having flat conductors that define the sensor conductors (360), wherein the sensor conductors run parallel to each other and are surrounded by an insulator (356), wherein parts of the insulator are removed to form access windows (372, 374) to the sensor conductors at connection points (378). [15] Battery pack interconnection arrangement (50) according to claim 14, wherein the access windows (372, 374) expose different sensor conductors (360) on each of the corresponding busbars (200) to establish an electrical connection to different busbars. [16] Sensor arrangement (500) for measuring parameters of busbars (200) that are electrically connected to cell terminals (24, 26) of battery cells (20) in a battery pack (10), the sensor arrangement comprising: a sensor wiring harness (300) with sensor modules (310) and sensor cables (350) connecting the sensor modules (302), wherein the sensor modules are configured to be electrically connected at the sensor points (302) to the corresponding busbars in order to acquire the sensor parameters of each of the corresponding busbars, each sensor module comprising a sensor housing and a sensor circuit (312, 314) held by the sensor housing, the sensor circuits being configured to be electrically connected to the corresponding busbars, the sensor cables extending parallel to each other in rows (204), the sensor cables being flat flexible cables having a plurality of sensor conductors (360), the sensor cables extending over each of the sensor modules, the sensor conductors being electrically connected to the corresponding sensor circuits of each of the sensor modules; and a control arrangement (400) which is connected to the sensor cables of the sensor cable harness, wherein the control arrangement comprises a control board (410) and control modules (450) which are connected to the control board, wherein each control module comprises module terminals (480) which are connected to control circuits of the control board, wherein the module terminals comprise counterpart sections which are connected to the sensor cables of the corresponding sensor cable, wherein the control modules (450) electrically connect the corresponding sensor cable to the control board. [17] Sensor cable harness (300) according to claim 16, wherein the control board (410) has a top (362) and a bottom (364), wherein the control board comprises slots (418) between the top and the bottom, the slots accommodating the control modules (450). [18] Sensor cable harness (300) according to claim 16, wherein the sensor cable (350) comprises a module window (376) that exposes all sensor conductors (360) in the module window, wherein the module window is aligned with the corresponding control module, wherein exposed sections of the sensor conductors in the module window are connected to the corresponding module terminals (480) in the module window. [19] Sensor cable harness (300) according to claim 16, wherein the module terminals (480) comprise counterpart pads (490), wherein the sensor conductors (360) are welded to the corresponding counterpart pads. [20] Battery pack (10), comprising: Battery cells (20) arranged in a matrix with multiple rows (204) and multiple columns (206) of battery cells, each battery cell comprising a first cell terminal (24) and a second cell terminal (26); and a battery pack interconnection arrangement (50) which is electrically connected to the first and second cell terminals of the battery cells, wherein the battery pack interconnection arrangement (10) comprises a busbar interconnection (100) and a sensor arrangement (500) which is electrically connected to the busbar interconnection; the busbar interconnection comprising a plurality of busbars (200) arranged in a matrix (202) with multiple rows and multiple columns of busbars, and a busbar support (110) holding the busbars, each busbar having a first counterpart end (215) for connecting to the first cell terminal of the corresponding battery cell and a second counterpart end (217) for connecting to the second cell terminal of the adjacent corresponding battery cell, the busbars electrically connecting the battery cells in the battery pack; the sensor arrangement comprising a sensor wiring harness (300) and a control arrangement (400) connected to the sensor wiring harness; The sensor wiring harness comprises sensor modules (310) and sensor cables (350) connected to the sensor modules, the sensor modules being electrically connected at sensor points to the corresponding busbars to acquire sensor parameters of each of the corresponding busbars, each sensor module comprising a sensor housing (320) and a sensor circuit (312) held by the sensor housing (320), the sensor circuits being configured to be electrically connected to the corresponding busbars, the sensor cables extending in parallel to each other in series, the sensor cables being flat flexible cables having a plurality of sensor conductors (360), the sensor cables extending over each of the sensor modules, the sensor conductors being electrically connected to the corresponding sensor circuits of each of the sensor modules; and the control arrangement which is connected to the sensor cables of the sensor wiring harness, wherein the control arrangement comprises a control board (410) and control modules (450) connected to the control board, wherein each control module comprises module terminals (480) connected to the control circuits of the control board, wherein the module terminals comprise counterpart sections connected to the sensor cables of the corresponding sensor cables, wherein the control modules electrically connect the corresponding sensor cable to the control board.

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